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Thermal Maintenance
S stems for Urea
Systems
Applications
pp
Jim Hartman
Controls Southeast,, Inc. ((CSI))
hartman@csiheat.com
Controls Southeast, Inc. is…
An Engineered Thermal Maintenance company that…
Designs and develops heating systems for
Refinery and Chemical Processes:
•Delayed
D l dC
Coking,
ki asphalt,
h lt SSolvent
l t deasphalting
d h lti
•Sulfur, heavy resid
•Urea, Caprolactum, polymers
TT HΔT CT JP
Very tight
Freeze Protection Standard Engineered Thermal range
g
Product
d System
3 q U A T
ControTrace
Process Piping
Process
Heat
Transfer
Compound
Heating
Medium
q U A T
4
ControHeat
• ControHeat for valves,, pumps,
p p , instrumentation
5
ControHeat
• Steel pressure chamber
embedded in aluminum
casting for excellent heat
transfer
• Designed,
g , built,, and tested in
accordance with ASME
Section VIII, Division 1
• Jacket for valves, pumps,
meters, fittings, flanges –
virtually any type of process
equipment
q p
6
Common Valve Heating Problems
• Poor heat transfer
contact
• Uneven heating
• Required steam pressure
is very high
• Can be tough to service
valves
• No
N flflow conditions
diti resultlt
in plugs
• Require heat blankets
blankets,
steam hoses, etc. to
unplug
q U A T
7
CSI Customer Examples
Oil & Gas Petrochemicals / Chemicals Engineering & Construction Other
8
Urea Application Areas
• Carbamate
vapor lines
• Vacuum
Separators
• Liquid
Urea lines
9
Heating Needs – Urea Melt Lines
• Thermal Objective: Maintain bulk process between
j p
132.7‐140°C
– Urea solidifies below 132.7°C
– More Biuret is formed above 140°C
• Typical Line Sizes: 2
Typical Line Sizes: 2‐4”,
4 , typical lengths: 600
typical lengths: 600‐1200
1200 ft
ft
• Current Heating Method: Jacketed Pipe
• Problems: Cost, Cross‐Contamination
Problems: Cost Cross‐Contamination
Benefit of ControTrace
11
Heating Needs - Evaporator
• Function: Separate water from urea
• Thermal Objective: Maintain bulk process between
133‐140°C
– Urea solidifies below 133°C
– Polymerisation forms above 140
forms above 140°C C
• Typical Diameter: 6‐12 ft; Height: 6‐12 ft.
• Current Heating Method: Electric or Tube Tracing
Current Heating Method: Electric or Tube Tracing
• Problem: Plugging / Fouling
B
Benefit
fit off ControTrace
C t T
1. Reliability of an Engineered system
2. Fouling
gp problems eliminated
12
Heating Needs – Urea Solution
Storage Tanks
• Function of Vessel: Storage of urea solution
g
• Thermal Objective: Maintain bulk process at or
above 80°C
above 80 C
– Urea “falls out” of solution below 80°C
• Current Heating Method: Electric or Tube Tracing
Current Heating Method: Electric or Tube Tracing
• Problems: External corrosion, solidification, cost
Benefit of ControTrace
1. Reliability
1 R li bilit off an E
Engineered
i d system
t
2. Less expensive than current approach
13
ControTrace for Tanks
1. Keeps material molten
2. No internal coils – eliminates need
to ever go into tank
3. D ’t h
Don’t have tto d
drain
i th
the ttank
k tto
maintain heating system
4
4. Eliminates corrosion in or on tank
5. An engineered solution guaranteed
to work
14
CSI Urea Customer Examples
M lt Urea
• Molten U h dli
handling, C b t vapor lines
Carbamate li
• ControTrace and ControHeat
15
CSI General Overview
CSI Sample Customer Locations
16
Controls Southeast, Inc.
