GE CO2 Quick start guide

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SalofCompanies
ModularizedGasLiquefactionPlants
Amodularizedapproachtosavecosts,whileincreasingproductivity,quality,
safety,andschedule.
LNG

SalofCompanies
LNG
Appendix I
TableofContents
1 Introduction..........................................................................................................................................2
2 ConceptualLayoutandFeasibility........................................................................................................3
3 ManufacturingProcess.........................................................................................................................5
3.1 MechanicalManufacturing...........................................................................................................5
3.1.1 SkidSteel...............................................................................................................................5
3.1.2 MaterialProcurement...........................................................................................................6
3.1.3 Piping.....................................................................................................................................7
3.1.4 ModuleSetup........................................................................................................................8
3.1.5 PressureTesting....................................................................................................................9
3.1.6 PipingInsulation....................................................................................................................9
3.2 ElectricalManufacturing.............................................................................................................10
3.2.1 ControlPanelAssembly......................................................................................................10
3.2.2 ControlPanelQualityAssurance.........................................................................................11
3.2.3 InstrumentationInstallation...............................................................................................11
3.2.4 ElectricalandControlWiring..............................................................................................12
3.3 ModulePaintingandCoating......................................................................................................14
4 QualityAssurance...............................................................................................................................15
4.1 PlantSetUp.................................................................................................................................15
4.2 Electrical
Testing.........................................................................................................................15
4.2.1 ModuleI/OandControlTesting.........................................................................................16
4.2.2 ModuleElectricalTesting....................................................................................................16
5 PreparationforTransport...................................................................................................................17
6 FieldInstallation..................................................................................................................................18
7 Conclusion...........................................................................................................................................20

1 Introduction
Salofisaworldleaderincryogenicplantdesignandfabricationwithaproventrackrecordofsupplying
fullyintegratedmodularizedplantsthatexceedcustomerrequirementsandmeetallrequiredlocal,
federal,andinternationalcodes.SalofhasdeliveredseveralLNGplantsandover110CO
2
Liquefaction
Facilitiesinstalledworldwide,since1977.WearelocatedinNewBraunfels,Texas,justafewminutes
outsideofSanAntonio,ona9acreplotthatisownedbySalof,whichcontainsoffices,300,000FT
2
of
enclosedmanufacturingspace,andadditionalspaceforoutdoorconstructionandfullplantassemblyas
required.
Ourphilosophyistobeontheleadingedgeoftechnologywithregardstoourplantdesign,
manufacturing,andmanagementtechniques.
OurdesignsstartusingtheindustrystandardAspentechHysys®modeling.Ourprocess
design
teamwillrunmultipleiterationstoinsureourdesignwillmeettheprojectrequirementsunder
differingscenarios,includingoffdesigncasesandturndownscenarios.
“SmartP&ID’s”areourstandard,takingconventionalP&ID’sastepfurtherbyintegratingall
taggeditemsintoaprojectdatabase. BentleySystemsAutoplantP&ID®
allowsthisattribute
datatobepassedontotheclientaftertheprojectiscompletedforprocesssafetyandasset
managementsystems.
3Dmodelingallowspremanufacturingwalkthrough andallowsmaintenanceandsafetydesign
considerationstobeintegratedintothedesign.Ourdesignersmodelallcomponentsof
the
planttoprovideourclientswithacomprehensivepremanufacturedviewoftheirplant.
CustomizedPLC/OIandDCSsolutionsaretailoredtoclientsneedswithourinhouseteam.FREE
technicalsupportviaremoteinternetconnectionwithcustomizedsecurityprotocolasclient
requiredisstandard.
Commissioning,startup,
andoperatortrainingusingourinhousepersonnel.Customized
documentationintegratingcurrentclientsystemsandoperatingproceduresisalsoavailable.
Warranty,parts,andonsitetechnicalserviceisprovidedviaoursistercompanyRiverCity
IndustrialRefrigerationCompany,Inc.(RCIR).
Salofhastheexpertiseandexperience,combinedwithcapabilityand
capacitytoundertakeanddeliver
thisprojectsuccessfully.Ourcurrentclientlistincludesallofthemajorindustrialgassuppliersandcan
attesttoourvalueaddedapproach.32yearsinthei ndustrygivesSalofaproventrackrecordof
MeetingCustomerRequirementswithSuperiorSolutions”.
