Tube Rupture Study of a 300 Bar Heat Exchanger

2014 ◽  
Author(s):  
Bas Megens
Keyword(s):  
Acoustic Emission ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Failure Mechanisms ◽  
Process Conditions ◽  
Safety Study ◽  
Entire Study ◽  
Root Cause ◽  
Potential Failure ◽  
Non Destructive

From a safety study a concern was raised about the probability of instant tube rupture in 300 bar heat exchangers in LDPE plants. A study has been performed in a multidisciplinary team to determine the potential failure mechanisms. Among the possible potential failure mechanisms those which can cause instant tube rupture were identified. Based on these potential failure mechanisms, non-destructive examinations were performed to investigate if these failure mechanisms were present and online acoustic emission measurements were performed to investigate during which process conditions the damage occurred. Eventually a cooler was dismantled to investigate the root cause of the damage. This paper describes the entire study.

Addressing Fouling by Qualifying Chemical Additives Using Novel Technologies

2021 ◽  
Author(s):  
Andrew Robert Farrell ◽  
Dario Marcello Frigo ◽  
Gordon Michael Graham ◽  
Robert Stalker ◽  
Ernesto Ivan Diestre Redondo ◽  
...  
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Emulsion Stability ◽  
Ambient Pressure ◽  
Screening Tests ◽  
Process Conditions ◽  
Screening Methods ◽  
Chemical Additives ◽  
Laboratory Techniques ◽  
Prediction And Prevention

Abstract Fouling of heat exchangers and production of stable emulsions in desalting units can present significant challenges in refinery operations. Often these difficulties occur due to the concurrent processing of two or more crude oils that are incompatible under process conditions. This paper describes a significant development in laboratory techniques for studying these issues and evaluating mitigation strategies. Asphaltenes compatibility was evaluated for oil mixtures that may be co-processed in the refinery using a deposition flow rig, and the results were compared with those obtained with more conventional tests: blending stability analysis by light scattering and various screening methods. The flow rig mimics the process conditions (elevated pressure, high temperature, flow-induced shear) and identifies whether deposition or precipitation will occur. The former can cause fouling of heat exchangers whereas the latter produces solids that can stabilize emulsions in the desalter. By varying the proportions of oils that were co-injected into the deposition flow rig, the range within which mixtures were unstable was found. By flowing through a capillary (to mimic a heat exchanger) and in-line filter, it was possible to identify whether precipitation of suspended flocs or fouling of the heat exchanger itself was the likely issue for each mixture. Emulsion-stability tests were conducted using a pressurized rig with an ersatz separator to mimic the desalting unit; results were compared with those obtained in conventional, ambient-pressure bottle tests. Oil(s) and refinery wash water were injected, mixed under representative shear, and allowed to separate within the typical residence time of the desalter. Chemical additives were tested to identify those that were effective at controlling any observed problems. Results obtained in either flow rig (using representative pressure, temperature, and shear) did not always match those obtained using conventional methods. Asphaltenes fouling occurred under conditions where it was not predicted by screening tests that were conducted at conditions not representative of the process and did not occur under conditions where it was predicted. Differences were also observed between the emulsion stability observed in bottle versus rig tests, though these should be viewed as complementary techniques. This paper presents new laboratory techniques for the prediction and prevention of refinery fouling and emulsion stability. They mimic conditions in the facilities much better than those typically used to date.

Analysis and Design of the “Solar One” Thermal Storage Subsystem Heat Exchangers

1984 ◽  
Vol 106 (3) ◽  
pp. 279-285
Author(s):  
F. R. Weiner
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Thermal Storage ◽  
Design Solution ◽  
Process Conditions ◽  
Analysis And Design ◽  
Heat Exchanger Design ◽  
Central Receiver ◽  
Final Design ◽  
Design Requirements

This paper describes the analysis and design of the five kinds of heat exchangers used in the thermal storage subsystem of the 10 MWe Solar Central Receiver Pilot Plant, now becoming more known as “Solar One.” The paper discusses the practices and standards used in the designs of the heat exchangers, lists the heat exchanger design requirements, and discusses the process conditions. The design assumptions and constraints, the geometrical considerations, and the tradeoff studies that were conducted to optimize the designs are also discussed. A description of each heat exchanger reveals the final design solution. Novel and unique features of a power plant that must operate on a daily sun-cycle are identified.

scholarly journals Heat Transfer Characteristics of Heat Exchangers for Waste Heat Recovery from a Billet Casting Process

Energies ◽  
2019 ◽  
Vol 12 (14) ◽  
pp. 2695
Author(s):  
Ju O Kang ◽  
Sung Chul Kim
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Waste Heat ◽  
Casting Process ◽  
Effective Area ◽  
Total Heat ◽  
Process Conditions ◽  
Heat Absorption ◽  
Industrial Facilities ◽  
The Difference

The application of the thermoelectric generator (TEG) system to various industrial facilities has been explored to reduce greenhouse gas emissions and improve the efficiency of such industrial facilities. In this study, numerical analysis was conducted according to the types and geometry of heat exchangers and manufacture process conditions to recover waste heat from a billet casting process using the TEG system. The total heat absorption increased by up to 10.0% depending on the geometry of the heat exchanger. Under natural convection conditions, the total heat absorption increased by up to 45.5%. As the minimum temperature increased, the effective area increased by five times. When a copper heat exchanger of direct conduction type was used, the difference between the maximum and minimum temperatures was significantly reduced compared to when a stainless steel heat exchanger was used. This confirmed that the copper heat exchanger is more favorable for securing a uniform heat exchanger temperature. A prototype TEG system, including a thermosyphon heat exchanger, was installed and a maximum power of 8.0 W and power density of 740 W/m2 was achieved at a hot side temperature of 130 °C. The results suggest the possibility of recovering waste heat from billet casting processes.

