A Modern Approach to Building Modular Design to

Increase Constructability and Adaptability

20 September 2018
Today’s Presentation

• Modularization concept
• Modularization: decision-making and drivers
• Module types
• Modularization design – a constructability approach
• Advantages and limitations of modularization
• 3 case studies
• Questions
Who is AG&P?
• AG&P has grown from a leading local construction company in
the Philippines to a global industrial infrastructure company
with world-leading credentials across three lines of business:
• Gas Logistics: LNG supply chain design, development
and marketing
• Modular Construction
• FieldCOM: Manpower services and site works

• Long heritage of delivering solutions to the world’s largest and

most demanding gas infrastructure projects

• World’s leading safety record

• Unrivalled global quality and safety standards for projects

anywhere in the world, regardless of location
Our History

1900 1971 - 1996 2016 - 2017 2018

Atlantic Gulf & Pacific Strong credentials Three lines of business: Gas AG&P achieves 50+ million
(AG&P) founded in the established in the global Logistics, Modular and Onsite consecutive man-hours with
Philippines energy, resources and Construction, FieldCOM zero Lost-Time Incidents
industrial sectors Manpower Services & Site
Works

1950 - 1970 1997 - 2015 2017 2018

Company becomes Manufacturing capacity AG&P commences first LNG AG&P becomes a leading
AG&P of Manila, a expanded to become one terminal project in India heavy industry large-scale
leading local construction of the largest fabrication followed by projects across mechanical and electrical
company facilities in Asia Asia and South America contractor
Unmatched Safety Record

safety incidents across all work sites globally

0
M man-hours consecutively without Lost-Time Incident (LTI) achieved
52 through our consistent commitment to safety (@ August 2018)

million cumulative man-hours with only one minor LTI, setting another
83 first for the global infrastructure industry (@ August 2018)

hectares of heavy fabrication and assembly space across two facilities,

150 each with a deep sea port - one of the largest in Asia

tons of annual production capacity delivered through advanced

125,000 technology, machinery and a layout that maximizes efficiencies

5
Modularization Concept
• Modular fabrication refers to the process of building and constructing equipment off-site in a
fabrication facility

• The completed product is delivered to the worksite and quickly installed and integrated into
field operations

• This differs from on-site construction in which the equipment or system is fully built at the
worksite

• Modular fabrication offers significant benefits over field construction: efficiency, speed, safety,
quality, economy, and convenience

• Modern day mantra: “Do more faster and with fewer resources”
Development in Module Design

Process
module

3rd Generation
Module
Equipment (divide the
2nd Generation project into
skid Modules process
(Equipment, blocks)
Pre-assembled
Units)
First
Generation
Modules (Pipe
Racks or PAR)
Pipe rack
Site envelope requirement for the plant is reducing
with modular design development
Modularization Allows Parallel Activities
Modularization – Decision Making

No
Technical
Start Stick built Project
Feasibility

Yes
Site Survey (Site Module Yard No
Develop Schedule Specific restriction Survey for Develop module
for Stick-built and and opportunities) productivity and definition & index
Modular cost Is
modularizat
Develop execution ion better
strategies and option
Modularization execution strength
Drivers

Yes
Develop definitive
cost estimate
Develop scope of Develop size of
modularization modules
Modularize the
Project
Modularization Drivers
• Cost Reduction
• Shifting of labour intensive work to low cost countries
• Reduce indirect costs (camp, construction supervisions, consumables etc. at site rates)
• Improved productivity (weather, flexible workforce, site accessibility etc.)
• Improved quality hence lower COQ.

• Schedule Reduction
• Shifting of labour intensive work to low cost countries
• Reduce indirect costs (camp, construction supervisions, consumables etc. at site rates)

• Risk Reduction
• Risk of labour strikes and arranging manpower resource is reduced
• Political risk exposure duration is reduced
• Exposure to working in difficult geographies is reduced
• Safety risk is reduced due to reduced onsite work hours
Questions to Ak

• Is field labor productivity < 80% of shop productivity?

