GESTRA Steam SystemsGESTRA
ENERGY TECHNOLOGY CO., LTD.
436 Soi On-nuch 39, Sukhumvit Rd., Suanluang, Bangkok Thailand 10250T l 0 2721 3860 F 0 2721 3869Tel : 0-2721-3860 Fax : 0-2721-3869Email : [email protected]
WORLD OF PUMPS l STEAM SYSTEM l SERVICE & ENGINEERING
GESTRA Steam SystemsGESTRA
Complete safety notes based on TRD 604, 72hFeedwater tank with deaerator
Boiler equipmentCondensate tankKondensatbehälter
Boiler
Condensate tank
Condensate monitoringBlowdown
I t itt d
Make-up watermonitoring
Boiler water qualitymonitoring
Intermittend blowdown
Wasseraufbereitung Kondensatüberwachung
monitoring
Water traetment Condensate monitoring
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GESTRA Steam SystemsGESTRA
Steam Boiler Equipment– up to PN320
Analog Digital - Bus
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GESTRA Steam SystemsGESTRA
SPECTOR - The right system makes all the difference
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GESTRA Steam SystemsGESTRA
New Installation with busConventional Installation - Point to point - Analog
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GESTRA Steam SystemsGESTRA
SPECTORbus Stecker / Plug System< / = 15m**
CAN Stift / Pi
CAN Buchse / Jack>15m max. 1000m*
/ 15m
Kabelausführung:Buchse / Jack Sensor
URB 2CAN Stift / Pin
Abschlusswiderstand / StiftTerminating Resistor / Pin
M20x1,5
Schaltschrank /Cabinet*Verteilerdose /
Junction box
Terminating Resistor / PinPartnr.: 1500977
**Buchse / OffenJack / Open
Junction box1501214
Buchse / StiftJack / Pin
*Offen / OffenOpen / Openoptional Jack / Open
1500973 [5m]1500974 [15m]
Jack / Pin1501021 [0,5m]1500969 [1m]1500970 [2m]
Open / Open392102 [50m Ring/Coil]RE2YCY 2X2X X,X mm²0,34 mm² 125m max
optional
Absalzventil / Blowdown valve BAE 46-4
1500971 [5m]1500972 [10m]
0,5 mm² 250m max.0,75mm² 1000m max
GESTRA Steam SystemsGESTRA
HMI BoilerhouseSiemens OP7 FANUC PLCSiemens OP7 FANUC PLC
PLC
Simatic Net ( MPI )
Profibus DP/FMSC Pr D D A A C CPPLC
Siemens S7-300
+ -NRS 1-40
CPU
Profibus
DI
DO
AI
AO
AN2
AN1
PSU
Burner 1
CAN – Bus Boiler 1NRS 1-40
CAN – Bus Boiler 2
Burner 2
+ -+ -
NRG 16-40 NRG 16-40NRG 16-42 NRG 16-42LRG 16-40 LRG 16-40NRG 26-40 NRG 26-40
GESTRA Steam SystemsGESTRA
SPECTORcontrol - Wir verbinden Welten !Büro-PC / Laptop Servicepartner / LieferantProzeß-Leitwarte
EthernetIntranet
GSM-NetzFestnetz via Modem
Profibus DP
GESTRA Steam SystemsGESTRA
อปกรณบงคบสาหรบหมอไอนาแบบ fire tube ตามกฏหมายของสหภาพยโรป EN12953 (Boiler Equipment acc. EN 12953)(Boiler Equipment acc. EN 12953)
Two Level gaugesTwo Level gauges• One direct and one indirect (Electrode)
Pressure Gauge Diameter 100mm• Test connector for test during operationTest connector for test during operation• Scale for test pressure of the boiler
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GESTRA Steam SystemsGESTRA
อปกรณบงคบสาหรบหมอไอนาแบบ fire tube ตามกฏหมายของสหภาพยโรป EN12953 (Boiler Equipment acc. EN 12953)
Bottom Drain valve
(Boiler Equipment acc. EN 12953)
• Could be used as a Blow down valveLevel Controller• With a non automatic burner control twiceHigh level alarm/pump off g p p• Must not be a separate Sensor
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GESTRA Steam SystemsGESTRA
อปกรณบงคบสาหรบหมอไอนาแบบ fire tube ตามกฏหมายของสหภาพยโรป EN12953 (Boiler Equipment acc. EN 12953)
Condensate Turbidity or TDS Alarm
(Boiler Equipment acc. EN 12953)
Condensate Turbidity or TDS Alarm• If oil,grease or some dangerous media could contaminate the feedwater
Low Level alarm 2X (Twice)
Pressure LimiterIf a pressure controller is required a separate transmitter is needed• If a pressure controller is required, a separate transmitter is needed.