Post Office Box 7500 Charlotte, NC USA 28241
PHONE: +1 704-644 5000
WEB: www.csiheat.com Contact: Jim Hartman, Hartman@csiheat.com
For over 30 years, the refining and petrochemical industries have enjoyed operational success using
ControTrace™ and ControHeat™ engineered bolt-on jacketing in lieu of jacketed piping and
conventional steam tracing. The use of Contro Trace™ has gained recognition for preventing corrosion
and plugging issues in vapor applications, which are common recurring problems when using
conventional steam or electrical tracing. ControTrace™ and ControHeat ™ engineered bolt-on jacketing
have been proven to be more reliable with lower CapX and OpX costs than jacketed piping on most liquid
applications. An additional benefit to ControTrace™ and ControHeat™ systems is a significant reduction
in the quantity of steam supply and condensate traps required versus jacketed piping or conventional
steam tracing. Importantly, Controls Southeast is the only company that provides single-source capability
to design, manufacture, and guarantee the heating system for both the piping and in-line process
equipment. The specific, detailed, 3D construction drawings provided with every bolt-on jacketing
system designed by Controls Southeast give a clear, to-scale representation of every component with its
orientation and location specified; this enables Operations and Maintenance to know specifically what is
beneath the insulation (see attached reference drawings).
Controls Southeast, Inc.
General Benefits:
1. More Reliable
a. Bolt-on jacketing eliminates the risk of cross-contamination.
b. ControTrace™ and ControHeat™ systems can be designed so that the performance of the
system is less susceptible to steam trap failure (i.e., maintain flow despite steam trap
failure).
c. System engineering, design, and component integration are completed by a thermal
maintenance specialist who considers every detail that may affect performance.
d. Hydraulic analysis and resulting steam routing are accomplished by a thermal
maintenance specialist and designed to minimize the quantity of steam traps.
2. Less Expensive
a. System results in lower CapX and OpX costs (2X-8X less steam consumption).
b. Less effort is required for the EPC:
i. Piping for bolt-on jacketing system can be engineered and designed as un-
jacketed system.
ii. Less rigid system, resulting in fewer expansion loops, less piping, less time to
stress analyze.
iii. Easier to field modify.
c. Excess flanges are eliminated, resulting in lower cost and maintenance.
Mail: Shipments:
Post Office Box 7500 12201 Nations Ford Road
Charlotte, NC 28241 Pineville, NC 28134
Phone: +1 704-644 5000
Web: www.csiheat.com
Contact: Jim Hartman, Hartman@csiheat.com
Controls Southeast, Inc.
1. More Reliable
a. Greater heat transfer surface contact area and 3-mm wall thickness increase robustness.
b. Finite-element modeling considers pipe wall temperature gradients to ensure temperature
maintenance above process dew-point to reduce corrosion/plugging potential.
e. A detailed evaluation determines the need for jacketing piping supports, flanges, and in-
line process equipment to eliminate localized cold spots.
f. System engineering, design, and component integration are completed by a thermal
maintenance specialist with 30 years of successful experience who considers every detail
that may affect performance.
c. Hydraulic analysis and resulting steam routing completed by a thermal maintenance
specialist and designed to minimize steam traps (2X-10X difference versus conventional
steam tracing depending on application).
2. Less Expensive
a. System results in lower CapX and OpX costs considering installation, steam traps, and
associated infrastructure.
ControHeat
Mail: Shipments:
Post Office Box 7500 12201 Nations Ford Road
Charlotte, NC 28241 Pineville, NC 28134
Phone: +1 704-644 5000
Web: www.csiheat.com
Contact: Jim Hartman, Hartman@csiheat.com
CSI Bulletin CTCH -1
CSI Bolt-On
Heating Systems
2 1/2" 13 3/4"
12 1/2"
3 7/8" R.
CL
PANEL 1A 3/4" SA105 150#
RFSO FLANGE
18 1/2" PART LINE 19"
14"
8"
3/4" SCH 40 X 6"
LONG SA106 GR B PIPE
3/16" 2 1/2"
EDGE
4" 4"
EDGE
1/4"
EDGE
4"
9 1/2"
2 3/4"
7 7/8"
EDGE
Heating Fluid
1
ControHeat Jackets Cover Valves
CSI makes ControHeat Bolt-On Jackets for
virtually any valve. Generally, there are two
types of jacket construction offered: One-
piece jackets, called UniJackets, for valves
sizes 3-inch and smaller; and two-piece
jackets for valves sizes 4-inch and larger.
