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 In addition to supplying the MCR® Cryogenic Heat Exchanger, Air Products offers a wide range of engineering services which form the basis for overall support of an LNG facility. During the design of the LNG plant, Air Products provides the process design for the liquefaction facility, the detailed design of the plant area surrounding the MCR® Cryogenic Heat Exchanger, and review and consultation for the plant owner or general contractor. Air Products also provides advisory services to the owner and engineering contractor during exchanger shipment, and field construction activities and at the time of plant commissioning and start-up.
Because Air Products does not compete with general engineering and construction firms, there has been a very cooperative relationship with general contractors on past LNG projects. This has created efficiency and reliability for the owner for the design and construction of the plant.
An owner using an Air Products process can benefit from the efficiency created by:
- Competitive bidding among engineering and construction firms;
- Knowledge of past plants and equipment supply sources;
- Sound field construction management;
- Shorter commissioning schedules;
- Faster start-up periods;
- Comprehensive operator training.
Engineering Scouting Studies During the project definition phase, Air Products participates with the plant owner in engineering studies to help define the natural gas liquefaction plant configuration and detailed design basis. These "Scouting Studies" generally examine the various process cycle alternatives, the choice of air versus water cooling, and options for selection of major plant equipment (such as compressors, drivers and main cryogenic heat exchangers). At this stage, sensitivity analyses can be performed to help identify which options are best suited to meet the overall plant requirements. The results of these studies are used by the plant owners to establish the detailed design basis, which includes the selected equipment configuration and the plant operating and design parameters which are to be used in the final design of the liquefaction system. Owners can achieve the benefits of cycle optimization and reduced capital and/or operating costs by involving Air Products early in the conceptual design phase.
Process Design Services  After establishing a firm design basis and often times well before the commitment of plant construction funds, the owner will require an overall design and cost estimate for the LNG plant. It is during this time that Air Products completes the detailed process design of the liquefaction area of the plant. Air Products provides the following process design services for the Liquefaction system in support of this effort:
- Process flowsheet (PFD)
- Heat and material balances
- Process description
- Line sizing criteria and controlling pressure drops
- Process equipment specifications for compressors, heat exchangers, separators, distillation columns, pumps, strainers and refrigerant vessels
- Relief and depressurizing analysis
- Sizing basis for control valves, strainers, and flow elements around the main cryogenic heat exchanger
- Insulation specification for MCHE
- General operating guidelines
Detailed Design Services During the detailed engineering, procurement and construction (EPC) phase of the LNG plant, a detailed design engineering package is produced by Air Products in support of the EPC contractor. This Class B engineering package provides the detailed design drawings for piping and platforms supported from the MCR* Cryogenic Heat Exchanger. Typical items supplied in this package are as follows:
- Orthographic piping drawings and CAD modeling of the cryogenic heat exchanger area together with isometric piping drawings.
- Design drawings of structural components for the MCR® Cryogenic Heat Exchanger such as platforms, ladders, and pipe supports.
- Foundation loading drawing.
Review and Construction Services During the project design and construction phases, the owner and engineering contractor customarily request Air Products to provide advisory services to review engineering documents prepared by the engineering contractor or others. Air Products will typically be involved in reviews of Piping & Instrumentation Diagrams (P&ID's) and Hazard/Operability Analyses (HAZOL) to help insure that the LNG plant is being constructed in accordance with Air Products process design.
Field Services Air Products provides advisory services during transportation, field installation, commissioning, training and start-up of the liquefaction system.
 Air Products also offers after start-up field services that include technical assistance with diagnosing plant operating problems and the maintenance and repair of the main cryogenic heat exchanger. Diagnostic services can range from assisting with the collection and evaluation of performance test results to identify plant bottlenecks. Our international field crews are fully qualified and experienced in aluminum welding, pressure vessel entry and repair. Air Products' field servicing capability is a valuable extension to its equipment and helps to ensure long-term efficient and reliable operation of the plant.
Other Services Feasibility Studies
Preliminary process design and optimization at an early stage of project development often leads to time and investment savings in the design and execution of the project. As a result, Air Products has been retained to perform numerous feasibility studies for a wide variety of clients worldwide.
Engineering Analyses
Analytical, engineering and computer capabilities are often applied to specific technical issues associated with operating an LNG facility. Examples of these are programs for analyzing rollover in LNG storage tanks, safety and hazards reviews, and flare and relief system analysis.
Advanced Process Controls
With the continued advancement in computer capability and with DYNSIMTM, Air Products continues to research and develop improved process control strategies for Baseload LNG processes. Recently a new robust regulatory control strategy has been developed and patented for use in operating facilities. Also methods of maximizing LNG production using the latest in advanced control technology, Model Predictive Control (MPC), have been explored with favorable results. These strategies layered together will increase the reliability and maximize LNG production of an owners LNG plant.
DYNSIMTM is a registered trademark of Air Products and Chemicals, Inc.
DYNSIMTM Dynamic Simulation Technology Click here to view larger version.
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