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
อปกรณบงคบสาหรบหมอไอนาแบบ fire tube ตามกฏหมายของสหภาพยโรป EN12953 (Boiler Equipment acc. EN 12953)
Temperature Limiter for Superheater
(Boiler Equipment acc. EN 12953)
• One Temperature gauge on every superheater stage
Automatic Temperature Control for superheated steam
Automatic pressure control (Burner control)
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GESTRA Steam SystemsGESTRA
อปกรณบงคบสาหรบหมอไอนาแบบ fire tube ตามกฏหมายของสหภาพยโรป EN12953 (Boiler Equipment acc. EN 12953)
If national laws allows a operation without constant supervision, the
(Boiler Equipment acc. EN 12953)
p pmaximum time is 24h.
If national laws allows the time could be extended to maximum 72h if some If national laws allows, the time could be extended to maximum 72h, if some additional parts are included.-Conductivity (TDS) Controly ( )-High Alarm-Condensate turbidity control twice, if feedwater can be contaminatedCondensate turbidity control twice, if feedwater can be contaminated
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GESTRA Steam SystemsGESTRA
Damages on shell boilersFrom the Magazine TÜ (Technical Supervision) gObserving time 1980 - 1986
Number of corrosion and Erosion damages
Part Total number Production failures Maintenance
Flame tube 20 0 20 (100%)Turning chamber 18 0 18 (100%)Smoke tubes 131 6 125 ( 95%)Shell 31 2 29( 94%)Bottom 10 1 9 ( 90%)Anchor 6 0 6 (100%)
Number of deforming damages Part Total number Production failures Maintenance
Flame tube 32 2 30 ( 94%) Turning chamber 9 1 8 ( 89%) Smoke tubes 7 0 7 (100%) Sh ll 1 0 1 (100%)Shell 1 0 1 (100%)Bottom 1 0 1 (100%) Anchor 1 1 0 ( 0%)
GESTRA Steam SystemsGESTRA
D h ll b ilDamages on shell boilersFrom the Magazine TÜ (Technical Supervision) Observing time 1980 - 1986
Number of fractures
Part Total number Production failures Maintenance
g
Flame tube 51 17 34 ( 67%)Turning chamber 130 61 69 ( 53%)Smoke tubes 246 90 156 ( 63%)
Failure reasons
Shell 52 33 19 ( 37%)Bottom 117 52 65 ( 56%)Anchor 156 116 40 ( 34%)
Failure reasons
Maintenance54 %39 % Production
Other failures
39 %7 %
GESTRA Steam SystemsGESTRA
f f fBoilers are fitted with a variety of controls to ensure the safe reliable operation of your Boiler. They can be split into three categories.
A. Water Level controls
B. Blowdown controls
C. Firing controls
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GESTRA Steam SystemsGESTRA
Water Level ControlsThe regulations concerning the control of Boilers vary from Country to Country. In general however we can say that most regulations require the Boiler to be fitted with :-
• Two independent low water alarmsTwo independent low water alarms
• A device to control the boilerwater level within specified limits
Most regulations also require the Boiler Alarms to be tested daily.
