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Structural Design of Modules for Energy and Industrial Facilities, 2024
- Cover
- Half Title
- Title Page
- Copyright Page
- Contents
- Task Committee on Onshore Heavy Industrial Modularization Guidelines
- Acknowledgments
- Preface
- Disclaimer
- Chapter 1: Overview [Go to Page]
- 1.1 Introduction
- 1.2 Report Purpose
- 1.3 Research
- 1.4 Modules [Go to Page]
- 1.4.1 Background
- 1.4.2 Buildings or Equivalent Structures [Go to Page]
- 1.4.2.1 Modular Buildings
- 1.4.2.2 Modular Building Splits
- 1.4.2.3 Modular Building Compliance Programs
- 1.4.2.4 Modular Building Design for Transportation
- 1.4.3 Structure Subassemblies
- 1.4.4 Pipe Racks
- 1.4.5 Packaged Units
- 1.4.6 Process Modules
- 1.5 Transportation Modes [Go to Page]
- 1.5.1 Land
- 1.5.2 Water
- 1.5.3 Air
- 1.6 Sustainability Considerations
- References
- Appendix 1A. Structure Subassemblies [Go to Page]
- 1A-1 Introduction
- 1A-2 Modular Steel Panel Types [Go to Page]
- 1A-2.1 Composite Floor Panels
- 1A-2.2 Pressure Restraint Walls
- 1A-2.3 Grating Floor Panels
- 1A-2.4 Checkered Plate Floor Panels
- 1A-2.5 Girt Trusses
- 1A-3.1 Ground Assemblies Using Modular Steel Floor Panels
- 1A-3.2 Silo Support Frames
- 1A-3.3 Roof Ground Assemblies
- 1A-3.4 Turbine Generator Tabletop Ground Preassembly
- 1A-3.5 Shop-Fabricated and Ground-Assembled Stair Tower Modules
- 1A-4 Economics of Modular Steel Floor and Wall Panels
- Chapter 2: Philosophy and Early Design Development Concepts [Go to Page]
- 2.1 Introduction [Go to Page]
- 2.1.1 Definitions
- 2.2 Modularization Objectives and Drivers
- 2.3 Modularization Strategy [Go to Page]
- 2.3.1 Modularization Design Workshops
- 2.3.2 Module Design Strategy
- 2.3.3 Module Layout
- 2.4 Civil/Structural Design Philosophies [Go to Page]
- 2.4.1 Target Reliability and Associated Reliability Indexes
- 2.4.2 Site Preparation and Foundation Design Strategy
- 2.4.3 Primary Steel Structure
- 2.4.4 Module Size, Structural System, and Connections [Go to Page]
- Module Size and Weight Constraints
- Selection of a Structural System
- Framing Configuration
- Rolled Shapes versus Built-Up Girders
- Bolted versus Welded Connections
- 2.4.5 Multidiscipline Supports
- 2.4.6 Marine Transport Structural Characteristics
- 2.4.7 Land Transport Structural Characteristics
- 2.5 Logistics Philosophy [Go to Page]
- 2.5.1 Marine Transport: Heavy-Lift Vessel and Barge
- 2.5.2 �Land Transport: Self-Propelled Modular Transporter and Propelled Modular Transporter and Rail
- 2.6 Weight Management Philosophy
- 2.7 Module Installation Philosophies
- 2.8 Interface/Project Management
- 2.9 Impact on Project Summary
- References
- Chapter 3: Front-End Engineering Design [Go to Page]
- 3.1 Introduction
- 3.2 Module Layout
- 3.3 Transportation [Go to Page]
- 3.3.1 Transportation for Planning and Schedule
- 3.3.2 Dimensional and Weight Limitations
- 3.3.3 Available Transportation Options
- 3.3.4 Water Transportation
- 3.3.5 Self-Propelled Modular Transporters
- 3.3.6 Trucks
- 3.3.7 Railway
- 3.3.8 Selection of Transportation Contractors
- 3.4 Module Structure Design Criteria
