File

Republic of Tunisia Cycle of Engineers Formation
Ministry of Higher Education and in Mechanical Engineering

Scientific Research
Discipline
University of Sfax ST-EN07/00

National School of Engineers Sfax
Final Year Project
Department of Mechanical Engineering
Serial N°: 2018-GEM003
GRADUATION PROJECT
Presented in
National School of Engineers Sfax

Department of Mechanical Engineering
In order to obtain
The National Diploma in Electro-Mechanical Engineering
by
Zied MSEDDI
Lube Oil Cooler System Improvement
Defended on September 8, 2018 in front of the committee formed of:
M. Aref MAALEJ President

M. Mounir BACCAR Member
M. Tarak DAMAK Supervisor
M. Mohamed BOUAZIZ Supervisor
M. Karim BEN THABET Supervisor
DEDICATION
From the bottom of my heart and with great pleasure, I dedicate this work
To my parents
Thanks to their tender encouragement and their great sacrifices, they have been able to
create the affectionate climate conducive to the pursuit of my studies.
No dedication could express my respect, my consideration and my deep feelings towards
them.
I pray the good Lord to bless them, to watch over them, hoping that they will always be proud
of me.
To my sister and my family

For their support and advice. May they find here all the esteem I feel for them, and the wish
for happiness and prosperity.
To all my friends and colleagues

They will find here the testimony of an infinite fidelity and friendship.
Zied
ACKNOWLEDGEMENTS
I have taken efforts in this project. However, it would not have been possible without
the kind support and help of many individuals and organizations. I would like to extend my
sincere thanks to all of them.
I am highly indebted to my supervisor professor M. Tarak DAMAK for his guidance and
constant supervision as well as for providing necessary information regarding the project and
for his support in completing the project.
I would like to express my gratitude towards my co-supervisor professor M. Mohamed

BOUAZIZ for his supervision and encouragement and the endless efforts that he did to help me
in completion of this project.
I would like to express my special gratitude and thanks to all mechanical department staff for
giving me such attention and time during these three years in ENIS and for giving me precious
knowledge.
I also want to thank my supervisor M. Karim BEN THABET who represents for me a model to
follow in work and who amaze me by his human behaviors and for his help during the
internship.
My sincere thanks and appreciations also goes to M. Ahmed ABDMOULEH for his supervision
and the endless efforts that he did to help me in completion of this project.
LIST OF CONTENTS
General Introduction ............................................................................................................................ 8

1 Introduction /justification of the project: ..................................................................................... 9
1.1 Scope and purpose of the project......................................................................................... 9
1.2 Structure of the Report ........................................................................................................ 9
1.3 Presentation of the operator ................................................................................................. 9
2 APO in Tunisia .......................................................................................................................... 10
CHAPTER 1 : Export Compressor Overview and Project Framework ........................................ 11

1 Introduction ............................................................................................................................... 12
2 Hasdrubal gas processing plant overview ................................................................................. 12
2.1 Hasdrubal terminal layout ................................................................................................. 12
2.2 Process description ............................................................................................................ 13
3 Export area overview................................................................................................................. 14
4 Export compressor overview ..................................................................................................... 15
4.1 Export compressor functional role .................................................................................... 15
4.2 Export compressor package composition .......................................................................... 15
5 Export compressor oil system ................................................................................................... 17
5.1 Lube oil subsystem ............................................................................................................ 17
5.1.1 Lube oil subsystem components................................................................................ 17
5.1.2 Lube oil subsystem operation .................................................................................... 17
5.2 Working oil subsystem ...................................................................................................... 18
5.2.1 Working oil subsystem components .......................................................................... 18
5.2.2 Working oil subsystem operation .............................................................................. 19
6 Lube oil cooling system issue ................................................................................................... 20
7 Purpose of the project ................................................................................................................ 20
8 Conclusion ................................................................................................................................. 21
CHAPTER 2 : Lube Oil Coolers Thermal Review and Vendor Proposal Validation .................. 22
1 Introduction ............................................................................................................................... 23
2 Air cooled heat exchangers overview and concepts .................................................................. 23
2.1 Process description ............................................................................................................ 23
2.2 Basic Components ............................................................................................................. 23
2.2.1 Heat exchanger bundle .............................................................................................. 23
2.2.1.1 Finned tubes .......................................................................................................... 24
2.2.2 Fans and drives .......................................................................................................... 24
2.3 Air coolers arrangement .................................................................................................... 25
3 Lube oil existing cooler system ................................................................................................. 25
3.1 Vendor first assumptions ................................................................................................... 25
3.2 Lube oil cooler basic design data ...................................................................................... 26
3.3 Thermal sizing review ....................................................................................................... 27
3.3.1 Overall transfer coefficient ........................................................................................ 27
3.3.2 Corrected log mean temperature difference ............................................................. 30
3.3.3 Outside extended surface of tube .............................................................................. 31
3.3.4 Heat exchanged rate .................................................................................................. 32
3.4 Performance assessment .................................................................................................... 32
4 Lube oil cooler system requirement .......................................................................................... 32
4.1 Required heat exchanged rate ............................................................................................ 32
4.2 Interpretation ..................................................................................................................... 32
5 Lube oil additional cooler system.............................................................................................. 33
5.1 Vender new assumptions ................................................................................................... 33
5.2 Basic design data ............................................................................................................... 34
5.3 Thermal sizing review ....................................................................................................... 35
5.3.1 Overall transfer coefficient ........................................................................................ 35
5.3.2 Corrected Mean Temperature Difference .................................................................. 36
5.3.3 Outside extended surface of the tube......................................................................... 37
5.3.4 Heat exchanged rate .................................................................................................. 37
5.4 Performance assessment .................................................................................................... 38
6 Vendor proposal validation ....................................................................................................... 38
7 Conclusion ................................................................................................................................. 38
CHAPTER 3 : Oil Cooler System Instrumentation Review and Proposed Monitoring Solution 39
1 Introduction ............................................................................................................................... 40
2 Control and instrumentation in oil and gas industries ............................................................... 40
2.1 Process instrumentation ..................................................................................................... 40
2.2 Process control and safety systems .................................................................................... 40
2.2.1 Distributed control system (DCS) ............................................................................. 41
2.2.2 Emergency shutdown system (ESD) ......................................................................... 41
2.2.3 Fire and gas control system (F&G) ........................................................................... 42
3 Oil cooler system control and instrumentation review .............................................................. 42
3.1 Instruments index .............................................................................................................. 42
3.2 Control and monitoring philosophy................................................................................... 43
3.3 Recommendation ............................................................................................................... 43
4 Oil circuit control and instrumentation review .......................................................................... 44
4.1 Working oil circuit ............................................................................................................ 44
4.1.1 Instruments index ...................................................................................................... 44
4.1.2 Control and monitoring philosophy........................................................................... 44
4.2 Lube oil circuit .................................................................................................................. 45
4.2.1 Instruments index ...................................................................................................... 45
4.2.2 Control and monitoring philosophy........................................................................... 45
4.3 Proposed solution .............................................................................................................. 46
5 Lube oil temperature transmitter datasheet ............................................................................... 46
5.1 Hazardous area certification (ATEX) ................................................................................ 46
5.2 NACE MR 01-75/ISO 15156 certification ........................................................................ 48
5.3 Temperature sensor ........................................................................................................... 48
5.4 Temperature transmitter .................................................................................................... 49
5.5 Thermowell ....................................................................................................................... 49
5.6 Safety integrity level (SIL) ................................................................................................ 50
6 Lube oil temperature transmitter loop drawing ......................................................................... 50
6.1 Field process area .............................................................................................................. 51
6.2 Marshalling cabinet ........................................................................................................... 51
6.3 DCS system cabinet........................................................................................................... 52
6.4 DCS display....................................................................................................................... 52
7 Conclusion ................................................................................................................................. 52
CHAPTER 4 : Distributed Control System Overview and Integration of a New Coolers Logic. 53
1 Introduction ............................................................................................................................... 54
2 Distributed control system overview ......................................................................................... 54
2.1 DCS system structure ........................................................................................................ 54
2.2 DCS Programming Languages .......................................................................................... 56
3 Foxboro Distributed Control System......................................................................................... 56
3.1 Foxboro I/A Series DCS highlights ................................................................................... 56
3.2 Main software packages .................................................................................................... 57
4 Current oil coolers control narrative.......................................................................................... 59
5 Proposed modification narrative................................................................................................ 62
5.1 Duty/Stand-by selection .................................................................................................... 62
5.2 Auto mode ......................................................................................................................... 62
6 Configuration and programming of the oil cooler system new logic ........................................ 64
6.1 Function block diagram ..................................................................................................... 64
6.2 Program development ........................................................................................................ 65
7 Test and evaluation of the program ........................................................................................... 66
8 Conclusion ................................................................................................................................. 66
General Conclusion ............................................................................................................................. 67
Bibliographical References ................................................................................................................. 68
APPENDIX .......................................................................................................................................... 69
LIST OF FIGURES
Figure 1 : Logo APO Tunisia .................................................................................................. 10

Figure 2 : Hasdrubal project locations and product routes ..................................................... 10
Figure 3 : Hasdrubal Terminal Layout .................................................................................... 12
Figure 4 : Hasdrubal Facilities Block Diagram ....................................................................... 13
Figure 5 : Export Compression System .................................................................................. 14
Figure 6 : Export compression unit ......................................................................................... 16
Figure 7 : Lube oil cicuit ......................................................................................................... 18
Figure 8 : Working oil circuit.................................................................................................. 19
Figure 9 : Heat exchanger bundle ........................................................................................... 23
Figure 10 : Fans and drives ..................................................................................................... 24
Figure 11 : Existing common cooler drawing ......................................................................... 25
Figure 12 : New lube oil cooler expansion ............................................................................. 33
Figure 13 : Process control and safety systems ....................................................................... 40
Figure 14 : Exemple of hazardous zone classification ............................................................ 47
Figure 15 : Temperature sensor............................................................................................... 48
Figure 16 : Thermowell assembly ........................................................................................... 50
Figure 17 : Instruments hooking up stages ............................................................................. 51
Figure 18 : DCS system architecture ...................................................................................... 54
Figure 19 : Foxview window .................................................................................................. 57
Figure 20 : Foxselect window ................................................................................................. 58
Figure 21 : ICC window .......................................................................................................... 59
Figure 22 : Oil cooler system Human machine interface ........................................................ 60
Figure 23 : Duty fans operating chart ..................................................................................... 62
Figure 24 : Stand-by fan operating chart................................................................................. 63
Figure 25 : Example of Function block diagram .................................................................... 65
Figure 26 : Oil cooler system new logic simulation ............................................................... 66
LIST OF TABELS
Table 1 : Maximum temperatures records ............................................................................... 20

