Active steam trap management saves over $4 million in under five years

Programme halts waste, improves the process and makes recommendations for future savings

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"The Spirax Sarco team have demonstrated the importance of active steam trap management and saved us hundreds of thousands of dollars’

Site Operations Manager

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Key Benefits
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  • Savings of almost $800,000 in the first year alone after implementing a steam trap audit programme. Within five years this figure had reached $4.7 million!
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  • Resolved the problem of freezing sulphur lines by replacing incorrectly specified steam traps with versions more suitable for the application.
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  • Identified potential savings of over $900,000 per year, by recommending the replacement of the damaged boiler blowdown heat recovery system (which was dumping valuable, hot blowdown to the sewer) with a packaged heat recovery system.
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  • Reduced the annual steam trap failure rate from 5.5% to 1.5% within five years.
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  • Eliminated waterhammer problems caused by a leaking high pressure steam trap and by identifying missing or cold (malfunctioning) steam traps.
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Overview
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An oil refinery in Texas was continuously experiencing a high failure rate on its 4,790-strong network of steam traps. The customer was also experiencing waterhammer problems caused by the accumulation of condensate, and freezing sulphur lines, caused by flooding in the tracing system. Eventually, losses were so high that the plant management team called upon Spirax Sarco to help them reduce their costs.

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The Spirax Sarco Solution
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A thorough steam trap audit carried out by our Energy Services Group revealed several problem areas:

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By replacing failed steam traps and putting in place a steam trap management programme, Spirax Sarco resolved most of the problems experienced by the customer.

According to the site operations manager:

“The audit programme has been in effect for several years and has resulted in significant steam savings at our facility."

In addition, Spirax Sarco has carried out a detailed steam leak survey and air / nitrogen leak survey, identifying additional annual savings of $160,000 and $460,000 respectively.

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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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