Engineered Thermal Maintenance Solutions: Presented by Controls Southeast, Inc

Engineered
Thermal Maintenance
Solutions
Presented by
Controls Southeast, Inc.
1
Controls Controls
Southeast, Inc. (CSI)
Southeast Inc.
Menu of Presentation Modules


CSI Overview (slide 3)

Facilities Virtual Tour (slide 31)

Thermal Maintenance Basics (slide 65)

Heating System Design Considerations (slide 88)

Sulfur Specific Applications (slide 121)

Sulfur Tank Applications (slide 179)

Delayed Coker Specific Applications (slide 214)

ControTrace Installation Overview (slide 242)

Frequently Asked Questions (slide 286)
CSI Overview
Controls Controls Southeast Inc.
CSI – Company Facts:
– Controls Southeast, Inc. was founded in 1969.
– Privately owned and operated
– 246 Employees (45 Engineers)
– Heavy product use in Refinery applications around the
world
– Extensive usage in chemical processing industry
– Product in over 40 Countries
– International fabrication certifications
• ASME, CRN, PED
– International Sales accounts for 1/3 of Total Sales
4
Controls Southeast, Inc.
CSI Headquarters
Charlotte, NC
5
120,000 sq. ft. on 10 acre site
CSI Products and Services
1. Bolt-on Heating Systems

– ControTrace
– ControHeat
2. Engineering System Design
3. Jacketed Piping
4. Process Piping
5. Specialty Fabrication
6. Project Management
6
Bolt-On Products: ControTrace
• 2”X1” rectangular tubing (SA 178) is

banded onto piping
• Designed within ASME Section VIII
• Compliant to ASME B31.3 Process
Piping code
• Contoured to fit pipe OD
• Process flows through piping
• Heating medium flows through tracing
• Use mastic to remove air gaps
• Add elements for more heat
7
Bolt-On CSI
Products: ControTrace
Overview
CSI Overview
How does ControTrace Work?
Process Piping
Basic Heat Transfer = Q = UAdT
U = Rate of Heat Transfer between

the Steam and the Process.
Process
A = Amount of Heating Area.
Heat
Transfer
Cement
dT = Difference in Temperature
between the Steam and the Heating Medium
Process.
ControTrace Heating Element
8
ControTrace Eliminates Steam-to-Process leaks that can occur using
jacketed pipe.
Chance for Cross-Contamination
Every core weld in a jacketed pipe Cross-Contamination concerns

system represents a potential leak are eliminated with the use of
problem ControTrace.
9
Applications: Pipe, Tanks, Vessels
Bolt-On
CSI Virtual Tour Products: ControHeat
ControHeat™ Bolt-On Jacketing Systems
Component
Steel
Aluminum Pressure
Casting Chamber
11
Bolt-On
CSI Virtual Tour Products: ControHeat
ControHeat Bolt-On Jackets For Pumps and Blowers

12
Other CSI Products
Jacketed piping – Largest JP supplier in N. America

Process Pipe – 200 Spools/week
Specialty Fabrication – Code stamp U, PP, R
Flexible metal hoses (jump-overs and jacketed)
Engineered Systems and Project Engineering
CSI Sample Customers
CSI General Overview
CSI Sample Customer Locations
CSI General Overview
CSI Sample Process Experience
Refineries Chemical Food

Sulfur Recovery Units -Caprolactum -Sugar
- Liquid lines -PET -Chocolate
- Look boxes -Fibers -Chicle
- Seal legs -Sulfuric Acid Production -Edible oils
- Vapor lines -Adhesives
- Tanks
-Phosphoric Acid
- Vessels
-Sterol
-Ethanol
Heavy Residuum
-Polymer plastic
-Delayed Coker -Ultam plastic
-Rose Units -Polyester
-Asphalt Transport -Carbon Fiber
-Tanks -Titanium Oxide
-Ethyl Alcohol
-Bisphenol-A
CSI Organization
• CSI Organization Structure

• Sales Resources for Clients
• Engineering Services
• Project Management
17
CSI
CSI Virtual Tour Organization
CSI
Technical Project Design
Sales Estimating Operations Finance
Services Management Engineering
Develop custom engineered

solution with client Accounting
Develop quote package for

solution Human
Resources
- Project Kickoff
- Counterpart to
client PM Shipping
- Technical Analysis
deliverables -Detailed Design

-Inventor 3D drawings
Organized to Match -Produce Custom Product
-Installation support
Client Project Workflow -Shipping
-Invoicing
CSI Virtual TourSales Resources
Sales Engineers (5):

- Middle East
- Western Canada
- Latin America
- United States:
• Southeast
• Midwest
• West Coast
• Gulf Texas Global sales coverage
• Northeast/Mid-Atlantic
backed up by technical
• International Rest of World
Application Support
Application Specialists (5) specialists
Authorized Agents (2)
- MB Technology (Korea)
- Thermex (Belgium)
Unique Service Offering
Services
1.Engineering Design
–Thermal and fluid modelling
–Piping design
–Pressure vessel design
–Integration
–Consulting
2.Project Management
–Manifold to Manifold responsibility
–Field services
–Training
–Troubleshooting
20
CSI Detailed Overview
Engineering Services
What Makes CSI Unique?

➢
CSI develops a custom, engineered design for every project application
➢
Considers all process factors*
➢
Backed by extensive proprietary finite element analysis software
➢
Design considers Capex, Operating and Maintenance Costs
➢
CSI system price includes products and Engineering/Program Mgt Services
➢
CSI provides a “Thermal Guarantee” for system performance
CSI optimizes the client design and considers all elements and
costs of the heat transfer dynamic to develop a custom engineered
solution guaranteed to work in the clients application
*process material, flow rate, environment, insulation, pipe material, contact surface specifics, support structure
➢
Design Deliverables:
➢
Thermal design application of JP/CT/CH products
➢
Steam Circuitry locations
➢
Optimization of steam circuitry
➢
Thermal Fluid flow/orifice design
➢
Steam consumption, energy usage
➢
Optimization of pipe and fittings
➢
Thermal guarantee of system performance
➢
3D Installation drawings
CSI handles all aspects of the design from supply manifold to

the return manifold
23 Example of CSI Drawings

Services
➢
Project Management:
➢
Single Point Interface
➢
Project manager is technically competent
➢
Maintains clear scope/expectation with client
➢
Integrates CSI’s work into Clients schedule requirements
➢
Ensures product is done on schedule
➢
Arranges shipment logistics
➢
Co-ordinates Installation training
➢
Helps client with any post-installation service requests
No worries experience for Client

How is this done without CSI?
➢
Use “Plant Standards”?
➢
“Trap every spool”
➢
“Max circuit length 50 ft”
➢
Falls to EPC Firm?
➢
Use 1 size fits all look up tables that don’t consider the process
specifics?
➢
Focus on trace hardware cost?
➢
Mechanical Contractor?
➢
Variable results based on installer discretion?
A lack of design analysis ownership for the heating system

The ValueTour
CSI Virtual of CSI Engineering Services
Consider a typical project players:
➢
Technology Provider, EPC, Mechanical Contractor
➢
As the project passes through, frequently, the thermal design system is treated too generally in
project specifications:
➢
“heat traced”
➢
“steam traced”
➢
“Heat trace in field”
➢
No one has ownership of validating that the implementation actually
supports the specific requirements of the process
This can lead to a crucial element of the process being built in the
field with no engineering analysis backing up what is done!
Don’t leave your Thermal Maintenance System Design to Chance!
1. Imprecise process/FEED specifications:

“Heavily Heat Traced”
2. EPC Contractor – Implementation Selection Risks:

 Lowest cost tracing hardware – without consideration of TOTAL capex
 No consideration of operating/maintenance costs
 No design analysis proving approach maintains specific process characteristics
 Actual implementation details left to mechanical contractor
This process gets you through commissioning, but what about the longer term?
Result?
 Excess Capex costs
 More manifolds and trap circuits than is really required, jacketed pipe used when not required
 Performance Issues:
 Plugging, corrosion, process contamination
 Excessive Operation Costs

 More steam energy used than required
 Maintenance Cost impact:

 Outside expense needed to restart lines
 Heat blankets, steam hoses, etc.
 Difficulty with re-installation, re-use after maintenance action
 Need to add-on fixes to solve problems

The CSI Value Proposition:
CSI Virtual Tour
Facilities/Products
CSI Virtual Tour
CSI Headquarters
Charlotte, NC
Engineered Thermal Maintenance Solutions

32
CSI Virtual Tour
1.Jacketed piping systems
2.Process Pipe
3.Specialty fabrication
4.Bolt-On Products
33
CSI Virtual Tour
CSI Virtual Tour
Jacketed Pipe - Fabrication Expertise
What Separates CSI?

