Modularization in Gas Processing Facilities



By Hamad Essa Aldossary

Kingdom of Saudi Arabia


The escalating demand for natural gas has intensified the focus on construction-optimizing methodologies, with project management emerging as a pivotal concept. Drawing inspiration from the theory of Scientific Management, which emphasizes efficiency and systematic approaches, the study investigates the application of these principles in modular construction. The case study of Jafurah Gas Plant Project exemplifies this approach. This research underscores the importance of merging project management principles and Scientific Management theory to enhance efficiency in modular construction.

Key words:      Modular Construction, Scientific Management, Jafurah Gas Plant Project, Natural Gas


Due to increased population growth, the demand for energy, particularly clean energy is at an all-time high. The increasing demand for energy has led to a proliferation of LNG liquefaction plant projects around the world. Liquefied natural gas (LNG) emerges as a pivotal factor in this scenario. Gas processing facilities are constructed in the world to tap into various gas production companies around the world; however, stakeholders invariably seek safe and effective solutions to cut costs and alleviate schedule delays. Offshore and onshore gas plants are challenging to construct on a tight project schedule, and this has necessitated the incorporation of modular projects. Modularization is a new method of construction that has revolutionized the way construction is carried out. To put it in simple terms, think of the change that would take place if there was no road traffic on your way to work; your travel time will be less. This is basically the modularization technique in the world of construction. In a broad definition, modularization is a construction technique where all components of a module are pre-assembled in an offsite location and then transported as one complete product to the process area. In this method, structural steel, equipment, piping, electrical, and instrumentation work are executed in distinct modules, which are then transported to the site for installation. Modularization, hence, emerges as a capable strategy of controlling costs, mitigating project schedule risk, and enhancing overall safety and quality performance (Castorani et al., 2018). The method can add many advantages to the project such as ability of parallel construction activities between site and modular yard, increase of manpower and equipment to maximize productivity, better quality assurance and reduces safety risks. While modularization poses heightened logistical concerns for transportation and materials delivery, early stakeholder alignment, detailed planning, and comprehensive coordination mitigate these challenges. Despite its effectiveness, many contractors are still struggling to successfully implement it in their projects. This study supports contractors to understand the modularization technique in terms of best practice implementation and overcoming its challenges, and how far it aligns with project management approaches of cost cutting and project schedule optimization.

Research Question and Hypothesis

The research question guiding this study is: “To what extent does the application of modularization enhance efficiency and cost cutting outcomes in the gas processing facilities? By exploring this question, this research aims at highlighting how the systematic application modularization in gas processing facilities enhances the efficiency, quality, and cost-effectiveness of a gas facility project that aligns with the principles of Scientific Management. It is proven that by adhering to these principles, modular construction processes will demonstrate shorter assembly times, reduced costs, higher quality control, and improved overall project outcomes. The paper examines Jafurah Gas Plant Project located in the Eastern Region of Saudi Arabia as a case study to answer the research question.


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How to cite this paper: Aldossary, H. E. (2024). Modularization in Gas Processing Facilities; PM World Journal, Vol. XIII, Issue III, March. Available online at https://pmworldlibrary.net/wp-content/uploads/2024/03/pmwj139-Mar2024-Aldossary-Modularization-in-gas-praocessing-facilities.pdf

About the Author

Hamad Essa Aldossary

Saudi Arabia


Hamad E. Aldossary holds a bachelor’s degree in mechanical engineering and Master’s degree in Business Administration. His master’s thesis was about hygienic production technologies and the appropriate management strategy in the manufacturing industry. He has eight years of experience in project management working on projects of different sizes. He is currently a Project Engineer at Saudi Aramco to execute one of the ambitious company’s mega projects (Jafurah Gas Plant). His focus as a project engineer is to implement the modularization concept successfully in the project. He is interested in developing the concept of project management to increase the efficiency of executing projects from feed phase to operations and start-up phases. He can be contacted at hamad.e.aldossary@gmail.com.