Modularization : a strategic guide to offsite preassembly for capital projects / Michael Kluck, Jin Ouk Choi.

Format:

Book

Author/Creator:

Kluck, Michael, author.

Choi, Jin Ouk, author.

Language:

English

Subjects (All):

Modular construction.

Physical Description:

1 online resource (253 pages)

Place of Publication:

Hoboken, New Jersey : John Wiley & Sons, Inc., [2023]

Summary:

Modularization A practical, hands-on guide to offsite preassembly, beginning with the project as just a concept gleam in the CEO's eye and winding all the way through implementation at the construction site. Modularization is a philosophy change! And along with that change, comes the need to understand the implementation requirements and project mindset adjustments that impact and influence all aspects of the modular project. To accomplish this, the book provides a complete (from beginning to end) identification and evaluation of the differences that make a modular project unique, starting with the very basics in terms of definitions and setting the groundwork of expectations by identifying benefits and challenges. Then, because the journey is as important as the destination, the reader is guided through the various project phases in a manner that reflects how they would be addressed in the workplace. From the very earliest identification of concepts, through early assessment and selection of the optimal choice to be finally carried into detailed design, the reader is acquainted with each phase of the development process, including explanations and relevant suggestions for many of the questions and issues that typically come up. A perfect reference for professional and technical leaders when developing the early, critical planning phases of modular projects, this guide offers useful examples and details on the fundamentals required to get a modular project started correctly and keep it on track. And, for those whom this is not their first foray into modular project management, this guide includes suggestions, examples, and/or lessons learned to make the subsequent module projects easier to implement. Recognized industry experts Michael Kluck and Dr. Jin Ouk Choi have authored this guide to modularization that is ideal for owners, contractors, project management, engineers, project controls, and procurement-in fact, anyone interested in improving current construction project management practices. In addition, its thought-provoking examples and project case studies provide the perfect platform for its instructional use in teaching modular concepts. Written from the perspective of both the Client/Owner and the EPC Contractor, this guide provides useful information needed for initial project management setup and technical details useful to working functional groups within the project. As such, it is truly a universal guide that can provide personnel at all levels within the project with the information needed to make project implementation more seamless. This book is written in terms of the large-scale industrial modularization project, but the steps and process are equally applicable to small-scale projects and projects outside the industrial construction realm. Some of the topics covered in this guide include: * The basics (to set a basis for major topic presentations) * Module configurations ("good, bad, and ugly") * A deep dive into modularization business case * Module team and project interactions * Module execution planning and timing * Success factors, pitfalls and avoidance * A walk through the "module project" * A modular project case exercise - tying it all together * Standardization - the next step * What the future holds

Contents:

Cover

Title Page

Copyright Page

Contents

Preface

Acknowledgements

Introduction

Chapter 1: What Is Modularization?

Chapter 2: Advantages and Challenges of Modularization

Chapter 3: Industry Status on Modularization

Chapter 4: What Is a Module?

Chapter 5: The Business Case for Modularization

Chapter 6: The Module Team and Execution Plan Differences

Chapter 7: Key Critical Success Factors for Modular Project Success

Chapter 8: The Fabrication Yard

Chapter 9: Module Considerations by Project Group

Chapter 10: A Practical Module Development Process

Chapter 11: Modularization Application Case Study Exercise

Chapter 12: Standardization: The Holy Grail of Pre-Assembly

Chapter 13: Innovative Technologies for Modularization

Chapter 14: Moving Forward

Chapter 15: Key Literature and Resources on Modularization

Chapter 1 What Is Modularization?