- 3.5 Constructability Study [Go to Page]
- 3.5.1 Planning and Logistics Management
- 3.5.2 Schedule Compression and Cost Reduction
- 3.5.3 Bolted versus Welded Connections
- 3.5.4 Extent of Field Construction versus Shop Fabrication
- 3.5.5 Selection of Fabrication Yard
- 3.6 Weight Management Procedure [Go to Page]
- 3.6.1 Weight and Center of Gravity Report
- 3.6.2 Weight Report Updates
- 3.7 Dimensional Control Basis
- 3.8 Risk Management
- 3.9 Permitting Plan
- 3.10 Schedule
- 3.11 Cost Estimate
- 3.12 Interface Matrix
- 3.13 Value Engineering
- References
- Chapter 4: Weight Management [Go to Page]
- 4.1 Purpose
- 4.2 Scope
- 4.3 Tailoring
- 4.4 Definitions
- 4.5 Acronyms
- 4.6 General Requirements [Go to Page]
- 4.6.1 Scope Determination
- 4.6.2 Complexity Evaluation [Go to Page]
- Design Parameters (Weight, Aspect Ratio, Equipment, and Disciplines Involved)
- Transportation
- Risk Acceptance
- 4.6.3 Management Decision Matrix [Go to Page]
- Checklist—Transportation (X-axis)
- The scoring system ranges from 4 to 30 points and addresses various aspects of transportation.
- 4.6.4 Definition of List of Tools and Setup (G, Y, R) [Go to Page]
- Setup: Define Units
- Setup: Three-Dimensional Model
- Setup: Weight Database
- 4.6.5 Use of Allowances (G, Y, R)
- 4.6.6 Establishment of a Module Datum Point
- 4.6.7 Use of Discipline Checklists (G, Y, R) [Go to Page]
- Architectural Item List
- Electrical Item List
- Heating, Ventilation, and Air-Conditioning Item List
- Instrumentation Item List
- Mechanical Item List
- Material and Corrosion Items List
- Piping Item List
- Safety, Environment, and Security Item List
- Structural Item List
- 4.7 Requirements for Various Project Phases [Go to Page]
- 4.7.1 Early Estimate of Pre-FEED and FEED (G, Y, R)
- 4.7.2 Detailed Design (G, Y, R) [Go to Page]
- Weight and Center of Gravity Limits (G, Y, R)
- 4.7.3 Fabrication (G, Y, R) [Go to Page]
- Types of Weight Management
- Shared Fabricator and Engineering Weight Management
- None to Very Little Fabricator Weight Management (G)
- Weight Shedding and Ballasting
- Carryover Work/Ship Loose
- 4.8 Procedures/Specifications [Go to Page]
- 4.8.1 Definition of Weight Management Procedure/Specification (G, Y, R) [Go to Page]
- Purpose
- References
- Definitions and Abbreviations
- Weight Management Goals
- Weight Management Policy
- Weight Report (Varies by Complexity)
- Executive Summary (G, Y, R)
- Introduction (Y, R)
- Module Reports (Y, R)
- Summary and Conclusions (Y, R)
- Appendixes (Varies by Complexity)
- As-Built Data (G, Y, R)
- 4.8.2 Define Vendor Weight Reporting Procedure/Specification (G, Y, R)
- 4.8.3 Definition of Fabricator Weight Management Procedure/Specification (G, Y, R) [Go to Page]
- Defining Fabricator Weighing Requirements (G, Y, R)
- As-Built (G, Y, R)
- 4.8.4 Job Bulletins (As Applicable)
- Chapter 5: Detailed Engineering [Go to Page]
- 5.1 Introduction
- 5.2 Design Loads [Go to Page]
- 5.2.1 In-Place
- 5.2.2 Land Transportation by Truck [Go to Page]
- Introduction
- Current Practice for Accelerations due to Transportation
- Cargo Securement Rules
- Acceleration Demands
