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1. MANAGEMENT SUMMARY
Heat exchangers are equipments that transfer heat from one medium to another. The proper
design, operating, and maintenance of heat exchanger will make process energy efficient, which
minimize energy loss and energy cost. Heat exchanger performance can deteriorate with time
and other interferences such as fouling, scaling, etc. It is necessary to access periodically the
heat exchanger performance in order to maintain the high efficiency level.
The developed spreadsheet comprises certain proven techniques of monitoring the
performance oh heat exchangers, coolers, condenser from the observed operating data of the
equipment. The heat exchanger performance will be calculated by the developed spreadsheet,
and the alert indicator will be reported to identify any low efficiency heat exchanger.
2. PURPOSE
The performance monitoring spreadsheet will be used to determine the overall heat transfer
coefficient for assessing the performance of heat exchanger. Any deviation form the design heat
transfer coefficient will indicate the occurrence of fouling and will imply for the requirement for
heat exchanger cleaning.
3. CALCULATION BACKGROUND
3.1 HEAT TRANSFER PRINCIPLE
3.1.1 Overall energy balances
To predict the performance of a heat exchanger, it is essential to relate the total heat
transfer rate to quantities such as the inlet and outlet fluid temperature, the overall heat transfer
coefficient, and the total surface area for heat transfer. Two such relations may readily be
obtained by applying overall energy balances to the hot and cold fluids, as shown in Figure 3.1
In particular, if q is the total rate of heat transfer between the hot and cold fluids and there is
negligible heat transfer between the exchanger and its surroundings, application of the steady
flow energy equation, gives
q = m&h (i h,i-i h,o) and q = m&c (i c,i-i c,o)
: i is the fluid enthalpy
The subscript h and c refer to the hot and cold fluids.
The subscript i and o designate the fluid inlet and outlet conditions.
Such an expression would be an extension of Newton’s law of cooling, with the overall heat
transfer coefficient (U) used in place of the single convection coefficient (h). However, since
T varies with the position in the heat exchanger, it is necessary to work with a rate equation of
the form
q = UATm
Where Tm is an appropriate mean temperature difference.
3.1.2 The Overall Coefficient
o Heat is transferred
From the hot fluid to the wall by convection.
Through the wall by conduction, and
From the wall to the cold fluid by convection.
o It is convenient to combine all the thermal resistances in the path of heat flow from
the hot fluid to the cold one into a single resistance R
o The total thermal resistance
Heat Transfer
To
Cold fluid
Wa
Ti
ll
Hot fluid
Ai Ao
hi ho
Ti To
Ri Rwall Ro
This following table shows the type of method which uses to calculated the heat duty
for each exchanger.
Heat Exchanger Type Type of method
AWP-1 well fluid coolers Shell&Tube Heat Curve
Feed Compr. Disch. Coolers PCHE Heat Curve
fuel gas heater Shell&Tube Specific heat capacity
membrane preheater Shell&Tube Heat Curve
Memguard regeneration heaters Shell&Tube Heat Curve
NGL Extraction Pre-cooler PCHE Heat Curve
Gas/Gas/Liguid exchanger PCHE 3-stream exchanger
Sales Gas Compr. Disch. Cooler PCHE Specific heat capacity
Stabilizer feed/bottom exchanger Shell&Tube Heat Curve
Stabilizer condenser Shell&Tube Heat Curve
Stabilizer condensate reboiler Shell&Tube Heat Curve
Stabilizer condensate cooler Shell&Tube Specific heat capacity
VRU comp. discharge cooler Shell&Tube Heat Curve
Table 3.1 The type of method for each heat exchanger
q US.gallons
min. = Cv SG.
P(psi.)
3.3 CALCULATION
All of the calculations in this spreadsheet are based on the following assumptions:
The heat exchangers are well insulated so there is no heat loss.
Some heat exchangers are operated in parallel. It has been assumed that gas equally
flows through parallel exchangers.
The gas/liquid flows to flare and to closed drain have been ignored.
The 40% CO2 design case is used for Stabilizer condensate cooler.
The Rich design case is used for Stabilizer feed/bottom exchangers, fuel gas heater
and VRU. Compressor Discharge cooler.
The Most likely design case data is used for others.
Figure 3.3 this figure show how to calculate the heat duty when the inlet temperature is changed.
