2016 Best Practices Award Winner (Construction Performance)
Fluor Canada – Shell Quest Project (Modularization Innovation)
Fluor developed an innovative approach, “3rd Gen Modular ExecutionSM” (3rd Gen), to modularization – reversing the traditional design method by having module strategy drive the layoutof facilities. The Shell Quest carbon capture and storage project was the first to fully implement the 3rd Gen approach. Project “silos” were eliminated and vendor data was required much earlier than in traditional projects. Where previously 20% of electrical/instrumentation and 60% of steel was modularized, use of 3rd Gen enabled 50% and 95%, respectively, to be modularized.
The team made critical decisions early-on and reduced the plot plan by 20%, thus meeting area constraints. Shifting labor hours from the field to more productive module fabrication facilities reduced the number of Fluor craft personnel on site from 1,000 to around 450 at peak – reducing craft density and exposure hours while improving worker productivity and safety. Additionally, materials quantities were reduced while costs were reduced versus initial project estimates.