- Acceleration Resistances—Friction
- Transverse Friction and Super Elevation
- 5.2.3 Self-Propelled Modular Transporter Transportation [Go to Page]
- Low-Speed Transport
- Average-Speed Transport
- High-Speed Transport
- Inclinations
- Internal Forces within Trailer Configuration
- 5.2.4 Water Transportation [Go to Page]
- Introduction
- Sea Vessel Motions: Analysis Methods
- 5.2.5 Lifting Loads [Go to Page]
- Crane Lifting
- Self-Propelled Modular Transporter (Lifting)
- Impact Factors
- 5.2.6 Setting Loads and Fabrication Yard Loads
- 5.2.7 Rail Loads
- 5.2.8 Wind Loads [Go to Page]
- Introduction
- In-Place Wind
- Wind Load for Truckable Modules
- Wind Loads for Sea Transportation
- Design Wind Speed—Reference Period
- Wind Force
- Wind Load for Land Transportation
- 5.3 Load Combinations [Go to Page]
- 5.3.1 Introduction
- 5.3.2 Allowable Stress Design
- 5.3.3 Load and Resistance Factor Design
- 5.3.4 Structural Reliability
- 5.3.5 Load Combinations [Go to Page]
- In-Place Load Combinations
- Module Transport Load Combinations
- Module Lifting Load Combinations
- Fabrication and Construction Load Combinations
- 5.3.6 Development of Load Criteria on Projects
- 5.4 Structural Design [Go to Page]
- 5.4.1 Structural Modeling and Analysis [Go to Page]
- Self-Propelled Modular Transporter Modeling
- Truck Transportation Modeling
- Water Transportation Modeling
- Center of Gravity Envelope Impact on Modeling
- Deflection Restrictions on Modeling
- Horizontal Displacements
- 5.4.2 Structural Members and Connections
- 5.4.3 General Design Criteria
- 5.4.4 DNV-ST-N001 Design Criteria
- 5.5 Fatigue Design [Go to Page]
- 5.5.1 Methodology
- 5.6 Other Considerations
- References
- Appendix 5A. Survey Data of Truck Transportation Design Loads
- Appendix 5B. Example of Transverse Wind with Truck Transportation Loads
- Reference
- Chapter 6: Module Yard Fabrication and Assembly [Go to Page]
- 6.1 Introduction
- 6.2 Modularizations, Prefabrication, and Packaged Equipment
- 6.3 Module Assembly and Erection
- 6.4 Module Fabrication Tolerances
- 6.5 Module Miscellaneous Supports
- 6.6 Module Weighing
- 6.7 Dimensional Control
- 6.8 Compliance Certification and Inspection
- 6.9 Fabrication Interface with Engineering
- References
- Chapter 7: Logistics and Transportation [Go to Page]
- 7.1 Introduction
- 7.2 Interfaces
- 7.3 Procurement and Planning [Go to Page]
- 7.3.1 Roles and Responsibilities
- 7.3.2 Operational Constraints
- 7.4 Water Transportation [Go to Page]
- 7.4.1 Marine Transport Methods [Go to Page]
- Loading and Discharging Methods
- Lift-On/Lift-Off
- Roll-On/Roll-Off
- Float-On/Float-Off
- 7.4.2 Available Ship Types [Go to Page]
- Container Ships
- Multipurpose Ships
- Conventional Heavy-Lift Ships
- Dock-Type Ships
- Semisubmersible Heavy-Lift Ships
- Module Carriers
- Barges
- 7.4.3 Transport Vessel Selection
- 7.4.4 Grillage and Sea Fastenings [Go to Page]
- Grillage
- Load Spreading
- Wooden Cribbing/dunnage
- Sea Fastenings
- Stoppers
- Pipe Bracings
- A-frames
- Bend Plate
- Chains and Wire Lashing
- Uplift Provisions
- Straps or Chains
- Clips
- 7.4.5 Internal Sea Fastenings