The occurred errors cannot be avoided since the specific heat capacity or heat
curve depend on a lot of parameters that are not taken in account (pressure, process
stream composition,…).
3.3.1.3 3-stream exchanger method for GAS/GAS/LIQUID EXCHANGER
For the Gas/Gas/Liquid exchanger, the calculation is different. From the data
sheet, this exchanger was calculated by separate into 2 exchangers (Gas/Gas
Section and Gas/Liquid Section).
So heat curves have to be estimated for overall heat duty (calculate from Gas (Hot
Side) inlet and outlet temperature) and Gas/Liquid Section heat duty (calculate from
Liquid (Cold side) inlet and outlet temperature). Then the Gas/Gas section heat duty
can be calculated from:
QGas/Gas = Qoverall - QGas/Liquid
After that the outlet temperature of the hot gas flow from the Gas/Gas section
exchanger will be able to calculate.
3.3.2 FLOW DETERMINATION
To determine the flow for flowline that does not have the flow indicator but has control
valve. The flow rate can be calculated as follows:
min. = Cv SG.
P(psi.)
q US.gallons
m3
q
h. = Cv
m3 P(bar) *14.50377(psi/bar) min. 1
* 60 *
SG. h. 264.1721 US.gallons
: q is the flow rate through the control valve.
Cv is Flow coefficient which can be calculated from the relationship between %Cv
and %opening valve from datasheet.
SG. Is specific gravity (1 for water).
∆P is pressure drop between inlet and outlet pressure.
3.3.3 PERFORMANCE MONITORING
The chosen indicator, to monitor the performance of each exchanger, is UA which can
be calculated from:
Q
UA
( FT )( LMTD)
: Q is heat duty (kW.)
LMTD is Log mean temperature difference, can be calculated from input data. (See
Appendix 6.5)
Correction factor (FT) for shell and tube heat exchangers can be calculated (See
Appendix 6.5) but for the printed circuit heat exchangers are set to be constant at the
designed value.
For each exchanger, the performance is defined by comparison the UA value with the
designed one.
UACalc.
% Performance 100%
UADesigned
And alerts will be launched when the performance is no more acceptable. Two different
levels are defined:
The first alert is set up at 95% of designed value.
The second at 90%.
4. SPREADSHEET STRUCTURE
4.1 STRUCTURE
The spreadsheet is composed of 4 worksheets and 17 modules (Visual Basics codes) within
the same file:
Worksheets:
The "User Guide", is the instruction to use this program
The "Input DATA" sheet is the sheet where data are collected. This sheet is protected to
avoid accidentally TAG No. data deletion.
The "Current status" sheet is the calculation sheet for exchanger performance. All
designed, collected and calculated data are given.
The "Report" sheet is used for tracing the history of the heat exchangers performance
and theirs status
Modules:
The “Allduty_ GasGasLiquid” module is used for calculate the overall heat duty for
Gas/Gas/Liquid exchanger.
The “heatduty_GasLiquidSection” module is used for calculate the Gas/Liquid section
heat duty.
The “FindTemp2” module is iterating function to find the outlet temperature from the
Gas/Gas section exchanger.
The “AWP1Cooler” module is used for calculate the AWP-1 well fluid cooler heat duty.
The “FeedBottomHeatX” module is used for calculate the stabilizer feed/bottom
exchanger heat duty.
The “FeedGasDiscCooler” module is used for calculate the feed gas compressor
discharge cooler heat duty.
The “LMTD_CorrectionFactor” module is used for calculate the log mean temperature
difference and correction factor for shell and tube heat exchanger.
The “Membranepreheater” module is used for calculate the membrane preheater heat
duty.
The “MemguardRegenerationheater” module is used for calculate the memguard
regeneration heater heat duty.
The “NGL_precooler” module is used for calculate the NGL precooler heat duty.
The “SalesGasDiscCooler” module is used for calculate the sales gas compressor
discharge cooler heat duty.
The “StabilizerCondenser” module is used for calculate the stabilizer condenser heat
duty.
The “StabilizerCondyCooler” module is used for calculate the stabilizer condensate
cooler heat duty.
The “StabilizerReboiler” module is used for calculate the stabilizer reboiler heat duty.
The “VRU” module is used for calculate the VRU. Compressor discharge cooler heat
duty.
