Appendix I LNG Salof Companies Modularized Gas Liquefaction Plants A modularized approach to save costs, while increasing productivity, quality, safety, and schedule.
Table of Contents 1 Introduction .......................................................................................................................................... 2 2 Conceptual Layout and Feasibility ........................................................................................................ 3 3 Manufacturing Process ......................................................................................................................... 5 3.1 3.1.1 Skid Steel ..........
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 CO2 Liquefaction Facilities installed worldwide, since 1977.
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.
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 just‐in‐time (JIT) approach that helps to streamline the process and improve the project schedule. 3.1 Mechanical Manufacturing 3.1.
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. Additional parts are inventoried and stored awaiting fabrication.
3.1.3 Piping The piping manufacturing 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.
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.
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 safety 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.
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.
3.2.2 Control Panel Quality Assurance Once the control panel assembly is complete 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 specification and a final checkout report is created.
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.
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 confirmation 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.
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.
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.
6 Field Installation The manufacturing process described 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.
Figure 20: Qualified Crane and rigging teams offload process modules into position Figure 21: Piping aligned during the setup process
7 Conclusion The manufacturing and assembly process above provides a fast‐track and expedited manufacturing method for the entire facility, which improves the overall project schedule by substantially limiting the amount of field installation work required to commission the facility. In addition, most of the required quality assurance and functionality tests have been performed before the process modules arrive at the customer location, which allows for additional schedule compression.
Figure 24: Shop set up Figure 25: On site assembled.
