Modules in process industry − A life cycle definition

- Modules are unmodifiable and reusable elements during planning and realization of a plant, representing a block of the process block diagram (BD).
- An assembly of two or more modules is regarded as 'modular'.
- In a 'block representation frame' information is collected and stored throughout the whole life cycle from process development on 'laboratory level', over module-based plant design for planning and realizing plants on 'miniplant level' and/or 'production plant level', to 'operation'.
- Process flow diagram (PFD) modules, piping and instrumentation diagrams (P&ID) modules, equipment modules and their characteristics, and 3D layout modules are structured and stored in 'module databases'.
- Computer-aided tools enable selection and configuration of modules from module databases by matching with presettings and process requirements.

The chemical and biochemical industry has to face the challenges of globalization, short product cycle times and volatile markets. Therefore, the lead time of development projects has to be shortened. Modules and module-based plant design are widely discussed to enable shorter time-to-market by reuse of engineering effort and standardization. In this paper general requirements on modules in process engineering and modules for particular applications in the chemical and biochemical industry are reviewed. This includes the impact of modules on the planning process and examples of realized modular equipment concepts. Based on this, a general terminology definition of 'modules' and of specific module types for the process industry is presented, whereas modules on various 'aggregation levels' are accounted. A 'block representation frame' stores information and tracks information fluxes along the whole process and plant life cycle and on different 'realization levels' from laboratory studies over miniplant validation to production plant design and operation.

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