October – December 2012MICA (p) 124/12/2011
IN THIS ISSUE:Spirax Sarco’s expertise in Oil and Petrochemical industry Page 2Product feature – Spirax Sarco Desuperheater Page 3 & 4 Rolling out the extra mile – Steam and rubber experts partnership Page 5Petrobras REPAR saves 550 kg/h of steam per boiler Page 6Steam & Condensate System Seminar Page 7
Spirax Sarco in the Oil andPetrochemical industry
Pass on your challenge to us
Steam accounts for approximately 50% of the total energy consumption in a typical refinery. Spirax Sarco can help you by:
Improving health and safetyThrough audits and preventative maintenance, we can help minimize steam leaks to reduce the risks of scalding and the consequences associated with poor visibility in a plant. We can identify the root causes of waterhammmer and eliminate it from your plant.
Improving process efficiency and reliabilityEnsuring that steam reaches your process at the correct: • Quantity• Quality• Pressure and temperature
Improving sustainabilityWe can identify opportunities for developing a solution for you that will enable condensate to be recovered and returned to the boilerhouse. This will give you savings in: • Energy costs and emissions• Water and water treatment chemicals used• Effluent discharged from site
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Spirax Sarco’s expertise in
Oil and Petrochemical industrySpirax Sarco understands the pressure that the Oil and Petrochemical industry is under to meet increasing legislation to reduce emissions, improve energy efficiency and reduce water consumption.
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Our knowledge and understanding of utilizing flash steam or re-energizing steam to higher pressures will reduce the amount of steam vented to atmosphere. In addition, our Steam System Services approach allows us to identify opportunities, implement the solutions required and offer on-going support to reduce the total cost of ownership of your steam and condensate system.
DesuperheatersSpirax Sarco has been providing desuperheaters to the Oil and petrochemical industry successfully for many years. Desuperheaters typically reduce superheated steam temperatures to within 3°C of the saturation temperature. To cool the superheated steam, a medium (usually water) is entrained and flashed into vapour by absorbing heat from the steam.
Superheated steam is an essential part of a steam system in the OPC industry. It is used for:• Steam turbines are driven using superheated steam. Wet
steam within a turbine would result in water droplets and erosion of the turbine blades, as well as increased friction.
• Higher pipeline velocities (up to 100 m / s) can be used. This means that smaller distribution pipelines can be used (provided that the pressure drop is not excessive).
• For continuously running plants, superheated steam means there is no condensation in the pipework, therefore, there is only a requirement for steam trapping during start-up.
However, for certain key applications the superheat must be removed and saturated steam is required for the process to be effective:• Although superheated steam contains a large amount
of heat energy, this energy is in three forms; enthalpy of water, enthalpy of evaporation (latent heat) and enthalpy of superheat. The bulk of the energy is in the enthalpy of evaporation, and the energy in the superheat represents
a smaller proportion. The transfer of energy from the superheated steam is slow because the initial phase requires the superheat to reduce in temperature to become saturated steam. This slows down the heat transfer process and the efficiency of the process. In contrast to this, saturated steam gives up all of the enthalpy of evaporation very fast because the steam condenses back to water. This is why saturated steam is used for fast heat transfer.
• Some processes (for example, distillation columns) perform less efficiently when supplied with superheated steam because of the time needed for the superheated steam to cool & become saturated steam.
• The higher temperatures of superheated steam may mean that higher rated, and hence more expensive equipment is required.
• The higher temperature of superheated steam may damage sensitive equipment.
To resolve this problem, desuperheaters are used to restore the saturated state produce discharge temperatures approaching saturation (typically to within 3°C of the saturation temperature as a minimum).
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For more information on desuperheaters, please contact our OPC team at [email protected]
Spirax Sarco has 2 types of desuperheaters commonly used in the OPC industry.
Venturi type desuperheatersThe venturi type desuperheater employs a restriction in the superheated steam pipeline to create a region of high velocity and turbulence where the cooling water is injected. This helps to establish intimate contact between the steam and the cooling water, improving the efficiency of the desuperheating process.
