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1 Aadil Mohammed Ismail (University ID-1021210366) Intern at GEA batignolles thermal technologies, Qatar. Pursuing B.tech (mechanical) at SRM university, Chennai , India .

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Acknowledgement

This report has been made as a journal of my experiences during my implant training here at GEA BTT, Qatar. I would like to thank the management and staff of GEA BTT who have helped me selflessly and showed me respect and treated me as one of their own during these days. I have learned so much about the practical applications of air cooled heat exchangers and air cooled condensers. I had studied the theory of heat exchangers in my course(B.tech) in subjects like thermodynamics and applied thermal engineering but now I have studied its application and I can proudly say I can help in the design and working of heat exchangers now. I would like to thank the foremen, Mr.John and Mr.Baburaj who helped me extensively while I was studying about the processes happening in the factory. I would also like to thank the staff working in the welding , finning and expansion departments who gave me a brief idea about their jobs. I would like to thank the quality control engineer Mr.Arun kumar who helped me and taught me about the module process and all the instruments used to inspect the heat exchangers. I extend my gratitude to Mr.Ram, the supervisor who was of help at all times. Last but not the least I would like to thank Mr.Ashraf , CFO, GEA-BTT Qatar who accepted my request for implant training here and made all this possible.

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INDEX

1. Acknowledgement ………………………………………………………2

2. Introduction ………………...…………………………………………….4

3. Tube manufacturing process ...........................................7

3.1 Hudson finning machine …..................................................................................7 3.2 McElroy machine ..................................................................................................10 3.3 Clamping machine …………………………………………………………………………………10

4. Bundling process ............................................................... 12

4.1 Building the Frame ..............................................................................................12 4.2 Building the bonnet...............................................................................................13 4.3 Preparation of tube sheets..................................................................................13 4.4 Tubing, expansion, welding and plugging. ....................................................14

5. Hydro-process .....................................................................17

6. The module process ............................................................18

6.1 Pre-structural assembly ............................................................19 6.2 Plenum assembly ....................................................................19 6.3 Mechanical assembly ...............................................................20 6.4 Testing (Inspection) .................................................................20 ---------------------------------------------------------X------------------------------------------------------

Introduction

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GEA is a multinational company based in Germany. It is one of the largest suppliers for the food supply industry. They have a wide range of other industries such as farm technologies, mechanical equipment, process engineering and refrigeration technologies. The group employed about 18,000 people worldwide as of 2013. GEA Heat Exchangers | GEA Batignolles Technologies Thermiques SAS

The company started in France when a private company “Locomotives Batignolles-Chatillon” made the factory in Nantes. GEA took over Batignolles

factory located in Nantes FRANCE and creates Batignolles Technologies

Thermiques SA. GEA Batignolles Technologies Thermiques became the main

partner of Japanese, European and American EPC contractors for the new

markets of emerging countries in Middle East and South Eastern Asia in the

1980’s-1990’s .

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In 2006 they opened two subsidiaries in China and Qatar. GEA Batignolles Technologies Thermiques in Qatar – Doha

In order to satisfy the increasing demand of the Middle East market and to be

a player in the growing economy of GCC countries, GEA Batignolles

Technologies Thermiques Qatar signed an agreement with the Qatari

group ALMANA Trad. Co. for the construction of the facilities, and rental of

the facilities through an operational lease. It is a 100% subsidiary of GEA

Batignolles Technologies .

• Production capacity:600 bundles/year.

• Assembly of tubes, tubing, welding, expansion, plugging, hydro-process, final assembly and quality control happens here. Erection of the Machines are sometimes done depending on the client requirement. Safety and security is very important and all the employees take it seriously. Major clients are oil refineries and ships.

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• Client list include major government companies like Qatar petroleum, Qatar-gas and Ras-gas and also companies in the private sector like Dolphin energy. Heat exchangers are also exported to companies from neighbouring countries like Aramco in Saudi Arabia.

