Special Focus Maintenance and Reliability

A. HOU and T. MITA, TLV International Inc.,

Kakogawa, Hyogo, Japan

Advanced steam system optimization program

The steam system forms an integral part of the safe, reliable 0
and profitable operation of a process plant. Steam constitutes -2
approximately 30% of the energy used in a typical petroleum

Steam reduction, metric tph

-4
refinery.1 It is utilized throughout the plant for motive, heating
and process purposes, such as in the steam turbine driver for -6
the recycle gas compressor, the reboiler for the depropanizer -8
column, and for stripping steam for the crude distillation unit. -10
Estimated total steam loss reduction at completion
of replacement work for 1,850 traps: 10.5 metric tph
The production process and its feed and product streams
-12 Flowmeter measurement results: 10 metric tph–12 metric tph
are the lifeline of the plant. In comparison, the steam system
often may receive less attention and might even be treated as a -14
Sept.-20 Sept.-30 Oct.-10 Oct.-20 Oct.-30 Nov.-09 Nov.-19 Nov.-29
“black box.” For instance, the recycle gas compressor, together Measurement period
with its steam turbine driver, are regarded as a critical asset,
but the steam traps around it, which are essential to ensure re- FIG. 1. Estimated and actual reduction in steam loss at one refinery
liable operation of the turbine, are often not managed in the (verified by flowmeter).
same manner. In addition, a reactive strategy is generally ad-
opted for maintenance and optimization of the steam system,
and, as a result, action is taken only after a problem becomes
too severe to ignore.
However, there can be great rewards in proactively optimiz-
ing the steam system. The benefits fall into two main categories:
1. Energy savings
2. Plant reliability improvement and reduced risk
of production loss.

Energy savings. Since 2005, plantwide steam system optimi-

zation programs implemented at refineries and petrochemical
plants in cooperation with a steam specialist company have pro-
duced significant energy savings.a
For example, 37 metric tph of steam losses were reduced
between 2005 and 2008 at a major Japanese refining group as
a result of improved steam trap survey and management prac-
tices (FIG. 1).2 The estimated steam reduction identified during
the initial survey was compared against the actual flowmeter-
measured steam reduction when subsequent maintenance work
progressed. The actual results confirmed the survey estimation
and opportunity expectations for energy reduction.
Based on more than 60 surveys focusing on steam energy
reduction conducted by the authors between 2005 and 2016 at FIG. 2. Failure of a steam pipe joint due to water hammer.
petroleum refineries and petrochemical plants around the world,
an average of 4.6% steam reduction potential was identified (for
an average total plant steam generation rate of 640 metric tph). cal complex in 2000 caused the disruption of steam supply to
downstream plants and suspended production for 4 wk (FIG. 2).3
Plant reliability improvement. Energy savings aside, the The subsequent investigation identified the failure mechanism
steam system can have an even greater impact on the safety and as condensate-induced water hammer, a dangerous but unfor-
reliability aspects of plant operations. A catastrophic failure of a tunately common phenomenon that can occur in a steam and
joint along an 18-in., 200-psig steam pipe at a large petrochemi- condensate system.4
Hydrocarbon Processing | MAY 2018 45
 Maintenance and Reliability

Several other instances of production disruptions, injuries ply dry, high-quality steam to its users, while continuously dis-
and, in some cases, fatalities caused by steam system prob- charging the condensate that is inevitably formed due to heat
lems, typically involving water hammer, can be found in pub- loss, without unnecessary steam leakages. The element that
lic records.5,6 shoulders the main responsibility is the steam trap found at
Apart from water hammer, a “non-optimized” steam system each condensate discharge location.
can lead to plant and equipment reliability problems in other Steam trap failures or design issues can quickly escalate into
ways. Wet steam supply is known to cause internal damage to production problems on a larger scale, such as the cases refer-
critical equipment, such as steam turbines or heat exchangers. enced in the previous section. At the very least, they can be a
Steam ejector vacuum system performance, vital to process significant source of energy loss, as past inspection results show
stability and product specifications, can be severely impaired that, on average, approximately 6.6 metric tph of steam leakage
by poor steam quality.7 Even steam tracing lines, a commonly due to trap failure can be expected from a medium-sized refin-
overlooked part of the steam system, can have the potential ery with a trap population of 10,000.
to cause substantial accidents and production outages if not The more serious issues result from insufficient condensate
maintained and managed properly.8 discharge, such as steam trap blockage failures, operational mis-
To realize the previously mentioned reliability improvement takes or design inadequacies. The water hammer accident pre-
and risk reduction benefits while maintaining energy efficiency, viously highlighted was caused by the isolation of a steam trap at
a comprehensive, structured and sustainable approach to steam a critical condensate discharge location. Inadequate condensate
system optimization is required. With emphasis on ensuring the discharge from stripping steam lines was identified as the lead-
competitiveness and profitability of any process plant, the key ing cause of water-induced pressure surges that led to damage of
phases of such an integrated approach are presented. distillation tower internals.9
Steam system optimization starts with ensuring the proper
PHASES OF STEAM SYSTEM OPTIMIZATION design and operation of these steam traps. Regular surveys of
the condensate discharge locations, combined with timely
Phase 1: Optimize all condensate discharge locations. maintenance action for the failed steam traps, are the basis of
The key aspect of a healthy steam system is its ability to sup- Phase 1 optimization.
However, conventional steam trap surveys may not be able to
fully identify the problem locations. Typical challenges include:10
• Providing efficient and sustainable database management
of a large steam trap population
• Ensuring that diagnostic equipment is accurate
and state-of-the-art
• Ensuring that inspection personnel and methodologies
are at the highest standards
• Identifying root causes of failure
• Selecting practical and cost-effective lifecycle solutions
that improve the performance of target applications
• Coordinating the inspection results with effective
maintenance actions.
A systematic and sustainable program that addresses the
challenges has been developed and implemented at 58 plants
in the refining and petrochemical industry since 2005.b The ac-
cumulated inspection records from more than 250,000 steam
traps over 12 yr as part of this program have proved to be unique
FIG. 3. Mapping trap condition, with an emphasis on locations and valuable data sources. When applied at the individual plant
with repeated failure. Deeper-color shades indicate higher failure level, the program enables time-based, location-specific histori-
frequencies. cal analysis that can reveal sections of the plant with higher-