The desuperheating process is carried out in two separate phases:1. The first stage of desuperheating occurs in the internal
diffuser. A portion of the steam is accelerated in the internal nozzle and the velocity is used to atomise the incoming water. The cooling water is injected into the diffuser through a number of small jets, which helps to further atomise the water.
2. In the second stage of desuperheating, a saturated mist or fog emerges from the internal diffuser into the main diffuser where it mixes with the remainder of the steam.
Rolling out the extra mile – Steam and rubber experts partnership
With the increasing demand for specialist understanding of the oil and petrochemical industry in 2009 Spirax Sarco Singapore created a dedicated OPC team.
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The OPC team has a background of chemical process engineering and industry experience. In 2011, this experience combined with hard work and persistence allowed us to collaborate closely with a customer’s EPC team for the engineering and design work on the steam and condensate system project on Jurong Island. Numerous challenges were faced as the end-user expected nothing less than their high quality and safety standards. Through consolidated resources, the SxS team overcame the initial hurdles to deliver the customized-packages that met the stringent criteria specified.
Advantages:• Good turndown – steam turndown of up to 50:1 is possible,
but operation and control is most efficient for a turndown of around 20:1.
• Very compact – with a short absorption length relative to the other types.
• Pressure drop is negligible.• The cooling water used can be cold, as the atomising steam
will preheat it.• Low approach to saturation temperature – typically to within
6°C of saturation temperature.
Venturi type desuperheater
Applications: Suitable for most plant applications, except where high turndowns of the cooling water are required.
Spray type desuperheatersA simple type of in-line Desuperheater with cooling water injected into the centre of the unit via an atomizing nozzle sprayed in the direction of the steam flow. Spray Type Desuperheaters are available in two options :
Simple Spray Type Nozzle Desuperheater (SND)The assembly is designed for mounting on a suitable flanged branch on the steam pipework. A thermal sleeve installed downstream of the unit is recommended.
Complete Spray Type Desuperheater (STD)A complete Desuperheater ready for installation including spray nozzle, nozzle housing, thermal sleeve and flanged shell.
Applications: Relatively constant load handling duties for simple industrial applications where a turndown to 3:1 is acceptable, depending upon process conditions
Simple spray nozzle type
desuperheater
Complete spray type desuperheater
In summary, the equipment provided by SxS was as follows:• Pivotrol Duplex Condensate
Return Pump Packages with MOM registration
• Pivotrol Simplex Condensate Return Pump Packages with MOM registration
• Desuperheaters • Steam Traps• Strainers• Air Traps/Liquid Drainers
The condensate pump packages are steam-driven, which complies with the strict requirement of the oil & gas industry. They are ideal for hazardous environment and suitably apt for energy conservation initiatives.
Desuperheaters supplied were designed and fabricated by Transvac, a product which is part of Spirax Sarco group. We worked closely with the EPC engineers to design the desuperheaters in accordance to the requirement of the process.
As part of our continuous commitment to provide expertise and sustainable solutions, we also made pre-installation and pre-commissioning visits to ensure that the items supplied will operate optimally.
Case Study, UKCase Study, UK6 7
To Learn MoreContact our Oil and Petrochemical team on +65 6349 0470.
Overview
Petrobras REPAR refinery suffered years of problems with their boiler pre-heaters, leading to poor temperature control of both the combustion gas and the boiler air supply.
Automatic pump traps eliminate stall on boiler air pre-heaters saving Petrobras 550 kg/h of steam
per boilerProblems included:• Waterhammer caused by a build-up of condensate.• Increased steam consumption resulting from poor temperature control, leading to excessive flue gas temperatures. • Preheater condensate being discarded to achieve the required temperatures, resulting in a waste of energy and water.
This problem led to Petrobras having to maintain the regenerator pre-heater at a higher set temperature, to prevent SO3 from condensing out (producing sulphuric acid) in the regenerator or chimney.
Spirax Sarco was able to provide Petrobras with APT14 automatic pump trap assemblies to solve the problem. Each unit removes condensate under all operating conditions, keeping the preheaters fully drained and efficient.
