Case Study-5

Case Study – Achieving 35% Capacity Increase                          Through Heating Medium Optimization

Challenge:                                                                                                  Increase in system volume due to design changes required additional expansion capacity (+35%), exceeding the limits of existing system design.

Approach:

• Performed comprehensive hydraulic assessment of the system and associated equipment.

• Evaluated expansion volume against vessel operating limits (25–75% operating range)

• Assessed viable options; installation of new equipment vs system modification.

Key Engineering Work:

• Developed an optimized solution by increasing system volume through piping instead of        installing a new expansion vessel.

• Utilized existing instrumentation (level transmitter & gauge), avoiding additional                      hardware.

• Achieved required capacity with minimal system modifications

• Incorporated additional plates included in Plate and Frame Heat Exchanger to support in-    crease heat load.

Safety & Compliance:

• Actively contributed to HAZOP, LOPA and dispersion analysis

• Successfully defended design decisions during multidisciplinary safety reviews

Results:

• Existing capacity increased to meet requirement (0.64 m³ )

• Heating medium system capacity capacity increased to support high demand.

• Reduced capital expenditure and minimized schedule impact.

Value:                                                                                                                                                  Delivered a fast, cost-effective and technically robust solution by optimizing existing system design rather than introducing new equipment.

Contact:                                                                                                                                          Supporting equipment suppliers and EPC contractors in solving real engineering challenges.