Table 2 : Existing cooler design data ..................................................................................... 26
Table 3 : New lube oil cooler design data ............................................................................... 34
Table 4 : Cooler instruments index ......................................................................................... 42
Table 5 : Working oil circuit instruments index...................................................................... 44
Table 6 : Lube oil circuit instruments index............................................................................ 45
General Introduction
Although air is much more freely available than water and costs nothing, process cooling has
historically been accomplished by cooling water. This is attributable to the much lower cost of
cooling by water, thanks to its substantially higher thermal conductivity and lower temperature.
However, with increasing shortages of cooling water and a consequent increase in its cost, air-
cooling has become more and more popular. Today, air-cooled heat exchangers (ACHEs) are a
common sight in the process industries.
Air Cooled Heat Exchangers are used mainly in refineries in oil processing and in the
processing and transportation of natural gas where the worldwide accepted API (American
Petroleum Institute) standard intended for the special requirements of such demanding
operations was developed many years ago, according to which almost all clients order such air-
cooled heat exchangers. In technical jargon, these heat exchangers are indicated as API-
exchangers. They are distinguished by their use at high operating temperatures and pressures,
with highly corrosive and flammable media requiring special structures, materials and
demanding welding procedures.
In this context, this project will present a detailed study of the lube oil cooling system at the
Hasdrubal plant, an approximate performance assessment of the coolers and the steps taken to
improve its operation.
Thus, I will explain in this report not only in an exhaustive way all the technical aspects that I
have been able to learn or to deepen, but also in a synthetic way all the tasks to certain technical
aspects that I have been confronted with.
Zied MSEDDI Page | 8

1 Introduction /justification of the project:
1.1 Scope and purpose of the project
The export gas compressor on the Hasdrubal plant experienced many trips since the
commissioning, which lead to the equipment shut down. The production supervisors claimed
that the frequent trip is due to high lube oil temperature.
For that purpose, an investigation was made by the vendor shows that the duty air coolers were
undersized and that the logic related to coolers is not adequate.
The proposed end of study project is to:
• Understand feed and export gas compressors process conditions, package composition
and auxiliary systems.
• Lube oil system detailed study Review exchanges duty versus required duty and validate
vendor proposal.
• Review coolers logic and propose a more appropriate one.
1.2 Structure of the Report
The remainder of the report is set out as follows:

Chapter 1 : Export compressor overview and project framework
Chapter 2 : Lube oil coolers thermal review and vendor proposal validation
Chapter 3 : Oil cooler system instrumentation review and proposed monitoring solution
Chapter 4 : Distributed control system overview and integration of the new coolers logic
1.3 Presentation of the operator
Company : APO (AMILCAR PETROLEUM OPERATIONS).

Address : Rue du Lac Windermere BP 60, Résidence Mezghani, Les Berges Du Lac
Phone : + 216 31 363 300
Fax: + 216 31 363 310 / + 216 31 363 311

2 APO in Tunisia
APO (Amilcar Petroleum Operations) is a joint venture between Shell upstream ltd (known
previously as British Gas Tunisia ltd) and ETAP (Tunisian Oil Activities Company), which
operates the Hasdrubal project encompassing the Hasdrubal platform and the Hasdrubal plant
located in Sfax since 2009.
Figure 1 : Logo APO Tunisia
The Hasdrubal gas field is located in the Mediterranean Sea off the coast of Tunisia. It lies
approximately 125 kilometers from the Tunisian coast in the Gulf of Gabes within 60 meters
of water as illustrated in the figures below.
The onshore processing facilities, Hasdrubal plant, produce Export Gas, Propane, Mixed
Butanes and Condensate/Oil Products. The Export gas is transported to the STEG tie-in at Ben
Sahloun via a 16km 18” pipeline.
Figure 2 : Hasdrubal project locations and product routes

CHAPTER 1 : Export Compressor Overview and Project

Framework

1 Introduction
Whether it’s for an LNG plant, a natural gas pipeline, or an offshore production platform,
compressors are widely used throughout the oil and gas industry. This chapter represents the
export compressor package composition and the lube oil system cooling issue in the Hasdrubal
terminal.
2 Hasdrubal gas processing plant overview
2.1 Hasdrubal terminal layout
The Hasdrubal plant is a set of units for processing gas that satisfies the source material standard
of a natural gas production facility and the sales gas standard.
The main gas processing requirements and the various stages of the Hasdrubal gas processing
facility is summarized in the following Figure.
Figure 3 : Hasdrubal Terminal Layout
MSEDDI Zied Page | 12

2.2 Process description
The feed gas into the plant from the Hasdrubal NUI platform is received onsite into a slug
catcher. The gas from the slug catcher is compressed and processed in an amine unit to remove
carbon dioxide and hydrogen sulphide. The gas is then dehydrated by molecular sieves. Natural
Gas Liquids are then removed by an NGL extraction unit before the gas is compressed and
exported from the site as sales gas via pipeline.
The condensate is dewatered and stabilized before being stored in three condensate storage
tanks and exported by pipeline to La Skhira.
The acid gas from the amine unit is sent to the Hannibal Gas Plant where it is treated along with
Hannibal’s acid gas stream. When the Hannibal plant is not available the acid gas is flared in
the LP Flare.
The Natural Gas Liquids from the NGL extraction unit are directed to a fractionation unit for
the production of commercial propane and butane according to Tunisian product specifications.
The produced water separated from the production stream in the condensate flash drum, the
condensate coalescer and the condensate stabilizer is directed to a new treatment system before
storage and export for disposal
Figure 4 : Hasdrubal Facilities Block Diagram

3 Export area overview
Lean gas from the NGL extraction system is further compressed by the export compressor (C-
0853) located in the export area. The hot discharge gas is cooled against air by the export
compressor aftercooler (E-0855) prior to metering.
Around 13.5 MMSCFD (million standard cubic feet per day) of lean gas is drawn from
downstream of the export compressor aftercooler for regeneration.
Downstream of the regeneration, the net Hasdrubal export stream is fiscally metered prior to
being sent to the export gas pipeline.
Figure 5 : Export Compression System

4 Export compressor overview
4.1 Export compressor functional role
By increasing the pressure of the gas, export compressors are used to help liquefy and transport
natural gas from one location or process to another and to meet a certain sales gas specification.
For the Hasdrubal terminal, the compression to the maximum sales gas pressure of 75 barg to
move the gas from the production site to the consumer via pipelines is met with an export
compression unit.
4.2 Export compressor package composition
Unlike compressors that work at a constant flow, the export compressor work at a constant
pressure and the performance is affected by external conditions such as changes in gas outlet
temperatures.
The export compression unit in the Hasdrubal terminal consist of the following elements
according to the API 617 standards:
• Main electric motor
In modern configurations of gas compressors, electric motors are used to rotates the shaft and
drive all the compressor’s impellers at the same speed.
• Low-speed coupling
Low speed coupling is used to connect the motor and the gearbox shafts together at their ends
for transmitting power.
• Variable speed planetary gear
Compressor speeds are modulated by a hydrodynamic variable speed planetary gear that allows
each compression stage to operate at the optimum speed and achieve the best efficiency
possible.
• High-speed coupling
High-speed coupling is used to connect the gearbox and the compressor shafts together at their
ends for transmitting power.

• Thermodynamic centrifugal compressor
A centrifugal compressor is a type of dynamic compressor, or turbo-compressor, with a radial

design that is used for achieving the required pressure rise.
• Control system
The integrated export compressor control system provides protection and monitoring to
maximize compressor safety against potentially dangerous, while improving process efficiency
and availability.
• Oil system
For continuous compressor operation, the oil system provides the lube oil to the radial and
thrust bearing of the compressor, while the working oil is provided to the hydrodynamic
variable speed planetary gear.
Figure 6 : Export compression unit

5 Export compressor oil system
5.1 Lube oil subsystem
The lube oil subsystem supplies oil to either cool or lubricate the internal components such as
the compressor and driver bearings.
5.1.1 Lube oil subsystem components
The major lube oil system components in a centrifugal compressor train include the following
elements as per the API 614 standards:
• Two positive displacement pumps (one main and one auxiliary)

• Air coolers with fixed speed electric motor driven fan motors
• Two filters connected in parallel
• Oil reservoir equipped with heaters to maintain oil at a correct temperature in the tank,
especially when the compressor is stationary.
5.1.2 Lube oil subsystem operation
The auxiliary pump driven by an electric motor is started to feed the lube oil circuit to lubricate
the shaft line before the compressor startup.
When in operation, the compressor lube oil is normally circulated by the main oil pump
(mechanical driven), while the auxiliary pump will serve as a standby. Those two pumps have
a common collector.
The lube oil flow coming from the compressor oil reservoir split into two paths, one will be
sent to the fan coolers, which cool it down and the other will not be cooled, and then monitored
by a temperature control valve mechanically operated which is set to maintain lube oil
temperature at 50°C by mixing the two inlet flows .
The lube oil downstream the temperature control valve is filtered by dual filters and delivered
to the bearings.
Upon leaving the bearings, the lube oil drains back to the reservoir.

