Steam Consumption Reduction with Steam Trap

MonitoringCecilia Goh

Deputy General Manager of Group TechnologyDenka Chemicals Holdings Asia Pacific Pte Ltd

Jonas BergeSenior Director Applied Technology

Emerson Automation Solutions, Singapore

Denka Co Ltd (Japan)

Denka Chemicals Holdings Asia Pacific Pte Ltd

Singapore Subsidiaries Regional Subsidiaries

Denka Singapore Pte Ltd

Denka Advantech Pte Ltd

Denka Infrastructure Pte

Ltd

Denka Life Innovation

Research Pte Ltd

Denka Infrastructure

Malaysia Pte Ltd

Denka Advanced Materials

Vietnam Co Ltd

• Located on Jurong Island

• Manufacture StyrenicPolymers

• Finished Goods are exported to >50 countries

Challenge: Steam Trap Failures

• Industry average is 12.5-25% traps failed in the population• Blowing steam: wasting energy• Trapping condensate potentially impact plant operation:

affecting product quality

• By surveying steam traps and replacing faulty traps steam loss can be stopped

• In the past, yearly manual steam trap surveys• Surveying traps manually is time consuming so it

cannot be done often enough• Therefore decided to automate steam trap monitoring

Solution: Industrial Internet of Things (IIoT)

• Connected service provided by Emerson Automation Solution• A weekly report listing which traps have failed and

need to be replaced• As a monthly report of estimated steam savings

and CO2 emissions• The 148 most critical traps were chosen

• High pressure• High capacity

• Subscription business model:• Did not buy any instrumentation• Instrumentation provided as part of service

contract

Solution: IIoT System Architecture

JB

ReportReport

3G

WirelessHART

Analytics Software in the Cloud

Wireless gateways on top of the control building

Wireless acoustic transmitter on each

steam trap

Work Process Transformation- Based on the steam trap failure report

• Failed steam traps are replaced very much sooner than what was ever possible in the past with yearly surveys

• Other steam system issues also identified• Valves in bypass or leakage

• Flange leaks

Result: Steam Consumption Reduced

• 7 month Proof of Concept (PoC) started August 2015• Steam consumption reduced by 7%• Full operation since March 2016• Now expanding with another 67 steam traps• Adding cooling tower gearbox vibration monitoring

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Steam Consumption

After0.257

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Before 0.278

Conclusion

• Steam trap failure cause steam loss

• Digital transformation of steam trap management

• IIoT-based connected services

• 7% steam savings are realized with prompt replacements