Refinery steam demand reduced by 25%

Steam demand at an ExxonMobil plant has been dramatically cut, thanks to the combined efforts of ExxonMobil Engineers and Spirax Sarco Specialists

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Key Benefits
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  • Steam boiler demand reduced from 850 tonnes / hour to 650 tonnes / hour.
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  • Process efficiency improvements by eliminating cold spots on the Slack Wax line.
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  • Steam trap failures cut by over 80%, leading to significant energy savings
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  • The installation of “quick fit” steam traps now allows failed traps to be replaced in minutes, rather than hours.
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  • The installation of “quick fit” steam traps now allows failed traps to be replaced in minutes, rather than hours.
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  • Reduction in pump seal failures resulting from improved steam quality.
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  • Dedicated Spirax Sarco Specialists on site ensuring ExxonMobil “gets the results it plans for”.
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Overview
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The cost of producing steam at ExxonMobil’s Fawley, UK plant had risen by 30% within a year, prompting engineers on site to seek the assistance of Spirax Sarco. A ‘Steam Team’ was created made up of on-site ExxonMobil engineers and Spirax Sarco specialists, to look at the problems and suggest solutions.

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The Spirax Sarco Solution
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Through the formation of the “Steam Team” a programme was set up to:

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  • Deal with the immediate problem of steam leaks
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  • Make improvements to the overall steam system design.
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Spirax Sarco experts provided on-site expertise whilst our Oil & Petrochemical Manager helped to define the on-going strategy for savings. Since its formation, the team has made significant and valuable savings thanks to a continuous programme of improvements:


For example, pump seal failures have reduced since Spirax Sarco made alterations to ensure the steam reaching the seals remains dry, greatly extending their life and subsequently becoming a new part of Exxon Mobil best practice.

Leaking steam traps were another major focus of the Steam Team’s campaign, where failures have been reduced from 30% to only 5%, leading to significant energy savings.

Proposing the UTD30 connector block allows the site-standard thermodynamic traps to be replaced in a matter of minutes by disconnecting just two bolts.

The causes of cold spots on the 3km-long Slack Wax line, (which must be kept warm for the wax to flow), were identified and eliminated, improving process performance.

‘It is the application of our knowledge that sets us apart and brings true ‘added value’ to the customer. Spirax Sarco is well known for trap management, however we are also experienced in auditing complex
processes, steam plant and equipment for energy optimisation’ Says Roger Ferryman, Spirax Sarco Oil & Petrochemical Manager.

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To learn more
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Contact our Oil and Petrochemical specialists on +44 (0)1242 521361.

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Call +44 (0)1242 521361 for more information

Key Facts
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  • By focussing on the steam and condensate system typically results in:
    • Significant energy savings.
    • Improved process efficiency.
    • Reduced maintenance.
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  • Modern “quick fit” steam traps allow easy and rapid replacement, significantly reducing maintenance time.
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  • Spirax Sarco can offer on-site expertise and have experience in working closely with our Customers own engineers or their preferred contractors.
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