Modularization




WorleyParsons is a world leader in the design of modular industrial facilities.
Our modular experience encompasses some of the worlds most hostile and remote locations including the arctic regions of Alaska, Canada and Russia, the dense forests of Colombia, Saudi Arabian deserts, and the remote Australian coastline. WorleyParsons has provided innovative and first-of-a-kind modular solutions to solve the unique challenges associated with our customers’ projects in remote locations and harsh environments.
Our modularization experience began in 1961 with a single skid-mounted, 10 tonne-perday sulphur recovery plant; the first of many designed and built as “package” plants for customers throughout the world. We followed this with the modular design for a 22,000 barrels per day (BPD) grassroots refinery in Alaska, beginning our long involvement with North Slope modular facilities which continues today.
Since these early days on the North Slope, WorleyParsons has expanded its modular capabilities to include the design and installation of facilities for upstream oil and gas processing, downstream refining, mining and minerals processing, and chemical industries in over 30 countries.
WorleyParsons combines its offshore design capability with its onshore Very Large Module (VLM) expertise to optimize module size and density. This approach results in smaller, more economical module footprints, and in some cases, increased logistics benefits. WorleyParsons also combines its proven EPCM track record and extreme environments and remote locations experience with its specialist in-house skills to provide customers with cost effective, innovative modular solutions.
45+ years continuous modular experience
Modular projects delivered in 30+ countries

Capability Overview

Working in Harsh and Remote Environments
WorleyParsons has experience working in some of the most hostile and remote areas
on the planet. Our experience spans arctic conditions in Alaska, Canada and Russia,
through to the unique challenges presented by the desert settings of Saudi Arabia and
Australia. Our long history in South East Asia and more recent expansion into West
Africa and South America, has also provided us with valuable experience in tropical
environments
Constructability in Conceptual Design Phase
WorleyParsons provides the core skill set of constructability at the earliest possible
point in the development of a modular project. This enables the core parameters of
maximum transportable mass, dimensions and Centre of Gravity (COG) position to be
considered with the optimal partitioning of the plant and process. Select, the specialist
front-end division of WorleyParsons, brings together the diverse range of skill sets in
this early value adding design phase.
Planning and Logistics Management
Over the past 45 years WorleyParsons has amassed a wealth of experience in
managing logistical complexities posed by world-scale international developments in
remote and harsh locales. In any project, highly localized or project-specific conditions
will often determine the optimum logistics arrangements to ensure the development and
ongoing operation of an efficient and effective supply chain. With 105 offices in across
34 countries, WorleyParsons’ local workforce can be relied upon to assist in clearing
the local logistics hurdles.
Offshore Topsides Design Experience
The offshore oil and gas industry has always worked within a space-constrained
modular environment since its beginning. As a leading global provider of design
services to the offshore industry WorleyParsons can bring this expertise to land-based
plant design. For example, offshore volume-to-weight densities can be applied in an
onshore context, allowing customers to realize the full potential of a modular execution
strategy.
Module Offloading Design
The site selection and design of coastal module offloading facilities has a significant
bearing on modularization concept development. The Module Offloading Facility
(MOF) and associated haulage road infrastructure is a considerable investment that
brings the trade-offs of maximizing module size whilst minimizing the pre-investment
in the coastal infrastructure into sharp focus. WorleyParsons has dedicated marine
coastal structure experts to designs harbors, MOF wharfs, breakwaters, and haulage
roads and undertake associated oceanographic studies which determine the seasonal
operability levels of the coastal facilities.
Schedule Compression and Cost Reduction
Whilst acting in an EPCM role, WorleyParsons can manage the additional challenges
of modular fabrication interfaces whilst delivering customers the schedule compression
and associated cost reduction benefits. By re-ordering its engineering workflow
WorleyParsons ensures schedule protection, aligning engineering delivery with the
module fabrication and shipping sequence, procurement schedules of long lead items
and the build methodology of fabricators.
Safety in Design
Maintaining a safe working environment and ensuring that human factors engineering
is applied to all aspects of the plant, is a key focus area for a modular design project.
WorleyParsons layout and safety engineers and our embedded Safety in Design
philosophy ensures that the design is focused on personnel, asset and environmental
protection from the initial conceptual development through to on-site commissioning.
Safety in Design is realized through activities such as 3D modeling of escape paths,
modeling to decrease blast pressures and QRA assessments.
Risk Identification and Management
The risks faced by a project employing a modular execution strategy differ from those
employing a traditional stick-build methodology. The Select division of WorleyParsons
is a specialist provider of risk assessment services to a diverse customer base. Our
Select team draws on the diverse skill sets of our global organization to provide
strategic advice and risk analysis services including:
• Qualitative and quantitative risk assessment
• Risk management strategy development
• Independent project assessment
• Peer reviews and benchmarking