➢
High Integrity Fabrication has been CSI’s Specialty for 3 decades
➢
Detailed Engineering Expertise for fully jacketed products
➢
Superior Project Management
➢
Unmatched Quality Program
CSI Virtual Tour
CSI Virtual Tour
Jacketed Pipe and Manifolds - Fabrication Expertise

High Integrity Fabrication is CSI’s Specialty
➢
Fabrication to Machine Tolerance
➢
Jacketed Polymer Distribution Manifolds
➢
Fiber Optic Reactors
CSI Virtual Tour
CSI Virtual Tour
Jacketed Pipe and Manifolds - Fabrication Expertise
High precision fabrication using custom

designed fixtures
CSI Virtual Tour
CSI Virtual Tour
Process Pipe
•200 Spools/Week capacity
•Competitive pricing
•Convenience to fab pipe and install
ControTrace at factory
• Logistics savings
• Lower cost to install
• High quality installation
CSI Virtual Tour
CSI Virtual Tour
Specialty Fabrication
•Code Stamp Pressure vessels

•Tanks
•Skid/Module Packages
•Pre- Installation of CT/CH
CSI Virtual Tour
CSI Virtual Tour
Fabrication Expertise
CSI’s Engineering & Design Team:

➢
30 Designers and Engineers
➢
2 Registered PE’s
➢
Disciplines - BSME, BSChE, MSME, BSEE
CSI Virtual Tour
CSI Virtual Tour
Pipe and Fabrication Design
➢
Design Capabilities in AutoCAD and/or Inventor
➢
Macro and Micro Stress Analysis
➢
Macro and Micro Thermal analysis
➢
Hydraulic Analysis and Flow Balancing
➢
Pipe optimization
CSI Virtual Tour
CSI Virtual Tour
(5) Quality Control Personnel ensure the highest quality in the industry
➢
(2) Level III Personnel for MT, RT, PT and VT
➢
(3) Level II Personnel for RT, PT, MT and UT
➢
Radiography Acceptance Rates at 99.5% according to criteria established by
National Regulatory Codes (ASME B31.3, B31.1) w/ 791 yards of weld
subjected to RT
CSI Virtual Tour
CSI Virtual Tour
All NDE completed in-house
UT LPT Boroscopic Helium Mass Spec
Radiography Mag Particle Hydrostatic Pneumatic Halide Leak
Feroxyl PMI
CSI Virtual Tour
CSI Virtual Tour
Shop Fabrication Capabilities
➢
70+ Fitter Welders certified to ASME Section IX Code
➢
Over 120,000 Square Feet of Shop Space
➢
U, PP, R, VR Stamps (built and tested in accordance with B31.1
or B31.3.)
CSI Virtual Tour
CSI Virtual Tour
Shop Fabrication Capabilities
Over 110 Qualified Weld Procedures

Carbon Steel Stainless Steels
Monel Hastelloy
Alloy 20 Inconel
Titanium Duplex
P-11, P-22 P-91
CSI Virtual Tour
CSI Virtual Tour
Design & Fabrication of Bolt-On Heating Systems
Bolt-On Technology
• ControHeat for Valves, Pumps & Meters
• ControTrace for Piping & Tanks
CSI Virtual Tour
CSI Virtual Tour
Design & Fabrication of Bolt-On Heating Systems
Bolt-On Technology is the preferred method of heating for many processes:

Sulphur Asphalt Coker Lines PET DMT
Adhesives Caprolactam Acrylic Acids Asphalt
CSI Virtual Tour
CSI Virtual Tour
How does ControTrace Work?
Process Piping
Basic Heat Transfer = Q = UAdT
U = Rate of Heat Transfer between the

Steam and the Process.
Process
A = Amount of Heating Area.
Heat
Transfer
Cement
dT = Difference in Temperature between
the Steam and the Process. Heating Medium
ControTrace Heating Element

CSI Virtual Tour
CSI Virtual Tour
ControTrace Eliminates Steam-to-Process leaks that can

occur using jacketed pipe.
Chance for Cross-Contamination
Every core weld in a jacketed pipe Cross-Contamination concerns

system represents a potential leak are eliminated with the use of
problem ControTrace.
CSI Virtual Tour
CSI Virtual Tour
Example of traditional Tube Tracing

and what happens after a just a few
cycles
CSI Virtual Tour
CSI Virtual Tour
Example of a ControTrace
system on 24” pipe.
It is evident that
ControTrace is a much
more robust and
permanent solution.
CSI Virtual Tour
CSI Virtual Tour
ControTrace is a very good option to heat tanks. This is a 34 foot

diameter DMT tank in Fayetteville, NC.
CSI Virtual Tour
CSI Virtual Tour
Because ControTrace is an Engineered System, any vessel may be

jacketed with very effective heating.
CSI Virtual Tour
CSI Virtual Tour
ControHeat For Valves, Pumps, & Instruments:
• Excellent Heat Transfer

• Wide Component Selection
• No Cross Contamination risk
• Line Size Components
• No Modification to Original Equipment
• 100% Surface Area Coverage achievable
CSI Virtual Tour
CSI Virtual Tour
ControHeat For Valves, Pumps, & Instruments:

Component
Steel
Aluminum Pressure
Casting Chamber
CSI Virtual Tour
CSI Virtual Tour
Pattern Shop:
ControHeat patterns are made by skilled craftsmen from blocks of Mahogany

CSI Virtual Tour
CSI Virtual Tour
Embedded within each jacket is a pressure chamber that is built and

tested in accordance with ASME Section VIII, Division I.
CSI Virtual Tour
CSI Virtual Tour
Embedded within each jacket is a pressure chamber that is built and

tested in accordance with ASME Section VIII, Division I.
CSI Virtual Tour
CSI Virtual Tour
ControHeat jackets are cast daily in the CSI foundry

CSI Virtual Tour
CSI Virtual Tour
ControHeat
jackets are easy
to install.
CSI Virtual Tour
CSI Virtual Tour
More than 6000 patterns are held in inventory at CSI

CSI Virtual Tour
CSI Virtual Tour
CSI Virtual Tour
CSI Virtual Tour
ControHeat Bolt-On Jackets For Pumps and Blowers

CSI Virtual Tour
CSI Virtual Tour
ControHeat Bolt-On Jackets for Instruments and Meters

CSI Virtual Tour
CSI Virtual Tour
Questions?
Thermal Maintenance Basics
Thermal
Thermal Maintenance
Maintenance Basics Basics
Thermal Maintenance – Maintaining process temperatures in

piping and equipment to prevent product freezing, maintain a
low viscosity or prevent condensation.
•
Thermal Maintenance Scenarios – Different reasons to heat pipelines
•
Thermal Maintenance Technologies – Different methods of heating
pipelines
Thermal
Thermal Maintenance
Applications Require Effective Heating
– High temperatures to…
• Maintain process attributes
• Promote chemical reaction
• Preserve flow-ability
• Prevent freezing
• Prevent corrosion
– Cooler temperatures to…
• Avoid over-reaction
• Prevent premature equipment failure
Thermal
Thermal Maintenance
Why do we heat pipelines?
1) To Maintain Bulk Process 2) To Maintain Minimum Pipe Wall

Temperature Temperature
Thermal
Thermal Maintenance
1) Maintain Bulk Process Temperature
• Maintaining a process liquid • Typical Piping

temperature • Small diameter piping –
• Prevent freezing 2”- 12”
• Perform Melt-out • Jacketed pipe or
ControTrace
• Applications
• Liquids with freeze points
• Sulphur • Typical Heating media
• Ammonia • Medium Pressure Steam
• Thermoplastics to maintain • Liquid Hot oil
low viscosity
• Coker feed
• Heavy oil residuals
• Asphalt / bitumen
Thermal
Thermal Maintenance
Bulk Process Example: Prevent Line Plugging (Liquid)
Failed Liquid Sulfur Line caused by Improper Heating

