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Monitor™ economic calculations answer common questions about the cost of fouling,

Economic Calculations

Monitor™ economic calculations answer common questions about the cost of fouling, the benefits to be gained from cleaning and help to develop an optimum cleaning strategy.

Cleaning Economics Reports

Monitor™ Cleaning Economics calculations determine the effects of cleaning exchangers in the Network.  These are shown in tabular form  and include:

• the cost of removing exchangers for cleaning
• the savings that could be made by cleaning selected exchangers
• the optimum cleaning cycles for each exchanger and for user-defined groups of exchangers.

In addition, one of the standard spreadsheet reports is the Fouling Cost Summary which shows the additional costs that have been incurred over a range of cases for the furnace to make up the duty lost. 

Economic Data Required

The Cleaning Economic calculations require the following data:

Globally:

• The Fuel Cost and the Furnace Efficiency are used when generating all economic reports. 
• The Length of Plant Run is only used in the optimum cleaning cycle report. 
• Fuel Cost expressed in $ per unit of duty.  The default value is the Solomon value for fuel oil.
• Furnace Efficiency. The fuel cost is divided by this value to obtain the total cost of the fuel.
• Length of Plant Run expressed as number of days between plant shutdowns.  This is used in the optimum cleaning cycle calculation.

For each exchanger:

• Date Last Cleaned. This is used in the optimum cleaning cycle report.
• Days to Clean. The number of days that an exchanger will be out of service when it is removed for cleaning.  This is used in the optimum cleaning cycle report.
• Cleaning Cost. The fixed costs (man time, cleaning materials, etc.) associated with removing and cleaning an exchanger.  This does not include additional costs incurred by the reduced Network duty.  This cost is used in the optimum cleaning cycle report.
• Clean Fouling Factor for the exchanger when returned to service after cleaning.  This is used in the Cleaning Economics calculation and the optimum cleaning cycle report.

How Cleaning Economics are Calculated

Fouling factors are first calculated for a selected Case.  These are used to calculate temperatures for all exchangers and at the furnace inlet.

Cost of removing exchangers for cleaning

The Network is solved and the furnace run-up temperature calculated with each exchanger in turn bypassed.  This determines the effect of removing the exchangers for cleaning in terms of lost enthalpy at the furnace inlet, also expressed as $/day. The program also calculates the amount by which the throughput would have to be reduced in order to maintain the furnace inlet temperature at its previous level.

Savings from cleaning

The fouling factor of each exchanger in turn is then set to its clean value and the Network is solved to obtain the increase in duty that this would produce at the furnace inlet.  This is shown as extra throughput which could be achieved and $/day.

Optimum cleaning cycles

The above results are then used, along with fixed costs, to calculate the optimum cleaning cycles for each exchanger.  The optimum cycle is that which minimises the annualised cost of fouling. By default, each exchanger is cleaned in turn.  Combinations of exchangers to be cleaned in addition to individual exchangers are defined in the User Defined Cleaning Economics Combinations Window.

Flexible Output

MONITOR's output capabilities are extensive.  

• You can export the PFD drawing to PowerPoint so that you can use it in a presentation. 
• You can get results tables displayed directly on the screen.
• You can have a summary of Reconciliation, Fouling and NFIT runs for a range of cases.
• You can plot results from a range of cases to view trends.

You can get the results of the current case displayed as a table directly on the screen.  

You can export these results to Word or to a Text file. 