2 ConceptualLayoutandFeasibility
Theprojectmanagersandsupervisorsworkcloselywiththe3Ddesignandengineeringteamsto
developalayoutthatiscompact, practical,andwillminimizefieldinstallationwork.Duringthe
preliminarydesignphasemajorequipmentislocatedontheskidbasesandthemainprocesslinesare
interconnected.
Thisinitial
designisthenreviewedbytheentireprojectteam,whichincludesrepresentativesfromthe
engineeringdepartment,themechanicalmanufacturingdepartment,theelectricalmanufacturing
department,andthecommissioningandservicedepartments.Thismultilevelandmultidiscipline
approachconfirmsthatthedesignis practicaltomanufacturewhilemaintainingtheeaseofoperation
and
serviceabilityofaplugandplaydesign.Ourclientsaregiventheopportunitytoparticipate inthis
processtotheextentthattheychose.
Figure1:Thecompleteplantdesignbeginswiththeconceptuallayout
Figure2:Eachmoduleisdetailedandreviewedforoperability.
3 ManufacturingProcess
Themanufacturinganddesignteamsworktogethercloselyandperformfrequentreviewsofthelayout
andmanufacturingprocesstoensurethatnodetailsaremissedoroverlooked.Manufacturingprintsare
issuedtotheworkshopusingajus tintime(JIT)approachthathelpstostreamlinetheprocessand
improvetheproject
schedule.
3.1 MechanicalManufacturing
3.1.1 SkidSteel
Afterthelayouthasbeenapprovedbythedesignteamand thecustomer,the3Dandstructural
designersbeginworkimmediatelyontheequipmentstructuralsupportandmodulebases.
Whenthestructuraldesignhasbeencompleted,includingdesignverification,themanufacturing
drawingsareissuedtotheworkshop
forconstructionviathecontrolleddocume nt system.
Thisdesign/manufacturingapproachallowsworktobeginontheskidsteelbasewhilethedetailed
pipingdesignworkcontinues.
Figure3:Skidsteelisthefirstphaseofthemodularmanufacturingprocess
3.1.2 MaterialProcurement
Thepipingandinstrumentationdrawings documentallindividualitemswithauniquetagnumber.
ThesetagnumberarestoredinourEnterpriseResourcePlanning(ERP)databasethatisusedfor
procurement,scheduling,andemployeeresourcingactivities.Operatinginajustintimeenvironment
themajorequipmentisreceived
andsetdirectlyontothemodulesteel.A dditionalpartsare
inventoriedandstoredawaitingfabrication.

Figure4:Majorequipmentsetinplace.
 
Figure5:Equipmentinventoriedandreadyforuse.
3.1.3 Piping
Thepipingma nufacturingprocessbeginsbyemployingqualifiedwelderswhoarerequiredtopassa
stringent6GweldingtestasoutlinedbyASME.Thereareseveraltechniquesemployedduringthepiping
assemblyprocessincludingshieldedmetalarcwelding(SMAW)andgastungstenarcwelding(GTAW).
Allweldsarevisually
inspectedandxraytestsareperformedasrequiredbyASMEstandards.
Qualityiscontrolledandensuredthroughtheuseofweldmapsthatcorrelatequalitytestswithagiven
weldersidentificationnumber/stamp.
Whenpracticalthepipingassembliesarefabricatedontheworkshopfloorbeforetheyareinsertedinto
the
module.Thesepipingassembliesarethenfitupandweldedinplaceasrequired.Thistechnique
increasesefficiencybyeliminatingmanytimeconsumingpositionweldsthatcancompromise
ergonomics,quality,andsafety.
InstallationofElectricaldevices,instrumentation,andpumpsandmotorsbeginswhenthepiping
installationreaches50%completion.
Figure
6:Pipingspoolsinstalledandreadyforpressuretesting.
3.1.4 ModuleSetup
Duringthemanufacturingprocessthemodulesaresetupandpositionedastheywillbeinthefield.At
thistimethemodulesareleveled,usingasitelevel,andinterconnectingpipeand/orpiperacksare
connectedandtestfit.
