Abstract:
An equipment retrofitting project method includes the steps of conducting sales, project management (PM)/design, production and field service phases. The PM/design phase includes the steps of providing a coordinate measuring machine (CMM) and measuring spatial and dimensional coordinates of natural gas compressor station components with the CMM at the compressor station location. The coordinates are related to a reference at the compressor station location. Output is provided from the CMM in the form of part coordinate system (PCS) data comprising the spatial and dimensional data associated with the components and a 3-D model is created from the PCS data. In the production phase new and/or refurbished components are produced utilizing the PCS data at a location remote from the equipment. In the field service phase the new or refurbished components are installed in the equipment.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to equipment retrofitting projects, and in particular to a method for retrofitting components of a remote facility, such as a natural gas compressor station. 
         [0003]    2. Description of the Related Art 
         [0004]    Various types of operating equipment require periodic service, including updating to meet current application demands. For example, natural gas compressor stations are part of a distribution system and are located at intervals along gas pipelines. Natural gas pipelines include “mainlines,” which extend across vast geographic areas and carry large quantities of natural gas at relatively high pressures from the producing fields to the major population centers. Compressors used for transporting natural gas include conventional reciprocating compressors, rotary screw compressors and turbine engines. Various other equipment components include intake side scrubbers and fillers, unloaders, suction/discharge valve assemblies, interstage coolers (for multistage compression) and post-compression coolers on the discharge side. The natural gas is routed through the compressor station components via suitable piping networks. 
         [0005]    Significant amounts of energy are consumed in transporting natural gas. Such energy can be provided by the natural gas as a fuel source for the compressors, or they can be driven by electrical power. Either way, compressor operating efficiencies are very important for the economic viability of pipeline systems. Such operating efficiency considerations have created a strong demand for compressor station updating and retrofitting services, particularly since investments in upgrading existing facilities and improving operating efficiencies tend to be relatively cost-effective and provide paybacks. Moreover, many compressor stations have been in operation for decades whereby revamping equipment to optimize operating efficiencies is periodically needed to take advantage of current state-of-the-art engineering and technology. 
         [0006]    Common services associated with upgrading compressor stations include retrofitting, reconfiguring and revamping equipment. The compressors themselves are sometimes restaged and recylindered. Optimizing operating efficiency normally involves specialized consultants, who employ sophisticated computer modeling and engineering design software. Typical retrofit and equipment upgrade projects can involve significant fabrication, machining and construction services, which tend to be highly customized and project-specific. Portions of the machining, fabrication and manufacturing work can be automated using available computer aided manufacturing (CAM) systems, which can receive design inputs from computer aided drafting and design (CADD) systems. 
         [0007]    The compressor stations are often located in relatively remote locations chosen for pipeline operating efficiencies and other considerations, including environmental. Geographic remoteness can contribute significantly to the costs of engineering projects, particularly those requiring sophisticated design, fabrication, construction and installation phases. Mobilizing and transporting personnel, components and equipment tends to involve expenses proportional to the remoteness and distances associated with projects. In other words, greater distances between consultants, component production facilities and jobsites often correlate to greater travel and transportation expenses, as well as time delays. These challenges are not limited to natural gas compressor station projects and are commonly encountered in various other types of projects where resources are geographically distant from the jobsites. Another, related cost consideration involves relocating workers and other resources on-site for extended periods of time. Such resources are often needed on-site due to the project-specific nature of the materials and components, which have to be field-adapted to accommodate close tolerances and specific field conditions. Scheduling is another important aspect of projects such as compressor stations, for which downtime can be disruptive of operations and expensive. Time out-of-service must generally be minimized. 
         [0008]    Previous compressor station projects tended to involve the considerations discussed above. Successfully retrofitting compressor stations commonly required significant on-site activity involving design and fabrication and the presence of construction personnel and equipment. An equipment retrofitting system would preferably address some or all of these considerations. For example, minimizing field activity in favor of shop or fabrication facility production is generally preferred because field operations tend to be inherently more expensive and less precise. Manufacturing, machining and fabricating components in a controlled environment, such as an off-site facility, tends to produce better results at a lower cost than comparable operations conducted on remote jobsites, which may be exposed to ambient conditions, including inclement weather, and other deficiencies. For example, field welding operations are commonly employed to obtain precise fits of components and interconnecting piping. However, if the precise locations of different connections in three-dimensional space could be determined in advance, much of the field welding activity could be replaced by pre-construction fabrication off-site. 
         [0009]    Heretofore there has not been available a method for retrofitting equipment with the advantages and features of the present invention. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0010]    In the practice of an aspect of the present invention, a method is provided for retrofitting equipment and includes sales, project management (PM)/design, production and field service phases. The existing system and conditions are modeled electronically in a three-dimensional modeling system using either relative or Earth-based coordinates (XYZ). Such three-dimensional electronic models are used for designing, machining, fabricating and manufacturing the systems being retrofitted, including various components and equipment. The relatively high accuracy of the software used for modeling the physical aspects of the projects enables remote prefabrication and pre-assembly procedures, which tend to minimize on-site activities by consultants, fabricators and others. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
           [0012]      FIG. 1  is a generalized flowchart showing an aspect of the equipment retrofitting method of the present invention. 