Input Data Reprint To enable you to check all your data, Monitor prints it all out at the start of the main results output. The network data include: connectivity  mechanical data  Case data include: stream temperatures, pressures, flowrates and properties exchanger temperatures mixer temperatures splitter ratios	MONITOR E5.136 Heat Exchanger Network Monitoring Page 1 Network: Metric Crude Workbook.mon Unit/Stream Summary Case: 20/05/2000 ============================================================================ --- Shell Side --- --- Tube Side --- HX Name In Out In Out E-201AB TPA1 TPA2 CR1 CR2 E-202 TPA0 TPA1 CR2 CR3 E-206AB CR4 CR5 LGO1 LGO2 E-210EF VGO2 VGO3 CR6 CR7 E-111CD MPA0 MPA1 CR8 CR9 E-523 CR12 CR13 VMP0 VMP1 E-232A VGO1 VGO2 CR10 CR11 E366AD RES0 RES1 CR14 CR15 Unit Name Type Product Feeds Mix1 Mixer CR8 CR5 CR7 Mix2 Mixer CR14 CR13 CR11 Unit Name Type Feed Products Split1 Splitter CR3 CR4 CR6 Split2 Splitter CR9 CR12 CR10 FEED STREAMS Stream Name Feed Unit CR1 E-201AB TPA0 E-202 LGO1 E-206AB VGO1 E-232A VMP0 E-523 MPA0 E-111CD RES0 E366AD MONITOR E5.136 Heat Exchanger Network Monitoring Page 2 Network: Metric Crude Workbook.mon Data Reconciliation Summary Case: 20/05/2000 ============================================================================ Unit Name Target? Variable E-201AB Yes Stream TPA0 flowrate E-202 Yes Stream TPA0 temperature E-206AB Yes Splitter Split1 E-210EF Yes Stream VGO1 flowrate E-111CD Yes Stream MPA0 temperature E-523 Yes Stream VMP0 flowrate E-232A Yes Splitter Split2 E366AD Yes Stream RES0 flowrate Mix1 No Mix2 No MONITOR E5.136 Heat Exchanger Network Monitoring Page 3 Network: Metric Crude Workbook.mon Tag Allocation Summary Case: 20/05/2000 ============================================================================ Unit Name Parameter(s) ------- Tag Names ------- E-201AB Shell, tube exit temperatures TI 0301 TI 0311 E-202 Shell, tube exit temperatures TI 0133 TI 0193 E-206AB Shell, tube exit temperatures TI 0032 TI 0021 E-210EF Shell, tube exit temperatures TI 0182 TI 0065 E-111CD Shell, tube exit temperatures TI 0026 TI 0039 E-523 Shell, tube exit temperatures TI 0087 TI 0091 E-232A Shell, tube exit temperatures TI 0062 TI 0055 E366AD Shell, tube exit temperatures TI 0190 TI 0175 FEED STREAMS Feed Name Parameter(s) ------- Tag Names ------- CR1 Feed temperature, Flowrate TI 0151 F3 F003 TPA0 Feed temperature, Flowrate TI 0005 F3 F023 LGO1 Feed temperature, Flowrate TI 0241 FH F321 VGO1 Feed temperature, Flowrate TI 0103 F3 F110 VMP0 Feed temperature, Flowrate TI 0009 F3 F521 MPA0 Feed temperature, Flowrate F3 F232 RES0 Feed temperature, Flowrate KR 2123 F3 2123 FEED STREAM PROPERTY IDENTIFIERS Feed Name Parameter(s) ---- Identifier Names --- CR1 Gravity CR1 Grav MONITOR E5.136 Heat Exchanger Network Monitoring Page 6 Network: Metric Crude Workbook.mon Network Definition Case: 20/05/2000 ============================================================================ Heat Exchanger Data Unit Name: E-201AB Connectivity Tube Feed CR1 Shell Feed TPA1 Tube Product CR2 Shell Product TPA2 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 1 Pitch 31.750 mm Shells in parallel 2 Pattern Square Shell ID 1397.00 mm Number 896 Length 6.10 m Baffle Cut 0.250 No. of passes 4 Baffle Spacing 508.00 mm Material Mild Steel No. of Baffles 11 ---------------------------------------------------------------------------- Unit Name: E-202 Connectivity Tube Feed CR2 Shell Feed TPA0 Tube Product CR3 Shell Product TPA1 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 1 Pitch 31.750 mm Shells in parallel 1 Pattern Square Shell ID 1295.00 mm Number 764 Length 6.10 m Baffle Cut 0.250 No. of passes 2 Baffle Spacing 464.00 mm Material Mild Steel No. of Baffles 12 ---------------------------------------------------------------------------- Unit Name: E-206AB Connectivity Tube Feed LGO1 Shell Feed CR4 Tube Product LGO2 Shell Product CR5 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 2 Pitch 31.750 mm Shells in parallel 1 Pattern Square Shell ID 1245.00 mm Number 720 Length 6.10 m Baffle Cut 0.250 No. of passes 2 Baffle Spacing 249.00 mm Material Mild Steel No. of Baffles 24 ---------------------------------------------------------------------------- MONITOR E5.136 Heat Exchanger Network Monitoring Page 7 Network: Metric Crude Workbook.mon Network Definition Case: 20/05/2000 ============================================================================ Heat Exchanger Data Unit Name: E-210EF Connectivity Tube Feed CR6 Shell Feed VGO2 Tube Product CR7 Shell Product VGO3 