Modularization


Worley is a world leader in the design of modular industrial facilities.
Our modular experience encompasses some of the worlds most hostile andremote locations including the arctic regions of Alaska, Canada andRussia, the dense forests of Colombia, Saudi Arabian deserts, and theremote Australian coastline. Worley has provided innovative andfirst-of-a-kind modular solutions to solve the unique challengesassociated with our customers’ projects in remote locations and harshenvironments.
Our modularization experience began in 1961 with asingle skid-mounted, 10 tonne-perday sulphur recovery plant; the firstof many designed and built as “package” plants for customers throughoutthe world. We followed this with the modular design for a 22,000barrels per day (BPD) grassroots refinery in Alaska, beginning our longinvolvement with North Slope modular facilities which continues today.
Sincethese early days on the North Slope, Worley has expanded itsmodular capabilities to include the design and installation offacilities for upstream oil and gas processing, downstream refining,mining and minerals processing, and chemical industries in over 30countries.
Worley combines its offshore design capabilitywith its onshore Very Large Module (VLM) expertise to optimize modulesize and density. This approach results in smaller, more economicalmodule footprints, and in some cases, increased logistics benefits.Worley also combines its proven EPCM track record and extremeenvironments and remote locations experience with its specialistin-house skills to provide customers with cost effective, innovativemodular solutions.
45+ years continuous modular experience
Modular projects delivered in 30+ countries

Capability Overview

Working in Harsh and Remote Environments
Worley 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
Worley 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 Worley, brings together the diverse range of skill sets in
this early value adding design phase.
Planning and Logistics Management
Over the past 45 years Worley 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, Worley’ 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 Worley 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. Worley 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, Worley 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
Worley 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.
Worley 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 Worley
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
Aspioneers of technology for oil and gas facilities on Alaska’s NorthSlope since the 1960s, Worley has a depth of knowledge of arcticenvironments unrivaled in the modular design industry.
Worleyhas been continuously engaged in the delivery of frontier arcticprograms for over 40 years and has pioneered many innovative solutionsthat have delivered project cost benefits in remote and hostileenvironments. Arctic-based innovations for oil and gas projects haveincluded extensive use of modularization, construction of icecauseways, 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
Coldweather projects demand our expertise to design and build costefficient and safe facilities in remote locations with minimalinfrastructure, a scarcity of skilled labor, and long logistics chains.Through our experience in arctic climates, Worley has developedspecialized logistical management and construction techniques forarctic climates which can be applied to applications all over the worldwhere harsh climates and resource constraints limit the amount of workthat can be effectively accomplished at remote constructions sites.
60+ major arctic oil and gas development projects undertaken
960+ modules on the Alaskan North Slope

Logistics and Installation
Typicaloverall schedule improvements of around 25% can be achieved by adaptingthe logistics management to suit a modular-build philosophy. The uniquechallenges presented by the parallel fabrication of multiple modules,remote locations and limited weather windows are managed byWorley through implementation of logistics management techniquesbased on vast modular experience.
Worley uses linked designand procurement processes to ensure that the arrival of material onsite is synchronized with the modular build method from the earliestconceptual stages of the project. Our logistical management processesalso address the additional challenges associated with maximizedparallel fabrication and procurement economies of scale that do notexist with a traditionally sequenced stick build methodology.
Worleyhas a wealth of experience on remote sites where the allowable annualconstruction season is as brief as ten weeks. Whether dealing with thechallenges of ice bound ports and permafrost in Alaska and over tenmetre tide swings or cyclonic weather and eight metre tides on theNorth-West coast of Australia, the module installation process requiresmeticulous planning if the value expected from a modular approach is tobe realized. Installation planning begins with the initial site surveysconducted during the feasibility stage of the project. Remote sites,with a narrow weather window typically require this early constructionwork to be undertaken over more than one season. For this reasonWorley carries out the installation engineering early in thedesign process (when the modular designs may not yet be finalized). Thechallenge facing the installation engineers is to balance the need fora robust design of the installation facilities whilst minimizingpreinvested CAPEX and limiting the environmental impact.
Functional testing 105% complete at sail away
1st ice road move of very large modules