HORIZONTAL WELL APPLICATION IN THE GHAWAR GAS RESERVOIRS

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King Fahd University of Petroleum Minerals
Mechanical Engineering Department COOP
PROGRAM ME351
MAJED AL-SHAHRANIID992967
ADVISOR Dr. MUMMER KALYON
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CONTENTS

• INTRODUCTION
• WORK ENVIRONMENT
• HEAT EXCHANGERS
• 2 CASE STUDIES
• CONCLUSION

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Introduction
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Cooperative Training PrograminSaudi
AramcoConsulting Services Department(CSD)
Heat Exchangers
Heat Transfer Group
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Work Environment
Consulting Services Department (CSD)
ESD
MCED
MECCD
RED
The mission of consulting services department
(CSD) is to provide technical consultations on
field problems and maintaining quality standards.
HUG
PEU
PVU
CEU
The responsibility of Process Equipment Unit
(PEU) is to offer technical consultations on the
parts related to pressure vessels, storage tanks
and heat transfer equipment.
Pressure Vessels Storage Tanks
boilers
Heat Transfer Equipments
Fired heaters
Heat exchangers
Insulation refractory materials
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HEAT EXCHANGERS
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HEAT EXCHANGERS
HEAT EXCHANGERS transfer heat from a hot fluid to
a colder fluid through the combined mechanisms of
conduction and forced convection.
ALL HEAT EXCHANGERS are similar in their
principle of operation however, heat exchangers
may differ in the specific fluids that are used
in the heat transfer process, the layout of the
metal tubes, and the configuration of the
enclosure.

• THE PURPOSES of the heat exchanger are
• change the temperature of fluid.
• change the phase of a fluid.

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HEAT EXCHANGERS
HEAT EXCHANGERS

1. Shell and tube heat exchangers.

2.Air cooled heat exchanger.
3.Double pipe heat exchanger.
4.Plate and frame heat exchanger.

1. Shell and tube heat exchangers.
2. Air cooled heat exchanger.
3. Double pipe heat exchanger.
4. Plate and frame heat exchanger.

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shell-and-tube heat exchanger
The shell-and-tube heat exchanger is the type
that is most commonly used in process plants.
SHELL
CHANAL
THE BUNDEL
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Air-Cooled Heat Exchangers
FANS
Types of Air-Cooled Heat Exchangers

1. Forced draft.
2. Induced draft.
3. Humidified forced draft.

BUNDEL
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CASE STUDY
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CASE STUDY1
Tube insertion Tube insertion is a new
technology that used to repairing the tube
failures by insert a tube with thin wall inside
the damaged tube. This method can be done without
replacing the existing tube.
This case study is about a problem in one of
Saudi Aramco air cooled heat exchangers.
Problem- The tube of a fin fan cooler at
Shaybah Producing Facilities has a problem which
is tube failure.

• This new method will lead to
• Protecting damaged tube inlets.
• Restoring plugged leaking tubes to active
  service.
• Restoring original compressive strength to
  weakened tube to tube sheet joints.

