Study of Heat Exchangers

Project Background

CE 1.2.1 Characteristics of the project

The project of Study of Heat Exchangers was eventually developed to provide various important and significant benefits to the society. Heat exchangers within any process system subsequently allow transfer of heat from any one source to the other. All of these heat exchangers remain in single line equipments and in case of any type of failure would be requiring the ceasing of the unit operation. The main guidelines of metallurgy, inspection, testing and construction were properly checked as well as studied within this project. Since, this was my first major project in engineering career; I made sure that the project was well executed. This project comprised of the detailed research of heat exchangers.

CE 1.2.2 Objectives developed for the project

This particular project of Study of Heat Exchangers has various significant objectives. They are as follows:

• To study and research heat exchangers with details.
• To learn about heat exchangers and the various classifications.

CE 1.2.3 My area of work

The project of Study of Heat Exchangers was first major project in mechanical engineering career. My major area of work was to research as well as document the entire project with details and with utmost sincerity. During this tenure of research and documentation, I acquired immense and important knowledge regarding heat exchangers. Moreover, I even assisted my project supervisor in this project and took proper follow ups for identifying the flaws.

CE 1.2.4 Project Group

Figure 1: People involved in the project

CE 1.2.5 My responsibilities throughout the project

I was an important part of the project. I had various and several roles and responsibilities throughout this project and I was successful in executing all of them. My first responsibility was to learn about the heat exchangers and do relevant and important research about this particular topic. My second important responsibility was to execute this project properly and perfectly. Furthermore, I also assisted my project supervisor in the entire project duration and made sure that my duties and responsibilities were perfectly executed. My final responsibility was to arrange weekly meetings with my project supervisor and head of the department. This helped us in understanding our project position and also in identifying the various flaws or errors within the project.

CE 1.3 Distinctive Activity

CE 1.3.1 Engineering knowledge and skills applied in the project

I have successfully utilized my mechanical engineering knowledge and skills for the major success of this project. I knew that if I will apply my skills and knowledge in the project properly, it is evident that the project will be a huge success. I am a hardworking person and have excellent problem solving skills. Since I was a quick learner, I utilized my experience in this particular project. I had also used my computer proficiency in the project, which included MS Office, MS Project and many more. My power of critical thinking is also applied here.

CE 1.3.3 Comprehending the Theory of Project

The project of Study of Heat Exchangers within plant under various guidelines of assembly, disassembly, testing, inspection and construction was the major attempt in this project. The heat exchangers are considered for a purpose of shell type as well as tube type comprise of the tube bundles that is enclosed within a shell for transferring heat. There are four classifications of heat exchangers. They are as follows:

1. i) TEMA style shell and tube heat exchanger
2. ii) Double Pipe or Hairpin Exchangers

iii) Air Cooled Heat Exchanger

1. iv) Compact and non tubular heat exchanger

There are various standards of these classifications. All of these standards mainly include TEMA or Tubular Exchanger Manufacturers Association, TEMA classes and many more.

The shell and tube heat exchanger was my major research subject in this particular project. This heat exchanger comprises of the tube bundles that are encased within a shell. The transfer of heat occurs between flowing liquids in tubes. The principal types of construction in this heat exchanger are as follows:

1. i) Fixed Tube sheet heat exchanger: The tube sheet is welded within the shell. Thus the tube sheet and shell materials are welded with one another. The cost of this heat exchanger is lower and no shell side gasket is present.
2. ii) Floating heat exchanger: The one tube sheet is subsequently fixed to the shell and any other tube sheet for packing rings that are compressed in the stuffing box by the packing follower rings. The floating heat exchanger utilized for the shell side services up to the 4137 kPa gauge pressure at temperature 31 degree C.

iii) U Tube heat Exchanger: The third type is the u tube heat exchanger. The tube bundles comprise of stationary tube sheet, support plates or baffles and hairpin tubes or spacers. This bundle could be removed from shell of heat exchanger. The main advantages of U tube heat exchanger mainly include providing minimum clearance within outer tube limit or other tubes. The utilization of the u tube construction has eventually increased properly with the major development of various hydraulic tube cleaners that could remove fouling residues.

