Smart Digital Analysis Technology for Air-Cooled Plant - jgc ...

Presentation Title(Front Cover ver.1)

© 2019 JGC Corporation

AIRLIZESM- Smart Digital Analysis Technology for Air-Cooled Plant

JGC Technology Forum 2019

Xidong HuEN Technology Center, PT Division

Contact: [email protected]

Copyright 2019 JG

C All Rights Reserved

Content

1. JGC AIRLIZESM Technology

2. Two Smart Digital Analysis Tools2.1 ThermoMapTM

2.2 HARviewTM

3. AIRLIZESM Case Solutions4. Benefit from AIRLIZESM Technology

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Content



2.2 HARviewTM


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Hot Spot Appears and Affect Equipment Performance

Production Reduction during Summer

Unstable Operation Under Unstable Wind Conditions

Do you have the following concerns?

Summer Summer

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AIRLIZESM is JGC’s Technology Brand of Comprehensive Life Cycle Engineering Support Services for Air-Cooled Plants (ACHE, GT, Cooling Tower etc.)

AIRLIZE is Aimed to Control Air to Minimize Hot Spot and Weather Impact Maximize Production and Plant Availability

What is AIRLIZESM ?


Note: From Google Picture

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Phase-1:Plant Survey

Phase-2:Identify Bottlenecks

Phase-3:Implement & Improve

• Identify bottlenecks• Study mitigations using

AIRLIZE Technology

• Collect data • Analyze data

• Engineering design • Implement

Phase-4: Evaluate

• Evaluate effectiveness of countermeasures

Steps toward Maximum & More Stable Production


For Existing Plants:

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LNG3 =Technology-Driven Workshop & Consulting


AIRLIZE: One of the LNG3

Technologies, but Not Limited to LNG Plants

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Content



2.2 HARviewTM


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2. Two Smart Digital Analysis Tools2.1 ThermoMapTM-Real-time Air Temperature Mapping

Thermal Couple

(1) Traditional Temperature Measurement

TR1

TR 2GT

GT

GT GT

Wind

Wind

Hot Air

Why conventional single-point temperature sensors are not sufficient for capturing the hot spot in time?

- Unsteady hot spot when wind speed & direction changes- Limited temperature data points for only some fixed locations- Enormous sensors are required to capture the temperature distribution for a large area

Hot Spot => Reduce Plant Performance


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Air Cooler Heat Exchanger

Copyright 2019 JG


Advantages of OFC (Optic Fiber Cable) Temperature Sensors

- Continuous Measurement in space and time(10cm-one data point)

- Capable of generating 2D Temperature Mapping- Compatibility with Advanced Process Control- Compatibility with Automated Fogging

Joint Developed Technology by

&OFC


Example-1 ACHE Air Intake and Outlet Measurement (2) Innovative Temperature Measurement

ACHE Air Discharge

ACHE Air Intake

ACHE Air Discharge

ACHE Air Intake


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Example-2 Monitoring Pipes for Leakage

Automatically detect pipe leakage on covered pipes Prevent serious incidents by immediately detecting failures Savings of maintenance costs by switching from time-based

maintenance to condition-based maintenance.

Pipes covered with thermal insulation.Water introduced to pipe through a gap.

Optical fiber laid inside thermal insulation

19:01 Addition of Water

Application1: FCC (Fluid Catalytic Cracking)

Application2: Storage Tanks

11/26 Note: Document Provided by Fujitsu

Copyright 2019 JG


Optical Fiber Thermometer Infrared Thermography

Method Contact Contact Non-contact

Measurement Range -190～340℃ -200～1200℃ -40～2000℃

MeasurementArea

Very Large（2～15km/ch 1～6ch/set）

1 point(One cable for single point)

Small（20° of view angle）

Cable-less

Number ofMeasurement points

So many（Tens of thousands）

1 Relies on pixel number（Several thousand）

Use for Atmospheric Temperature Measurement Yes Yes No

Use in ExplosionProof Areas Yes No No

Temperature Accuracy Good Very Good Relies on material of object

Measurement Variation for each sensor point No Yes Relies on material of object

Many pointsand serial dataare suitable for

analysis

Signal

Optical Fiber

32°C

41°C

36°C

Signal


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Note:Document Provided by Fujitsu

Copyright 2019 JG


2. Two Smart Digital Analysis Tools2.2 HARviewTM-Innovation for Air Control in Air-Cooled Plants

Weather condition has significant impact on the performance of air used equipment.

Weather dependent hot spot results in air temperature increase and finally reduce the equipment performance.

Plant Area Higher Ambient Temperature=> Lower Production

Ambient Temperature versus Production


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HARviewTM helps to visualize the weather conditions and hot spot. HARviewTM aims to minimize the weather impact on the plant production.

