CLEAN GREEN MOTORING SMART PLANT PUMP IT UP - Cryostar

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SMART PLANTClever design with Smart PlantCryostar is a recognized original equipmentmanufacturer (OEM) for a wide range of rotatingmachines. To better serve its customers,Cryostar has added new engineering capabilitiesfor process plants. As a result, Cryostardeveloped and delivered the Cryostar Ecorel onboard liquefaction plant process. For design,Cryostar now uses Smart Plant to pre-engineersmall-scale process plants for geothermal powerplants and small-scale natural gas liquefactionplants.When Cryostar extended its scope to becomea small-scale process supplier, selecting themost appropriate engineering tool was vital.After a careful benchmark including visits tobusinesses using various tools, Cryostar chose a fullyintegrated software suite: Smart Plant.The core module of Smart Plant is a piping andstructures design module. Smart Plant 3D enablesthe designer to build 3D piping layouts around civilengineering structures and process components. Thepicture above shows an example of a 3D layout for afeasibility study.Before starting the three-dimensional plant design,the process and instrumentation diagram is drawnwith Smart Plant P&ID. In addition, equipment,instrumentation, specific piping classes and insulationspecifications are fed into the database, which iscommon to all engineering activities.The benefit is that the P&ID and the 3D layout areautomatically linked. The P&ID remains the masterdocument and design changes can be monitored andupdated during the design process. In comparisonwith using two different tools for the P&ID and the3D layout, there are fewer errors and greater engineeringproductivity with Smart Plant.At any time, designers can extract piping isometricdrawings and lists of materials and components fromSmart Plant. The information is always consistentwith the latest P&ID and the specifications saved inSmart Plant. Engineers use piping isometric drawingsand other construction documents directly formanufacturing and installation.3D layout for a feasibility study of a Cryostar small-scale natural gasliquefaction plant designed with Smart Plant 3D.and trade-offs can be mutually decided. Smart PlantReview clearly increases the level of customer satisfactionregarding in plant design.Today, based on an existing P&ID and on existingprocess calculations, Cryostar is able to pre-engineera geothermal process plant or a small-scale liquefactionplant in a few weeks. Following detailed engineering,Cryostar can issue complete documentationwithin pre-defined formats and, in terms of content,the level of consistency between the various plantconstruction documents is excellent. Beyond thisdesign tool, Cryostar’s organisation, methods andresources have all been adjusted to supply optimisedprocesses in the fields of natural gas small-scale liquefactionand geothermal power plants.In addition to an integrated solution for process plantengineering, Smart Plant suite also provides a userfriendlytool for 3D reviews with customers. Thetool enables Cryostar engineers to directly interactwith their customers who can virtually visit the plantbefore approving the relevant design phase. Togetherthey address maintenance and operation issues early,Typical isometric drawing for piping manufacturing andinstallation.8 Spring 2009
COMMISSIONING STORYEcoRel commissioning inside storyCryostar’s commissioning activities on the re-liquefaction systems for the 14 Qatar gas Q Max vessels began atthe end of 2007. The first gas trial took place in August 2008 with H1675 Al Mozah built by Samsung HeavyIndustries (SHI). At 266,000m3 Mozah, named after the wife of the emir of Qatar, is the largest LNG carrier everbuilt. As this article goes to press, seven vessels have passed gas trials and been delivered. This is a technician’sinside story of the commissioning and gas trials process. Noise, heat and humidity during summer, and the cold during winter are all part of daily life for the Cryostartechnicians in charge of preparing and regulating the different machines and instruments of the EcoRel project.“The noise of the portable pneumatic tools used by the shipyard is very irritating within this mass of steel,” saysRichard Brun, service engineer.Workers are constantly aware of the level of dangeron site. Openings in the ground, loose wires,high-level obstacles and working at height makethe commissioning perilous. “The other day, aworker welded, as I was calibrating a gate belowhim. I had not seen him,” says Richard Brun. “Inaddition to these difficulties, we are sometimesunable to make ourselves understood becausemany workers speak little or no English.” An EcoRel gas trial is the ultimate Cryostarsystem test to officially demonstrate and deliverre-liquefaction equipment to clients: the shipyardand owner. This mission occurs with theship at sea and is well managed by six Cryostarengineers and technicians working as two teams splitting the various tasks and responsibilities to supervise activitiesaround the clock. The team works very closely with the shipyards representatives as well as all other partiessuch as the owner, the class, and other suppliers present. The gas trial starts with a number of internal tests toassess the good functioning and stability of the re-liquefaction plant. Once the system’s durability and performanceare revealed, the official demonstration and acceptance test can proceed. The system will run over a period of approximately70 continuous hours, during which time fatigue will peak and tension will increase to its maximum.The entire gas trial lasts some three weeks from the time of departure to fill the tanks with gas to the time ofunloading gas at the receiving terminal.However, the gas trial is also a great human adventure. Up to ten nationalities can meet for duration of severalweeks. Approximately 90 people share accommodation. Between three and four technicians live together in thesame room, sometime with only a single bed. Space and privacy are limited, and sleeping bags are often the mostcomfortable beds available.For Cryostar, cooperation between team members is the key. Each individual contributes their expertise and knowledgeto successfully carry out this mission under the best conditions and provide total satisfaction to both clientsand inspectors.RESSOURCES FOR ECO REL COMMISSIONING AND GAS TRIALPRE-COMMISSIONING / COMMISSIONINGGAS TRIALResources Number of hours Resources Number of hoursMechanical technician/engineer 5 1042 2 87Instrumentalist/electrical technician/engineer 4 355 2 294Vessel manager 1 177 1 87Process engineer 4 426 3 792TOTAL14 2000(200 working days)8 1260(126 workings days)(resources allocated to the commissioning and Gas Trial of one EcoRel re-liquefaction Plant)Spring 20099
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CLEAN GREEN MOTORING SMART PLANT PUMP IT UP - Cryostar

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