Figure 7 : Lube oil cicuit
5.2 Working oil subsystem
The working oil subsystem supplies oil to the hydrodynamic variable speed planetary gear
components such as the torque converter and the actuator.
5.2.1 Working oil subsystem components
The export compressor working oil system is mainly composed by the following elements as
per the vendor (Voith) design:
• one positive displacement pumps

• Air coolers with fixed speed electric motor driven fan motors (Same coolers for the
L.O and the W.O).
• Oil reservoir equipped with heaters to maintain oil at a correct temperature in the tank,
especially when the compressor is stationary.

5.2.2 Working oil subsystem operation
When in operation, the working oil is drawn from the reservoir by the main pump (mechanical
driven) and is fed to the working oil circuit under pressure.
Similar to the lube oil system, the working oil flow coming from compressor oil reservoir split
into two paths, one will be sent to the fan coolers, which cool it down and the other will not be
cooled, and then monitored by a temperature control valve mechanically operated which is set
to maintain lube working temperature at 60°C by mixing the two inlet flows.
The working oil downstream the temperature control valve is delivered to the torque converter
and the VEHS actuator.
Upon leaving the torque converter and the VEHS actuator, the working oil drains back to the
reservoir.
Figure 8 : Working oil circuit

6 Lube oil cooling system issue
Production reported high lube oil temperature downstream the coolers of the export gas
compressor when working at full rate and during high summer ambient temperatures. To cool
the oil, 3 fans are continuously working whereas only 2 should be working as per design. So no
standby fan is available anymore in case of a maintenance issue or high ambient temperature.
Maximum temperatures recorded for the LO downstream the coolers, during summertime, are
given in the following table:
Table 1 : Maximum temperatures records
L.O After Cooler Temperature Export Gas Compressor

Alarm setting 55 ℃
Trip setting 60 ℃
Summertime 58.3 ℃
• L.O temperature downstream air-cooler reached alarm value (>55 deg°C) even with 3 fans
in operation.
• L.O temperature downstream air-cooler reached trip value (60 deg°C) if only 2 fans were
kept in operation.
As a temporary solution, production claimed that mist water has been sprayed on the fin fan
coolers to decrease the lube oil temperature on the LO cooler outlets and avoid unexpected high
high temperature trips of the gas compressors.
Recently, an investigation was made by the vendor shows that the existing coolers are
undersized and a new lube oil cooler should be added as a back-up for the existing ones.
7 Purpose of the project
The project involves improving the operation of the lube oil cooling system in order to provide
higher availability of the export compressor. My graduation project focuses on the validation
of the new vendor proposal and the integration of a new coolers logic on the system DCS. For
that, I was part of the engineering team in charge of this project.

For the fulfillment of the objective, the following tasks were defined:
• Review exchanges duty versus required duty and validates vendor proposal
• Review coolers instruments configuration and propose a more appropriate one
• Review coolers logic and propose a more appropriate one
8 Conclusion
This chapter was an initialization to the project, in which we gave a presentation of the
Hasdrubal gas processing plant as well as a presentation of the export area. Subsequently, we
presented the export compressor process conditions, package composition, and auxiliary
systems. This chapter ends with a presentation of the project framework as well as the different
tasks to be carried out during my graduation project.

CHAPTER 2 : lube oil coolers thermal review and vendor proposal validation
CHAPTER 2 : Lube Oil Coolers Thermal Review and Vendor

Proposal Validation

1 Introduction
An air-cooled exchanger (ACHE) is used in petrochemical plants and refineries to cool fluids
with ambient air. This chapter describes the general design of the air-cooled exchangers used
to cool the lube and the working oils and presents a method of approximate sizing to evaluate
the vender final proposal.
2 Air cooled heat exchangers overview and concepts
2.1 Process description
Air coolers heat exchangers are built according to the ASME Code (section VIII), since they
are pressure vessels. For refinery and petrochemical services, most customers include API 661
(Air-Cooled Heat Exchangers for General Refinery Service) in their specifications.
Their operating principle is straightforward, the hot process fluid enters the tubes on one end
while ambient air flows over and between the externally finned surfaces.
2.2 Basic Components
2.2.1 Heat exchanger bundle
The heat exchanger bundle is an assembly of the tubes, headers, tube supporting structure and
frames as shown in the figure below
Figure 9 : Heat exchanger bundle

• Plug headers
Plug headers introduce the hot fluid into the tubes and collect the cold fluid. They consist of a
rectangular, welded box, the inlet, and the outlet nozzles as well as the partition plate that create
the required number of tube passes.
The plug hole opposite each tube in the plug-sheet allows partial access to each tube and
plugging in case of leakage
2.2.1.1 Finned tubes
The aluminum fins are normally applied to the tubes to provide an extended surface on the
airside, in order to compensate for the relatively low heat transfer coefficient of the air to the
tube. During fabrication, a fin-strip of aluminum is preformed into an L-shape and then wound
onto the tube under tension
2.2.2 Fans and drives
The cooling air that is required for the cooling process is moved through the heat exchanger
bundles by axial fans that displace very large volumes of air against a low static pressure.
The axial fan drive unit is composed of the bearing block for the fan impeller, the v-belt drive,
the pulleys and the drive motor.
The space between the fans and the tube bundle is enclosed by a plenum chamber, which directs
the air.
Figure 10 : Fans and drives

2.3 Air coolers arrangement
Air-cooled heat exchangers are classified as a forced draft when the tube section is located on
the discharge side of the fan, or as an induced draft when the tube section is located on the
suction side of the fan.
In our case, since the fans are located beneath the tube bundle and force air up through the tubes
to dissipate heat, the air coolers heat exchangers are considered as a forced draft.
This design allows easy access to mechanical components and direct access to the tube bundle
itself.
3 Lube oil existing cooler system
3.1 Vendor first assumptions
To cool the oil, as the vendor first assumption, one common air-cooler for LO and WO
including two separate bundles and three fans in common are required (two in duty and one in
standby).
Figure 11 : Existing common cooler drawing

3.2 Lube oil cooler basic design data
Table 2 : Existing cooler design data
Dimensions
Bundle size 1,28 x 8,70 (m x m)
Number of passes, np 1
Number of rows of tubes, nr 5
Tubes number 88
Tubes outside diameter, Nt 25,4 (mm)
Tubes thickness 1,651 (mm)
Finned tubes length 8200 (mm)
Number of Fins per meter, Nf 433 (fin/m)
Fins outside diameter 57,15 (mm)
Fins thickness 0,35 (mm)
Performance Data-Tubeside
Fluid name Oil ISO VG 46
Total fluid Flow quantity, Wt 9,15 (kg/s)
Inlet oil temperature, T1 66,7 (℃)
Outlet oil temperature, T2 55,6 (℃)
Oil viscosity, µ 13,61 (mPa.s)
Oil Specific heat, Cp 2,055 (kJ/(kg.℃))
Thermal conductivity, K 0,1291 (W (m. ℃))
Performance Data-Airside
Air flow quantity, Wa 41,21 (kg/s)
Ambient temperature, t1 40 (℃)
Specific, Cpair 1,01 (kJ/(kg.℃))

3.3 Thermal sizing review
3.3.1 Overall transfer coefficient
The overall heat transfer coefficient represents the total resistance to heat transfer from one
fluid to another, therefore, it can be defined as the following form:
1/Ux = (1/ht)*(Ax/Ai) + rdt*(Ax/Ai) + (rmx) + (1/ha) (1)
Where:
ht : Tube side film coefficient, in m2•K/W
Ax : Outside extended surface of tube, in m2
Ai : Inside surface area of the tube, in m2
rdt : fluid fouling factor
rmx : Tube metal resistance
ha : Air side film coefficient, in m2•K/W
• Tube side film coefficient
The procedure for calculating the tube side film coefficient for a fin fan air cooler is as follows:
o Step 1: calculate the tube-side mass velocity
The mass velocity through the tube inside cross-sectional area (At) is calculated using the
equation:
Gt = ((Wt*Np) / (Nt*At)) (2)
Gt = ((9,15*1) / (88*(π*(22,098)2) / 4)
= 271,108 kg/m2.s

o Step 2: calculate the modified Reynolds number
The modified Reynolds number is calculated using the equation:
Nr = (Di*Gt) / μ (3)
Nr = (22,098*271,108) / 13,61
= 440,187
o Step 3: determine the correlation factor
For the calculated Reynolds number (Nr = 440,187) and for (1000*L)/Di = 371, the Correlation
factor is determined from the appendix 2.1 : we obtain J = 1,9
o Step 4: calculate the Prandtl number
The Prandtl number is calculated using the equation:
Pr = (Cp*μ) / k (4)
Pr = (2,055 *13,61) / 0,1291
= 216,642
o Step 5: determine the correction factor for fluid viscosity within the tubes
Depends on the fluid within the tubes, the correction factor is determined from the appendix
2.2. In our case, as it is a lubricating oil, then we obtain Φ = 0,85
o Step 6: calculate the tube side film coefficient
The tube side film coefficient is calculated using the equation:
ht = (((J*K*φ*(Pr) (1/3)) / Di) * nr (5)
ht = (((2*0,1291*0.85*(216,642) (1/3)) / 22.098) * 5 *1
= 283,33 W/m2.℃

• Air-side film coefficient
The procedure for calculating the air side film coefficient for a fin fan air cooler is as follows:
o Step 1: calculate the air side mass velocity
The mass velocity through the total face area of the bundle is calculated using the equation:
Ga = Wa/Fa (6)
Ga = 41,21 / (8,7*1,28)
= 3,7
o Step 2: determine the air side film coefficient
For the calculated air side mass velocity (Ga = 3,7), the air side film coefficient is determined
from the appendix 2.3: we obtain ha = 50 W/m2.℃.
• Tube metal resistance
Rmx is omitted from calculations since metal resistance is small compared to other resistances
• Fluid fouling factor
After a period of time, the heat transfer surfaces of a heat exchanger may become coated with
deposits from the heat transfer fluids or corrosion. In either case, the additional resistance to
heat transfer due to these materials decreases the performance of the heat exchanger and must
be accounted for.
Some typical values of film resistances are given in appendix 2.4, in our case we obtain
rdt = 0,00018 m2.℃ /W.
• Area ratio of finned tube
According to the fin height value (15.9 mm), the area ratio of finned tube is determined from
appendix 2.5: we obtain Ar = 21,4.

