Modular Plant Design Approaches

We recently completed 88 modular units at 1888 in Oakland, which is now permanent shelter for the homeless, being run by HCEB. We’ve certainly had our ups and downs on modular projects in the past, so I wanted to share a few of the critical things we’ve learned from them. To start, modular construction can offer time savings that equal dollars (and most agree that if savings are to be achieved, this is where it happens) but it requires careful planning upfront to avoid costly delays later. - Early Coordination is Critical Cost savings come from speed resulting in reduced carrying costs relies on backend efficiency, not upfront expenses. Expect higher early costs for design and coordination to prevent site issues. - Keep it Simple This may be generally true, but particularly so with modular design. More corners (in plan or section) increase costs. - Define Key Connection Points MEP, structural tie-ins, exterior skin, and roof must align. Carefully consider these connections to avoid expensive rework. - Establish a Responsibility Matrix Clearly define who handles factory vs. site work (MEP connections, finishes, structural tie-ins). Avoid scope gaps between factory, GC, and set contractor. - Plan for Storage and Logistics Timing is never perfect—modules may need storage before installation. Ensure proper staging, crane access, and transport coordination in advance. - Quality Assurance Beyond State Inspections State inspections confirm code compliance, not necessarily construction quality. Implement independent QA checks at factories and site for alignment, waterproofing, and tolerances. - Protect Set Units from Weather Modules are exposed between placement and final enclosure. Plan for temporary protection—tarps, shrink wrap, or other covers—in case of unexpected or inclement weather. Final Thought Modular can be fast and save cost —but only if planned right. Upfront work prevents delays, misalignment, and costly fixes. If you made it this far you must be a true modular nerd (like me). What challenges have you faced with modular projects? Photos by Bénédicte Lassalle

Modularisation in #GreenHydrogen Projects Whether you’re building a 10 MW pilot or a 500 MW commercial plant, the question is no longer which #electrolyser? but how modular? India’s developers & EPCs are now moving towards factory-built, pre-tested #modularelectrolysers & balance-of-plant (#BOP) systems-because modularity saves time, reduces risk & accelerates the journey from drawing board to first #hydrogen What Modularisation Means Instead of building the full plant on-site, modularisation shifts 60–80% of construction, integration & testing to the factory #Electrolyserstacks, #powerelectronics, #cooling, #gastreatment, #waterpurification & #controlsystems are mounted on skids or containers-fully wired, piped & tested before shipment At site, these modules are simply plugged in, interconnected & commissioned, often producing hydrogen within 2–3 weeks, compared to 3–4 months for traditional builds 7 Factors to Get It Right 1 Define the Modular Boundary Decide early whether modules include just stacks+power systems or full BOP (#compressors, #dryers, #cooling). Clarity upfront avoids integration rework 2 Interface Standardisation Adopt uniform piping, electrical & communication interfaces (OPC-UA/Modbus). The magic is in repeatability-every skid identical, every connection pre-engineered 3 Factory Acceptance Testing (#FAT) FAT is the biggest risk reducer-validating performance, safety interlocks, leaks & control logic before modules leave the factory. Well-run FATs cut commissioning time by 40–50% 4 Safety & Certification Explosion-proof electricals, leak detection, ventilation, purging & isolation systems. Factory testing ensures every module meets standards before shipment 5 Logistics & Installation Modules designed within transport limits (20/40 ft containers or skids up to 40 tonnes) simplify mobilization, even to remote sites. Minimal on-site welding & scaffolding 6 O&M & Scalability Each module operates semi-autonomously, simplifying maintenance. Future expansion? Just add identical skids-plug, test & integrate. Ideal for phased projects up to GW scale 7 Digital Integration Each module should carry its own PLC & sensors, linked to a supervisory #SCADA. This allows real-time performance monitoring, predictive maintenance & future digital-twin integration Modular vs. On-site-The Cost Story While modular systems can add 3–5% higher factory fabrication cost, they typically deliver: 10–15% lower total installed cost (TIC) due to reduced site labour, rework & schedule savings 30–40% faster commissioning, saving months of interest during construction (IDC) Up to 50% reduction in site man-hours, reducing safety exposure & supervision costs Earlier revenue by 2–3 months, critical in large-scale green hydrogen projects where every week saved matters financially A small upfront premium buys predictability, replicability & scale-key ingredients in the global hydrogen race #sanjeevsharmagh2

