key word /

/ -type LIF

0.2 Cost DownFmm type 0.1 mm Vapor CondenserHorizontal Cut DatasheetInformation Vertical BaffleH/EBaffle cutBaffle cut Datasheet percentage

/ pe(

F Typeshell H/E vapor partial Condensate H/EVapor / condensaer) 2 Vent tube head/end vaporaccumulate tubeequal distribution FEEDC3 Chiller(Kettle type, Shellside C3NozzleSide BD C3Tubeside HC Bottomwith Pulsation Manual HAWIYAH Gas)C3NozzleBottom PlateSide Shell side tubedamage LC Kettle Kettle type Chiller Level reboiler Controller (2phase feed) Level300mmBubbling MLNG Dua Compressor

Pearl GTL

Sperger pipe

DEPS ReviewSperger hellNozzle24 Nozzle PipeSperge Shell r Shell PipeBundle

RABIGH

Drain&Vent DatasheetDrain&Vent NozzleLicenser Date vent/drain NozzleVendornozzle Sheet nozzle plughole

DatasheetP&ID Check

//

STAR

BEDD399,42kg/cm2G) Document Steam 249,39kg/cm2G Re (42kg/cm2sat. steam gen emp.253 C)

Haradh

Hydrate Skin temp

S&T Exch.Tube CondensateHydrate sideCondensate)Hydrate Bypass lineBypas Shellside(C3 Liquid HTRICheck HTRI WarningBaffle

Surface condenser QAPCOEP2 Fouling

B Vender DatasheetCleanliness FactorClea nliness Factor Fouling Factor 2

Steam HeaderH/E (CV, ,Desurper Heater) Hydrate Hydrate2 35

Tube Side P Steam Surface Vender CondenserHEI Cleanliness Fouling Cleanl FactorVender iness

QAPCOEP2

type / fouling factor , Design margin Licenser Vendor PlateHTRIF ouling FactorDuty Margin

LicenserDatasheetHTRIFou ling FactorVendor

LicenserDatasheet P lateVendorCri teria V ender by L oss, Upset separat or

BPC

Al lowable pressure drop Tube bundle Static

U tubeTube side Static head vaporizerTubeP P Headtube JOB Bundle H/E L

Nahai LOP

Thermal stress Kettle U-tube

PERTAMINA PKM PJ / vacuum residue

ShellTube Zero Flow ConditionShell Tube Shell Kettle UTypeTubeUTube Tube Tu Turn down Tube37Block DownTube Turn Down ValveTurn Block OperationTube DownTube Valve/

FCC

( Turndown Normal keep

FCCMain Column Bottom Steam Stream()Steam Turn Down Tube(Hot Side) SteamHot Bottom QuenchQuench line Tub e/Schell Steams side (kettle) tube shutdown

H/E Nanha co ntrol i

Motor/AFC feed back AFC /Operator

AFC

Condensate Stab. Reboiler(Horiz. Thermo.)SUS Stab. FeedSUS 316L TubeCS Tube

Stab. Feed CS Tube Stab. FeedFouling Stab. Bottom

Haradh

Free water

Condensate Stab. Reboiler(Horiz. Thermo.)Fouling

FEE D100%x2Reboiler /

Spec. Design practice OCW CorrosionVib C ration orrosion OCW Corrosion Critical CS ALBRCladCS Design practice

Shell DEPOCWTube SideSS24m/ sFou ling ServiceCleaning TubeShell , Shell DEPSSTube24m/s Circulat ion "CS + Cu/Ni

Waste Shell DEPOCWTube WaterSlop Oil Side TankHC WaxWaste WaterTube CriticalByOCWShell Pass Demineralised WaterCS

Deviate

contam SMDSDebottle ination) Design Necking practice Criticai ty SMDSDebottle Necking Design SMDSDebottle ub Necking e -BR SOHAR tube

Vendor Tube AlAlBr Br

AlBr Vendo r


Person

No.Type

EPKB EPKB EPKB

Tech. Data Tech. Data Tech. Data

1 S&T

2 S&T JGCEnglish et al. Insulation

3 S&T

BD ManualHTRI BD Manual

4 S&T

S&T Exch.TubesideSeparat or HTRIS&T Exch.(Reboiler, ShellsideSteam)Tube Tubeside CondenserTubeFlooding LPG (-41C) (8C) 5C

5 S&T

6 S&T

7 S&T

Box-Air Agitation Typeok TubesideEG Foster Wheeler2 Gas/Gas(ST items4,000Tube20m Exch.) F-TypeLong Tubeside in/out : -63C/ 11C BaffleInsulationBaffle Shellside in/out : 16C/-44C Cold box (Core), S&T LNG PlantC3HC Exch.Fin tubeButt Gas WeldS&T Exch.

