Modularization Technical Overview - DSD 20151209

BW-OPS-DEL-FRMV20130412
DSD - Modularization Presentation
Modularization Technical &
Commercial Overview
Department of State Development
Advanced Modular Solutions
By Alan Millett
9th December 2015

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be used for any other purpose without prior written consent of Barker Wentworth.
Barker Wentworth has prepared this report on the basis of information supplied to us by the Department of State Development. Nothing in
this report should be taken to imply that Barker Wentworth has verified any information supplied to us, or has in any way carried out an
independent validation. We have considered and relied upon information provided by the Department of State Development and its
management in relation to the scope of work. We have not verified, and do not assume responsibility for the accuracy or completeness of
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all of which are accordingly subject to change. In preparing this document, we have relied upon and assumed, without independent
verification, the accuracy and completeness of any information available publicly.
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This document is prepared solely for internal use by the Department of State Development. It is confidential to the Department of State
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Page 2
Disclaimer

3
Modularization Overview
• Modularization Project Management
• Engineering
• Procurement
• Fabrication & Pre-Assembly
• Sea Transport
• Land Transport
• Module Placement & Tie In

DSD: Modularization
Modularization Project Management
Pre-Feasibility is the critical phase for the assessment
of modularization and the associated economic and
risk profile. This is fundamental to the Client’s
management decision making process. The keys study
areas required are:
The exact detail of the Feasibility Study work will only
be apparent after completion of the PFS. It should be
noted that many aspects of strategy and delivery
method influence the focus of the Feasibility Study. In
general key feasibility studies areas required are:
The Implementation Phase deliverable will mirror the
execution and planning identified in the Feasibility
Study. In general key implementation phase areas
required are:
ENGINEERING
 Develop design criteria including engineering
philosophy and consideration to modularization
and pre-assembly;
 Define engineering philosophies for specification,
design standards, procurement strategies,
engineering development and progression
through conceptual to shop detail;
 Develop conceptual engineering where PFD’s and
General Layouts are frozen;
 Identify facility battery limits either geographic or
process dependent on execution methodology;
 High level module identification and module index
development;
 Identify commissioning requirements and general
sequence including governing. ie. power, feed
stock etc.
 Scope fully defined and frozen;
 P&ID frozen and process design finalised;
 All equipment and materials specifications
complete and ready for procurement process;
 Basic engineering completed to a percentage for
execution of a stick build (50%-60%) or pre-
assembly (80%-90%)
 Detailed engineering completed for initial 3
months of Implementation Phase construction
sequence;
 Detailed module identification and module index
development;
 Fully define commissioning sequence and
schedule including resource requirements and
vendor support.
 Manage the development and interface of all
detailed engineering and shop drawing
development;
 Support the development and integration of all
vendor data package engineering into the detailed
engineering effort:
 Fully define planning and implement the
resourcing required to support the commissioning
schedule
 Address quality and technical queries from
construction and fabrication resources;
 Manage commissioning resourcing and execution;
 Develop handover packages.
PRE-FEASIBILITY PHASE FEASIBILITY PHASE IMPLEMENTATION PHASE

DSD: Modularization
 Identification of limiting logistics parameters,
bathymetric, berth and access corridors;
 Identification od shipping and oversize
transportation options and associated economics;
 Identification of offshore fabrication facilities and
associated economics;
 Development of high level site construction
sequence and significant equipment for
installation on site.
 Construction sequence fully defined and all key
equipment identified;
 Shipping and land transport delivery methodology
finalised and scope of services fully defined and
service providers selected;
 Fabrication facilities selected and scope of work
defined and facilities selected;
 Site construction scope of work fully defined and
resources identified for implementation phase
 Manage offshore fabrication and assembly;
 Manage oversize logistics and transportation;
 Manage multi-discipline site construction
requirements;
 Support commissioning.
COMMERCIAL
 Identify procurement requirements for bulks and
critical tagged equipment procurement planning;
 Develop contracting strategy and commercial
requirements for offshore fabrication, logistics
and onshore installation;
 Identification of resources for site installation and
development of high level execution commercial
execution strategy and contract development
requirements.
 All purchase orders for major bulks and tagged
equipment completed and ready for issue;
 Contract strategies fully defined and all pre-
qualifications and commercial documents
complete for each implementation phase work
package complete and ready for issue.
 Manage all contracts and process accounts to
owners requirements;
 Manage all procurement expediting and bulk
logistics;
 Coordinate vendor data and information packages
for commissioning and handover requirements.
CONSTRUCTION & OVERSIZE LOGISTICS

