Engineering Precision Without Borders

By ZB International

In today’s industry, the complexity of engineering problems is rising—but so is our ability to solve them across geographies. Thanks to digital collaboration, engineering precision now transcends national borders.

In this case study, we explore how a team of remote experts from Thailand and India solved a complex heat exchanger sizing and layout optimization challenge during a brownfield expansion at a chemical plant. What unfolded was a remarkable example of how remote teamwork, advanced design tools, and shared technical expertise can create real-world impact.

The Problem: A Choking Bottleneck in Plant Throughput

A large chemical processing plant in Thailand faced a growing issue. Its distillation unit was hampered by an undersized overhead condenser, a shell-and-tube heat exchanger that couldn’t handle the required vapor load. The result: unstable column pressure, off-spec product, and reduced throughput.

Initial analysis by the local team indicated that a 20% increase in heat duty was required. But retrofitting the exchanger wasn’t straightforward. Space was constrained, and any design changes needed to comply with ASME standards while ensuring integration with existing utilities and pipe racks.

Recognizing the need for deeper thermal and mechanical expertise, the Thai team reached out to a trusted partner engineering group in India—setting the stage for a cross-border engineering alliance.

The Global Team: India & Thailand Unite

With engineers from two countries, the team included process engineers, mechanical designers, and layout specialists. Despite being based in different time zones, the collaboration ran seamlessly due to three key strategies:

• Video Calls via MS Team and Zoom: Regular online meetings with screen sharing allowed real-time discussions on process flows, datasheets, and 3D models.
• Shared Cloud Workspaces: Secure platforms enabled both teams to upload and co-edit P&IDs, simulation outputs, and layout drawings.
• Time-Zone Collaboration: With only a 1.5-hour difference between India and Thailand, teams scheduled handover calls daily, allowing for continuous work cycles and rapid progress.

Tools of the Trade: From Simulation to Design

The cross-border team deployed industry-standard tools to tackle the challenge holistically:

• HTRI for Thermal Design

Using HTRI Xchanger Suite, the team tested various configurations—modifying shell diameters, baffle cuts, and tube passes—to maximize heat transfer within limited space. An optimized design emerged that met performance targets while staying within plot constraints.

• CodeCalc for Mechanical Checks

Thai mechanical engineers validated pressure thicknesses, nozzle reinforcements, and flange ratings using CodeCalc (part of the PV Elite suite). Cross-verification by the Indian team ensured compliance with ASME Section VIII Division 1.

• CAD-Based Layout Review

The 3D plant model was reviewed live on MS Team and Zoom. To accommodate the new exchanger footprint, layout engineers proposed rotating the equipment and rerouting a pipe rack—minimizing structural modifications and avoiding interference with maintenance access.

Multitier Verification: No Room for Error

Given the criticality of the equipment, the project underwent multiple layers of review:

• Peer Review: Design outputs from HTRI and Aspen were cross-checked by engineers from both teams.
• Expert Advice: A senior thermal consultant joined via Skype to validate the design and suggested an enhanced baffle arrangement for improved efficiency.
• Client Walkthrough: Thai plant managers reviewed the layout using a shared 3D model. Operational feedback was incorporated into the final design.
• On-Site Travel: One Indian mechanical expert traveled to Thailand for the tie-in and commissioning phase—bridging the gap between paper and plant.

Results: Throughput Up, Energy Down

The new heat exchanger was fabricated and installed within six weeks. After startup:

• Plant throughput improved by 15%, reducing bottlenecks.
• Pressure swings were eliminated, ensuring more stable distillation.
• Cooling utility loads were optimized, resulting in energy savings.
• Operators praised the improved layout accessibility and maintenance visibility.

Lessons Learned: Engineering Without Borders

This project proved several truths for modern plant design:

Global Engineering Works: Tapping into expert networks—even across borders—accelerates problem-solving.
Digital Tools Enable Precision: Simulation software like Aspen and HTRI aren’t just tools—they’re bridges between design and reality.
Remote Doesn’t Mean Distant: Regular communication, screen sharing, and cultural respect build trust across teams.
Physical Presence Still Matters: For critical tie-ins, expert travel remains valuable.

Conclusion

As the chemical industry evolves, so must our methods of collaboration. This case stands as a testament that engineering precision is no longer limited by geography. Whether you’re in Bangkok or Bangalore, the ability to bring together specialized minds through digital platforms is redefining how we solve the toughest plant challenges.

In an increasingly interconnected world, the future belongs to those who can engineer without borders.