Introduction of

Plant Diagnosis and Lifetime Improvement Service

Enhancing planetary health​

JGC Corporation
EN Technology Center
April, 2022
 Outline of PLANT PLUS

• PLANT PLUS is JGC’s Comprehensive Engineering Service which has been developed to support the needs
and to resolve the concerns of the existing plant owners across the world, and based on more than 1,000
plant diagnosis and improvement experiences for 50 years

• PLANT PLUS is comprised of four core technologies:

 Computational Fluid Dynamics (CFD)
 Structural Analysis
 Materials & Corrosion
 Acoustic Engineering

• PLANT PLUS can offer a variety of effective solutions for existing plant owners.
 Improve operational efficiency
 Reduce and eliminate operational risks
 Predict defects across the plants
 Propose plant modification plan in accordance with the most up-to-date technologies and standards

© 2022 JGC GROUP ​Enhancing planetary health 2

 Core Technologies and Work Flow

CFD CLICK
HERE Materials & Corrosion
CLICK
HERE

Improvement of Facility Plant Life Extension Program

･ Efficiency of ACHE ･VOC emission ･Remaining Life Assessment
(HARView®) (VOCSIM) ･Corrosion Consulting, Materials Selection
･ Thermal Efficiency ･Energy Saving ･Inspection & Maintenance Strategy
for Furnace ･Erosion ･Reliable Repair Planning
･ Mixing Performance ･Flow Distribution ･Troubleshooting
Conditions Proposals
・Site Condition ・Stable Operation
・Operating Condition ・Economic Efficiency,
Competitiveness Improvement
Structural Integrity of Equipment Noise Assessment
・LTA/Damages ･Deformation/Failure ・Noise Survey
・Flange Leak ･ Continuous Operation ・Noise Contour Map
・ Vibration Level ・Noise Mitigation Plan

Structural Analysis CLICK

HERE Acoustic Engineering CLICK
HERE

© 2022 JGC GROUP ​Enhancing planetary health 3

 Application of PLANT PLUS

© 2022 JGC GROUP ​Enhancing planetary health 4

 Role in Plant Maintenance Lifecycle

supports strategy development and

planning for maintenance and revamp
PLAN
(Maintenance/Revamp)
Maintenance/Revamp planning
Cost estimation
Work plan preparation

ACTION DO
(Revamp/Strategy) (Maintenance/Revamp Work)
RCA Plant Maintenance Work Order
Maintenance Strategy / Lifecycle Material management
Planning of Revamp Budget control

CHECK
(Inspection・Diagnosis)
Diagnosis and analysis of
inspection record

© 2022 JGC GROUP ​Enhancing planetary health 5

 Frequently Asked Questions and Concerns

 Can our plant improve energy efficiency?

 Which improvement plan is the most efficient?
 How can we prevent failures?
 Should we replace our corroded/damaged equipment?
 How can we prevent and/or reduce vibration?

can provide solutions!

© 2022 JGC GROUP ​Enhancing planetary health 6
Examples of Improvement of Facility
- Computational Fluid Dynamics (CFD) -
Enhancing planetary health​

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 Fired Heater Improvement

Do you have any of these issues? Examples of combustion and heat transfer
analysis of Furnace (CFD)
Poor performance and unreliable operation
Reducing maintenance interval due to severe
material degradation
Need for engineering consulting partner for heater Radiant coils
modification

Fired Heater Improvement Solution

Burner
• Utilized Computational Fluid Dynamics (CFD) to simulate Combustion
and Heat Transfer
• Assessed as-installed Heater Performance based on operation data and As-installed
Wall-side Center
CFD Results
• Identified O&M Issues and their Root Causes
• Proposed and Evaluated Performance and Reliability Improvement Plan
•Burner Layout Optimization for Replacement Lowered coil skin temperature
•Windbox Modification for Uniform Air Flow Distribution to each
As-Improved
burner
• Provided the Technical Guidance for the Implementation of the
proposed solutions Analysis of Radiant Coils

