GE CO2 Quick start guide

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SalofCompanies

ModularizedGasLiquefactionPlants

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Amodularizedapproachtosavecosts,whileincreasingproductivity,quality,

safety,andschedule.

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LNG

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SalofCompanies

LNG

Appendix I

TableofContents

1 Introduction..........................................................................................................................................2

2 ConceptualLayoutandFeasibility........................................................................................................3

3 ManufacturingProcess.........................................................................................................................5

3.1 MechanicalManufacturing...........................................................................................................5

3.1.1 SkidSteel...............................................................................................................................5

3.1.2 MaterialProcurement...........................................................................................................6

3.1.3 Piping.....................................................................................................................................7

3.1.4 ModuleSetup........................................................................................................................8

3.1.5 PressureTesting....................................................................................................................9

3.1.6 PipingInsulation....................................................................................................................9

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3.2 ElectricalManufacturing.............................................................................................................10

3.2.1 ControlPanelAssembly......................................................................................................10

3.2.2 ControlPanelQualityAssurance.........................................................................................11

3.2.3 InstrumentationInstallation...............................................................................................11

3.2.4 ElectricalandControlWiring..............................................................................................12

3.3 ModulePaintingandCoating......................................................................................................14

4 QualityAssurance...............................................................................................................................15

4.1 PlantSetUp.................................................................................................................................15

4.2 Electrical

Testing.........................................................................................................................15

4.2.1 ModuleI/OandControlTesting.........................................................................................16

4.2.2 ModuleElectricalTesting....................................................................................................16

5 PreparationforTransport...................................................................................................................17

6 FieldInstallation..................................................................................................................................18

7 Conclusion...........................................................................................................................................20

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1 Introduction

Salofisaworldleaderincryogenicplantdesignandfabricationwithaproventrackrecordofsupplying

fullyintegratedmodularizedplantsthatexceedcustomerrequirementsandmeetallrequiredlocal,

federal,andinternationalcodes.SalofhasdeliveredseveralLNGplantsandover110CO

Liquefaction

Facilitiesinstalledworldwide,since1977.WearelocatedinNewBraunfels,Texas,justafewminutes

outsideofSanAntonio,ona9acreplotthatisownedbySalof,whichcontainsoffices,300,000FT

of

enclosedmanufacturingspace,andadditionalspaceforoutdoorconstructionandfullplantassemblyas

required.

Ourphilosophyistobeontheleadingedgeoftechnologywithregardstoourplantdesign,

manufacturing,andmanagementtechniques.

 OurdesignsstartusingtheindustrystandardAspentechHysys®modeling.Ourprocess

design

teamwillrunmultipleiterationstoinsureourdesignwillmeettheprojectrequirementsunder

differingscenarios,includingoff‐designcasesandturndownscenarios.

 “SmartP&ID’s”areourstandard,takingconventionalP&ID’sastepfurtherbyintegratingall

taggeditemsintoaprojectdatabase. BentleySystemsAutoplantP&ID®

allowsthisattribute

datatobepassedontotheclientaftertheprojectiscompletedforprocesssafetyandasset

managementsystems.

 3Dmodelingallowspre‐manufacturingwalkthrough andallowsmaintenanceandsafetydesign

considerationstobeintegratedintothedesign.Ourdesignersmodelallcomponentsof

the

planttoprovideourclientswithacomprehensivepre‐manufacturedviewoftheirplant.

 CustomizedPLC/OIandDCSsolutionsaretailoredtoclientsneedswithourin‐houseteam.FREE

technicalsupportviaremoteinternetconnectionwithcustomizedsecurityprotocolasclient

requiredisstandard.

 Commissioning,startup,

andoperatortrainingusingourinhousepersonnel.Customized

documentationintegratingcurrentclientsystemsandoperatingproceduresisalsoavailable.

 Warranty,parts,andonsitetechnicalserviceisprovidedviaoursistercompanyRiverCity

IndustrialRefrigerationCompany,Inc.(RCIR).

Salofhastheexpertiseandexperience,combinedwithcapabilityand

capacitytoundertakeanddeliver

thisprojectsuccessfully.Ourcurrentclientlistincludesallofthemajorindustrialgassuppliersandcan

attesttoourvalueaddedapproach.32yearsinthei ndustrygivesSalofaproventrackrecordof

“MeetingCustomerRequirementswithSuperiorSolutions”.

