Steam trap maintenance at Petrobras results in energy … rlam.pdf · Steam trap maintenance at...
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Steam trap maintenance at Petrobras results in energy savings Overview Since 1999 Spirax Sarco has had a steam trap maintenance contract set up with Petrobras RLAM. Petrobras RLAM is located in São Francisco do Conde, Bahia, and is the oldest refinery in Brazil. The main products produced at the refinery include propane, propene, isobutane, domestic gas, gasoline, naphtha petrochemical, kerosene, jet fuel, paraffin, fuel oils and asphalt. “Improved product quality, enabling compliance to specification, and savings of $4.5 million. Achieved by eliminating problems related to the solidification of process fluids.” The survey Of the 25 steam system units at Petrobras RLAM, which Spirax Sarco maintains, most of the steam is destined for the steam tracing lines. During our surveys, we have frequently found problems heating several of the products used and produced by RLAM. Following a survey of the ‘Unit 32’ steam system (an atmospheric and vacuum distillation unit), we uncovered a number of problems with a turnkey system supplied by one of our competitors, which were as follows: Components were not within specification and low quality, causing inefficiency of the heating system in the lines. This was due to a large amount of accumulated condensate, reducing heat transfer between the steam tracing line and the product in the pipeline, which further led to the product being ‘frozen’). Purged systems using collective draining (Group trapping) contributed to the accumulation of condensate in the system. A large and increasing number of leaking steam traps which were passing steam was causing pressurisation of the condensate return lines. From the 116 tonnes / month of steam consumed, only 10% was returned as condensate to the boiler. A large number of steam traps in the steam tracing lines were installed in a vertical position, causing leakage. Low pressure (3.5 bar) and medium pressure (12 bar) condensate return lines were linked, thereby locking the low-pressure line steam traps. This problem was linked to pressurisation caused by the leaking steam traps on the medium-pressure line. According to the consultant technician, Petrobras RLAM had lost approximately US$20m during 2004, due to the cumulative effect of all these problems. Case study: Oil and petrochemicals 1 of 2
Transcript of Steam trap maintenance at Petrobras results in energy … rlam.pdf · Steam trap maintenance at...
Steam trap maintenance at Petrobras results in energy savings
Overview Since 1999 Spirax Sarco has had a steam trap maintenance contract set up with Petrobras RLAM. Petrobras RLAM is located in São Francisco do Conde, Bahia, and is the oldest refinery in Brazil. The main products produced at the refinery include propane, propene, isobutane, domestic gas, gasoline, naphtha petrochemical, kerosene, jet fuel, paraffin, fuel oils and asphalt.
“Improved product quality, enabling compliance to specification, and savings of $4.5 million.
Achieved by eliminating problems related to thesolidification of process fluids.”
The survey Of the 25 steam system units at Petrobras RLAM, which Spirax Sarco maintains, most of the steam is destined for the steam tracing lines. During our surveys, we have frequently found problems heating several of the products used and produced by RLAM. Following a survey of the ‘Unit 32’ steam system (an atmospheric and vacuum distillation unit), we uncovered a number of problems with a turnkey system supplied by one of our competitors, which were as follows: Components were not within specification and low quality,
causing inefficiency of the heating system in the lines. This was due to a large amount of accumulated condensate, reducing heat transfer between the steam tracing line and the product in the pipeline, which further led to the product being ‘frozen’).
Purged systems using collective draining (Group trapping)
contributed to the accumulation of condensate in the system.
A large and increasing number of leaking steam traps
which were passing steam was causing pressurisation of the condensate return lines.
From the 116 tonnes / month of steam consumed, only
10% was returned as condensate to the boiler. A large number of steam traps in the steam tracing lines
were installed in a vertical position, causing leakage. Low pressure (3.5 bar) and medium pressure (12 bar)
condensate return lines were linked, thereby locking the low-pressure line steam traps. This problem was linked to pressurisation caused by the leaking steam traps on the medium-pressure line.
According to the consultant technician, Petrobras RLAM had lost approximately US$20m during 2004, due to the cumulative effect of all these problems.
Case study: Oil and petrochemicals 1 of 2
Spirax-Sarco Limited
Cheltenham UK
GL53 8ER
t: +44 (0)1242 521361
f: +44 (0)1242 573342
www.SpiraxSarco.com
Solution A technical and economic viability study was raised to look at the adequacy of the draining points, which recommended: Separate trapping of tracers, which would solve the problem
of frozen products. Consequently these products would benefit from improved quality, meeting the correct specification and the desired standard.
That the low and medium pressure condensate systems
should be separated. That all steam traps in vertical lines should be installed in the
correct position, applying diffusers and UTD quick fit connector thermodynamic steam traps, in accordance with the NR-116 (Petrobras standard).
A pumping system was designed to allow the return of all condensate to the boiler house. There was also evidence of a lower level of effluent generation, not just because of the water recycling, but also by the reduction of gases and other fuels used by the boilers. Spirax Sarco advised Petrobras’ regarding the Health, Environment and Safety (SMS) issues, concerning noise and energy waste, and compliance with the ABAST Industrial Area manual, which includes the Corporative Project of Qualification in SMS. Results Spirax Sarco have installed 500 draining sets (DF diffusers
and UTDs) in this unit and supplied supervision where the products were installed.
In accordance with estimates made by Petrobras,
approximately US$4.5m will be saved, once the process products have reached high quality.
All products meet the Petrobras standard. Energy savings have been currently estimated at
US$88 890. Elimination of steam leakage from the steam traps.
Case study: Oil and petrochemicals
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