SHELL-N-TUBE - IUAC, New · PDF fileSHELL-N-TUBE CHALLENGES OF MAKING ... • Design...
Transcript of SHELL-N-TUBE - IUAC, New · PDF fileSHELL-N-TUBE CHALLENGES OF MAKING ... • Design...
SHELL-N-TUBECHALLENGES OF MAKING
CRYOGENIC SYSTEMS PAST - PRESENT – FUTURE
BYSHANKAR GHOSH
WORKSHOP ON CRYOGENIC SCIENCE AND TECHNOLOGY IN INDIA
ORGANIZED BYINTER – UNIVERSITY ACCELERATOR CENTRE
SHELL-N-TUBE
SOLUTION PROVIDERS TO CRYOGENIC INDUSTRY
SINCE 1987
LINKING PRODUCERS & USERS OF
INDUSTRIAL GASES
AGENDA
List of products developed in past with its associated problems
Present product development activities
Future vision
CRYOGENIC VAPORISERS1989 - ALL COPPER
VAPORISER UPTO
4000 NM3/HR –LOX
FOR STEEL PLANTS
2005 - ALL
ALUMINIUM
LOX/LIN/LAR
VAPORISERS UPTO
30000 NM3 /HR
MOBILE LIQUID NITROGEN VAPORISATION SYSTEM FORPETROLEUM INDUSTRY
A product conceived and developed to meet a specific customer need for in situ purging of flammable product pipeline.
Challenges included
• Modification of existing vaporiser design to take on additional transit loads over bad roads .
• Simple and easy to operate control system
• Design of trailer and selection of locally available prime mover to meet the mobility requirement
CHALLENGES OF MAKING CRYOGENIC VAPORISERSInlet distribution feeder of cryo fluids
Minimising pressure drop in large flow and peak flow condition
Material selection - Copper / SS / Aluminum or SS lined aluminum
Optimising system pressure drop
Establishing brazing/welding procedure and quality assurance
Incorporation of advanced welding processes and fabrication techniques for aluminum vaporisers
Development of weld preparation and weld procedure for high quality al welding
Development of transit damage protectors and standardised field testing procedure
CRYOGENIC SYSTEM ASSISTANCE TO INDIAN AIR FORCESERVICING AND RE EVACUATION OF LIQUID OXYGEN TANKS
TROUBLE SHOOTING AND RESTORATION OF ULTRA HIGH PRESSURE LIQUID NITROGEN SYSTEM 350 BAR OPERATING INCORPORATING SUBMERSED HYDRAULIC MOTOR OPERATED PUMP AND FULLY AUTOMATED OPERATING SYSTEM
CRYOGENIC PHASE SEPERATORS FOR ANIMAL HUSBANDRY AND RESEARCH LABORATORIES
Development of low cost Indian alternative to imported cryo fluid phase separators to meet the objective of efficient and quick filling of small cryo-cans
Final equipment cost 25% of imported equipment with same performance and much simplified operation
Rugged design to meet Indian road field handling conditions
WIDE NECK CRYOGENIC DEWAR FOR FOOD AND BEVERAGE INDUSTRY
Design and manufacturing challenges
Low liquid nitrogen boil off
Compact inner vessel support system
Easy to use and maintain
Integrated operating safety
USE OF LIQUID NITROGEN IN STEM CELL BASED RESERACH
Use of portable liquid nitrogen cylinders for cryo preservation of biological specimens and stem cell related research complete with super insulated small dia liquid nitrogen flexible supply line
REPAIR OF POWDER VACUUM INSUALTED CRYOGENIC TANKS
Main problems are:
Getting vacuum level good enough for accurate mass spectrometer based leak detection
Perlite removal from annulus
Positive identification of leak zone and repair in cramped quarters
High moisture degassing
Long evacuation period even with high capacity multi stage pumping capability
SUPER INUSALTED TANK REAPAIR FOR OIL AND GAS INDUSTRY
Development and sourcing of cryogenic piping components
Effective use of mass spectrometer leak detection methods
Achieving good stable vacuum of the order 10 micron or less in high moisture environment
Development of suitable technology for inner vessel and annulus plumbing defect identification and rectification including inner vessel support replacement
HIGH PRESSURE – HIGH FLOW GAS DELIVERY SYSTEM FOR LASER INDUSTRY
Challenges:Meeting high flow demand of up to 200 m3
/ hr at 31 bar on continuous basis.