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y
GESTRA Steam SystemsGESTRA
Former German Regulation - TRDWater limiter – Mechanical Float
body
magnetmagnet switch
Owing to the physical measurement principle
rod
Owing to the physical measurement principle and the experience obtained in practice, which is also reflected in the TÜV damage data files, additional requirements for the operation were 11
measuring chamber
additional requirements for the operation were issued in the later development of the technical rules; these included a reduction of the maximum permissible boiler water conductivity
float
maximum permissible boiler-water conductivity from 8,000 to 300 μS/cm, regular replacement of the magnetic switches etc. – measures
hi h i d d b il d which were intended to prevent boiler damage but at the same time in-creased the operating costs
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GESTRA Steam SystemsGESTRA
Problem not only from the moving part but Water limiter – Mechanical Float
y g palso the boiler water quality
Float gets struck from scale and dirt Pitting
Pitures extracted from other Safety Technology Bureau/ DIWENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Test Requirement EN 1295 9 for Mechanical Float in EU
Water limiter – Mechanical Float
Test Requirement EN 1295-9 for Mechanical Float in EU
Fl t M t i 250 000 t t lFloat Movement : min 250,000 test cyclesElectromechanical switches : min 100,000 cycleO t id fl t d i id h b i 10 Outside float and inside chamber : min 10 mmNo float switches for LW in EU
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GESTRA Steam SystemsGESTRA
Developement of GESTRA boiler control equipment
20101999
NRG 261981ER 961978
ER 551977ER 7719721969
1980ER 83-3
2010NRG 16
SIL355ER 771972
MR 16First self monitoring
1969ER 14
First Capacitance
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860First Conductive
GESTRA Steam SystemsGESTRA
หลกการวดของอเลกโทรด (Measuring Principals) ไฟฟ Conductive: F l l d t ti /ON OFF C t l หลกการนาไฟฟา - Conductive: For level detection/ON-OFF Control
(For Conductive Liquid >0.5 uS/cm) Low level limiters Low level limiters Multiple tip electrodes Conductivity Control
หลกการตวเกบประจ - Capacitance: For modulating Level Control
(For Conductive Liquid and Non-Conductive Liquid) Level control Integrated High level Alarm Integrated High level Alarm
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GESTRA Steam SystemsGESTRA
Comparison: Conductivity(ON-OFF)/ Capacitance(Continuous)Intermittent with fixed switch points Continuous with variable switch points
High level -Alarm High level-Alarm
Pump Off
Pump On
Set point
Low level -Alarm
Low level - alarm
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GESTRA Steam SystemsGESTRA
หลกการนาไฟฟา - Conductive : Simple level alarm
Isolatorinsulator
MeßspitzeProbe tip
MeßgefäßMeasuring chamber
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GESTRA Steam SystemsGESTRA
Possible danger of limiter with ‘‘conventional design“
2
insulator
Probe tip
11
Measuring chamber
Short curcuit by means of deposits1 Short curcuit by means of deposits
condensation after steam penetration2
1
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GESTRA Steam SystemsGESTRA
Simple level alarm
Isolatorinsulator
MeßspitzeProbe tip Electrode rod is covered by PTFE to protect the short circuit
MeßgefäßMeasuring chamber
p
**spacer to lock for multipleElectrode tip
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GESTRA Steam SystemsGESTRA
Selection of Controller
extracted from “National Board BULLETIN“ Issue : winter 1999
Spacer to lock electrode tips
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GESTRA Steam SystemsGESTRA
Water level limiter ”special design” self monitoring
monitoring electrode
first insulator
g
d i l tsecond insulator
Monitoring electrodeinsulatorprobe tip
insulator
Probe tip
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GESTRA Steam SystemsGESTRA
State of the Art Technology - Self Monitoring Level Limiter
Device StatusWh t t b idStatus(Alarm,Configuration,Watch Dog)
Wheatstone bridge
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GESTRA Steam SystemsGESTRA
Boiler Equipment acc. TRD
For boiler operation acc.to TRD 604 (max. 72 hrs without supervision) two self-monitoring low –level limiters are required and for boiler operation to TRD602(max. 2 hrs) only one self-monitoring low-level limiter is necessary
Boiler Equipment acc to PED EN 12952 and EN12953 Boiler Equipment acc.to PED, EN 12952 and EN12953 Self-monitoring equipment with periodic-self checking is required for boilers with temperature/pressure rating > 1 bar and > 120’C and a volume > 50 lwith temperature/pressure rating > 1 bar and > 120 C and a volume > 50 lTwo self-monitoring low-level for 24 hrs without supervision
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GESTRA Steam SystemsGESTRA
Function Safety acc.to PED, EN 12952 and EN12953
Si th i t ti l t d d IEC 61508 d IEC 61511 f f ti l Since the international standards IEC 61508 and IEC 61511 for functional safety came into effect there has been an ever-increasing demand for analysing equipment and process instruments that meet the requirementsanalysing equipment and process instruments that meet the requirementsaccording to SIL (Safety Integrity Level) classification. The European directivesEN12952 and 12953 demand that a hazard analysis shall be carried out for yeach limiting device function and appropriate levels of functional safety beImplemented.N t 1 t t ” T i l S f t I t it L l (SIL) i t f b il Note 1 states :” Typical Safety Integrity Level (SIL) requirements for boiler protective systems are not less than 2”
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GESTRA Steam SystemsGESTRA
Safety Integrity Level (SIL) Overview
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GESTRA Steam SystemsGESTRA
Safety Integrity Level (SIL) of GESTRA low water limiter
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GESTRA Steam SystemsGESTRA
ON-OFF LEVEL CONTROL APPLICATION
Pump on/off
Pump off
Low Alarm 2Pump on
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Multiple tip electrode
GESTRA Steam SystemsGESTRA
On- Off level control with self monitoring low level alarm
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GESTRA Steam SystemsGESTRA
On/Off Level ControlAdvantagesAdvantages
Simple, suitable for low capacity boiler(<3-5 t/h), condensate and feed tank
I i f i t t Inexpensive for investment
Good for ‘stand by’ boilers.
