Full-service supplier of air separation plants, oxygen and nitrogen generators and CO2 plants. Gas & liquid supplier to end users and to distributors of bulk liquids & packaged gases. Project descriptions of representative plants manufactured and/ or relocated with reconditioning and upgrades by UIG

UIG Project Showcase

 All-New ASU / Bulk Cryogenic Liquid Plants

 

UIG designed and supplied all-new air separation plant and liquefier plant for bulk merchant liquid production. Similar plants were supplied to Airgas Merchant Gases in Carrollton KY and New Carlisle IN.

UIG designed and supplied all-new cryogenic air separation plant and liquefier supplied to Airgas - process and loading areas.

 UIG designed and supplied onsite gas and  bulk  liquid  production  plant

Cold boxes, product storage, 
and  trailer  loading  areas

   
UIG has designed and supplied multiple all-new air separation and merchant liquid production plants to Airgas, a major manufacturer and distributor of bulk liquid products and packaged gases.  This page focuses on the New Carlisle Indiana air separation plant,  which came on-stream in December, 2008, and the Carrollton  Kentucky air separation plant began service in May, 2009. 

A third bulk liquid and onsite gas production plant is in service in Tennessee, and others are in the project execution phase.

The cryogenic Air Separation Unit (ASU) section of the plants produce pure oxygen, nitrogen, and argon.  A portion of the available gas production is compressed and delivered to an onsite gas customer via pipeline. 

The liquefier section of each plant (NLU) generates the refrigeration required to produce more than 350 tons per day of oxygen, nitrogen and argon as bulk liquid products. Production rates for liquid oxygen (LOX) and liquid nitrogen (LIN) can be varied to reflect changes in near-term demand projections for each of these cryogenic refrigerated liquid products.   

The total engineering, procurement, construction and commissioning scope required to design and install these plants was split between UIG and the purchaser.

  • UIG was responsible for overall plant process design, detailed engineering for mechanical, electrical and instrumentation items, and procurement and fabrication responsibility for the process equipment and instrumentation and control systems associated with the ASU and Liquefier.
  • The plant purchaser was responsible for site preparation and field construction activities, including buildings, roads and utilities. The purchaser was also responsible for procurement and installation of the field-erected product storage tanks.

UIG designed and supplied the product loading facilities - providing pumps, valves, instruments, piping specialties; computer control logic and equipment.  UIG also provided design and supply of cryogenic piping to and from the product storage tanks.

UIG field advisory and supervision personnel provided support throughout the project during critical construction activities, plant commissioning and plant start-ups.

Cold Box 3-D design drawing
 
The following series of pictures show portions of the fabrication, transportation, field assembly and construction work for these plants. 
 
 
 
Cold Box Fabrication, Transport, Inspection, and Pre-erection Site Work

Cold boxes are a distinctive feature of every cryogenic air separation and liquefaction plant. They house process components which operate at very cold temperatures, such as heat exchangers and distillation columns.

Cold boxes are shop fabricated, field-insulated process modules. Process and mechanical design considerations required that the air separation (ASU) cold box be designed, fabricated and shipped as four modules; to be interconnected at the site. The liquefier cold boxes (NLU) were fabricated, shipped and erected as a single unit.

 
Shop-fabricated cold box modules leave the fabrication shop and are transported to the plant site:
Inside an ASU cold box module under construction in cold box fabrication shop. ASU cold box module nearing completion in fabrication shop. An ASU cold box module leaving fabrication shop. An ASU cold box module in transit to plant site.
 
Prior to arrival of the ASU and NLU cold box modules, lay down areas were prepared at the site. Stout timbers were used as "paving" to support the cold box modules and the cranes required to erect them. 

The foundations for the cold boxes and those required for other plant components were poured well in advance of cold box arrival to allow time for curing. 
 
Arriving at the plant site, the cold box modules are unloaded and inspected.  
 
The modules are made ready for lifting - and separately-shipped cold box components are installed.   
 
While still in the horizontal position, pre-fabricated platforms and ladders were attached to the exterior walls of the cold box modules.

ASU and NLU Cold Box Erection and Construction

During erection, each inspected and prepared cold box module was raised to the vertical position in the staging area and re-inspected. It was then lifted and moved to its intended location; where it was set down and secured to its foundation and/ or interconnected with adjacent modules. 