LNG Plant Tech. Data

8 S&T

Crude preheatTubesideFoulingSel (SRC) f CleaningSPIRELF Tube

Sprirelf tube TubeSpring Fouling Tech. Data tube Elf SRC PFD, P&ID Tech. Data

9 S&T

LP Steam-60CHC GasS&T Exch.

10 S&T

(-28C)High Pour PointAFC

TubesideHC Gas, TubesideLP Steam, ShellsideC3S&T Exch.Steam Vendor (BTT)Steam CoilLouver Welded Ti tubeSeamless Ti tube

Tech. Data

11 S&T

S&T CoolerTi tube

Tech. Data

12 S&T

Crude Unit

Crude Unit26 ItemsS&T Exch.5 ItemsF-Type Exch. US-Twist TubeHE Capa.Up

U10-100

13 S&T

Twist Tube Bundle20up

Welded Ti tube FType HE Type PlateS&T

14 S&T

2-SeriesH-Type Demethanizer Reboiler

Tech.Dat a
PSR PJ2-SeriesH-Type ReboilerType Gascket Material LL&MISS DB

14 Plate

PlantCCW CoolerScrubber Water Cooler

Examples of Mistake

Mistake in Mechanical Construction

Mistake Cause/Countermeasure

No.
Recommendation

Client/Unit

key word

1 Maruzen Sekiyu Condenser, - F-type design was applied to many HEs for type (Seal) cost down. Due to loss of elasticity of (Chiba)
Since the thickness of seal strip was required in the design stage. selected at 0.2mm, once it was bended during maintenance, it did not return to the original shape due to lack of elasticity. Large clearance caused by bended seal strip resulted heavy leakage. The standard thickness had been revised to 0.1mm afterwards.

Responsi Classify ble Provision/consideration for maintenance is Mech.

seal strip, thermal performance had lost significantly because of leakage.

2 Kashima Chemical

Condenser, Baffle-cut

Horizontal cut baffle had been applied to Since there was no room to indicate the the condenser. Baffles were pushed to one baffle cut orientation on the data sheet end and stacked after start-up. in the past age, no information had been transferred to mechanical engineer. Datasheet had been revised afterwards. Consideration or attention to the welding in mechanical design was not sufficient.

Vertical cut shall be applied for the Process fluid contained vapor. Pay also attention to the baffle cut percentage.

3 Shin Nittetsu Chemical/ BTX

F-type (seal)

Seal strip of F-Type long baffle had been damaged by bulge of welding line inside the shell.

Actual equipment will not be manufactured Mech. ideally. There will always be tolerances. Process engineer shall also pay attention to the actual mechanical construction of heat exchangers.

4 Shin Nittetsu Chemical/ BTX

Condenser, Since no dam baffle was provided in the Partial partial condenser, the condensate ran bycondenser, Two- passing at the bottom of shell and was not phase, Baffle cooled.

Providing liquid seal by piping outside HE Pay attention to the HE handling two phase Process together with vent line for pressure flow. Liquid bypass or vapor pockets will equalization, performance had been cause troubles. Do not apply multi-tubeachieved. pass to two-phase flow if possible because vapor pocket causes mal-distribution in the tubes. Actual record only includes side entry nozzle or bottom entry nozzle with pulsation plate for C3 refrigerant. Nozzle location had been changed to side entry during manufacturing. This will be mentioned in BD Manual.

5 HAWIYAH

Kettle-type, Shell-side, Two-phase

FEED had specified bottom inlet nozzle without any provision for the kettle type C3 chiller. Shell side is propane refrigerant and tube side is hydrocarbon gas. It was found that there was no experience of this feed nozzle arrangement for C3 chiller.

Process

6 MLNG Dua

Kettle-type, Two-phase, Level

Due to heavy bubbling inside kettle vaporizer, liquid level fluctuation and massive entrainment had resulted trip of the C3 refrigerant compressor. Since level control span was very narrow 300mm, it was not possible to decrease liquid level along the span.

As short term basis, it was operated by lowering the liquid level. Finally, new nozzles were provided at lower side of the shell to increase the span length.

