LNG Operator Demands Integrated Industrial Solutions For Plant StartUp
An operator of an onshore Liquefied Natural Gas (LNG) micro fuel facility sought integrated solutions from a single source contractor. Ongoing activities with multiple construction groups were working compressed schedules in order to ready the facility for a re-purposed product. Direct technical commissioning support became an value target during the early phase of project execution, as pressure testing and torque value verification for 600+ connection joints demanded specific expertise.
LOCATION
San Juan, Puerto Rico
SPECIFICATIONS
Operator Type: Downstream
Facility Type: Micro Fuel Handling
Hydrocarbon Type: LNG
SCOPE OF WORK
Provide torque verification and hydrostatic pressure testing on facility piping.
CHALLENGES
600+ flanges
International equipment logistics
Working at heights
Expedited time line for planning and mobilization
Project planning and readiness required efficient communication without a site survey
Inadequate pressure testing tie-in points warranted a Management of Change process that required an approved deviation from best practice approaches
Due to welded valve placement, standard isolation practices required additional safety measures
PLAN OF EXECUTION
Project Planning & Preparation
Reviewed P&ID’s and Isometric drawings from two different engineering firms.
Identified manufacturer’s recommended torque values.
Planned with client for Customs requirements and entry.
Evaluation of tools for SOW completion.
Developed a serialized weatherproof torque verification tag containing all relevant data per joint.
Reviewed test and cleaning procedures/requirements.
Utilized teams of cross trained personnel for both bolting and pressure testing.
Scope Execution
Hydraulic Bolting and Flange Management System coordination.
On site project management support.
Connection integrity management on all joints.
Reviewed test packs and verified test pressures, durations, and boundaries.
All bolted joints were checked to verify proper joint alignment.
All studs were checked for proper material, size, length, and lubrication.
All bolted joints were torqued to client specifications.
Cleaned systems with compressed air in accordance with client procedures.
TECHNICAL ACHIEVEMENTS & BENEFITS
Successful integration with end user and general contractor management, consultants, and field personnel.
Provided integrated management and project controls.
Reviewed and mapped bolted connections as per design and construction drawings.
Changed test medium selection from demineralized water to readily available nitrogen. This provided cost savings on the testing and drying phase.
Provided final reports on torqued connections, and applied a tagging system verifying work was performed and completed in accordance with the regulation/standard.