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 2 Pitch 31.750 mm Shells in parallel 1 Pattern Square Shell ID 1295.00 mm Number 764 Length 6.10 m Baffle Cut 0.250 No. of passes 2 Baffle Spacing 259.00 mm Material Mild Steel No. of Baffles 22 ---------------------------------------------------------------------------- Unit Name: E-111CD Connectivity Tube Feed CR8 Shell Feed MPA0 Tube Product CR9 Shell Product MPA1 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 2 Pitch 31.750 mm Shells in parallel 1 Pattern Square Shell ID 1219.00 mm Number 807 Length 6.10 m Baffle Cut 0.250 No. of passes 4 Baffle Spacing 516.00 mm Material Mild Steel No. of Baffles 11 ---------------------------------------------------------------------------- Unit Name: E-523 Connectivity Tube Feed VMP0 Shell Feed CR12 Tube Product VMP1 Shell Product CR13 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 1 Pitch 31.750 mm Shells in parallel 1 Pattern Rot. square Shell ID 1400.00 mm Number 910 Length 6.10 m Baffle Cut 0.250 No. of passes 2 Baffle Spacing 280.00 mm Material Mild Steel No. of Baffles 20 ---------------------------------------------------------------------------- MONITOR E5.136 Heat Exchanger Network Monitoring Page 8 Network: Metric Crude Workbook.mon Network Definition Case: 20/05/2000 ============================================================================ Heat Exchanger Data Unit Name: E-232A Connectivity Tube Feed CR10 Shell Feed VGO1 Tube Product CR11 Shell Product VGO2 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 1 Pitch 31.750 mm Shells in parallel 1 Pattern Square Shell ID 991.00 mm Number 398 Length 6.10 m Baffle Cut 0.250 No. of passes 2 Baffle Spacing 394.00 mm Material Mild Steel No. of Baffles 15 ---------------------------------------------------------------------------- Unit Name: E366AD Connectivity Tube Feed CR14 Shell Feed RES0 Tube Product CR15 Shell Product RES1 Tube Side Shell Side Outside Diameter 25.400 mm TEMA Type AET BWG 12 Shells in series 2 Pitch 31.750 mm Shells in parallel 2 Pattern Square Shell ID 1397.00 mm Number 880 Length 6.10 m Baffle Cut 0.250 No. of passes 4 Baffle Spacing 280.00 mm Material Mild Steel No. of Baffles 20 ---------------------------------------------------------------------------- MONITOR E5.136 Heat Exchanger Network Monitoring Page 9 Network: Metric Crude Workbook.mon Network Definition Case: 20/05/2000 ============================================================================ Mixer Data Unit Name: Mix1 -------- Feed Streams CR5 CR7 Product stream CR8 Unit Name: Mix2 -------- Feed Streams CR13 CR11 Product stream CR14 Splitter Data Unit Name: Split1 -------- Feed stream CR3 Product Streams CR4 CR6 Unit Name: Split2 -------- Feed stream CR9 Product Streams CR12 CR10 MONITOR E5.136 Heat Exchanger Network Monitoring Page 10 Network: Metric Crude Workbook.mon Case Specification Data Case: 20/05/2000 ============================================================================ Exchanger Case Data Unit Name Shell Temp Tube Temp Spec side Bypass? E-201AB 165.13 °C 141.47 °C Tube N E-202 181.98 °C 147.87 °C Tube N E-206AB 177.94 °C 213.93 °C Shell N E-210EF 178.55 °C 166.13 °C Tube N E-111CD 210.73 °C 179.03 °C Tube N E-523 183.47 °C 199.24 °C Shell N E-232A 313.96 °C 189.08 °C Tube N E366AD 251.24 °C 225.35 °C Tube N MONITOR E5.136 Heat Exchanger Network Monitoring Page 11 Network: Metric Crude Workbook.mon Case Specification Data Case: 20/05/2000 ============================================================================ Mixer Case Data Unit Name Option Outlet Temp Mix1 Temperature Calculated Mix2 Temperature Calculated Splitter Case Data Product Fractions Unit Name 1 2 3 Split1 0.5000 0.5000 Split2 0.5000 0.5000 MONITOR E5.136 Heat Exchanger Network Monitoring Page 12 Network: Metric Crude Workbook.mon Case Specification Data Case: 20/05/2000 ============================================================================ Feed Stream Data Stream Name: CR1 Stream Type Liquid Hydrocarbon Spec. gravity 0.84000 Temperature 128.52 °C UOPK factor 12.1000 Pressure 30.30 Bar Water fraction 0.0000 Flow Basis (W/V/G) V Flowrate 713.11 m3/hr Stream Name: TPA0 Stream Type Liquid Hydrocarbon Spec. gravity 0.79000 Temperature 188.14 °C UOPK factor 11.9800 Pressure 6.00 Bar Water fraction 0.0000 Flow Basis (W/V/G) V Flowrate 659.88 m3/hr Stream Name: LGO1 Stream Type Liquid Hydrocarbon Spec. gravity 0.85000 Temperature 235.53 °C UOPK factor 11.8700 Pressure 6.30 Bar Water fraction 0.0000 Flow Basis (W/V/G) V Flowrate 171.31 m3/hr Stream Name: VGO1 Stream Type Liquid