           [0013]      FIG. 2  is a flowchart showing a sales phase. 
           [0014]      FIG. 3  is a flowchart showing a continuation of the sales phase. 
           [0015]      FIG. 4  is a flowchart showing a continuation of the sales phase and a project management/design phase. 
           [0016]      FIG. 5  is a flowchart showing a continuation of the project management/design phase. 
           [0017]      FIG. 6  is a flowchart showing a continuation of the project management/design phase and production and field service phases. 
           [0018]      FIG. 7  is a flowchart showing continuations of the production and field service phases. 
           [0019]      FIG. 8  is a perspective view of components of a natural gas compressor station, which can be modeled from coordinate measuring machine (CMM) data imported to a parametric computer aided drafting and design (CADD) modeling application. 
           [0020]      FIG. 9  is a perspective view of a component of the natural gas compressor station, which can be manufactured from a production drawing based on the CADD model. 
           [0021]      FIG. 10  is a field generated inspection report form based on CMM-derived data using a part coordinate system (PCS). 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     I. Introduction and Environment 
       [0022]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
         [0023]    Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, base, front, back, right and left refer to the invention as oriented in the view being referred to. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning. 
       II. Equipment Retrofitting Method  2   
       [0024]    Referring to the drawings in more detail, the reference numeral  2  generally designates an equipment retrofitting method embodying an aspect of the present invention. As shown in  FIG. 1 , the method  2  generally involves a sales phase  4 , a project management (PM)/design phase  6 , a production phase  8  and a field service phase  10 . 
         [0025]    As shown in  FIG. 2 , the sales phase commences with a determination at step  12  of customers that are suitable for the entity (consultant, provider and/or vendor) operating the method  2 , utilizing resources such as, for example, a general customer list at  14  and a specific resource, such as an engineering account manager customer list at step  16 . Sales opportunities are validated at  18 , leading to steps comprising revamping information gathering document at  20 , producing project economic calculator at  22 , information gathering document at  24 , project web access (PWA) production schedule at  26  and master field schedule at  28 . A negative decision at Quote Job? decision box  30  leads to communicating the result to the customer at  32 . An affirmative decision leads to a field sales audit at  34  utilizing a field audit tool kit at  36  and leading to reconfiguring an audit review at  38 . 
         [0026]      FIG. 3  continues from connecting arrow A in  FIG. 2  and includes portions of the sales and PM/design phases  4 ,  6 . A proposal is developed at  40 , the proposal template reconfigured at  42 , standard terms are provided at  44 , the costing template is reconfigured at  46 , the process sizing template is provided at  48 , the compressor performance calculations are performed at  50  and engineering account manager reports are provided at  52 . The proposal is presented at  54 , leading to a Win Job? decision box at  56 , from which a negative decision leads to the step of communicating why the job was lost at  58 . An affirmative decision at  56  leads to purchasing long lead items at  58  (e.g., heads, shells, etc. for a compressor station retrofit project). 
         [0027]    A job purchase order (PO) file is created at  60 . An order entry is created at  62 , distributed at  64  and entered at  65 . A sales announcement is made at  66 , the parameters of which can be defined at  68 . The entity can employ appropriate communications, accolades and acknowledgments for “winning” a sales order, which can motivate, reward, congratulate and inspire employees. A kickoff meeting is scheduled at step  70  and conducted at  72 . A kickoff summary is distributed at  74 , a production schedule is created at  76  and the project schedule is created at  78 . 
         [0028]    Connecting arrow B in  FIG. 3  leads to facilitating the kickoff meeting at  80  in  FIG. 4 . An Order Entry Costing Summary Request Met? decision box  82  (negative decision) leads to evaluating issues and determining actions to resolve at  84 , communicating actions to customer at  86  and Customer Approves Change? decision box  88 , from which a negative decision loops back to evaluating issues at  84 . An affirmative decision from  88  loops back to distributing kickoff summary at  74  (C 1  reference to  FIG. 3 ). An affirmative decision at  82  leads to the project manager (PM) creating a project job folder and transferring sales data thereto at  90 , from which a work order folder is created at  92 , a PM checklist is created at  94  and a progress invoice is created at  96 . Long lead material is purchased at  98  and entered into the job PO file at  100 . The PM marks the drawings for an issued for approval (IFA) model at  102  whereat the drawings and documents are sent to the customer, the designer creates vessel calculations at  104  and process and instrumentation diagram (P &amp; ID), general arrangement (GA), vessel and spool drawings at  106 . An advanced pressure vessel (APV) program is created at  108  and safety code compliance calculations (e.g., state or provincial pressure vessel codes, which may be based on American Society of Mechanical Engineers (ASME)) standards) are performed at  110 . The project is modeled at  112 , based on which the designer creates IFA drawings at  114  and a drawing checklist is created at  116 . A designer checklist (in order entry document) is created at  118  and a computer-aided drafting and design (CADD) application occurs at  120 . 