© 2022 JGC GROUP ​Enhancing planetary health 8

 Fired Heater Improvement
Workflow ＆ Result Our Strengths
• Years of experience in serving domestic customers for
Gathering Information
performance improvement of fired heaters utilizing the advanced
CFD simulation
Analyzing Issues / • Extensive experience in Combustion and Heat Transfer modeling
Developing Hypothesis
and evaluating heater designs
• Collaboration with Material Engineering experts
CFD Planning/Simulation
• Customer-Focused Global Engineering Service Provider
(Design Evaluation) Improvement Ideas

CFD Simulation Our Experiences

(Design Verification)

50+ 15+
 Shorter Flame length
 More Uniform Air Distribution
Final Improved Design  Lower Coil Skin Temperature
Sufficient Heat Flux on Coils
Plants Years


Solution Implementation  Reliable Operation Fired heater design evaluation Simulation-based engineering
 Higher Performance and improvement studies with service for plant diagnosis
 Extended Life the advance CFD simulations and lifetime improvement

© 2022 JGC GROUP ​Enhancing planetary health 9

 OPTIMIZATION FOR INSTRUMENT POSITION

• A feedback loop in plant control may suffer from controllability issues caused by instrument installed at an
improper location where the flow field is not well established or uneven

• PLANT PLUS offers recommendations on optimal instrument positions for better controllability of your asset
based on our flow simulation

EXAMPLE
At thermocouple insertion position (A), fluid
After improvement Before improvement Fluid Temperature
temperature was non-uniform. On the other
hand, at thermocouple insertion position (C), Thermocouple High
the fluid temperature become uniform. Thus, VERTICAL SECTION
suitable thermocouple insertion position (C)
was proposed.
Flow direction Intersection
C
B A
HORIZONTAL SECTION Low
Low temp. High temp.
Insertion position fluid fluid
© 2022 JGC GROUP ​Enhancing planetary health 10
 SEPARATION EFFICIENCY FOR GAS-LIQUID SEPARATOR

• Our modeling approach enables us to simulate a complex flow with liquid and gas inside a separator

• PLANT PLUS offers engineering solutions to improve under-performing gas-liquid separators by our detailed
simulation technology

EXAMPLE
By appropriate direction of the inlet nozzle, inlet gas including mist was separated
into gas (blue) and liquid (red) at each exit nozzles with sufficient separation
efficiency.
High

Inlet nozzle
Exit nozzle
(gas + liquid)
(gas)

Volume fraction
of liquid

Exit nozzle
(liquid)
Low

© 2022 JGC GROUP ​Enhancing planetary health 11

 OPERABILITY IMPROVEMENT OF FIRED HEATER

• Operability of fired heaters is a primary concern. The common issues of aged heaters are hot spots, coking,
flame impingement to the heating coils, and flame stability

• PLANT PLUS can identify the potential cause of the above issues and develop solutions to improve the
operability of your heating equipment with years of experience

Coil Skin Temperature

EXAMPLE High
Estimation for distribution of heat flux and tube surface
temperature, leading to best proposal for optimization of the Radiant Coil
thermo couple position, burner selection and so on.

Burner flame Low

© 2022 JGC GROUP ​Enhancing planetary health 12

 DIAGNOSIS FOR ERODED PIPE

• Failure of a pipeline component with breakage and fluid leaks often results in expensive repairs, considerable
down time, and hazards to the plant workers. Erosion is one of the wear mechanisms that can cause such a
failure; especially around elbow, valve, and reducer carrying multi-phase flow containing solid particles or
liquid droplets.

• PLANT PLUS can assess the remaining life of the pipeline component experiencing wall thinning due to
erosion and develop solutions to extend its remaining life.