Hydrocarbon Spec. gravity 0.91000 Temperature 347.20 °C UOPK factor 11.7900 Pressure 7.50 Bar Water fraction 0.0000 Flow Basis (W/V/G) V Flowrate 70.02 m3/hr Stream Name: VMP0 Stream Type Liquid Hydrocarbon Spec. gravity 0.86000 Temperature 244.68 °C UOPK factor 11.8300 Pressure 18.50 Bar Water fraction 0.0000 Flow Basis (W/V/G) V Flowrate 49.35 m3/hr Stream Name: MPA0 Stream Type Liquid Hydrocarbon Spec. gravity 0.86000 Temperature 250.00 °C UOPK factor 11.8400 Pressure 5.70 Bar Water fraction 0.0000 Flow Basis (W/V/G) V Flowrate 367.09 m3/hr Stream Name: RES0 Stream Type Liquid Hydrocarbon Spec. gravity 0.96700 Temperature 339.75 °C UOPK factor 11.7100 Pressure 24.50 Bar Water fraction 0.0000 Flow Basis (W/V/G) V Flowrate 261.51 m3/hr
Reconciliation Monitor uses measured plant temperatures and flowrates to calculate heat exchanger fouling factors. The Data Reconciliation calculation identifies inconsistencies in the input data and enables you to obtain a more consistent set of data for the fouling calculation. Reconciliation output shows the duties calculated from the supplied flowrates and temperatures for each side of target exchanger and the differences between them. It also shows the differences between the target and calculated temperatures of the  products of target mixers. The same data are then shown after the reconciliation has been completed. The table shows by how much feed stream temperatures and flowrates and splitter ratios have been changed to achieve a reconciled data set.	** Input Data Balances ** Exchanger Shell duty Tube duty Diff % Diff Gcal/hr Gcal/hr Gcal/hr E-201AB 5.55 4.53 1.019 18.36 E-202 2.06 2.27 0.213 9.38 E-206AB 5.50 2.05 3.440 62.55 E-210EF 5.65 3.31 2.346 41.48 E-111CD 8.13 2.59 5.534 68.05 E-523 0.83 1.25 0.416 33.28 E-232A 1.52 1.89 0.371 19.60 E366AD 15.27 15.19 0.087 0.57 ** Reconciliation Complete - Solution reached ** ** Final Calculation Results ** Exchanger Shell duty Tube duty Diff % Diff Gcal/hr Gcal/hr Gcal/hr E-201AB 4.53 4.53 0.000 0.00 E-202 2.27 2.27 0.000 0.00 E-206AB 2.05 2.05 0.000 0.00 E-210EF 5.38 5.38 0.000 0.00 E-111CD 3.96 3.96 0.000 0.00 E-523 1.03 1.03 0.000 0.00 E-232A 1.45 1.45 0.000 0.00 E366AD 15.44 15.44 0.000 0.00 ** Feed Streams ** ------- Temperatures ------- -------- Flowrates --------- Stream Old temp New temp Diff Old flow New flow % Diff °C °C °C kg/hr kg/hr CR1 128.52 128.52 0.00 598437. 598437. 0.00 TPA0 188.14 190.29 2.15 520805. 425160. -18.36 LGO1 235.53 235.53 0.00 145474. 145474. 0.00 VGO1 347.20 347.20 0.00 63657. 60547. -4.88 VMP0 244.68 244.68 0.00 42400. 34940. -17.59 MPA0 250.00 230.13 -19.86 315394. 315394. 0.00 RES0 339.75 339.75 0.00 252637. 255316. 1.06 ** Splitter Results ** Unit Stream Initial Final Stream Initial Final Split1 CR4 0.5000 0.1872 CR6 0.5000 0.8127 Split2 CR12 0.5000 0.6176 CR10 0.5000 0.3823
Fouling After a reprint of the input data, the fouling report shows tabular results for each type of heat exchanger in turn, followed by results for all other types of unit operation in turn. Finally, the temperatures, pressures, flows and properties are presented for all the streams in the Network.  Heat exchanger results include: Exchanger duties, clean and dirty coefficients Tube and shell velocities and Reynold's Numbers Mixer temperatures and duties Stream temperatures, rates and properties.	Heat Exchanger Results Case: 20/05/2000 ============================================================================ HX Name Duty U Clean U Dirty Total Length Effect- Fouling Gcal/hr - kcal/m2.hr.°C - Area m2 m iveness m2.hr.°C/kcal E-201AB 4.532 419.04 138.33 872.3 6.10 0.315 0.00484 E-202 2.276 577.91 148.36 371.9 6.10 0.170 0.00501 E-206AB 2.060 287.93 47.95 700.9 6.10 0.343 0.01738 E-210EF 5.380 291.00 99.02 743.8 6.10 0.815 0.00666 E-111CD 3.968 602.17 108.81 785.6 6.10 0.314 0.00753 E-523 1.031 108.26 64.62 443.0 6.10 0.692 0.00624 E-232A 1.450 289.64 51.33 193.7 6.10 0.197 0.01603 E366AD 15.441 358.51 104.72 1713.4 6.10 0.574 0.00676 Duty weighted: 104.76 0.00744 -- Shell Side -- --- Tube Side -- HX Name Temp In / Out Temp In / Out LMTD MTD FT °C °C °C °C °C °C E-201AB 181.98 165.13 128.52 141.47 38.53 37.56 0.9749 E-202 190.30 181.98 141.47 147.87 41.46 41.25 0.9948 E-206AB 147.87 177.94 235.53 213.93 61.73 61.29 0.9928 E-210EF 313.96 178.55 147.87 166.13 74.50 73.05 0.9805 E-111CD 230.13 210.73 168.36 179.03 46.60 46.42 0.9960 E-523 179.03 183.47 244.68 199.24 37.00 36.01 0.9732 E-232A 347.20 313.96 179.03 189.08 146.22 145.84 0.9973 E366AD 339.75 251.24 185.62 225.35 87.76 86.06 0.9806 -- Shell Side -- --- Tube Side -- HX Name Pres In / Out Pres In / Out Shell Flow Tube Flow Bar Bar Bar Bar kg/hr kg/hr E-201AB 5.020 4.813 30.300 29.736 425159.7 598437.3 E-202 6.000 5.020 29.736 29.361 425159.7 598437.3 E-206AB 29.361 28.273 6.300 6.238 112057.4 145473.7 E-210EF 7.436 7.116 29.361 28.860 60547.2 486379.9 E-111CD 5.700 4.769 28.273 23.411 315394.3 598437.3 E-523 23.411 20.522 18.500 18.499 369612.8 34940.1 E-232A 7.500 7.436 23.411 23.208 60547.2 228824.5 E366AD 24.500 23.566 20.522 19.394 255316.0 598437.3 ---- Shell Side ---- ---- Tube Side ----- Normalised HX Name Reynolds Velocity Reynolds Velocity U Value Number m/s Number m/s kcal/m2.hr.