Lower side of LC nozzle shall be provided Process as low as possible to achieve wide control span. LC nozzles with calming baffles shall be provided apart from the feed nozzle in order to minimize effects from liquid level fluctuation. According to DEP, after several cases were studied, it was concluded that the number of nozzles shall be increased from 2 to 4. Finally, the shell size had been increased as client decision. For two phase feed, bottom nozzle with sparger or side nozzle with distributor are the possible solution. This will be mentioned in BD Manual.

7 Pearl GTL

Kettle-type, Sparger-pipe, Entrainment

During design review, no provision of sparger pipe was found. If the sparger shall be provided without design modification, the bundle shall be elevated to give a bottom side clearance for it and consequently the shell size shall be increased.

Process/ Mech.

No.
Mistake The main cause is that the licenser date sheet, which has no space of check mark for drain and vent valves, were utilized without care. The data sheet itself shall be verified before utilization, comparing with JGC data sheet. Each data sheet shall be checked for consistency with P&ID before the issuance because the mechanical engineer will not check the consistency. Cause/Countermeasure Recommendation

Client/Unit

key word

8 RABIGH

AFC, Vent/Drain Nozzle

Since the drain and vent nozzles were not specified mistakenly in the data sheet, vendor did not provide those nozzles, but only plug holes.

Responsi Classify ble Process/ Mech.

Input of PP/ Program to be applied/ Lack of knowledge Steam The HE, which was designed at saturate 9 STAR
The main cause was that the steam condition given in BEDD 399deg.C, 42kg/cm2G) was not used in the design, but that of licensor document 249deg.C, 39kg/cm2G was used. Decreasing regeneration gas flow rate, the required heating up was achieved. Finally, a desuperheater was provided. The main cause was that the hydrate formation did not checked in the design stage. Adopting a bypass line newly, HE was continuing the operation. Former HTRI could not check the performance for high viscosity sufficiently. Since the latest HTRI will give a warning in case of laminar flow, increasing flow velocity, countermeasure such as increasing number of baffle shall be studied.

condition, LMTD

condition of steam, however, could not heat regeneration gas upto the specified temperature because the steam was actually superheated and consequently HTA was not enough for heating.

The steam condition such as temperature Process and pressure at the HE shall be determined taking into account all necessary pressure drop between steam header and HE inlet such as CV, flow element, piping and desuperheater. Note that the degree of superheat will be increased due to pressure drop. Check hydrate formation and design HE Process system properly. There are two types of hydrate, methane type has higher formation temperature by 25deg.C than that of propane type. If there will be a possibility of laminar flow caused by deep cooling and high viscosity, allocation to the tube side should be considered so that the uniformity of temperature can be assured. Note that high viscosity should also be considered in pressure drop calculation.

10 Haradh

Hydrate, Skin temperature

The pressure drop of tube side (low temperature condensate) increased significantly due to hydrate formation. Shell side hot fluid was C3 liquid.

11 Maruzen Oil Chiba/ Oil cooler

Viscosity, Laminar flow, Shell side, Maldistributio n

Since the cold shell side fluid fell laminar flow region, shell side temperature became ununiform. B-stream was cooled too much across the tube bundle so that high viscosity caused by cooling made the B-stream flow small. To this end, bypass flow of bundle, which is still hot, was increasedand cooling was not sufficient. Since usually cleanliness is used in the design of the surface condenser, insufficient communication with vendor and late confirmation to use cleanliness are the main causes. After negotiation with the client, the design with cleanliness was agreed by the client. Vendor commented that, as a usual design criteria of the plate HE, fouling contingency should be accounted by the duty margin, not TEMA fouling factor.

Process

12 QAPCOEP2

Surface condenser, Cleanliness, Fouling factor

The surface condenser was designed by using cleanliness factor given in vendor data sheet. However, client intension was to use cleanliness factor or seawater fouling factor, whichever is severe. If the fouling factor would be applied, cost would be more than double.

Steam surface condenser will be designed in accordance with HEI. Fouling factor shall be confirmed with vendor and client without exception.

Process

13 QAPCOEP2

Plate HE, Fouling factor, Design margin, Licensor

Data sheet for plate HE prepared by licensor indicated fouling factor based on TEMA. However, vendor complained on that fouling factor.

Engineer is requested to examine the data sheet even prepared by the licensor and understand the vendor has own design criteria or method. Since there is some possibility to be rejected the vendor's criteria by client, the engineer shall consider for case by case.

Process

14 Kureha/ Sodium Integrated condenser at Hydrosulfide tower top, Plant

There was no problem in the design stage. However, entrainment was relatively heavy and caused loss of product quality.

Entrainment, Flooding

Flooding velocity was checked by using several equations but no problem was found. Finally, a helical separator and a mist eliminator were installed downstream of the condenser.