Rapid execution of Business Planning, EPC and Production Improvement

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Technology-1 : Weather SimulationWeather Simulation versus Actual Measurement

Technology-2: CFD Analysis

0.4 1.5 3.2 1.0 1.1 1.10.2 0.5 1.2 0.8 0.8 0.90.3 0.3 0.7 0.7 0.6 0.70.3 0.2 0.3 0.6 0.6 0.60.2 0.1 0.1 0.6 0.5 0.60.1 0.1 0.1 0.8 0.6 0.50.2 0.1 0.1 1.0 0.8 0.60.3 0.3 0.3 1.5 1.1 0.70.6 0.6 0.6 2.1 1.6 0.9

0.2 0.2 0.1 0.9 1.0 1.2 1.5 1.3 1.1 2.9 2.1 1.20.1 0.1 0.1 0.9 1.3 1.7 2.1 1.9 1.6 2.8 1.9 1.30.0 0.1 0.4 0.5 1.2 1.9 3.1 2.7 2.5 2.3 1.5 1.50.0 0.2 0.6 0.2 0.8 1.8 4.4 4.0 3.8 3.0 1.9 1.90.0 0.1 0.3 0.1 0.5 1.3 6.0 5.6 4.9 5.1 3.2 2.70.0 0.0 0.1 0.1 0.3 1.0 7.4 6.7 5.6 6.2 3.9 3.20.0 0.0 0.0 0.1 0.4 0.9 7.9 7.4 6.6 5.6 3.9 3.40.0 0.0 0.0 0.3 0.6 1.4 8.0 7.6 7.3 4.3 3.5 3.50.0 0.0 0.0 0.8 1.6 2.5 7.8 7.5 7.1 3.3 3.3 3.60.0 0.0 0.1 1.5 3.0 3.9 7.4 6.9 6.1 3.2 3.3 3.70.0 0.0 0.1 1.6 3.7 4.7 6.9 6.1 4.6 3.5 3.2 3.60.0 0.1 0.2 1.0 2.8 4.8 6.6 5.9 4.4 3.8 2.9 3.00.0 0.1 0.2 0.7 2.0 4.2 6.2 5.7 5.1 3.7 3.1 2.70.0 0.0 0.1 0.5 1.5 3.2 5.6 5.1 4.8 3.5 3.1 2.80.1 0.1 0.1 0.4 1.0 2.1 4.8 4.2 3.9 3.4 3.2 2.80.3 0.2 0.2 0.4 0.7 1.2 4.3 3.9 3.6 3.5 3.3 2.90.8 0.6 0.4 0.4 0.5 0.8 4.2 3.8 3.6 3.4 3.2 2.80.7 0.5 0.4 0.3 0.4 0.6 4.2 3.9 3.6 3.3 3.0 2.50.3 0.2 0.2 0.1 0.2 0.4 4.2 3.8 3.5 2.9 2.6 2.10.1 0.1 0.1 0.1 0.1 0.2 3.9 3.5 3.2 2.5 2.2 1.80.1 0.0 0.1 0.0 0.1 0.2 3.5 3.1 2.7 2.1 1.7 1.50.0 0.0 0.0 0.0 0.1 0.1 2.9 2.5 2.1 1.6 1.4 1.30.0 0.0 0.1 0.1 0.1 0.1 2.3 1.9 1.5 1.2 1.1 1.30.0 0.1 0.1 0.2 0.2 0.3 1.7 1.4 1.1 0.9 1.0 1.40.1 0.3 0.7 0.5 0.6 1.0 1.2 1.1 1.0 0.9 1.0 1.50.3 1.3 2.5 1.6 1.9 2.6 1.1 1.2 1.4 1.2 1.2 1.5