°C E-201AB 34382.47 0.63 26160.44 1.57 138.34 E-202 87308.62 1.50 33668.58 1.86 148.36 E-206AB 17967.31 0.68 17254.36 0.52 47.95 E-210EF 8541.65 0.33 30628.63 1.53 99.02 E-111CD 36635.28 0.97 82290.08 3.64 108.82 E-523 54199.61 1.80 2927.48 0.10 64.62 E-232A 11796.50 0.31 34458.64 1.42 51.33 E366AD 10482.34 0.56 47753.38 1.72 104.72 MONITOR E5.136 Heat Exchanger Network Monitoring Page 14 Network: Metric Crude Workbook.mon Ancillary Unit Results Case: 20/05/2000 ============================================================================ Mixer Data Unit Name Feeds Product Temperature Pressure Duty °C Bar Gcal/hr Mix1 CR5 CR8 168.36 28.27 0.00 CR7 Mix2 CR13 CR14 185.62 20.52 0.00 CR11 Splitter Data Unit Name Feed Products Fractions Flowrates kg/hr Split1 CR3 CR4 0.1873 112057.4 CR6 0.8127 486379.9 Split2 CR9 CR12 0.6176 369612.8 CR10 0.3824 228824.5 MONITOR E5.136 Heat Exchanger Network Monitoring Page 15 Network: Metric Crude Workbook.mon Stream Results Case: 20/05/2000 ============================================================================ Stream Name CR1 CR10 CR11 CR12 Temperature °C 128.52 179.03 189.08 179.03 Pressure Bar 30.30 23.41 23.21 23.41 Weight Flow kg/hr 598437.3 228824.5 228824.5 369612.8 Std Liq Vol Flow m3/hr 713.11 272.67 272.67 440.44 Enthalpy kcal/kg 112.348 142.787 149.125 142.787 Gcal/hr 67.233 32.673 34.123 52.776 Liquid Weight Fraction 1.0000 1.0000 1.0000 1.0000 Water Weight Fraction 0.0000 0.0000 0.0000 0.0000 UOPK 12.10 12.10 12.10 12.10 API Gravity 36.95 36.95 36.95 36.95 Specific Gravity 0.8400 0.8400 0.8400 0.8400 Liquid: Density kg/m3 765.053 729.087 721.663 729.087 Viscosity cP 0.972 0.618 0.572 0.618 Conductivity kcal/hr.m.°C 0.0972 0.0911 0.0899 0.0911 Specific Heat kcal/kg.°C 0.5785 0.6261 0.6351 0.6261 Vapour: Density kg/m3 0.000 0.000 0.000 0.000 Viscosity cP 0.000 0.000 0.000 0.000 Conductivity kcal/hr.m.°C 0.0000 0.0000 0.0000 0.0000 Specific Heat kcal/kg.°C 0.0000 0.0000 0.0000 0.0000 Stream Name CR13 CR14 CR15 CR2 Temperature °C 183.47 185.62 225.35 141.47 Pressure Bar 20.52 20.52 19.39 29.74 Weight Flow kg/hr 369612.8 598437.3 598437.3 598437.3 Std Liq Vol Flow m3/hr 440.44 713.11 713.11 713.11 Enthalpy kcal/kg 145.576 146.933 172.735 119.921 Gcal/hr 53.807 87.930 103.371 71.765 Liquid Weight Fraction 1.0000 1.0000 1.0000 1.0000 Water Weight Fraction 0.0000 0.0000 0.0000 0.0000 UOPK 12.10 12.10 12.10 12.10 API Gravity 36.95 36.95 36.95 36.95 Specific Gravity 0.8400 0.8400 0.8400 0.8400 Liquid: Density kg/m3 725.819 724.230 694.001 756.029 Viscosity cP 0.597 0.587 0.446 0.854 Conductivity kcal/hr.m.°C 0.0905 0.0903 0.0855 0.0956 Specific Heat kcal/kg.°C 0.6301 0.6320 0.6664 0.5911 Vapour: Density kg/m3 0.000 0.000 0.000 0.000 Viscosity cP 0.000 0.000 0.000 0.000 Conductivity kcal/hr.m.°C 0.0000 0.0000 0.0000 0.0000 Specific Heat kcal/kg.°C 0.0000 0.0000 0.0000 0.0000 MONITOR E5.136 Heat Exchanger Network Monitoring Page 16 Network: Metric Crude Workbook.mon Stream Results Case: 20/05/2000 ============================================================================ Stream Name CR3 CR4 CR5 CR6 Temperature °C 147.87 147.87 177.94 147.87 Pressure Bar 29.36 29.36 28.27 29.36 Weight Flow kg/hr 598437.3 112057.4 112057.4 486379.9 Std Liq Vol Flow m3/hr 713.11 133.53 133.53 579.58 Enthalpy kcal/kg 123.724 123.724 142.105 123.724 Gcal/hr 74.041 13.864 15.924 60.177 Liquid Weight Fraction 1.0000 1.0000 1.0000 1.0000 Water Weight Fraction 0.0000 0.0000 0.0000 0.0000 UOPK 12.10 12.10 12.10 12.10 API Gravity 36.95 36.95 36.95 36.95 Specific Gravity 0.8400 0.8400 0.8400 0.8400 Liquid: Density kg/m3 751.521 751.521 729.886 751.521 Viscosity cP 0.804 0.804 0.623 0.804 Conductivity kcal/hr.m.°C 0.0949 0.0949 0.0912 0.0949 Specific Heat kcal/kg.°C 0.5972 0.5972 0.6251 0.5972 Vapour: Density kg/m3 0.000 0.000 0.000 0.000 Viscosity cP 0.000 0.000 0.000 0.000 Conductivity kcal/hr.m.°C 0.0000 0.0000 0.0000 0.0000 Specific Heat kcal/kg.