Thermal
Thermal Maintenance
2) Maintain Minimum Wall Temperature
• Maintaining the pipe wall • Typical Piping

temperature • Large diameter piping
• prevent condensation causing 12”-84”
corrosion/plating/salting • Conventional tracing or
• prevent localized solidification ControTrace
• Applications
• normally applies for vapors • Typical Heating media
• sulphur tail gas • Medium Pressure Steam
• sulphur sweep air • Occasionally liquid hot oil
• Sour Water Stripper Gas
• sulphur degas
Thermal
Thermal Maintenance
Maintain Minimum Wall Temperature Example: Sulphur depositing on pipe
Improperly Heated Tail Gas Line

Thermal
Thermal Maintenance
Maintain Minimum Wall Temperature Example: Line Plugging (Vapor)
Failed Tail Gas Line caused by Improper Heating

Thermal
Thermal Maintenance
Maintain Minimum Wall Temperature Example: Corrosion on TG Pipe
Corrosion rates measured as high as 30 mils/month

Thermal
Thermal Maintenance
Maintain Minimum Wall Temperature Example: Corrosion of vapor
space on Tank wall
Failed Liquid Sulfur Storage Tank caused by Improper Heating

Thermal
Thermal Maintenance
Maintain Minimum Wall Temperature Example: Corrosion of vapor
space on Tank roof
Failed Sulfur Tank Roof after (7) years in Service

Thermal
Thermal Maintenance
What happens when vapor systems are treated with liquid

application solutions?
Thermal
Thermal Maintenance
Vapor Applications are Sensitive to Cold Spots
– Pipe Supports
– Flange Pair Big heat sinks!
– Nozzle Attachments
Heating Design must

take this into account!
Thermal
Thermal Maintenance
Some applications require both Bulk and Wall Temperature

Maintenance
Vapor space
Keep walls above
250°F to prevent:
• Sulfur solidification
• Corrosion
• Pyrophoric FeS
• Fire/explosion
Molten sulfur
Keep above 275°F to
maintain flow-ability
Thermal
Thermal Maintenance
Technologies
Jacketed Pipe
Tube/Electrical
Tracing
ControTrace TM
Bolt-On System
Thermal
Thermal Maintenance
Jacketed Pipe
Core Pipe Jacket Pipe
•
Fully envelope core pipe
with outer pipe
•
Conductive Heat
Transfer Path from
Steam through wall into
process
Process
Heating Medium
Insulation
Thermal
Thermal Maintenance
Tube Trace

Install stainless or copper Core Pipe
tubes under insulation

Convective Heat Transfer
from airspace to pipe
Process
Insulation
Tube Trace with

Heating Medium
Thermal
Thermal Maintenance
ControTrace Core Pipe


2” x 1” Boiler Tube Insulation
contoured to pipe size
straps onto pipe

Conductive Heat Transfer
Path from Steam through
Heating Medium
wall into process
Process
Heat Transfer
ControTrace TM Cement
Thermal
Thermal Maintenance
ControTrace uses finite
element software to
provide:

Number of Elements required to
meet the application requirement

Bulk Process Temperature

Temperature Gradient along entire
pipe wall

Rate of heat transfer

Out of Steam (steam
consumption)

Into Process
Thermal
Thermal Maintenance
Vapor Applications Require Thermal Modeling
VS.
Must Account for Process material and flow rates!

Thermal
Thermal Maintenance
Cost Comparison Summary

Jacketed Pipe
– Very High Capital Cost
– High Steam Consumption
– High Number of Steam and Condensate Manifolds
ControTrace
– Moderate Capital Cost (25% - 100% less than JP)
– Low Steam Consumption
– Low Number of Steam and Condensate Manifolds
Tube Tracing
– Low Capital Cost
– Low Steam Consumption
– Very High Number of Steam and Condensate Manifolds because each
tube is supplied and trapped independently.
Thermal
Thermal Maintenance
ControTrace TM
Questions? Bolt-On System
Tube Tracing
Jacketed Pipe
Heating System Design Considerations
Jacketing System Design
ControTrace System Design (Basics)

1) ControTrace System Engineering
2) Sizing, Positioning, Spacing
3) Thermal Expansion Allowance
4) Heating Medium Circuitry
Steam System Design (Deep Dive)

5) Steam Supply and Condensate Removal
6) Proper Stream Trap Selection
89
Jacketing
Jacketing System
System Design Design-
– ControTrace Systems
ControTrace Systems
ControTrace System Design (Basics)
1) ControTrace System Engineering
2) Sizing, Positioning, Spacing
3) Thermal Expansion Allowance
4) Heating Medium Circuitry
90
Jacketing
Jacketing System
ControTrace Systems
ControTrace System Engineering

Each System is Thermally Modelled
BEFORE we offer our system to your
specifications.

Output:

Number of Elements required to
meet the application requirement

Bulk Process Temperature

Temperature Gradient along entire
pipe wall

Rate of heat transfer

Out of Steam (steam
consumption)

Into Process
91
Jacketing
Jacketing System
ControTrace Systems

System Isometric for construction with
piece orientation

Individual Part Numbers with
Installation Orientation and allowable
spacing requirements

Steam & Condensate Locations

Individual Hose sizing and Routing

Support Coverage
92
Jacketing
Jacketing System
ControTrace Systems
• Each circuit is designed for Nominal Pipe Heat Steam
heat load and steam usage Steam Pipe Size Length Load Usage
Circuit (in) (ft) (BTU/hr) (lb/hr)
1A 6 4.2 7,794 8.7
1B 6 4.2 7,794 8.7
2A 8 158.3 37,703 42.1
2B 8 158.3 37,703 42.1
3A 8 199.6 46,750 52.1
3B 8 199.6 46,750 52.1
4A 8 121.5 31,010 34.6
4B 8 121.5 31,010 34.6
5A 8 123.5 28,260 31.5
5B 8 123.5 28,260 31.5
6A 8 198.5 46,525 51.9
6B 8 198.5 46,525 51.9
7A 8 152.5 35,938 40.1
7B 8 152.5 35,938 40.1
Total 1,916.20 467,960 522.0
93
Jacketing
Jacketing System
ControTrace Systems
Sizing, Positioning and Spacing of ControTrace
– ControTrace has the same general profile no matter what size pipe it
is applied (2” x 1”).
(ControTrace is also made in a 1 1/2” x 3/4” profile for 1 1/2” pipe and down)
– The larger the pipe, the more elements are added.

(Example, a 4” DMT line may have 2 elements where an 8” line may have 4 elements)
– With every application, CSI performs a thermal analysis to determine

the exact coverage requirements for that application. A process
guarantee is offered with every system.
94
Jacketing
Jacketing System
ControTrace Systems
– Is the heating medium vapor or liquid?

• If vapor, avoid placement on top.
– Are there pipe supports welded to the

bottom of the pipe?
• If so, avoid placement on bottom.
– Is the goal to maintain uniform wall temperature

instead of bulk process temperature?
• If so, the Elements must be spaced evenly.
95
Jacketing
Jacketing System
ControTrace Systems
ControTrace Positioning by Heating Medium

# of Elements Vapor (steam) Liquid (hot oil)
1 90, 180 or 270 0, 90, 180 or 270
2 90 & 270 90 & 270 or 0 & 180
3 90, 180 & 270 any 3
4 or more CSI fabrication CSI Fabrication
96
Jacketing
Jacketing System
ControTrace Systems
Examples of Multi-Element:
Vapor (Steam) Liquid (Hot Oil)
97
Jacketing
Jacketing System
ControTrace Systems
1a) Between Elements - There should always be a 2” gap between elements of