Based on the different results found previously and according to the equation (1), the
approximate overall heat transfer coefficient will be calculated as follows:
Ux = 1 / ((1/ht)*(Ax/Ai) + rdt*(Ax/Ai) + (1/ha))
= 1 / ((1/ht)*((Do/Di)*Ar) + rdt*((Do/Di)*Ar) + (1/ha))
= 1 / ((1/283,33)*((25,4 /22,098)*21,4) + 0,00018 *((25,4 /22,098)*21,4) + (1/50))
= 9,35 W/m2.C
3.3.2 Corrected log mean temperature difference
The CMTD represents the effective average temperature difference between the two heat
transfer fluids over the length of the heat exchanger and it’s calculated as the following
procedure:
o Step 1: calculate the approximate air temperature rise
The approximate air temperature rise is calculated using the equation:
Δta = ((Ux+1)/10) * (((T1+T2)/2) – t1) (7)
Δta = ((9.371+1)/10) * (((66,7+55,6)/2) – 40)
= 5,418 ℃
t2 = t1 + Δta
= 40 + 5,418
= 45,418 ℃
o Step 2: calculate the log mean temperature difference
The log mean temperature difference is calculated using the equation:
LMTD = (ΔT1 - ΔT2) / ln (ΔT1/ΔT2) (8)

ΔT1 = T1 - t2
= 66,7 – 40
= 21,281 ℃
ΔT2 = T2 – t1
= 55,6 – 45,418
= 15,6 ℃
LMTD = (21,281-15,6) / ln (21,281/15,6)
= 18,293
o Step 3: determine the correction factor
Depends on the geometry of the heat exchanger and the inlet and outlet temperatures of the hot
and cold fluid streams, the correction factor is determined from the appendix 2.6. In our case,
we obtain : F = 0.95
o Step 4: calculate the corrected log mean temperature difference
The corrected mean temperature difference is calculated using the equation:
CMTD = LNTD*F (9)
CMTD = 18,293*0.95
= 17,43
3.3.3 Outside extended surface of tube
The fin thickness is omitted from calculations since its small compared to other dimensions,
then, the outside extended surface of tube is calculated as the following equation
Ax = (((((Df) 2 - (Do) 2)*π)/4)*2)*Nt*Nf*Lt (10)
Ax = (((((0,05715) 2 - (0,0254) 2)*π)/4)*2)*88*433*8,2
= 1286,367 m2

3.3.4 Heat exchanged rate
The heat transfer rate across the existing heat exchanger is expressed in the form below
Q = Ux*Ax*CMTD (11)
Q1 = 9,35*1286,367 *17,434
= 209 kW
3.4 Performance assessment
Based on the results of the sizing review performed above and considering a maximum ambient
air temperature of 40 °C, the maximum available heat exchanged rate of the existing cooler will
be esteemed by 209 kW.
In case of considering a maximum ambient air temperature of 30 °C, we notice that the existing
cooler will be able to deliver a maximum heat exchanged rate esteemed by 310 kW.
4 Lube oil cooler system requirement
4.1 Required heat exchanged rate
As a three ways self-control valve controls the temperature at cooler outlet, by bypassing the
oil flow. It shall open the flow to the cooler at 50℃, therefore, the equation for the required
heat exchanged rate become:
Q = Wa*Cp*(T1-T2) (12)
Q = 9,15*2,055*(66,7-50)
= 314 kW
4.2 Interpretation
Comparing the results of the existing cooler performance assessment and the required cooler
heat duty estimation, we find that:
• During the cold season, the existing lube oil cooler is oversized and can achieve the
optimal desired process temperature (50 °C).

• During the hot season (ambient air temperature of 40 °C), the existing lube oil cooler is
undersized and cannot achieve the optimal desired process temperature (50 °C).
5 Lube oil additional cooler system
5.1 Vender new assumptions
As mentioned previously, to increase heat dissipation capacity of the existing lube oil coolers
and to implement a permanent solution to deal with this issue, it was agreed to connect the
existing lube oil coolers in a serial configuration with a new one that includes one bundle and
one fan.
Figure 12 : New lube oil cooler expansion

5.2 Basic design data
Table 3 : New lube oil cooler design data
Dimensions
Bundle size 2,42 x 2,70 (m x m)
Number of passes, np 2
Number of rows of tubes, nr 5
Tubes number, Nt 170
Tubes outside diameter 25,4 (mm)
Tubes thickness 1,651 (mm)
Finned tubes length 2400 (mm)
Number of Fins per meter, Nf 433 (fin/m)
Fins outside diameter 57,15 (mm)
Fins thickness 0,35 (mm)
Performance Data-Tubeside
Fluid name Oil ISO VG 46
Total fluid Flow quantity, Wt 9,15 (kg/s)
Inlet oil temperature, T1 55,6 (℃)
Outlet oil temperature, T2 50 (℃)
Oil viscosity, µ 19,56 (mPa.s)
Oil Specific heat, Cp 2,015 (kJ/(kg.℃))
Thermal conductivity, K 0,1302 (W (m. ℃))
Performance Data-Airside
Air flow quantity, Wa 22,65 (kg/s)
Ambient temperature, t1 40 (℃)
Specific, Cpair 1,01 (kJ/(kg.℃))

5.3 Thermal sizing review
5.3.1 Overall transfer coefficient
The same procedure used previously for calculating the overall transfer coefficient is applied
as follows:
• Tube side film coefficient
The same procedure used previously for calculating the side film coefficient is applied as
follows:
o Step 1: calculate the tube-side mass velocity using equation (2)
Gt = ((9,15*2) / (170*(π*(22,098)2) / 4)
= 280,67 kg/m2.s
o Step 2: calculate the modified Reynolds number using equation (3)
Nr = (22,098*280,67) / 19,56
= 317,095
o Step 3: determine the correlation factor
For the calculated Reynolds number (Nr = 317,095) and for (1000*L)/Di = 108,6, the
Correlation factor is determined from the appendix 2.1: we obtain J = 2,7.
o Step 4: calculate the Prandtl number using the equation (4)
Pr = (2,015 *19,56) / 0,1302
= 302,720
o Step 5: determine the correction factor for fluid viscosity within the tubes
Since it's the same fluid studied previously. Then we obtain: Φ = 0,85
o Step 6: calculate the tube side film coefficient using the equation (5)
ht = (((1,7*0,1302*0.85*(302,720) (1/3)) / 22.098)*5
= 453,964 W/m2.℃

• Air side film coefficient Calculation
The same procedure used previously for calculating the air film coefficient is applied as follows:
o Step 1: calculate the air side mass velocity using the equation (6)
Ga = 22,65 / (2,4*2,7)
= 3,5
o Step 2 determine the air side film coefficient
For the calculated air side mass velocity (Ga = 3,5), the air side film coefficient is determined
from the appendix 2.3: we obtain ha = 48 W/m2.℃
Based on the different results found previously and according to the equation (1), the
approximate overall heat transfer coefficient will be calculated as follows:
Ux = 1 / ((1/ht)*(Ax/Ai) + rdt*(Ax/Ai) + (1/ha))
= 1 / ((1/ht)*((Do/Di)*Ar) + rdt*((Do/Di)*Ar) + (1/ha))
= 1 / ((1/453,964)*((25,4 /22,098)*21,4) + 0,000172 *((25,4 /22,098)*21,4) + (1/48))
= 12,752 W/m2.C
5.3.2 Corrected Mean Temperature Difference
The corrected mean temperature difference (CMTD) is calculated as the same procedure used
previously:
o Step 1: calculate the approximate air temperature rise using the equation (7)
Δta = ((9.371+1)/10) * (((55,6+50)/2) – 40)
= 4,451 ℃
t2 = t1 + Δta = 40 + 4,451
= 44,451 ℃

o Step 2: Log Mean Temperature Difference using the equation (8)
ΔT1 = T1 - t2 = 55,6 – 40
= 15,6 ℃
ΔT2 = T2 – t1 = 50 – 44,451
= 5,548 ℃
LMTD = (15,6 – 5,548) / ln (15,6/5,548)
= 10,563
o Step 3: determine the correction factor
The correction factor is determined from the appendix 2.7. In our case we obtain, F = 1
• Step 4: calculate the corrected mean temperature difference using the equation (9)
CMTD = 10,563*1
= 10,563
5.3.3 Outside extended surface of the tube
The outside extended surface of tube is calculated using the same method used previously in
equation (10).
Ax = (((((0,05715) 2 - (0,0254) 2)*π)/4)*2)*433*177*2,4
= 757,274 m2
5.3.4 Heat exchanged rate
The heat exchanged rate across the new heat exchanger is calculated using the equation (11)
Q2 =12,752*757,274*10,563
= 104,104 kW

5.4 Performance assessment
Considering a maximum ambient air temperature of 40 °C, the maximum available heat
exchanged rate of the additional cooler will be esteemed by 104 kW.
Since the two lube oil coolers are mounted in a serial configuration, the two heat exchange rate
delivered by each one can be superposed to give a global heat exchanger rate esteemed by 313
kW, which is the suitable value to reach the required outlet lube oil temperature.
6 Vendor proposal validation
As per the above draft, sizing review we mainly consider that four fans are required to cool the
lube oil, consequently the new lube oil cooler system configuration will be as follows:
• During cold season: the existing cooler will be operating with 2 fans in duty and 1 fan
in standby, while the additional cooler will be not operating during this season.
• During hot season: the existing cooler will be operating with 2 fans in duty and 1 fan
in stand-by, and the additional cooler will be operating with 1 fan in duty.
7 Conclusion
In this chapter, the thermal design of the lube oil coolers was checked, its performance has been
evaluated for several operating conditions and the required duty has been estimated in order to
validate the vendor final implemented proposal. These documents provide the basis for the
thermal sizing the fin fan air coolers.