052E1105 052E1103 051E1105 051E1103

052E1004

052E1005

052E1003

052E1001

0.1 0.2 0.3

0.1

031E1002 1.1

1.3 4.6

1.3

052E1006

1.4

032E1002

022E1004

052E1002

0.7 1.9

1.8

051E1004

051E1005

051E1002051E1003

051E1001

051E1006

051E1101

021E10031.0 0.9 1.0

021E10041.1 1.0 0.8

052E1101

022E1003

0.2 0.6 0.8 1.1

1.8 3.1 3.0 4.02.0 2.9 2.6 4.01.1 2.0 2.2 3.70.5 2.8 1.1 1.8

1.0 0.90.8 0.4 1.4 1.4

052E1105 1.5 3.3 052E1103 051E1105 051E1103

0.3 1.3

0.4

0.5 1.3

052E1002 051E1002

1.1

2.2 1.3

0.8 0.2 3.6 2.3

0.9 0.8 4.3

051E1101

0.3 0.3 1.6

0.3 0.2 052E11010.7 0.5

0.3 0.3

1.1 0.5 4.2 2.8

052E10060.4 1.9

0.4 2.1

051E1001

0.6 0.3 5.8 4.6

0.7 -0.1 052E1001 6.6 5.5

4.3

2.5 3.4051E1003

0.2 1.2 1.3 3.2

0.8 2.9052E1003

6.8 5.3

7.1 6.4 2.6 4.0

051E10062.9

0.1 -0.1

021E1003

0.9

2.7

1.6 1.3 1.5

2.2 051E1004

0.5 0.1 3.7 2.6

0.6

032E1002 031E1002

022E1003

022E1004 021E1004

0.0 0.2

0.5

1.5

2.6

2.5

2.0

0.9

3.1

3.4

2.3051E1005

0.1

1.4

1.5

0.7

0.9

0.9

0.6 1.0

1.4

1.6

1.3

1.2

0.2

0.4

1.10.7

1.9

1.8

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1.3

0.8

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0.1

1.7 052E1004

052E10050.4 0.1 5.5

CFD simulation Actual MeasurementACHE Intake Temperature Comparison

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Content



2.2 HARviewTM


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Plant Type: LNG PlantActivity: Hot Spot and ACHE Air Flow Investigation

3. AIRLIZESM Case SolutionsCase-1 Hot Spot and ACHE Air Flow Investigation for LNG Plant

Visualize Air Flow Measure ACHE Air Flow Measure Temp

0

5

10

15

20

25N

NNE

NE

ENE

E

ESE

SE

SSES

SSW

SW

WSW

W

WNW

NW

NNW

Wind Rose_16th April-24th April

<1<2<3<4<5<6<7<8<9<10<11<12

Analyze Weather Data

Note: From Chevron HP

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The picture has been deleted.

The picture has been deleted.

Copyright 2019 JG


MR-GT PR-GTGT Intake

SEHot Spot

ΔT: +10℃

Wind Direction Change= 180°within 5 minutes

Hot Spot ΔT: +10℃

Heat SourceNW

13:00:00 14:00:00 15:00:00 16:00:00

NW NW

SE

13:00 14:00 15:00 16:00


Investigate Impact of Wind Change on Hot Spot Occurrence through Data Analysis

Air Cooled Heat Exchanger

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The picture

has been deleted.

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C2C1

C3Plant North

①② ①②

①②87% 86%

80%76% 76%

93%

50%

60%

70%

80%

90%

100%

C1-① C1-② C2-① C2-② C3-① C3-②

Mea

sure

d Ai

r Flo

w/D

esig

n Fl

ow


• The fan air capacity of condenser coolers is around 80% of design air flow.

• The mitigation of increasing ACHE air flow rate was proposed.

Measured ACHE Air Flow Rate Diagnose the Performance of ACHEs

Air Cooled Heat Exchanger

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3. AIRLIZESM Case SolutionsCase-2 Hot Air Recirculation Study for Refinery Plant

Plant Type: Refinery PlantActivity: Hot Air Recirculation CFD Study and Mitigation Proposal


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Build CFD Model with Sufficient Details Perform Case Studies to Investigate the Reasons of Hot Spot Consider Mitigations and Confirm the Effect

CFD Model CFD ModelPlant Picture


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Validation of CFD Prediction Accuracy

E-060E-019E-026 E-022E-028

4.5

3.2

E-027

E-702

E-251E-208

E-015

5.3 7.4 8.4 8.8 8.3 7.2 5.4 4.0

0.6

E-413C E-160 E-020

8.9 8.3 8.0 7.5 7.2 5.7 3.1 2.9 3.2 2.7 1.8 0.9

E-112 E-701

8.9 6.4 8.4 9.4 8.0 5.7 3.9

1.3

2.9

E-203 E-206 E-257

2.7 3.4 3.9 4.1 4.0 4.1 4.2 3.8 3.2 2.4 1.7

S-5m/s3.54.82.0

Actual Measured Data

>5℃4-5℃3-4℃2-3℃1-2℃<1℃


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Confirm the effect of different mitigation plans and economical gain

Mitigation Details Evaluation Results

Plan-1 Install Vertical Wall at the ACHE outlet 1 ℃ Reduction

Plan-2 Install Vertical Wall and Wind Screen + 2℃ Reduction

Plan-3 Install Mist at the Fan Intake 4~5℃ Reduction

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AIRLIZEWorkshop

HAR Digital Business Case Study(Weather Analysis, Operational Data Analysis)

HAR Digital Demonstration(CFD, HAR Predictive Model Development, Verification)

HAR DigitalImplementation(APC, Predictive Model Installation)

ThermpMapInstallation & Reinforce HAR Digital

HARView Diagnosis(CFD, Aircooler and GT Performance Survey)

ANNUAL LNG INCREASE

2~3%PER TRAIN

1 MONTH 3 MONTH 6~10 MONTH

8~12 MONTH6 MONTH

HARView Mitigation(Wind Screen, Fogging, Ventilation Improvement)

8~12 MONTH

ANNUAL LNG INCREASE

2~3%PER Train

ANNUAL LNG INCREASE

1~2%PER Train

Initiative 1 : HARViewTM, ThermoMapTM

Initiative 2 : HAR Digital

4. Benefit from AIRLIZESM Technology- An Example for LNG Plant

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Smart Digital Analysis Technology for Air-Cooled Plant - jgc ...

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