Product category:
Energy management; Boiler control
News Release from: Spirax Sarco | Subject: INEOS Silicas
Edited by the Processingtalk Editorial
Team on 24 April 2006
Steam trap surveys payback within four
months!
Spirax Sarco steam trap surveys are highlighting energy and maintenance savings that have achieved paybacks of less than four months at a chemicals producer in Warrington
Spirax Sarco steam trap surveys are highlighting energy and maintenance savings that are achieving paybacks of less than four months at a chemicals producer in Warrington The first survey at the site also revealed a 50% failure rate for fixed orifice traps from another supplier
This article was originally published on Processingtalk on 30 Jan 2003 at 8.00am (UK)
Related stories
New integrated flowmeter for steam applications
Spirax Sarco has launched Diva, the first spring-loaded variable area flowmeter to integrate a flow sensing device, temperature sensor, connection accessories and flow computer into a compact unit
Steam trap replacement saves chemical plant GBP50k
A Spirax Sarco survey of the steam system at Great Lakes Chemicals at Trafford Park in Manchester have led to substantial energy savings and improvements in maintenance procedures
Following the success of an initial survey, INEOS Silicas has rolled out a programme of trap surveys around its entire Warrington site, which has a population of several hundred steam traps.
"It's hard to fully quantify the savings, but I'd say the payback on a survey is typically three to four months," says Mr Andy Hitchin, Energy Manager, INEOS Silicas.
Furthermore, INEOS Silicas decided to opt for Spirax Sarco steam traps with Quick-fit fittings.
Further reading
Steam system survey helps Busy Bee win funding
A Spirax Sarco survey has helped Busy Bee Laundry win a 100 per cent, interest-free loan from the local development agency for a programme of energy saving changes to its steam and hot water system
Slow opening valve brings fast savings
An automatic slow opening valve from Spirax Sarco has helped textile dyer Bulmer and Lumb to halve the cost of the steam it uses for processing and space heating at its Bradford site
This installation gave them double block and bleed, which enables them to replace any faulty traps without waiting months for a scheduled plant shutdown and means the company can benefit from energy savings immediately.
INEOS Silicas is a world leader in silica and alumina technology, with over 900 employees and eight manufacturing sites in five continents.
Its products include liquid and solid silicates, gel and precipitated silicas and a range of zeolites for detergent and other applications.
Production rates vary at the Warrington site, consuming up to 50 tonnes of steam an hour via an extensive distribution system.
The initial two-day steam trap survey was ordered after it became clear that a significant number of traps had failed.
"They didn't cause us any problems with our process, but they were obviously wasting energy," Mr Hitchin says.
The failures also created a maintenance issue, since condensate was not being removed effectively and was accumulating in the pipes.
INEOS Silicas asked Spirax Sarco to focus on the traps around the boiler plant and the pipework leading to the process plant.
The survey found a particular problem with the fixed orifice traps.
Frustratingly, INEOS Silicas had to sit on the results for several months until the next plant shutdown, because it was impossible to isolate the affected traps and remove them safely while the plant was up and running.
This is a common problem on many sites and the Warrington plant sometimes operates for up to three years without a break.
Since then, INEOS Silicas has standardised on Spirax Sarco steam traps equipped with Quick-fit fittings.
The Quick-fit system allows maintenance staff to isolate a defective trap and remove it safely in a matter of minutes, "Now if we spot a problem, we can do something about it straight away," says Mr Hitchin.
The company has also asked Spirax Sarco to continue providing annual surveys to keep the plant running as energy efficiently as possible.
"No one can afford to waste energy these days, especially with the way gas prices are rising," added Mr Hitchin.
• Spirax Sarco: contact details and other news
• Email this article to a colleague
• Register for the free Processingtalk email newsletter
• Processingtalk Home Page
Search the Pro-Talk network of sites