CHAPTER 3 : Oil cooler instrumentation review and monitoring proposal
CHAPTER 3 : Oil Cooler System Instrumentation Review and

Proposed Monitoring Solution

1 Introduction
Costly air cooler failures and consequential plant production downtime can be avoided by
monitoring these machines with an effective monitoring solution. This chapter describes the air
cooler heat exchangers control and monitoring system improvement proposal and presents the
required instruments for this purpose and their specifications.
2 Control and instrumentation in oil and gas industries
2.1 Process instrumentation
In oil and gas industries, instrumentation is used to monitor and control the operating conditions
of the facility, which helps to meet safety, environmental regulations, quality and productivity,
profitable operation and stable plant operation objectives.
2.2 Process control and safety systems
Process control and safety systems make sure industrial processes are carried out efficiently,
consistently and with as little variation as possible. They are installed in industrial settings to
help maintain throughput, quality, and energy efficiency and make sure working practices are
carried out safely and profitably.
Process control and safety systems measure, monitor and control manufacturing processes and
activities. They identify and correct any abnormalities or variations from specified values, the
aim is to make sure that production is consistent.
Figure 13 : Process control and safety systems

In the process control systems, we have three main control system as the following:
2.2.1 Distributed control system (DCS)
DCS system is the core of an automated process control system. It ensures fulfillment of all
main functions of control, visualization, registration and reporting of the process including:
o Automatic regulation
o Program (logic) control
o Remote control (start, shutdown, change of set points)
o Alarms and notifications management
o Collection and processing of process and equipment data
o Graphic presentation of process and equipment condition data
o Detection and alarm of emergencies and deviations of the process from preset limits
o Keeping of event log
o Registration and archiving of process parameters
o Report generation
o Data exchange with external systems
2.2.2 Emergency shutdown system (ESD)
ESD system ensures priority control of process equipment, which is required for switching the
process in safe mode. The system performs the following functions:
o Collection and processing of ESD-connected information about process parameters and

equipment state
o Detection and alarm of emergencies and process deviations from preset limits
o Automatic shutdown of production facilities in case of parameters deviation from preset
limits or manual shutdown by the operator
o Alarms and notifications management
o Prevention of repeated start of production facilities until the cause of shutdown is
eliminated or forced unlocking is performed

2.2.3 Fire and gas control system (F&G)
F&G system is designed for automation of fire and gas protection facilities at hazardous
production sites and performs the following functions:
o Collection and processing of information about fire and operation of fire-fighting units
in case of fire and in normal mode
o Automatic control of alarm systems
F&G system provides also control of fire protection technological complex, which includes the
following components:
o Fire water pump station with water pumps, foam pumps, and circulating pumps
o Foaming agent dosing systems with tanks and pipelines
o Input control devices, fire detectors and warning systems, installed on the process and
administration equipment.
3 Oil cooler system control and instrumentation review
3.1 Instruments index
From the piping and instrumentation diagram shown in the appendix 3.1, all the oil cooler
system instrument tag number are gathered along with its associated information such as service
description and instrument type in the instrument index below.
Table 4 : Cooler instruments index
Tag number Instrument type Service system

TI-08407 Temperature indication lube oil inlet temperature ---
TI-08408 Temperature indication Working oil inlet temperature ---
TI-08409 Temperature indication lube oil outlet temperature ---
TI-08410 Temperature indication Working oil outlet temperature ---
TIT-08468 Temperature indicating transmitter Ambient temperature control DCS
TAH-08468 Temperature alarm high Ambient temperature DCS
TAL-08468 Temperature alarm low Ambient temperature DCS

3.2 Control and monitoring philosophy
• Distributed control system
The oil cooler system operation is mainly controlled by the temperature transmitter (TIT-08468)
so that the stand-by fan will be started on high ambient temperature (TAH-08468) and stopped
when the temperature is back to normal (TAL-08468).
• Emergency shutdown system
Each fan of the oil cooler system is equipped with a vibration switch that senses vibration,
triggers an alarm and shuts down the fan if the vibration exceeds a preset threshold level.
3.3 Recommendation
In order to enhance the operation and improve total equipment reliability, the oil cooler system
operating sequence should be controlled by the outlet oil temperature (to make sure that the
outlet temperature is in accordance with the target operating range).
For that, it was recommended to replace the ambient temperature transmitter (TAL-08468) by
another one adequate to our application.

4 Oil circuit control and instrumentation review
4.1 Working oil circuit
4.1.1 Instruments index
From the piping and instrumentation diagram shown in the appendix 3.2, all the working oil
circuit instrument tag number are gathered along with its associated information such as service
Table 5 : Working oil circuit instruments index

TIT-08463 Temperature indicator transmitter cooler outlet oil temperature DCS
TAH-08463 Temperature alarm high cooler outlet oil temperature DCS
TAL-08463 Temperature alarm low cooler outlet oil temperature DCS
TIT-08467A Temperature indicator transmitter VEHS outlet oil temperature ESD
TAHH-08467A Temperature alarm high high VEHS outlet oil temperature ESD
TALL-08467A Temperature alarm low low VEHS outlet oil temperature ESD
TIT-08467B Temperature indicating transmitter VEHS outlet oil temperature DCS
TAH-08467B Temperature alarm high VEHS outlet oil temperature DCS
TAL-08467B Temperature alarm low VEHS outlet oil temperature DCS
4.1.2 Control and monitoring philosophy
Working oil temperature at the cooler outlet is checked by the temperature transmitter
(TlT08463), which initiates a high alarm (TAH-08463) if the temperature increases above the
high level and a low alarm (TAL-08463) if the temperature decrease below the low level.
Downstream the VEHS, the working oil temperature is controlled by the temperature
transmitter (TIT-08467B) which triggers a high alarm (TAH-08467B) if the temperature of the
oil exceeds the high level and a low alarm (TAL-08467B) if the temperature decrease below
the low level

If the temperature transmitter (TIT08466B) goes out of scale, it enters into a safe mode and
initiates the dedicated trip (TAHH-08466B) or (TALL-08466B). When the input trip disappears
and the associated trip memory disappears, the operator can reset it with the push button.
4.2 Lube oil circuit
4.2.1 Instruments index
From the piping and instrumentation diagram shown in the appendix 3.2, all the lube oil circuit
instrument tag number are gathered along with its associated information such as service
Table 6 : Lube oil circuit instruments index

TIT-08466A Temperature indicating transmitter filter oil outlet temperature ESD
TAHH-08466A Temperature alarm high high filter oil outlet temperature ESD
TALL-08466A Temperature alarm low low filter oil outlet temperature ESD
TIT-08466B Temperature indicating transmitter filter oil outlet temperature DCS
TAH-08466B Temperature alarm high filter oil outlet temperature DCS
TAL-08466B Temperature alarm low filter oil outlet temperature DCS
4.2.2 Control and monitoring philosophy
lube oil temperature downstream filters is checked by the temperature transmitter (TlT-
08466B), which initiates a high alarm (TAH-08466B) if the temperature increases above the
high level and a low alarm (TAL-08466B) if the temperature decrease below the low level.
If the temperature transmitter (TIT-08466A) goes out of scale, it enters into a safe mode and
initiates the dedicated trip (TAHH-08466A) or (TALL-08466A). When the input trip
disappears and the associated trip memory disappears, the operator can reset it with the push
button.

4.3 Proposed solution
Since the lubricating oil has a tighter temperature tolerance range than that of the working oil
and by checking the availability of the instruments, as a solution, it has been approved to
perform the following tasks:
• For the DCS system: replace the ambient temperature transmitter (TIT-08468) by the
lube oil temperature transmitter (TIT-08466B) for controlling the oil cooler system
operating sequence which going lead to change in the oil cooling system logic.
• For the ESD system: keep the existing operation philosophy.
5 Lube oil temperature transmitter datasheet
The instrument datasheet is a document containing specification and information of the

measurement devices. This datasheet along with its supporting vendor data is stored and will
be referred during construction, operation and maintenance.
Preparing the temperature transmitter (TIT-08466B) datasheet as shown in the appendix 3.3
requires some references, the following steps describe the workflow:
5.1 Hazardous area certification (ATEX)
ATEX is an abbreviation for "ATmosphere EXplosible". At the same time, ATEX is the
abbreviated name of the European Directive 2014/34/EC concerning the placing on the market
of explosion-proof electrical and mechanical equipment, components and protective systems.
• Hazardous zone classification
Hazardous places are classified in terms of zones (0, 1 or 2) on the basis of the frequency and
duration of the occurrence of an explosive atmosphere.
In our case, the (TIT-08466B) is hooked in a place, where an explosive atmosphere consisting
of a mixture with air of dangerous substances in the form of gas is likely to occur in normal
operation occasionally. For that, according to the ATEX regulation, the (TIT-08466B) should
be approved for use in such a place classified as zone 1.

Figure 14 : Exemple of hazardous zone classification
• Gas Groups
ATEX regulation defines four groups of gases (I, IIA, IIB, IIC), based on how easily ignitable
they are (by a flame or spark, not via self-ignition).
Groups IIA, IIB and IIC are increasing by the order of sensitivity to ignition sources, so
equipment designed for use in gas group IIB is also safe to use in the less ignitable gas group
IIA and equipment designed for use in gas group IIC can be used with gas groups IIA, IIB and
IIC.
Consequently, for a high protection level, the (TIT-08466B) is rated for gas group IIC.
• Temperature class
When selecting an instrument, it is crucial that the self-ignition temperature of the fuel is
significantly above the maximum possible surface temperature. The maximum possible surface
temperature of the equipment is indicated in the ATEX explosion classification as a ‘T’ value,
ranging from T1 to T6 in order of decreasing value (so T6 is the safer).
For the (TIT-08466B), the maximum possible surface temperature is marked as T6 (that's mean
that the maximum allowable surface temperature is 85℃).
• Protection Concepts
There are varying types of equipment that can be used within ATEX zones to ensure that the
potential for an explosion is removed or greatly reduced. That equipment must be designed and
manufactured in accordance with particular construction parameters known as protection
concepts whose depend on the main use of the equipment.