Disadvantages
Intense thermal shock stress in the boiler
Leads to strongly modulating operation of burner
Integration into a heat recovery concept or exhaust gas cooling using the i i i l i t ibleconomizer principle is not possible
More wear and tear on the feed pump and control gear and burner
Variable steam pressure and flow rate.
More boiler water carry over. ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Principle capacitance measurement
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GESTRA Steam SystemsGESTRA
Capacitance level probe
Measuring pipe20 mA
Measuring pipe
insulator4-20 mA adjustable for the whole probe
Measuring chamber
length
4 mAplug
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GESTRA Steam SystemsGESTRA
Principle capacitance level measurement
Capacitive Reactance XC
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GESTRA Steam SystemsGESTRA
Modulating level control with Control Valve or Pump c/w Invertor
Frequency driven feedwater control
Steam4...20 mA
Speise-wasser
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wasser
GESTRA Steam SystemsGESTRA
Modulating Level ControlAdvantages Economic Operation (economizer) Higher steam quality (reduce carry over) Steady steam pressure and flow rate. No strongly modulating operation of burner and more efficient
burner operation. Less thermal stress on the boiler shell. Less wear and tear on the feed pump and burner. Capability of adapting to difficult situations regarding the
controlled system e g sudden change of steam consuptioncontrolled system e.g. sudden change of steam consuptionDisadvantages Less suitable for ‘stand by’ operation Less suitable for stand by operation.
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GESTRA Steam SystemsGESTRA
Influence of the boiler capacity on the low level switchpoint
Main steam valve Main steam valveMain steam valve Main steam valveLow level limiter Low level limiter
Steam area Steam area
Combustion tube
Fire tube
Shell boiler without steam production Shell boiler with steam productionShell boiler without steam production Shell boiler with steam production
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GESTRA Steam SystemsGESTRA
Sudden increasing steam consumption in the boiler leads to : Pressure drop in the boiler
Extension of steam bubbles
Increasing water level
Closure of the control valve
Pressure drop leads to increasing burner output
Steam bubbles are compressed
Water level decreases partial below low level
Boiler is shut down due to low level alarm !
Remedy ????
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GESTRA Steam SystemsGESTRA
Three element control
TICDD
NLIC
Boiler
W
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GESTRA Steam SystemsGESTRA
Mode of Boiler Operation - Movie Sudden increase in steam consumption Sudden increase in steam consumption Boiler performance during feedwater filling without economizer Operation at higher level or lower pressure of boiler design Operation at higher level or lower pressure of boiler design. Three elements control for sudden change of steam consumption
download : http://www gestra com/academy/academyTV phpdownload : http://www.gestra.com/academy/academyTV.php
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GESTRA Steam SystemsGESTRA
Boiler equipment with SPECTORbus
Manual valve is not allowed for measuring chamber outside boiler if the level control is water level limiter
Possible for level control only
GESTRA Steam SystemsGESTRA
Water Impurities
Raw water
Dissolved Suspended Scum forming Dissolved Dissolved solids
Suspended solids
Scum forming substance
Dissolved gases
Alkaline hardness (temporary)
Non- Alkaline Hardness
(permanent)Non-Scale Forming
SaltsOxygen/
Carbon dioxideCarbonates/
Sulphates of Calcium & Magnesium
(p )Silica and also calcium
and magnesium in sulphate/chlorides
Sodium salt (sodium bicarbonate etc.)
