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Air Separation Unit (ASU plant) produces cryogenic gases Oxygen, Nitrogen and Argon from air.
The plant is designed to produce 23 tons Oxygen 2.3 tons Nitrogen and 900kg Argon for every
twenty four hours, during standard production. Currently the plant is not meeting these
standards and is operating at a production efficiency of 60 percent or less. Many factors affect
production efficiency such as ingress of impurities, leakages, failure of cooling system and
failure of any plant support systems. Currently the cooling tower is operating below 20 percent
efficiency thereby reducing plant production output significantly. The aim of the project is to
improve production efficiency by optimizing the underperforming cooling tower. The methods
used to collect data involve data collection by questionnaires, lab tests, observation and
investigation of the tower by troubleshooting to known parameters that reduce tower
efficiency. Results from the project showed that the fill of the tower was heavily corroded and
scaled also……….reduced the tower efficiency. By fixing these problems plant efficiency should
increase. The project gives platform for continual improvement of the plant. If all
recommendations are done and the plant still does not reach optimum conditions it means
there is need to look into other plant sections eliminating the cooling system.
To justify the project of improving the cooling system, the cooling tower efficiency for the
month of April is calculated below. The expected temperatures from the tower and the actual
temperatures are shown in table value. The monetary value of the loss incurred if the plant is
not working at optimum conditions is also given below.
𝑟𝑎𝑛𝑔𝑒
Efficiency = x100
(𝑟𝑎𝑛𝑔𝑒+𝑎𝑝𝑝𝑟𝑜𝑎𝑐ℎ)
30/4/18 41 38 3 12138 0
Cooling tower efficiency ranges from 3.8 % to 12.8 percent which is less than fifty percent
hence the need to investigate the tower.
Heat
Cooling tower Plant process
exchanger
3. Estimated loss experienced per annum in terms of monetary value if plant is not operating at
optimum conditions.
Oxygen
From the month of April from the table above the average daily production of Oxygen is 16897
The loss per annum in kilograms is 6103 X 365 days=2 227 595
The Current cost of bulk oxygen per kg is $ 0.89
Nitrogen
From the month of April from the table above the average daily production of Nitrogen is 1019
The standard amount of Nitrogen expected to be produced per day is 2.3 tons
2 X 467565=935130
Argon
The ASPEN P 600 plant is an air separation unit that separates ambient air into liquid products
Oxygen, Nitrogen and Argon. At optimum conditions during standard production the plant is
expected to produce 23 tons liquid Oxygen ,2.3 tons liquid Nitrogen and 900kg Argon. There are
three different modes of production standard production, maximum oxygen production and
maximum oxygen and nitrogen production. Maximum oxygen production means more oxygen
product that surpasses the 23 tons of standard production. The current condition of the plant is
that at maximum oxygen production the plant is producing around 16 tons or less.
The process of producing liquid oxygen, nitrogen and argon production involves sucking of air
through the Feed Air compressor inlet filter where filtration of air begins in the process of
removing impurities that either have a plugging effect, corrosive effect or can cause explosion.
From the filters, the air enters the compressor where the pressure is boosted. From the FAC the
air enters the chiller where the air is chilled by a refrigeration system causing the water vapor
to condense. The air free of the vapor moves to the active adsorption beds which removes
impurities such as carbon dioxide and any remaining moisture. The air then flows to the main
heat exchanger where air is cooled to optimum temperature for air separation process. The air
then enters the columns where distillation occurs and liquid products are formed.
Production efficiency is affected by many factors such as failure of support systems such as
cooling water system which affects efficiency of many plant machinery, adsorption beds which
lead to moisture, carbon dioxide and hydrocarbon ingress. Clogged inlet filters, system leaks,
failure of refrigeration system, plant operator incompetency also affect production efficiency.
Failure of the adsorption beds means carbon dioxide ingress occurs. Carbon dioxide has a
plugging effect on the plant. Carbon dioxide should always be below 2 ppm. The carbon dioxide
analyzer after the adsorption beds is currently reading below 1 ppm to show that there is no
carbon dioxide ingress and the adsorption beds are functioning well.
Moisture ingress is another factor that affects plant production. Moisture ingress results from
malfunction of the chiller and adsorption beds. The adsorption beds are currently working
effectively as shown by its capability to remove carbon dioxide. A plant thaw was recently done
to remove any moisture in the plant. Plant thaws are done twice per year. Plant thawing
involves applying heat to the columns and necessary support equipment in order to melt ice
and improve plant efficiency.
Clogged filters at the inlet also affect plant efficiency. If the filters are clogged it means some of
the impurities will be able to pass through to the process. Clogged filters also reduce air into
the process. The specification on the differential pressure gauge that shows clogged filters is 2
but the current differential pressure gauge reading is 0.2.
System gas leaks and lube oil also affect plant efficiency. The state of lube oil determines how
efficient the plant equipment will run. Lube oil is present in all plant compressors. System gas
loss means loss of product and raw materials thus decreasing the output. During the plant
shutdown in February maintenance was done on plant. Oil was changed and is due for changing
in August thus the quality of the oil is still in good condition. Leak detection tests where done
also during maintenance thus we can assume no leakages are occurring.
Cooling is used for various reasons in the plant. It is used in after coolers of the Feed Air
Compressor and Nitrogen Recycle compressors to cool air (FAC)and nitrogen(NRC) after
compression to remove heat of compression. Cooling water is also used in the cooler after the
turbine booster to remove heat of compression. Cooling water is used in the chiller
refrigeration unit. Machinery have oil lubrication system that requires cooling. Efficient cooling
enhances the working of machinery also optimizing the plant. All this cooling is provided by
cascade cooling system.
The Cascade cooling system consists of two independent cooling loops- open loop system and
closed loop system. The open loop system and the closed loop system are linked by a plate heat
exchanger. Heat is absorbed from the plant through the closed loop system and then
transferred to the open loop system at the heat exchanger. The open loop system then rejects
heat to the atmosphere via a round staged induced draught cooling tower.
There are two plate heat exchangers that alternate to be used. The current cooling tower
efficiency is below 25 percent and water with high temperature is circulating within the plant
affecting all the above-mentioned stages reducing plant efficiency.
METHODOLOGY
Components of the cooling system include the cooling tower, plate heat exchanger, pipes and
water softener.
The methods that will be used to gather data includes questionnaires and observation and
analysis
Your participation in this study is completely voluntary. There are no foreseeable risks
associated with this project and it is important for us to learn your opinion. If you feel
uncomfortable answering any questions you are free to withdraw survey at any point.
A. Good
B. Average
C. Poorly
A. Yes
B. No
Q3.To what extent do you think that the efficiency of the plant is related to the cooling system
A. Greater (above 50%)
C. there is no relationship
Q4.In your opinion is plant machinery being affected by the cooling system
A. Yes
B. No
Q5.Is there need to design a new cooling system and purchase new equipment
A. Yes
B. No
Q6.Which plant equipment or machinery is /are underperforming. You are free to select more
than one option on this question
B. Turbines E. Columns
Q5.What are the other factors that you may suspect to cause plant underperformance
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THE END
FACTORS THAT CAUSE COOLING TOWER EFFICIENCY TO DECREASE