• Is field labor cost > 30% of shop labor cost?
• Is there a high probability of severe weather during the construction phase at site?
• Do field labor requirements and availability of skilled labor restrict the stick built construction?
• Do national or local content requirements restrict the quantum that can be modularized?
• Do shipping limits allow module transportation?
• Is the site ready to receive modules ? Skidway for heavy modules, lifting equipment, access to Jetty
• Permitting costs and encumbrances?
• Is crane capacity available and economical?
• Is fabrication capacity available?
• How will modularization affect the schedule?
• Are equipment spacing requirements reasonable for modularization?
Modularization Cost Benefits

Discipline Norm Fabrication Yard Site (Stick built) Driving factors

Piping Pre-fabrication Man-hour/dia-inch 1–2 2–4 Mix of size of joints, type of material, wall thickness

Pipe Support
Man-hour/tons 90 – 100 130 – 150 Mix of light, medium and heavy steel
Fabrication

Mix of size of joints, type of material, wall thickness, accessibility

Piping Erection Man-hour/dia-inch 2–4 4–5
to welder

Pipe Support Erection Man-hour/tons 60 – 70 120 – 140 Mix of light, medium and heavy steel, accessibility to welder

Pipe Pressure Testing Man-hour/linear meter 0.4 - 0.5 0.75 – 1.5 Test packs preparation

Structural Erection Man-hour/ton 50 – 60 90 – 100 Mix of light, medium and heavy steel

Electrical Man-hour/lm 0.25 – 0.5 0.75 – 1.0

Instrumentation Man-hour/ea 5 11

Equipment Installation Man-hour/ton 50 75 Assemblies to be lifted

Insulation (Equipment) Man-hour/sq.m 5 8 Type of Insulation and thickness

Insulation (Piping) Man-hour/m 3 5 Type of Insulation and thickness

Painting Man-hour/sq.m 1.0 1.75 System of paint to be followed, quantity of touch-ups.

Modularization Schedule Benefits
• Overlap between civil construction and Mechanical, E&I
Stick Built Projects
Civil
works can be increased in case of modularization
Mechanical, E&I
Commissioning • In order to attain the maximum benefits, modularization
should start early in the project lifecycle
Modular Project Early Start
Civil
Shop fab
Mechanical, E&I

Commissioning

Modular Project Late Start

Civil
Shop fab
Mechanical, E&I

Commissioning
Module Types

Pre-Assembled Piperack Modules:

Pre-Assembled Units (PAU) Modules: Fully assembled piping modules includes
majorly piping, steel structures, electrical
Fully assembled and pre-commissioned multi- and instrument cable trays, fireproofing
disciplined process modules ready to install and and insulation that minimizes piping
commission at site fabrication at site. Suitable for main
process pipe racks, off-site and utility pipe
racks

Equipment Skids:
Pre-Assembled Manifold (PAM) Modules: Complete equipment package, easily
Fully assembled manifold modules includes majorly transportable with support frames and
valves, piping, steel structures, tagged E&I, cable structures. Process equipment, piping, E&I
trays, fireproofing and insulation bulks. High fabrication quality is maintained
vis-a-vis stick built
 Stability in Design

• Temporary pipe support is added for

stability during transportation
• Pipes are installed and blinded up to
battery limit
• Cable on trays are installed and
coiled up to battery limit
Stability of Equipment During Transportation
Additional temporary members (if required) for stability during the
transportation to avoid misalignment
 Modular Design

• Improving exiting connections from

stick-built design against moment,
shear and tension considering the
acceleration during transportation
• Additional temporary members (if
required) for stability of module during
transportation
• Connection checks either welded or
bolted
 Modular Design Considerations