DSD: Modularization
 Develop execution delivery report consistent with
a Pre-Feasibility Study;
 Develop a Work Breakdown Structured Schedule
based on engineering, commercial, construction
and commissioning consideration and any
permitting or specific legislation or municipal
requirement specific to the project location
 Complete economic assessment of stick built vs
pre-assembly delivery models;
 Develop the Work Breakdown Structured Cost
Estimate model for the project delivery;
 Development of Feasibility Study requirements
and associated planning for delivery of the
Feasibility Study to a Level 3 cost estimate,
schedule and execution strategy document.
 Execution Strategy Document complete and
issued for Implementation Phase use;
 Finalise Level 3 Schedule with fully detailed
construction, fabrication and logistics scheduled
developed for the first 3 months of initial
implementation schedule;
 Cost Estimate model for project implementation
phase completed with prevailing risk profile
contingencies sums identified and applied;
 Development of detailed implementation phase
planning and early works programs that need to
straddle internal Client’s approval periods;
 Develop implementation phase safety and
environmental management planning;
 Develop implementation phase quality
management strategy and planning.
 Manage all implementation phase project and
construction management, and project controls;
 Manage site safety and environmental execution
 Manage quality systems
 Manage documentation and handover process
post commissioning
 Complete project close out for commercial and
accounting
PRINCIPLE DELIVERABLES
The principle deliverable for the PFS is a Level 1 Cost
Estimate and Schedule with an accompanying
Execution Strategy Document in accordance with the
Client’s requirements.
The principle deliverable for the FS is a Level 3 Cost
Estimate and Schedule with an accompanying
Execution Strategy Document in accordance with the
Client’s requirements.
The principle deliverable of implementation is
execution of project scope, schedule, budget, quality
and safety in accordance with the Client’s
requirements.
PROJECT ENGINEERING & CONTROLS

7
Modularization FEED Study Economics
Degree of modularization for a project requires a project specific business case including risk
management, contracting strategy, technical considerations, logistics and location challenges, and cost
and schedule economic revaluation.
PRE-ASSEMBLY COST STICK BUILT COSTS
 Offshore Fabrication & Assembly
 Oversize Ocean Transport
 Oversize Land Transport
 Bulk Freight Transport
 Landing Facility
 Site Placement & Installation
 Highway Improvements
 Supporting Infrastructure
 Contractor Distributable
 EPCM / EPC Costs
 Financing Costs
 Fabrication Offsite
 Site Installation Construction
 Site Installation Equipment
 Bulk Freight Transport
 Supporting Infrastructure
 Contractor Distributable
 EPCM / EPC Costs
 Financing Costs

8
Total
Module
Cost
Benefits On-Site
Stick Build
Cost
Reduced
O/Head
Schedule
Costs
Reduced
Financing
Costs
Additional
Transport
Costs
Risk
Mitigation
Reduced
Site
Infrastruct
ure Costs
Additional
Engineerin
g Costs
Module
Yard Costs
Additional
QA/QC
Costs
Additional
Bracing
Costs
Taxes &
Duties
MODULARIZATION PRESENTATION
Benefits of Modularisation

9
Basic
Engineering
Modularization
FEED Study
Plant
Engineering
Structural
Engineering
Transport
Engineering
Detailed
Engineering
Engineering

10
The structures are designed based on the most economical size to transport and placement on site,
based on assessment completed during the module feasibility study.
Engineering Design & Management
The design requires the input from a multi-disciplined team: Planning and scheduling are critical and influenced by:
 Modularization Project Managers
 General Plant Designers
 Modularization Designers
 OEMs
 Fabricator Shop Detailers
 Heavy Lift & Land Transport Specialists
 Naval Architects & Marine Engineers
 Project Surveyors
 Insurance & Risk Specialists
 Turnover & Commissioning Schedule
 Construction Area Sequence
 Module Installation Sequence
 Roll Ship Dates for Equipment & Materials
 Engineering Deliverables
Project controls are significant:
 Document Control
 PAM Master LOG
 Inspection Test Procedures