- 7.4.6 Loading and Offloading
- 7.4.7 Marine Warranty Surveyor
- 7.4.8 Studies [Go to Page]
- Route-Specific Voyage Study
- Bathymetry Surveys
- 7.4.9 Motion Monitoring
- 7.5 Land Transportation [Go to Page]
- 7.5.1 Self-Propelled Modular Transporter
- 7.5.2 Truck
- 7.5.3 Rail
- 7.5.4 Stability during Land Transportation
- 7.5.5 Route Survey
- 7.5.6 Lashing [Go to Page]
- Lashing for Stability of the Cargo
- Lashing for Internal Forces
- Lashing for Local Stability of the Trailer
- 7.6 Lifting and Setting [Go to Page]
- 7.6.1 Lifting Devices
- 7.6.2 Crane Lifts
- 7.6.3 Self-Propelled Modular Transporter Lifting
- 7.6.4 Buildings
- 7.7 Other Considerations [Go to Page]
- 7.7.1 Air Transportation
- 7.7.2 Weight Management
- 7.7.3 Staging and Transshipment Areas [Go to Page]
- Staging
- Transshipment
- 7.7.4 Material Offloading Facilities
- 7.7.5 Heavy-Haul Roads
- 7.7.6 Permits and Customs Clearance
- References
- Appendix 7A. Sample Tiedown Calculations
- References
- Appendix 7B. Structural Modeling of Self-Propelled Modular Transporter Systems [Go to Page]
- 7B-1 Terms and Definitions
- 7B-2 Support of the Self-Propelled Modular Transporter System [Go to Page]
- 7B-2.1 Self-Propelled Modular Transporter System Deflection Influence on Module Support
- 7B-2.2 Hydraulic Zone Modeling
- 7B-3 Calculations [Go to Page]
- 7B-3.1 Single Beam Approach
- 7B-3.2 Double-Beam Approach
- 7B.3.3 Finite Element Analysis Approaches
- 7B.4 Conclusions
- Appendix 7C. Barge Analysis Sample Calculation
- Chapter 8: Site Construction and Installation [Go to Page]
- 8.1 Introduction
- 8.2 Module Assembly and Site Preparation
- 8.3 Site Preparation
- 8.4 Module Placement Leveling and Alignment
- 8.5 Module Offloading Facility
- 8.6 Quality Assurance Inspections
- 8.7 Construction Execution: Work Package Concept
- Reference
- Chapter 9: Lessons Learned and Case Histories [Go to Page]
- 9.1 Introduction
- 9.2 Revisiting Early Design Assumptions
- 9.3 Fabrication and Lift
- 9.4 Marine Transportation [Go to Page]
- 9.4.1 Impact on Fabrication Yard owing to Conservative Engineering Assumptions
- 9.4.2 Conclusion
- 9.5 Dimensional Control [Go to Page]
- 9.5.1 Pipe Rack Base Datum for Measurements
- 9.5.2 Two-Dimensional Best-Fit Mapping Process
- 9.6 Ductwork Fabrication Tolerances
- 9.7 Licensed Surveyor’s Experiences [Go to Page]
- 9.7.1 Mirrored Drawings
- 9.7.2 Russian Experiences
- 9.7.3 Flange-to-Flange Hookups
- 9.7.4 Sags and Shims
- 9.7.5 Dimensional Control for Large Modules
- 9.7.6 Medium Module Dimensional Control
- 9.7.7 Small Module Dimensional Control
- 9.8 Major Oil and Gas Company Project Case History [Go to Page]
- 9.8.1 Gulf Coast Project Pipe racks
- 9.8.2 Dimensional Control
- 9.8.3 Height Constraints
- 9.8.4 Coating Systems
- 9.8.5 Structural Subassemblies
- 9.8.6 Main Learnings
- 9.9 Crane Selection Case History
- 9.10 Fabrication Yard Lifting Capacities [Go to Page]
- 9.10.1 Governing Criteria for Module Setting
- 9.11 Clash Detection
- 9.12 Schedule Delays
- 9.13 Tons, Long Tons, Short Tons, and Tonnes
- 9.14 Permits
- Reference
- Index [Go to Page]
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