MAIN UNIT ASSEMBLYTHERMOPAC

Shell Thermia B

DEAERATOR CUM EXPANSION TANKDEAERATORBUFFEREXPANSIONINSULATION

Best performer in most demanding conditions

Shell Thermia B

TsTfHEAT SOURCETf - (FLUID) FILM TEMPERATURETb - (FLUID) BULK TEMPERATURETs - (TUBE METAL) SKIN TEMPERATURETb

Best performer in most demanding conditions

Shell Thermia B

Fluid Flow & Heat Transfer CoefficientsOn Heat Transfer effect of

Fluid velocitySurface texture

is very important

At slow speeds over smooth surface,flow is usually laminar.

Best performer in most demanding conditions

Shell Thermia B

Fluid Flow & Heat Transfer CoefficientsAt Higher speeds with rougher surfaces, condition of turbulent flow will arise.

To achieve maximum rates of Heat Transfer it is important to encourage Turbulent flow irrespective of whether the fluid is absorbing or discharging the heat.

Best performer in most demanding conditions

Shell Thermia B

ABCXYZABC is Temperature GradientXYZ is Velocity GradientFlow characteristics and Velocity/ Temperature Gradients

Best performer in most demanding conditions

Shell Thermia B

THERMIC FLUID SELECTION CRITERIA 1. Operating experience2. Operating Hazards :Toxicity, explosiveness & flammability.3. Handling problems4. Availability and cost

Best performer in most demanding conditions

Shell Thermia B

THERMIC FLUID SELECTION CRITERIA 5. Bulk / Film temperatures.6. Thermal properties :Specific heat, conductivity, Heat transfer coefficient7. Degradation rate.8. Pumping properties

Best performer in most demanding conditions

Shell Thermia B

Requirements from a thermic fluid

Low solidification temperature.Good thermal stability.Low viscosity over the whole temp. range (also in the start-up condition).Good heat transfer properties.High specific evaporation enthalpy (when used as vapours).

Best performer in most demanding conditions

Shell Thermia B

Requirements from a thermic fluid

Low corrosion tendency for the materials of the apparatus Non toxic and non - smelly.Low sensitivity to impurities (e.g.. oxygen).Low fire risk.Low risk to the environment on leakage.Possibility of easy destruction (passing used material into the natural circulation circuit).Economy of operation

Best performer in most demanding conditions

Shell Thermia B

Heat Transfer Fluid RequirementsGood Thermal StabilityHigh Heat Transfer CoefficientsLow Vapor Pressure at Operating TemperaturesLow Viscosity to ease the Propagation of Turbulent FlowNon Corrosive to metalsNon toxic

Best performer in most demanding conditions

Shell Thermia B

Chemical CompositionMineral oils are mixture of hydrocarbonsAlkanes: Have carbon atoms arranged in straight or branched chains.Cycloalkanes: Contain some rings of carbon atoms.Aromatics:Contains rings of carbon atoms but a lower proportion of hydrogen than cycloalkanes.

Best performer in most demanding conditions

Shell Thermia B

Chemical CompositionIn addition, mineral oils may also contain small quantities of hetero atom compounds (sometimes known as asphaltenes) - organic compounds which contain elements like oxygen, nitrogen and sulphur.

Best performer in most demanding conditions

Shell Thermia B

Chemical CompositionViscosityIndexOxidationStabilitySolvencyBoundaryLubricationAlkanesAromaticsCycloalkanesAsphaltenesHighestMost ResistantWorstWorstBestBestLeast ResistantLowest

Best performer in most demanding conditions

Shell Thermia B

Base Oils and Fluid PerformanceVISCOSITYSURFACE ACTIVITYSOLVENCYVOLATILITYOXIDATIONSTABILITYPUMPABILITY, LOW TEMP. PROPERTIES, ENERGY LOSSES, PUMP WEAREMULSIFICATION, METAL CORROSIONSEAL COMPATIBILITYOIL CONSUMPTION, THICKENING, DEPOSIT FORMATION, VAPOUR PRESSUREDEPOSIT FORMATION, OIL THICKENING, ACIDITY BUILDUP, CORROSION OF METALS

Best performer in most demanding conditions

Shell Thermia B

ViscosityViscosity increases with oxidation.Viscosity decreases with thermal cracking.Viscosity affects turbulence of flow.Viscosity at operating temperature is more important.

Best performer in most demanding conditions

Shell Thermia B

Flash PointLowering of flash point is indication of something wrong but not necessarily dangerous.Method of sampling is very important.Sustenance of flash point during operation is very important from safety view point.

