Steam is critical to many oil refinery processes. For example, it’s used in fractionating towers, steam-cracking processes and steam reforming. In addition, steam is used in heat exchangers to provide thermal energy for nearly every process in the refinery.
Although steam systems are typically quite reliable, they must be properly maintained. This can place considerable pressure on an in-house maintenance staff that may have experienced personnel reductions or lost employees with steam engineering knowledge and experience. Many factors can affect maintaining a steam system at its optimum efficiency levels.
A large refinery in the Gulf Coast region of the U.S. realized the need for — and importance of — an on-site partner to take ownership and responsibility for its entire steam system and to ensure optimum steam system productivity, energy efficiency, safety and compliance be attained. The refinery chose Spirax Sarco as on-site partner.
The on-site partnership between the refinery and Spirax Sarco involved the implementation of a Spirax Sarco Steam System Asset Management program. Components of the program included steam trap management, steam and condensate leak management, and steam system optimization. To execute the program, Spirax Sarco provided the resources and expertise necessary to achieve the results expected from steam system optimization.
Spirax Sarco engineers work with plant personnel to implement steam system improvements and help maintain the resulting performance gains. Steam System Asset Management program solutions can include the design and implementation of system efficiency improvements, the supply and installation of replacement products and parts, and total steam system management. Services fall into three main categories: surveys and audits, installation and service, and engineering and design.
Audit identifies challenges — and opportunities
Before developing an asset management partnership, a steam system audit must be performed. If properly executed, an audit does more than just expose problems; it seeks to identify areas in a steam system where improvements can be made in reliability, performance and cost-effectiveness. An audit establishes the scope of initial work required to correct as-found problems and creates a baseline for optimum steam system performance. In addition, the audit allows Spirax Sarco to generate a tactical road map to identify, evaluate, prioritize and resolve steam system issues, as well as other opportunities for steam system improvement.
The program at the refinery initially targeted failed-open steam traps and steam leaks that were wasting steam energy, failed-closed steam traps that posed an operational and safety concern due to the potential for waterhammer, and other utility leaks from compressed air and nitrogen services. Before the refinery had implemented the Steam System Asset Management program, waterhammer had caused severe damage in the refinery. This situation was the primary motivation for addressing steam trap failures — especially those that had failed-closed.
Proof in numbers
As the program advanced, the number of failed-open steam traps decreased, which is typical when regular steamtrap maintenance is performed and steam system best practices are followed. Within a four -year period, the failed-open steam trap failure rate dropped from 7 percent to 3.6 percent. The failed-closed steam trap failure rate on steam mains drip applications dropped from 8.3 percent to only 0.6 percent.
In addition to saving steam energy operating costs, the work performed under the Steam System Asset Management program significantly reduced the potential for waterhammer in the steam distribution lines and the associated concern of system failure and safety incidents.
The Spirax Sarco Steam System Asset Management program saved the refinery more than $9.3 million annually because of the reduction in steam, compressed air and nitrogen consumption. So far, the cumulative savings are even higher: more than $23.4 million.
Because of the tremendous success of this partnership, the petroleum company is considering the Steam System Asset Management program at its other refineries.
For more information, visit www.Spiraxsarco.com or call (800) 883-4411.