FIG. 4. Examples of steam applications.

46 MAY 2018 | HydrocarbonProcessing.com
 Maintenance and Reliability

than-usual failure rates, indicative of deeper problems that had An original methodology has been developed for the quan-
previously remained hidden (FIG. 3). titative risk assessment of steam-using equipment and steam
These inspection records have also been used as the basis of distribution systems.d The base probability of failure (PoF) of
an extensive set of generic failure frequencies for steam traps, the steam-using equipment is derived from industry-generic
covering a wide range of designs, operating pressures and appli- failure frequencies and combined with the PoF of the compo-
cations. The large sample population size, the significant length nents associated with the equipment (e.g., steam trap PoF based
of recording time and the accuracy of the inspection data lend on generic failure frequencies outlined in the previous section).
statistical credibility to failure frequencies, therefore providing a Actual onsite conditions are accounted for using probability
reliable and effective basis for risk-based decisionmaking.11 factors that tailor the PoF for specific steam-using equipment.14
The matrix, shown in FIG. 7, is an example of this methodolo-
Phase 2: Optimize steam applications. The steam-using gy as applied to a depropanizer reboiler system in a refinery. The
equipment, or steam applications, in a process plant may come risk was quantified based on the conditions at the time of assess-
in a variety of configurations, but the basic principles of steam ment, and the potential reduced risk was simulated based on the
engineering and utilization do not change (FIG. 4). mitigation actions identified to be appropriate for that system.
Based on these basic engineering principles, plantwide sur- Assessment data enables the asset owner to objectively visu-
veys have been performed for refineries and petrochemical alize the equipment’s criticality against the other equipment to
plants, covering all steam applications (typically 200–300 in be maintained, while providing a means for cost-benefit analy-
each plant).c sis and selection of the most appropriate course of action.
During one such survey at a petroleum refinery, a vaporizer Furthermore, the calculated PoF is time-dependent, so the
in the lubricants unit was found to be operating suboptimally. failure risk at the time of assessment and in subsequent years
The operators had long suspected that the solvent deasphalting can be projected, enabling proactive risk mitigation planning.
process was bottlenecked by the solvent recovery rate (FIG. 5). A risk-based approach to steam system maintenance opti-
An onsite investigation identified that the total backpres- mization not only prioritizes the various steam assets and ap-
sure from the steam condensate return system was higher than
the steam operating pressure of the vaporizer. This situation,
known as a “stall” condition,12 caused the steam condensate to Steam Steam
build up and subcool in the heat exchanger, reducing heat trans-
fer rates (FIG. 6).
In these situations, it is common for the unit operator to re- LP HP
sort to either operating the equipment with the condensate by- vaporizer vaporizer
pass valve open, or discharging the condensate to drain, remov-
ing the backpressure. However, this usually results in steam loss
(and increased backpressure in the return line) as the open by- Vacuum
pass is unable to modulate to load changes, or discharges valu- residue
Deasphalting
able condensate to drain, which could otherwise be recovered. tower
Instead, a more appropriate solution was engineered using
equipment specialized for overcoming stall conditions. The Solvent
production rate was increased, which resulted in an annual ben-
efit of $600,000. Deasphalted
oil stripper
In addition to energy loss, water hammer, stall issues—such
as those previously outlined—and other common steam appli- Asphalt
cation problems identified through Phase 2 steam application
surveys include: FIG. 5. Vaporizer problem in the deasphalting process.
• Heat exchanger temperature cycling
• Steam turbine damage
• Sulfur pit, tank coils and steam trace heating issues
• Flare tip damage.
In many of these cases, the main driving factor for optimi-
zation is the reduction of risk, whether from production loss,
component damage, environmental impact or personnel injury.
Accordingly, the decision-making process toward prioritizing
and justifying the optimization action relies heavily on a risk-
based approach, such as the guidelines developed by the Ameri-
can Petroleum Institute (API).13
Up to this time, risk-based assessments of process plant as-
sets have generally discounted the influence from the steam
system components, such as the steam traps. However, the risk
contribution from these components is undeniable, as seen in
FIG. 6. Condensate buildup in heat exchanger tubes.
the examples described previously.
Hydrocarbon Processing | MAY 2018 47
 Maintenance and Reliability