Key Benefits• Savings of approximately 550 kg/h of steam per boiler,
achieved via accurate temperature control of the combustion gases used to pre-heat the boiler air supply.
• Elimination of the production of corrosive sulphuric acid in the regenerative preheater and boiler chimneys.
• Elimination of waterhammer in boiler air pre-heaters.• Increased energy savings and reduced condensate losses
due to the much higher rate of condensate return.
The Spirax Sarco Solution
Spirax Sarco realised that during the warmer months, when ambient air requires minimal heating, the boiler preheater temperature control valve would throttle to reduce the steam pressure. This, combined with backpressure in the condensate line reduced the differential pressure across the steam traps thus dramatically reducing preheater capacity. The units would begin to flood with condensate - a condition known as stall - leading to poor temperature control and waterhammer.
Events & Information8
SINGAPORESpirax Sarco Pte Ltd (Regional Office)464 Tagore Industrial AvenueSingapore 787833Tel: (65) 6349 0480Fax: (65) 6459 6854Contact: Kwek Chin LeongE-mail: [email protected]
HONG KONGSpirax Sarco Pte Ltd (Hong Kong Branch)Unit 1507, 15/F, Prosperity Center,Chong Yip StreetKwun Tong, Kowloon, Hong KongTel: (852) 2754 9828Fax: (852) 2754 3660Contact: Alfred WongE-mail: [email protected]
PHILIPPINESSpirax Sarco Pte Ltd (Philippines Branch)Natividad Building2308 Chino Roces Ave ExtMakati City, PhilippinesTel: (63) 2812 8654Fax: (63) 2812 8673Contact: Peter RorisonE-mail: [email protected]
VIETNAMSpirax Sarco Vietnam Rep Office64 / 22 Pho Quang, Ward 2Tan Binh Dist, Ho Chi Minh City, Vietnam Tel: (84) 08 9974324Fax: (84) 08 4086909Contact: Nguyen Thanh HaiE-mail: [email protected]
INDONESIASpirax Sarco Rep OfficeJln Zeni No. 4Mampang ParapatanJakarta 12790, IndonesiaTel: (62) 021 797 3332Fax: (62) 021 798 2156Contact: Cosner TambunanE-mail: [email protected]
PT Petrolog Multi Usaha MandiriSpirax Sarco Rep OfficeJln Zeni No. 4Mampang ParapatanJakarta 12790, IndonesiaTel: (62) 021 790 1480Fax: (62) 021 798 2156Contact: Budi SetiawanE-mail: [email protected]
PT Centrindo PalmaxBlok F No. 2-3 KompleksBrayan, Prima Jl. KL. YosSudaruso, Tanjung MuliaMedan, IndonesiaTel: (62-61) 6642784 / 6642785Fax: (62-61) 6642786Contact: SugiantoE-mail: [email protected]
MALAYSIASpirax Sarco Sdn Bhd 25, Jalan PJS 11/1Bandar Sunway46150 Petaling Jaya, Selangor Darul Ehsan.Tel: (603) 5635 3323 Fax: (603) 5635 7717E-mail: [email protected]
Spirax Sarco
Singapore Steam & Condensate System Seminar
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To register, please logon to www.spiraxsarco.com/sg or send your enquiries to [email protected]
*Note: W.E.F 1 Jan 2013, the training course fee will be adjusted to S$450 per participant.
Date : 13 - 14 December 2012Time : 9 am – 5 pmVenue : Orchid Country Club Center Cost : S$350 per participant subjected to 7% GST
Participants will learn about• The fundamentals of steam• Steam Distribution• Steam Trapping• Steam trap sizing & selection• Estimating steam load• Effective condensate removal from
heat exchangers• Condensate Recovery• Pressure Reduction
Who will benefit?Designers, plant engineers, senior technicians and those involved in the day to day running of the steam & condensate services.
ObjectivesTo give a good understanding of the purpose and operation of steam & condensate systems and factors affecting their performance and plant output.