Arctic Modular Solutions
As pioneers of technology for oil and gas facilities on Alaska’s North Slope since the 1960s, WorleyParsons has a depth of knowledge of arctic environments unrivaled in the modular design industry.
WorleyParsons has been continuously engaged in the delivery of frontier arctic programs for over 40 years and has pioneered many innovative solutions that have delivered project cost benefits in remote and hostile environments. Arctic-based innovations for oil and gas projects have included extensive use of modularization, construction of ice causeways, separation and high pressure gas re-injection,
waterflood, and miscible injection. The major oil and gas field development projects undertaken for arctic conditions include:
• 43 in Alaskan arctic since 1960s
• 10 in Russian arctic since 1994
• 12 in Canadian arctic since 1951
Cold weather projects demand our expertise to design and build cost efficient and safe facilities in remote locations with minimal infrastructure, a scarcity of skilled labor, and long logistics chains. Through our experience in arctic climates, WorleyParsons has developed specialized logistical management and construction techniques for arctic climates which can be applied to applications all over the world where harsh climates and resource constraints limit the amount of work that can be effectively accomplished at remote constructions sites.
60+ major arctic oil and gas development projects undertaken
960+ modules on the Alaskan North Slope

Project: Miscible Injectant Expansion (MIX), USA
Customer: BP Exploration Alaska
Phases:
The MIX project increased the quantity of miscible injectant produced by the
Central Gas Facility at Prudhoe Bay while increasing the field gas off-take by
600 MMSCFD and natural gas liquids production by 4,000 barrels per day.
The project scope included the addition of a new 38,000 horsepower gas turbinedriven
booster compressor, upgrading eight existing gas injection compressors, four
existing booster compressors, two existing refrigeration compressors, and replacing
two existing miscible injectant compressors. The module involved weighed 2,300
tonnes.
Project: Alpine Development Project, USA
Customer: ConocoPhillips Alaska
Phases:
The development of the Alpine oil field in the Colville River Delta, west of the Prudhoe
Bay field, was to yield 429 million barrels of high-grade crude oil at a peak rate of
80,000 BPD. WorleyParsons carried out conceptualization and management of
the fabrication and construction of all grassroot processing facilities and supporting
infrastructure that conditioned the crude oil prior to transportation down to the Trans-
Alaskan Pipeline System. The project involved 17 modules and skids weighing
11,000 tonnes with major ocean ice road movement of all modules. WorleyParsons
also completed the conceptualization through detail design on subsequent facility
expansions and debottlenecking to increase throughput from 80,000 to 140,000 BPD.
Project: Sakhalin 1 – Onshore Production Facility, Russia
Customer: Exxon Neftgas Limited (ENL)
Phases:
WorleyParsons undertook the conceptual and detailed engineering (engineering and
procurement via joint venture) for the $2.5 billion onshore oil and gas processing facility
located eight kilometers west of the beach at Chavyo, Sakhalin Island. Modularization
was extensively used in the concept development of these facilities to help mitigate the
risks associated with the extreme conditions, lack of local infrastructure and the remote
nature of the site. Module designs included 21 process and utility modules, eight prefabricated
air coolers, twelve pre-assembled pipe racks and two fully dressed flare
stacks. WorleyParsons also managed the movement of the 35,000 tonnes of modules
in two sealifts from South Korea.
Project: Sunrise Oil Sands Development, Canada
Customer: Husky Energy
Phases:
WorleyParsons developed a super module strategy for the multi billion dollar Sunrise
Oilsands SAG D Facility. The strategy called for the development of 2,500 tonne plant
process modules that would be transported from Asia to a site near Fort McMurray
Alberta, Canada to offset cost and schedule constraints imposed by the local market.
The logistics of utilizing the Arctic Route through the Beauport Sea were very
challenging. WorleyParsons team followed our proven super module work processes
and provided the added benefit of reducing the process facility foot print by 50%.
These innovations resulted in an approximate 25% savings on the project TIC.
