Cold box erection required carefully coordinated use of multiple heavy-duty cranes. A lifting plan was developed well in advance to ensure that the process proceeded in a safe and efficient manner.  All erection-related field work was coordinated and closely supervised by experienced UIG personnel. 

 

Erection, Phase 1:  Lifting and tailing cranes raise the first cold box module to the upright position.

Preparing to lift the first ASU cold box module. Preparing to lift the first ASU cold box module Raising the first ASU cold box module to the vertical.  Tailing crane supports bottom of module. First ASU module in vertical position, about to be moved to foundation.
 
The bottom-level ASU module is then moved to, and lowered onto, its foundation; and securely attached. 
First ASU module lifted from ground - being moved to foundation First ASU module being moved to foundation First ASU module being placed on foundation.  First ASU module being set on founation. Compressor building to the rear.  Liquid storage tank foundations in foreground.
 

Erection Phase 2: The second ASU cold box module is set, anchored and joined to the first.

Second ASU cold box module raised to vertical.  Being inspected prior to lift from ground. Second ASU cold box module on its way to its foundation.  Second ASU cold box module approaches it foundation.  Second ASU cold box module final positioning.
 

Erection Phase 3:  The liquefier cold box is lifted and moved into position.  

Liquefier (NLU) cold box about to be raised to vertical.  Note comprssor building on right and first two ASU cold box modules in place. Liquefier (NLU) cold box being raised by lifting and tailing cranes.  Two ASU cold box modules and comressor building in right rear. Liquefier (NLU) cold box approaches vertical.  Note that smaller crane is lift crane, large crane is tailing crane. Liquefier (NLU) cold box lifted off ground.
 
The liquefier is installed on its own foundation near the partially-assembled ASU cold box.
Liquefier (NLU) cold box approaching foundation

Liquefier (NLU) cold box being set near partially-assembled ASU cold box

Liquefier (NLU) cold box being set.  Two additional  ASU cold box modules await erection and setting atop the first two modules.
 

Erection, Phase 4:  The first upper level ASU cold box module is lifted and inspected.

Preparing to raise the third ASU cold box module. Cranes being set up to raise the third ASU cold box module. Raising the third ASU cold box module Third ASU cold box module raised to vertical.
 
The module is moved to position, lowered onto, and secured to, the previously-set ASU modules.
Third ASU cold box module leaves the ground. Note platforms and ladders. Third ASU cold box module being swung into position. Module has been rotated, showing open side. Third ASU cold box module approaches first two modules.  Observers ensure damage-free, sucessful mating. Third ASU cold box module being secured atop the first two ASU cold box modules.
 

Erection, Phase 5:  The last of the tour ASU cold box modules is lifted, inspected, and raised. 

Final inspection of fourth ASU cold box module prior to lifting Raising the final ASU cold box module. Inspecting the fourth ASU cold box module in vertical position, prior to raising it above ground. Final ASU cold box module begins journey to the second tier of the ASU cold box module stack.
 
The final module is aligned with the adjacent lower-level and upper-level modules, then secured.
Fourth ASU cold box module nearing final postion. Final ASU cold box module being guided into place Inspection and connection operations as final ASU cold box module is secured in place

ASU cold box side view.

 
After erecting the cold box modules, internal process line interconnections were made, internal Instrumentation and control system component installations were finalized, and the cold boxes were filled with insulation.
 

Other Site Work

At the time the cold boxes were delivered and erected, work was proceeding in all areas of the plant site. 
Photos of the finished air separation plant
can be viewed at the top of this page.

Field erected storage tanks rise at site of UIG-supplied plant supplied to Airgas.  Overview of compressor building, molecular sieve unit, cold boxes, and liquid storage tanks under construction in New Carlisle, IN. View from air of overall construction site in New Carlisle Indiana.  UIG supplied cold boxes and other process equipment in center of site - including equipment in compressor building. Airgas handled field construction and purchase of field-erected storage tanks.
 
Links to related Grand Opening celebration news and other information:
 
 UIG New Cryogenic Plants UIG Engineering and Field  Services UIG Products & Services Overview Cryogenic Air Separation  Technology Overview
 

Universal Industrial Gases, Inc.
2200 Northwood Ave. Suite 3
Easton, Pennsylvania 18045-2239 USA

Phone (610) 559-7967 Fax (610) 515-0945

All material contained herein Copyright 2003 / 2014 UIG.