16 MARCH 2015 ◗ pharmpro.com
MODULAR CONSTRUCTION TECHNOLOGIES
Modular Processes and
Systems
Delivering speed to market, quality and cost savings
The dynamic nature and globalization of the phar- maceutical market has driven industry engineer- ing, construction and commissioning practitioners to new levels of creativity -- the pursuit of speed to market combined with constant pressure to
reduce overall project costs and schedules, as well as to
mitigate an unlimited range of risks while still maintaining
overall quality. Modularization of process and facility systems or complete facilities have proven to be a lean
project delivery technique that aids in the achievement of these goals.
Originally applied to describe process skids,
“modular” was a connotation of a complete facility,
organized in shipping container sized units, built
at a remote location, transported to the owner’s
address, and reassembled on site. The modules
consist of structural frames fit-out with architectural
elements. Mechanical, electrical and plumbing
(MEP) systems and process equipment are already
integrated, commissioned, and at times, IQ. This
approach offers many benefits in the appropriate
context as a rapid response to areas where construction
techniques for cGMP facilities are not available. However,
it does not fit the bill for most of today’s construction projects, such as those that consist of expansions, renovations,
and upgrades to existing plants. For these projects, facility
owners can take advantage of a customized modular
project delivery approach to reduce the overall project
schedule, increase quality with minimal disruption to site
operations, and gain potential cost benefits.
Modular project delivery (MPD) offers several significant
major benefits, including: enhanced quality control that
is achievable in shop fabrication versus field fabrication;
reduced waste; reduced impact on current operations; and
simplified site logistics. Transferring labor hours away from
the owner’s site can: reduce cost, as design and fabrication
can be performed at a lower labor cost venue; reduce
pressure on facility infrastructure, such as parking; reduce
disruption to the owner’s operations; and reduce numerous risks, such as the risk of accidents and injuries on the
owner’s site.
PLANNING AND EXECUTION
Today, lean project delivery is applied by most project
teams from the development of a concept for new and
renovated facilities. Project teams are immediately considering modularization options for the project to ensure
that subsequent phases accommodate modularization
objectives. The process that is typically employed today is
depicted in the following diagram (Figure 1).
During project conceptualization, project teams analyze
a broad array of options based on the associated impact
on cost and schedule. The facility design can be modified
to take advantage of the selected decisions to achieve
the benefits of modularization without the costs and
disadvantages of a full-blown shipping container module
solution. Options include: prefabricated process and utility
equipment, such as skid-mounted clean-in-place or reheat
equipment; pre-piped and pre-wired air-handling units
(AHUs); modular penthouses complete with air handlers,
chillers, and MCCs; large “super-skids” that can be broken
down for shipment and reassembled quickly in the field;
and modular wall systems and modular pipe racks for
HVAC piping and ductwork, plumbing, process piping,
electrical and controls.
In some instances, when full-plant deliveries via shipping containers are appropriate, the owner should be
aware of the limitations and impacts. Increases in engineering costs and committing to a set floor plan and
equipment list at an early stage of the project are just two
of the major considerations when deciding to execute the
entire project utilizing shipping container style modular
◗ By John Gilroy, P.E., Lean Certified
Figure 1
John Gilroy