Coastal Modular Solutions
Coastal construction enables the module size to be maximized with the associated benefit of minimizing on-site labor and exposure of the labor force to harsh environments.
The use of a Module Offloading Facility (MOF) wharf enables the module size to be increased to well over 5,000 tonnes where the plant is located near an existing waterway. WorleyParsons’ Very Large Modules (VLMs) initiative was conceived with the objective of increasing the weight of modules installed on the North Slope, Alaska. This work resulted in the setting of new benchmarks of modularization within this remote region. The use of VLMs clearly brings the advantage of maximizing the use of offsite fabrication, thereby minimizing site-based man-hours and increasing the extent of yard based pre-commissioning. Larger modules will also result in a lower steel-toequipment ratio. The on-site benefits of larger modules are well recognized in the area of minimizing site based man-hours. Yet it is the additional benefits - the decreased risk to personnel safety; limiting the chance of project schedule slippage due to adverse weather conditions; and reducing exposure to labor unrest - that can provide the surety that customers require to gain sanction for a project in a remote location. With the proven capability of lower cost fabricators within China, South Korea, South East Asia and the Middle East, combined with the ability of these contractors to accommodate total module tonnages in excess of 100,000 tonnes, there is renewed interest across a wide range of industries in VLM solutions to the complex processing sector. Pushing the upper boundaries of module size and density WorleyParsons’ single integrated offshore topsides designs are approaching 25,000 tonnes. Whilst these topside are destined for offshore installation via a float-over installation technique, WorleyParsons continues to seek cross-industry transfer of ideas to maximise benefits gained within the offshore design arena for use on onshore modular projects.
5000 tonne modules delivered to Alaska’s North Slope
Single integrated modules weighting 25,000 tonne designed for the offshore industry

Project: LNG Phase V, Australia
Customer: Woodside Energy Limited
Phases:
Built in Indonesia and offloaded on the North West Shelf, Australia, LNG Phase
V is the world’s first modular LNG plant.
The US$2 billon LNG expansion of Woodside’s Burrup peninsular LNG facility pioneered modularization for LNG plants and will add 4.2 million tonnes per year of LNG production and pioneered modularization for LNG plants. WorleyParsons, via a joint venture, is executing this expansion project under an EPCM contract. It was the first large scale liquefaction plant in the world to be designed and built in preassembled modules and racks. The key components consist of more than 70 modules constructed in Batam, Indonesia, The largest module was 36 m high and weighed
more than 2,000 tonnes.
Project: Alkylation Project , USA
Customer: Chevron
Phases:
Recognized as a “Pacesetter Project” for Chevron, this project saw all new process units modularized into 95 truckable modules and skids with heaviest at 100 tonnes.
The modules were fabricated in Louisiana and shipped through the Panama Canal to California for offloading and installation in Chevron’s California refinery. Project: GHX-2 Gas Plant Expansion , USA
Customer: BP/ARCO Alaska
Phases:
The project increased the annual average field gas off-take capacity by over 40% to 7.5 bscfd. The facilities were constructed in the Gulf Coast (Louisiana) and barged to
the North Slope of Alaska resulting in 29 VLMs being sea-lifted in a two year period.The primary modules were four frame 6 tandem/compressor modules; two 270 MBPD
gathering center modules; and a 65 MBPD NGL low temperature separation module. The seven modules weighing 5,000 tonnes were 100% complete at the assembly
site and achieved 105% completion before sail which established new industry benchmarks. These modules were moved up to 15 kilometers over undulating gravel roads.
Project: Endicott Enhanced Oil Recovery Project, USA
Customer: BP Exploration Inc
Phases:
Making extensive use of modularization the Endicott EOR project consisted of
processing, compressing and distribution of a miscible injectant (MI) fluid to the Main
Production Island (MPI) and the Satellite Drilling Island (SDI) for injection into wells
serving the Endicott formation. The MI fluid is injected into selected wells to increase
oil production from the field through a water alternating gas (WAG) EOR program.
