• Transportation limitations of module

envelope
• Weight control
• Transportation analysis by either land or
sea
– Normally design of transportation
beams or grillage directly above the
transporters or barge and sea-
fastening
• Lifting design including pad eye/lifting lug
design
Modular Design Considerations
Modular Construction Advantages

Traditional thought process Advantages

• Modularization logistics costs are relatively • Modularization reduces the foot print
high • Savings on cable and piping quantity
• Cost of freight is added • Quality control in singular location
• Effort and costs for loading, unloading and • Early production schedule in controlled
transportation to site environment
• Parallel work-fronts/construction are
engaged to accelerate project schedule
• All stages of project are done in-house to
reduce third-party vendor liability issues,
ensuring our commitment to schedule
• Pragmatic approach to reduce burden on
project owner
• Interchangeability is improved in case of
defect or damage
Modular Construction Limitations

• Execution sequence is fixed

• Committed module delivery schedule and routes
• Increased engineering man-hours
• Increased use of steel
• Risk of loss and damage during transportation
• Heavier construction cranes are needed at site
• Facilities to receive modules at site – Jetty, SPMT
• More planning, communication and organization is needed
• Limitation of load-out capacity of yards
• Limitation of transportation vessels carrying capacity
• Limitation of number of axels that can carry the module
Goro Nickel Mining Project
• Client: VALE
• Owner: Goro Nickel Mining
• Location: New Caledonia
• VALE’s Goro Nickel Project in New Caledonia was at-the-time the largest
ferro-nickel processing plant with yearly output of 60,000 tons of nickel
and 5,400 tons of cobalt
• AG&P constructed 90% of the project infrastructure totaling 22,000 MT
with a peak manpower of 3,500 (nearly 12 million man-hours completed
without LTI)
• AG&P’s scope of work on-site included:
• Shop / detailed drawings, engineering, partial supply and full supply of
materials and other tertiary items, material management (free-
issues),fabrication, surface preparation and painting, yard erection,
insulation, galvanizing, testing /inspection, pre-commissioning, export
packing and crating and load-out FAS AG&P marine bulkhead testers
and clerical staff)
• Installation and modification of structural / mechanical, electrical /
instrumentation systems
• Total man-hours: 11.9 million man-hours competed without LTI
Whiting Refinery Modernization Project
• AG&P manufactured the world’s first modularized complex coker unit for
BP’s Whiting Refinery
• 91 modules weighing a combined 17,000 MT, representing one of the
largest and most complex cokers ever made, were shipped from AG&P’s
yard in the Philippines to its ultimate destination and assembly point in
Lake Michigan - a 47-day, one-way voyage
• AG&P’s scope of work included shop drawings and constructability
evaluation of detailed engineering, fabrication and transportation of
structural steel, assembly, QA/QC testing, site area preparation and
protective coating, fireproofing and insulation of the final structures,
painting and protective sealing
• AG&P completed the project ahead of schedule and with zero LTIs
leading to several HSEQ and performance awards
Ichthys LNG - Electrical & Instrumentation Rooms
• AG&P was awarded the contract to deliver mission-ready, bio-secure e-
house modules, the electrical backbone of the liquefaction plant for the
Ichthys LNG Project in Darwin, Australia
• AG&P successfully finished an over $400 M contract to manufacture 29
Local Electrical Rooms (LERs) and Local Instrumentation Rooms (LIRs)
with a combined weight of 16,515 MT for the $35 billion Ichthys project
• Operator: INPEX
• Client: JKC Consortium (Japan Gas, KBR & Chiyoda)
• Location: Darwin, Australia

AG&P E-HOUSE PACKAGE

TYPE No. of Units Weight (MT)

Substation 2 1,683
LER 15 9,950
LIR 9 4,824
Stair Tower 3 58

Total 29 16,515
Yard 1 Facilities Overview

25
Pipe Fabrication in Yard 1
17 Hectares of Available Material Laydown Area Automated Layout & Cutting of Pipe Supports

Key workshop features:

• 3 band saws up to 1,200 mm
• 3 beam coping robots up to 1,200 mm
• 2 drilling units up to 1,200 mm
• 2 pipe coping robots up to 1,200 mm
• 4 oxy / plasma plate cutting tables up to 300 mm
oxy / 50 mm plasma
• 1 laser cutting station from 0.5 to 12 mm
• 3 plate drilling stations
26
Pipe Fabrication in Yard 1 (cont’d)
Automated Pipe Spool Fabrication from Root Pass to Cap Manual Fabrication of Small Bore Piping and Pipes
Welding Over 48”
Most pipes will be fabricated via AG&P’s automated pipe spool
system

Key workshop features:

• 3 automated processing lines for cutting, beveling, fit-up and
welding of:
o Carbon steel – 2” to 24”
o Carbon steel – 24” to 48”
o Stainless steel – 2” to 24”
• Key equipment includes:
o CNC band saw machines
o CNC 5-axis flame / plasma cutting and profiling station
o CNC high-speed ending beveling stations

27
Pipe Fabrication in Yard 1 (cont’d)
Blasting & Painting at Automated & Manual Paint In-house Procedure for Preservation of Prefabricated
Shops Pipe Spools
AG&P has 3 automatic blasting lines (plates, sections
and pipes) to blast and prime the pipe spools and
supports

Placement of end caps Application of preservation

coating

Packing of pipes Loading of cradle / spools

28
260,000-m2 Heavy Modularization Area
Load bearing capacity: Up to 50 MT/m2

29
Yard 2 facilities overview
Direct access to Batangas International Port

Office

Fabrication
shops
Warehouse Warehouse

Heavy modularization area

Heavy
modularization
area

Heavy-lift ship Quay

30
State-of-the-art Production Shops
• Yard 2 utilizes the latest
automated machinery and
equipment including band saw,
beveling machine, CNC drilling
machine, CNC plasma cutting
machine, pipe coasters and pipe
rotators
• Fabrication shops: 17,600 m2
• Blast & paint shops: 1,980 m2
• Warehouse: 8,000 m2

31
Blasting and Painting Shop – Yard 2

Blasting and painting shop Yard 2

Dimension: 50MW x 25ML x 20 MH

Equipment:
Dust Collector
Dehumidifier
8 Blasting Nozzle each
287,000-m2 Heavy Modularization Area
Load bearing capacity: 10 – 30 MT/m2

33
Methodology
Construction & Load-Out Methodology
1. Fabrication of all steel members and assemble sub panels at fabrication shop
2. Transport all steel members and assembled panels to galvanizing prior to delivery to assembly
area

Fabrication Shop

Fabricated structural members

Construction & Load-Out Methodology
3. Installation of temporary supports for Panel 1 and 2
Construction & Load-Out Methodology
4. Upending of Panel 1 using tandem crane set up
➢ installation of Panel 1 on top of temporary supports. Provide guy lines to support the panel
temporarily
Construction & Load-Out Methodology
5. Upending of Panel 2 using tandem crane set up
➢ Installation of Panel 2 on top of temporary supports. Provide guy lines to support the panel
temporarily
Construction & Load-Out Methodology
6. Installation of Panel 2 on top of temporary supports. Provide guy lines to support the panel
temporarily
Construction & Load-Out Methodology
7. Installation of Panel A between Panel 1 and 2. Alignment and squareness to be checked prior to
bolt tightening
Construction & Load-Out Methodology
8. Installation of Panel B between Panel 1 and 2. Alignment and squareness to be checked prior to
bolt tightening
Construction & Load-Out Methodology
9. Installation of stick built members between Panel A and B. Alignment and squareness to be
checked prior to bolt tightening
Construction & Load-Out Methodology
10. Installation of temporary supports for Panel 3
Construction & Load-Out Methodology
11. Installation of Panel 3 on top of temporary supports. Provide guy lines to support the panel
temporarily
Construction & Load-Out Methodology
12. Installation of Panel C between Panel 2 and 3. Alignment and squareness to be checked prior to
bolt tightening
.
Construction & Load-Out Methodology
13. Installation of Panel C between Panel 2 and 3. Alignment and squareness to be checked prior to
bolt tightening
.
Construction & Load-Out Methodology
14. Installation of stick built members between Panel C and D. Alignment and squareness to be
checked prior to bolt tightening
Construction & Load-Out Methodology
15. Installation of grating on 1st level
Construction & Load-Out Methodology
16. Installation of equipment on first level
Construction & Load-Out Methodology
17. Installation of panels and stick built members on second level. Follow items 7-15 for the
installation sequence
Construction & Load-Out Methodology
18. Installation of stick built bracing on first level
Construction & Load-Out Methodology

