A pioneer in the field of module solutions

The Modularization Option

Ichthys Project Onshore LNG Facilities – image courtesy of INPEX

The Modularization Case Weighing the factors on module versus stick build or a hybrid solution takes the right partner with an in-depth understanding of the design, logistics and construction challenges. With KBR, you work with an expert that has successfully completed more modular studies, pre-FEEDs, FEEDs, and Detailed Designs than anyone in the industry.

The modular decision requires careful assessment of all variables including location, laydown, labor, logistics, safety, availability of materials and quality. KBR is a neutral partner with extensive constructability experience that can help you find the right solution that is best for your project’s unique challenges, to help you achieve on-time, safe and cost-effective execution.

In both offshore and onshore environments, greenfield and brownfield sites for hydrocarbon fluids, we have the experience and capabilities to conceive an effective modularization plan.

Michael KluckSr. Project Manager – Engineering, Project Execution

■■ Dedicated, Highly Experienced Modularization Teams: Our module experts have designed and procured over 1.5 million tons of modules since 2000 alone, acquiring the right experience and capabilities to help our clients ensure timely project completion.

■■ In-depth Global Fabrication Expertise: We have worked with and provided project supervision for nearly all the Tier 1, 2 & 3 fabricators worldwide, keeping critical path modules on schedule.

■■ Proven Tools & Systems: We have the customized systems for modules: 3D CAD, 4D and Materials Management in addition to our suite of engineering, procurement and cost and schedule project controls tools, to help our clients ensure project success and on-time delivery.

■■ Logistics Approach and Focus: Our logistics teams since 2000 have transported 20 million tons of material over 8 million miles, mitigating risks and focusing on delivery of equipment and materials, including heavy lift modules, anywhere, anytime, helping our clients maximize project return.

■■ Commissioning & Startup: Our system-based approach begins with the end in mind, starting this planning in the engineering and procurement phases of FEED and Detailed Design in order to effectively maximize the hook-up and pre-commissioning activities in the fabrication yard, minimize carry over work to site and deliver an easy efficient start-up.

Why KBR

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“ Modularization has recently become a bit of a buzz word within the industry. While it can be very advantageous, it must not be assumed to be a ‘one size fits all’ solution. KBR has successfully worked with clients at all phases of a project’s execution to confirm the correct project specific input is analyzed early enough to consider the entire breadth of modularization possibilities. ”

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Types of Modules

SKIDS

■■ Specialty technical equipment is supplied on skids

■■ Associated ancillary equipment, access platforms, ladders, etc. are attached to the package unit

■■ Usually built by equipment vendor or his subcontractor

■■ Weight and size is limited by existing mechanical handling facilities at supplier shop facilities and nearest port, restrictions on route from port to site and cranage at site

■■ Large amount of hook-up required on site

PreaSSembleD racKS (Pars)

■■ Complete modularized sections of a process unit or offsite pipe rack

■■ Typically contains piping, valves, instrumentation and electrical hardware

■■ Can be fabricated by a large range of fabrication facilities

■■ Loaded out by trailers or lifted by crane

■■ Sizes limited by the length capable of being transported and set at site

PreaSSembleD unItS (Paus)

■■ Multiple pieces of equipment are packaged together on a single rigid frame designed to resist the forces experienced during transit and installation

■■ Specialist fabricator required

■■ Requires quay facilities at fabrication yard

■■ Usually single level with weight seldom exceeding 2,000 tons

■■ Partial hook-up and commissioning at the fabrication yard

large moDuleS

■■ Larger than PAUs and generally contain whole/several systems

■■ Specialist fabricator required: most piping & instrumentation and electrical is installed

■■ Major piperacks can be part of the module or may be stand-alone modules

■■ Requires large quay to receive transportation barge

■■ Modules of up to 15,000 tons have been installed on offshore platforms

Modularization in construction has been around for well over one hundred years, but increased in popularity during the early 20th century. From 1910 to 1940, Sears Roebuck sold more than 500,000 pre-fabricated homes in the U.S. alone.

As Gas Monetization became more commercially viable, modularization of gas treatment facilities steadily increased.

Currently, with newer technologies, greater transportation options, increased lifting capabilities and an increased demand for products and services, modularization continues to provide economic options to owners.

KBR is considered a pioneer in the field of modular construction – we built the first modular offshore platform in the North Sea over 40 years ago. Having been at the forefront of study and design enhancements in modular construction for over 50 years, KBR has proven itself as a world-class modularization contractor.

In both Offshore and Onshore environments, greenfield and brownfield sites, for hydrocarbon fluids, KBR has forged a dominant global role in assisting owners to develop their assets commercially.

When assessing constructability of a planned facility, KBR has the experience and capabilities to conceive an effective modularization plan.

When it comes to modularization, at Kbr, We Deliver.