Logistics and Installation
Typical overall schedule improvements of around 25% can be achieved by adapting the logistics management to suit a modular-build philosophy. The unique challenges presented by the parallel fabrication of multiple modules, remote locations and limited weather windows are managed by WorleyParsons through implementation of logistics management techniques based on vast modular experience.
WorleyParsons uses linked design and procurement processes to ensure that the arrival of material on site is synchronized with the modular build method from the earliest conceptual stages of the project. Our logistical management processes also address the additional challenges associated with maximized parallel fabrication and procurement economies of scale that do not exist with a traditionally sequenced stick build methodology.
WorleyParsons has a wealth of experience on remote sites where the allowable annual construction season is as brief as ten weeks. Whether dealing with the challenges of ice bound ports and permafrost in Alaska and over ten metre tide swings or cyclonic weather and eight metre tides on the North-West coast of Australia, the module installation process requires meticulous planning if the value expected from a modular approach is to be realized. Installation planning begins with the initial site surveys conducted during the feasibility stage of the project. Remote sites, with a narrow weather window typically require this early construction work to be undertaken over more than one season. For this reason WorleyParsons carries out the installation engineering early in the design process (when the modular designs may not yet be finalized). The challenge facing the installation engineers is to balance the need for a robust design of the installation facilities whilst minimizing preinvested CAPEX and limiting the environmental impact.
Functional testing 105% complete at sail away
1st ice road move of very large modules

Project: Parsons Lake North Pad Detail. Canada
Customer: ConocoPhillips
Phases:
The key challenges for this 245 mmscfd gas and 3,900 bbls/d liquid plant for
the Mackenzie Gas Pipeline were the construction and logistics in the remote
northern environment.
Larger modules to be used for the main processing areas fabricated in Vancouver,
shipped by ocean barge to Tuktoyaktuk for staging and moved to site via a direct
overland ice road. The infrastructure modules, packages and other truckable freight
loads were transported by road to Hay River, by river barge to Tuktoyaktuk for staging,
then over the Mackenzie River Highway and a winter ice road to the site. Significant
cost and schedule needs are associated with provision of the gravel pad for the facility
and the construction of a road and airstrip to support the facility.
Project: Olympic Dam, Australia
Customer: BHP Billiton
Phases:
WorleyParsons has developed a modular strategy for this multi billion dollar copper
processing facility some 600km inland from Adelaide in South Australia. The strategy
called for the development of 3,500 tonne plant process modules that would be
transported from Asia to the Olympic Dam site in South Australia. The WorleyParsons
team followed our proven Super Module work processes and provided the added
benefit of Asia procurement.
Project: Bacton Gas Terminal Sulphur Recovery Units, United Kingdom
Customer: Phillips Petroleum
Phases:
Three sulfur recovery units, in completely modularized form, were designed and
fabricated by WorleyParsons for the Phillips Petroleum Bacton Gas Terminal. The 40
tonne units were transported to site on multi-wheel trailers and set adjacent to each
other such that the access ways connected. The units were four meters wide, nine
meters long and five meters high. On-site completion of the facility was accomplished
in ten weeks.

Project: Red Dog Mine, USA
Customer: Cominco Alaska Inc.
Phases:
WorleyParsons provided EPCM services for the 6,000-std Zinc-Lead Concentrator and
Auxiliary Facilities in Kotzebue, Alaska - the largest lead zinc mine in the world. The
project involved extensive modular design including 11 modules/skids (12,000 tonnes
total shipment) which were shipped 96 kilometers inland up 6% grades through an
arctic port. The logistics were very difficult due to climatic conditions resulting in short
operating windows.













Modular Innovations
WorleyParsons has a history of introducing innovation to modular design, project methods and procedures, labor relations, logistics and execution strategy. The continuing development of economically marginal developments and remote sites with harsh environmental conditions demands innovation.  WorleyParsons works in collaboration with our customers to explore new methods and ideas, without which many succeeding projects would never have been implemented. Innovative concepts and technologies developed include:
• Truckable skids, removing field development from the schedule constraint of narrow sealift windows
• Jumbo modules up to 5,000 tonnes
• Functional check-out in the USA Lower 48 (L48) taking functional testing and L48 completion to 105%
• Designs for transition zone crossings, armor protection, operational analysis of sacrificial gravel structures as a result of our work related to ice dynamics and wave run up
• Worldwide assessment of construction sites that led to dramatic savings in erection cost at a new fabrication site
• Negotiated the first Project Labor Agreement with the International Building Trades that coordinated all construction operations in the Northwest and Alaska North Slope
WorleyParsons continually challenges the norm in its approach to modular design and construction. Our modular design teams consist of some of the industry’s most experienced managers and engineers to realize the maximum benefit of modularization for our customers’ projects.
1st large-scale modular LNG plant
1st modularized arctic mining facility

