Case Study: Ultimus Engineering redesigned a line heater to meet changing and unexpected operating conditions originally designed by another engineering firm. The more appropriately sized water bath increased efficiencies by 25%.
The Client: The client, a premier oil and natural gas company engaged in the exploration, development, and production of natural gas and oil in the Appalachian presented a need for a more efficient heat exchanger. As a largely integrated organization, they closely monitored their well conditions, and when things changed, they sought an expert in processing equipment.
The Goals: Ultimus Engineering was tasked with process condition analysis, engineering design, and manufacturing and assembly drawings for a workover line heater.
The Challenge: The equipment was originally designed by a different company, and after the operating conditions changed, the customer turned to Ultimus to help resize a more appropriate water bath. The new heat exchanger needed to stay within certain footprint requirements, both on the skid, and under the separator vessel. Additionally, inlet and outlet elevations were hard spec’d to be able to hook up to existing equipment.
The Results: After the design and implementation of the new water-based heat exchanger, a 25% increase in efficiency through reduced energy consumption and increased throughput was obtained. Full process condition evaluations dictated different sized internal piping and a new firetube size. The client retained Ultimus to also design and draft the fabrication drawings as well as 3D model to confirm compatibility with the existing equipment. Ultimus was able to work with existing drawings and models to make sure the design was correct, and the installation was seamless.