• Some of the major operations take place in France and some parts are also imported for instance, the headers.

• Tube parts are imported from India and Korea. • The quality and finish are done according to the customer preference. For

example, some shipping companies demand high quality finish and titanium tubes etc. to avoid corrosion.

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TUBE MANUFACTURING PROCESS

Majority of the tubes used in the manufacture of heat exchangers here is made of the material SA-179. The tube is made out of an aluminium hollow tube inside which carbon steel is finned using the Hudson finning machine. An aluminium strip is coiled above this using the McElroy machine. It is then clamped with a clamping machine. The clamp is made out of aluminium or carbon steel. HUDSON FINNING MACHINE

It is used to fin carbon steel tube inside the aluminium tube. It has the following parts. • Molette(3) -the milling tool • Spindle shafts(3) –at 120˚ with each other. • Universal joint –at the centre of the machine • Finning heads – 1”(8.5 fpi, 10 fpi, 10-11 fpi)

1”¼(8.5 fpi, 10 fpi, 10-11 fpi) 1”½(10 fpi, 10-11 fpi)

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Figure: The Hudson finning machine

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2”(10 fpi, 10-11 fpi) • Discs- 87”, 90”, 100”, 111”, 116” Bath preparation for coolant • 2 drums of processing oil (morlina oil from shell) • 2 tins of sodium carbonate • ≈1070 litres of water Extruded tube defects • Rip (spiral) • Overburden fins • 2*2 • Micro jam • Bent fins • Spread out

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McElroy MACHINE

It is used to coil aluminium strip of 0.4 diameter over the finned product. A very large roll of aluminium is used and when the finned product from the Hudson machine passes through it is coiled rapidly over it.

It uses the lubricant tellus-32 and the coolant dromus-32.

CLAMPING MACHINE

it is used to clamp the finished part after it comes out of the McElroy machine. The clamps are usually made of aluminium or carbon steel. It has a male part and a female part which are fed from different points. They are then clamped together over the coiled tube. The tubes are now ready. They are fixed to the headers.

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Figure: The tubes after their arrangement in a bundle.

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Bundling process

There are two types of products which are generally made. • ACC- Air cooled condenser. • ACHE- Air cooled heat exchanger. Bundling consists of a variety of functions so as to get the tubes in a proper arrangement. All these processes are completed and it is left for defect check and hydro process. The processes are explained below. BUILDING THE FRAME

• Area assembly is prepared. • Side walls are prepared. • Lower beams and accessories are positioned. • Tube sheets are fitted. • Necessary accessories like nuts and bolts are fixed. • Dimensions are verified.

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PREPARATION OF BONNET

• Edges are prepared by properly bevelling the surfaces. • Headers with the nozzles are fit up on both the ends. • The end plates are then weld. • Blasting is done and primer is applied. • Welding is done up to 25mm before the primer is applied.

PREPARATION OF TUBE SHEETS

• The location to be weld is cleaned first. • End plates are fixed on both ends • Blasting and painting is done • The tube sheets are cleaned by a power tool to ensure a good weld.

TUBING

• 3 tubes are first positioned in order to compare the length of the tube to the

length between the header boxes.

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• First row is tubed. • The tube is adjusted into the header boxes. • The other rows are tubed after that. • The upper beams, external angles and lifting channels are installed and bolted

properly. EXPANSION

• The tube projection for each row should be checked before expansion • The tube outer diameter, thickness and length should be measured to select the

expansion tool • Expansion tool is adjusted to the width of the header. • Since expansion machine is automatic the parameters are set on the machine to

perform expansion • Mandrel is inserted the tube via plugs • The expansion is measured.

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WELDING

• Welding type : GTAW machine • Gas : SG-A • Shielding mixture : Argon/99.997% • Current: DC • Tungsten type: 2,4witstar WS2 • Positions to be welded are then marked on the header • Set parameters on CPU to perform the welding operation according to WPS • Check the weld using 24V light

PLUGGING

• A wire brunch is used to clean the plug sheet first • Aluminium 600 locks is fixed on the gasket • Install plugs on the header plug shear thread The plugs are then tightened

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16 Figure: The bundling process is finished and the bundle is kept for hydro-process.