ControTrace to allow for growth.
98
Jacketing
Jacketing System
ControTrace Systems
1b) Between Elements – Where a zero gap is required, staggering the ControTrace is
recommended.
99
Jacketing
Jacketing System
ControTrace Systems
2) Slip-On Flanges –
– The ControTrace should end 1” behind the back of a Slip-On or Lap
Joint Flange.
– For flange pair over 4”, flange jackets are recommended.
3) Weld-Neck Flanges –
- ControTrace should end at the weld crown.
- For Flange pair over 2”, flange jackets are
recommended.
100
Jacketing
Jacketing System
ControTrace Systems
Thermal Expansion
The coefficient of linear thermal expansion is the ratio of the change in length per
degree F (imperial) to the length.
Linear thermal expansion for some common metals can be found in the table below:
Temperature Range Thermal Expansion
Metal (oF) (microinch/(in oF))
Aluminum 68 - 212 13.1
Cast Iron, gray 32 - 212 5.8
Chromium 3.3
Copper 68 - 572 9.8
Gold 7.9
Hastelloy C 70 - 200 5.3
Inconel 68 - 212 6.4
Monel 32 - 212 7.8
Nickel Wrought 77 - 212 7.4
Tin 32 - 212 12.8
Titanium 68 - 200 4.8
T(oC) = 5/9[T(oF) - 32]
1 in (inch) = 25.4 mm
1 ft (foot) = 0.3048 m
101
Jacketing
Jacketing System
ControTrace Systems
Thermal Expansion
• Standard ControTrace
Design allows only (1) fitting
in a section of ControTrace
• Standard maximum length

should be held to 40 feet
102
Jacketing
Jacketing System
ControTrace Systems
Heating Medium Circuitry Guidelines
Vapor (Steam or Hot Oil Vapor)

– General Guidelines
• Enter High, Exit Low.
• Steam Traps must be at the lowest point in the system.
• No increases in elevation within a circuit.
• Size traps properly.
– ControTrace Specific Guidelines

• If 1-2 elements are used, each element MUST be trapped independently,
headered panels must also be trapped independently.
• No more than 10 jumpers in any circuit.
• No more than 150 linear feet of ControTrace in any circuit.
103
Jacketing
Jacketing System
ControTrace Systems
Liquid (Hot Oil, Hot Water, Water/Glycol)

– General Guidelines
• Enter Low, Exit High.
• No decreases in elevation within a circuit without venting potential vapor
lock locations.
• Avoid long vertical rises within a circuit.
– ControTrace Specific Guidelines

• Avoid splitting flows and running parallel in multiple element systems.
This can cause uneven flows.
• No more than 10 jumpers in any circuit.
• No more than 100 linear feet of ControTrace in any circuit.
104
Jacketing
Jacketing System
ControTrace Systems
Jumper Connections
– Typically 1/2” minimum diameter to avoid large pressure drops
– No more than 10 hoses (or any other jumper) in any circuit (vapor or liquid).
– Orient jumpers to be below elevation of adjoining elements
(more important for vapor than liquid).
105
Jacketing
Jacketing System
ControTrace Systems
Questions about ControTrace Design?
106
Jacketing
Jacketing System
– Steam Systems
Steam Systems
Steam System Design (Deep Dive)
1) Steam Supply and Condensate Removal
http://www.csiheat.com/csi_university/steam/steam_lab_video.aspx
2) Proper Stream Trap Selection
107
Steam Trap Selection for CT / JP
Summary
Inverted Bucket
Recommended – no special considerations
Float / Free Float

Acceptable – must consider continuous air purging
Thermodynamic
Acceptable – must consider condensate return pressure
Thermostatic
Unacceptable – creates a column of condensate in the jacketing
CT / JP Trap Requirements
Remove Condensate
CT / JP designed for live steam

Thermostatic traps back up condensate
Remove Air
Air exist during start-up and during normal operation

Not all trap designs consider the presence of air during normal operation
Operate at Reduced Differential Pressure
Reduced steam pressure due to jump-overs

Increased condensate return pressure due to utility design
CT
CT/ JP Trap
/ JP Requirements
Trap Requirements
Differential Pressure
Inverted Bucket
Inverted Bucket
Inverted Bucket
Float
Float
Float
Float Trap
Float & Thermostatic Trap

Thermodynamic
Thermodynamic
Thermodynamic
Thermostatic
Thermostatic
Thermostatic
Thermostatic
Summary Summary
Inverted Bucket
Recommended – no special considerations
Float / Free Float

Acceptable – must consider continuous air purging
Thermodynamic
Acceptable – must consider condensate return pressure
Thermostatic
Unacceptable – creates a column of condensate in the jacketing
Sulfur Specific Applications
121
Sulfur Applications – Simplified SRU/TGU Schematic

TGTU Bypass Lines
Amine Acid
Gas (AAG) Tail Gas Lines
Sour Water
Stripper Gas TGTU
(SWS) 1st 2nd 3rd
Condenser Condenser Condenser
Su
lf ur
Ru
nd
ow
n Pit Sweep Lines
Bulk Sulfur Sulfur Transfer Lines
Storage
Sulfur Loading Lines

Sulfur Pit
122
Sulfur Sulfur Specific Applications
Specific Applications
Why do we keep Liquid Sulfur

Lines hot? 100,000 Cp

Sulfur freezes at 247 F (119 C)

Sulfur becomes very viscous at 321 F
(160 C) (5,000 to 100,000 cp)
Degassed Sulfur Curve

123
SulfurSulfur
SpecificSpecific Applications
Applications– Liquid Sulfur –
Liquid Sulphur
Historically, Jacketed Pipe is chosen on liquid Sulfur
applications…….Why?
124
SulfurSulfur
Liquid Sulphur
Historically, Jacketed Pipe is chosen on liquid Sulfur
•
100% Heating Surface Area
•
Very Efficient Heat Transfer path between Heating Medium and Process
•
No other Technology (tube tracing) was considered practical
125
Technology Gap
SulfurSulfur
Liquid Sulphur
However, Jacketed Pipe comes with hidden costs
•
High Capital Expense from Engineering and Fabrication Efforts and from
increased Infrastructure Costs
•
High Operating Expense from increased steam consumption
•
High Maintenance Expense from cross-contamination shutdowns
126
Technology Gap
SulfurSulfur
Liquid Sulphur
Jacketed Pipe Capital Cost Drivers

No Standard Modelling software for
Jacketed Pipe

Stress Analysis requires special attention to
model Jacketed Pipe – Expansion Loops
Approximately 150’ (50m)

Flanges Required every 20 – 40 ft (6-12m)

Crosses instead of Elbows add Engineering
time and Fabrication Costs

Plant standards require short steam circuits
(typically 40 ft (12 m)) which increases
infrastructure costs considerably
127
SulfurSulfur
Liquid Sulphur
Jacketed Pipe Capital Expense vs. ControTrace
128
SulfurSulfur
Liquid Sulphur
Jacketed Pipe Steam Consumption vs. ControTrace
129
SulfurSulfur
Liquid Sulphur
Annual Steam Savings with ControTrace
TCO: 10,000’
COP- Rodeo: 4,000’
Assumptions
 JP consumes 4X steam of CT
 Considers all lines < 12” NPS
 $5/ton of steam
130
SulfurSulfur
Liquid Sulphur
Jacketed Pipe enables Cross-Contamination between
Sulfur and Steam
Over time, leaks are expected in jacketed pipe. Normally, steam leaks into
the Sulfur. If steam is turned off or the Sulfur line is pressurized
unexpectedly, Sulfur can enter the steam system!
131
SulfurSulfur
Liquid Sulphur
Cross-Contamination can be dangerous
132
SulfurSulfur
Liquid Sulphur
ControTrace is a proven technology
•
Reduces Capital Expense $$
•
Reduces Steam Consumption $$
•
Eliminates Cross-Contamination $$
133
SulfurSulfur
Liquid Sulphur
Liquid Sulfur Projects
BP

