SHELL-N-TUBECHALLENGES OF MAKING

CRYOGENIC SYSTEMS PAST - PRESENT – FUTURE

BYSHANKAR GHOSH

WORKSHOP ON CRYOGENIC SCIENCE AND TECHNOLOGY IN INDIA

ORGANIZED BYINTER – UNIVERSITY ACCELERATOR CENTRE

SHELL-N-TUBE

SOLUTION PROVIDERS TO CRYOGENIC INDUSTRY

SINCE 1987

LINKING PRODUCERS & USERS OF

INDUSTRIAL GASES

AGENDA

List of products developed in past with its associated problems

Present product development activities

Future vision

CRYOGENIC VAPORISERS1989 - ALL COPPER

VAPORISER UPTO

4000 NM3/HR –LOX

FOR STEEL PLANTS

2005 - ALL

ALUMINIUM

LOX/LIN/LAR

VAPORISERS UPTO

30000 NM3 /HR

MOBILE LIQUID NITROGEN VAPORISATION SYSTEM FORPETROLEUM INDUSTRY

A product conceived and developed to meet a specific customer need for in situ purging of flammable product pipeline.

Challenges included

• Modification of existing vaporiser design to take on additional transit loads over bad roads .

• Simple and easy to operate control system

• Design of trailer and selection of locally available prime mover to meet the mobility requirement

CHALLENGES OF MAKING CRYOGENIC VAPORISERSInlet distribution feeder of cryo fluids

Minimising pressure drop in large flow and peak flow condition

Material selection - Copper / SS / Aluminum or SS lined aluminum

Optimising system pressure drop

Establishing brazing/welding procedure and quality assurance

Incorporation of advanced welding processes and fabrication techniques for aluminum vaporisers

Development of weld preparation and weld procedure for high quality al welding

Development of transit damage protectors and standardised field testing procedure

CRYOGENIC SYSTEM ASSISTANCE TO INDIAN AIR FORCESERVICING AND RE EVACUATION OF LIQUID OXYGEN TANKS

TROUBLE SHOOTING AND RESTORATION OF ULTRA HIGH PRESSURE LIQUID NITROGEN SYSTEM 350 BAR OPERATING INCORPORATING SUBMERSED HYDRAULIC MOTOR OPERATED PUMP AND FULLY AUTOMATED OPERATING SYSTEM

CRYOGENIC PHASE SEPERATORS FOR ANIMAL HUSBANDRY AND RESEARCH LABORATORIES

Development of low cost Indian alternative to imported cryo fluid phase separators to meet the objective of efficient and quick filling of small cryo-cans

Final equipment cost 25% of imported equipment with same performance and much simplified operation

Rugged design to meet Indian road field handling conditions

WIDE NECK CRYOGENIC DEWAR FOR FOOD AND BEVERAGE INDUSTRY

Design and manufacturing challenges

Low liquid nitrogen boil off

Compact inner vessel support system

Easy to use and maintain

Integrated operating safety

USE OF LIQUID NITROGEN IN STEM CELL BASED RESERACH

Use of portable liquid nitrogen cylinders for cryo preservation of biological specimens and stem cell related research complete with super insulated small dia liquid nitrogen flexible supply line

REPAIR OF POWDER VACUUM INSUALTED CRYOGENIC TANKS

Main problems are:

Getting vacuum level good enough for accurate mass spectrometer based leak detection

Perlite removal from annulus

Positive identification of leak zone and repair in cramped quarters

High moisture degassing

Long evacuation period even with high capacity multi stage pumping capability

SUPER INUSALTED TANK REAPAIR FOR OIL AND GAS INDUSTRY

Development and sourcing of cryogenic piping components

Effective use of mass spectrometer leak detection methods

Achieving good stable vacuum of the order 10 micron or less in high moisture environment

Development of suitable technology for inner vessel and annulus plumbing defect identification and rectification including inner vessel support replacement

HIGH PRESSURE – HIGH FLOW GAS DELIVERY SYSTEM FOR LASER INDUSTRY

Challenges:Meeting high flow demand of up to 200 m3

/ hr at 31 bar on continuous basis.