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GESTRA Steam SystemsGESTRA
Steam boiler blow down
High TDSDilution of boiler water
t ll bl lLow TDS
to max, allowable value
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GESTRA Steam SystemsGESTRA
Table 5.1 Feed water for Steam Boiler & Hot Water Boilers
Pressure
Visibility
Unit Feed water für Steam Boilerwith TDS content
Auxiliary Water for Hot water boilers
Value
Clear, no suspended solidsyConductivity at 25°C
PH-value at 25°C
Total hardness
I (F )
, psee
Iron (Fe)
Copper (Cu)
Silica (SiO2)
O (O2)
Not defined yet. See table 5-2 for Boiler water values
Oxygen (O2)
Oil/Grease (Turbidity)
Organic matter
GESTRA Steam SystemsGESTRA
Table 5.2 Boiler water for Steam Boiler & Hot Water BoilersBoiler water for steam boiler Boiler water
Unit
Pressure
boilerFeed water conductivity
> 30µS/cm
Feed water cond
≤ 30µS/cm
for Hot waterGenerators
Value
VisibilityConductivity at 25°CPH-value at 25°C
Clear, no stable foam
See table 5-1
Acid capacity up to pH 8.2
Silica (SiO2)Phosphate (PO4)
Pressure depending, see picture 5-2
Organic matter
GESTRA Steam SystemsGESTRA
Why Blowdown?
To keep TDS or Conductivity within the permissible limit to avoid the followings
Foaming and Carry Over Poor Steam Quality [wet steam, erosion waterhammer] Corrosion Scale Formation O h ti Overheating Poor Heat Transfer Poor Boiler Control Poor Boiler Control Boiler Damage
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GESTRA Steam SystemsGESTRA
Why Blowdown?
Boiler Tube Blocked with Sludge Caused by Insufficient Blowdown
Boiler Feedwater Line Blocked with Sludge from Feed tank.
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GESTRA Steam SystemsGESTRA
Why Blowdown?
Break-down of hardness insideThe Boiler
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GESTRA Steam SystemsGESTRA
Tube Rupture by Overheating
427’CSURFACE TEMPERATURE
252’C
315’C The saturation temperaturwater at 40 Barg = 252’C
252’C252 C
Scaled boiler tubeClean boiler tube
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GESTRA Steam SystemsGESTRA
Former Accidents Caused from Poor BlowdownWhy Blowdown?
Former Accidents Caused from Poor Blowdown
23mm scale
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GESTRA Steam SystemsGESTRA
Former Accidents Caused from Poor BlowdownWhy Blowdown?Former Accidents Caused from Poor Blowdown
หมอไอนาระเบดของเกดจาก OVER HEAT ทสวนลางของทอไฟใหญ
โรงงานฟอกยอมผายนส มตะกรนจบหนาททอไฟใหญหนาไมตากวา 2 หน
มโคลนตะกอนสะสมอยใตทอไฟใหญมาก
เหลกทสรางหมอไอนาเปนเหลกคณภาพตา ทน เหลกทสรางหมอไอนาเปนเหลกคณภาพตา ทน
อณหภมไดตา
เกดจาก OVER PRESSURE เนองจากเกดจาก OVER PRESSURE เนองจาก
ทอไฟใหญมการกรอนพรนเปนหลมลกและบาง
มาก
ขอมลทวไป
การออกแบบและการสรางหมอไอนาไมเปนไป
ตามมาตรฐาน โดยทอไฟใหญม Ø โต 44 นว
ตงอยทถนนเทพารกษ อาเภอบางพล จงหวด สมทรปราการ
ระเบดวนท 7 กมภาพนธ 2546
มผเสยชวต 5 คน มผบาดเจบ 12 คน
แตไมมวงแหวนรด
ขอมล : สานกเทคโนโลยความปลอดภย กรมโรงงานอตสาหกรรม Tel 02-202-4222, www.diw.go.th
GESTRA Steam SystemsGESTRA
Scale and Sludge due to Poor Blowdown
Pitures extracted from other Safety Technology Bureau/ DIW
GESTRA Steam SystemsGESTRA
Fuel losses because of deposits in the boiler
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GESTRA Steam SystemsGESTRA
Cunductivity expressed in different units
10000 µS/cm equals approx 1 0°Baume10000 µS/cm equals approx. 1,0°Baume
1 S/ l 0 5 TDS1µS/cm equals approx.0,5 ppm TDS
1 S/ 1 0 h1 µS/cm approx. 1,0µmho
1 S/ l 0 5 lt lit1µS/cm equals approx. 0,5 mg salt per liter
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GESTRA Steam SystemsGESTRA
Temperature influence on conductivity
actual = 25 ( 1 + / 100 (Tactual -25°C)) = 2-3 %/ C 2 3 %/ C
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GESTRA Steam SystemsGESTRA
TDS ControlThe measuring priciple of the conductivity is simmilar to the The measuring priciple of the conductivity is simmilar to the conductive level measurementThe main difference is a defined measuring area (cell constant) of the probe g ( ) ptip that has constant and to be submerged in water at any time.