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CASE STUDY1
staggered type
INDUCED DRAFT
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THREE BAYS
ONE BUNDLE
ONE BAYS
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Process Side Tube Side Fluid    
Name Water    
Flow Rate 62603(lb/hr) 7.88798 (kg/sec) 28396 (kg/hr)
Temp. In 130 F 54.44 C 327.6 K
Temp Out 98 F 36.667C 309.817K
Specific Heat 0.999(Btu/lb F)    
Viscosity 0.769(cP) 1.86028(Ib/ft.hr)  
Density 62.116(lb/ft3)    
Thermal Conductivity 0.3585(Btu/(hr ft F))    
Fouling Resistance 0.001(ft² F hr/Btu)    
Process Side Air Side    
Name      
Flow Rate 137151(ft³/min) 9924.4(Ib/min) 595463.99(lb/hr)
Temp. In 90 F 32.22 C 305.4 K
Temp Out 103.94 F 39.97C 313.12K
Specific Heat 0.2407(Btu/lb F)    
Viscosity 0.185(cP) 0.0447(Ib/ft.hr) 0.000746(Ib/ft.min)
Density 0.07248(lb/ft3)    
Thermal Conductivity 0.015206(Btu/(hr ft F))    
Fouling Resistance 0.002(ft² F hr/Btu)    
This table represents the Properties of water at
130 ºF
This table represents the Properties of air at 90
ºF
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THE TUBE AND BUNDLE PARAMETER
  in ft
Fin diameter (Df) 2.25 0.1875
Tube (OD) 1 0.0833
Tube (ID) 0.87 0.0725
Wall Thickness ?x 0.065 0.005417
Tube Length L 360 30
Cooler Width 273.96 22.83
Tube Layout staggered  
Pitch of Tubes in Plane Perpendicular to Air Flow (SL) 3 0.25
Pitch of Tubes in Direction of Air Flow (ST) 3 0.25
Fin Height (H) 0.625 0.0521
Fin Width (w) 0.016 0.00133
(ws) 0.116 0.00967
Fin Spacing (s) 0.1 0.00833
of tubes(N) 264  
of rows(NL) 6  
of Tubes in one row(NT) 44  
of passes 6  
Thermal cond.(Fin material) 110  
Thermal cond.(Tube material) 8.2  
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Area calculations
Surface area of fins (AF)
AF ((NLPi)/(sw))(0.5(Df²-Dr²) Dfw)
36944.02 ft²
Surface area b/w fins (Aw)
Aw ((NLPi)/(sw))(Drs)
1785.4 ft²
Surface area of tubes with fins (A)
A AwAF
38729.4 ft²
Surface area of tubes without fins (AT)
2072.623 ft²
AT NLPiDr
Frontal area (Ao)
Ao L cooler width
684.9 ft²
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Minimum flow area (Amin)
A1 NTL(St-Dr-((2wh)/ (ws)))
201.13 ft²
Or
SD (SL² (ST/2)²)½
(0.25² (0.25/2)²)½

0.2792 ft
A22NtL(SD-Dr-((2wh)/ (ws)))
479.254 ft²
201.13 ft²
Then (Amin)
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To find the air side Coefficient of heat
transfer ha
681.12 ft/ min
V max V approach/?
The maximum velocity
595463.99 Ib/hr
The Mass flow rate
Ma V max Amin ?a
5513.3743
Rea (V max Dr ?a)/ µa
The Reynolds number
0.708
Pr (µ Cp/ kt)
The Prandtl number
34.428
Nu 0.242(Re 0.658)((s/h) 0.297)((St/Sl)
-0.091)(Pr (1/3))F1F2
The Nusselt number
F1 factor of fluid property variation. Assume it
F11. F2 factor of number of tube rows.
When the number of tube rows6 and staggered type.
The Coefficient of heat transfer ha
F2 0.95.
6.285 (Btu/ft².hr. ºF)
ha Nu kt / Dr
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To Find Fin efficiency ?f
?f (tanh (((2ha/ (w?f)) ½) ?)/ (((2h/
(w?f)) ½) ?)
? (Dr/2)((Df/Dr)-1)(10.35ln (Df/Dr)) 0.0669
?f 0.8891
Effective Air Side Heat Transfer Coefficient
Based on Total Surface Area h'a
((?fAFAw)/A)(ha) 5.628 (Btu/hr.ft². ºF)
Effective Air Side Heat Transfer Coefficient
Based on External Surface Area without Fins ha'r
h'a (A/AT) 105.14 (Btu/hr.ft². ºF)
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To find the tube side Heat Transfer Coefficient
ht
26.1566 in²
The Crosse sectional area At
At (piID²/4)(N/Ntp)
95.736 Ib/s. ft²
Gt mt/At
Mass flux Gt








