REFINERIES

Eiminate trap maintenance and improve energy efficiency

Refineries have the challenge of providing sufficient maintenance for large steam trap populations -- 1,000 to 10,000 traps are common.  A large number of these traps are for tracing and distribution lines. In addition, refineries have process applications such as tanks, evaporators, heat exchangers, reboilers and boiler preheat coils, some of which are critical for plant production.  The typical lifespan of a mechanical steam trap running 24/7 is 2-5 years (Consult with your manufacturer for their specs on trap life expectancy).  A refinery with 10,000 traps would need to be repairing or replacing about 3,000 traps per year to retain the plant's efficiency.  This level of maintenance is nearly impossible and is rarely done.  A refinery can expect to save 10-30% of fuel consumption for trapped steam by converting its steam traps to a permanent condensate removal system. 

The permanent condensate removal system from MEI Resources is practically maintenance-free.  Customers typically blow down the y-strainers once a year.  Most refineries have more maintenance needs than staff, and, after installing the system, maintenance people can be reassigned to other key tasks. The stainless steel condensate removal units have no moving parts to wear out or fail closed and have a lifetime warranty.

In a tracing system, a blowing trap can lose more steam to the return than the equipment can transfer to the product.  This is why in tracing systems the fuel savings from installing a permanent condensate removal system can be a very high percentage of total fuel usage for trapped steam.

Improve heat transfer along product lines

Maintenance personnel at refineries have often been faced with a trade-off between mechanical traps with good heat transfer capability, but poor reliability, and mechanical traps that are more reliable, but have less heat transfer capability.  The venturi traps make this trade-off unnecessary by providing a permanent condensate removal solution with superior heat transfer capability, keeping product lines hot and valves easy to turn. 

There is a possibility that a refinery may need fewer Enercon orifice traps than mechanical traps, depending on the way the systems are piped.  A tracer will be pressurized equally, and the temperature at the trap will be higher in an Enercon trap installed at 300 feet than in a mechanical trap installed at 150 feet, as long as radiant losses are less than the supply capability.  This is because Enercon traps operate on a continuous flow basis with no mechanism to stop that flow.  A simple demonstration of this can be shown on site before any decisions are made.  A technician would review the piping system and provide recommendations to the plant personnel in charge of the piping and condensate removal system, with final decisions left up to the plant.

Reduce condensate problems

Steam will be dryer with the venturi condensate removal system.  Steam is made up of heat and water, and, when the heat is lost, steam turns back to water.  In steam systems with mechanical steam traps, when heat from steam is lost, vapor condenses at the bottom of the pipe and, finally, makes its way to the mechanical trap.  With the Enercon system, the constant change in pressure and continuous flow results in much less condensed water on the heat transfer side of the equipment.  The BTU count is higher in the heat transfer chamber, and water isn't acting as an insulator.  Condensate is eliminated from the system immediately.  Water hammer, which can cause pipe damage, corrosion, inconsistent temperatures and other problems caused by excess condensate in the system will be greatly reduced, making the work environment safer.  

Improve startup times

With properly-sized orifice traps, the venturi system works better for plants during shutdown and startup. Initially, there will be a little backup, as there is with any trap system, but then the lines will clear and pressurize faster with the venturi traps, because there is a specific flow direction for the condensate. The average startup time improvement is 25%.

Eliminate trap-related freezing problems in northern climates

Outdoor refineries in northern locations, such as the oilsands region of Alberta, can have freezing problems in winter.  Because they are continuous flow, the Enercon condensate removal units don't freeze, which prevents product lines from freezing and disrupting flow of product.  The permanent Enercon system has proven completely reliable in distribution lines and in applications with widely varying loads in -40 degree weather. 

Plant personnel often ask whether the venturi trap will plug.  Typically there isn't a plugging issue with a superheated supply, because there is no carry-over bringing the contaminants out into the system.  If you have an issue with older piping that is flaking or leaving debris, there is a strainer in front of each orifice with a mesh smaller than the orifice opening.  Since the system is continuous flow, anything smaller than the orifice will pass right through.