For the condenser where gas is upward shall be checked on the and entrainment carefully. If will cause adverse effect such product or upset of downstream provide mist separator.

flowing Process flooding entrainment as loss of equipment,

No.
Mistake In the past experience, an orifice per tube was provided to equalize pressure drop. In this design, based on the past experience, small and long tubes were used to achieve high pressure drop resulted from the maldistribution study. If the allowable pressure drop is quite small, re-examine the process design and conditions. If the static head is significant compared to the friction loss, bundle size shall be reduced. For this kind of rare case, study recent lessons learnt. Cause/Countermeasure Recommendation

Client/Unit

key word

15 BPC

Small allowable pressure drop, Static head, Maldistributio n

When U-tube HE was used as tube side vaporizer, because the tube side pressure drop was quite small, liquid static head caused maldistribution between inner and outer tube rows.

Responsi Classify ble Process

Insufficient Controllability/ Various Operation Mode

The HE was already fabricated at that time. The HE was analyzed for the thermal stress by finite element method in detail. The results were reported to the client that no problem was expected. If the materials are different between shell and tube side, consideration to all of operating conditions such as start-up, shut down, and intermittent operation shall be given in the design. U-tube is better to use in this kind of case.

16 CSPC Nahai LOP

Intermittent operation, Thermal stress, Kettle, U-tube

Zero flow condition, where low pressure steam was not introduced, was not indicated on the data sheet because of no attention to the intermittent condition. Significant thermal stress on the tubesheet due to the difference of thermal expansion between tube and shell had been expected. Although the shell type was selected as kettle, however, the rear head type was not selected U-tube.

Process

17 PERTAMINA PKM PJ/ vacuum residue

Turn down, Due to supercooling under turn down Tubes were grouped into 30 and 70% each Solidification operation, the tube side fluid solidified. associated with valves, those groups were , selected to meet the turn down condition. Supercooling, Control

If the solidification of the fluid is expected under the turn down condition, provide necessary valves and a facility for depressuring and draining out.

Process

18 Fuji Oil/ FCC Supercooling, For the steam generator against FCC main

Solidification , Heavy oil, Turn down, Control, Flow scheme

After cleaning, the bottom quench line was column bottom stream (heavy oil), tube provided to the other side so that bottom side hot fluid was choked due to recycling was possible while the solidification of heavy oil caused by temperature was maintained. supercooling under turn down operation. There was no control system on the cold steam side which shall adjust the system against changing of hot side flow rate. Also, the cold shell side was common for the two bundles for hot tube side fluid so that the system was already unsymmetrical. Once one side of bundle choked, whole system shall be shut down. Furthermore, quench line, which can be used bottom recycling, was provided to only one side of bundle. This also caused whole unit shut down.

A study to prevent shut down due to Process solidification shall be done considering all of operating conditions as well as normal operation. The control system and system configuration shall be adopted to maintain the temperature above the solidification temperature. If two or more system will be provided, make them independent so as to avoid whole shut down.

19 CSPC Nanhai LOP Plate HE,

Since high pressure drop designed by Deleting the level control pot, a pressure A skill to be noticed without calculation Level control, vendor was not recognized/confirmed during differential controller between HE inlet shall be trained aside from sufficient Static head, design stage, elevation of level control and outlet was provided. communication with vendor. Pressure drop pot was not sufficient to accommodate such high pressure drop.

Process

20 Feedback from commissioning

AFC, Temperature control

Where motor start/stop control was adopted No information. to control the AFC outlet temperature, client operator claimed that the number of start/stop was so frequent.

Considering climatic condition change, Process number of fans, and so on, select appropriate control method or combination of the methods such as bypass control, louver control, fan pitch control, number of fan control and fan start/stop control.

No.
Mistake Cause/Countermeasure Recommendation

Client/Unit

key word

Responsi Classify ble Material research /Process Material research /Process

Material Selection
Since the stabilizer feed contained salt If there is a possibility that the water, chlorine attacked stainless tube. stabilizer feed contains salt water, use Material had been changed to carbon steel. carbon steel tube for the reboiler. Technically unknown problem. If two reboilers 100%x2 are provided in the FEED book, it is better not to delete one.

21 Haradh

Chlorine ion, Stainless, Free water, Temperature

Stainless 316L used in the condensate stabilizer reboiler (Horizontal thermosiphon) had cracked.