Very large valves like 20-inch gate valves
may utilize more than two pieces to
accommodate ease of installation.
1
Here’s How The
ControHeat Jacket Works:
1. Pressurized heating fluid enters the
pressure chamber embedded in the
aluminum casting.The pressure cham-
ber may be either carbon steel or stain-
less steel.
2
Designed for hot-oil
Control valves with vapor service, this
integral jackets often two-piece
require very long lead times for ControHeat jacket
deliveries. Sometimes the long with flanged
delivery times force instrument connections and
engineers to sacrifice performance for extended coverage for
availability. ControHeat Jackets allow you to select mating flanges is used in
the optimum valve for the process without concern 650°F service on a 20-inch ball
for the jacket. valve in a polymer reactor operation.
Any ControHeat Valve Jacket can be designed to This UniJacket on an off-the-shelf sampling valve
heat mating pipe flanges as shown on these plug keeps the valve plug-free, ready to operate
valve jackets used in BPA service. at all times.
UniJacket installed on
Three-way ball valves are easily heated with ball valve. CSI insulated
ControHeat Jackets. Various styles of actuator flexible jumpovers connect
brackets can be accommodated. the jacket to ControTrace
Elements heating adjacent piping.
3
ControHeat Jackets for Pumps
ControHeat Bolt-On Jackets are widely used heated for foodstuffs such as chocolate,
throughout the processing industry to improve syrups and dairy products. In some batch-type
pump efficiencies, prevent motor operations, pump
burnout and jacketing may be
promote uniform process- needed during
ing temperatures. Some start-up only. In
critical metering pump pumping applications
applications require jack- like sulfur, phthalic
eting to assure accurate anhydride, or DMT, not
throughput. Certain gear only does the pump cas-
pump applications require ing need to be heated at all
jacketing to minimize times, the backplate also may need
degradation of polymers heating. When pump manufacturers do not
and other products that are offer jacketed backplates, CSI offers both
shear sensitive. The barrels of fabricated bolt-on heating jackets as well
progressive cavity pumps may need to be as ControHeat Jackets.
Two Metering
Diaphragm Pumps
with ControHeat
Jackets. The jackets
cover four High-Pressure
pump heads Piston Pump with
as well as check 3-phase electric
valve assemblies. ControHeat Jacket.
4
ControHeat Jackets for Meters & Instruments
Accurate process data and chemical tees. Few of these components
and process perfor- are available with integral jackets. The
mance often depend ControHeat Jacket has a history of
on instruments, meters successful service with these
and safety devices operat- components. In fact, several
ing at elevated process manufacturers of these
temperatures. CSI makes jack- products have
ets for many types of meters, standardized on the
instruments and related equipment: ControHeat Jacket
DP cells, vortex shedding meters, to complement
rupture discs, coriolis flow meters, their product lines.
viscometers, tank vents, level indicators
Condensables in gas streams can collect and ControHeat Jacket on a Brookfield Viscometer
choke the flow in flame arrestor passages. increases the instrument’s operating range and longevi-
ControHeat Jackets keep the passages clear. ty, as well as improving accuracy of data collected.
5
ControTrace Elements Heat Pipe
ControTrace Heating Elements have performed The most popular size of ControTrace is a
very well in diverse applications from chocolate 1”x 2” rectangular
to polyester resin. Numerous plants have Process Piping shape with the pipe-
drastically curtailed their use of jacketed side surface formed to
pipe, preferring to use ControTrace on match the outside diame-
process piping for DMT, rosins, ter of the pipe on which it
sulfur, cyanuric chloride, acrylic will be placed. Normally, a
acid, hot melts and numerous non-drying heat-transfer
bottoms recirculating lines. Process cement is used to promote
Some of these plants fabricate heat transfer between the
the elements in the field. Others element and the pipe wall.
depend on CSI for the complete For nominal pipe sizes of 11/2”
service of design, fabrication and and less, a smaller size of
installation of the bolt-on heating ControTrace
system. Heat ( 3/4”x11/2”) is avail-
ControTrace Elements are Transfer able. Other element
Heating Medium Cement
formed from carbon steel, SA178 sizes may be
Gr. A boiler tubing. The elements ordered on a
are pressure rated in accordance ControTrace custom basis. Stainless steel
with the ASME Boiler and Heating Element ControTrace is also offered for very
Pressure Vessel Code, Section VIII, Div.1. aggressive environments.