In the case of measurement and control devices, such as ours, the explosion protection
techniques used is the intrinsic safety ‘ia’.
5.2 NACE MR 01-75/ISO 15156 certification
NACE MR0175/ISO 15156 standards give requirements and recommendations for the selection
and qualification of equipment used in oil and natural gas production and natural gas treatment
plants in H2S-containing environments, whose failure could pose a risk to the health and safety
of the public and personnel or to the equipment itself.
In our case, such as the process fluid is the lube oil, there is no risk of H2S presence, for that
the certificate is not required.
5.3 Temperature sensor
Temperature sensors measure the amount of heat energy that is generated by the system, allow
us to detect any physical change to that temperature and produce either an analog or a digital
output.
Figure 15 : Temperature sensor
In our case, the supplied sensor is a resistance temperature detector (RTD) with following
features:
o Type : PT100 (PT100 has a resistance of 100 ohms at 0 °C)

o Configuration : direct mount 2-wires
o Tolerance Class : Standard IEC 60751 defines PT100 resistance accuracy classes and
corresponding tolerances. Briefly, the tolerance categories adopted for our case is the
Class A.

o Calibration standard : The IEC 60751 standard specifies the requirement and the
characteristics of the Industrial platinum resistance thermometers and platinum
temperature sensors calibration practices.
5.4 Temperature transmitter
A temperature transmitter is a device that connects to a temperature sensor to transmit the signal
elsewhere for monitoring and control purposes. Its main role is to isolate the temperature signal,
filter any noise, amplify and convert the temperature sensor's signal for further use.
• Output signal
The transmitted temperature signal should be scaled inside the temperature transmitter to
accommodate the needs of the application, in such a way, the (4mA) can be used to represent
the lowest temperature value and the (20mA) can be used to represent the highest temperature
value.
• Communication signal
The temperature transmitters can communicate additional information beyond the normal
process variable and be configurable via the conventional 4- to 20-mA current loop by utilizing
the highway addressable remote transducer (HART) protocol.
• IEC 60529 certification
The protection of the envelopes against the penetration of dirt or the penetration of liquids is
defined according to the IEC 60529 standard. Since The temperature, transmitters will be
exposed to an environment where moisture and dust are prevalent, this certification becomes
required (Protection degree IP66).
5.5 Thermowell
Thermowells are used to guard temperature sensors such as against damage from excessive
pressure, material velocity and corrosion. They also increase the longevity of the sensor, allow
sensor replacement without draining the system and reduce the probability of contamination.

Thermowells are categorized according to the design of the stem, in our case, the mounted one
is a threaded type.
Figure 16 : Thermowell assembly
5.6 Safety integrity level (SIL)
Safety integrity level offers an objective rating that represents how well a product development
process prevents “Systematic” failures and how well a product’s design offers resistance against
“random” failures, given assumed operating conditions, in simpler terms, SIL is a measure of
the reliability of the product. IEC 61508 defines SIL levels or categories from 1 to 4, with 4
providing the highest level of reliability.
In our application, the SIL certificate is not required since it is not a critical process case.
6 Lube oil temperature transmitter loop drawing
A loop diagram shows you how measurement devices are arranged in the loop. From the loop
diagram, we can identify the connections between the devices and the communication path.
This is helpful when installing, troubleshooting or maintaining a loop.

Preparing the temperature transmitter (TIT-08466B) loop drawing as shown in the appendix
3.4, requires some references, the following steps describe the workflow:
Figure 17 : Instruments hooking up stages
6.1 Field process area
The (TIT-08466B) is hooked-up with 1-pair cable extended to the junction box in the process
area, in a way that every wire of the homerun cable is landed on terminal strips of the junction
box. For easy identification, the terminals are labeled by cable pair number (+) and (-).
6.2 Marshalling cabinet
The marshalling panel is placed between the DCS system panel and the field instruments. It
main function is to interface the incoming field cable (which is normally a multipair cable) and
the I/O (Input/Output) card connection in a way that’s not only cost-effective, robust and
durable, but which is also well ordered and easily maintainable.

In our application, the marshalling cabinet has the following cable routing:
o The multipair field cables enter the marshalling cabinet through the bottom of the
cabinet.
o Then each wire of the incoming multipair field cable is terminated in the surge
protection devices or surge arrester.
o From the surge protection devices, there will be a cross wiring that matches the field
signal and the I/O address assignment in the termination board
o The dedicated system cable is then routed from the termination board to the I/O card in
the CMS cabinet.
6.3 DCS system cabinet
DCS cabinet is designed to accommodate the system hardware such as the CP modules and the
I/O nodules.
In our application, the DCS system cabinet has the following cable routing:
o The system cable that comes from marshalling cabinet will be directed into the intended
I/O cards address.
o The field signal will be digitally processed by this I/O cards and then sent to the CP
module for further digital logic processing.
6.4 DCS display
A serial digital data transmission link connecting the DCS controller to the DCS display station.
It allows the graphical user to follow the temperature instrument readings.
7 Conclusion
In this chapter, the proposed control and monitoring solution of the oil cooler system has been
completed and approved by the different project accountable and the required documents have
been elaborated. These documents provide the basis of the instruments specification and
installation procedure that has been used in the proposed solution.

CHAPTER 4 : DCS Overview and Integration of a New Coolers Logic
CHAPTER 4 : Distributed Control System Overview and

Integration of a New Coolers Logic

1 Introduction
DCS (Distributed Control System) is a solution for managing complex plant processes in an
efficient, consistent, and secure way. In this chapter, the oil cooler system new operating logic
and its automation using DCS System are represented.
2 Distributed control system overview
In certain hazardous applications such as petrochemical plants and refineries, process control
is very important, however, loss of control can cause an explosion of the plant, for that purpose
DCS (Distributed Control System) systems are used to control the production line in the
industry. They are well suited to batch processes and have an ability to handle complex
interlocks and timing between operations and it allows for various control loops, using a
graphical representation of function blocks.
2.1 DCS system structure
As shown in the diagram below, the basic elements comprised in a DCS include the engineering
workstation, the operator station or HMI, the CPU units, the I/O modules, the smart devices,
and the communication system.
Figure 18 : DCS system architecture

• Inputs/output modules
I/O modules are building blocks of the industrial control system used in end equipment such as
PLC and DCS for interconnecting real-world analog and digital signals to data acquisition,
monitoring, or control systems. The input modules are used to monitor the status of a load or a
sensor, while, the output modules are used to switch AC and DC loads from logic signal levels.
• CP modules
CP modules can be placed near to field devices (sensors and actuators) or certain location where
these field devices are connected via the communication link. It receives the instructions from
the engineering station like set point and other parameters and directly controls field devices.
It can sense and control both analog and digital inputs/outputs by analog and digital I/O
modules. These modules are extendable according to the number of inputs and outputs. It
collects the information from discrete field devices and sends this information to operating and
engineering stations.
• Operator Station
Operator Stations are used to monitor the entire plant parameters graphically, to log the data in
plant database systems and to display the Trends of various process parameters, in order to
increase process availability and reduce unplanned shutdowns.
These operating stations are of different types such as in some operating stations, (PC’s) are
used to monitor only parameters, some for only trend display, some for data logging and
alarming requirements.
• Engineering station
Engineering stations are the supervisory controller over the entire distributed control system. It
can be a PC or any other computer that has dedicated engineering software.
This engineering station offers powerful configuration tools that allow the user to perform
engineering functions such as creating new loops, creating various input and output points,
modifying sequential and continuous control logic, configuring various distributed devices,
preparing documentation for each input/output device, etc.

• Working & Operation of DCS System
The operation of DCS goes like this; Sensors senses the process information and send it to the
local I/O modules, to which actuators are also connected in order to control the process
parameters. The information or data from these remote modules is gathered to the process
control unit via the field bus.
The collected information is further processed, analyzed and produces the output results based
on the control logic implemented in the controller. The results or control actions are then carried
to the actuator devices via the field bus.
The DCS configuring, commissioning and control logic implementation are carried out at the
engineering station as mentioned earlier. The operator able to view and send control actions
manually at operation stations.
2.2 DCS Programming Languages
The IEC 61131-3 standard (industrial automation systems standards) defines 5 kinds of
programming languages:
o Instruction List (IL)

o Ladder Diagram (LD)
o Function Block Diagram (FBD)
o Structured Text (ST)
o Sequential Function Chart (SFC)
3 Foxboro Distributed Control System
For the Hasdrubal terminal, the implemented DCS system is a Foxboro I / A series type supplied
by Schneider Electric.
3.1 Foxboro I/A Series DCS highlights
The I/A Series distributed control system from Foxboro, measurably improves plant-wide
operations, performance and asset utilization in today’s modern manufacturing enterprise.
The I/A Series system includes a set of application packages that are used to perform automatic
and manual system management functions such as:

o Automatic Functions:
− Monitor system equipment status.

