Steam Consumption Reduction with Steam Trap
MonitoringCecilia Goh
Deputy General Manager of Group TechnologyDenka Chemicals Holdings Asia Pacific Pte Ltd
Jonas BergeSenior Director Applied Technology
Emerson Automation Solutions, Singapore
Denka Co Ltd (Japan)
Denka Chemicals Holdings Asia Pacific Pte Ltd
Singapore Subsidiaries Regional Subsidiaries
Denka Singapore Pte Ltd
Denka Advantech Pte Ltd
Denka Infrastructure Pte
Ltd
Denka Life Innovation
Research Pte Ltd
Denka Infrastructure
Malaysia Pte Ltd
Denka Advanced Materials
Vietnam Co Ltd
• Located on Jurong Island
• Manufacture StyrenicPolymers
• Finished Goods are exported to >50 countries
Challenge: Steam Trap Failures
• Industry average is 12.5-25% traps failed in the population• Blowing steam: wasting energy• Trapping condensate potentially impact plant operation:
affecting product quality
• By surveying steam traps and replacing faulty traps steam loss can be stopped
• In the past, yearly manual steam trap surveys• Surveying traps manually is time consuming so it
cannot be done often enough• Therefore decided to automate steam trap monitoring
Solution: Industrial Internet of Things (IIoT)
• Connected service provided by Emerson Automation Solution• A weekly report listing which traps have failed and
need to be replaced• As a monthly report of estimated steam savings
and CO2 emissions• The 148 most critical traps were chosen
• High pressure• High capacity
• Subscription business model:• Did not buy any instrumentation• Instrumentation provided as part of service
contract
Solution: IIoT System Architecture
JB
ReportReport
3G
WirelessHART
Analytics Software in the Cloud
Wireless gateways on top of the control building
Wireless acoustic transmitter on each
steam trap
Work Process Transformation- Based on the steam trap failure report
• Failed steam traps are replaced very much sooner than what was ever possible in the past with yearly surveys
• Other steam system issues also identified• Valves in bypass or leakage
• Flange leaks
Result: Steam Consumption Reduced
• 7 month Proof of Concept (PoC) started August 2015• Steam consumption reduced by 7%• Full operation since March 2016• Now expanding with another 67 steam traps• Adding cooling tower gearbox vibration monitoring
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Ton
Ste
am /
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rod
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Steam Consumption
After0.257
Operation
Before 0.278