EXAMPLE
Distribution of erosion rate induced by
particles or droplets can be predicted by High High
CFD simulation with high accuracy. As a
result, the remaining life of the component
Velocity of Erosion
can be estimated. Particles Rate

Low Low
Particle Trajectories Distribution of Erosion Rate
© 2022 JGC GROUP ​Enhancing planetary health 13
 POLUTION PREVENTION

• The toxic or high temperature gas released from the stack may become a hazard to the plant workers and
possibly neighbors of the plant if they are not properly studied or there are any changes in the plant
operation

• PLANT PLUS estimates the affected area even with complex plant layout and assess its impact to the health
and environment

EXAMPLE
Based on the simulation results of flue gas
dispersion, solutions capable of preventing
4 ppm
hot and toxic gas from harming human 4 ppm
10 ppm
health and affecting plant operation can be 10 ppm
20 ppm
proposed. 20 ppm
100 ppm 100 ppm

Tower
Stack

Distribution of SO2 concentration predicted by CFD Distribution of SO2 concentration around the tower
© 2022 JGC GROUP ​Enhancing planetary health 14
 PERFORMANCE IMPROVEMENT FOR ACHE

• Hot Air Recirculation (HAR) highly dependent on local wind conditions and plant layout significantly reduces
the Air-Cooled Heat Exchanger (ACHE) performance

• PLANT PLUS offers a systematic HAR analysis package (HARview R ) to optimize the ACHE performance for the
specific local condition

EXAMPLE
- HAR CFD analysis is firstly performed to reproduce the current conditions.
- The effect of various mitigations can be evaluated by CFD analysis.
- The most effective and practical mitigation plan will be proposed. Recirculation between trains
Hot exhaust air
Cross
wind
ACHE ACHE

Self
recirculation Intake air

HAR CFD Analysis Hot Air Recirculation (HAR) Phenomenon

© 2022 JGC GROUP ​Enhancing planetary health 15
 ASSESSMENT OF FLOW DISTRIBUTION
• One of the key elements in the piping design is to properly distribute the process fluid flow as intended to
ensure that downstream equipment can function at its best performance. This becomes more challenging
with the multi-phase process fluid.

• PLANT PLUS can evaluate flow distribution within a pipeline system with multiple paths and develop
solutions, which can be applied for pipeline system found in various process plants. (for example, tournament
header of air-cooled heat exchangers (ACHE) in refinery plant and inlet piping of slug catcher in gas treatment
plant).

EXAMPLE
It is important to ensure that vapor is
distributed into each nozzle as evenly as
possible for manifold inlet piping of ACHE.
Based on the simulated flow distribution,
the header design can be improved for
more even distribution by taking counter-
measures if necessary.
Flow Distribution for Liquid (Red) Distribution of Liquid Flow Rate

© 2022 JGC GROUP ​Enhancing planetary health 16

 SUSTAINABLE/COST-EFFECTIVE VOC EMISSION MANAGEMENT

• Today’s plant owners are required to comply with more stringent environmental regulations while remaining
profitable.

• PLANT PLUS offers an optimized engineering solution to manage VOC (Volatile Organic Compounds) emission
from storage tanks by minimizing VOC recovery unit size as well as N2 usage with our advanced simulation
technology.

EXAMPLE
State-of-the-art VOC emission modeling can
predict the amount of VOC emitted from
the storage tank which needs to be
removed by the recovery unit. This
technology allows us to properly size the
VOC recovery unit so that the plant owners
can save both CAPEX and OPEX

© 2022 JGC GROUP ​Enhancing planetary health 17

Examples of Structural Integrity of Equipment
- Structural Analysis -
Enhancing planetary health​

18
 Plant Diagnosis and Lifetime Improvement Service

Do you have any of these issues? Examples of Finite Element Analysis (FEA)

Mechanical damage occurred! Stress

High
Can we continue operation? Should we replace?
What is the root cause?
Which improvement plan is the most efficient?

