LOTOS BIOPALIWA BIODIESEL PLANT PROJECT€¦ · provide a single holistic heat-trace system that took advantage of common control panel logic. With the construction schedule running

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PROJECT DETAILS

Client: Lotos Biopaliwa

Location: Czechowice-Dziedzice, Poland

Completion Date: May, 2008

Contract Scope: Engineering Design, Material Supply, Installation Supervision and Commissioning for the Electrical Heat-Tracing System

Applications: Temperature Maintenance and Pipe Freeze Protection for Biodiesel Plant

Technology: nVent RAYCHEM Self-Regulating and Mineral Insulated Heat-Tracing Systems, and RAYCHEM RAYSTAT-ECO-10 and TCON-CSD/20 Control and Monitoring System

KEY CHALLENGES

The biodiesel plant’s construction was carried out in two phases. Phase one included the main production of the plant by Prochem in conjunction with MAN Ferrostal, process licensee, who provided the engineering specification. Phase two involved the creation of the off-site infrastructure, including storage tanks for raw materials and finished product, pump stations, and pipelines between the facilities. Therefore, design of the heat-trace system involved combining two different sources of engineering documentation to provide a single holistic heat-trace system that took advantage of common control panel logic.

With the construction schedule running behind, nVent was left with a very short timescale to design, procure, install, and commission the entire heat management system.

LOTOS BIOPALIWA BIODIESEL PLANT PROJECT

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Raychem-WPCS-H59134-LotosBiodieselPlant-EN-1805

With decades of experience in designing, manufacturing and installing heat management systems, PTM was able to provide a comprehensive solution to Lotos Biopaliwa’ unique needs. The use of multiple heat trace technologies, a unique controller platform, and intelligent design around long line heating requirements ultimately lead to the success of this project.

nVent provides unique solutions for various applications and offers a full suite of optimization strategies customized for a given application resulting in the highest reliability and performance at a reduced CAPEX/OPEX for the project.

SOLUTION

nVent’s solution was to design and engineer the heat-tracing system using 3D modeling tools that not only abbreviated the design process, but also streamlined its execution. The system was designed with circuits that provided frost protection and process heating for the products being carried or stored in a variety of materials including stainless and carbon steel.

The system was charged to handle ambient temperatures of -25°C to 40°C, maintain temperatures of 5°C to 65°C, and maximum exposure temperatures from 50°C to 200°C. This project combined six different nVent products to offer the most effective and efficient solution for the 16-km heating system.

The company's Hew-Therm XPI polymer-insulated cabling for long transfer pipes and tanks made up 10.5 km of the heating system. Constructed with a PTFE jacket, these cables are able to withstand exceptionally high temperatures and are chemical resistant. The system's shorter circuits utilized RAYCHEM's parallel-circuit heating systems in a variety of self-regulating or power-limiting formats.

All of the heating systems selected offer the additional advantage of being terminated easily in the field, which was an extremely important factor for this project as the bulk of the system had to be installed on-site in just two weeks' time.

Monitoring and control of the frost protection circuits was provided by the company’s RAYCHEM RAYSTAT-ECO-10 ambient sensing energy-saving controllers, while the process heating control was managed by RAYCHEM TCONCSD/20 temperature controllers. The process heating control was installed within nVent-designed control panels and linked to local PT100 sensors.

The entire project took just four months from conception to completion, beginning in January and ending in May of 2008.

PRODUCTS

To meet the needs of this challenging application, nVent offered a Heat Management System which included:

• RAYCHEM BTV, QTVR, XTV, VPL; Hew-Therm XPI and XPI-NH heating cables

• Complementary cold leads

• RAYCHEM RAYSTAT-ECO-10 controllers and contactors for frost protection

• RAYCHEM TCON-CSD/20 controllers, contactors and PT100 sensors for process heating

• Power and control panels

BENEFITS

Through innovative execution techniques and a broad depth of product capability, nVent was able to provide a complete heat-trace solution to the client that was fully linked – products to controllers – all within a very demanding time-frame.

Tanks Lotos Biopaliwa site

Lotos Biopaliwa construction

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