STEAM TRAPS ENERGY EFFICIENCY PROJECTS
- 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
Four phases are considered in projects to improve efficiency and steam savings in traps:
IBERIAN LUBE OILS COMPANY, S.A. (ILBOC) is a joint venture (JV) between SK LUBRICANTS (South Korea, world leader in the lube base oil market) and REPSOL PETROLEO (first refining company in Spain). ILBOC began its production becoming the biggest production plant of new generation lube base oils in Europe.
This large-scale wireless ISA100 steam traps and valves monitoring has reduced costs related to installation of sensors and simplified the process of monitoring 904 elements (possibly the world's largest current ISA100 installation) by combining in a single management platform several applications:
- Fight against Climate Change. Monitoring steam leaks and energy efficiency in steam traps.
- Safety. Monitoring hazardous gas leaks in safety valves.
- Employee Health and Safety. Detection of toxic gas (H2S) detection in the environment.
- Prevention of Catastrophic Risks Detection of explosive gas (hydrocarbons) in the environment.
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
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).
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
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
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
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.
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.
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.
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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.