PLANT PLUSSM Solution Low

• JGC’s simulation-based engineering service (1) External Corrosion (2) Stress Distribution in Flange
Analysis Model by Laser Scanning Caused by Bolt Tightening
• Investigate the root cause of the mechanical damage
• Diagnose whether a damaged equipment can continue
operation or should be reinforced, revamped partially,
replaced totally
 Leads to reduced cost of repair/revamp
• Propose effective improvement/reinforcement plan
(3) Creep Deformation of Vessel during PWHT

© 2022 JGC GROUP ​Enhancing planetary health 19

 Plant Diagnosis and Lifetime Improvement Service
Workflow ＆ Result Our Strengths
Example: Large opening • Diagnosed from various perspectives such as
Data and Information Collection discovered during Turnaround
Step-1 international design codes, fitness-for-service codes,
post construction codes, guidelines often used in the
Site Survey (if necessary) plant industry, and JGC own company standards
Step-2
• Provided quantitative and easy-to-understand study
Scenario Planning: results and countermeasures using structural analysis
Root Cause, Damage Mechanism techniques such as finite element analysis (FEA)
Step-3
Improvement/Reinforcement Plan
Assessed buckling risk Our Experiences
for vessel with large hole
Plan Mitigation against Risks

1000 50+
Step-4

Assessment Results
• High Possibility Root Cause Plant Diagnoses
Step-5 Years
• Effective Solutions
Structural analysis technology, Simulation-based engineering
computational fluid dynamics service for plant diagnosis
technology and noise and lifetime improvement
assessment/control technology
Proposed reinforcement plan for 1,000+ diagnoses

© 2022 JGC GROUP ​Enhancing planetary health 20

 ASSESSMENT FOR DAMAGED EQUIPMENT
• PLANT PLUS can evaluate whether a damaged equipment (metal loss, crack-like flaws, distortions, dents,
etc.) can continue operation or not. This assessment can save the cost of replacement or reinforcement.

• JGC has much experience and knowledge of the following Fitness-For-Service codes: API 579-1/ASME FFS-1,
BS 7910, WES 2820 (The Japan Welding Engineering Society*), etc. *JGC is a committee member of this code.

EXAMPLE

① Analysis model of Local metal loss around ② Analysis model of corroded pipe and
equipment nozzle stress distribution

© 2022 JGC GROUP ​Enhancing planetary health 21

 DIAGNOSIS OF VIBRATION
• PLANT PLUS can provide the following services.
 Vibration measurement (speed, direction, dominant frequency)
 Assessment of vibration level by referring the various criteria (ISO, API, JIS or JGC company standards, etc.)
 Root cause study
 Proposal of countermeasures

• JGC has solved more than 300 vibration troubles for the following facilities.
 Rotating machines (pumps, compressors, agitators, air fin coolers etc.)
 Towers, tanks, heat exchangers
 Piping system, instruments, platforms, foundations
EXAMPLE Motor
Rotating
machine

Foundation

① Vibration response of pressure gauge ② Vibration response of rotating machine

© 2022 JGC GROUP ​Enhancing planetary health 22
 ROOT CAUSE & COUNTERMEASURES OF DEFORMATION/FAILURE
• PLANT PLUS can investigate the root cause, propose the countermeasures, and evaluate whether you can
operate continuously.
EXAMPLE
① Flange Leakage ② Deformation of Piping Support
Analyze deformation amount, generated The magnitude of the load which caused the
stress, bolt axial force, gasket surface deformation can be studied by FEA. PLANT
pressure, thermal expansion/contraction and PLUS can propose how reinforce against the
bolt fastening force load mentioned above.

High
Run pipe
Support
pipe
H-beam

”A”
”A”
Low

VIEW”A”-”A”
Temperature distribution and deformation of flange Deformation of support by elastic-plastic analysis

© 2022 JGC GROUP ​Enhancing planetary health 23

 ROOT CAUSE & COUNTERMEASURES OF DEFORMATION/FAILURE
(continued)

EXAMPLE
③ Deformation of Expansion Joint ④ Abnormal Temperature Rising, Fire Damage
Thermal expansion behavior and the load When the trouble such as abnormal
which cause the deformation can be studied temperature rising or fire occurs, PLANT PLUS
by FEA. can study the stress generated on structures
and assess the remaining life.

Deformed expansion joint

Creep rapture of furnace tube

Deformation studied by FEA

© 2022 JGC GROUP ​Enhancing planetary health 24
 EVALUATION FOR SEISMIC DESIGN
• JGC has much experience and knowledge of the seismic design.

• PLANT PLUS can evaluate the existing/aging facilities from the following view points.
 Do they satisfy the latest requirements in design code?
 What kind of modification and/or reinforcement are necessary?