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Thus the bundling process is completed and a frame with required number of tubes are arranged properly , tubed, expanded, weld and plugged. We have to check for defects now by ultrasonic testing, magnetic testing and penetrator test. After that the hydro process is done to check weather there are any leakages in the system.

HYDRO-PROCESS

One of the most important process done here is the hydro-process or hydro testing. Since fluids(crude oil , water, helium, hot air etc. ) are going to pass through the heat exchanger in high pressure at high temperatures it is necessary to test if there is any leakage in the system this can only be tried by passing fluids through it at high pressures and then check for leakages. First air is passed through the nozzle and it goes through the tube. After this the pressure is increased. There are three pressure indexes here:- • Maximum pressure • Standard pressure • Basic pressure The inspectors from the client side companies come and check this. They decide which pressure index to check. In gas refineries etc. , to avoid fatalities due to the poisonous gas Hydrogen sulphide, helium is passed through to find out leakages.

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After air is passed through, water is passed throughout the pipes and high pressure is given again. It is then kept like that for an hour to see how the pipe withstands the pressure. The water is then drained out and the tubes are heated for 7-8 hours until it is totally dry. Silica gel is kept in the tubes to avoid moisture formation which will lead to corrosion. If the client specifies, the heat exchangers are filled with that particular gas. Some companies prefer nitrogen for this purpose. The staff here do a complete check before the inspectors arrive so that the process is smooth and no errors can be found. Hence the major operations in the factory is complete.

THE MODULE PROCESS:

It is the final process that happens in the company. This happens outside the factory unit . Here the module is made ,its dimensions are measured. The instruments are prepared and its calibration validity is checked. Once the module is prepared the bundle after hydro-process is fixed above it and various tests are conducted. After this the final product is disassembled and dispatched. The following process happens:-

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PRE-STRUCTURAL ASSEMBLY • Verification and preparation of materials, structures and bolting has to be

done before the module gets erected. • Column and v-brace is kept on the floor using the gantry crane. • The vertical columns and V-bracing are assembled with the angular support . • Assemble beams and side-beams forming a square. • Install the required components and bolt it well. • The walkway components are installed. • Dimensions are checked and verified.

PLENUM ASSEMBLY

• The conical structure containing the fans is assembled on the ground. It has

base plates and axial plates. • After it is competed the ring and the fan is fixed and then it is kept over the

structure using the gantry crane.

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MECHANICAL ASSEMBLY

• The other parts , i.e. motor , driver pulley and driven pulley are fixed on the module and the whole structure is complete.

• The module will now be approached by engineers from the company and the client side for inspection and quality checking.

TESTING (INSPECTION)

The heat exchanger is tested on various parameters • The ambient temperature is calculated before the noise test. • The air flow velocity in induce draft type using Anemometer with rotating vane

under the bundle. The wind velocity is measured using a digital Anemometer. Wind velocity should not exceed 4.5 m/s.

• The noise power level using the sound level meter.(under the motor, at a height of 7 meters, at a height of around 13.7 metres). The maximum sound should no exceed 85 db.

• The fan belt tension is checked using the belt tension tester. • The driving pulley and driven pulley alignment is checked using the spirit level.

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21 Figure: The tools for inspection ready for the test.

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• The airside pressure drop inside the plenums is measured using the pilot tube and numerical Manometer.

• The level of vibration of the supporting structures are checked using the vibration meter. Maximum amplitude of vibration is 150microns. It is checked on 3 or 4 locations.

The product is now inspected and ready to be disassembled and transported to the client.

AADIL MOHAMMED ISMAIL 10212120366

The finished product is being inspected here by the client-side engineers and the quality control engineer