The Cryostar Magazine N°2 : pdf file

N°2Autumn 2003Testing times atCRYOSTARBeing at the cuttingedge of equipment testtechnologyCRYOSTAR turbineson the SLEIPNER gasplatformsSuccessful technologicalchallenge turns intoindustry standardCRYOSTAR inclean fuel trialsCRYOSTAR Automation expertiseserving a cleaner environment

Testing times at CryostarFor CRYOSTAR, leadership of the global cryogenic equipment market is synonymouswith being at the cutting edge of equipment test technology. Every product – be itfresh off the assembly line or recently refurbished – is subject to stringent testingbefore delivery. When it comes to its products CRYOSTAR’s ethos is simple: equipmentreliability and guaranteed performance!CRYOSTAR has made majorinvestments in test equipmenttechnology, including a uniqueLN2 test stand, allowingdifferent simulations, and aturbine / compressor test site,complete with data capturefacilities.Now CRYOSTAR customerscan witness-test the equipmentthey have ordered. Here, TheCRYOSTAR magazine reportson two typical witness-tests at itsHesingue facility, in France – one,a series of pumps for Linde, ofGermany, and the other a test of aTP 120 turbine for Air Products,of the United States.Mutual confidence and trustLinde’s pumps test – Over theyears, Klaus Fertig, Linde’sProject Manager, Plant Design,and CRYOSTAR have built astrong, tried and tested, workingrelationship based on mutualconfidence and trust.When it comes to important andtechnically difficult projects,Linde’s representative is thereto witness tests in real time.CRYOSTAR’s engineers deal withany customer query on the spot.Michèle Mendes, CRYOSTAR’sProject Manager, Pumps, has theoverview of the Linde account.She takes Klaus Fertig throughthe testing programme, step-bystep,to ensure CRYOSTAR’spreparations are in line withLinde’s expectations.One of the principles appliedby CRYOSTAR is to rigorouslypost-production test all products.This guarantees every piece ofequipment meets CRYOSTAR’sstringent standards.This also allows CRYOSTAR toprovide the customer with prewitness-test results performedwith liquid nitrogen and originalmotor. Such was the detailprovided by CRYOSTAR on the15 pumps tested post-productionfor Linde’s project in the MiddleEast, that Klaus Fertig was confidentenough to only wish towitness-test two.The two chosen were the mostcritical for the project, a VP 3/310and a VP 2/310. These vertical,multi-stage pumps were developedby CRYOSTAR in the course ofthe 1990’s to face the growingdemand for higher efficiency ofAutumn 2003 3

TESTING TIMES AT CRYOSTARThis allows easy access totest data and quick onwardcommunication by CRYOSTAR’sQuality Assurance Department ofthe Quality Data Book, completewith all certificates and testdocuments.For the TP 120, Air Productswas looking for a high, specificrefrigeration load, namely133.4 kW cold power obtainedwith an 87 per cent overallisentropic efficiency at a flow rateof 9321 Nm3/hour.Air Products’ Colin Thomas, inspectionengineer, was welcomedto witness-test the turbine byCRYOSTAR project managerBrice Wuyam.In line with CRYOSTAR’sequipment guarantee and testingpolicy, the TP 120 had alreadybeen put through its paces andemerged with flying colours.Now it was under the scrutinyof Air Products’ representativeColin Thomas, who first checkedthe piping and instrumentationdiagram.He then ensured the test procedureswere understood, namelythe aerodynamic performance followedby test running three hoursat nominal speed (25 900rpm),then one hour at maximumcontinuous speed (27 195rpm),followed by three minutes at tripspeed (28 355rpm).Overlooking the test rig frominside the noise-insulated controlroom, Colin Thomas was ableto track the main runningparameters of the turbine. Thisis possible because the turbinetest stand is equipped with thelatest in supervision and dataacquisition systems, the Delta V(Emerson Process Management).This allows engineers in real timeto:> Assess the performances of themachines and their transfer tothe engineers of the aero-designdepartment;> Monitor the tests from thecontrol room; and> Supervise the entire test stand,e.g. the air compressors to drivethe turbine, the cooling tower,etc.With the test in progress, the AirProducts representative was ableto conduct further checks, reviewthe Quality Data Book, as well asleave the control room and walkby the turbine to physically gaugeits performance.Once testing ended, all data wastransferred to engineer FrankHaensel, of CRYOSTAR’s Aero-Design Department. In less than30 minutes, Frank met with ColinThomas to show and explain theresults and compare them withthe predicted data. There wastotal customer satisfaction.Meanwhile, CRYOSTAR engineersdismantled the turbine cartridge,and within the hour, the partswere shown to Colin Thomasfor a visual check, mainly of theshaft, the seals, the bearings andthe wheel.The Air Products representativesigned the release note for theTP 120. After the turbine cartridgereassembly and installation on theskid, the machine was packed andreleased for shipment to Brazil– just one week after the test.These two test days demonstrateCRYOSTAR’s commitment tocustomer satisfaction and atransparent working relationshipbetween the company’s engineersand the customer.Autumn 2003 5