Project: Endicott Project, USA
Customer: BP
Phases:
The Endicott innovation program reduced the project budget by more than 50%.
The role of innovation was fundamental to the Endicott project success story. At
mobilization the preliminary engineering team were presented with an estimated project budget value of US$3 billion. Working in tandem with our customer to break from the paradigms of the past - and with a one-year period to perform preliminary design optimizations studies - the installed cost for the Endicott Facility was reduced to US$1.4 billion.
Project: Hammerfest Project Mono Ethylene Glycol Facilities, Norway
Customer: Statoil
Phases:
ColtWorleyParsons were responsible for engineering, procurement and construction
supervision services for the design and development of a modular glycol reclaiming
plant for the Melkøya Island LNG project near Hammerfest, Norway. The three main
process modules, each weighing 550 to 750 tonnes, were fabricated in the Netherlands and transported by ocean-going barge and overland using multiwheelers and gantry crane system for final setting in place at the Northern Norway site. The innovations employed resulted in several million dollars of cost savings despite the significant design constraints imposed as a result of this being one of the last modular contracts awarded. The project was completed on schedule and 10% below budget.

Project: Long Haul Projects, USA
Customer: Various
Phases:
In order to relieve inland field developments from the constraint of sealift, truckable
modules were developed. WorleyParsons designed the first arctic drillsite skids. These consisted of 40-tonne truckable generic designs that were shipped via the 1,350 kilometer TAPS haul road. Shown (right) is the trucking of a 100 tonne module to the North Slope in Alaska.
Project: Humber Refining Diesel Hydrodesulfurizer, United Kingdom
Customer: ConocPhillips
Phases:
As part of a major upgrade program, WorleyParsons executed an EPC contract for
this 45,000 bpsd diesel hydrodesulfurizer (DHDS) unit for virgin distillate streams.
The majority of the plant was pre-fabricated as modules and vendor assembled units
There was a total of seven modules/skids the largest weighing 580 tonnes, with a total
shipment weight of 3,800 tonnes.













Select
Select is the specialist front-end division of WorleyParsons. The experts who make up Select recognize that making the right decisions during the initial stages of a project is essential to maximizing ultimate business outcomes. Select is an integral part of WorleyParsons’ global project delivery capability. Select provides pre-FEED services to asset owners, operators and investors by utilizing WorleyParsons’ extensive real-world experience in total project delivery, asset operation and industry best practice. These services enable customers to be confident that the critical decisions made in the conceptual stages of a project will satisfy their ultimate business objectives.
For modular projects, Select assembles the multidisciplinary teams required to provide the necessary detail from concept through to the investment decision gate. This can include developing the underlying execution strategy, undertaking the screening level plant design, assessing the modular versus stickbuild tradeoffs, determining the optimal plant location and identifying the supporting infrastructure development needed. These teams include plant design and infrastructure engineers, geotechnical and marine consultants, construction management, procurement and supply chain logistics staff, planning engineers and cost estimators. Working in tandem with WorleyParsons’
specialist environmental group, the team also provides expertise in planning, permitting, facility siting, transportation corridor selection, environmental management, water supply and waste management. In presenting the overall project financial analysis and execution schedule, Select accesses the global database of major capital projects within WorleyParsons, enabling customers to support their strategic investment decisions with accurate and reliable development planning data
.
13 international Select operating centers:
• Abu Dhabi
• Arcadia
• Bangkok
• Brisbane
• Calgary
• Houston
• Jakarta
• Kuala Lumpur
• London
• Melbourne
• Perth
• Reading
• Singapore

Project: Remote Gas Plant Development, Oman
Customer: Petroleum Development Oman (PDO)

Phases:
Select undertook a detailed process and front-end engineering design study for
a gas treatment plant in Oman.
To reduce the field skilled labor requirements, an extensive study was carried out to
maximize modular construction. Modules for the inlet facilities equipment, gas/gas
exchangers, high/low temperature separators and turbo-expanders were developed
within this study. The remoteness of the site and the difficult access roads to it
precluded the use of large size modules; it was therefore necessary to limit overall
sizes to 4 meters wide, 4 meters high, 9 meters long and a maximum weight of 35
tonnes.