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2 ConceptualLayoutandFeasibility

Theprojectmanagersandsupervisorsworkcloselywiththe3‐Ddesignandengineeringteamsto

developalayoutthatiscompact, practical,andwillminimizefieldinstallationwork.Duringthe

preliminarydesignphasemajorequipmentislocatedontheskidbasesandthemainprocesslinesare

interconnected.

Thisinitial

designisthenreviewedbytheentireprojectteam,whichincludesrepresentativesfromthe

engineeringdepartment,themechanicalmanufacturingdepartment,theelectricalmanufacturing

department,andthecommissioningandservicedepartments.Thismultilevelandmultidiscipline

approachconfirmsthatthedesignis practicaltomanufacturewhilemaintainingtheeaseofoperation

and

serviceabilityofaplug‐and‐playdesign.Ourclientsaregiventheopportunitytoparticipate inthis

processtotheextentthattheychose.

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Figure1:Thecompleteplantdesignbeginswiththeconceptuallayout

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Figure2:Eachmoduleisdetailedandreviewedforoperability.

3 ManufacturingProcess

Themanufacturinganddesignteamsworktogethercloselyandperformfrequentreviewsofthelayout

andmanufacturingprocesstoensurethatnodetailsaremissedoroverlooked.Manufacturingprintsare

issuedtotheworkshopusingajus t‐in‐time(JIT)approachthathelpstostreamlinetheprocessand

improvetheproject

schedule.

3.1 MechanicalManufacturing

3.1.1 SkidSteel

Afterthelayouthasbeenapprovedbythedesignteamand thecustomer,the3‐Dandstructural

designersbeginworkimmediatelyontheequipmentstructuralsupportandmodulebases.

Whenthestructuraldesignhasbeencompleted,includingdesignverification,themanufacturing

drawingsareissuedtotheworkshop

forconstructionviathecontrolleddocume nt system.

Thisdesign/manufacturingapproachallowsworktobeginontheskidsteelbasewhilethedetailed

pipingdesignworkcontinues.

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Figure3:Skidsteelisthefirstphaseofthemodularmanufacturingprocess

3.1.2 MaterialProcurement

Thepipingandinstrumentationdrawings documentallindividualitemswithauniquetagnumber.

ThesetagnumberarestoredinourEnterpriseResourcePlanning(ERP)databasethatisusedfor

procurement,scheduling,andemployeeresourcingactivities.Operatinginajustintimeenvironment

themajorequipmentisreceived

andsetdirectlyontothemodulesteel.A dditionalpartsare

inventoriedandstoredawaitingfabrication.





Figure4:Majorequipmentsetinplace.

  

Figure5:Equipmentinventoriedandreadyforuse.



3.1.3 Piping

Thepipingma nufacturingprocessbeginsbyemployingqualifiedwelderswhoarerequiredtopassa

stringent6GweldingtestasoutlinedbyASME.Thereareseveraltechniquesemployedduringthepiping

assemblyprocessincludingshieldedmetalarcwelding(SMAW)andgastungstenarcwelding(GTAW).

Allweldsarevisually

inspectedandx‐raytestsareperformedasrequiredbyASMEstandards.

Qualityiscontrolledandensuredthroughtheuseofweldmapsthatcorrelatequalitytestswithagiven

weldersidentificationnumber/stamp.

Whenpracticalthepipingassembliesarefabricatedontheworkshopfloorbeforetheyareinsertedinto

the

module.Thesepipingassembliesarethenfitupandweldedinplaceasrequired.Thistechnique

increasesefficiencybyeliminatingmanytime‐consumingpositionweldsthatcancompromise

ergonomics,quality,andsafety.

InstallationofElectricaldevices,instrumentation,andpumpsandmotorsbeginswhenthepiping

installationreaches50%completion.



Figure

6:Pipingspoolsinstalledandreadyforpressuretesting.



3.1.4 ModuleSetup

Duringthemanufacturingprocessthemodulesaresetupandpositionedastheywillbeinthefield.At

thistimethemodulesareleveled,usingasitelevel,andinterconnectingpipeand/orpiperacksare

connectedandtestfit.