− Monitor network communications.
− Generate system alarm messages.
− Notify operators at designed workstations.
o Manual Functions:
− View system equipment status.
− Set system date and time.
− Acknowledge system alarms.
− Change system equipment status.
− Execute station diagnostics tests.
− Inhibit station and peripheral system alarms.
3.2 Main software packages
• Foxview
FoxView is the I/A Series user interface between you and the process. From FoxView, you can
interact with any or all of the real-time plant, field, and process data available in the I/A Series
system.
Figure 19 : Foxview window

The FoxView software provides the following functions:
o Graphical display of real-time information from sensor, actuators and control functions
o Entry into user-configurable operating environments
o Access to process alarms
o Direct access to dynamic process displays
• Foxselect
The FoxSelect software (the Compound and Block Overview Display) provides the following
functions:
o Bring detail displays (Block Detail Displays, Compound Detail Displays, or Station
Block Detail Displays) into FoxView.
o Turn ON and OFF compounds and their associated blocks.
o View a list of blocks within all connected stations, and sort the list by different criteria
Figure 20 : Foxselect window
• Integrated Control Configurator (ICC)
The ICC software offers the following functions in coordination with FoxView:
o Integrated engineering environment for designing and maintaining control

strategies, composite display objects, and configuring the I/A Series system
o Capability to create and re-use new block types from standard I/A Series block types
by adding or modifying properties
o Option to import and export portions of the database or the entire project, making it
available to other sites

Figure 21 : ICC window
• FoxDraw
FoxDraw is the display builder/configurator used to create and maintain graphics displays for
viewing process dynamics. Displays can represent the plant, a process area, or a detailed portion
of the process.
The FoxDraw software provides the following functions:
o Drawing tools and graphic object palettes to create process displays representing the
plant, a process area, or a portion of the process.
o Connect display objects to process variables and operator picks, providing dynamic
updates as a method of interacting with the process.
4 Current oil coolers control narrative
• Human machine interface (HMI)
Human-machine interface (HMI) is a component of certain devices that are capable of handling
human-machine interactions. The interface consists of hardware and software that allow user
inputs to be translated as signals for machines that, in turn, provide the required result to the
user.

The main HMI requirements of the oil cooler system are presented as the following:
o Hardwired signals to MCC (Motor control center) for each fan:

− Emergency stop order
o Digital serial communication link to MCC (for each fan):
− Start/stop order
o Digital serial communication link from MCC (Motor control center):
− Run status
− Fault (alarm)
− Available/unavailable (alarm)
o Push button on HMI (CMS):
− Auto/ manual mode selection (for each fan)
− Duty/stand-by selection
− Start button (for each fan)
− Stop button (for each fan)
Figure 22 : Oil cooler system Human machine interface
• Fail to start
A timer is initiated on the start order to MCC. At the end of this timer if the run status from
MCC is not present there is a Fail to Start alarm.

• Forcing to Manual stop mode
If one of the followings events occurs for one fan, this fan is forced in Manual mode and stop
• Unavailable ( Alarm)
• Fault (Alarm)
• Fail to start ( Alarm )
• High vibrations (vibration switches)
• Auto/Manual mode selection
This configuration allows for operation in both manual or automatic mode. When switched to
automatic by the operator the external inputs will maneuver the oil coolers.
When switched to manual mode, the last coolers configuration will be maintained until
operator's input.
• Duty/Stand-by mode selection
To increase the system availability, the operator shall be able to select a priority function.
Thereby, two coolers will be assigned in duty and will thus normally be in operation, while
the other one is assigned standby.
• Auto mode
In Auto mode, the fans are controlled by the "Oil system start/stop" sequence. The duty fans
will start when the oil system is started and stopped when the oil system stops.
The stand-by fan will be started if one of the duty fans fails or on high ambient temperature, it
will be stopped when the temperature is back to normal and duty fans are working.
• Manual mode
In Manual mode, the fans can be started and stopped via Start and Stop push buttons on HMI
(CMS).
• Alarm management
As mentioned in the previous chapter, the warning alarm configuration is as follows:
o When the lube oil temperature increases above the high level (57℃), TIT08466B
initiates a high alarm (TAH08466B).

o When the working oil temperature increases above the high level (65℃), TIT08463
initiates a high alarm (TAH08463
5 Proposed modification narrative
5.1 Duty/Stand-by selection
Since the new lube oil cooler was added as a back-up for the existing coolers during the hot
season, it cannot be selected as main. For that purpose, When one fan from the existing cooler
(E-0856A, E-0856B or E-0856C) is assigned in stand-by, the two other fans will automatically
be assigned in duty, while the new cooler fan (E-0856CD) cannot be selected either in duty or
in standby.
5.2 Auto mode
• Duty fans
Once the automatic mode is selected, the duty fans will be started if lube oil temperature exceeds
51℃ or working oil temperature exceeds 61℃ and stopped when lube temperature is reduced
to 48℃ and working temperature reduced to 58℃.
Figure 23 : Duty fans operating chart

• Standby fans
The standby fans will be started if one of those scenarios occurs:
o One of the duty fans fails

o Lube oil temperature exceeds stand-by high set point (57 ℃)
o Working oil temperature exceeds stand-by high set point (65 ℃)
It will be stopped when all those conditions are reached:
o Duty fans are working

o Lube oil temperature is back to stand-by low set point (54 ℃)
o Working oil temperature is back to stand-by low set point (61 ℃)
Figure 24 : Stand-by fan operating chart
• Backup fan
The backup fan (E-0856CD) will be started if the lube oil temperature exceeds the high set point
(54℃). It will be stopped when lube temperature back to normal (low set point) (50℃).

6 Configuration and programming of the oil cooler system new logic
The Foxboro I/A Series DCS controllers can be configured using the function block diagram
(FBD) as a graphical language. For time-saving reasons and since it's a new language, the
following automation steps have been performed in coordination with the responsible DCS
engineer.
6.1 Function block diagram
The Function Block Diagram (FBD) is a graphical language for programmable logic controller
design that can describe the function between input variables and output variables.
The function block diagram programming language provided with automation studio offers the
following possibilities:
o Digital and analog inputs and outputs

o Logic operations
o Logic comparison expressions
o Arithmetic operations
o Function blocks
o Diagnostic tools
A function block is a program organizational unit, which can return one or more values.
Therefore, it can have one or more inputs and outputs.
Those pre-programmed functions and function blocks make it possible to solve complex tasks
using FBD with minimum previous knowledge of the programming language.

Figure 25 : Example of Function block diagram
6.2 Program development
For the fulfillment of the previous oil cooler system DCS modifications and using the ICC
software supplied by Foxboro, the following function blocks were used:
o 1 CALCA (Calculation block-advanced) block in which the logic was translated as

shown in the appendix 4.2.
o 3 GDEV (General device block) blocks use the running feedback indication to define if
the coolers is running, stopped, going to run, going to stop, or mismatch.

7 Test and evaluation of the program
An offline testing of logic was performed using the FoxView software supplied by Foxboro in
order to simulate the new cooler system operating, behavior and its responses in conjunction
with the DCS.
Figure 26 : Oil cooler system new logic simulation
8 Conclusion
In this chapter, the distributed control system has been defined and a new oil cooling system
logic has been elaborated so as to ensure a more adequate operation. The designed logic has
been set up and we validate it with an offline simulation.

General Conclusion
General Conclusion
During the graduation project, I described the various steps that have contributed to realizing
the APO project. I tried to explain thoroughly the different parts included in the project.
For the fulfillment of the project, at the first part, I started with checking the lube oil coolers
exchanges duty versus the required one according to the specification given and validating the
vendor proposal. Then, for the second part, I checked the system instrumentation package and
I proposed a new monitoring solution, which was led to some modifications in the oil cooling
system logic.
To conclude, it should be noted that during this project, I tried to discover the profession of an
oil and gas project engineer and to adapt to this profile. Indeed, an engineer can have the
technical skills but to be a good project engineer, it is necessary to be a good communicator to
understand always the need of the customers and manage to satisfy them.
This internship realized in the APO Company, allowed me to integrate a structure that has
brought me a lot as an engineer.
From a technical point of view, first, I was able to familiarize myself with the environment of
the company and the project engineering field, then, I held a various positions during the project
execution, which allowed me to understand each engineering discipline role and
responsibilities. This is a real asset like the majority of the oil and gas production companies in
the world find that the project study and management is a mandatory service within the
company.
From a personal point of view, this period spent within the company were very beneficial and
extremely rewarding. It was also an opportunity to put in practice the knowledge acquired
throughout my education and especially it allowed me to live new experiences and to appreciate
various notions such as teamwork, organization and distribution of tasks, documentation, and
respect for work and deadlines.

Bibliographical References
Bibliographical References
[1] Amilcar Petroleum Operations, « Official APO Website », available on the web via
< www.etap.com.tn >.
[2] Amilcar Petroleum Operations, Installation, Operation & Maintenance Manual, Internal
document in APO.
[3] General Electric, « Official GE Website » , available on the web via « www.ge.com ».
[4] American Petroleum Institute API 661, Petroleum, Petrochemical, and Natural Gas
Industries Air-Cooled Heat Exchangers, Seventh Edition, July 2013.
[5] Gas Processors Suppliers Association, Engineering Data Book [Gas Processing], Twelfth
SI Edition, 2004.
[6] Nuovo Pignone, Air-Cooled Heat Exchangers Specifications, Internal document in APO.
[7] ATEX, Atex Essential Explosion Protection, Available on the web via « https://ww.stahl-
syberg.no/ShowFile.ashx?FileInstanceId=b4819fd4-06c4-4786-82d4-57086111b83f ».
[8] The International Society of Automation (ISA), Control and Field Instrumentation
Documentation, Available on the web via « https://www.isa.org/pdfs/news/chapter7-control-
loop ».
[9] International Electrotechnical Commission (IEC), Available on the web via « http://
www.iec.ch ».
[10] Emerson process management, Rosemount 3144P Temperature Transmitter Datasheet,

Available on the web via « https://www.emerson.com/documents/automation/product-data-
sheet-rosemount-3144p-temperature-transmitter-en-73128.pdf ».
[11] Schneider Electric, Foxboro I/A series Pactware Manual, Available on the web via
« https://fr.scribd.com/document/151451256/Pactware-Manual-1».

