Energy savings through automatic steam tracing header control

In a typical refinery or chemical plant, 80% to 90% of steam traps are used for winterization or instrumentation tracing.

Plant operators generally turn on the steam supply headers for these tracer lines in mid-October and leave them running through April; some plants leave them running year-round. But when the ambient temperature is above 40 °F there is no freeze concern, so the tracer lines don't need to be in service and only add to energy costs. Depending on your location, the local temperature may be above 45 °F for 30% (Mid-Atlantic or Midwest) to 90% (Gulf Coast or South) of the winter season.

PT Series 60 AMBIENTEMP Valves automatically turn the steam supply to tracer line manifolds on and off, and can deliver significant energy savings.

A worked example

Using some conservative assumptions:

• A Gulf Coast plant runs its tracer lines for 180 days in winter.
• The local temperature is above 45 °F for 80% of the winter.
• Each steam tracing manifold serves eight tracer lines.
• Each tracer trap uses about 50 lb of steam an hour.
• Steam costs about $10 per 1,000 lb.
• A Series 60 AMBIENTEMP Valve is installed at the steam supply header at an estimated cost of $2,000 (labor and material).

The seasonal steam energy savings can be estimated as:

These savings pay back the investment within the first month of operation. Actual savings depend on plant location, energy cost, number of tracers per header and so on, but this valve has been field-proven in a variety of real-world environments to deliver tangible, significant cost savings.

Questions about applying this valve? Call Process Technology at 215-628-2222.