Carson, CA – Jacobs - 3 SRU Rundown, Transfer Lines

Texas City, TX - Sulfur Loading/Unloading Lines

Whiting, IN – Petrofac – Sulfur Degas Lines
ConocoPhillips

Rodeo, CA – Fluor / CBI – Sulfur Rundown, Transfer Lines

Sweeny, TX – SNC / CBI - Sulphur Transfer Lines

Trainer, PA – Sulfur Rundown, Transfer Lines

Borger, TX - Sulfur Degas Lines
ExxonMobil / Esso / Imperial


Torrance, CA – Transfer Lines

Baton Rouge, LA - Transfer Lines

Joliet, IL – Ambitech / CBI – Sulfur Rundown Lines

England - Various Project

Sarnia, ON – Loading/Unloading Arms
134
SulfurSulfur
Liquid Sulphur
Flint Hills

St. Paul, MN – (2) Sulfur Degas Lines

Corpus Christi, TX - 1 ½ Mile 18” Liquid Sulphur Transfer Line
Marathon

Garyville, LA – Jacobs - 850 t/d SRU Rundown Lines

Canton, OH – Loading/Unloading Lines
Opti-Nexen

Long Lake, AB – Fluor – Sulfur Rundown, Transfer Lines
Petro-Canada

Edmonton, AB – Jacobs - Sulfur Rundown, Transfer Lines
Shell

Deer Park, TX - Liquid Sulfur Transfer Lines

Scotford, AB – Liquid Sulfur Transfer Lines, Rundown Lines, Seal Legs

Jumping Pound, AB – Liquid Sulfur Transfer Lines
135
SulfurSulfur
Liquid Sulphur
SK Energy

South Korea – Sulfur Rundown, Transfer Lines
Sunoco

Philadelphia, PA – Sulfur Rundown Lines
Syncrude

Canada UE1 - 2 mile Transfer Line
TCO

Kazakhstan - 2450 t/d SRU – Parsons/Fluor Daniel - Sulfur Rundown, Transfer Lines

Kazakhstan - 4 Sulfur Degas Unit Lines
Valero

Three Rivers, TX – Sulfur Rundown and Transfer Lines

Memphis, TN - Sulfur Rundown and Transfer Lines

Lima, OH – Petrofac - Sulfur Rundown and Transfer Lines
136
SulfurSulfur
Liquid Sulphur
Sample ControTrace Projects – Long transfer lines
Syncrude, Alberta - 2 mile 8” Liquid Sulfur Transfer Line
Sincor, Venezuela – 2 ½ mile 16” Liquid Sulfur Transfer Line
Flint Hills, Corpus Christi - 1 ½ mile 18” Liquid Sulfur Transfer Line
ControTrace has even larger savings on Long Transfer Lines:

•
Allows use of butt-welded construction instead of crosses and tees at elbows
•
Use far fewer (approx. 1/3 less) expansion loops with ControTrace
•
Allows long circuit length to be used (200-250ft/61-76m – average on above projects)
137
SulfurSulfur
Liquid Sulphur
Questions about Liquid Sulfur Thermal Maintenance?
140 ControTrace Fills the Gap

SulfurSulfur
Applications– Vapor Lines –
Vapor Lines
Why do we keep Sulfur-laden
Gas Lines hot?

Prevent Condensation inside pipe

Prevent Sulfur from freezing on
carbon steel which causes Wet-
Sulfur Corrosion
Improper Heated Tail Gas Line
141
Sulfur Specific
Applications– Tail Gas – Tail Gas
Historically, Tube Tracing is chosen on Tail Gas

142
Sulfur Specific
Historically, Tube Tracing is chosen on Tail Gas

•
Jacketed Pipe is too expensive
•
“Just add some heat” was acceptable practice in the past
•
No other Technology was considered practical
143
Technology Gap
Sulfur Specific
However, Tube Tracing comes with hidden costs

•
Can not meet the thermal requirements which leads to corrosion
•
Increases the Capital Expense with high infrastructure requirements
•
Increases the Operations Expense with too many traps to maintain and
with too many steam leaks to chase
144
Technology Gap
Sulfur Specific
Why Heat Tail Gas Lines?


Goal is to Maintain pipe wall temperature, not gas temperature

Keep wall temperature above vapour dew-point
How Freezing / Condensation occurs


Saturated Tail Gas contacts cooler wall  Condensation

Pipe Wall < 247°F (119C)  solid Sulfur freezing

Frozen Sulfur is good insulator (3X k of CalSil)

H2O reaches wall  Wet Sulfur Corrosion
145
Sulfur Specific
Pipe wall temperature modelling is required Look-up chart does not provide wall
with Finite Element Analysis temperature distribution
VS.
146
Tube Tracing is NOT Engineered
Sulfur Specific
153
Sulfur Specific
154
Sulfur Specific
155
ControTrace is Engineered
Sulfur Specific
156
Sulfur Specific
Design Output with every

ControTrace System

System Isometric for construction
with piece orientation

Individual Part Numbers with
Installation Orientation and
allowable spacing requirements

Steam & Condensate Locations

Individual Hose sizing and
Routing

Support Coverage
157
Sulfur Specific
Heating system (Cap-Ex)
Utilities infrastructure – S/C manifolds,

pre-ins. tubing, field labor (Cap-Ex)
Ongoing operational expenses to

maintain system/utilities (Op-Ex)
159
Sulfur Specific
Tube Tracing comes with high Infrastructure Costs
160
Sulfur Specific
Consider the Steam System from steam manifold to condensate return line.
Condensate return
header @ 15-25 psig
5-10 psig loss in

jacketing system
Steam
Riser
0 – 2 psig 20-40 feet
dynamic (10-20 psig)
loss
25 – 45
50 psig psig
Steam Trap
Supply 38-43 Location
psig
161
Sulfur Specific
Consider the Steam System from steam manifold to condensate return line.
Item $ ea. Qty/circuit $/circuit

Supply manifold, 14-position $9,000 1/14 $643
Return manifold, 14-position $14,000 1/14 $1,000
Pre-ins. tubing from supply to tracer (50 ft) $14/ft 50 ft $700
Pre-ins. tubing from tracer to return (50 ft) $14/ft 50 ft $700
Labor to install pre-ins tubing (9 ft/hr, $50/hr) $5.55/ft 100 ft $556
Swagelok connections $21 4 $84
Total cost per circuit $3,683
Total cost per supply $1,663
Total cost per return $2,020
162
Sulfur Specific
Example: 600 ft (183 m) long 84” Tail Gas line
Start-up Vent
Quench Bypass
From TGU
Incinerator
Final Condenser
To TGU Start-up Recycle
163
Before Circuitry
Sulfur Specific
Tube Tracing ControTrace System


28 tube tracers required according to 
18 Elements of ControTrace required
“charts” from Finite Element Model

196 Traps to Maintain (600 / 86 
22 Traps to Maintain (Through
X 28 = 196) Detailed Design)

16,800 feet of tubing need to be 
98 Pre-Engineered Panels need to be
installed correctly installed correctly

Contact Area needs to be maintained 
Contact Area is predetermined by the
with each individual tracer by field design
crews

Average circuit length = 50 ft (15 m) of

Average circuit length = 86 ft (26 m) pipe
of pipe
164
Sulfur Specific
165
Tube Trace Circuitry
Sulfur Specific
166
ControTrace Circuitry
Sulfur Specific
How does ControTrace save so many traps?
18 individual ControTrace elements

167
Sulfur Specific
How does ControTrace save so many traps?
2 steam supplies
Flexible metal
jumper hoses will
connect these
panels to the next
panels to extend
circuit length
168 18 Headered ControTrace Elements

Sulfur Specific
Tail gas line with ControTrace

for 70” NPS
169
Sulfur Specific
Steam Trap Savings of ControTrace vs. Tube Tracing

900
CT
800 TTe
10X
700 TT
Steam Trap Quantity
600
500
400
300 5X
200
100
0
10 20 30 40 50 60 70
Pipe Size (in)
CT= ControTrace, TTe= Tube tracing w/ HTC, TT= Tube tracing

170
Sulfur Specific
Cost Savings of ControTrace vs. Tube Tracing
50%
50 psig
150 psig
% Cost Savings with CT versus TTe
40%
30%
20%
10%
0%
10 20 30 40 50 60 70
Pipe size (in)
CT= ControTrace, TTe= Tube tracing w/ HTC

171
Sulfur Specific
172
Sulfur Specific
KTL’s 44” Line to Incinerator
173
Sulfur Specific
KTL’s 44” Line to Incinerator
174
Sulfur Specific
Sulfur Gas Projects