°C 0.0000 0.0000 0.0000 0.0000 Stream Name CR7 CR8 CR9 LGO1 Temperature °C 166.13 168.36 179.03 235.53 Pressure Bar 28.86 28.27 23.41 6.30 Weight Flow kg/hr 486379.9 598437.3 598437.3 145473.7 Std Liq Vol Flow m3/hr 579.58 713.11 713.11 171.31 Enthalpy kcal/kg 134.786 136.157 142.787 176.559 Gcal/hr 65.557 81.481 85.449 25.685 Liquid Weight Fraction 1.0000 1.0000 1.0000 1.0000 Water Weight Fraction 0.0000 0.0000 0.0000 0.0000 UOPK 12.10 12.10 12.10 11.87 API Gravity 36.95 36.95 36.95 34.97 Specific Gravity 0.8400 0.8400 0.8400 0.8500 Liquid: Density kg/m3 738.477 736.867 729.087 693.291 Viscosity cP 0.686 0.673 0.618 0.391 Conductivity kcal/hr.m.°C 0.0926 0.0924 0.0911 0.0842 Specific Heat kcal/kg.°C 0.6143 0.6164 0.6261 0.6644 Vapour: Density kg/m3 0.000 0.000 0.000 0.000 Viscosity cP 0.000 0.000 0.000 0.000 Conductivity kcal/hr.m.°C 0.0000 0.0000 0.0000 0.0000 Specific Heat kcal/kg.°C 0.0000 0.0000 0.0000 0.0000 MONITOR E5.136 Heat Exchanger Network Monitoring Page 17 Network: Metric Crude Workbook.mon Stream Results Case: 20/05/2000 ============================================================================ Stream Name LGO2 MPA0 MPA1 RES0 Temperature °C 213.93 230.13 210.73 339.75 Pressure Bar 6.24 5.70 4.77 24.50 Weight Flow kg/hr 145473.7 315394.3 315394.3 255316.0 Std Liq Vol Flow m3/hr 171.31 367.09 367.09 264.28 Enthalpy kcal/kg 162.400 171.576 158.995 234.372 Gcal/hr 23.625 54.114 50.146 59.839 Liquid Weight Fraction 1.0000 1.0000 1.0000 1.0000 Water Weight Fraction 0.0000 0.0000 0.0000 0.0000 UOPK 11.87 11.84 11.84 11.71 API Gravity 34.97 33.03 33.03 14.83 Specific Gravity 0.8500 0.8600 0.8600 0.9670 Liquid: Density kg/m3 710.550 710.770 725.754 781.374 Viscosity cP 0.447 0.449 0.511 0.816 Conductivity kcal/hr.m.°C 0.0868 0.0849 0.0872 0.0716 Specific Heat kcal/kg.°C 0.6465 0.6565 0.6403 0.7155 Vapour: Density kg/m3 0.000 0.000 0.000 0.000 Viscosity cP 0.000 0.000 0.000 0.000 Conductivity kcal/hr.m.°C 0.0000 0.0000 0.0000 0.0000 Specific Heat kcal/kg.°C 0.0000 0.0000 0.0000 0.0000 Stream Name RES1 TPA0 TPA1 TPA2 Temperature °C 251.24 190.30 181.98 165.13 Pressure Bar 23.57 6.00 5.02 4.81 Weight Flow kg/hr 255316.0 425159.7 425159.7 425159.7 Std Liq Vol Flow m3/hr 264.28 538.69 538.69 538.69 Enthalpy kcal/kg 173.895 155.288 149.935 139.275 Gcal/hr 44.398 66.022 63.746 59.214 Liquid Weight Fraction 1.0000 1.0000 1.0000 1.0000 Water Weight Fraction 0.0000 0.0000 0.0000 0.0000 UOPK 11.71 11.98 11.98 11.98 API Gravity 14.83 47.61 47.61 47.61 Specific Gravity 0.9670 0.7900 0.7900 0.7900 Liquid: Density kg/m3 836.450 649.437 657.063 672.111 Viscosity cP 1.626 0.276 0.290 0.320 Conductivity kcal/hr.m.°C 0.0823 0.0897 0.0907 0.0928 Specific Heat kcal/kg.°C 0.6491 0.6472 0.6401 0.6252 Vapour: Density kg/m3 0.000 0.000 0.000 0.000 Viscosity cP 0.000 0.000 0.000 0.000 Conductivity kcal/hr.m.°C 0.0000 0.0000 0.0000 0.0000 Specific Heat kcal/kg.°C 0.0000 0.0000 0.0000 0.0000 MONITOR E5.136 Heat Exchanger Network Monitoring Page 18 Network: Metric Crude Workbook.mon Stream Results Case: 20/05/2000 ============================================================================ Stream Name VGO1 VGO2 VGO3 VMP0 Temperature °C 347.20 313.96 178.55 244.68 Pressure Bar 7.50 7.44 7.12 18.50 Weight Flow kg/hr 60547.2 60547.2 60547.2 34940.1 Std Liq Vol Flow m3/hr 66.60 66.60 66.60 40.67 Enthalpy kcal/kg 246.689 222.737 133.875 181.124 Gcal/hr 14.936 13.486 8.106 6.328 Liquid Weight Fraction 1.0000 1.0000 1.0000 1.0000 Water Weight Fraction 0.0000 0.0000 0.0000 0.0000 UOPK 11.79 11.79 11.79 11.83 API Gravity 23.99 23.99 23.99 33.03 Specific Gravity 0.9100 0.9100 0.9100 0.8600 Liquid: Density kg/m3 691.426 717.100 810.810 698.922 Viscosity cP 0.422 0.502 1.388 0.407 Conductivity kcal/hr.m.°C 0.0707 0.0747 0.0911 0.0831 Specific Heat kcal/kg.°C 0.7319 0.7090 0.5989 0.6679 Vapour: Density kg/m3 0.000 0.000 0.000 0.000 Viscosity cP 0.000 0.000 0.000 0.000 Conductivity kcal/hr.m.°C 0.0000 0.0000 0.0000 0.0000 Specific Heat kcal/kg.°C 0.0000 0.0000 0.0000 0.0000 Stream Name VMP1 Temperature °C 199.24 Pressure Bar 18.50 Weight Flow kg/hr 34940.1 Std Liq Vol Flow m3/hr 40.67 Enthalpy kcal/kg 151.623 Gcal/hr 5.298 Liquid Weight Fraction 1.0000 Water Weight Fraction 0.0000 UOPK 11.83 API Gravity 33.03 Specific Gravity 0.8600 Liquid: Density kg/m3 734.201 Viscosity cP 0.549 Conductivity kcal/hr.m.°C 0.0886 Specific Heat kcal/kg.°C 0.6301 Vapour: Density kg/m3 0.000 Viscosity cP 0.000 Conductivity kcal/hr.m.°C 0.0000 Specific Heat kcal/kg.°C 0.0000