plications, but also enables selection of the most cost-effective pressure of a particular steam level, are examples of methods
maintenance actions. that have been used effectively to rebalance the steam systems
of large process plants.
Phase 3: Optimize the steam balance. The balancing The impact of such projects on the overall steam/water/
of a plant's steam, water and electrical power is a delicate and power balance can be simulated using proprietary balance
continuous effort (FIG. 9). For instance, processes and utili- models.e The practicality and accuracy of the simulation model
ties may be adjusted to meet new requirements due to product depend heavily on the quality of its parameters, especially the
mix changes, or steam applications may be optimized, causing steam consumption (or generation) flowrates of every steam
the steam balance to shift into a venting state (i.e., excess low- application. This can be challenging when flowrates for most
pressure steam). In some cases, a straightforward solution is to applications are unmetered.
alternate between steam turbine and electric motor drivers, or For this reason, an effective approach is to combine Phase
to adjust letdown valves to maintain an optimal system balance. 3 balance analysis together with the Phase 2 survey, where all
However, these actions may not fully eliminate the venting steam applications are reviewed for optimization, as was per-
situation, and a combination of other methods may be required formed at a North American refinery in 2011.15
to optimize the steam balance. Practical and efficient means to
more fully utilize excess lower-pressure steam, or tweaking the THE HUMAN SIDE OF THE
OPTIMIZATION EQUATION
After implementing each phase of steam system optimiza-
tion, changes to the steam system mean that the system may
gradually start to deviate from its optimized condition if no fur-
ther actions are taken.
Just as the human body can maintain its healthy state through
a habit of regular health checks for early problem detection and
timely treatment, a process plant can maintain its optimal state
only through a sustainable program of regular steam system in-
spections and timely corrective actions.
Past analysis of large accidents in the hydrocarbon and
chemical industries indicated that, after mechanical failure, the
second leading cause of accident losses was direct operational
errors.16 In other words, human and organizational factors play a
significant part in the safe and reliable operation of a plant. This
is also recognized in API RP 581, which defines the PoF as:
PoF = gff ∙ Df (t) ∙ FMS
where:
FIG. 7. Risk assessment of a depropanizer reboiler. The 5-yr risk gff = the generic failure frequency of the equipment item
mitigation value was estimated at $1.2 MM. Df (t) = the damage factor, which accounts for the relevant
damage mechanism and inspection effectiveness
FMS = the management systems factor.
FMS accounts for the quality of the organization’s manage-
ment system and its influence on the overall plant integrity.

FIG. 8. A 10-yr risk projection, based on the PoF function calculated

at the time of the assessment. FIG. 9. Example of a steam balance for a refinery.