Related Success

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1990 1995 2000 2005 2010 2015

Shell EA FPSONigeria

ConocoPhillips Belanak FPSOIndonesia

BP Block 18 FPSOAngola

Shell MalampayaPhillipines

Petrobras Barracuda/Carratinga FPSOBrazil

Total CLOV FPSOAngola

Chevron Agbami FPSONigeria

Chevron Tombua-LandanaAngola

Total Pazflor FPSOAngola

BP Glen Lyon FPSONorth Sea

Woodside LNG Train 3Karratha, Australia

Gas Monetization EPCGas Monetization EPC: ModularOffshore Oil & Gas EPC: ModularOffshore Projects

Malaysia LNG DuaBintulu, Malaysia

Malaysia LNG DuaBintulu, Malaysia

Woodside LNG Train 4Karratha, Australia

SEGAS LNG Train 1Damietta, Egypt

NLNG Trains 4 & 5Bonny Island, Nigeria

Skikda New Train LNGSkikda, Algeria

Statoil Karstø ExpansionProcessing PlantNorway

Kitimat LNGBC, Canada

INPEX - operated Ichthys LNG ProjectDarwin, Australia

Statoil Karstø UpgradeProcessing PlantNorway

Magnolia LNG (MLNG)Louisiana, USA

NLNG Train 6Bonny Island, Nigeria

Chevron GTLEscavros, Nigeria

QatarGas LNG Trains 1 & 2Doha, Qatar

Pertamina LNG “H”Kalimantan, Indonesia

NLNG Train 3Bonny Island, Nigeria

NLNG Trains 1 & 2Bonny Island, Nigeria

Tangguh LNGPapua, Indonesia

Yemen LNGBal Haf, Yemen

PEMEX EPC-1Mexico

Chevron Benguela-BelizeAngola

1995: NLNG 2007: Skikda

2012: INPEX - operated Ichthys LNG Project

2004: Petrobras Barracuda/Carratinga FPSO2000: Shell EA FPSO

2008: BP Glen Lyon FPSO

1990: Woodside LNG

Offshore or onshore, greenfield or brownfield sites, when project economics favor a modular solution, KBR delivers. Our rich history of module solutions backed by our long standing relationships with module fabricators around the world and strengthened by our commitment to safety, quality, structural integrity and on-time delivery make us the right partner for your module project.

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KBR Delivers Module Solutions

With over 1.5 million tons of modules designed, fabricated and installed (or in progress), KBR is a world leading module contractor

Global Reach

KBR’s global network of offices and execution centers provide the ability to deploy the best resources to a project while minimizing travel and relocation costs.

Best in Class, Tools, Systems & Processes

KBR uses proven industry leading best practice tools, systems and processes on every project. Total security enabled transparency, anywhere, any place, any time.

Modularization Achievements

■■ First modularized GTL facility in Africa (Nigeria)

■■ >1.5 million tons of modules designed and fabricated

Lessons Learned

KBR has well developed Lessons Learned databases established over many years and projects. These valuable assets are used on every project to ensure success.

Proven Performance

KBR offers tried, tested and proven performance over many years, in all locations, in various project scenarios meeting our customers’ expectations…We Deliver.

Fabrication Yard Relationships

KBR has worked with most of the world’s fabricators: Tier 1, 2 & 3. These long standing relationships assist us to deliver modular solutions on time and minimizes on-site hook-up & commissioning.

Resources

KBR employs over 22,000 of the world’s most talented and experienced people. We staff major projects worldwide. Over 30% of our global team has modular experience.

Vast Project Experience

KBR has led many of the world’s large and mega-projects over the past 20 years. In remote locations requiring flexible solutions, KBR consistently helps our clients deliver projects on time and on budget.

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The Modularization Path

A successful module plan works through the recognized project phases: Conceptual ➔■FEED ➔■Detailed Design & Procurement ➔■

Fabrication ➔■Construction ➔■Turn-Over & Start-Up.

This plan is also subject to the same project relationship between influence and cost.

Influence is high in the early phases and drops off dramatically as decisions are made and costs are committed.

Project success and maximum ROI requires experienced inputs at the outset. KBR has successfully completed more modular studies, pre-FEEDs and FEEDs than most contractors.

On modular design, We Deliver.

A typical modularization path follows a familiar project progression.

Detailed Design & ProcurementConceptual Feasibility Definition Commissioning

& Start-upFabrication & Construction

INFL

UE

NC

EIN

FLU

ENCE

COST

TICFID

S T U D Y F E E D E P C

PROjECT COnCEPTEvaluate site, labor market, community,

housing, access, ROI...

COnSTRuCTABILITYAssess laydown area, materials, cost analysis, schedule, path of construction, fabrication yards,

delivery. Safety in design.

ECOnOMIC AnALYSISPerform analysis on engineering, bulk materials,

shipping, logistics, camp, all of the relevant factors.

DEVELOP MODuLE TEAMComposed of competent personnel from

previous projects, the right people for the job. Apply lessons learned.

MAnAGEMEnT BuY-In & SuPPORTEssential to have complete client buy-in.

EARLY MODuLE DEFInITIOnDefine module envelope. Develop scope for hydraulics, pipe stress, dimensions, maintenance access, transport, weight management.

DETAILED DESIGn

MODuLE COnSTRuCTIOn / HOOK-uP

SYSTEMS-BASED START-uP

LOGISTICS & TRAnSPORTATIOnPROCuREMEnTLOnG-LEAD ITEMS

© 2015 KBR. All Rights Reserved. K15002

KBR Headquarters601 Jefferson StreetHouston, Texas 77002, USA +1 713 753-2000

We Deliver. KBR works alongside clients worldwide to deliver any project, any time, any place—making us a leader in the engineering, construction and services industries.

KBR, Inc. is a global technology, engineering, procurement and construction company serving the hydrocarbons and government services industries, employing over 22,000 people worldwide with customers in more than 80 countries and operations in 40 countries. We are proud to work with our customers across the globe to provide technology, value-added consulting services and integrated EPC skills to help ensure consistent project delivery with predictable results.

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