Methane Pyrolysis Skid to Produce Hydrogen from Natural Gas (pilot plant)

This project scope included 3D modeling and analysis for piping and structural steel. Applicable codes were ASME B31.3 for Process pining and ASME B31.12 for Hydrogen piping and pipelines. The skid consisted exclusively of proprietary equipment supplied by licensors. The key design challenge was to accommodate all the equipment including piping, tubing, instrumentation and electrical components within in the customer specified skid dimensions.

The layout for this double decker skid had to be developed to accommodate approximately 106 process lines in addition to multiple control valves and special inline items within the heavily constrained skid envelope. In addition to this space constraint wall panels were also required to enclose the skid boundaries. This situation presented a unique challenge for providing adequate access for operation and maintenance activities in the skid.

To address this dedicated access doors and davit arm assembly for lifting and ventilation requirements had to be met with duct fans and adjustable louvers. Several lines had to analyzed for 1500 deg. F temperature which resulted in high piping stresses and required careful evaluation and provision of expansion bellows at certain locations. Dynamic analysis of the structure had to be performed due to involvement of rotating equipment. The structural analysis also required to verify removal of some members required for maintenance activities. At one location a unique solution was conceived by projecting the structural frame outside the limits of the basic structural frame to accommodate the equipment and still maintain adequate clearance.