Baffles are utilized for supporting tubes and thus enabling the most desirable velocity to be properly maintained or prevented from flow induced vibration. All these baffles increment the transfer of heat with the production of turbulence and cross flow. The maximum baffle spacing is limited by the requirement to provide adequate support for the tubes. Closer baffle spacing will result in poor bundle penetration by shell side fluid and difficulty in mechanical cleaning of outside of tubes.  As baffle spacing is decreased pressure drop increases at much faster rate than does the heat transfer coefficient. So there is optimum baffle spacing that will result in highest efficiency. There are two types of baffles. They are Rod baffles and segmental baffles. The segmental baffles are maximum shell side heat transfer rates in the forced convection could be obtained by the cross flow of fluid. For maximizing flowing type, the building the segmental cut baffles is done and also with no tubes in windows. The second type of baffles is rod baffles. The rod baffles for the extension via the lanes within tube rows. The flow of shell side is uniform or parallel in tubes.

The failure of heat exchanger is again important for this project. The tube vibration takes place within forcing frequency and tube natural frequency. The failure dependency within content of energy or amplitude and the tube vibration is affected by the tube unsupported span. The modes of failure are tube to tube sheet joint leak, fatigue, damage due to collision of tube to tube and cutting of tube wall at baffle location.

There are some of the basic selection criteria of the heat exchangers. The maintenance aspects of shell and tube heat exchangers are given for determining when heat exchanger should be located within vertical or horizontal position for requirements of inspection and maintenance. The fluid allocation of shell side and tube side comprises of various criteria like most corrosive, high pressure, severe fouling, pressure drop and many more.

According to TEMA of heat exchangers, there are some of the classes of this heat exchanger. The classes are as follows:

1. i) Class R: This particular class of the heat exchanger specifies the design, fabrication, and materials of unfired shell and tube heat exchangers for the generally severe requirements of petroleum and related process applications. Equipment fabricated in accordance with these standards is designed for safety and durability under the rigorous service.
2. ii) Class C: This class of heat exchanger specifies design, fabrication, and materials of unfired shell and tube heat exchangers for the generally moderate requirements of commercial and general process applications. Equipment fabricated in accordance with these standards is designed for maximum economy and overall compactness consistent with safety and service requirements.

iii) Class B: This class of heat exchanger specifies design, fabrication, and materials of unfired shell and tube heat exchangers for chemical process service. Equipment fabricated in accordance with these standards is designed for maximum economy and overall compactness consistent with safety and service requirements.

The fixed tube sheet heat exchanger comprise of straight tubes, which are absolutely secured in every end to the tube sheets welded to shell. This construction might have the removable covers of channel, integral tube sheets and bonnet type covers of channel. The major benefit of fixed tube sheet construction is for the lower cost and simpler construction. The u tube heat exchanger is bent as the U shape. The advantage of a U-tube heat exchanger is that because one end is free, the bundle can expand or contract in response to stress differentials.

CE 1.3.4 Identified issues and their solutions

1.3.4.1 Issues

The most significant issue that we faced in the project was while understanding the classification of heat exchangers. I was not sure about the classification.

1.3.4.2 Solutions

For solving this particular problem, I researched about the types of heat exchangers properly. Hence I was able to understand as well as identify all the types of heat exchangers without difficulties.

Name of the project:  KNPC Clean Fuels Project or CFP- Delayed coker heater for MAA Unit 136 – Delayed Coker Unit (DCU)

Location of the project: Please fill

Project Duration: May 2012 to August 2012

Organization: CB & I Lummus

Role and Designation during the time: Team Member of the project

CE 2.2 Project Background

CE 2.2.1 Characteristics of the project

This project of KNPC Clean Fuels Project or CFP: Delayed coker heater was my second major project in engineering career. This particular project was designed to process 37,000 BPSD of hydro treated vacuum residuum from the existing Vacuum Unit (VR-83) and the new Vacuum Rerun Unit (VR-183) into the following products of fuel gas, naphtha, kerosene, diesel, heavy coker gas oil, and anode grade coke. DCU-136 is designed by the Licensor, CBI Lummus (formerly ABB Lummus Global).

CE 2.2.2 Objectives developed for the project

The project of KNPC Clean Fuels Project or CFP: Delayed coker heater comprises of two important objectives. The objectives are as follows:

• To make the delayed coker heater.
• To process 37000 BPSD of hydro treated vacuum residuum from Vacuum Unit.