92.475 ft/min
Ub, t Gt/?t
Tube Side Velocity Ub,t
Ret (Gt ID)/µt
13431.9
Tube Side Reynolds Number Ret
5.184
Pr µtCP/K
The Prandtl number
0.006873
ft 0.046((Ret) (-0.2))
Friction factor ft
89.15134
Nut 0.023((Ret) (0.8))((Pr) (0.4))
Tube Side Nusselt Number Nut
440.8534(Btu/hr.ft².F)
ht Nu(k/ID)
Tube Side Heat Transfer Coefficient ht
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To find the Overall heat transfer coefficient Ur
1/Ur I/har (OD/ (2?f))(ln (OD/ID))
(1/ht)(OD/ID)
1/Ur 0.012826 ft².F.hr/Btu Uclean Ur 77.965
Btu/hr. ft².F rf, d Ff, t (ID/OD)Ff, s
0.002741 ft².F.hr/Btu 1/Ud (I/Ur) rf, d
0.015567 ft².F.hr/Btu Uservice Ud 64.238
Btu/hr. ft².F
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OD1 in ID 0.87in Thick 0.065in
OD1in NEW ID0.8149in Insert tube
thick0.02756in NEW thick0.09255in
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BEFORE
AFTER
Crosse sectional area At At26.16in² Mass flux
Gt Gt 5744.16 Ib/min. ft² Tube Side
Velocity Ub,t Ub, t 92.475 ft/min Tube Side
Reynolds Number Ret Ret 13431.9 Pr
5.184 Friction factor ft ft 0.006873 Tube
Side Nusselt Number Nut Nut 89.15 Tube Side
Heat Transfer Coefficient ht ht
440.85(Btu/hr.ft².F)
Crosse sectional area At At22.95in² Mass flux
Gt Gt 6547.18 Ib/min. ft² Tube Side Velocity
Ub,t Ub, t 105.403 ft/min Tube Side Reynolds
Number Ret Ret 14340.034 Pr 5.184 Friction
factor ft ft 0.0067834 Tube Side Nusselt
Number Nut Nut 93.94 Tube Side Heat Transfer
Coefficient ht ht 495.9 (Btu/hr.ft².F)
Uservice Ud 63.87 Btu/hr. ft².F
Uservice Ud 64.238 Btu/hr. ft².F
The tube insertion would cost only one third of
the retubing
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CASE STUDY2
This case study is about a new channel cylinder
of shell and tube heat exchanger.
The out side diameter of the channel cylinder is
44.75 then the outside radius is 22.375. The
inside diameter of the channel cylinder is
38.500 then the inside radius is 19.25. The
thickness of the channel cylinder is 3.125. The
internal design pressure is 2296 Psi. The design
temperature is 875ºF.
This channel cylinder has 44 3/4"O.D, 32" length
and 3 1/8" wall.
After machining process the inspection found
different thicknesses when he measures it by
using ultra sonic
3.084 and 3.078
tmin (PR)/(SE-(0.6P))
The stress of this material SA-336F22CL3 forging
at875ºF can be found by using The American
Society of Mechanical Engineers (ASME) section
II part D.
P internal design pressure, psi R the inside
radius, in S maximum allowable stress value,
psi E joint efficiency.
S stress
S16100psi _at_ T875ºF
3.084 and 3.078
tmin (229619.25)/(161001-(0.62296)) 3.002
in MWAP SEt/(R0.6t) 1610013.125/
(19.250.63.125) 2381.66 psi
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Conclusion

• I Got hands-on experience on heat exchangers.
• In my first case staduy, the method of tube
  inserts is acceptable from thermal point of view.
  
• I did some Field Trips
• 1. AlQatif Project
• 2. Uthmaniyah Gas Plant
• 3. Juaymah Gas Plant
• 4. The Saudi Aramco Shell Refinery Company
• 5. Juaymah Heat Exchanger Shop
• The co-operative training program (co-op) is very
  important issue through university studying. It
  is helpful for the applied engineering students
  because it gives them an idea and background
  about the field work and that will be helping
  students after the graduation.

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Thank you for your attention
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DONE BY MAJED SAAD AL-SHAHRANI