💧 Ceramic membranes + offsite modular construction = a smarter future for water treatment 💧 Following last week's White Paper and considering Stephen Slessor's comments, it's clear to me the UK water industry is under increasing pressure to deliver assets that are more resilient, more sustainable, and more cost-effective over their whole life. There are two approaches proving to be powerful when combined successfully for drinking water treatment: ceramic membranes & offsite modular construction. Ceramic membranes are gaining real momentum because they solve many of the challenges associated with go-to traditional polymeric systems: ✅ Exceptional durability and extended design life (20+ years) ✅ High resistance to chemicals (disinfection/CIP, etc), temperature, and abrasion ✅ Much-improved fouling performance and stable flux ✅ Lower whole-life costs through reduced capex including replacement and infrequent downtime In short, ceramics deliver high performance with genuine long-term value. However, its important to note that the technology deployment alone is not sufficient: asset delivery is also critically important for success. That’s where offsite modular construction acts as a #disruptor: ✅ Shortened programme, alongside more consistent build quality ✅ Reduced onsite disruption and safety risk ✅ Lower carbon footprint ✅ Greater cost certainty When ceramic membranes are combined with factory-built modularity, we create plants that are not only better performing, but quicker, safer, and more sustainable to deliver. A great RSE project example is Bonnycraig WTW, Scottish Water's first ceramic membrane modular water treatment works, see link: https://lnkd.in/edWRmgt8 The plant was: ✅ Fully designed, assembled, and tested offsite ✅ Delivered using transportable treatment units (17No TTUs) ✅ Faster to build, lower in carbon, and more predictable in cost ✅ A major milestone for ceramic membrane adoption in the UK This project shows how ceramic technology and modular construction work hand-in-hand: ceramics provide robustness and process reliability, while modularisation provides speed, quality, and delivery certainty. Supporting this is RSE’s m-CTU® (modular Ceramic Treatment Unit) platform: a productised, repeatable ceramic membrane solution that: ✅Standardises design and performance ✅Reduces engineering and programme risk ✅Speeds up deployment ✅Improves cost and carbon predictability ✅Scales easily for different treatment capacities (in MLD) Instead of reinventing every plant, m-CTU® allows clients to benefit from a proven, optimised solution that can be rapidly configured to meet their needs. The combination of: 🟦 Ceramic membrane performance 🟦 Offsite modular build efficiency 🟦 Product-based delivery through products like the m-CTU® Will help the industry to reach tangible outcomes, which is what we really need to meet our ambitious targets.

Green #Ammonia #NH3 Production at Small-scale. Technological Status and Perspectives for Modular Production Systems Deutsche Gesellschaft für Internationale Zusammenarbeit GmbH International Power-to-X Hub International Climate Initiative Federal Ministry for Economic Affairs and Energy Philip Miltrup Birgit Scheppat Decentralised Green Ammonia: Unlocking Local, Sustainable Production This study analyses large and small-scale production and explores how the challenges of the latter can be turned into advantages. As the world transitions to low-carbon energy, green ammonia emerges as a key player—not only as a CO₂-free energy carrier but also as a sustainable feedstock for fertilizers and industrial applications. The study highlights how small-scale, decentralised ammonia production could transform local energy and agricultural systems. Here are four key insights from the study: 1. Small-scale production is not just “downsized” large-scale plants Unlike traditional ammonia facilities, which rely on centralised fossil-based hydrogen and continuous operation, modular systems use renewable-powered electrolysis for H₂ generation. Small-scale production is therefore not just a ‘downsized’ version of large-scale plants – it requires distinct solutions in engineering, infrastructure, operation, maintenance, and staffing. These plants are designed for flexibility, rapid response to fluctuating electricity supply, and low-maintenance operation in remote or off-grid locations. 2. Innovative process adaptations enable efficiency at lower scales Miniaturised Haber-Bosch processes face challenges such as heat loss, high compression energy, and limited load flexibility. Sorption-assisted separation enables operation at lower temperatures and pressures, reduces compression energy, improves efficiency, and at the same time enhances flexibility for intermittent renewable power. 3. Infrastructure for small-scale ammonia is modular, containerised, and automated. Small-scale ammonia plants shift the infrastructure and operational paradigm: instead of complex heat recovery networks, cryogenic air separation, and large on-site staff, they rely on compact PSA/membrane N₂ units, containerised water treatment, high automation, and remote monitoring. This makes them deployable in remote or weak-grid locations. 4. Decentralised ammonia supports local applications and energy independence On-site ammonia can be directly converted into liquid fertilizers for precision agriculture, serve as a local energy carrier, or be used in small industrial processes. This reduces dependence on long supply chains, enhances regional resilience, and enables new sustainable business models in agriculture and industry.

Design products, process, plants and infrastructure are shifting from projects to products.     I see one move that cuts through disconnected people, processes and data. Productize your design work. Treat repeatable scope as configurable modules with defined interfaces, a single source of truth, and clear change rules. Do that, and collaboration stops being heroics, interoperability pain eases, and re-use beats re-invention.     The market signals are hard to ignore. Modular programs have shown 20–50% faster timelines. Capital projects still overshoot budgets by about 79% and slip by months or years. Around 41% of the US construction workforce is expected to retire by 2031, while buildings account for 39% of energy-related emissions and modular methods can cut site waste by 70–90%. Cloud-based collaboration and digital twins are closing the loop between design, fabrication and assembly so teams work from one living model, not stale documents.     What does this look like in practice for E&U? Build a standard module catalog for common plant systems and site packages. Define interface contracts so teams can work in parallel without constant meetings. Keep one connected model as the system of record, with lightweight change control that ties requirements, design, and field feedback. Start with one asset class, prove cycle time and quality, then scale.