Normalised Output Normalisation is the technique Monitor uses to remove the effect of the changes in external parameters, such as crude and product variations, to determine a true picture of the degradation of network performance due to fouling alone. The calculated fouling factors from each case are superimposed onto the feeds from a selected base case and the resultant temperatures reported. Normalisation output includes: fouling resistances used exchanger exit temperatures run-up stream temperature	** NFIT Calculation Results ** Exchanger Fouling Shell exit Tube Exit Name Factor Temperature Temperature m2.hr.°C/kcal °C °C E-201AB 0.00443 165.49 142.36 E-202 0.00661 183.49 147.60 E-206AB 0.00901 188.98 205.40 E-210EF 0.01110 198.45 163.50 E-111CD 0.01680 219.13 174.45 E-523 0.01323 178.35 205.11 E-232A 0.01706 314.60 184.37 E366AD 0.01248 271.50 212.03 Normalised Furnace Inlet Temperature: CR15 212.03 °C
Cleaning Economics Cleaning Economics calculations determine the effect of cleaning exchangers in the Network and an optimum cleaning cycle for each exchanger. Cleaning output includes: The cost of removing each  exchanger as the additional fuel cost/day to make up the duty and as the loss in throughput if the duty was not made up by the furnace. The increase in duty of the complete Network after each exchanger has been cleaned expressed as a reduced furnace cost to maintain current operation and an increased throughput which could be achieved if furnace duty was not reduced. The Optimum Cleaning Cycle period which provides the lowest annualised cost of fouling. The savings shown are compared with the cost of cleaning once at the end of the plant run.	Monitor Cleaning Economics Report --------------------------------- Cost of removing exchangers for cleaning Exchanger Current Network Duty Additional Throughput CR15 Removed Duty Decrease Fuel Cost Loss Temp Gcal/hr Gcal/hr $/day kg/day °C NONE - - - 205.44 E-201AB 5.97 3.016 840 1,189,353 197.17 E-202 2.48 0.879 245 346,884 203.04 E-206AB 2.56 1.690 471 666,758 200.82 E-210EF 4.25 2.764 769 1,089,944 197.86 E-111CD 2.71 2.017 562 795,662 199.92 E-523 2.25 1.820 507 717,823 200.46 E-232A 1.48 0.449 125 177,247 204.22 E366AD 12.69 12.689 3,534 5,003,627 169.97 Savings by cleaning selected exchangers Exchanger Duty Fuel Additional CR15 Cleaned Increase Savings Throughput Temp Gcal/hr $/day kg/day °C ALL 21.631 6,025 8,529,810 262.36 E-201AB 1.652 460 651,577 209.94 E-202 1.505 419 593,730 209.54 E-206AB 0.598 167 235,962 207.07 E-210EF 0.714 199 281,742 207.39 E-111CD 7.482 2,084 2,950,591 225.59 E-523 5.060 1,410 1,995,504 219.13 E-232A 0.820 228 323,383 207.68 E366AD 10.001 2,786 3,943,848 232.26 Optimum Cleaning Cycles Exchanger Optimum Cycle Cost of Fouling Savings Days $/yr $/yr E-201AB 406 26,999 14,406 E-202 399 24,193 13,386 E-206AB 649 15,637 2,181 E-210EF 613 17,629 3,046 E-111CD 185 55,836 113,721 E-523 224 45,651 70,497 E-232A 533 17,610 4,746 E366AD 204 82,382 145,634
Splitter Optimisation Splitter Optimisation determines splitter product ratios which maximise the heat recovery of the Network. This minimises the required furnace duty for the Network. Optimisation output includes: Initial and final enthalpy and temperature of the chosen run-up stream. all exchanger inlet and outlet temperatures and flowrates at the optimum splitter setting.	** Splitter Optimisation Results ** Furnace ------- Enthalpy (Gcal/hr ) ------ --- Temperature (°C) --- Inlet Initial Final Diff %Change Initial Final Diff CR8 65.44 65.70 0.26 0.39 171.65 172.53 0.88 ** Splitter Results ** Unit Stream Initial Final Minimum Maximum Split1 CR4 0.4000 0.6943 0.0000 1.0000 CR6 0.6000 0.3057 0.0000 1.0000 ** Exchanger Temperatures and Flowrates ** Exchanger -- Exit temperatures (°C) -- ---- Flowrates (kg/hr) ---- Name Shell Tube Shell Tube E-201AB 159.02 141.62 447003.1 475141.6 E-202 173.92 147.78 447003.1 475141.6 E-206AB 169.29 175.58 329883.7 138931.1 E-210EF 173.07 179.85 33994.7 145257.8 E-111CD 216.82 175.16 528056.5 475141.6 E-523 186.03 206.99 237570.8 37066.8 E-232A 302.04 182.47 33994.7 237570.8 E366AD 210.61 215.78 146678.3 475141.6