BP

Carson, CA – Jacobs - Rebuild TGTU Lines

Texas City, TX - TGTU Lines, Pit Sweep Lines

Whiting, IN – Petrofac - Pit Sweep Lines
ConocoPhillips

Rodeo, CA – Fluor / CBI - Pit Sweep Lines

Wilmington, CA - Pit Sweep Lines

Wood River, IL – Amine Acid Gas Lines

Trainer, PA - Pit Sweep Lines, TGTU Lines
ExxonMobil / Esso / Imperial


Baytown, TX TGTU Lines Pit Sweep Lines

Torrence, CA - Pit Sweep Lines

Baton Rouge, LA – TGTU Lines, Pit Sweep Lines

Beaumont, TX - Pit Sweep Lines

Joliet, IL – Ambitech / CBI - Pit Sweep Lines, TGTU Lines

England - Various Projects
175
Sulfur Specific
Sulfur Gas Projects

Flint Hills

St. Paul, MN – TGU Lines
Marathon

Garyville, LA – Jacobs - 850 t/d SRU AAG, SWS & TGTU Lines

Catlettsburg, KY - 2 TGTU Lines

St. Paul Park, MN - TGTU Lines
Opti-Nexen

Long Lake, AB – Fluor – TGTU Lines
Petro-Canada

Edmonton, AB – Jacobs - TGTU Lines
Shell

Deer Park, TX – TGTU Lines, Pit Sweep Lines

Scotford Upgrader – Jacobs - AAG, SWS & TGTU Lines

Anacortes, WA – AAG & TGTU Lines

Caroline Upgrader – TGTU Lines
176
Sulfur Specific
Sulfur Gas Projects

Suncor

Fort McMurray, AB – Jacobs - (Voyager) - SWS, AAG & TGTU Lines
Sunoco

Philadelphia, PA – Bantrel & CBl – TGTU Lines

Toledo, OH – Fluor & CBI - TGTU Lines

Marcus Hook, PA – CBI - TGTU Lines
Takreer

Abu Dhabi - SWS Lines
TCO Kazahkstan

2450 t/d SRU – Parsons/Fluor Daniel - AAG, SWS & TGTU Lines
Valero

Paulsboro, NJ – Rebuild TGTU Lines

Three Rivers, TX - AAG, SWS, TGTU & Pit Sweep Lines

Memphis, TN - AAG, SWS, TGTU & Pit Sweep

Lima, OH – Petrofac - AAG, SWS, TGTU & Pit Sweep

Port Arthur, TX - Pit Sweep, Oxygen Enrichment & SWS Lines
177
Sulfur Specific
Questions about Tail Gas Thermal Maintenance?
178
ControTrace Fills the Gap
Thermal Maintenance
Systems for Sulphur
Tank Applications
179
Sulphur Tank Applications
• Where/what are the problems?

• What is the cause of the
problems?
• Is there a better way?
180
Sulphur Specific Applications – Tanks
Historically, Internal Coils or External Plate Coils are

preferred in Liquid Sulphur Storage applications...WHY?
•
Maintaining bulk Sulphur temperature was the only goal in the past
•
Fully Jacketing Tanks and Vessels are too expensive
181
Sulphur Specific Applications –
Liquid Storage

Sulphur Tanks are a very corrosive environment

Lets examine some results of coils...
Roof Corrosion
182
Sulphur Tank Corrosion Example
Corrosion in
vapor space
183
Sulphur
condensing on
roof and
building up
Roof supports
corroded and
collapsing
184
185
Internal Coil Corrosion
Water trapped under
insulation causes
external corrosion
186
Sulphur
SulphurTank
Tank Corrosion Example
Corrosion Example
Fire in tank from

pyrophoric FeS
187
Summary of Sulphur Tank Problems
Problem Consequence
Coil Corrosion Take Tank out of service to
replace coils
Vapor Space Corrosion Take tank out of service to
repair panels
External Corrosion Take tank out of service to
repair panels
Sulphur build-up on roof Collapsed roof
Iron Sulfide formation Tank fires
Why do these problems occur?

188
Sulphur Tank Problem Cause
SULFUR CORROSION RESULTING FROM SOLID SULFUR DEPOSITION
Air
Purge Inner Fe surface (<100°C)
(H2O)
Solid S8
H2O condensation
S8
O2 H2O SO2 Expanded
view Porous
H2S H2O + SO2 Solid S8
140°C Liq. S8
H2O (vap)
• Cooling of roof may result from • Solid sulfur insulates Fe

removing liquid S8 from the tank; surface allowing it to cool < 100°C
most likely when only a steam coil • H2O diffuses through porous
is used to heat the sulfur solid sulfur
• Fe / S8 contact corrosion
H2O
Fe + S8 Fe Sx
189
How Can These Problems be Prevented?
Heating of Sulphur Tank must

consider Two Objectives:
1. Keep Sulphur Molten
2. and keep all wall and roof
surfaces above sulphur
condensation temperature!
Requires complex heat transfer analysis

of all elements in the system
190
Many Variables Affect
Sulphur Tank Heating
Sweep Air Flow

w (lb/hr) @ Tair
Qair = Heat Loss from

sweep air to ambient
(includes loss thru roof)
Tair
Sweep Air Flow
Qinternal = Heat Transfer Tank w (lb/hr) @ Tamb
from molten sulphur Height
Qsulphur = Heat Loss from to vapor space
sulphur to ambient
Sulphur
Qinput = Heat Transfer Level
to molten sulphur
Tsulphur
Plus other key variables:

• Insulation thickness Qground = Heat Transfer from
• Insulation type molten sulphur to ground
• Nozzles/attachments on tanks
191
ControTrace Tank Jackets
• Address both Sulphur Tank Heating Objectives!

Vapor space
Keep walls above
250°F to prevent:
• sulphur
solidification
• Corrosion
• Pyrophoric FeS
• Fire/explosion
Molten sulphur
Keep above 275°F to
maintain flow-ability
192
192
ControTrace Tank Jacket
an Engineered Solution
QCT QSweep Air
QRoof, Finite Element Analysis model created for
Roof, every tank to determine ControTrace
Vapor coverage to maintain Min wall
Vapor temperature at every spot on the tank.
All Variables Considered:
QCT Sides, QVapor QSides, •
•
Nozzles
Attachments
• Sweep air flow rates
Vapor Space Vapor • Sweep air temperature
• Maintenance temperature
• Worst case environment
• Insulation thickness
• Insulation type
QCT Sides, QSides, •

•
Low liquid level
High liquid level
• Heating media
Liquid • Roof shape
Liquid • Process input temperature
• Tank height
• Tank Diameter
ΣQin> •
•
Tank material and thickness
Pad details
QGround • Ground characteristics
193
193 ΣQout
ControTrace TankJacket
ControTrace Tank Jacket
an
anEngineered Solution
Engineered Solution
Computational Fluid Dynamics Model used in addition to Finite

Element Analysis Model for Large Tank Designs to validate circulation
and uniform molten state
CFD Modeling heat loss to the ground
194
CFD model setup: Axisymmetric
195
© Controls Southeast, Inc., 2010. This information may not be reproduced in part or in whole, without the expressed written permission of CSI.
Model results: Temp gradients
Axis of symmetry
vapor
liquid
ground
196
CFD model results: Circulation
197
Model results: Circulation
vapor
• Average sulfur velocity is 0.002 fps

ground
CFD model results
• Very large tanks can be heated using external heating

only
• Key is heating the vapor space as well as the liquid
• Maximum diameter is limited by the heat input rate
(sulfur temperature at the wall cannot exceed 318°F)
199
Model validation – Tanks in Service
• Two tanks in service with ControTrace system only
– Wall temperatures collected in July 2008
– Temperatures midway between elements (coolest point)
– Temperatures at different vertical locations in vapor space
Model Actual Delta