1.1 Definitions

1.1.1 Modularization

1.1.2 Module

1.1.3 Percentage Modularization

1.2 "Planning for Modularization" as a Best Practice

1.3 Current State of the Construction Industry

1.3.1 How Did the Construction Industry End Up in Such a Sad State of Affairs?

1.3.2 The Solution: Modularization

1.3.3 Why Aren't All Jobs Modular?

1.3.4 Are Module Jobs More Expensive?

1.4 Three Distinct Module Options (or Circumstances)

1.4.1 Very Limited

1.4.2 Selective Implementation

1.4.3 Maximized Modularization

1.5 What Modularization Is "Not"

1.5.1 Panacea (a Solution for All Difficulties)

1.5.2 Constant

1.5.3 Easy

1.6 Summary

References

Chapter 2 Advantages and Challenges of Modularization

2.1 Why Do Fabrication Yards Have an Advantage?

2.1.1 Obvious Reasons

2.1.2 Less Obvious Reasons

2.2 Advantages of Modularization

2.2.1 Reduced Capital Costs

2.2.2 Improved Schedule Performance.

2.2.3 Increased Productivity

2.2.4 Improved Predictability (Surety/Reliability) or Less Variability

2.2.5 Increased Safety and Quality Performance

2.2.6 Increased Sustainability Performance (Green Benefits)

2.2.7 Site and Site Construction Team Benefits

2.3 Challenges

2.3.1 Critical Path (Reduction in Flexibility)

2.3.2 Upfront Cost (and Pre-Commitment)

2.3.3 Barriers to Engineering

2.3.4 Acceleration of Procurement

2.3.5 Owner and Contractor Capabilities

2.3.6 Module Fabricator Skills and Capabilities

2.3.7 Extensive Coordination

2.3.8 Logistics (Module Transportation)

2.3.9 Others

2.4 Summary

Chapter 3 Industry Status on Modularization

3.1 Modular Projects Case Study

3.1.1 Case Study Methodologies

3.1.2 Sample Characteristics

3.2 Results (Industry Status on Modularization)

3.2.1 Advantages of Modularization

3.2.2 Cost and Schedule Savings Compared to Stick-Built

3.2.3 Recognized Project Difficulties and Impediments to Modularization Application

3.2.4 Business Case Drivers for Modularization

3.2.5 Types of Module Units

3.2.6 Number, Size, and Weight of Modules

3.2.7 Characteristics of Job Site and Module Fabrication/Assembly Shops

3.3 Summary

Acknowledgments

Chapter 4 What Is a Module?