Best performer in most demanding conditions

Shell Thermia B

Flash PointCOC (IP36/ASTM D 92) or IP 35PMCC (IP 34/ ASTM D 93)Difference between the two flash points will be typically 15 0 CRepeatability difference: +/- 70 CReproducibility difference:+/- 160 C

Best performer in most demanding conditions

Shell Thermia B

Oxidation StabilityEffect of Oxygen (or Air) on oil propertiesVarious component of oil vary in oxidation resistance.Modern refining removes components with low oxidation resistanceHigher the temperature higher will be rate of oxidation Copper & its alloys are catalysts for oxidation

Best performer in most demanding conditions

Shell Thermia B

Oxidation StabilityOxygen attacks hydrocarbons to form unstable peroxide derivatives.Some unstable peroxides further react to form acidic products which are oil soluble.Some form non soluble gum and sludge.Acidity and insoluble matter is measure of oxidation of oil.

Best performer in most demanding conditions

Shell Thermia B

Oxidation StabilitySevere oxidation results in viscosity increaseOxidation in Heat transfer system takes place mainly in DE tankPump may suck air causing oxidationRecharging of leaked fluid is also a source of oxidation

Best performer in most demanding conditions

Shell Thermia B

Thermal StabilityMineral oil is complex mixture of hydrocarbons varying in structure and molecular weight each with its own characteristic breakdown temperatures.Cracking is rupture of a carbon-carbon or carbon-hydrogen bond.Cracking reduces viscosity.Cracking reduces flash point.

Best performer in most demanding conditions

Shell Thermia B

Thermal StabilityLower weight molecular join to make heavy molecules which appear as deposits

Deposits lower heat transfer efficiency

Best performer in most demanding conditions

Shell Thermia B

Other PropertiesVapour Pressure: It is function of volatilityPour Point:Important for initial startupDensity : For designing thermic fluid systemSpecific Heat CorrosivenessFire Point

Best performer in most demanding conditions

Shell Thermia B

Specific Heat varies from 0.45 at 30oC to 0.70 at 300oC. Unit : Kcal/Kg

FLASH POINT of fresh oil =200 to 235oCFIRE POINT =Flash Point + 30oCSpecific Heat & Fire Point

Best performer in most demanding conditions

Shell Thermia B

Boiling Point Temperature at which change of phase takes place.330o to 371oCBoiling point can vary from 330o to 371oC

Best performer in most demanding conditions

Shell Thermia B

Thermic Fluid degradationParticulate fouling :Deposition of suspended matterReaction fouling :Cracking, coking, polymerisationSolubility fouling :Deposition of Dissolved solids

Best performer in most demanding conditions

Shell Thermia B

CONTAMINATIONProcessMaterial

Corrosion Products

Lubricants

Sludge

Water

Cu + Cu AlloysThermic FluidDegraded ThermicFluidMixing differentbrands of Thermic Fluids

Best performer in most demanding conditions

Shell Thermia B

Thermic fluid degredation processOXIDATION

+

CRACKING

+

CONTAMINATIONLOWERVISCOSITY+

LIGHTER HYDROCARBONS

+LOWER FLASHPOINTFORMATIONOF DEPOSITS

Best performer in most demanding conditions

Shell Thermia B

Thermic fluid degradation Oxidation

Temp > 100oC + O2 > O2 > Temp

Cracking

C-C-CC-H-CHCarbonaceousResidueAcceleratesDegradationcccccccccccTemp

Best performer in most demanding conditions

Shell Thermia B

THERMIC FLUID DEGRADATIONMAJOR FACTORSOxidation - Exposure to airCoking - High film temperatureFormation of low boilersThermal cracking Dehydrogenation - gas formationReaction with foreign matter

Best performer in most demanding conditions

Shell Thermia B

MERGER OF STRENGTHSBHARAT SHELL LTD.SHELL IS WORLD LEADER IN PETROLEUM SECTORLONG EXPERIENCE AND INDEPTH UNDERSTANDING OF THERMIC FLUIDSCOUNTRY WIDE NETWORKLONG TERM PLANS IN INDIA

Best performer in most demanding conditions

Shell Thermia B

MERGER OF STRENGTHSTHERMAX LTD.PIONEERS IN THE FIELD THERMIC FLUID HEATING TECHNOLOGYSUBSTANTIAL MARKET SHARE IN THERMIC FLUID HEATERSEXPERIENCE IN VARIETY OF HEATING MEDIA AND FUELSWIDE SALES & SERVICE NETWORK

Best performer in most demanding conditions

Shell Thermia B

BENEFITS OF TIEUPTO CUSTOMERS

JOINT GUARANTEE FROM OEM & OIL SUPPLIER--PEACE OF MINDMOST COMPATIBLE PRODUCTS-- BEST PERFORMANCEINTEGRATED PACKAGE OF PRODUCTS AND SERVICES-- CONVENIENCE