CE 2.2.3 My area of work

This project of KNPC Clean Fuels Project or CFP: Delayed coker heater was executed properly. As the mechanical engineer, my main area of work was to document the entire project. I made sure that the project documentation was done perfectly. My other area of work in the project was to arrange for various meetings and gatherings of the project. I did this at the end of every week for understanding whether the project would be successful or not or whether we are lagging behind.

CE 2.2.4 Project Group

Figure 1: People involved in the project

CE 2.2.5 My responsibilities throughout the project

I was an important part of the project. I had various important responsibilities within the project. My first and the foremost responsibility in this project of KNPC Clean Fuels Project or CFP: Delayed coker heater was to document the entire project properly. I knew that if the project report was made perfectly, the project is bound to be a success. My next responsibility was to assist my project supervisor in the project. Another important responsibility that I had to execute in this project was providing guidance to my juniors. I even applied my knowledge and skills within the project for successfully completing the project.

CE 2.3 Distinctive Activity

CE 2.3.1 Engineering knowledge and skills applied in the project

I have utilized my mechanical engineering skills and knowledge for the success of the project. I knew that if I will apply my skills and knowledge in the project properly, it is evident that the project will be a huge success. I am a hardworking person and have excellent problem solving skills. Since I was a quick learner, I utilized my experience in this particular project. I had also used my computer proficiency in the project, which included MS Office, MS Project and many more. My power of critical thinking is also applied here.

CE 2.3.3 Comprehending the Theory of Project

The entire process of delayed coking is eventually utilized for the purpose of cracking heavy oils, normally vacuum residue within important and valuable lighter liquid products with solid coke as the by products.  The process of delayed coking has brought significant impact on operation or design of the delayed coking units. The demand of the liquid petroleum products has increased the price of crude oil and there is a sharp difference between light as well as heavy crudes. The shift towards the processing of lower quality, crudes of lower costs or tar sands bitumen have subsequently created the requirements in converting large quantity of vacuum residue. Hence, the application of delayed coking is increased exponentially.

The process of delayed coking is given below:

1. i) Thermal Cracking Process converting residual oils to liquid products
2. ii) Byproducts Off gas and Petroleum Coke

iii) Feed stocks characteristics vary widely

1. iv) Some feed stocks pose challenges which affect heater and therefore unit run length
2. v) It is important to maintain the Delayed Coker on line for as long as possible and at maximum throughput.
3. vi) If the refinery did not have the Delayed Coker in operation it would have to cut back on the Crude Unit and shut down or cut back various other units that rely on the products for feed stock.

The process of fired heater is given below:

1. i) The Fired Heater run length is the key component affecting the Delayed Coking Unit Onstream Factor.
2. ii) All the heat for the Process is supplied by the Fired Heater

iii) Heater Run Length has a direct role in the profitability of the unit and ultimately the entire refinery

1. iv) Even considering the ability to spall and decoke online, there is still loss of production and maintenance costs associated with short run lengths.

The process of feed stocks is given below:

1. i) Shift to lower quality heavier Crudes
2. ii) Higher levels of asphaltenes, metals, sulfur and naphthenic acids

iii) No longer operating on fixed feed slate. A variety of available crudes are selected from the market

1. iv) Some feeds are not compatible
2. v) Refinery expansion requiring higher severity operation
3. vi) All have contributed to shorter run lengths.

Delayed coking is considered as the endothermic thermal cracking procedure, which needs huge heat for supplying to reacting feed stock at the temperature of 500 degree C. The pressure is dropped to a lower point and the tube metal temperature is incremented. Furthermore, the coke deposition rate helps in determining coker heater run length. There are some of the major advantages of this particular process of coker heater. They are as follows:

1. i) Optimizes operating conditions and product slate
2. ii) Maximizes run length and provides high efficiency

iii) Higher on-stream factor

1. iv) Enhanced operational safety with shorter cycle time
2. v) Maximizes drum life for all drum sizes
3. vi) Maximizes distillate production

vii) Improved unit on stream time

viii) Reduces fugitive emissions and waste effluents

1. ix) Operating cost savings
2. x) Reduced investment and maintenance costs
3. xi) Provides sludge disposal capability

Figure 2: Process Flow Diagram of heater coker

The delayed coking is the semi continuous procedure by utilizing alternating drums, which are switched off line after filling. This specific process is responsible for supporting facilities including handling, coke cutting and closed blow down. The system of water recovery is also supported within this procedure. The combined stream is heated in the furnace to initiate coke formation in the coke drums. Coke drum overhead vapour flows to the fractionators where it is separated into wet gas, and coker liquid product such as unstabilized naphtha, light gasoil, and heavy gasoil. The average or normal rates of heat flux for the coker heaters is extremely lesser than the usual refinery process heaters within the sole range of 24,400 kcal/hr m². There are higher residence times for promoting the coke deposition.