         [0029]    From  114  the method proceeds to  FIG. 5  in the PM/design phase  6  via C. The PM arranges a site visit at  122  and checks the IFA drawings at  124 . The PM and the designer perform a site audit at  126  and coordinate measuring machine (CMM) inspection of the existing package occurs at  128 . The designer updates the issued for construction (IFC) model and drawings at  130  with the CADD application at  132 . The PM issues IFC drawings to the customer for approval at  132 , leading to Customer Approves Drawings? decision box  134 , with a negative decision leading to the PM advising the designer of drafting issues at  136  and the PM advising the designer and sales of scope changes at  138  and providing a change notice document at  140 . Step  138  loops back to step  82  in  FIG. 4  via connecting arrow G. 
         [0030]    An affirmative decision at  134  leads to  FIG. 6  via connecting arrow D and to the step of the designer printing the IFC drawings package at  142 . The PM verifies and signs the IFC drawings package and creates an industrial test plan (ITP) document at  144  and orders detailed material at  146 , which can be expedited at  148  with the materials being received at  150 . A progress invoice is created at  152 , a receiving report is created at  154 , job POs are created at  156  and a material traceability report (MTR) is created at  158 . The designer distributes the IFC drawing package at  160  and the drawing release form at  162 . Quality-control (QC) signs for the vessels (e.g., in a compressor station project) at  164 , leading to an ABSA QC manual step at  165 . 
         [0031]    From  150  a pressure material step occurs at  166  leading to pressure shop fabrication at  168 , which leads to QC vessel sign off at  170  and leads to a vessel nameplate step at  172 . Step  168  also leads to a spool and vessel production checklist at  174 , PWA at  176  and task timesheets at  178 . A material requisition step occurs at  180  and CMM inspection of completed parts occurs at  182 . 
         [0032]    Step  170  leads to staging assembly material at  184  ( FIG. 7 ) via connecting arrow E, which leads to assembly shop fabrication at  186 , PWA at  188 , task timesheets at  190 , ITP at  192  and material requisition sheet at  193 . Paint step  194  occurs after either  168  (via connecting arrow F) or  186  and product is shipped at  196 . A ship loose list is created at  198  and a shipping log is created at  200 . From step  196  the method also proceeds to product field installation at  202 , field scheduling at  204 , a field project completion document at  206  and a field checklist at  208 . Also from step  202  the PM invoices the customer at  210 , creating an invoice at  212 , the scheduler sends a loyalty survey at  214  followed by a loyalty survey step at  216  and the project ends at  218 . 
       III. Compressor Station Retrofit Project Application 
       [0033]    In an exemplary application of the equipment retrofitting project method embodying an aspect of the present invention, a compressor station is retrofit.  FIG. 8  shows components of a typical compressor station, which is generally designated by the reference numeral  250  and includes a reciprocating compressor  252  connected to intercoolers  254 , which discharge to process spools  256 . The process spools  256  include multiple connecting flanges  258 , which connect the spools  256  to adjacent upstream and downstream components, and interconnect spool sections  260 ,  262 . The precise locations of the connecting flanges  258  are determined by the CMM to a desired degree of accuracy with respect to three axes (X, Y, Z). Such 3-D PCS data is transferred from the field inspection equipment (including the CMM) to a suitable CADD system for creating production drawings. The production drawings can show the process spool  256  isolated from the other components, as shown in  FIG. 9 . Alternatively, the components can be modeled in three dimensions entirely electronically, with digital data providing the input to a computer aided manufacturing (CAM) system. The data associated with the process spool  256  can be referenced or included in data annotations  259 , which are keyed to different features of the component, such as the flanges  258  of the process spool  256 . Such data can include nominal and measured XYZ positional information based on the PCS, tolerances, measured positional data, deviation, etc. and can be recorded on field survey reports, such as a form  270  shown in  FIG. 10 . 
         [0034]    It will be appreciated that the functionality of the entire process  2  is facilitated and enhanced by the CMM providing a relatively precise, 3-D model in electronic (i.e. digital) format for accurately designing, modeling, manufacturing and fabricating new and replacement components remote from the jobsite. By locating such components, including their interconnections, in the 3-D (XYZ) part coordinate system (PCS) based on a chosen reference point, fieldwork traditionally performed at the jobsite can be significantly reduced and the actual construction and installation (field service) phase of the project expedited because fit and interchangeability aspects have been worked out offsite. The CMM modeling procedure can incorporate a wide variety of modeling, design and manufacturing functions relating to physical attributes associated with the existing equipment and the reconditioned and/or new components being installed. For example, physical dimensions in three dimensions (XYZ) can be provided for components standalone and in relation to other components on the project. Thus, the CMM-based model avoids problems with misfitting and interfering components, which problems are addressed and solved according to the present method prior to the commencement of the installation and construction phases on-site. Other functionalities of the method include bill-of-material generation, QC, procurement, scheduling, testing, construction management and invoicing. 
         [0035]    It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.