CLEAN FUELSCryostar in clean fuels trialsCryostar Automation has joined haulage firmthe Hardstaff Group and cryogenic equipmentmanufacturer M1 Engineering to develop new gasfilling station using ‘no gas loss technology’.For the project a combined LCNG (liquid andcompressed natural gas) automated filling station hasbeen installed at Hardstaff’s Nottinghamshire site.Not only is it the first time that an English firm hasinvested in a twin LCNG filling station of this nature,but the project is the first to receive funding fromthe UK government’s alternative fuels PowerShiftprogramme.Hardstaff managing director Trevor Fletcher said:“Natural gas is the cheapest fossil-based fuel on themarket – and then there’s the environmental benefitsand value that ‘going green’ adds to our customerproposition.”Cryostar and M1M1Engineering has been involved in supplyingfirst generation LNG fuelling equipment to othercompanies in the UK, while Cryostar Automation’sprocess control experience and expertise in fullyautomatic gas filling stations for industrial use werekey.M1’s managing director Peter Fox said: “This was anopportunity to bring together two companies withcomplementary strengths to design, build and installan innovative solution that would meet a client’s veryspecific needs.”Cryostar contributed the buffer tank, pumps,vaporisers, interconnecting pipe work, electricalcables and automatic control cabinets for the LCNGdispensing while M1 Engineering provided the LNGtank, pumping and metering systems, pipe work andelectrical equipment for the LNG dispensing.TechnologyThe result of that partnership is a technologicallyadvanced, yet easy to operate gas refuelling station,comprised of:> One 44,000 litres tank, capable of storing up to17,000 kgs of LNG;> Two LNG cryogenic pumps 22 kW type Fillesafe41.3/40 with two automatic valves;> Two atmospheric vaporisers 64 tubes, 750 Nm3/h for420 barg design, the station being rated for continuousdirect fill for four vehicles per hour at 840 water litresper vehicle, but has design capacity for expansion tosix vehicles per hour;> One automatic buffer skid to control CH4vaporisation, the automatic fuelling and decanting of2,400 litres (water capacity) of gas at 300 barg, andthe vessel truck fuelling. An integrated flow meterallowing to measure and record the mass of CNGfilled in the truck;> An ex-proof operator interface allowing theoperator to make a request to the system which willautomatically launch the fuelling procedure; and> A Triscan operator identification module bymeans of magnetic disc. The fuelling system has apermanent communication with this interface givingaccess to the fuelling system and providing in realtime the mass filled by the driver to record and printthe bill receipt.Beside the CNG filling capability, LNG can befilled at the rate of maximum 150 litres per minute,completing a tank fill in less than five minutes.Technical and safety considerations, such asexplosive atmosphere areas, number of trucks to fuel,risk assessment, HAZOP, pressure and temperaturecontrol, and fuelling time, have been integrated in thestation.Technical dataTr u c k s C N G f u e l l i n g c a p a c i t y p e r d a yTr u c k s f i l l e d p e r h o u r C N GTr u c k s L N G f u e l l i n g c a p a c i t y p e r d a yTr u c k s f i l l e d p e r h o u r L N GF i l l s a f e p u m p s f l o w r a t e ( l / m i n )B u f f e r p r e s s u r e ( B a r g )Vo l u m e o f b u f f e r ( c a p a c i t y )Tr u c k f u e l l i n g p r e s s u r e ( B a r g )Tr u c k v e s s e l v o l u m e ( c a p a c i t y )3 0410 08 t o 102 x17 = 3 43 0 02 4 0 0 w a t e r l i t r e s2 5 08 0 0 w a t e r l i t r e s6Autumn 2003

