Case Study-2

Case Study – Thermal Expansion in Condensate Line

Challenge:                                                                                          Blocked-in liquid (~100 kg) between two valves caused thermal expansion due to heat              tracing (20°C), resulting in pressure exceeding design limits.

Approach:                                                                                        Systematic analysis using API 521 methodology and process simulations.

Key Engineering Work:

• Multi-component thermal expansion calculations (liquid + pipe expansion)

• Phase behaviour analysis using UniSim simulation

• Evaluation of vapor pocket stability

• Expansion drum feasibility assessment

• Relief valve sizing and feasibility assessment

• Flange leakage risk analysis

• Control valve performance and leakage evaluation

Solution Implemented:

• Mechanical stop installed to prevent full closure

• Verified through supplier testing and operating data

Results:

• Eliminated overpressure risk

• Avoided flare system modification

• Prevented hydrocarbon leakage and fire risk

• Delivered cost-effective solution with no major redesign

Value:                                                                                                       Smart process engineering enabled safe, reliable and economical solution without additional equipment or major  changes.

Contact:                                                                                                                                           Available for support in thermal expansion and process system challenges