PAGE:
DOCUMENT NUMBER:
1
DOCUMENT TYPE:
CS100101RB0810
REVISION:
Case Study
DOCUMENT TITLE:
0
REVISION DATE:
Replacing an XP condenser on an existing process chiller
within a petrochemical plant
08-10-10
1.0 The Problem
1.1
One or our most valued petro-chemical customers within the Gulf
Coast had a explosion proof process chiller that was less than 10 years old. The
chiller was purchased from a USA chiller manufacturer and was built with quality
components. Unfortunately, the air-cooled condenser on the approximately 250
ton air-cooled explosion proof process chiller was almost completely corroded
due to an H2S release and heavy exposure to Chlorine within the plant. The
customer received estimates to replace the chiller in access of 2.3 million dollars.
The excessive cost was due to the location of the chiller within the plant, the cost
of getting a direct cooling rental chiller in place, and many other specific plant
replacement difficulties.
2.0 The Solution
2.1
Our engineers reviewed the previous chiller submittal data as well as the site-specific difficulties. After analyzing the
entire chiller, it was found that the evaporator (via an eddy current test) and compressors (checked via run hours, ability to load and
unload, discharge pressure and amp draw) were found to be in very good condition. Therefore, a replacement condenser was designed
in order to fit onto the existing chiller. In order to better survive in the environment the replacement condenser was built with 0.006”
copper fin stock, ultra heavy copper tubes, and stainless steel hardware. The entire condenser was built in accordance with Class 1
Division 2, Group C & D area classification requirements and featured: explosion proof motors, anti-static condenser fan blades, rigid
conduit with final flexible termination, a stainless steel NEMA4X control panel, and seals for the area classification. The entire new
condenser replacement was completed with a 5 man crew team over a weekend. The process chiller was back online by Monday and
the plant has ZERO unexpected down time. The entire project was able to be completed for ~$135,000.00
3.0 Added benefit
3.1
As an added benefit to the site, condenser hand rails were built and
installed on the new condenser. Due to safety requirements within the
plant, every time a condenser fan motor needs to be replaced the customer
would have to pay $1,500 - $5,000.00. This was due to a variable cost to
get scaffolding built around the entire air-cooled condenser (a safety
requirement within the plant to prevent injury due to a fall). With the new
hand rail system designed and installed, scaffolding was no longer needed
when replacing condenser fan motors.