BUSINESS CENTRESLocal service brings China successC hina i s t h e m o s t p o p u l o u s c o u ntr y i n t h e world a n d a lready h a s t h e s eve nthl a r g e s t e c o n o my. R e forms s t a r t e d i n t h e l a t e 1970 s h ave t ra n s formed t h ee c o n o my from agricultural to industrial.The upturn, which has occurred since, has openedup the economy to the world. For CRYOSTAR,the leading provider of cryogenic equipment andtechnology, China has been a success story driven bycustomer service and engineering expertise.With operations now based in Hangzhou, two hoursdrive from Shanghai, the initial decision to expandinto China was a simple case of meeting customerneeds.The operation in Zhejiang province enablesCRYOSTAR to deliver international expertise ata local level – an approach so successful that thebusiness has been forced to expand its force of serviceengineers.CRYOSTAR now offers China customers a full rangeof total solutions in terms of cryogenic pumps andturbines supplies, as well as engineers dedicatedto delivering best customer support in process anddistribution applications, locally. Customers alsobenefited from clear communications and quickerresponse times. As a result, an increasing numberare endowing CRYOSTAR with ‘preferred supplier’status.After sales service and the expertise of the localengineering team remains crucial to CRYOSTAR’scontinued success in China. As part of this customersCHINAenjoy access to CRYOSTAR’s complete range ofservices, including spare parts supplies, technical,commissioning and repairs assistance.This dedication to engineering technology andservice was instrumental in CRYOSTAR beingcommissioned to provide China’s first-ever liquidexpansion turbines.These new turbines are for use in air separation unitsand natural gas liquefaction plants. The attractionof the CRYOSTAR technology is significant savingsin energy costs or, alternatively, an ability to raiseproduction levels.As the world leader in distribution pump technology,CRYOSTAR has also supplied more than 30 trailerpumping systems to customers in China. The systemsvary from the basic plug-in type, to the Mixtransystem, a combination of alternator and plug-in, andthe Hytran system, which utilises an hydraulic drive.For CRYOSTAR, China is a success story. Combinerising demand for cryogenic equipment withinternational expertise and services delivered locally,and one begins to see why CRYOSTAR is going fromstrength to strength in one of the world’s fastestgrowing economies.Autumn 2003 7

CUSTOMERSHarald HunderbakkeSTATOILCryostar turbines onthe Sleipner gas platformsLead engineer : conceptualdevelopment of rotatingmechanical equipmentSLEIPNER, a gas platform inthe North Sea went on stream1 st October 1993. It was thefirst-ever platform equippedwith magnetic bearing turboexpanders. For the 10thanniversary of this event, wespoke to Harald Underbakke, thelead engineer responsible for theconceptual development of all rotatingmechanical equipment atSTATOIL. He was also part ofthe commissioning team for theSLEIPNER project.The CRYOSTAR magazine: First please tell us aboutthe SLEIPNER project.Harald Underbakke: The SLEIPNER project isa natural gas and condensate field developmentconsisting of two fields producing 45 million Sm3/daygas and 25,000 Sm3/day condensate (equivalent of160,000 barrels/day). The SLEIPNER A platformis a fully integrated platform with drilling, livingquarters and gas production plant. It is the first directgas production platform for STATOIL.How strategic was it to be on stream 1 st October 1993?HU: It was vital. It was the first test for STATOIL asa large-scale gas supplier. SLEIPNER is part of theTROLL (see @ a glance panel) gas sales agreementand the SLEIPNER A platform was the sole producerduring the first three years. Any delay would haveresulted in penalties in addition to the lost productionincome.Why did STATOIL chose, what at that time was newtechnology, in magnetic bearing turbo expanders andCRYOSTAR for such a vital and strategic project?HU: CRYOSTAR wasn’t readily associated withturbo expander manufacturing for hydrocarbonapplications. However, the company and its expertisewere well known to STATOIL through its operatingrecord on cryogenic pumps. So CRYOSTAR wasalready a qualified supplier. STATOIL is a leader innew technology development, as is CRYOSTAR, so wetook the decision to invite CRYOSTAR to participate.The potential of magnetic bearing technologyHow did it work out?HU: Today we can say that it was the right choice.There were some issues both mechanical andelectrical the first operating year, but these have nowbeen resolved by design upgrades. The operation hasbeen stable for the last nine years and the availabilityof these machines is amongst the very best of allrotating machinery we have.What is the main advantage of these machines today?HU: Availability. SLEIPNER needs to runcontinuously. That means planned shutdowns arealmost as bad and costly as unplanned shutdowns.The level of availability reached with CRYOSTARmachines is higher than average.Do you believe that the availability could be furtherincreased?HU: This would be difficult, since there is not muchimprovement potential left. The availability of all thevital spare parts is the enabling factor to reach this level.STATOIL Group profile> STATOIL is an integrated oil and gas company with a strong focus onexploration and production; Represented in 25 countries with 17,115employees Head office is in Stavanger;> The leading operator on the Norwegian continental shelf and oneof the world’s largest offshore oil operators;> Participant in a number of international oil and gas finds and in risingproduction from fields in Azerbaijan, Angola and Venezuela;The largest supplier of natural gas in Norway to a growing Europeanmarket;> One of the world’s largest net sellers of crude, including sales onbehalf of the Norwegian state. Extensive sales of oil products andnatural gas liquids; and> Has 1,883 gas service stations in nine countries.Photo Statoil8Autumn 2003