The “AllFunction” module includes the function about checking status and copying the
calculated data to the Report sheet.
The “FlowCv” module is used for calculated the flow rate.
In normal use, no access to these modules is required.
3.2
3
Cp (kJ/kg-˚C.)
2.8
2.6
2.4
2.2
2
20 40 60 80 100 120 140
Tem perature (˚C.)
Figure 7.1 Specific Heat Capacity curve for Sales Gas Discharge Coolers
The following equations are used for calculation the specific heat capacity:
Equation: specific heat(kJ/kg°C) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 57 -0.0168 3.7319
57-71.167 -0.0118 3.4483
71.167-96.667 -0.0071 3.1068
96.667-113.667 -0.0039 2.804
higher than 113.667 -0.0025 2.6484
2.7
2.6
2.5
Cp (kJ/kg-˚C.)
2.4
2.3
2.2
2.1
2
20 40 60 80 100 120 140
Tem perature (˚C.)
The following equations are used for calculation the specific heat capacity:
Equation: specific heat(kJ/kg°C) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 50 0.0051 1.9198
50-62 0.0052 1.9169
62-80 0.0053 1.9113
80-101 0.0054 1.8976
101-113 0.0057 1.8765
higher than 113 0.0059 1.8482
35000
30000
25000
20000
Q (kJ)
15000
10000
5000
0
-5000 10 30 50 70 90 110 130 150 170
Temperature (˚C.)
Figure 7.3 Heat curve (Qout) for Feed Gas Compr, Discharge Cooler
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 22.5 -400 37083
22.5-25 -388.89 36833
25-27.5 -371.11 36389
27.5-30 -356.67 35992
30-32.5 -342.22 35558
32.5-35 -306.67 34403
35-37.5 -290 33819
37.5-40 -285.56 33653
40-42.5 -282.22 33519
42.5-45 -271.11 33047
45-60 -252.26 32198
60-70 -241.39 31539
70-100 -232.22 30879
100-130 -226.73 30344
130-140 -215.46 28886
higher than140 -226.86 30479
9000
7000
5000
Q (kJ)
3000
1000
Figure 7.4 Heat curve (Qin) for Feed Gas Compr. Discharge Cooler
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
100-140 -226.87 30423
10000
8000
6000
Q (kJ)
4000
2000
0
10 30 50 70 90 110 130 150
-2000
Tem perature (˚C.)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 29 134.11 -4429.8
29-34 113.44 -3825.5
34-41.5 100.87 -3403.2
41.5-51.5 95.886 -3195.6
51.5-74 90.462 -2909.2
74-104 86.443 -2613.8
higher than 104 85.086 -2476.9
1000
500
0
15 20 25 30 35 40 45
Q (kJ)
-500
-1000
-1500
-2000
Tem perature (˚C.)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 23 147.26 -4767.6
23-27 138.04 -4554.5
27-31 128.52 -4297.4
31-36 104.51 -3554.4
higher than 36 100.97 -3427.7
10000
8000
6000
Q (kJ)
4000
2000
0
10 60 110 160 210 260 310
-2000
Tem perature (˚C.)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 35 38.202 -1473.1
35-45 35.002 -1361
45-65 32.612 -1251.2
65-85 30.978 -1146.6
85-105 30.234 -1084.1
105-197.5 30.118 -1076.6
197.5-242.5 31.237 -1293.1
242.5-275 32.151 -1513.1
higher than275 32.883 -1713.7
400
300
200
100
Q (kJ)
0
-100 20 25 30 35 40 45 50 55 60
-200
-300
-400
Tem perature (˚C.)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 31 43.505 -1639.3
31-34 37.065 -1439.5
34-39 35.897 -1399.6
39-44 34.723 -1353.8
higher than 44 33.712 -1309.3
20000
15000
10000
Q (kJ)
5000
0
15 25 35 45 55 65
-5000
Tem perature (˚C.)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 22.5 -592.62 26290
22.5-25 -579.31 25990
25-27.5 -565.47 25644
27.5-30 -551.16 25251
30-32.5 -536.52 24812
32.5-35 -521.77 24332
35-37.5 -507.12 23819
37.5-40 -492.69 23278
40-42.5 -432.71 20879
42.5-52.5 -380.96 18670
higher than 52.5 -369.76 18088
7500
5500
3500
1500
Q (kJ)
-500
30 35 40 45 50 55 60 65 70
-2500
-4500
-6500
Tem perature (˚C.)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 40 -501.58 23794
40-42.5 -431.46 20995
42.5-45 -388.93 19187
45-50 -382.61 18902
50-55 -375.57 18550
55-60 -369.86 18236
higher than 60 -365.22 17958
7.2.5 Gas/Gas/Liquid exchanger
7.2.5.1 Gas (hot side)
- Heat curve for Qout with pressure drop 0.7 bar.
