Detailed design, procurement and fabrication are executed in parallel which allows for overall project schedule compression.
During detailed engineering, Koch Modular provides the client with all the information necessary to prepare the jobsite for delivery, obtain permits and streamline the installation process. These items include foundation loads, anchor bolt patterns, piping tie-in coordinates, electrical drawings, PSV calculations and emissions summary, modular lifting plan, shipped loose items, and a comprehensive installation manual.
The 3D piping model allows for a series of model reviews, where the client can take a virtual walk-through of the modules before fabrication begins, helping with the approvals that effect operation, maintenance, and access requirements.
After process equipment is fabricated and inspected, it is all shipped to the module assembly shop along with other procured components such as instrumentation and manual valves. The module assembly shop installs all equipment into structural steel frames. After the equipment is mounted in the steel structures, all point to point process and utility piping is installed. Instruments are wired to remote I/O control panels mounted on the first floor of each module. The modules are complete with ladder or stair tower access, lighting, a process control system (if desired), equipment and piping insulation, safety showers and eye wash stations, a fire suppression system, utility stations and convenience receptacles.
The final activity in this phase is a customer-witnessed final inspection and Factory Acceptance Test (FAT) performed at the module assembly shop.
Stage 4: Shipping and Installation
Modular process systems engineered by Koch Modular are specially designed for transport by road, rail, water, or air, and arrive ready to install. Koch Modular has extensive experience and vendor relationships with freight forwarders to safely and efficiently ship systems of various shapes and sizes to locations worldwide.
Process modules are staged to arrive at the plant in sequential order. Once modules are set on foundations, they are anchored for stability. The remaining installation effort includes installing any shipped-loose items and completing process and utility piping tie-ins, and necessary electrical connections.
Koch Modular provides a lifting plan and comprehensive installation manual to support the installation process. Our customer’s typically use a local Engineering, Procurement and Construction Company to install the Koch Modular modules and to provide the balance of plant scope of supply which includes foundations, utility generation and distribution, storage tanks, pipe racks, motor control center, etc.
Koch Modular engineers are available to provide on-site installation support, as required by our customers.
Stage 5: Commissioning, Start-up, and Performance Test
Once the modules are installed, commissioning and functional testing is performed to insure there are no leaks in the system and everything is in working order. Control valves are cycled, instruments and the control system are checked, and pump operation is verified, just to name a few of the activities performed. Koch Modular supplies a complete checklist of commissioning activities in the installation and operating manual.
Continuing project support is extended to all customers after module shipment to participate in commissioning, start-up, troubleshooting, operator training, or validation.
Koch Modular operating manuals contain all the information needed for successful commissioning, startup, shutdown, and troubleshooting of the modular process system.
- Performance & Design Basis
- Process Operation, Description, and Control Philosophy
- Commissioning: Instrument & Equipment Checkout
- Hydraulic Start-up and Test Procedure
- Process Startup & Shutdown Instructions
- Quality Control & Troubleshooting
- Reference List of Alarms and Interlocks
- Suggested Tuning Constants