Best performer in most demanding conditions

Shell Thermia B

SOME OPERATING CHALLENGESUNCONTROLLED MIXINGINERT GAS BLANKETING NOT THEREDE TANK TEMPERATURE IS HIGHOPERATING TEMPERATURE VARIES BY 10 TO 20 DEG C.LACK OF PERIODIC OIL ANALYSIS PROGRAMMEABSOLETE CRITERIA FOR DISCARDING OILPILFERAGE/ MIXINGPOOR RECORDING PRACTICES

Best performer in most demanding conditions

Shell Thermia B

SOME OPERATING CHALLENGESSPURIOUS PRODUCT TOPUPPOOR OPERATING KNOWLEDGEREPORTING OF COMPLAINTS UNSTRUCTUREDCOLLECTION & TRANSPORTATION OF SAMPLES VERY POOR

Best performer in most demanding conditions

Shell Thermia B

HOW DOES SHELL THERMIA B TAKE CARE OF THESE OPERATING CHALLENGESUNCONTROLLED MIXINGINERT GAS BLANKETING NOT THEREDE TANK TEMPERATURES HIGHOPERATING TEMPERATURE VARIATION BY 10 TO 20 DEG CTEST BEFORE MIXINGINBUILT FACTOR OF SAFETYHIGH ON ANTI OXIDATION PROPERTYINBUILT FACTOR OF SAFETY

Best performer in most demanding conditions

Shell Thermia B

HOW DOES SHELL THERMIA B TAKE CARE OF THESE OPERATING CHALLENGESCONTD.LACK OF PERIODIC OIL ANALYSIS PROGRAMME

ABSOLUTE DISCARD CRITERIAPILFERAGE/ MIXINGPOOR RECORDING PRACTICESSHELL CAREON TRENDS GIVEN BY SHELL CARE.DEDICATED TRANSPORT VEHICLESSHELL CARE OCM CUSTOMER EDUCATION

Best performer in most demanding conditions

Shell Thermia B

HOW DOES SHELL THERMIA B TAKE CARE OF THESE OPERATING CHALLENGES..CONTD.SPURIOUS PRODUCT TOPUPPOOR OPERATING KNOWLEDGEREPORTING OF COMPLAINTS UNSTRUCTUREDCOLLECTION & TRANSPORTATION OF SAMPLES VERY POOR

SHELL CARE MONITORINGCUSTOMER TRAINING COMPLAINT HANDLING SYSTEM

SHELL CARE KIT

Best performer in most demanding conditions

Shell Thermia B

Best performer in most demanding conditions

Thermia BDENSITY AT 150 0.868FLASH POINT COC 2100CVISCOSITY AT 400 25 CST AT 1000 4.65 CST AT 3000 0.5 CSTPOUR POINT -90 CTHERMAL EXP/ 0C 0 .00076NEUTRALIZATION NO.(mg KOH/g) 0.05

PLUS EDENSITY AT 150 0.868FLASH POINT COC 2100CVISCOSITY AT 400 25 CST AT 1000 4.65 CST AT 3000 0.5 CSTPOUR POINT -90 CTHERMAL EXP/ 0C 0 .00076NEUTRALIZATION NO.(mg KOH/g) 0.05

SHELL THERMIA

BEST PERFORMER IN MOST DEMANDING CONDITIONS

Shell Thermia B

SERVICES INBUILT CONDITION MONITORING PROGRAM (Shell CARE) APPLICATION ADVICE WIDE SALES & SERVICE NETWORK CUSTOMER EDUCATION & TRAINING COMPLAINT HANDLING

Best performer in most demanding conditions

Shell Thermia B

CUSTOMER BENEFITS

COST SAVINGS. CONVENIENCE

PEACE OF MIND

SHELL THERMIA

Best performer in most demanding conditions

Shell Thermia B

CUSTOMER BENEFITSCOST SAVINGSREDUCED FLUID CONSUMPTIONLONG OIL LIFELOW WASTE OIL DISPOSAL COSTSLOW PRODUCTION LOSSESAVOIDANCE OF USE OF COSTLY SYNTHETIC PRODUCTS