CUSTOMERSWhat about performance?HU: There has been no decline of the goodperformance over time. We have operated at 110 percent of the design conditions since 1994. After 10years of operation there is no significant wear on thewheels, the labyrinths or the nozzles. We had erosionon the compressor diffusor in an early stage, maybedue to particles remaining in the piping, but nothingelse since.In summer of 1993 STATOIL purchased fourCRYOSTAR turbo expanders for the SLEIPNER Tplatform, even though there was not much operatingexperience on the first 4 units. Why?HU: At that stage, due to the good co-operation withCRYOSTAR and due to what we learned during theextensive testing on SLEIPNER A, we considered itthe right choice. It was also a form of standardisationand reduced the personnel training.What is your impression of CRYOSTAR?HU: Good technical staff. Good engineeringcapabilities. Rapid and good response, keen to trynew technologies and high quality equipment ingeneral.How would you conclude?HU: The implementation of the CRYOSTAR turboexpander was a challenging development projectwhich became a success. It established the magneticbearing turbo expander standard for offshore andonshore hydrocarbon applications.TROLL - @ a glanceThe TROLL gas sales agreements (TGSA) concluded in 1986-88 marked a departure in relation to earlier contracts for Norwegian gas exports.Whilethe latter were ‘depletion’ deals covering output from a single field, the TGSA are ‘supply’ contracts. They undertake to deliver a specified volumeto an agreed quality from any field. TROLL and the SLEIPNER area serve as guarantors of these deliveries. This approach offers greater flexibility forthe sellers and enhanced security for buyers. The first TGSAs were concluded on 30 May 1986. As subsequently expanded, they commit companies inBelgium, France, the Netherlands, Germany, Spain and Austria to take around 1,000 billion cubic metres of Norwegian gas over 30 years. Gas contractsare often signed long before deliveries begin, and before production facilities or pipelines have been constructed. Deliveries under the TGSA beganfrom the SLEIPNER A platform on 1 October 1993 and from TROLL A platform in 1996.NewsGreen oxygen-service componentsCRYOSTAR recently installed a new state-of-the-art degreasing plant for cleaning of components. This fully automatic machine uses the latesttechnology to prepare components for oxygen service, using solvents as cleaning agents. The machine operates with a high degree of safetyand without environmental impact. This allows CRYOSTAR to provide superior quality, clean components for both original and spare parts(which, on request, can be vacuum packed and sealed, ready for use). This investment shows CRYOSTAR’s commitment to its customers,safety and the environment!30 Years of CRYOSTAR in France!In 1973, CRYOSTAR (then based in Pratteln, Switzerland) constructed a secondmanufacturing facility in France.Near the borders of Switzerland and Germany,just five minutes from the EuroAirport Basel Mulhouse, CRYOSTAR Francestarted production in September 1973. The first products shipped from theHésingue facility were.... food freezing tunnels! Very soon after, CRYOSTARFrance produced pumps, vaporizers and turbines, and in 1975 became the onlymanufacturing plant. To celebrate this milestone, on 17 September 2003, anOpen Day was arranged for customers,suppliers and business partners fromall around Europe. It provided aunique opportunity for CRYOSTARand its personnel to demonstrate theircapabilities through presentation of thecompany’s designed and manufacturedproducts.Innovative Service AgreementIn an effort to improve plant reliability throughpreventative maintenance, BOC’s PGS Europeand CRYOSTAR have developed a new service,unique in the Industrial Gases Industry.In terms of the agreement, CRYOSTAR takesresponsibility for all spare parts managementand is appointed as preferred supplier forequipment and services for all types of cryogenicrotating equipment and its maintenancework. The spare parts stocks will be managedfrom CRYOSTAR UK, located in Hellaby.PGS Europe will also benefit from CRYOSTAR’stechnical and consulting support. This partnershipoffers increased equipment reliability, coupledwith reduced maintenance costs.Autumn 2003 9