4.1 Common Terms

4.1.1 Pre-Assembled Pipe Rack or Pre-Assembled Rack (PAR)

4.1.2 Pre-Assembled Units (PAU)

4.1.3 Skid Mounted Unit (SMU) or Vendor Package Unit (VPU)

4.1.4 Vendor Assembled Unit (VAU)

4.1.5 Pre-Assembled Structure (PAS)

4.2 Other Terms

4.2.1 Small PAU/Medium PAU/Large PAU/Super PAU/Mega (or Small/Medium/Large/Very Large/Mega Equipment Modules)

4.2.2 Small PAR/Medium PAR/Large/Very Large PAR (or Small/Medium/Large/Very Large Pipe Rack Modules)

4.3 Module Considerations

4.3.1 Plot Plan Development.

4.3.2 What Does Such an Exercise Look Like?

4.3.3 Why Analyze the Process?

4.3.4 Steps in Maximizing Module Efficiency

4.3.5 Additional Module Considerations

4.4 Summary

Chapter 5 The Business Case for Modularization

5.1 Fundamentals of the Business Case

5.1.1 What Makes a "Good" Module Candidate?

5.1.2 Every Project Has Some Amount of Modularization

5.1.3 Three Distinct Levels of Involvement

5.1.4 Advantages and Challenges

5.2 Important Factors to Consider

5.2.1 Universal Key Project Drivers

5.2.2 Additional Project-Specific Factors

5.3 The Business Case Process

5.4 The Business Case Model

Project Analysis

The 13-Step Business Case Flowchart

5.5 The 13-Step Business Case Flowchart

Step 1 Modularization Technical Feasibility

Step 2 Identify Module Drivers

Step 3 Analyze Module Potential

Step 4 Perform Options Analysis

Step 5 Develop Module Scope, and Step 6 Develop Module Size

Step 7 Produce Module Definition and Index

Step 8 Develop Execution Strategy and Execution Plan

Step 9 Produce a Definitive Cost Estimate

Step 10 Produce a Definitive Schedule

Step 11 Check Module Viability

Step 12 Proceed with Modularization to the Next Project Phase

Step 13 Fall Back to Stick-Built

5.6 How Often Should the Business Case Flowchart Be Utilized?

5.7 Summary

Chapter 6 The Module Team and Execution Plan Differences

6.1 The Module Team

6.1.1 A Module-Savvy Leader

6.1.2 The Module Team Members

6.1.3 Critical Team Members

6.1.4 Integration into Project Management

6.1.5 Module Team Growth

6.2 Execution Plan Differences (EPDs)

6.2.1 Guiding Principles

6.2.2 Topics of Execution Plan Differences

6.2.3 Detailed List of Execution Plan Differences

6.2.4 Timing of Execution Plan Differences

6.3 Summary.

References

Chapter 7 Key Critical Success Factors for Modular Project Success

7.1 Modularization Critical Success Factors (CSFs)

7.1.1 CSF Labels and Descriptions

7.1.2 Frequent Module Job Mistakes

7.1.3 Responsibility and Timing of CSFs

7.1.4 Most Delayed CSFs in Terms of Accomplishment Timing

7.2 Association between Modularization CSF and Project Performance

7.3 Training Exercise

7.3.1 Instructions for the Training Exercise

Chapter 8 The Fabrication Yard

8.1 Basic Benefits of the Fab Yard

8.2 Manufacturing and Construction Mixture

8.3 AWP and Module Fabrication

8.4 Selecting a Fabrication Yard

8.4.1 Project Size

8.4.2 Number of Yards Utilized

8.4.3 Location of the Yard

8.4.4 Complexity

8.5 Contracting Strategy

8.5.1 Type of Contract

8.5.2 The Best Type of Subcontract

8.6 Division of Responsibility

8.7 Summary

Reference

Chapter 9 Module Considerations by Project Group

9.1 Engineering Considerations

9.1.1 Module Evolution

9.1.2 Operations and Maintenance Input

9.1.3 Structural Engineering Is King

9.2 Scheduling Considerations

9.3 Procurement Considerations

9.3.1 Fabrication Yard Interfacing

9.4 Sub-Contract Considerations

9.4.1 Heavy Haul (HH)

9.4.2 Vessel Transport

9.4.3 Module Offloading Facility (MOF)

9.4.4 Heavy Lift (HL)

9.4.5 Pipe Spools and Galvanized Structural Steel Fabrication

9.5 Fabrication Considerations

9.5.1 Bolted vs. Welded

9.5.2 Structural Shapes

9.6 Completion/Testing/Prep Considerations

9.6.1 Shipping Incomplete

9.6.2 Ship Loose

9.7 Load-out Considerations

9.7.1 Land Load-out and Self-Propelled Modular Transporters (SPMTs)

9.7.2 Marine Onloading and Offloading

9.7.3 Capacity of the Wharf or Quay

9.8 Module Movement Considerations

9.9 Module Responsibility Matrix.

9.10 Shipping Considerations

9.10.1 Tying or Fastening the Module

9.10.2 Movement to Site and Hook-Up

9.11 Construction Considerations

9.11.1 Understand the Schedule

9.11.2 Understand the Modules

9.12 Summary

Chapter 10 A Practical Module Development Process

10.1 Introduction

10.2 Initial Project Analysis

10.2.1 Reality Check Questions

10.3 Early Discussions

10.4 Module Tenets

10.4.1 Definitions

10.4.2 Boundaries and Limitations

10.4.3 Cost

10.4.4 Impacts

10.4.5 Experience

10.4.6 Commitment

10.5 Project Drivers

10.5.1 Cost versus Schedule

10.5.2 Other Drivers

10.5.3 Owner-Furnished Equipment

10.5.4 The Module Team

10.5.5 How Many and How Big?

10.6 The Five-Step Module Development Process

10.6.1 Step #1 The Stick-Built versus Module Comparison

10.6.2 Step #2 The Module Layout

10.6.3 Step #3 Expand and Accept

10.6.4 Step #4 Schedule

10.6.5 Step #5 Cost

10.6.6 Other Activities

10.7 Concerns to Watch Out For (Lessons Learned)

10.8 The Inevitable Question

10.8.1 The Late Requested Module Study

10.8.2 Less Ambitious Options

10.9 A Couple of Observations from Experience

10.9.1 Underestimation

10.9.2 Under-Collaboration

10.10 Conclusion

Chapter 11 Modularization Application Case Study Exercise

11.1 Oil and Gas (Downstream) LNG Modularization Project Scenario1

11.2 General Project Description and Background

11.3 Additional Project Site/Existing Facilities Information

11.3.1 General Information

11.3.2 Potential African Supply Bases

11.3.3 Opportunity Island

11.3.4 Asian Fabrication Yards

11.3.5 The Houston Engineering Offices

11.3.6 Project Scope

11.3.7 Project Characteristics

11.3.8 Project Stakeholders

11.3.9 Modularization

11.4 In-Class Exercise

Opportunity Framing (FEL-0).

11.4.1 Suggested Student Development Activities.

Notes:

Description based on print version record.

Includes bibliographical references and index.

Other Format:

Print version: Kluck, Michael Modularization

ISBN:

9781119824831

9781119824824

1119824826