Hydrocarbon Processing - March 2021 - 75
Maintenance and Reliability
circuit (tubing connecting steam
supply/return manifolds to circuit
supply/return points)
* Steam trap for each circuit
* Steam trap for each supply manifold
* Fittings and hardware required to
connect all the above components.
Note: In this example, proprietary Technology 1a tube tracing could have also
been used as an intermediate technology
between the tube tracing and the proprietary Technology 2b. Doing so would have
resulted in additional cost savings. However, the customer chose not to pursue
this option as they preferred the simplicity
of using a smaller number of technologies.
Additional utility infrastructure also creates additional operating expenses. These
expenses take the form of additional steam
consumption to support the extra heat
load, and the form of additional maintenance cost to maintain the traps (TABLE 3).
The cost basis of this project's individual items is summarized in TABLE 4. Note
that this project utilized high-pressure
steam, which required more expensive
manifolds and steam traps. A more typical
steam pressure would have resulted in lower utility infrastructure costs and lower operating costs for both options. The impact
of this change on purchase cost would be
relatively small, with savings shifting from
78% to roughly 76%. The impact on operating cost would be more significant, with
savings shifting from $3.4 MM/yr to $2.1
MM/yr for steam cost and $454,000/yr to
$175,000/yr for trap maintenance.
This and the following examples all
use pre-insulated tubing to supply and
return the heating fluid to the tracing.
Pre-insulated tubing typically has a higher
purchase cost than traditional hard pipe,
but it provides significant time savings
during installation.
Example B: Optimizing utility infrastructure (Strategy 3). The author's
company provided a heating system for a
major Middle Eastern refinery expansion
project. The engineering, procurement
and construction contractor had already
placed manifolds throughout the plant
before the author's company was engaged on the project. The author's company was asked to optimize the manifold
utilization and applied its proprietary algorithmc. The expectation was that some
portion of the planned manifolds would
prove unnecessary and could be removed
were not optimized to the extent
that they could have been.
The cost basis of this project's individual
items is summarized in TABLE 6. 0.75-in.
tubing is used for each circuit supply run
and 0.5-in. tubing is used for each circuit
return run.
from the plan. This expectation proved to
be true; optimization resulted in the removal of 15% of the manifolds and a total
cost reduction of 43% (TABLE 5).
While the cost savings are significant,
employing the proprietary algorithm on
most projects will yield even more significant savings. Two factors affecting
this project that limited the cost savings
potential were:
1. The planned manifold locations
were based on a previous project
for a very similar plant utilizing
the same heating technology.
Thus, the planned locations were
actually very good approximations
of what would be needed, much
better than on an average project.
2. Only manifold locations that
were already planned could be
used. The author's company was
engaged late in the project cycle.
Planned manifolds could be
eliminated, but adding manifold
locations was not an option. Thus,
the resulting manifold locations
Example C: Optimizing the bid
structure (Strategy 4). The author's
company provided a bid for another major Middle Eastern refinery expansion
project. This bid included the application
of all three optimization strategies:
1. Optimization of technology
by using a combination of
tube tracing and proprietary
Technology 1a in place of tube
tracing alone.
2. Optimization of circuit lengths
via engineering calculations.
3. Optimization of manifold
quantity and placement via
a proprietary algorithmc.
The lump-sum bid was being compared
to another vendor's per-unit bid. The
TABLE 5. Optimization techniques provided a cost reduction of 43%
Planned
Optimized
Number of manifolds
186
159
Number of used ports
1,116
762
225,000
80,000
$3,187,000
$1,820,000
Total length of tubing, ft
Total cost
TABLE 6. Cost basis for a heating system for a Middle Eastern refinery expansion project
Item
Cost
4-port supply manifold
$2,540.82/each
8-port supply manifold
$3,787.26/each
12-port supply manifold
$5,250.84
4-port return manifold
$948.93/each
8-port return manifold
$1,731.48/each
12-port return manifold
$2,499.93/each
Trap station with steam trap
0.75-in. stainless-steel, pre-insulated tubing
0.5-in. stainless-steel, pre-insulated tubing
$964.44/each
$6.56/ft
$4.69/ft
0.75-in. tubing x NPT adapter
$32.67/each
0.75-in. tubing union
$55.22/each
0.75-in. tubing x JIC adapter
$69.67/each
0.5-in. tubing x 0.75-in. NPT adapter
$27.36/each
0.5-in. tubing union
$33.97/each
0.5-in. tubing x 0.75-in. JIC adapter
$55.78/each
Hydrocarbon Processing | MARCH 2021
75
Hydrocarbon Processing - March 2021
Table of Contents for the Digital Edition of Hydrocarbon Processing - March 2021
Contents
Hydrocarbon Processing - March 2021 - Intro
Hydrocarbon Processing - March 2021 - Cover1
Hydrocarbon Processing - March 2021 - Cover2
Hydrocarbon Processing - March 2021 - Contents
Hydrocarbon Processing - March 2021 - 4
Hydrocarbon Processing - March 2021 - 5
Hydrocarbon Processing - March 2021 - 6
Hydrocarbon Processing - March 2021 - 7
Hydrocarbon Processing - March 2021 - 8
Hydrocarbon Processing - March 2021 - 9
Hydrocarbon Processing - March 2021 - 10
Hydrocarbon Processing - March 2021 - 10A
Hydrocarbon Processing - March 2021 - 10B
Hydrocarbon Processing - March 2021 - 11
Hydrocarbon Processing - March 2021 - 12
Hydrocarbon Processing - March 2021 - 13
Hydrocarbon Processing - March 2021 - 14
Hydrocarbon Processing - March 2021 - 15
Hydrocarbon Processing - March 2021 - 16
Hydrocarbon Processing - March 2021 - 17
Hydrocarbon Processing - March 2021 - 18
Hydrocarbon Processing - March 2021 - 19