PRODUCTSMRP – the cutting edgeof technologyCRYOSTAR is developing a newreciprocating cryogenic pump under thebrand name of MRP (Modular ReciprocatingPump). This is a new concept in modular pumpsand will be available with two different strokelengths to cover a large range of flows from4-25l/min, with a maximum discharge pressureof 420barg. The maximum speed will belimited to 400rpm in order to increase the durabilityof parts subject to wear.Modular Aspects:To meet the needs of multi- markets, the MRP isbeing developed using a modular philosophy, withthe following key points:> There are two stroke lengths available using thesame cold end and piston to cover a flow range from4-25l/min;> The crank drive can be oil or grease lubricated;> An oil-seal cartridge that can be dismantled easily;> A tapping to fit a temperature probe in the couplingarea to detect seal leakage;> A tapping to fit a temperature probe in the crankdrive housing to measure the oil temperature; and> Tappings for a nitrogen purge to prevent moistureentering the crank drive.Cold end:The technology is being developed with the followingkey points at the fore:> The cold end has a sophisticated insulated cylinderwith a robust and large vacuum chamber to reducethe required NPSH to almost zero and to reduce thecool down time and liquid losses. The insulation hasalso been designed to avoid any mechanical stresson the welds in order to improve the life-time ofthe cylinder, the reliability and safety of this highpressure component;> The suction valve profile has been designed toreduce the pressure drop of liquid into the cylinder;> The numbers of high-pressure seals (piston rings)have been increased to improve the volumetricefficiency;> The low-pressure seal arrangement is a new designwhich will noticeably increase the seal life time; andThe cold end will be in accordance with the latestsafety regulations (PED-CE97/23, etc...)Crank Drive:Features:> The crank drive is a new design which allows for theuse of either grease or oil lubricated bearings;> However, with oil lubrication, the life-time of thebearings will be increased two-fold.> To maintain a strict alignment, a static DU sleeve isno longer used. This is replaced by special segmentslocated on the cross head in order to reduce the radialclearances and the friction coefficient. The noiseand vibration levels are reduced, even at maximumdischarge pressure;> From the safety point of view, oxygen compatibleoil will be available; and> Simplified maintenance procedures enable fasterdisassembly and reassembly.If you would like more information about the MRPand/or other CRYOSTAR technologies contact yourlocal CRYOSTAR office.10Autumn 2003

EVENTS & TOOLSEventsNovember 24-27, 2003WELDEX-2003, 3 rd internationalspecialized exhibition of materials,equipment and technologies forwelding, Sokolniki Culture &Exhibition Centre, Moscow,Russia.February 3-5, 2004WeldMex 2004, the World TradeCenter, Mexico City, Mexico.For more details:www.weldmex.comMarch 3-5, 2004Flame tech,Amsterdam, Netherlands.March 21-24, 2004The 14th Liquefied NaturalGas Conference and Exhibition(LNG14), Qatar InternationalExhibition Center, Doha, Qatar.For more details:www.lng14.comMay 5-14, 200420th Intl Cryogenic Engineeringconference, Beijing, China.Tools and datas:Argon and Hydrogen Conversion DataWe have decided to dedicate this section of our magazine to include usefull tools and datas that are handy in ourindustry. In this issue, the Argon and hydrogen conversion data table.Weight Gas LiquidPounds (Lb) Kilograms (KG) Cubic Feet (SCF) Cubic Meters (Nm3) Gallons (Gal) Liters (L)Argon1 Pound 1.000000 0.453592 9.708160 0.255114 0.085959 0.3253891 Kilogram 2.204622 1.000000 21.402828 0.562430 0.189506 0.7173601 SCF Gas 0.103006 0.046723 1.000000 0.026285 0.008854 0.0335171 Nm 3 Gas 3.919818 1.777999 38.044053 1.000000 0.336942 1.2754661 Gal Liquid 11.633494 5.276864 112.939821 2.967866 1.000000 3.7854121 L Liquid 3.073244 1.394000 29.835543 0.784027 0.264172 1.000000Hydrogen1 Pound 1.000000 0.453592 192.021870 5.047380 1.692942 6.4084831 Kilogram 2.204622 1.000000 423.335731 11.127566 3.732298 14.1282851 SCF Gas 0.005208 0.002362 1.000000 0.026285 0.008816 0.0333741 Nm 3 Gas 0.198123 0.089867 38.044053 1.000000 0.335410 1.2696651 Gal Liquid 0.590688 0.267931 113.424961 2.981425 1.000000 3.7854121 L Liquid 0.156043 0.070780 29.963703 0.787609 0.264172 1.000000SCF (Standard Cubic Foot) gas measured at 1 atmosphere and 70°F.Liquid measured at 1 atmosphere and boiling temperature.Hydrogen gas values expressed in the stable conditions 75% ortho,25% pure.Nm3 (normal cubic meter) measured at 1 atmosphere and 0°C.All values rounded to nearest 4/5 significant numbers.Hydrogen liquid values expressed in the stable para condition.Autumn 2003 11

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