Best performer in most demanding conditions

Shell Thermia B

CUSTOMER BENEFITSCONVENIENCE

WIDE SALES & SERVICE NETWORKSINGLE POINT OF RESPONSIBILITY

Best performer in most demanding conditions

Shell Thermia B

NATIONWIDE NETWORK110,000 mt p.a LOBPLOBP,

TALOJAC&F,DEPOTS40 C&F, LOCATIONS90 THERMAXDEALERSALL INDIA THERMAX & BSL SALES FORCE

Best performer in most demanding conditions

Shell Thermia B

CUSTOMER BENEFITSPEACE OF MINDMAJOR OEM APPROVALINBUILT CONDITION MONITORING PROGRAMSHELL R&D AND BACKUPSAFE TO USEGUARANTEED BY SHELL & THERMAX JOINTLY

Best performer in most demanding conditions

Shell Thermia B

All Oils are not the sameSo what ? What is in it for me ?Shell Thermia B

Shell Thermia B

Open Market MixExtraction Co.Refining Co.Base Oil Spot MarketSN 100, 150, 500, BSYENXYZABCDOilsOils

Shell Thermia B

Shell Base OilsExtraction Company Refining Company Blending Plant Shell Oils

Shell Thermia B

Does Variability really matter ?

Shell Thermia B

Does Variability really matter ?

Shell Thermia B

Non variable FormulationVertically Integrated PropositionExclusive non variable formulation 19 base oil parameters defined & controlled

Shell Thermia B

Potential ProblemsLow Temperature PerformanceEngine WearFatigueCorrosionOil LifeDeposit formationStorage StabilitySeal CompatibilityFoaming, Emulsification & Air ReleaseEnergy Loss

Shell Thermia B

SHELL THERMIA B : Key characteristicsBulk Temperature upto : 3200CFilm Temperature upto : 3400CDensity @ 150C : 0.868Flash point (COC) : 2100CKin Viscosity @ 400C : 25 cSt @ 1000C : 4.65 cSt @ 3000C : 0.5 cStPour Point : -90C Thermal Expansion/0C : 0.00076Neutralization Number : 0.05 mg KOH/g

Best performer in most demanding conditions

Shell Thermia B

Shell Thermia B

FEATURES

Benefits for you

High Oxidation Stability

Longer oil life and higher heat transfer characteristics

High Thermal Stability

Lower top ups, hence lower Thermic fluid consumption

Better Viscosity -Temperature Characteristics ( See Graph)

Promotes turbulent flow for better heat transfer efficiency

Higher fresh oil Flash point

Lower top up and longer life of oil.

Higher Specific heat Temperature behaviour

Greater heat carrying capacity- better efficiency of heater

Higher Thermal conductivity

Higher rate of heat transfer across temperature gradient.

Lower Pour point

Higher level of refining, hence better Thermic fluid.

Shell Thermia B

Shell CARE

Best performer in most demanding conditions

Shell Thermia B

Shell Lube Analyst : .What is it ?! Oil condition monitoring programInterpretationDiagnosisRemedial Action

Best performer in most demanding conditions

Shell Thermia B

Shell Lube Analyst : .Why ?!Trend analysisUniform testing facilitiesMonitors equipment conditionOnly where the oil is in contact with parts

Best performer in most demanding conditions

Shell Thermia B

Shell Lube Analyst : .How?!Sample courier infrastructureExpert diagnoticiansQuick Reports (within max 72 hours)

Best performer in most demanding conditions

Shell Thermia B

Shell Lube Analyst : .How?!Welcome KitClearly defined & controlled processWorld class testing facility

Best performer in most demanding conditions

Shell Thermia B

Shell Lube analyst CARE limits for in-service heat transfer oil

Best performer in most demanding conditions

Shell Thermia B

All Shell Thermia customers

2 tests per year without any costs

One time registration fee: Rs. 1500 /- only

RegistrationsTSFs, TSRsDirectShell Lube Analyst : .for me ?!

Best performer in most demanding conditions

Shell Thermia B

Shell Lube Analyst - How does it operate ?!

Best performer in most demanding conditions

Shell Thermia B

Feed back on oil condition Minimize unscheduled shut downsOptimization of oil life in the system Increased equipment availabilityPeace of MindLOW COST OF OPERATION - IT SAVES YOU MONEY Benefits of Shell Lube Analyst

Shell Thermia B

BENEFITS OF SHELL THERMIA B PROPOSITIONMOST RELIABLE PRODUCT FOR INDIAN WORKING CONDITIONS

Shell Lube Analyst + NO ADDITIONAL COST + DIAGNOSIS & REMEDY BY EXPERTS + WORLDCLASS OCM PROGRAMME + 72 HOURS TURN AROUND TIME

Best performer in most demanding conditions

Shell Thermia B

SERVICES INBUILT CONDITION MONITORING PROGRAM (SHELL CARE) APPLICATION ADVICE LOGISTIC SUPPORT AVAILABLE ANYTIME BY SHELL STAFF CUSTOMER EDUCATION & TRAINING COMPLAINT HANDLING

Best performer in most demanding conditions

Shell Thermia B

Total solution ProductServiceLogistics

Best performer in most demanding conditions

All physical parameters may be the same but still an oil will be different.Crude oil Cos will sell to Refining Cos and they will sell base oils depending the supply demand variances in the open market. Pure Trading for the best price. Most lubricant companies today have a certain style of functioning. They buy their oils from a refinery that is not their own. They ship these oils using another companies pipelines or vessels and their trucks are not always tamperproof. With this change of hands they risk a loss of quality at each and every stage.