Hydrocarbon Processing - March 2021 - 20
Hydrocarbon Processing - March 2021 - 21
Hydrocarbon Processing - March 2021 - 22
Hydrocarbon Processing - March 2021 - 23
Hydrocarbon Processing - March 2021 - 24
Hydrocarbon Processing - March 2021 - 25
Hydrocarbon Processing - March 2021 - 26
Hydrocarbon Processing - March 2021 - 27
Hydrocarbon Processing - March 2021 - 28
Hydrocarbon Processing - March 2021 - 29
Hydrocarbon Processing - March 2021 - 30
Hydrocarbon Processing - March 2021 - 31
Hydrocarbon Processing - March 2021 - 32
Hydrocarbon Processing - March 2021 - 33
Hydrocarbon Processing - March 2021 - 34
Hydrocarbon Processing - March 2021 - 35
Hydrocarbon Processing - March 2021 - 36
Hydrocarbon Processing - March 2021 - 37
Hydrocarbon Processing - March 2021 - 38
Hydrocarbon Processing - March 2021 - 39
Hydrocarbon Processing - March 2021 - 40
Hydrocarbon Processing - March 2021 - 41
Hydrocarbon Processing - March 2021 - 42
Hydrocarbon Processing - March 2021 - 43
Hydrocarbon Processing - March 2021 - 44
Hydrocarbon Processing - March 2021 - 45
Hydrocarbon Processing - March 2021 - 46
Hydrocarbon Processing - March 2021 - 47
Hydrocarbon Processing - March 2021 - 48
Hydrocarbon Processing - March 2021 - 49
Hydrocarbon Processing - March 2021 - 50
Hydrocarbon Processing - March 2021 - 51
Hydrocarbon Processing - March 2021 - 52
Hydrocarbon Processing - March 2021 - 53
Hydrocarbon Processing - March 2021 - 54
Hydrocarbon Processing - March 2021 - 55
Hydrocarbon Processing - March 2021 - 56
Hydrocarbon Processing - March 2021 - 57
Hydrocarbon Processing - March 2021 - 58
Hydrocarbon Processing - March 2021 - 59
Hydrocarbon Processing - March 2021 - 60
Hydrocarbon Processing - March 2021 - 61
Hydrocarbon Processing - March 2021 - 62
Hydrocarbon Processing - March 2021 - 63
Hydrocarbon Processing - March 2021 - 64
Hydrocarbon Processing - March 2021 - 65
Hydrocarbon Processing - March 2021 - 66
Hydrocarbon Processing - March 2021 - 67
Hydrocarbon Processing - March 2021 - 68
Hydrocarbon Processing - March 2021 - 69
Hydrocarbon Processing - March 2021 - 70
Hydrocarbon Processing - March 2021 - 71
Hydrocarbon Processing - March 2021 - 72
Hydrocarbon Processing - March 2021 - 73
Hydrocarbon Processing - March 2021 - 74
Hydrocarbon Processing - March 2021 - 75
Hydrocarbon Processing - March 2021 - 76
Hydrocarbon Processing - March 2021 - 77
Hydrocarbon Processing - March 2021 - 78
Hydrocarbon Processing - March 2021 - 79
Hydrocarbon Processing - March 2021 - 80
Hydrocarbon Processing - March 2021 - 81
Hydrocarbon Processing - March 2021 - 82
Hydrocarbon Processing - March 2021 - 83
Hydrocarbon Processing - March 2021 - 84
Hydrocarbon Processing - March 2021 - 85
Hydrocarbon Processing - March 2021 - 86
Hydrocarbon Processing - March 2021 - 87
Hydrocarbon Processing - March 2021 - 88
Hydrocarbon Processing - March 2021 - 88A
Hydrocarbon Processing - March 2021 - 88B
Hydrocarbon Processing - March 2021 - 89
Hydrocarbon Processing - March 2021 - 90
Hydrocarbon Processing - March 2021 - Cover3
Hydrocarbon Processing - March 2021 - Cover4
https://www.nxtbook.com/gulfenergyinfo/gulfpub/HPI-Market-Data-2023-v3
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202101
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020_v2
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202012
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202009
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202008
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202007
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202006
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202005
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202004
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202003
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202002
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202001
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201911
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201909
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201908
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201907
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201906
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201905
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201904
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201903
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201902
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201901
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201812
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201811
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201810
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201809
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201808
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201807
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201806
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201805
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201804
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201803
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201802
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201801
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201712
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201711
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201709
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201703
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201702
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201701
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2017mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201612
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201611
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201610
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201609
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201509
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201508
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