Enhancing Construction Safety And Efficiency In Brownfield Petroleum Refinery Expansions: A Feasibility Study Of Modular Construction In India

Abstract

The petroleum industry in India is undergoing significant expansion, particularly in brownfield refinery projects, which involve expanding existing facilities and / or integrating newly installed facilities with existing ones. Cost overruns and delays in completion are often faced challenges in Indian Projects when being executed in a conventional stick-built approach, coupled with operational disruptions wherever projects involve brownfield expansion. Construction safety is a significant challenge in brownfield refinery expansion projects due to the concurrent execution of multiple activities near operational units that handle hydrocarbon materials at high pressures and temperatures above their ignition points. To address these challenges, modular construction can be adopted as against the conventional stick-built approach. Modular construction is a method where modules are fabricated away from the project site, mainly in the contractor’s yard, and assembled at the site. This study explores the feasibility and effectiveness of modular construction in brownfield petroleum refinery expansion projects in India. It assesses the benefits, challenges, and potential for modular construction to improve project timelines, reduce costs, enhance safety, and improve environmental sustainability. Through a case study analysis, site visits and interviews, and a related literature review, the study identifies key barriers to adoption, such as logistical issues, Engineering errors and modifications, and high initial costs. Additionally, the research compares modular construction with traditional methods regarding time, cost, and construction safety specific to execution in operating petroleum refineries. The study concludes by proposing recommendations for adopting modular construction into future refinery expansion projects in India to the extent possible. The findings target informing industry stakeholders on how modular construction can be leveraged to optimize project performance and contribute to the petroleum sector’s growth by addressing specific challenges concerning construction safety in operating refineries.