Successful Sealing of Heat Exchangers Due to the Implementation of New Technology in a Gasket System

2005 ◽  
Author(s):  
Julie L. Simonton ◽  
David W. Reeves
Keyword(s):  
Thermal Expansion ◽  
Heat Exchanger ◽  
Test Data ◽  
Heat Exchangers ◽  
New Technology ◽  
Process Conditions ◽  
Successful Implementation ◽  
Differential Thermal Expansion ◽  
Effective Seal ◽  
Subsequent Failure

Research into the historical use and subsequent failure of double-jacketed type gaskets in heat exchangers has yielded the characteristics necessary for leak elimination and the realization that maintaining a seal cannot be achieved by gasket specification alone. An evaluation of the heat exchanger, stud load, tightening method, gasket specification, proper installation procedures, process conditions, as well as stud selection must each be carefully considered to consistently create an effective seal. This paper highlights field test data from a refinery on the differential thermal expansion of flanges and how the gasketed connection is affected. Laboratory test data, specifically Radial Shear Tightness Test, or Ra.S.T., data, which mimics the radial shearing effects on a gasket in a heat exchanger, as well as verifying the effects on the gaskets in the field, is also presented. The details of the new technology in a gasket system for heat exchangers, perfected in conjunction with Chevron and Lamons Gasket Company, will be presented along with its successful implementation at a major petrochemical refinery.

Numerical Study of Corrugation Amplitude Influence of a Wavy Fin in Overall Performance of a Compact Heat Exchanger

2014 ◽  
Vol 659 ◽  
pp. 405-410 ◽  
Author(s):  
Vlad Martian ◽  
Septimiu Albetel ◽  
Mihai Nagi
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Numerical Study ◽  
Special Kind ◽  
Cfd Simulations ◽  
Entire Study ◽  
Extended Surface ◽  
Extended Surfaces ◽  
Active Research ◽  
Goodness Factor

In the past few decades heat exchangers, especially air cooled ones, have become very important equipment in different fields of industry. This led to an active research in finding ways to reduce their overall size and costs. A very important role played in reducing the size of the heat exchanger is the convection capability of air, by being the lowest one, dictates the overall size of the heat exchanger. For this reason we are forced to use extended heat transfer surfaces on the air size. The geometry of such extended surfaces has a high impact on heat and pressure drop performances. The present paper focuses on a study, conducted at RAAL S.A. with the support of University “Politehnica” of Timișoara, to find the influence of the corrugation amplitude of a special kind of extended surface named wavy fin, in the overall performances of a heat exchangers by means of area goodness factor (j/f). Designing and building the different geometries needed in the study will be overkill for the company so we have decided to conduct this study with the help of CFD simulations. In order for this to work we will validate the numerical model with the help of a single experimental test, reducing the time and cost of the entire study. These results are afterwards used to modify the fin’s design to obtain an optimum one.

Failure Analysis Process Flows and Common Failure Mechanisms in Flip-Chip Packaged Device

2000 ◽  
Author(s):  
Steve Hsiung ◽  
Victer Chan
Keyword(s):  
Failure Analysis ◽  
Flip Chip ◽  
Failure Mechanisms ◽  
Fault Identification ◽  
Process Flow ◽  
Packaging Technology ◽  
Root Cause ◽  
Analysis Process ◽  
Complex Construction ◽  
Non Destructive

Abstract With the increasing complexity of packaging technology, especially Flip-chip, package failure analysts face challenges to identify failure root cause. Due to the complex construction of Flip-chip packages, the conventional failure analysis process flow needs to be enhanced. Thus, generating a bench marked failure analysis process flow specifically for Flip-chip packaged devices becomes necessary. In this paper, the failure analysis process flow for Flip-chip package devices along with different failure mechanisms will be discussed and demonstrated. For instance, even in a simple continuity-open failure, instead of cross-sectioning the device as the initial fault identification step, the process flow details how to start from non-destructive C-SAM, TDR, to destructive die removal, polishing and finally cross-sectioning.

Root Cause Analyses of Metal Bridging for Copper Damascene Process

2005 ◽  
Author(s):  
Z. G. Song ◽  
S. P. Neo ◽  
S. K. Loh ◽  
C. K. Oh
Keyword(s):  
Failure Mechanisms ◽  
Copper Corrosion ◽  
Microelectronic Device ◽  
Root Cause ◽  
Damascene Process ◽  
New Process ◽  
Copper Cmp

Abstract New process will introduce new failure mechanisms during microelectronic device manufacturing. Even if the same defect, its root causes can be different for different processes. For aluminum(Al)-tungsten(W) metallization, the root cause of metal bridging is quite simple and mostly it is blocked etch or under-etch. But, for copper damascene process, the root causes of metal bridging are complicated. This paper has discussed the various root causes of metal bridging for copper damascene process, such as those related to litho-etch issue, copper CMP issue, copper corrosion issue and so on.

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