.Exploration : All the way from Exploration to Delivery we have total control over every process that goes into making the purest Lubricant for the Customer..Refining :Since base oil is the major constituent in any lubricant and especially in thermic fluids, their quality is critical for high performance. Shell Companies have a stringent system of assessing and approving base oils and have over 20 approved refineries around the world to supply the base stocks for our Thermic Fluids. While there are over 70 refineries in the world from Shell..Base oils : Bharat Shell does not use rerefined oils as base stocks since they would fall short of our international quality standards.. Transportation : Shell Approved Sea vessels are used for importing base oils. The entire Vessels voyage history and performance are assessed by the Shell Shipping company. BSL follows detailed Testing procedures before accepting the cargo for discharge into our shore tanks. Top Middle and Bottom (TMB) sampling is done for each compartment of the vessel is done. No remnants of earlier unloading can contaminate the pipeline. Trading of base oils is based on 3 parameters. This does not look at the inside story. You could get a product cheap because of Suppliers constraints like high inventory or financial pressure, or it may be and more likely so because it is a poor product.The top slide shows the criteria that is considered in yellow and orange in the open spot market.Paraffins have higher Pour point,compared to naphthenes but Paraffins show better oxidation and thermal stability and more preferred for Thermic fluids. But paraffins with lower pourpoints due to better refining are the best product. S2( 0.02%) is important for TFs as it is a natural antioxidant. If the oil is hydrotreated, this % reduces. Hence now it is preferred to use Solvent Neutral refined Base oils. N2 is higher in Naphthenes forms nitrous derivatives like Nitrous Oxides and forms deposits. Not preferred in TFs. The % of Mono aromatics and Di -aromatics and Poly-aromatics in a base oil adverse to TF applications. The lower the better. Not preferred inTFs.Straight chain Paraffin content is most preferred in TF base oils. Most stable to Oxidation & Thermal Cracking.

Branched Paraffins and Flash point we have already Covered. Branched chains compared to straight chains are less stable to Heat. So we would prefer a source of base oil which would give a higher % of Straight chain in ParaffinsFree Acids in the base oil are also not preferred. Organo acids - all add up to the initial level of acidity which would accelerate rate of oxidation. Total polar content - Basically the property which describes the oils ability to absorb additives. Its important for naphthenic oils( for refrigeration/ cutting oils - Not preferred in Thermic fluids, as they destabilise bonding.Residual carbon should be very low, as they will coagulate with the carbon depositing in the system - Affects heat transfer efficiency and filtration.Oxidation performance - Thermal oxidation stability test( TOST) : Higher is better as lesser topup.Air release and demulsibility is a property important for turbine oils- To avoid cavitation. Not of importance in Thermic Fluids.

Shell has direct control from The Exploration of crude oil to the blend of lubricants. Shell Products across the world are non variable. The quality of product manufactured in Bangladesh or the UK would be the same, as it would follow the same stringent norms laid down by Shell LQS ( lubricant quality standards). For Thermic fluid applications the ones marked in red are the main problems. The cost cannot be compared in Rupees per litre. But in number of mandays and production stoppages and fuel costs.Oxidation stability and thermal stability are genetic to the base oil. We have already seen the difference in sourcing of base oils can make for these properties. The oxidation stabilitythe Thermal stability The physical parameters shown are something which translated directly in front of the customer. Like Higher fresh oil flash point : Lower top ups is the obvious indication. Longer life as the datum level is higher.Variation of Viscosity with Temp. Graph : Correct viscometrics promotes turbulent flow implying better heat transfer-- Pumping costs lower - Energy savings !! Fuel savings !!!5% Higher specific Heat ensures higher heat carrying capacity for same temp gradient. More heat transfer Better efficiency.Thermal conductivity : 7% Faster heat transfer and thus lesser production times. All this leads to one thing : we dont talk to customer on price. We talk on production cost per ton. We cannot quantify this any more as this is different for each customer. Fuel costs,size of system, temperature required etc, But we can ask customer to roughly approximate benefits for his system.