• Object equipment: Tanks, Tower, Piping, Nuclear Equipment, etc.

EXAMPLE

An integrated analysis model of Deformation by

① Strength analysis of columns and tower and table top response analysis
braces of spherical tank ② Seismic response analysis
© 2022 JGC GROUP ​Enhancing planetary health 25
Plant Life Extension Program (PLEP)
- Materials & Corrosion -
Enhancing planetary health​
 Plant Life Extension Program (PLEP)

Do you have any issues about plant materials ?  TML setting at RV manifold

 Hot insulation setting up to WI point

Plant Aging  Assessment of
flow distribution
Approaching the life, material degradation is accelerating…
 Fixing flow meter
Operating Condition Changing malfunction
Conditions becoming more severe, deviating the design range…  TMS setting at
Competitiveness Stagnating condenser downstream

O&M cost increasing, maintenance intervals shortening… Example of Improvement for CDU Overhead System

PLEP Solutions
• Identification of facility and locations having
materials and inspection concerns
• Suggestion of practical and economical solutions
to solve the concerns
• Projection of revamp work, inspection and
maintenance work, etc., to extend plant life
Inspection Result and Thermal Fitness For Service about
Spray Coating for Life Extension Local Thinning Area

© 2022 JGC GROUP ​Enhancing planetary health 27

 Plant Life Extension Program (PLEP)
Workflow ＆ Result Our Strengths
1st Step: Plant Integrity Assessment (PIA)  One-stop service of engineering, construction and
Finding / Screening maintenance services to make convenient for client
 Assessment of materials selection, inspection program, etc.
 Practical and efficient approaches including workshops
 Site visit and discussion with client.
and site observations will provide best solutions
 Easy methods without special software will avoid client
2nd Step: Integrity Improvement Initiative (III)
burden
Detail Study
 Client and JGC joint team to conduct detailed plant diagnosis, and to  Flexible program will run along with client’s demands to
develop improvement strategy and action plans. the goal.

3rd Step: Life Extension Project (LEP) Our Experience

Project Development and Execution
 CDU/VDU, Asia
 The team to complete the project in line with conclusions.
83 findings / 22 recommendations
Plant Life Extension & Reliability Improvement
 Gas Processing Unit, Middle East
Result of PLEP 116 findings / 34 recommendations
 GOSP, Middle East
88 findings / 7 key recommendations

© 2022 JGC GROUP ​Enhancing planetary health 28

Noise Assessment
- Acoustic Engineering -
Enhancing planetary health​

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 Noise Assessment

Do you have any of these issues? Noise contour map

High
Noisy work environment
High costs noise mitigation for noise emitters
Need for consulting partner for noise Sound
Pressure
assessment Level

Noise Assessment Solutions

Low
• By noise survey;
Example of noise mitigation plan (acoustic insulation)
 identified noise sources
 produced noise contour maps before and after
noise mitigation plans
• Propose most effective and cost-minimum noise
mitigation plans based on result of noise simulation
• Verify the effectiveness of noise mitigation plans

Before After

© 2022 JGC GROUP ​Enhancing planetary health 30

 Noise Assessment
Workflow ＆ Result Our Strengths
• Experienced for noise assessment/control technologies to
Assessment
domestic and overseas clients for many years, and solved
Goal setting various noise problems
• Provided services for noise survey, evaluation, planning of
Noise survey & analysis countermeasures, and confirmation of effectiveness after
implementation of countermeasures
Identification of noise sources
Our Experiences
Mitigation Planning

Proposal of practical noise mitigation plans

600+ 50+
Implementation
Cases Years
Implementation of noise mitigation plans Noise assessment/control We have been accumulating
technology for 600+ cases. noise assessment/control
technologies for more than 50
Verification of effectiveness years through EPC businesses
and consulting services.

© 2022 JGC GROUP ​Enhancing planetary health 31

 If you want to know more, please feel free to contact us.

[email protected]
+81-45-682-8615

© 2022 JGC GROUP ​Enhancing planetary health 32