Calculation Histories This report summarises the Reconciliation and/or Fouling and/or NFIT results for all cases within a range you select. It is particularly useful for troubleshooting data errors.   The report here shows a range of Data Reconciliation results, including some failed cases. You can choose to display all cases or just failed cases.	MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 08/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached ** MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 09/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached ** ** ERROR - Temperature crossover in unit E-206AB Cold in = 116.57 Hot out = 96.50 MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 10/07/2000 ============================================================================ ** Reconciliation Complete - Sum of squares does not change ** ** Warning - Flowrate of stream VGO1 is zero ** Warning - Flowrate of stream VGO1 has reduced by more than 90% MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 11/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached ** ** ERROR - Temperature decreases on both sides of E-206AB MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 12/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached ** ** ERROR - Temperature decreases on both sides of E-206AB MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 13/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached ** ** ERROR - Temperature crossover in unit E-523 Cold in = 170.32 Hot out = 167.42 MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 14/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached ** MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 15/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached ** MONITOR E5.136 Heat Exchanger Network Monitoring Network: Metric Crude Workbook.mon Data Reconciliation Case: 16/07/2000 ============================================================================ ** Reconciliation Complete - Solution reached **
Plotted Output
For monitoring over a time period, by far the most meaningful form of output is that presented in graphical format. There are a number of standard, predefined reports. You may also define your own reports to include the parameters, units and/or streams that you require. The data for the selected report are written to a text file which is then opened automatically in Excel. A plot is created for each set of data in the spreadsheet. You may then modify and save the workbook or copy plots or data into other applications. The standard reports are:
Reconciliation This report compares results for data reconciliation over the range of Cases. It shows: the initial duty imbalance for target exchangers and the initial and final duties on the shell and tube sides for each exchanger. changes in flowrate and temperature of feed streams.
Heat Transfer This report contains heat transfer data for all the exchangers in the Network and any normalised furnace inlet temperatures. For each exchanger there are plots for: duty fouling U-values .. clean, actual and normalised tube velocity shell velocity effectiveness
Fouling Cost This report shows the additional costs incurred when a furnace makes up the duty lost because of fouling.  The spreadsheet plots the following on separate worksheets: The normalised furnace inlet temperature. The Cost/day of the additional furnace duty required to make up for the network duty loss caused by the current level of fouling. The cumulative additional furnace duty required since the start of the specified period.  The cumulative fuel cost of the exchanger fouling since the start of the specified period.
Stream Temperatures This report shows the temperatures of all streams in the Network.  Feed streams, product streams and internal streams are presented separately and are plotted on separate worksheets. Compare this plot of the actual furnace inlet stream temperatures with the normalised plot abov.  This shows the benefit of normalisation to give a more meaningful presentation of the true effect of fouling.
Weight and Volume Flow Rates These two reports show the weight and volume flowrates of all streams in the Network. Feed streams, product streams and internal streams are presented separately and are plotted on separate worksheets.
	Weight Flowrates
	Volume Flowrates
Pressures The pressure at the inlet and outlet of each exchanger is listed on this report along with pressure drops. The plots for each exchanger are on separate worksheets and show: Shell side inlet and outlet pressures Shell side pressure drops Tube side inlet and outlet pressures Tube side pressure drops
User Defined Spreadsheet Outputs If none of the standard spreadsheet reports meets your requirements, you may define your own reports. You may specify a Exchanger duty, U (actual and clean), fouling factor, velocities, Re, temperatures, MTD, LMTD and Ft. Pump duty, heater and cooler temperatures and splitter ratios. Stream temperatures, pressures, flowrate and liquid fraction.

EHSQ (Environment,Health,Safety and Quality)