Tank 1 (Northeast US)
9.1m dia X 4.9m high
August 2007 start-up 133°C 132-134°C 1°C
146 m3/hr (86 cfm) sweep air rate
50% sulphur level
Tank 2 (Gulf Coast US)
13.7m dia X 12.2m high
March 2007 start-up 143°C 140-143°C 3°C
530 m3/hr (312 cfm) sweep air rate
34% sulphur level
200
Successful track record
End User Location Diameter Height Year
CLIMAX MOLYBDENUM FORT MADISON, IA. USA 35ft 20ft 2003
RAVENSTHORPE JERDACUTTUP, WA, AUSTRALIA 25ft (roof only) 21ft 2005
CONOCO PHILLIPS TRAINER, PA, USA 30ft 16ft 2006
MARATHON ASHLAND GARYVILLE, LA, USA 40ft 48ft 2006
CONOCO PHILLIPS SWEENY, TX, USA 45ft 40ft 2006
CONOCO PHILLIPS RODEO, CA, USA 30ft 30ft 2008
GS CALTEX YEOSU, SOUTH KOREA 46ft 36ft 2008
SHELL FORT SASKATCHEWAN, AB, CANADA 84ft (roof only) 32ft 2008
MARATHON ASHLAND GARYVILLE, LA, USA 40ft 48ft 2009
VALERO REFINING HOUSTON, TX, USA 31ft 25ft 2008
HUSKY INDUSTRIES LLOYDMINSTER, AB, CANADA 72ft (roof only) 20ft 2009
BP ROTTERDAM, NETHERLANDS 28ft 36ft 2009
CONOCO PHILLIPS WOOD RIVER, IL, USA 52ft 30ft 2009
SHELL ANACORTES, WA, USA 13ft 10ft 2009
ROQUETTE AMERICA KEOKUK, IA, USA 14ft 22ft 2010
BP WHITING, IN,USA 64ft 48ft 2010
BP WHITING, IN,USA 64ft 48ft 2010
GS CALTEX DAESON, SOUTH KOREA 91ft 26ft 2010
GS CALTEX DAESON, SOUTH KOREA 91ft 26ft 2010
201
Sample ControTrace Tank Photos
202
Wall Detail
Roof Detail
203
ControTrace Tank Benefit Summary
 Keeps Sulphur Molten
 No internal coils – eliminates need to ever go into tank
 Eliminates corrosion in vapor space (roof and walls)
 Eliminates sulphur tank fires from Iron Sulfide build-up
 Eliminates risk of roof collapse from weight of sulphur
build-up
 Eliminates cost of sulphur tank corrosion allowance
 An Engineered solution guaranteed to work
204
ControTrace can also Jacket Vessels
 Custom fabrication capability allow conformance to any surface

 Engineering analysis customized to every application
205
Installation
206
Installation
Installation
207
Installation
Installation
208
Installation
Installation
209
Installation
Installation
Lift Installation
Scaffolding Installation
210
Installation Complete
Installation Complete
211
Tank design optimization
• Key design parameters which affect ControTrace Cost:

– Steam pressure
– Low liquid level
– Insulation thickness and type
– Sweep air flow rates
– Sweep air temperature
– Tank geometry
CSI can help you optimize these variables

to minimize tank heating costs
212
Project execution
• Single point of contact assigned from PM

• CSI deliverables include:
– Complete engineered system
– Formal thermal analysis
– Installation drawings
– Installation materials (bosses, clips, hardware, HTC)
– System circuitry and all required jump-over hoses
– Field installation training/support
• Items by others
– Installation
– Insulation
213
Thermal Maintenance
Systems for
Delayed Coker
Applications
Coker end-user feedback
Chevron ● CNRL ● ConocoPhillips ● Hovensa ● Lyondell ● Marathon ● Shell ● Total
● Foster Wheeler ● Conoco Phillips ● CBI-Lummus
• Refinery Visits
• Technology Providers
• Feedback from presentations
at Coking.com
• ControTrace Users
215
Results of Discussions
• Where/what are the problems?

• Why are they having problems?
• Is there a better way?
• CSI overview
216
Main Problem - Plugging

Missed coker cycles
Flushing oil
Ceramic heat blankets
600 psig steam
Specific areas subject to plugging
218
Typical Specific Problem Areas
• Wedge meters in front of Furnaces
– Trouble with plugging
– Need to use flushing oil to keep free
– Use of Ceramic heat blankets to operate
• Redundant pump lines
– No-flow side plugs, can’t operate when
needed
• Resid feed lines plug
– Ceramic heat blankets - Flushing oil
– Hydroblasting - Steam hoses
– Ram pumping
• ET Lines
– Pre-mature coking from crossed
lines
– Uneven temperature distribution
– Failed systems allow plugged lines
219
Why are they having problems?
220
No heat needed if flowing
Coker Feed Flowing Through 8" Line Without Heating
610
600
Process Temperature (F)
590
580
570
560
550
0 2,000 4,000 6,000 8,000 10,000
Pipe Length (ft)
221
No flow = real design condition
• When does this happen?
– Bypass lines (NNF)
– Turnarounds
– Upsets
• Need melt-out capability also!
222
Inadequate specifications
• Typical P&ID:
– “Heat Trace”, “Heavy Tracing”
• Problem?
– Does not specify what outcome is required!
– A single tube trace could be used and meet spec
– Need to define more specific requirement:
Steam tracing design basis: (1) Maintain process at 325F during no flow and (2)
raise process temperature from ambient to 325F within 12 hr after loss of
utilities. Vendor is required to supply calculations to show compliance.
223
Heavier Resid Makes it Worse
Heavier More Heavier

Crude Efficient Resid
sources processing To coker
224
Historical heating methods
ineffective
Tube Tracing Electric Tracing
q  U  A  T q  Constant  qambient _ loss  q process

225
Historical heating methods
Tube Tracing Electric Tracing
Poor conductive heating Lower inherent reliability due to
number of active components
Usually requires HP steam Crossed cables can lead to coking
in line
Difficult to contact valves Difficult to contact valves
High installer variability High installer variability
Frequently distorted during Temperature controlled only at
maintenance actions thermostat points
Both give the illusion of “working” when lines are flowing!
226
Low expectations of heating
system
• Common Coping Mechanisms:
– Flushing oil procedures to clear lines
• Send product to slop system for future re-treat
• Uses up capacity of Delayed Coker
– Ceramic heat blankets
• Usually external service $3,000-10,000/day
– Hydro-blasting or other mechanical removal
Workarounds Common – Why Tolerated,

if ET or Tube Tracing is “Working”?
227
Is there a better way?
228
CSI overview
1.Heated piping systems
2.Engr. services
3.Process piping
4.Specialty fabrication
229
A More Robust Solution: ControTrace
• Process flows through piping
• 2”X1” rectangular tubing is
banded onto piping
• Designed with ASME Section VIII
• Contoured to fit pipe OD
• Heating medium flows through
tracing
• Use mastic to remove air gaps
• Add elements for more heat
q  U  A  T
230
How ControTrace works
1.HTC
between CT
nd pipe
2.Completely
insulated
q  U  A  T
Process Temperature
231
Maintenance
Higher U and A with ControTrace
CT
232
ControTrace on piping
233
ControTrace on tanks/vessels
234
ControHeat
• ControHeat for valves, pumps, instrumentation
235
ControHeat for components
236
Impact on melt-out time
Melt-out time - 8"NPS
100
90
80
Tube Trace
70
Melt-out Time (hours)
ControTrace
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8
Tube Trace Coverage
237
Enhanced technology value
Heating system cost
Ongoing Costs:
1. 1. Missed Coker cycles
2. 2. Flushing oil
3. 3. Ceramic heat blankets
4. 4. HP (600psig) steam
238
ControTrace Implementation Areas
Chevron, Conoco-Phillips and Marathon – Plugging Eliminated!

239
CSI bolt-on refinery successes
• BP – Carson, Cherry Point, Texas City, Whiting
• Chevron – El Segundo, Pascagoula, Salt Lake City
• ConocoPhillips – Borger, Rodeo, Sweeny, Trainer
• Exxon – Baton Rouge, Baytown, Beaumont, Sid Richardson, Torrance
• Flint Hills – Corpus Christi, Pine Bend, Rosemount
• Lyondell – Houston
• Marathon – Canton, Cattletsburg, Detroit, Garyville, Robinson, St. Paul
• Opti/Nexen – Fort MacMurray
• PetroCanada – Edmonton
• Shell – Anacortes, Caroline, Deerpark, Fort McMurray, Martinez, Shantz
• Sinclair – Tulsa, Wyoming
• Sincor & Petrozuata – Venezuela
• Suncor – Commerce City, Fort MacMurray, Sarnia
• Sunoco – Eagle Point, Marcus Hook, Philadelphia
• Syncrude – Fort MacMurray
• TCO – Kazakhstan
• Valero – Ardmore, Corpus Christi, Houston, Lima, Memphis, Norco/ St. Charles,
Paulsboro, Three Rivers, Wilmington
240
Summary & recommendations
• Specify required thermal duty for the system
• Require vendors to perform engineering to:
– Meet thermal duty
• Consider CT to:
– Solve heating problems
– Eliminate costly coping mechanisms
– Enhance value proposition
241
CONTROTRACE INSTALLATION
Overview
OBJECTIVES
Installation Tools & Heat Transfer Cement