APPENDIX
APPENDIX
Mseddi Zied Page | 69

APPENDIX
Appendix 1 :
Export compressor shaft line piping & instrumentation drawing

APPENDIX
Appendix 2 : The different abacus used for the identification of the

calculation parameters
Appendix 2.1 : J factor correlation to calculate inside film coefficient, ht

APPENDIX
Appendix 2.2 : correction factor for fluid viscosity within the tubes
Appendix 2.3 : Air film coefficient, ha

APPENDIX
Appendix 2.4 : Typical fouling factors
Appendix 2.5 : Finned tube Data for 25.4 mm OD tubes
Appendix 2.6 : MTD Correction Factors (1 Pass – Cross Flow, Both Fluids
Unmixed)

APPENDIX
Appendix 2.7 : MTD Correction Factors (2 Pass – Cross Flow, Both Fluids
Unmixed)

APPENDIX
Appendix 3.1 :
Air cooler circuit piping & instrumentation drawings

APPENDIX
Appendix 3.2 :
Lube oil and working oil circuit piping & instrumentation

drawings

APPENDIX
Appendix 3.3 :
Lube oil temperature transmitter datasheet

APPENDIX
Appendix 3.4 :
Lube oil temperature transmitter loop drawing

APPENDIX
Appendix 4 : CALCA block configuration
NAME = NEW_CLR_FAN:MAINLOGIC
TYPE = CALCA
DESCRP =
PERIOD = 1
PHASE = 0
LOOPID =
BI02 = :CLRA.MMAIND
BI04 = :CLRB.MMAIND
BI06 = :CLRC.MMAIND
INITMA = 1
TIMINI = 0
M01 = 48
M02 = 51
M03 = 54
M04 = 57
M05 = 58
M06 = 61
M07 = 61
M08 = 65
STEP01 = SUB RI01 M02 ; L.O. TEMP > M02

STEP02 = SSP M11 ; START DUTY CLRS
STEP03 = NOP
STEP04 = SUB M01 RI01 ; L.O. TEMP < M01
STEP05 = SSN M24
STEP06 = CLR M11 ; STOP DUTY CLRS
STEP07 = SUB RI01 M04 ; L.O. TEMP > M04
STEP08 = SSP M12 ; START STANDBY CLR
STEP09 = NOP
STEP10 = SUB M03 RI01 ; L.O. TEMP < M03
STEP11 = SSN M24
STEP12 = CLR M12 ; STOP STANDBY CLR
STEP13 = SUB RI02 M06 ; W.O TEMP > M06

STEP14 = SSP M13 ; START DUTY CLRS
STEP15 = NOP
STEP16 = SUB M05 RI02 ; W.O. TEMP < M05
STEP17 = SSN M24
STEP18 = CLR M13 ; STOP DUTY CLRS
STEP19 = SUB RI02 M08 ; W.O. TEMP > M08
STEP20 = SSP M14 ; START STANDBY CLR
STEP21 = NOP
STEP22 = SUB M07 RI02 ; W.O. TEMP < M07
STEP23 = SSN M24
STEP24 = CLR M14 ; STOP STANDBY CLR
STEP25 = ; ----------------------
STEP26 = AND ~BI01 BI02 ; CLR A DUTY AND MM
STEP27 = AND ~BI03 BI04 ; CLR B DUTY AND MM
STEP28 = AND ~BI05 BI06 ; CLR C DUTY AND MM
STEP29 = OR 3
STEP30 = NOP
STEP31 = OUT M15 ; START STANDBY CLR IS ONE FAILED
STEP32 = OR M11 M13
STEP33 = OUT BO07 ; START DUTY CLRS
STEP34 = OR M12 M14
STEP35 = OR M15
STEP36 = OUT BO08 ; START STANDBY CLR
STEP37 = ;-------------------------
STEP38 = AND ~BI01 BO07 ; CLR A DUTY & REQ TO STRT
STEP39 = AND BI01 BO08 ; CLR A STANDBY & REQ TO ST
STEP40 = OR 2
STEP41 = OUT BO01
STEP42 = AND ~BI03 BO07 ; CLR B DUTY & REQ TO STRT
STEP43 = AND BI03 BO08 ; CLR B STANDBY & REQ TO ST
STEP44 = OR 2
STEP45 = OUT BO02
STEP46 = AND ~BI05 BO07 ; CLR C DUTY & REQ TO STRT
STEP47 = AND BI05 BO08 ; CLR C STANDBY & REQ TO ST
STEP48 = OR 2
STEP49 = OUT BO03
STEP50 = END
END
Lube Oil Cooler System Improvement
Zied MSEDDI
‫ الهدف من هذا المشروع هو تجنب ارتفاع درجة حرارة زيت التشحيم التي واجهت ضاغط تصدير الغاز في‬: ‫الخالصة‬
‫ يتم تحديد المهام التالية‬،‫ لتحقيق الهدف‬.‫مصنع صدربعل‬
‫ فهم ظروف عمل ضواغط تصدير الغاز وتكوين النظام‬-
‫ دراسة مفصلة لنظام زيت التشحيم‬-
‫ مراجعة تبادالت المبردات واستحقاقات النظام المطلوبة‬-
‫ التحقق من صحة اقتراح البائع‬-
‫ مراجعة منطق عمل المبردات واقتراح منطق أكثر مالءمة منه‬-
Résumé : L’objectif de ce projet est d’éviter la température élevée des huiles de

lubrification qui a subi le compresseur de gaz d’exportation de l’usine Hasdrubal. Pour
la réalisation de l'objectif, les tâches suivantes sont définies :
- Comprendre les conditions de traitement des compresseurs de gaz à l'exportation et la
composition du système
-Réaliser une étude détaillée du système d'huile lubrifiante
-Revoir les échanges des refroidisseurs et les droits requis du systeme et valider la
proposition du fournisseur.
-Révisez la logique des refroidisseurs et proposez-en une plus appropriée.
Abstract : The objective of this project is to avoid the high lube oil temperature that
experienced the feed and export gas compressor on Hasdrubal plant. For the fulfillment
of the objective, the following tasks are defined:
-Understand export gas compressors process conditions and package composition
-lube oil system detailed study
-Review coolers exchanges duty versus required duty and validate vendor proposal.
-Review coolers logic and propose a more appropriate one.
‫ أجهزة التحكم‬، )‫ (نظام التحكم الموزعة‬DCS ، ‫ مبردات الهواء‬، ‫ ضاغط‬: ‫المفاتيح‬
Mots clés : compresseur, refroidisseurs d'air à ailettes, DCS (système de contrôle

distribué), instrumentation
Key-words : compressor, fin fan air coolers , DCS (distributed control system),
instrumentation

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Republic of Tunisia Cycle of Engineers Formation

Ministry of Higher Education and in Mechanical Engineering

University of Sfax ST-EN07/00

National School of Engineers Sfax

The National Diploma in Electro-Mechanical Engineering

Lube Oil Cooler System Improvement

Defended on September 8, 2018 in front of the committee formed of:

M. Aref MAALEJ President

To my sister and my family

To all my friends and colleagues

I would like to express my gratitude towards my co-supervisor professor M. Mohamed

General Introduction ............................................................................................................................ 8

CHAPTER 1 : Export Compressor Overview and Project Framework ........................................ 11

Figure 1 : Logo APO Tunisia .................................................................................................. 10

Table 1 : Maximum temperatures records ............................................................................... 20

Zied MSEDDI Page | 8

1 Introduction /justification of the project:

1.1 Scope and purpose of the project

The proposed end of study project is to:

1.2 Structure of the Report

The remainder of the report is set out as follows:

1.3 Presentation of the operator

Company : APO (AMILCAR PETROLEUM OPERATIONS).

Zied MSEDDI Page | 9

Figure 1 : Logo APO Tunisia

Figure 2 : Hasdrubal project locations and product routes

Zied MSEDDI Page | 10

CHAPTER 1 : Export Compressor Overview and Project

Zied MSEDDI Page | 11

2 Hasdrubal gas processing plant overview

2.1 Hasdrubal terminal layout

Figure 3 : Hasdrubal Terminal Layout

MSEDDI Zied Page | 12

2.2 Process description

Figure 4 : Hasdrubal Facilities Block Diagram

MSEDDI Zied Page | 13

3 Export area overview

Figure 5 : Export Compression System

MSEDDI Zied Page | 14

4 Export compressor overview

4.1 Export compressor functional role

4.2 Export compressor package composition

• Main electric motor

• Variable speed planetary gear

MSEDDI Zied Page | 15

• Thermodynamic centrifugal compressor

A centrifugal compressor is a type of dynamic compressor, or turbo-compressor, with a radial

Figure 6 : Export compression unit

MSEDDI Zied Page | 16

5 Export compressor oil system

5.1 Lube oil subsystem

5.1.1 Lube oil subsystem components

• Two positive displacement pumps (one main and one auxiliary)

5.1.2 Lube oil subsystem operation

MSEDDI Zied Page | 17

Figure 7 : Lube oil cicuit

5.2 Working oil subsystem

5.2.1 Working oil subsystem components

• one positive displacement pumps

MSEDDI Zied Page | 18

5.2.2 Working oil subsystem operation

Figure 8 : Working oil circuit

MSEDDI Zied Page | 19

6 Lube oil cooling system issue

1/Ux = (1/ht)(Ax/Ai) + rdt(Ax/Ai) + (rmx) + (1/ha) (1)

Gt = ((WtNp) / (NtAt)) (2)

ht = (((JKφ(Pr) (1/3)) / Di) nr (5)

ht = (((20,12910.85(216,642) (1/3)) / 22.098) 5 *1

Ux = 1 / ((1/ht)(Ax/Ai) + rdt(Ax/Ai) + (1/ha))

= 1 / ((1/ht)((Do/Di)Ar) + rdt((Do/Di)Ar) + (1/ha))

= 1 / ((1/283,33)((25,4 /22,098)21,4) + 0,00018 ((25,4 /22,098)21,4) + (1/50))