Ininstanceswherethereareheightconstraintsat

ourmanufacturingfacilitydummiesand/ormockups

aremanufacturedtoensurethattheupperandlowermoduleswillfittogetherasdesigned.



Figure7:Multipleprocessmodules are setupinthemanufacturingspacebeforepipingbegins.



Figure8:Equipment"dum mies"arecre atedwhererequiredtointerconnectequipment.

3.1.5 PressureTesting

Beforethepressuretestisallowedtobeginthemanufacturingmanagerand/orsupervisorwillensure

thattheSalofcompaniesHSEproceduresarefollowedandthatallteammembersinvolvedinthe

procedurehavebeenbriefed,toensureemployeesa fetyatalltimesduring thepressuretest. 

Themanufacturing

managerand/orHSEcoordinatorwillsupervisethepressuretesttoensurethatit

conformstotheSalofcompanies’pressuretestingprocedureand requirements.

Duringthepreparationstagesofthepressuretesttherequiredinstrumentationissetupandits

calibrationisconfirmed.Nextthefinalpipingassemblyisinspectedto

ensurethatproperbolting and

gasketsareinstalled.

Thepressuretestisexecutedinstagesthatallowanysystemleakstobeidentifiedandcorrectedbefore

thepressureisincreasedtothenextstage.Thisincremental approachtopressuretestingincreases

qualityandsafetywhileprovidingaleakfreeprocessmodule.



3.1.6 PipingInsulation

Withthepressuretestandanyotherrequirednondestructivetesting(NDT)completetheprocesspiping

isreadytobeinsulated.Theinsulationthicknessisselectedbasedontheprocessdesign,thermal

requirements,andcustomerspecifications.Thedesignthicknessoftheinsulationisverifiedusing

softwaretoolssuch

as3Eplus.

Theinsulationandprotectivejacketingisinstalledbyprofessionalsusingpre‐moldedpipingmaterials,

blockmaterial,andwoolproductsasdirectedbytheengineeringteam.



Figure9:Calciumsilicateblockinsulationisinstalledonvessels.Preformedpipinginsulationismitercut

tocreatecustomfit.

3.2 ElectricalManufacturing

3.2.1 ControlPanelAssembly

AllcontrolpanelsaredesignedandmanufacturedtocomplywithNFPA,NEC,UL,andstateandlocal

regulations.

Beforeconstructionofthecontrolpanelsbeginsthepanelshopmanagerreceivesacontrolledsetof

drawings,asprescribedbytheSalofCompaniesISOprocess,fromthedesignteam

thatincludesa

completebillofmaterials,layout,andwiringdiagrams,andanyspecificcustomerrequirements.

Thecontrolpanelassemblyprocessstartswithatechnicianmountingtherequiredequipmentontothe

enclosuresubpanel,orbackingpanel,whichincludesPLChardware, powersupplies,wireduct,and

wiringterminals.Thesubpanelis

removedfromtheenclosuretofacilitateincreasedaccess,ergonomics,

andqualityoftheequipmentinstallation.

Thepaneldevicesarethenwiredandinterconnectedpertheprojectdrawingsandeachindividualwire

islabeledforeasyidentification.

Customidentificationplacardsarecreatedforeachpanelthat containspertinentinformationaboutthe

design

andspecificationofagivenpanel.Additionalplacardsareinstalledontheexteriorofthepanelto

includecustomerlogosandsafetywarnings,asrequired.

Theenclosuredoorsareoutfittedwithanyrequiredbuttons,switches,ordisplaysbeforethesubpanelis

reinstalledintheenclosure.

Thesubpanelisthenreinstalled

intotheenclosureandsecured.Agroundingwireisconnectedfromthe

hingeddoorontheenclosuretothesubpanelforelectricalsafety.Finallythewiringdiagramsusedto

constructandassemblethepanelareinsertedinthedoorpocketbeforethepanelcontinuesontothe

electricalqualityassurancedepartment.



Figure10:MainPLCcontrolpanel.

3.2.2 ControlPanelQualityAssurance

Oncethecontrolpanelassemblyiscom pletethepanelistransportedtothequalityassurance

department.Thequalityassurancepersonnelensurethatthepanelconstructionconformstothe

specifieddrawingset,allrelevantcustomer,and regulatorystandards.