This was met by CHART’s specially designed LASER-CYL liquid based gas delivery system
LIQUID NITROGEN TRANSFER SYSTEM FOR PHARMA INDUSTRY WITH MLI-VACUUM INSULATED LINES
LOW PRESSURE DROP HIGH FLOW SYSTEM UPTO 2000 LTR/HR
VACUUM INSULATED MANFOLDING FOR LIQUID NITROGEN SUPPLY TO MULTIPLE PROCESS REACTORS SIMULTANEOUSLY
ADDITIONAL SAFETY FEATURES FOR INDOOR OPERATION
MULTI LAYER INSULATED VACUUM JACKETED PIPELINE FORFISH FREEZING APPLICATION
Challenges • Optimising the evacuation
and mass spectrometer leak testing cycle to maximise productivity
• Development of field support team for prompt assistance to end user in installation and commissioning
• Design standardisation for prompt delivery and achieve economy of scale
• Lowering cost of production to meet competition from overseas .
FLEXIBLE MULTI LAYER INSULATED VACUUM JACKETED PIPINGFOR INDUSTRY
To meet the specific need of making reliable and leak tight end connections for a vacuum insulated pipeline system under field conditions
Optimising outer flexible jacket size
Maximising insulation layer density.
Operating safety
Low heat in-leak to assure frost free operation
VACUUM INSULATED PIPELINE FOR INDIAN SPACE RESEARCH ORGANISATION
6” / 10” multi layer vacuum jacketed piping custom designed for liquid oxygen and liquid hydrogen transfer application
Development of suitable thermal compensators
Inner pipe all metallic support systems
Vacuum monitoring provision in individual pipe spools
Development of multi stage high vacuum system and on line mass spectrometer leak detection capability
81 BAR WORKING PRESSURE VACUUM INSULETED LIQUID HYDROGEN PIPING FOR
INDIAN SPACE PROGRAMMEDevelopment of high pressure thermal compensators
Development of high pressure testing techniques for individual spool test incorporating bellows
Achieving very good stable vacuum in ambient temperature – less than 5 micron and sometime less than 1 micron 72 hrs after pump stop
Multi stage surface cleaning procedure
LOX-GHe COOLER IN LN2 BATH FOR INDIAN SPACE PROGRAMME
Design of efficient cooling coils for simultaneous cooling of helium gas and sub-cooling of liquid oxygen in liquid nitrogen bath
Development of low conductivity load bearing and anti rotating supports
Development of multi layer insulation application technology
Achieving good vacuum stability with complex annulus geometry .
OUR CHALLENGES TODAY IN CRYOGENICS
Manufacture of low temperature adsorption base pilot plant for argon purification
LNG user system based on 100 KL liquid natural gas tank and adequate re-gasification heat exchanger for industries changing over to alternative clean burning fuel .
FUTURE CHALLENGES FOR INDUSTRIAL CRYOGENIC IN INDIA• Large dia multi layer vacuum insulated LNG transfer lines for
ship to shore transfer efficiently with inner line dia from 12 to 36 inches.
• A wide variety of liquefied natural gas based user stations to meet customer specific needs ranging from vehicle fuelling operation to power generation to stand by storage or peak shaving operations as power and more importantly fossil fuel cost goes up
• Onboard vehicle tanks for automobiles-trucks-locomotives and may be some day for container ships
• Liquid hydrogen storage tanks and user systems
• Economic multilayer insulated cryo containers both standard and wide neck type to meet the growing demands of animal husbandry and biological industry