This was met by CHART’s specially designed LASER-CYL liquid based gas delivery system

LIQUID NITROGEN TRANSFER SYSTEM FOR PHARMA INDUSTRY WITH MLI-VACUUM INSULATED LINES

LOW PRESSURE DROP HIGH FLOW SYSTEM UPTO 2000 LTR/HR

VACUUM INSULATED MANFOLDING FOR LIQUID NITROGEN SUPPLY TO MULTIPLE PROCESS REACTORS SIMULTANEOUSLY

ADDITIONAL SAFETY FEATURES FOR INDOOR OPERATION

MULTI LAYER INSULATED VACUUM JACKETED PIPELINE FORFISH FREEZING APPLICATION

Challenges • Optimising the evacuation

and mass spectrometer leak testing cycle to maximise productivity

• Development of field support team for prompt assistance to end user in installation and commissioning

• Design standardisation for prompt delivery and achieve economy of scale

• Lowering cost of production to meet competition from overseas .

FLEXIBLE MULTI LAYER INSULATED VACUUM JACKETED PIPINGFOR INDUSTRY

To meet the specific need of making reliable and leak tight end connections for a vacuum insulated pipeline system under field conditions

Optimising outer flexible jacket size

Maximising insulation layer density.

Operating safety

Low heat in-leak to assure frost free operation

VACUUM INSULATED PIPELINE FOR INDIAN SPACE RESEARCH ORGANISATION

6” / 10” multi layer vacuum jacketed piping custom designed for liquid oxygen and liquid hydrogen transfer application

Development of suitable thermal compensators

Inner pipe all metallic support systems

Vacuum monitoring provision in individual pipe spools

Development of multi stage high vacuum system and on line mass spectrometer leak detection capability

81 BAR WORKING PRESSURE VACUUM INSULETED LIQUID HYDROGEN PIPING FOR

INDIAN SPACE PROGRAMMEDevelopment of high pressure thermal compensators

Development of high pressure testing techniques for individual spool test incorporating bellows

Achieving very good stable vacuum in ambient temperature – less than 5 micron and sometime less than 1 micron 72 hrs after pump stop

Multi stage surface cleaning procedure

ISRO Certificate for 40 NB, 81 bar VI PIPE

LOX-GHe COOLER IN LN2 BATH FOR INDIAN SPACE PROGRAMME

Design of efficient cooling coils for simultaneous cooling of helium gas and sub-cooling of liquid oxygen in liquid nitrogen bath

Development of low conductivity load bearing and anti rotating supports

Development of multi layer insulation application technology

Achieving good vacuum stability with complex annulus geometry .

LOX – GHe Cooler Performance Certificate

OUR CHALLENGES TODAY IN CRYOGENICS

Manufacture of low temperature adsorption base pilot plant for argon purification

LNG user system based on 100 KL liquid natural gas tank and adequate re-gasification heat exchanger for industries changing over to alternative clean burning fuel .

CRYOGENIC ADSORPTION BASED COVER GAS PURIFICATION SYSTEM for IGCAR

FUTURE CHALLENGES FOR INDUSTRIAL CRYOGENIC IN INDIA• Large dia multi layer vacuum insulated LNG transfer lines for

ship to shore transfer efficiently with inner line dia from 12 to 36 inches.

• A wide variety of liquefied natural gas based user stations to meet customer specific needs ranging from vehicle fuelling operation to power generation to stand by storage or peak shaving operations as power and more importantly fossil fuel cost goes up

• Onboard vehicle tanks for automobiles-trucks-locomotives and may be some day for container ships

• Liquid hydrogen storage tanks and user systems

• Economic multilayer insulated cryo containers both standard and wide neck type to meet the growing demands of animal husbandry and biological industry

LNG Systems

LNG Installation

LNG as Vehicle Fuel

LNG BACKUP SYSTEM

SHELL-N-TUBE

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