Preparation of GT-204 EO
Concentrator for installation

Upending of GT-204 EO
Concentrator
Goro Nickel Mining Project
Crane – 01 Load Data
Equipment WT. 363.50 Mt
Crane Hook Wt. (600mt) / WT. 16.00 Mt
Weight Of Shackles 0.63 Mt
Weight Of Slings 0.92 Mt
Weight Of Spreader Beam 2.03 Mt
Total Lift Weight 383.08 Mt
Dynamic Amplification Factor -- %
Total Lift Weight W/ DAF 383.08 Mt
Crane Data: Terex Cc6800 SSL
Boom In Use Main
Track Centers 9.60 Meter
Car Body Counterweight 250.00 Mt
Main Boom Length -- Meter
Jib Boom Length 102.00 Meter
Super Lift C/W @ 24 Meter 450 Mt
Working Radius 24.00 Meter
Lifting Capacity 441.00 Mt
Crane Efficiency: 383.08 / 441.00 X 100 =
86.86%

Lifting Configuration of GT-204 EO

Concentrator
Construction & Load-Out Methodology
21. Installation of GT-204 EO Concentrator and other equipment
Construction & Load-Out Methodology
22. Installation of equipment on second level
Construction & Load-Out Methodology
23. Installation of panels and stick built members on third level. Follow items 7-15 for the installation
sequence
Construction & Load-Out Methodology
24. Installation of stick built bracing on second level
Construction & Load-Out Methodology
25. Installation of equipment on third level
Construction & Load-Out Methodology
26. Installation of pre – assembled Panel 1 27. Installation of remaining stick built
on 4th level on top of columns. Alignment members to complete the fourth level
and squareness to be checked prior to bolt deck
tightening
Construction & Load-Out Methodology
28. Installation of stick built bracing on second level
Construction & Load-Out Methodology
29. Installation of E&I , Piping and HVAC supports
Construction & Load-Out Methodology
30. Installation of remaining steel members and equipment platform on top of fourth level deck
Construction & Load-Out Methodology
31. Installation of remaining equipment on top of fourth level deck
Construction & Load-Out Methodology
32. Installation of panel on first level for equipment platform
Construction & Load-Out Methodology
33. Installation of remaining equipment on first level
Construction & Load-Out Methodology
34. Installation of remaining panel on first level for pipe rack structure
Construction & Load-Out Methodology
35. Installation of pre-assembled pipe rack on top of first level deck
Construction & Load-Out Methodology
36. Installation of all pipe spools, E&I and piping components
Construction & Load-Out Methodology
37. Installation of stair towers, handrails and other remaining miscellaneous steel, architectural and
HVAC components
Construction & Load-Out Methodology
38. Complete installation of electrical and instrumentation components. Final inspection prior to
testing / pre-commissioning
Construction & Load-Out Methodology
39. Positioning of 7 rows of 54 axles of SPMT underneath the module
28th Floor, Tower 2, Insular Corporate Centre, Insular Life Drive, Filinvest Corporate City, Alabang, Muntinlupa City 1781, Philippines
Phone: +63 (2) 663 2100 l Fax: +63 (2) 663 2199 l www.agp.ph