FEED Engineering for Modular Green Ammonia Plant by Pan Gulf Technologies Limited
Introduction
As the world is steadily moving towards hydrogen economy, in the growing pursuit of sustainable energy, green ammonia plants are redefining efficiency and scalability.
This case study highlights how Pan Gulf Technologies Limited executed a Front-End Engineering Design (FEED) exercise for a modular green ammonia plant, integrating process, piping, and structural design to deliver a fully functional model ahead of schedule.
About the Project:
Generally, ammonia plants are site built. Our client, a renowned technology licensor in the ammonia sector, this time they envisioned developing a green ammonia plant in a modular configuration — where all equipment, piping, cabling, and instrumentation would be pre-fitted and assembled within structural modules. These modules would later be transported and installed on-site, resulting in a fully operational ammonia facility with minimal on-site construction.
The client entrusted Pan Gulf Technologies Limited with the complete FEED modularisation assignment, providing the initial process inputs and design data.
Project Scope:
Pan Gulf Technologies Limited was responsible for:
• Reviewing all basic engineering inputs for modular plant design.
• Preparing preliminary process and equipment datasheets.
• Selecting reference equipment based on in-house knowledge.
• Executing 3D modular plant modeling for piping, equipment, and instrumentation.
• Conducting constructability and transportability reviews.
• Implementing collaboration using BIM 360 for seamless coordination
Challenges Faced:
The project presented multiple challenges, including:
• Tight deadlines for the FEED review with the client’s end-customer.
• Complex modular configuration involving prefabrication of equipment, piping, instrumentation and cabling.
• Compliance with transportation norms in the target country for module sizing.
• Coordinating between multiple engineering teams across time zones.
Solutions Delivered by Pan Gulf Technologies Limited:
• Rapid Team Mobilization – The project team was ramped up within a week, comprising process engineers and experienced 3D modelers.
• Collaborative Modeling Approach – Process and piping teams worked in parallel, ensuring smooth data flow and real-time model progression.
• Optimized Modular Design – Module dimensions were adjusted to comply with road transport limitations while maintaining constructability.
• Constructability Reviews – Joint sessions with the client’s fabrication and construction teams refined the model for ease of assembly and installation.
• Integrated BIM 360 Workflow – The use of Autodesk BIM 360 enhanced multi-disciplinary collaboration, version control, and remote review efficiency.
Results Achieved:
FEED model delivered ahead of schedule
• Improved constructability and fabrication convenience through design optimization
• Enhanced client satisfaction with proactive engagement and transparent communication
• Full visualization of modular plant assembly enabling downstream EPC execution planning
Through innovation, collaboration, and thorough knowledge of Plant 3D software, Pan Gulf Technologies Limited successfully completed the modularisation of a Green Ammonia Plant at FEED level, setting new benchmarks in modular engineering design. Delivering one day ahead of schedule, this project exemplifies our commitment to client success, engineering excellence, and sustainable plant design.
At Pan Gulf Technologies Limited — customer success is a way of life.
By Kapil Kale ( Vice President – Plant Engineering )
“Learn more about Pan Gulf Technologies Limited Plant Engineering Services”