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Final Presentation for the Process Engineering Co-Op Position
- 1. Joseph Wrona Drexel Class of 2019 BS Chemical Engineering 2018 Spring/Summer Co-Op Presentation
- 2. What is Process Engineering Anyway? • Steady State Maintenance? • Online definitions: • “the branch of engineering that is concerned with industrial processes, especially continuous ones” • “focuses on the design, operation, control, optimization and intensification of chemical, physical, and biological processes” • Baking (Batch) vs Cooking (Dynamic)
- 3. Overview • Projects • Cooling Water Heat Exchanger Monitoring • Alarm Rationalization • Fin Fan Heat Exchanger Monitoring • Other Tasks and Activities • Overall Experience • Acknowledgements
- 4. Cooling Water Heat Exchanger Monitoring • Responsibility • Field Measurements • Data Input/logging • Project Goals • Performance monitoring • Value • Heat transfer calculation methods • Data rating sheets • Excel macros and organization
- 5. • Contribution • CW Heat Exchanger Archive • Field notes section and macro Cooling Water Heat Exchanger Monitoring Continued...
- 6. Alarm Rationalization • Responsibility • “Meeting Scribe” • Documentation of actions implemented • Project Goals • Document and manage inhibited and standing alarms • Eliminate unnecessary alarms • Improved operator efficiency
- 10. Alarm Rationalization Continued... • Value • Process control and Refinery Details • Foxboro DCS • Alarm configuration • ALARMS vs ALERTS • IOBAD, STATE, DEVIATION, OUT OF RANGE • Implications • Health/safety, mechanical integrity, quality control, economics • Contribution • Meeting efficiency
- 11. Fin Fan Heat Exchanger Monitoring • Responsibility • Calculation Method • Develop Models • Seek relevant documentation and information • P&ID’s • PI • Console Supervisors • Process Engineering team • Lab [eq. 1] 𝑸 = 𝑼 ∙ 𝑨 ∙ 𝑪𝑴𝑻𝑫 C𝑀𝑇𝐷 = 𝐹 ∙ 𝑀𝑇𝐷 = 𝐹 ∙ 𝑇ℎ,𝑖𝑛−𝑇𝑐,𝑜𝑢𝑡 − 𝑇ℎ,𝑜𝑢𝑡−𝑇 𝑐,𝑖𝑛 log 𝑇ℎ,𝑖𝑛−𝑇 𝑐,𝑜𝑢𝑡 𝑇ℎ,𝑜𝑢𝑡−𝑇 𝑐,𝑖𝑛 [eq. 2] 𝑸 = [ 𝒎𝑪𝒑 𝑻𝒊𝒏 − 𝑻 𝒐𝒖𝒕 ] 𝒉 = [ 𝒎𝑪𝒑 𝑻 𝒐𝒖𝒕 − 𝑻𝒊𝒏 ] 𝒄 Case 1: Complete Condensation [eq 2a] 𝑸 = 𝒎𝑪𝒑 𝒗𝒂𝒑 𝑻 𝒉,𝒊𝒏 − 𝑻 𝒉,𝑫𝑷 + 𝒎𝑯 𝒗𝒂𝒑 + 𝒎𝑪𝒑𝒍𝒊𝒒 𝑻 𝒉,𝑫𝑷 − 𝑻 𝒉,𝒐𝒖𝒕 Case 2: Partial Condensation [eq 2b] 𝑸 = 𝒎(𝒚𝑪𝒑 𝒗𝒂𝒑 + 𝒙𝑪𝒑𝒍𝒊𝒒) 𝑻 𝒉,𝒊𝒏 − 𝑻 𝒉,𝒐𝒖𝒕 + ∆𝒚 𝒎𝑯 𝒗𝒂𝒑
- 12. Fin Fan Heat Exchanger Monitoring Continued… Calculations Model Results Data Used for Model and calculations Notes Exchanger Specs Graphing Options
- 13. [eq. 1] 𝑸 = 𝑼 ∙ 𝑨 ∙ 𝑪𝑴𝑻𝑫 [eq. 2] 𝑸 = [ 𝒎𝑪𝒑 𝑻𝒊𝒏 − 𝑻 𝒐𝒖𝒕 ] 𝒉 = [ 𝒎𝑪𝒑 𝑻 𝒐𝒖𝒕 − 𝑻𝒊𝒏 ] 𝒄 Case 2: Partial Condensation [eq 2b] 𝑸 = 𝒎(𝒚𝑪𝒑 𝒗𝒂𝒑 + 𝒙𝑪𝒑𝒍𝒊𝒒) 𝑻 𝒉,𝒊𝒏 − 𝑻 𝒉,𝒐𝒖𝒕 + ∆𝒚 𝒎𝑯 𝒗𝒂𝒑 Fin Fan Heat Exchanger Monitoring Continued…
- 14. Fin Fan Heat Exchanger Monitoring Continued… Fin Fan Process Fluid Outlet Temperature Overall Heat Transfer Coefficient, U 𝑸 = 𝑼 ∙ 𝑨 ∙ 𝑪𝑴𝑻𝑫
- 15. Fin Fan Heat Exchanger Monitoring Continued…
- 16. • Value • Problem solving • Use of academic skillset • Effective use of resources • Valid assumptions • Leadership and Team Cooperation • Comprehensible Organization • Contribution • Equipment maintenance and management • Future Savings • Reliable and simple template for future monitoring Fin Fan Heat Exchanger Monitoring Continued…
- 17. Other Tasks and Activities • Field Experience • Unit Walkdowns • Clay Treater Changeout • Routine Tasks • ULSG Stream Request • Inventory Reports • Toxic Release • Isocracker Catalyst • T/A items • Vessel drawings • Log sheets • PI Displays • Peabody Heater • D2 Treating • Routine Meetings
- 18. Overall Experience • Industry Experience • Workflow and Organization • Meetings, Reports, Company Divisions • Implications and Consequences • Operation, Economic, Safety • Chemical Engineering Applications • Intuition • Expand academic skillset • Engineering Tools and Software • Excel • PI System • Pro/II, Petro-SIM, ProSim • Flowel • Foxboro DCS • Documentum (MSDS, Rating Sheets, Design Drawings, AutoCAD) • P&ID’s/PFD’s • Personal Workflow Development
- 19. Acknowledgments • Technical Team • Roger Lanouette, Greg Merrill, Tom Carr, Sharon Watkins, Ed Sullivan, Kevin Harkness, John Meyers, Tom Hartman, Kayla Erickson, Bob Rowntree, John Bigus, Chelsey Sassine, Tam Tran, Anh Nguyen, Bruce Gansner, Paul Maghan • Operations • Area Leads, Consoles, and Operators • Lab • Mike Poissant, John Sklodowski, Otis Horton • Other • Justin Irick and GE team Questions?
Editor's Notes
- School taught towards research Dynamic in: Economy End Product Current inventory (Crude is not just Crude) Tools