Additionallyallscrewedwiringconnectionswithinthepanelare

torquedtothevendorspe cification and

afinalcheckoutreportiscreated.Thequality assurancepersonnelassignaULlabeltothepanelbefore

itistransportedtothemechanicalmanufacturi ngareatobemountedontheprocessmodule.

3.2.3 InstrumentationInstallation

Beforetheinstallationoftheinstrumentationbeginsour

projectteamworkstogethertoidentifythe

installationlocationandmountingtypeforeachrequireddevice,includingtransmitters,switches,etc.

Carefulattentionispaidtothelayoutoftheseinstrumentstoensurethattheycanbeeasilyviewedby

theplantoperationsstafffromtheedgeoftheprocessmodule.This

evaluationdictatestheplacement

oftransmitters,includingdecisionsaboutwhetherornotadeviceisdirectlymountedtotheprocess

streamorremotemountedonasuitableinstrumentstand.



Figure11:Remotemountedinstrumentationracksallowoperationsstafftoea sily viewthedevicefrom

theskidedge.

3.2.4 ElectricalandControlWiring

Theelectricalcableandconduit/cabletrayroutingispredeterminedbythedesignteambefore

installationbegins.Theinstallationteamdeterminesthesizeofconduitand/orcabletraybasedonthe

numberofconductorsthateachconduit/cabletrayisrequiredtocontain.

Dissimilarvoltagesaresegregatedto

preventcrosstalkand/orinterference.Shieldedcableisusedto

carryanalogsignalandeachmulti‐con ductor cableisidentifiedwithapermanentsleevedwirelabel.

Allconduitandcabletrayissecuredtothemodule withbracketsandclampsasrequired.

Ininstanceswhereconduitisuse d,theconduithubs,

pullfittings,andjunctionsareofaheavyduty

constructionandequippedwithgasketstopreventmoistureingr ess.Liquidtightflexibleconduitisused

toconnecttheenddevicetothemai nconduittrunk.Thisflexibleconnectionallowsthedevicetobe

easilyfieldservicedanddampenstheeffectofvibration,

whileprovidingaprotectivesheathtothe

devicewiring.



Figure12:Modulecabletrayandwiringfrompaneltodevice.

InsituationswhereSalofisprovidingamotorcontrolcenter(MCC)and/orcontrolroombuildingthe

electricalandinstrumentcableconnectionsusedtointerconnectthesebuildingstotheprocessmodules

aretestfitatourfactory.Thisincludesthe

installationofcabletrayandconduitsupportsbetweenthe

processmodulesandthecontrolbuildingsaswellasprefabricatedelectricalpenetrationsintothe

building.Thisadditionallayerofelectricalpreparationexpeditesthefieldsetupandcommissioning

processwhilecontrollingqualitybyallowingwiringissuestobeidentifiedandcorrectedbefore

the

processmodulesaredeliveredtothecustomerlocation.



Figure13:Fieldwiringconnectionsaretestfittothecontrolbuildingstoincreasequalityandefficiency.



Figure14:Alabyrinthofcabletraykeepstheinstallationcleanandtheplantrunningsmooth.

3.3 ModulePaintingandCoating

Afterthemechanicalandelectricalmanufacturing workiscompletetheprocessmodulesareprepared

forpaint.Thepaintandcoatingsthatareselectedforagivenprojectaredesignedtoprovideadequate

corrosionprotectionandaresuitableforoutdooruse.



Figure15:Theprocessmoduleis"tapedoff"andready

forpaint.



4 QualityAssurance

4.1 PlantSetUp

Inordertoconfirmtheplantwillgotogetherquicklyandeasilyinthefieldweareabletoassemblethe

plantinouryardasifitwastheprojectsite.Thisallowsclientconf irmationofentireplantassembly,as

wellas100%factoryacceptancetestingoftheplantcontrol

system.

 



Figure16:Transporting,rigging,andaligningmoduletomoduleconnections.

4.2 ElectricalTesting

Electricalqualityassuranceisdividedintotwocategories.Thefirstoftheseisthecontrolsystemfactory

acceptancetest(FAT),whilethesecondistheelectri calpowerqualityassuranceprogram.