22 Haradh

Chlorine ion, Stainless, Free water, Temperature

Heavy fouling had occurred in the Since the stabilizer feed contained salt condensate stabilizer reboiler (Horizontal water, fouling occurred in the reboiler. thermosiphon). The operating temperature at the stabilizer bottom had been decreased.

23 SMDSDebottle Seawater, Material, Necking

The idea was rejected because fluid stagnation inside the HE cannot be eliminated so that the chemical injection is insufficient and vibration will be expected by changing the fluid allocation.

Velocity, Stagnation

Shell DEP clearly indicates that OCW (Seawater) shall be allocated to tube side, and that the tube side velocity shall be higher than 2 - 4m/s for SS. This is intending to ease the cleaning under maintenance considering heavy fouling service and minimize the deposit of bio-fouling. Changing the fluid allocation between tube and shell, cost down idea was proposed providing relaxation of material and decreasing of heat transfer area. However, that idea was rejected.

Without concrete reason, it is difficult Material to change the client specification or research criteria. For the corrosion protection by applying chemical injection, it is required to check if there is no stagnation inside the HE.

24 SMDSDebottle Seawater, Material, Necking

The proposal of carbon steel was rejected because this equipment was critical item and it is difficult to control the corrosion for stagnant portion of OCW inside HE only by means of the chemical injection. Tubesheet material was selected as CS with Al-Br clad.

Velocity, Stagnation

Shell DEP clearly indicates that the tube side velocity shall be higher than 2 4m/s for SS. However, if we follow this criteria strictly, since the pressure drop would be significantly large, circulation of water would be impossible. Therefore, to decrease the velocity, "CS+Chemical Injection" had been proposed. Finally, material Cu/Ni had been selected.

Without concrete reason, it is difficult Material to change the client specification or research criteria. For the critical equipment, more on reliability is prioritize than the cost down.

25 SMDSDebottle Seawater, Material, Necking

Velocity, Stagnation

Shell DEP clearly indicates that OCW (Seawater) shall be allocated to tube side. Re-allocation of waste water, which had a higher possibility of plugging than OCW due to wax component, to tube side was proposed to increase maintainability. This was agreed.

Originally, this HE was not a critical equipment because the downstream facility can be operated without cooling by this. This HE was provided to decrease oil solubility in the water after cooling and storing in the slop oil tank. Therefore, bypass operation is possible. Furthermore, demineralized water can be used instead of OCW. To this end, the client could agree to use the carbon steel. Vendor pointed out that the injection of ferrous ion is required as well as the velocity limitation in order to control the corrosion. Finally, the ferrous ion injection package had been provided.

Although it is difficult to change the client specification or criteria without concrete reason, if the alternate will give more advantage for safety or operability, the client can agree with.

Material research

26 SOHAR

Seawater, Corrosion, AlBr tube, Velocity, Ferrous ion injection

As the tube material of seawater cooler, Al-Br was selected considering only velocity limitation. Later, corrosion was expected due to insufficient provision.

It is necessary to confirm vendor if the Material ferrous ion injection is required when Al- research Br is selected as a tube material.

Commissioning/ QAQC/ Operation

No.
Mistake 3x6mm diameter weep holes were provided. After plugging these holes, the performance was achieved as per design. studied carefully for (1) small size HE 500mm or less, (2) tube side vaporizer/condenser. A drain valve, which can be used as a Process sampling connection as well, shall be provided at downstream of low pressure utility line such as steam, CW and seawater where possibility of shutdown is expected due to the leakage. This will be also requested in HAZOP. When several AFC are provided adjacently, the study of recirculation shall be done taking into account wind velocity, wind direction and adjacent structure/buildings. Cause/Countermeasure Recommendation

Client/Unit

key word

27 Seibu Gas

Weep hole

The performance of BEU type LPG vaporizer (LPG; tube side, Steam; shell side) was not achieved. Outlet temperature is so low because of leakage. To identify the problem HE, sampling had been done by loosing the seawater outlet flange of each cooler. Even maintenance, drain valve is useful.

Responsi Classify ble The cause is oversight of fabrication Mech./ drawing. Necessity of weep holes shall be QAQC

28 CPX

Tube leak, Drain valve, Sampling

Product had leaked to the seawater side due to a crack in a product cooler. Since there was no drain line on the seawater outlet line, it took long time to identify the product cooler which was leaking.

29 general/ AFC
Layout was studied by using CFD (Computer Fluid Dynamics) and it was confirmed that provision of seal plate was effective.

Hot air Several AFC were provided adjacently. recirculation, Recirculation of air had caused elevated CFD temperature of intake air.

EN Techno./ Process