How To Install Single Element ControTrace
How To Install ControTrace Panels For Pipe
How To Install ControTrace Panels For Tanks
How To Install ControHeats
How To Install Hoses
INSTALLATION TOOLS
INSTALLATION TOOLS
Only basic tools are required for installation of ControTrace. The following tools are recommended:
1. A banding tool
2. A 3” putty knife
3. Banding clamps
4. Banding (CSI supplied only)
5. Tape measure
6. Tin snips
7. Straight screwdriver
8. A small ballpeen hammer
9. ¾ to 1 ½ ton come-along
10. Channel lock pliers
11. Wrenches: 1 ¼”, 1 1/8”, 7/8”, 3/4”
12. Ratchet(s) and socket(s): 7/8”
13. Cement ( Grade 1 or Grade B ) *see
installation drawings for correct grade
Suggested material:
Rubber gloves and a Tyvek suit

HOW TO INSTALL SINGLE
ELEMENT CONTROTRACE
BASIC STEPS
• Use System Isometric to Determine Location of
EachControTrace Element
• Dry Fit ControTrace Elements to Check for
Accuracy of Fit
• Apply Heat Transfer Cement
• Secure ControTrace to Pipe with Stainless Steel
Banding
BASIC STEPS
Every CSI ControTrace project is supplied with a system isometric
that shows a minimum of the ControTrace mark #, location, hose
routing, heating media supply location/returns & orientation.
CONTROTRACE TAG
CONTROTRACE TAG
A high temperature paper tag is attached

to each piece of fabricated Contro Trace.
The information included on the tag is:
mark #, design ratings, CSI sales order #,
and job order #.
Locate the CT mark number on the system isometric to determine the physical location.
Dry Fit
DRY FIT
Once the pieces of ControTrace have been
identified and located in accordance with
the installation drawings, the pieces
should be “dry fit” in position. This
allows the correct spacing to be set
between the elements and the overall
system length to be verified to the as -built
pipe.
During the dry fit process, imperfections
on the pipe surface, such as excessive
weld crowns and O.D. mismatch, should
be corrected. This will ensure optimal
contact between the Contro Trace and the
pipe surface.
NOTE: If weld seam exceeds 1/8” height,
grind flush for optimal fit.
APPLYING CEMENT
APPLYING CEMENT
PLACE BANDING
PLACING BANDING
FOR A GOOD FIT, CEMENT SHOULD
SQUEEZE OUT
CLEAN EXCESS CEMENT OFF
HOW TO INSTALL
CONTROTRACE PANELS FOR
PIPING
DRY FIT PANEL AND MARK WITH
SOAP STONE
APPLY CEMENT
USEUSE BOLTING FIRST
BOLTING FIRST
IN SOME
IN SOME CASES, CASES AIS USEFUL
A COME-ALONG
COME-ALONG IS USEFUL
EXAMPLES
EXAMPLES OFOFFINISHED
FINSHED PRODUCT
PRODUCT
HOW TO INSTALL
CONTROTRACE PANELS ON
TANKS
DRY FIT ADRY FITOFAEACH
SAMPLE SAMPLE
TYPE OF PANEL
OF EACH TYPE OF PANEL
APPLYCEMENT
APPLY CEMENT
HANG
HANG PANEL PANEL ONCLIPS
ON WELDED
WELDED CLIPS
SECURE
SECURE WITHBOSS
WITH BOSS MATERIALS
MATERIALS
Install Panel
INSTALL PANELby
BYPanel
PANEL
COMPLETED SULFUR
COMPLETED SULFUR TANK
TANK
SULFUR
SULFUR STORAGE
STORAGE TANK (horizontal)
(horizontal)
Boss
BOSS TOto hold UNISTRUT
HOLD Unistrut
HOW TO INSTALL
CONTROHEATS
TOOLSREQUIRED
TOOLS REQUIRED
SCOOP GRADE 1 CEMENT OUT WITH
RUBBER GLOVES AND SPREAD EVENLY
(1/2” thickness)
SECURE WITH BOLTING MATERIAL
CLEAN EXCESS OFF(grade 1 cement can
not be reused. Do not put back in container)
HOW TO INSTALL HOSES
The Jumper Hoses should be attached after the ControTrace has
been completely installed. Again refer to the installation drawings
for details. This drawing shows jumper hoses connecting two
element panels.
Jumper hoses should be installed to form a “p-trap” to
hold condensate. The loop of the “p” should hang down to
prevent condensate from building up inside the
trace elements.
Frequently Asked Questions

Insulation over ControTrace

Crosses in Liquid Sulfur Service

ControHeat Installation
286
Frequently
Frequently AskedAsked Questions
Questions - HTC – HTC
Q: What is the purpose of Heat Transfer Cement (HTC)?
A: Ensure good conduction heat transfer between CT/CH and pipe/vessel/instrument by eliminating
any air gaps. Note: HTC thermal conductivity is not as good as metal, but it is 15X better than air.
Q: What Grade do I use for ControTrace?

A: Use Grade B for CT and Grade 1 for CH.
Q: What are the primary differences between Grade B and Grade 1?

A: Grade B is a grease-based compound that is not water soluble. It remains pliable at room
temperatures and will not cure. Grade-1, on the other hand, is a hardening cement that cures once
exposed to ambient and temperature. Grade B has a upper temperature limit of 400°F, whereas Grade
1 has an upper limit of 750°F.
Q: What is the shelf life of HTC?

A: Grade B has an unlimited shelf life, and Grade 1 has a shelf life of one year.
Q: How thick should the HTC layer be with ControTrace??

A: Liberally apply a ¼” layer to the side of the ControTrace which will be in contact with the pipe or
vessel. After tightening the CT to the pipe/vessel, excess HTC should squeeze out and leave no more
than a 1/8” (3mm) layer of HTC between the CT/pipe.
293
Frequently
Frequently AskedAsked Questions
Questions - HTC – HTC
Q: What are the long-term aging characteristics of Grade B HTC?

A: Although Grade B is not a non-hardening cement, after months of service at operating heating
medium temperatures, Grade B HTC’s grease base will dry, and the HTC will harden. The thermal
conductivity is based on this final state of the product. Grade 1 HTC’s does harden (it is water based
and after it dries, it hardens) thermal conductivity is not affected by time and/or temperature.
Q:What is the weather resistance of Grade B?

A: Prior to exposure to operating temperatures, Grade B is weather- and water-resistant. If the
insulation is removed after extended service life, exposure to heavy rain could lead to partial removal
of the HTC. If this occurs, inspection and potential re-application should be done prior to re-
insulation.
Q:What is the weather resistance of Grade 1?

A: Grade 1 should not be exposed to rain prior to its being fully cured. Once cured, a light rain should
not affect its integrity, but exposure to a prolonged, hard rain is not recommended.
294

Engineered Thermal Maintenance Solutions: Presented by Controls Southeast, Inc

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engineered Thermal Maintenance Solutions: Presented by Controls Southeast, Inc

Uploaded by

Copyright:

Available Formats

Engineered

Menu of Presentation Modules

1. Bolt-on Heating Systems

• 2”X1” rectangular tubing (SA 178) is

U = Rate of Heat Transfer between

ControTrace Heating Element

Every core weld in a jacketed pipe Cross-Contamination concerns

ControHeat Bolt-On Jackets For Pumps and Blowers

Jacketed piping – Largest JP supplier in N. America

Refineries Chemical Food

• CSI Organization Structure

Develop custom engineered

Develop quote package for

deliverables -Detailed Design

Sales Engineers (5):

What Makes CSI Unique?

CSI handles all aspects of the design from supply manifold to

23 Example of CSI Drawings

No worries experience for Client

A lack of design analysis ownership for the heating system

1. Imprecise process/FEED specifications:

2. EPC Contractor – Implementation Selection Risks:

 Excessive Operation Costs

 Maintenance Cost impact:

 Heat blankets, steam hoses, etc.

 Difficulty with re-installation, re-use after maintenance action

 Need to add-on fixes to solve problems