PRODUCTION • PROCESSING • HANDLING
Gas Heater TEMA type: Tube length (mm) Shell ID (mm) Weight each shell (kg) Shells per train Total weight 4 trains (kg) Shells required 4 trains
reduced by a factor of two, however they need to be slightly heavier)
l Less crane and handling cost (50% less crane and handling cost. Te number of items is reduced by 50% and the handling will not be increased due to the weight increase)
l Less transportation (40% savings, the number of items is reduced by a factor of two, however the extra weight per item will increase the cost slightly)
l Fewer items means less maintenance and therefore less maintenance cost (50% fewer spare parts)
l Less piping (50% less connections) l Less installation time and costs (50% less items to be installed)
l Less spare parts storage l Considerably less capital investment
For the gas heater design no significant savings in the thermal design could be realised. However the design could be optimised by changing the nozzle locations. Instead of radial nozzles, axial nozzles were used. Tis reduces the overall plot space and weight of the channels. Secondly all welding was eliminated by use of a forged channel. See the image on the right for comparison between design from datasheet and the new design. Te benefits are less material, no welding, hence no welding docs were required and a minimal non destructive examination (NDE). For BHT the lead-time was reduced significantly and risks during project execution minimised. Most importantly, this solution results in considerable client benefits – most importantly, higher integrity due to weldless design, but also less plot space, less weight for transport and foundation) and less weight to handle during maintenance. All of these heat exchangers are vibration free and have a complete thermal guarantee.
LESS IS MORE Since the market in Iran opened up again, a lot of projects that have been on hold for a long time, are being revived. Tese kind of projects (in Iran or anywhere else for that matter) create a lot of
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The gas heater following datasheet design (bottom) and the new design(top)
opportunities for both plant owners and operation managers. Tey might, for instance, take the chance to have another look at the cost of ownership of the plant, in terms of energy consumption and maintenance requirements, but also the capital investment in terms of material and plot space being used. A company such as BHT loves to take up such a challenge. Te above case study highlights what the result of such an endeavour can be. In this particular scenario, the number – and more importantly the total weight and plot space – have been reduced dramatically. Especially for the inlet gas cooler and the treated gas cooler, these changes will have an impact on the total layout of the plant, since the trains no longer consist of four heat exchangers per train, but just two. And the major impact of the gas heater is, as mentioned before, the higher integrity due to the weldless design. Tese outcomes of smarter design are directly translated into advantages for both the plant owner and the plant manager. l
For more information ✔ at
www.engineerlive.com/iog
Conventional BEM 1,929 930
20,800 1
83,400 4
Alternative BEM 1,929 930
15,100 1
60,400 4
New design of gas heater compared to the old design
Femke Schaefer is with Bronswerk (BHT).
www.bronswerk.com
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