Thesetwostepsareoftenexecutedinparalleltoimprovetheprojectschedule.

4.2.1 ModuleI/OandControlTesting

Factoryacceptancetesting(FAT)isperformedoneachproject’scontrolsystembeforeitisdeliveredto

thecustomer.Thisrigoroustestingprocedureinvolvesdevicelevelwiringintegritychecks(point‐to‐

point)andcompletecontrolsystemfunctionalityverification.

Thepoint‐to‐pointI/Ocheckverifiesthat

eachdeviceiswiredinaccordancewithregulatorycodes,

Salof'sownqualitypolicy,andterminatedtothecorrectlocationwithinthecontrolpanel.

Thecontrolsystemfunctionalitytestisasimulation‐basedtestwherethecompletecontrolsystemis

interconnectedanditsfunctionalityverifiedbycomputersimulation.Anyitemsthat

areidentifiedtobe

noncompliantarecorrectedduringthistestingperiod.

4.2.2 ModuleElectricalTesting

Totheextentpossible,allprocessmoduleelectricaldevices are poweredupbeforethepackageis

deliveredtothecustomerlocation.Thisportionofthequalityassurancemethodwillverifythatthere

havebeennopremature

devicefailures,short‐circuits,orinstallationerrors.

Ininstanceswhereelectricaldevicescannotbepoweredforverificationtheyaretestedusin ga

megohmetertoverifythattheinternalresistanceiswithinthemanufacturer’stolerance.



Figure17:Controlroomcompletionandcontrolsystemtesting.



5 PreparationforTransport

Beforetheprocessmodulesaretransportedtheelectricalandinstrumentationcablesthatareusedto

interconnecttheprocessmodulestotheMCC/controlbuildingaredisconnected,clearlyidentified,and

safelystoredbeforeshipping.Thecabletraysusedtointerconnect theprocessskidsandthesebuildings

areremoved,labeled,andpackagedforloose

shipment.

Theprocessmodulesarethencratedandinmanyinstancesshrink‐wrappedbeforetransport.This

preservationstepensuresthattherewillbenodamagetotheskidsbeforetheyarriveatthecustomer

location.

Itemswhicharedesignatedtobeshippedseparatelyfromtheprocessskidsareloadedinto

appropriate

shippingcontainersandsecured.

Finallythecompletedmoduleand/orshippingcontainersareloadedupfortransportationtothe

customerlocation.



Figure18:Processmodulecratedforinternationalshipping.Shrink‐wrappedprocessmodulescanbe

seeninthebackground

6 FieldInstallation

Themanufacturingprocessdescribe dabovehasbeenperfectedwiththe successfulexecutionofmore

than130projectstocreatehigh‐qualityandeasytooperateplug‐and‐playfacilities.Thissection

describesthefieldinstallationandsetupprocessforagiven facility.

Astheprocessmodulesaredeliveredtothecustomer

locationtheyareoffloadedfromthetransport

vehiclesandinstalledonconcreteslabsand/orpilings.Nexttheprocesspipingisflangedtogetherwith

thepiperackand/oradjacentprocessmodulebeforetheprocessmodulesarefinallyanchoredtothe

concrete.

Whiletheprocessmodulesarebeinginterconnectedandsecuredto

theconcrete.Theship looseitems

areunpackedandinstalled.Thisincludesaircoolersandinterconnecti ngcabletrays.

Withthemechanicalporti o nofthefieldinstallationcompleteandallprocesspipingconnectedand

tightenedtheelectricalcablesareconnectedtothecontrolroom/MCCbuilding.

Whentheelectricalconnections,theprocessmodules

arecompletethecommissioningteambeginsthe

finalI/Ocheckout.

Whiletheelectricalteamcompletesthepre‐commissioningproceduresforthecontrolsystemand

electricaldevicesthemechanicalteamcompletestheleaktesttoensurethatalloftheprocess

connectionsaretight.

Withpre‐commissioningcompletedtheSalof

commissioningteamworkscloselywiththecustomerto

introduceprocessgastothefacility.



Figure19:Sampleriggingdiagram. 



Figure20:QualifiedCraneandriggingteamsoffloadprocessmodulesintoposition



Figure21:Pipingalignedduringthesetupprocess

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