The double fired coker heater with the burners firing a specific combination of the fuel gas as well as heavy fuel has operated successfully for over two years. There is a basic comparison between syngas and offgas. The comparison is provided below:

Table 1: Comparison between Offgas and Syngas

The burners should be meeting the range of operation that is needed for both fuels and this burner technology is eventually developed. CFD or computational fluid dynamics of all these burners or associated firing patterns assure that expected flux profiles would be meeting the needs for maintaining unit run lengths for the delayed coker heaters.

The proven applications within the project of delayed coking services majorly involve:

1. i) Coker feed preheat exchangers for reduced surface requirement.
2. ii) Coker fractionators’ overhead condenser with reduced surface requirement and reduction in pressure drop.

iii) Debutanizer overhead or stripper overhead condensers with the reduction of surface requirements.

1. iv) Compressor inter stage as well as discharge of the coolers with reduced requirement of surface and reduction in pressure dropping.

CE 2.3.4 Identified issues and their solutions

2.3.4.1 Issues

The main problem that we faced in the project was during designing the coker heater. The person who was given the responsibility to make the design made it completely wrong. Since, coker heater was the main requirement in our project; the designing was required to be made perfect.

2.3.4.2 Solutions

I gave suggestions to my co workers for solving the issue as this was bringing delay in the project. I made the project design myself and thus was successful in making the project design perfect.

CE 2.3.5 Plan to produce creative and innovative work

We made a significant plan for our project. Our plan was to bring out creative and innovative work by working mutually. We divided our work perfectly and every one carried out their responsibility with utmost sincerity and perfection.

 Competency Demonstration Report

 Continuing Professional Development

I have successfully completed my B. Tech in Mechanical Engineering from The Institution of Engineers, India A.M.I.E.  (Associate Member of Institution of Engineers) . I have also completed Diploma in Mechanical Engineering from Pusa Polytechnic, New Delhi in the year of 2007. Currently, I am working as an International Sales Manager in Environmental Equipment Company Ltd. I have even worked in various other reputed organizations. I had various responsibilities in my work and I had been a part of several important projects. Therefore, I want to apply in the Australian Immigration (Engineers Australia) for increasing my professional skills and knowledge.

Academic Qualification

Work Experience

Career Resume

Personal Details

Name: Kulwinder Singh

Nationality: Indian

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E–mail: Please fill

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Date of Birth: Please fill

Career Conspectus

Seeking assignments in Sales, Business Development, Design Engineering or Project Management with an organization of high repute & to reach at the zenith of organization hierarchy through continuous self development by way of learning and experiencing the critical aspects of technology and management.

Work Experience

Educational Qualification

Project Experience

• MRPL, Mangalore Refinery and Petrochemicals Limited.
• SONATRACH/ANADARKO Association, Algeria.
• SECCO Petrochemical Project, Shanghai Secco Petrochemical Co.
• JG SUMMIT Petrochemical Corporation.
• KNPC refinery Expansion Project ,Kuwait
• Shell Moerdijk, The Netherlands
• NOCL, Tamilnadu.
• Guru Gobind Singh Refinery, Punjab
• CARTAGENA Refinery Exapansion Project,COLOMBIA.
• BCPL, Assam India.
• Jubail Refinery, SaudiArabia.
• Yambu Refinery Expansion Project, Saudi Arabia,
• Rosneft Expanion Project (Kosmolosk, Russia)
• Shell ECC, Singapore
• Westlake Expanison Project, Lousiana
• LG Chem, Korea
• Petronas Revamp, Malaysia.
• KNPC clean fuel project.

Technical Skills

• Operating Systems: Windows XP, 7, 8 and 10.
• Application Packages: Microsoft Office.
• In House built proprietary software
• AutoCAD

Declaration:

I, the undersigned, hereby declare that information furnished above is true, correct & complete to the best of my knowledge.

Date:                                                                                                               Signature

(Kulwinder Singh)

Professional Engineering: Summary Statement