STEAM TRAPS ENERGY EFFICIENCY PROJECTS

OBJECT:

   ♦ Reduce steam consumption by more than 15%
   ♦ Maintain failure rate in steam traps less than 0.5%
   ♦ Reduce inspection and maintenance costs of steam traps
   ♦ Maximize efficiency of steam and condensate networks

PROJECT PHASES

Four phases are considered in projects to improve efficiency and steam savings in traps:

Its objective is to quantify as accurately as possible the total amount of steam losses due to the status of the steam traps, known as the project’s BASE LINE or steam-saving potential. There are several evaluation methods but the most reliable is applying the Masoneilan formula, approved by the United Nations Organization for CDM projects (Clean Development Mechanism – Kyoto Protocol).
Consists in analyzing the different options, in terms of the type of trap, technologies and available monitoring architectures, reliability, future maintenance cost, etc., associated with development of the project, and evaluate each of them to obtain a comparative cost-benefit study that allows to determine the viability and profitability of each option, and if appropriate, select the most advantageous option.
This phase consists of performing the detailed engineering and then executing all the construction tasks and installation works of the elements selected in the previous phase. It also includes the areas of testing, start-up, personnel training, …, corresponding to the execution of the project. Note that monitoring is necessary, but not enough to achieve the project’s objectives.
This is the most important phase and consists of analyzing the information obtained by the monitoring system and immediately taking the necessary actions to correct the steam leaks and incidents detected by the system. That is what we call “INTENSIVE MAINTENANCE”. The urgency in applying these preventive and corrective actions is fundamental to achieve the objectives of the project.

 

OUTSTANDING REFERENCES

REPSOL REFINERY - PUERTOLLANO

This refinery has been a pioneer in the world in implementing one steam saving project by using intelligent steam traps Bitherm SmartWatchWeb (year 2001). Once the excellent results were verified, they have implemented this technology in multiple Process Units. One of the greatest successes of these projects was evident in the Desulphurization and Vacuum Distillation Units, where the steam installations are very critical due to processing of solidifiable or high viscosity products. Here the enormous utility of Bitherm SmartWatchWeb intelligent steam traps has been proved, not only for the substantial steam savings achieved, but also for improvement of operating conditions and important increase in reliability one steam network in said Process Units (see reference published by REPSOL).

These projects have been developed turnkey mode by PURGADORES DE CONDENSADO SL (BITHERM Group) , including the implementation of the Intensive Maintenance Methodology in the following Process Units:

♦ Desulfurization Unit 639
♦ Desulfurization Unit 644
Desulfurization Unit 661
Vacuum Distillation Unit 624
Cocke Unit 641
Olefin unit 802
Benzene Unit 810
Lubricants Unit 701
Lubricants Unit 710
Lubricants Unit 720
Lubricants Unit 721
Lubricants Unit 731

PETRONOR REFINERY - MUSKIZ

Their first project of steam savings by intelligent steam traps Bitherm SmartWatchWeb was realized in 2010. Since then they have realized several similar projects, all of them with excellent results of increase of reliability, reduction of costs of inspection and maintenance, improvement in operating conditions and high steam savings (see reference publishedin their own website). The results have also been published in his journal "Gaztelu Berri" (read article).

These projects have been developed by BITHERM turnkey mode, including implementation of Intensive Maintenance methodology in the following Process Units:

Asphalt Unit
Desulfurization Unit SR3
Desulfurization Unit SR4
Desulfurization Unit SR5
Desulfurization Unit SR6
Vacuum Distillation Unit V3
Coke unit CK6

At the same time, the use of BiTherm Magnus multi-element steam traps has improved performance and energy efficiency of steam in their tanks and heat exchangers.(see reference).

REPSOL REFINERY - CARTAGENA

Their first steam saving project using intelligent steam traps Bitherm SmartWatchWeb was carried out in this refinery in 2006. Highlighting the excellent results of increased reliability and efficiency, reduced inspection and maintenance costs, improved operating conditions and high steam savings. These projects have been developed in turnkey mode, implementing the Intensive Maintenance Methodology in the following Process Units (see reference):

Deasphalted 2 - Unit 751
Furfural 3 - Unit 752
Dewaxing 3 - Unit 753
Vacuum 4 - Unit 754
Desulfurization Unit 685

REPSOL REFINERY - CORUÑA

In this refinery, since 2003 we have carried out several steam-saving projects using intelligent steam traps Bitherm SmartWatchWeb. Highlight the excellent results of increased reliability and efficiency, reduction of inspection and maintenance costs, improvement in operating conditions and high steam savings. These projects have been developed turnkey mode, implementing the Intensive Maintenance Methodology in the following Process Units:

Unit 1303 - Coque
Unit 1301 - Vacuum 2
Unit 1220 - PRA 3
Unit 1314 - PRA 4
Unit 1201 - Crude 1
Unit 1203 - Vacuum 1
Unit 1204 - Platforming 1
Unit 1206 - Gases 1

CEPSA REFINERY - HUELVA

Their first steam-savings project using intelligent steam traps Bitherm SmartWatchWeb was carried out in this refinery in 2013. Since then, several projects of the same type have been carried out, all of them with very satisfactory results. The failure rate in traps has been reduced to practically zero, improving the reliability of the installations. These projects have been developed turnkey mode by Bitherm Group, implementing the Intensive Maintenance methodology in the following Process Units:

Two 2 Desulfurization Units
Unit Area 7
Pipe racks and tanks areas

SAUDI ARAMCO - RAS TANURA REFINERY

This refinery has carried out in 2017 the first steam saving project using intelligent Bitherm SmartWatchWeb traps. The project has been developed in turnkey mode by BITHERM GROUP in collaboration with the local Saudi company TANAJIB.

Highlight the excellent results of increased reliability and efficiency, reduction of inspection and maintenance costs, improvement in operating conditions and high steam savings. Highlight the enormous interest of SAUDI ARAMCO to implement new technologies for energy optimization and reduction of atmospheric emissions and / or pollutants in its facilities, in accordance with its policy of sustainable growth and environmental protection.

SAUDI ARAMCO - JAZAN REFINERY

This refinery is in the construction phase. Bitherm Group in collaboration with the local Saudi company TANAJIB has supplied more than 6,000 monitored intelligent steam traps BITHERM SmartWatchWeb since 2016, for various Process Units.

Highlight the enormous interest of SAUDI ARAMCO to implement new technologies for energy optimization and reduction of atmospheric emissions and / or pollutants in its facilities, in accordance with its policy of sustainable growth and environmental protection.

LIMITATIONS OF ULTRASOUND

The detection of ultrasound has become a tool of great predictive maintenance value for the detection of gas or steam leaks in valves. However, it is necessary to know its limitations when applied to steam leak detection in steam traps, where the discharge of condensate generates flash steam that can be mistakenly interpreted as live leak.

¿WHY BITHERM...?

Our Solutions

We provide excellence in technology, innovative solutions, quality, experience and extensive references of projects carried out in Refineries and Petrochemicals over thousands of traps and steam traps, backed by excellent results and strong benefits for our customers.

Our Mission

Satisfy the expectations of our customers. We are committed to a Social Responsibility policy with a firm commitment to sustainable growth, respectful of the environment, training, health and safety.

Our Vision

The mission of BITHERM GROUP is to research, create, produce and market technological products with high added value that, in addition to satisfying the needs of the industry, contribute to the health and safety of goods and people. Our vision is to lead the intelligent solutions sector in order to provide solutions of great value to society.