1. CSI can turnkey the complete heated piping system. CSI provides the front-end
engineering and drawings, fabricates the pipe and ControTrace (securing the ControTrace on
the pipe), and installs the system in your plant. Another frequently used option is production by
CSI of both the piping and ControTrace Elements, installing the elements on the pipe, insulating the
finished assemblies, and shipping the system to the field for
installation by others. We have the flexibility, of course, to provide
only specified portions of the project.
2. Based on isometric drawings provided by the customer, CSI spools the elements
and, with the customer’s approval, fabricates finished ControTrace pieces, tests them, and ships
them to the field, ready for installation on the pipe by others.
6
ControTrace coverage of elbows, In the application depicted in the accompanying
even in smaller pipe diameters, photo, ControTrace Elements proved to be a cost
as shown here, can be accom- saving alternative to all-stainless steel jacketed
plished on both the throat and pipe. With no external pressure, core piping was
the heel. Side coverage of elbows selected based on internal process requirements.
also is frequently used. This allowed a thinner pipe wall and saved money.
ControTrace is used successfully on piping in The design of the ControTrace coverage on a particular
refineries, terminals, barges and acid plants. piping run depends on the process thermal require-
Combined with ControHeat jackets, as on the ball ments, pipe schedules, and the type and thickness of
joints in this application, uniform heat can be insulation used. In this application CSI designers deter-
provided to the the entire system very economically. mined that heating elements placed normal to the
process flow would provide the most uniform coverage.
7
ControTrace Heating Elements for Tanks & Vessels
Storage tanks and vessels fabricated for conic heads
up to 25 feet in diameter are as well as elliptical heads.
in service with ControTrace Generally, systems that
elements providing uniform utilize a liquid heating
heat over their entire medium are designed in a
surfaces. serpentine configuration.
The ControTrace Element Systems that use a vapor
configuration can be heating medium are usually
designed for liquid or vapor constructed for parallel
heating media. A key benefit medium flow. When parallel
of ControTrace is that flow must be used on a
elements can be dispersed liquid system, flow diverters
evenly around the vessel, can be placed inside the
assuring the uniform heat ControTrace assemblies to
coverage. Jackets can be channel the liquid.
8
Engineering Support for Bolt-On Heating Systems
A major segment of CSI’s total engineers and designers who manage
business is the design and fabri- jacketed piping projects also design and
cation of jacketed piping manage projects for bolt-on
systems. The continu- heating systems. The
ing evolution of CSI singular focus of this
Bolt-On Heating cumulative experi-
Systems is linked ence, from initial
directly to the quotations through
knowledge and process start-up, is a
experience we gain satisfied customer
in jacketed piping, that likes doing
because the same business with CSI.
2. The second computer program, more sophisticated than the first, uses
finite difference modeling to profile the crossectional thermal performance
of the bolt-on heating system. The results yield a detailed temperature
profile of the piping system at equilibrium, the heat lost to the atmosphere
through the insulation, and the net heat input to the process. This pro-
gram considers the thermal conductivities of the system components as
well as film coefficients of both the process and the heating fluid.
3 3/8"
2 5/16" R.
15"
2 5/8" R
END VIEW TOP VIEW
57 1/4"
68"
EDGE
EDGE
EDGE
4"
10 1/4"
4"
18 3/4 12 1/8"
6 9/16 7 1/4
13 1/8
12 1/2"
6 1/8
R2 1/8
R3 3/4
1/2 6 1/16 11 11/16 1/2
11 3/4"-3000# TH'D FULL CPLG'S
(2) TWO EA. PER HALF
5/8
1
5/8 3 1/8
4 3/4
2 3/8 1 1/8
1 3/4