Multi-Million Manufacturing Facility Custom Test Rig Test
Project Details
Air Products PLC is the largest global supplier of hydrogen, helium and select performance chemicals. They embarked on a multi-million pound project to establish a new manufacturing facility at Tanjung Langsat in Malaysia. The new facility aims to increase their capacity to produce air separation plants. This will enable Air Products PLC to meet the heightened demand for oxygen following the COVID-19 pandemic.
Air Products PLC wanted to improve the performance and reliability of their air separation plants, while ensuring their manufacturing process was efficient. For a new test rig design and construction, they needed a company that could manage a large installation globally. They chose to partner with TechServ due to its expertise in large-scale motion control, multi-channel data acquisition and advanced programming.
TechServ closely collaborated with Air Products PLC to develop an innovative test rig. This would enable more efficient manufacturing of reliable, high-performance air separation plants. The initial development of the rig presented significant challenges and introduced a completely new system for both partners.
In an air separation plant, the liquid distributor trays play a crucial role in ensuring the efficient operation of the column. These trays distribute liquefied air evenly across the surface area of the liquid gas interface. This maximises process efficiency and minimises energy consumption.
The 6m x 10m test rig design included 36 high-precision 200mm square burettes, which could accurately measure water flow rates. TechServ designed methods that used laser technology to accurately locate a large 5m diameter tray relative to the rig.
Using laser detectors, the test rig system maps the liquid distributor and calculates the flow of liquid through each distribution hole. It can accommodate trays with up to 2,500 holes. At the end of each test, a distribution map is produced that highlights areas of high and low flow. Necessary adjustments can then be made before the trays are mounted in the column.
The advanced test rig system features complex motion control powered by Trio EtherCat drives, along with multi-channel, high-speed data acquisition and processing. All of this is seamlessly integrated into an intuitive operator interface, ensuring ease of use for Air Products PLC.
TechServ completed the test rig design, manufacture and programming in the UK. The company then visited Air Products PLC in Johor Bahiu, Southern Malaysia, to service it. Since supplying the first rig in 1995, TechServ has continued to enhance and refine the system. The latest rig is the fourth iteration.
The test rig now plays a vital role in improving the efficiency of Air Products PLC’s air separation plants, helping to reduce both energy and manufacturing costs. They have sold, designed and built over 1000 air separation plants globally. As a key component of their manufacturing facility, the test rig design ensures every distributor tray is thoroughly tested and optimised before installation. This helps to guarantee high performance and reliability for every air separation plant produced.