Ininstanceswherethereareheightconstraintsat
ourmanufacturingfacilitydummiesand/ormockups
aremanufacturedtoensurethattheupperandlowermoduleswillfittogetherasdesigned.
Figure7:Multipleprocessmodules are setupinthemanufacturingspacebeforepipingbegins.
Figure8:Equipment"dum mies"arecre atedwhererequiredtointerconnectequipment.
3.1.5 PressureTesting
Beforethepressuretestisallowedtobeginthemanufacturingmanagerand/orsupervisorwillensure
thattheSalofcompaniesHSEproceduresarefollowedandthatallteammembersinvolvedinthe
procedurehavebeenbriefed,toensureemployeesa fetyatalltimesduring thepressuretest. 
Themanufacturing
managerand/orHSEcoordinatorwillsupervisethepressuretesttoensurethatit
conformstotheSalofcompanies’pressuretestingprocedureand requirements.
Duringthepreparationstagesofthepressuretesttherequiredinstrumentationissetupandits
calibrationisconfirmed.Nextthefinalpipingassemblyisinspectedto
ensurethatproperbolting and
gasketsareinstalled.
Thepressuretestisexecutedinstagesthatallowanysystemleakstobeidentifiedandcorrectedbefore
thepressureisincreasedtothenextstage.Thisincremental approachtopressuretestingincreases
qualityandsafetywhileprovidingaleakfreeprocessmodule.
3.1.6 PipingInsulation
Withthepressuretestandanyotherrequirednondestructivetesting(NDT)completetheprocesspiping
isreadytobeinsulated.Theinsulationthicknessisselectedbasedontheprocessdesign,thermal
requirements,andcustomerspecifications.Thedesignthicknessoftheinsulationisverifiedusing
softwaretoolssuch
as3Eplus.
Theinsulationandprotectivejacketingisinstalledbyprofessionalsusingpremoldedpipingmaterials,
blockmaterial,andwoolproductsasdirectedbytheengineeringteam.
Figure9:Calciumsilicateblockinsulationisinstalledonvessels.Preformedpipinginsulationismitercut
tocreatecustomfit.
3.2 ElectricalManufacturing
3.2.1 ControlPanelAssembly
AllcontrolpanelsaredesignedandmanufacturedtocomplywithNFPA,NEC,UL,andstateandlocal
regulations.
Beforeconstructionofthecontrolpanelsbeginsthepanelshopmanagerreceivesacontrolledsetof
drawings,asprescribedbytheSalofCompaniesISOprocess,fromthedesignteam
thatincludesa
completebillofmaterials,layout,andwiringdiagrams,andanyspecificcustomerrequirements.
Thecontrolpanelassemblyprocessstartswithatechnicianmountingtherequiredequipmentontothe
enclosuresubpanel,orbackingpanel,whichincludesPLChardware, powersupplies,wireduct,and
wiringterminals.Thesubpanelis
removedfromtheenclosuretofacilitateincreasedaccess,ergonomics,
andqualityoftheequipmentinstallation.
Thepaneldevicesarethenwiredandinterconnectedpertheprojectdrawingsandeachindividualwire
islabeledforeasyidentification.
Customidentificationplacardsarecreatedforeachpanelthat containspertinentinformationaboutthe
design
andspecificationofagivenpanel.Additionalplacardsareinstalledontheexteriorofthepanelto
includecustomerlogosandsafetywarnings,asrequired.
Theenclosuredoorsareoutfittedwithanyrequiredbuttons,switches,ordisplaysbeforethesubpanelis
reinstalledintheenclosure.
Thesubpanelisthenreinstalled
intotheenclosureandsecured.Agroundingwireisconnectedfromthe
hingeddoorontheenclosuretothesubpanelforelectricalsafety.Finallythewiringdiagramsusedto
constructandassemblethepanelareinsertedinthedoorpocketbeforethepanelcontinuesontothe
electricalqualityassurancedepartment.
Figure10:MainPLCcontrolpanel.
3.2.2 ControlPanelQualityAssurance
Oncethecontrolpanelassemblyiscom pletethepanelistransportedtothequalityassurance
department.Thequalityassurancepersonnelensurethatthepanelconstructionconformstothe
specifieddrawingset,allrelevantcustomer,and regulatorystandards.