48 MAY 2018 | HydrocarbonProcessing.com
 Maintenance and Reliability

In this definition, a weak management approach can increase 8

Kletz, T., What went wrong? Case histories of process plant disasters, 4th Ed.,
Elsevier, 1999.
the probability of failure by a factor of 100 over a plant with 9
Kister, H. Z., “What caused tower malfunctions in the last 50 years?” Chemical
“perfect” management. Engineering Research and Design, January 2003.
Accordingly, an effective approach to steam system opti- 10
Walter, J. P., “Implement a sustainable steam-trap management program,”
mization must include improvements to the human aspects of Chemical Engineering Progress, January 2014.
11
Pittiglio, P., P. Bragatto and C. Delle Site, “Updated failure rates and risk manage-
plant operation. For example, best practices identified through ment in process industries,” Energy Procedia, January 2014.
field surveys can provide feedback to improve standard operat- 12
Risko, J. R., “Steam heat exchangers are underworked and over-surfaced,”
ing procedures. The problems observed and the implementa- Chemical Engineering, November 2004.
13
American Petroleum Institute (API) Recommended Practice 581, “Risk-based
tion progress of their solutions can be tracked to ensure comple- Inspection Methodology,” 3rd Ed., April 2016.
tion and prevent future recurrences, while being recorded for 14
Cane, B., “Risk-based methodology for industrial steam systems,” Inspectioneering
use in ongoing training and educational materials. Journal, May 2017.
Technological advancements and next-generation analytics 15
Chen, M. and F. Roberto, “ExxonMobil Beaumont Chemical Plant study of
steam and condensate systems for the entire plant,” 34th Industrial Energy
are enabling more powerful tools to assist and streamline de- Technology Conference 2012.
cisionmaking throughout the organization. A key element is 16
Krembs, J. A. and J. M. Connolly, “Analysis shows process industry accident
the increasing visualization of performance and reliability in- losses rising,” Oil and Gas Journal, August 1990.
dicators made possible by advanced (or more affordable) sen-
sors. However, simply expanding the scope of online monitor- GUOXIAN “ALAN” HOU is a Senior Consulting Engineer at TLV
International Inc. He has 12 yr of industry experience, including
ing increases the risk of operators being overwhelmed by data leading steam system optimization projects for refining and
overload and alarm fatigue, as well. Instead, the true value of petrochemical plants in 17 countries. He graduated with an
visualization should be captured by integrating the data with honors degree in chemical engineering from the National
University of Singapore and is an AEE Certified Energy Manager.
expert knowledge and system experience to create relevant
outputs, such as failure prediction models.f These outputs can TETSUYA MITA is a Principal Consulting Engineer at TLV
subsequently complement reliable, risk-based selection of the International Inc. He has served in various technical and
mitigation actions and ultimately allow time and resources to leadership positions in the TLV group since 1995. He was a
be redirected to more critical tasks or further optimization op- pioneer in establishing TLV’s Consulting and Engineering
Service function and developed several survey techniques for
portunities in the plant. steam system optimization for the oil and gas industry. He holds
a BEng degree in materials chemistry from Ryukoku University.
Takeaways. The accumulation of know-how in the engineering
and study of steam systems for process plants has brought about
the realization that problems present in the steam system can
have harmful effects on production. Simultaneously, it has creat-
ed advancements in the condition monitoring and timely optimi- NEW VERSION
zation of steam-using equipment and their associated steam sys-
tem components. A novel methodology has been developed for
the quantitative, risk-based assessment of the steam system and InstruCalc
related equipment. Integrating this methodology into a struc- CONTROL VALVES • FLOW ELEMENTS • RELIEF DEVICES • PROCESS DATA
tured, sustainable program provides the means to ensure higher
efficiency and integrity of the entire steam system asset.
InstruCalc 9.0 calculates the size of control valves,
NOTES flow elements and relief devices and calculates fluid
a
Refers to TLV Co. Ltd.’s Steam System Optimization Program (SSOP) properties, pipe pressure loss and liquid waterhammer
b
Refers to TLV Co. Ltd.’s Best Practice of Steam Trap Management Program
flow. Easy to use and accurate, it is the only sizing
(BPSTM)
c
Refers to TLV Co. Ltd.’s CES Survey program you need, enabling you to: Size more than 50
d
Refers to TLV Co. Ltd.’s Steam System Risk Mitigation (SSRM) different instruments; Calculate process data at flow
e
Refers to SteamSystemBalance.net conditions for 54 fluids, in either mixtures or single
f
Refers to iBPSSM.net components, and 66 gases, and; Calculate the orifice
size, flowrate or differential range, which enables the
LITERATURE CITED
user to select the flowrate with optimum accuracy.
1
United States Environmental Protection Agency, “Energy efficiency improvement
and cost saving opportunities for petroleum refineries,” February 2015.
2
Hara, Y., “Jyumandai no suchimu torappu kara no jyoki roe sakugen” [Reduction Updates include Engineering Standard
in steam losses from 100,000 steam traps], Journal of Energy Conservation, April
2010.
Upgrades and Operational Improvements
3
Galante, C and S. Pointer, “Catastrophic water hammer in a steam dead leg,” Loss in InstruCalc Version 9.0
Prevention Bulletin, ISS. 167, October 2002.
4
Health and Safety Executive, “Major incident investigation report, BP Please contact J’Nette Davis-Nichols
Grangemouth Scotland 29th May–10th June 2000,” August 2003.
5
Kletz, T., “Imperial chemical industries petrochemicals division,” Safety newsletter
for more information.
number 43, August 1972. GulfPub.com/InstruCalc or call +1 (713) 520-4426.
6
Kletz, T., “Imperial chemical industries petrochemicals division,” Safety newsletter
number 57, October 1973.
7
Lieberman, N. and R. Cardoso, “Troubleshoot operation of a steam ejector
vacuum system,” Hydrocarbon Processing, February 2016.

Hydrocarbon Processing | MAY 2018 49