6000
4000
2000
0
10 15 20 25 30 35 40
Temperature (˚C.)
Figure 7.11 Heat curve (Qout) for Gas/Gas/Liquid exchanger (Gas hot side)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 17 -617.56 20992
17-19 -607.66 20824
19-21 -597.54 20632
21-23 -587.12 20413
23-25 -576.37 20166
25-27 -565.28 19888
27-29 -553.87 19580
29-31 -542.21 19242
31-33 -530.41 18876
higher than 33 -518.59 18486
10000
Q (kJ)
5000
0
5 10 15 20 25 30 35 40 45 50
-5000
Temperature (˚C.)
Figure 7.12 Heat curve (Qout) for Gas/Gas/Liquid exchanger (Gas hot side)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 15 -632.93 21008
15-17 -615.95 20761
17-19 -606.07 20593
19-21 -595.96 20400
21-23 -585.53 20181
23-26 -572 19868
26-28 -557.96 19505
28-31 -543.45 19097
31-33 -528.7 18641
33-35 -516.86 18251
35-38 -502.24 17737
38-41 -484.98 17081
41-42 -414.42 14191
higher than 42 -383.35 12885
9500
7500
5500
3500
Q (kJ)
1500
-500
15 20 25 30 35 40 45 50 55 60
-2500
-4500
-6500
Tem perature (˚C.)
Figure 7.13 Heat curve (Qin) for Gas/Gas/Liquid exchanger (Gas hot side)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 23 -591.31 20702
23-25 -577.96 20397
25-28 -564.06 20047
28-30 -549.72 19648
30-32 -538 19296
32-34 -526.19 18918
34-36 -514.42 18518
36-39 -499.88 17993
39-41 -485.48 17433
41-42 -404.37 14108
42-46 -386.49 13356
higher than 46 -380.01 13058
4000
3500
3000
2500
Q (kJ)
2000
1500
1000
500
0
-15 -5 -500 5 15 25 35
Tem perature (˚C.)
Figure 7.14 Heat curve (Qout) for Gas/Gas/Liquid exchanger (Liquid side)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than (-5) 79.9 450.74
(-5)-2 82.175 461.27
2.0-8.0 85.093 455.69
8.0-14.0 88.181 430.87
14.0-19.0 91.249 388.32
19-24 94.128 333.61
24-27 96.405 279.64
higher than 27 98.044 235.42
2000
1500
1000
Q (kJ)
500
0
-15 -10 -5 0 5 10 15 20
-500
Tem perature (˚C.)
Figure 7.15 Heat curve (Qin) for Gas/Gas/Liquid exchanger (Liquid side)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than (-4) 79.579 389.88
(-)4.0-3 81.971 398.89
3.0-9.0 84.825 390.59
higher than 9 87.845 363.28
11000
9000
7000
5000
Q (kJ)
3000
1000
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 100 -68.726 14221
100-130 -74.4 14781
130-155 -79.3 15415
155-188 -85.702 16420
188-188.25 -155.89 29602
188.25-188.5 -170.75 32399
higher than 188.5 -168.79 32027
3800
2800
1800
800
Q (kJ)
-200
150 160 170 180 190 200 210 220
-1200
-2200
-3200
Tem perature (˚C.)
The following equations are used for calculation the heat duty:
Equation: Heat duty(kW.) = (m x temperature) + c
Temperature (°C.) slope (m) y-intercept(c)
lower than 175 -84.384 16210
175-191.3 -88.323 16901
191.3-191.4 -129.5 24773
191.4-191.8 -170.66 32652
higher than191.8 -169.29 32387
(20.5 *P')
CT = (1- P')
2 0.5
P' - 2 + 2
ln
2
- 2 - 20.5
P'