Additionallyallscrewedwiringconnectionswithinthepanelare
torquedtothevendorspe cification and
afinalcheckoutreportiscreated.Thequality assurancepersonnelassignaULlabeltothepanelbefore
itistransportedtothemechanicalmanufacturi ngareatobemountedontheprocessmodule.
3.2.3 InstrumentationInstallation
Beforetheinstallationoftheinstrumentationbeginsour
projectteamworkstogethertoidentifythe
installationlocationandmountingtypeforeachrequireddevice,includingtransmitters,switches,etc.
Carefulattentionispaidtothelayoutoftheseinstrumentstoensurethattheycanbeeasilyviewedby
theplantoperationsstafffromtheedgeoftheprocessmodule.This
evaluationdictatestheplacement
oftransmitters,includingdecisionsaboutwhetherornotadeviceisdirectlymountedtotheprocess
streamorremotemountedonasuitableinstrumentstand.
Figure11:Remotemountedinstrumentationracksallowoperationsstafftoea sily viewthedevicefrom
theskidedge.
3.2.4 ElectricalandControlWiring
Theelectricalcableandconduit/cabletrayroutingispredeterminedbythedesignteambefore
installationbegins.Theinstallationteamdeterminesthesizeofconduitand/orcabletraybasedonthe
numberofconductorsthateachconduit/cabletrayisrequiredtocontain.
Dissimilarvoltagesaresegregatedto
preventcrosstalkand/orinterference.Shieldedcableisusedto
carryanalogsignalandeachmulticon ductor cableisidentifiedwithapermanentsleevedwirelabel.
Allconduitandcabletrayissecuredtothemodule withbracketsandclampsasrequired.
Ininstanceswhereconduitisuse d,theconduithubs,
pullfittings,andjunctionsareofaheavyduty
constructionandequippedwithgasketstopreventmoistureingr ess.Liquidtightflexibleconduitisused
toconnecttheenddevicetothemai nconduittrunk.Thisflexibleconnectionallowsthedevicetobe
easilyfieldservicedanddampenstheeffectofvibration,
whileprovidingaprotectivesheathtothe
devicewiring.
Figure12:Modulecabletrayandwiringfrompaneltodevice.
InsituationswhereSalofisprovidingamotorcontrolcenter(MCC)and/orcontrolroombuildingthe
electricalandinstrumentcableconnectionsusedtointerconnectthesebuildingstotheprocessmodules
aretestfitatourfactory.Thisincludesthe
installationofcabletrayandconduitsupportsbetweenthe
processmodulesandthecontrolbuildingsaswellasprefabricatedelectricalpenetrationsintothe
building.Thisadditionallayerofelectricalpreparationexpeditesthefieldsetupandcommissioning
processwhilecontrollingqualitybyallowingwiringissuestobeidentifiedandcorrectedbefore
the
processmodulesaredeliveredtothecustomerlocation.
Figure13:Fieldwiringconnectionsaretestfittothecontrolbuildingstoincreasequalityandefficiency.
Figure14:Alabyrinthofcabletraykeepstheinstallationcleanandtheplantrunningsmooth.
3.3 ModulePaintingandCoating
Afterthemechanicalandelectricalmanufacturing workiscompletetheprocessmodulesareprepared
forpaint.Thepaintandcoatingsthatareselectedforagivenprojectaredesignedtoprovideadequate
corrosionprotectionandaresuitableforoutdooruse.
Figure15:Theprocessmoduleis"tapedoff"andready
forpaint.
4 QualityAssurance
4.1 PlantSetUp
Inordertoconfirmtheplantwillgotogetherquicklyandeasilyinthefieldweareabletoassemblethe
plantinouryardasifitwastheprojectsite.Thisallowsclientconf irmationofentireplantassembly,as
wellas100%factoryacceptancetestingoftheplantcontrol
system.
Figure16:Transporting,rigging,andaligningmoduletomoduleconnections.
4.2 ElectricalTesting
Electricalqualityassuranceisdividedintotwocategories.Thefirstoftheseisthecontrolsystemfactory
acceptancetest(FAT),whilethesecondistheelectri calpowerqualityassuranceprogram.