11
Types of Pre-assembled Modules

12
MODULARIZATION PRESENTATION
A number of organisations are currently
supplying modularised mineral
processing plants for beneficiation and
recovery of a wide range of
commodities.
Package Mineral Processing Plants

13
 Development of correct contracting
strategy is critical factor affecting the
success of a project.
 It is important to place the project risk
with the organisations which have the
capability to control and/or manage the
risk
Procurement & Contracts

14
Stick Built Project Modularized Project
Equipment
Delivery
Port
Ship Port
Truck
Site Install
Equipment
Delivery
Port
Ship Port
Truck
Site Install
Equipment
Delivery
Port
Ship
Port Truck
Pre-Assembly
Yard
Load Out
Modules
Ship Port
Module
Transport
Site Install
Modularization increases the
procurement complexity – the
number of delivery locations
impact ordering and material
tracking
Bulk
Materials
Major
Equipment
Modules
Procurement Complexity

15
Fabrication &
Pre-Assembly
Sea Transport
Land TransportSite Installation
Pre-assembly & Modularization

16
Selection of Pre-Assembly Yard is based on “Fit For
Purpose” requirements for a particular project:
 Contracting Strategy
 Technical Capability
 Location
 Capacity
 Facilities
 Port and Logistics Requirements
 QA/QC
 Taxes and Duties
 Australian Quarantine
Fabrication & Pre-Assembly Yard

17
Sea transport significant cost of modularization
vessel selection based on:
 Port arrangement at Pre-Assembly Yard and
Receiving Location
 Vessel Type – RORO, LOLO, Barge
 Transit Route – Speed, Length, Weather Climate
 Cargo Mix – Weather & Tween Deck
 Chartering Lead Time & Availability
 Cargo Specification – Size, Weight, Cong
 Voyages per Vessel
Sea Transport

18
Traffic Study/Route Assessment
 Quantify construction and operational
traffic loads
 Confirm haulage vehicle & load
dimensions
 Route traffic capacity assessment – model
capacity and delay
 Route physical clearances assessment
 Route traffic safety assessment
 Detailed route inspections
 Review workshop to agree outcomes,
scope of mitigation or strengthening works
 Identify upgrading works required
Land Transport

19
SMPTs used for:
 Large heavy PAMs and SuperPAMs
 Loading & Unloading RORO Vessels
 Low bearing capacity of roads &
wharf structures.
 Accurate placement of modules
Normally limited to:
 Short travel distances < 20 kms
 Travel speed < 3 km/h loaded
Land Transport - SPMT

Normally used for:
 Long distance travel
 Travel speed 40 – 60 km/h
 Ground pressure limited ~ 4t/m²
Limited to:
 Module mass > 800 tonnes
 Module size > 45m L x 12m W
 Road geometry – grade, sag, crest,
curve
 Towed and pushed by number of
trucks depending on load
dimensions, truck brand and weight
20
Land Transport – K24 Flat Trailer

21
Installation method dependent on module
size and number of modules.
 SPMT placement
 Crane placement
 Jacking – Stand jacks & gantry tower
lifting systems
 Skidding
3M105/6/7-
Module LxWxH:
28x30x40M
2,200MT
Smelter Building
& Tower
Modularization
(train n°1)
3M104-Module
LxWxH:
28x30x25M
2,500MT
3M103-Module
LxWxH: 21x35x15M
2,300MT
3M101- Module
LxWxH:
20x35x31M
2,450MT
Furnace –
Stick
building in
Site
Module Installation

22
Economics of crane installation dependent on
mobilisation costs vs number of lifts.
Crane requires:
 Pad to be engineered and compacted
 Adequate space, and reach vs lift
consideration
 Rigging system applies only vertical forces
to structural members
 Spreader bar lattice & square lift rigging
concept used to ensure no transverse
lifting forces are introduced to structure
Module Installation - Crane

23
SPMT are used to install PAMs:
 Directly onto foundations
 PAM mass in excess of site crane
capacity
 PAM positioning accuracy +/- 2mm
 PAM dimensions excessive (LxWxH)
Module Installation - SPMT

24
Tower Jacking
Module Installation - Jacking

25
Skidding method utilised where location, arrangement, size or mass requires an innovated
solution.
Module Installation - Skidding

Modularization Technical Overview - DSD 20151209

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