Thesetwostepsareoftenexecutedinparalleltoimprovetheprojectschedule.
4.2.1 ModuleI/OandControlTesting
Factoryacceptancetesting(FAT)isperformedoneachproject’scontrolsystembeforeitisdeliveredto
thecustomer.Thisrigoroustestingprocedureinvolvesdevicelevelwiringintegritychecks(pointto
point)andcompletecontrolsystemfunctionalityverification.
ThepointtopointI/Ocheckverifiesthat
eachdeviceiswiredinaccordancewithregulatorycodes,
Salof'sownqualitypolicy,andterminatedtothecorrectlocationwithinthecontrolpanel.
Thecontrolsystemfunctionalitytestisasimulationbasedtestwherethecompletecontrolsystemis
interconnectedanditsfunctionalityverifiedbycomputersimulation.Anyitemsthat
areidentifiedtobe
noncompliantarecorrectedduringthistestingperiod.
4.2.2 ModuleElectricalTesting
Totheextentpossible,allprocessmoduleelectricaldevices are poweredupbeforethepackageis
deliveredtothecustomerlocation.Thisportionofthequalityassurancemethodwillverifythatthere
havebeennopremature
devicefailures,shortcircuits,orinstallationerrors.
Ininstanceswhereelectricaldevicescannotbepoweredforverificationtheyaretestedusin ga
megohmetertoverifythattheinternalresistanceiswithinthemanufacturer’stolerance.

Figure17:Controlroomcompletionandcontrolsystemtesting.
5 PreparationforTransport
Beforetheprocessmodulesaretransportedtheelectricalandinstrumentationcablesthatareusedto
interconnecttheprocessmodulestotheMCC/controlbuildingaredisconnected,clearlyidentified,and
safelystoredbeforeshipping.Thecabletraysusedtointerconnect theprocessskidsandthesebuildings
areremoved,labeled,andpackagedforloose
shipment.
Theprocessmodulesarethencratedandinmanyinstancesshrinkwrappedbeforetransport.This
preservationstepensuresthattherewillbenodamagetotheskidsbeforetheyarriveatthecustomer
location.
Itemswhicharedesignatedtobeshippedseparatelyfromtheprocessskidsareloadedinto
appropriate
shippingcontainersandsecured.
Finallythecompletedmoduleand/orshippingcontainersareloadedupfortransportationtothe
customerlocation.
Figure18:Processmodulecratedforinternationalshipping.Shrinkwrappedprocessmodulescanbe
seeninthebackground
6 FieldInstallation
Themanufacturingprocessdescribe dabovehasbeenperfectedwiththe successfulexecutionofmore
than130projectstocreatehighqualityandeasytooperateplugandplayfacilities.Thissection
describesthefieldinstallationandsetupprocessforagiven facility.
Astheprocessmodulesaredeliveredtothecustomer
locationtheyareoffloadedfromthetransport
vehiclesandinstalledonconcreteslabsand/orpilings.Nexttheprocesspipingisflangedtogetherwith
thepiperackand/oradjacentprocessmodulebeforetheprocessmodulesarefinallyanchoredtothe
concrete.
Whiletheprocessmodulesarebeinginterconnectedandsecuredto
theconcrete.Theship looseitems
areunpackedandinstalled.Thisincludesaircoolersandinterconnecti ngcabletrays.
Withthemechanicalporti o nofthefieldinstallationcompleteandallprocesspipingconnectedand
tightenedtheelectricalcablesareconnectedtothecontrolroom/MCCbuilding.
Whentheelectricalconnections,theprocessmodules
arecompletethecommissioningteambeginsthe
finalI/Ocheckout.
Whiletheelectricalteamcompletestheprecommissioningproceduresforthecontrolsystemand
electricaldevicesthemechanicalteamcompletestheleaktesttoensurethatalloftheprocess
connectionsaretight.
WithprecommissioningcompletedtheSalof
commissioningteamworkscloselywiththecustomerto
introduceprocessgastothefacility.
Figure19:Sampleriggingdiagram.
Figure20:QualifiedCraneandriggingteamsoffloadprocessmodulesintoposition
Figure21:Pipingalignedduringthesetupprocess
/