The TDS value referes to a temperature of 25°C.The temperature influence The TDS value referes to a temperature of 25 C.The temperature influence is compensated either by automatic or manual temperature compensation.
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GESTRA Steam SystemsGESTRA
Concept Design of Conductivity Electrode
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GESTRA Steam SystemsGESTRA
Permissible Salt Content or TDS Limit
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GESTRA Steam SystemsGESTRA
American Boiler Manufacturer Association (ABMA)
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GESTRA Steam SystemsGESTRA
How much to Blowdown and How to Blowdown in order to Save Energy?in order to Save Energy?
GESTRA Steam SystemsGESTRA
Blow down quantity (A)
The amount of water is calulated from: Max Conductivity/TDS of the Boilerwater K K in S/cm or ppm Max. Conductivity/TDS of the Boilerwater K K in S/cm or ppm Max. Conductivity/TDS of the Feedwater S S in S/cm or ppm M St it f B il QQ i K /h Max. Steam capacity of Boiler QQ in Kg/h
F lFormula:
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GESTRA Steam SystemsGESTRA
Saving by Maintaining TDS at the right set pointEx : Boiler 8 t/h, 10 barg[sensible heat = 782kJ/kg, latent heat =2000 kJ/kg], 80% load, Feed g[ g g]water TDS 150 ppm, Operate 7200 h/year, steam cost 1000 Baht/ton
Boiler Water TDS = 2500 ppmBoiler Water TDS = 2500 ppm Boiler Water TDS = 3000 ppmBoiler Water TDS = 3000 ppm Boiler Water TDS = 3500 ppmBoiler Water TDS = 3500 ppmBoiler Water TDS = 2500 ppmBoiler Water TDS = 2500 ppm
Bl d Q tit 409 k /hBl d Q tit 409 k /h
Boiler Water TDS 3000 ppmBoiler Water TDS 3000 ppm
Bl d Q tit 337 k /hBl d Q tit 337 k /h
Boiler Water TDS 3500 ppmBoiler Water TDS 3500 ppm
Blowdown Quantity = 287 kg/hBlowdown Quantity = 287 kg/hBlowdown Quantity = 409 kg/hBlowdown Quantity = 409 kg/h Blowdown Quantity = 337 kg/hBlowdown Quantity = 337 kg/h Blowdown Quantity = 287 kg/hBlowdown Quantity = 287 kg/h
Blowdown water energy : 409x782 = 319,838 kJ/h[ ~136 kg/h steam]
Blowdown water energy : 409x782 = 319,838 kJ/h[ ~136 kg/h steam]
Blowdown water energy : 337x782 = 263,534 kJ/h[ ~112 kg/h steam]
Blowdown water energy : 337x782 = 263,534 kJ/h[ ~112 kg/h steam]
Blowdown water energy : 287x782 = 224,434 kJ/h[ ~96 kg/h steam]
Blowdown water energy : 287x782 = 224,434 kJ/h[ ~96 kg/h steam][ ~136 kg/h steam]
= 0.98 MBaht/ year[ ~136 kg/h steam]= 0.98 MBaht/ year
[ ~112 kg/h steam]= 0.8 MBaht/ year[ ~112 kg/h steam]= 0.8 MBaht/ year
[ ~96 kg/h steam]= 0.69 MBaht/ year[ ~96 kg/h steam]= 0.69 MBaht/ year
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GESTRA Steam SystemsGESTRA
Blowdown Methods
Continuous Blowdown- Surface Intermittent Blowdown - Bottom
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Continuous Blowdown- Surface Intermittent Blowdown - Bottom
GESTRA Steam SystemsGESTRA
Conductivity Control Characteristic
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GESTRA Steam SystemsGESTRA
Surface Blowdown System – Modulating Control
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Surface Blowdown System – Modulating Control
Combination:Controller LRS1 7Controller LRS1-7Probe LRG 16-9Surface Blowdown Valve BAE46-3Ouputs: Max. Alarm 4 20 mA for actual conductivity 4-20 mA for actual conductivity Operate Surface Blowdown Valve
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Surface Blowdown Valve BAE46 - Design -Flash steam
B il tBoiler water
4-stage nozzle to reduce pressure gradually with the expansion chamber for each stage to decrase the velocity from flash steam resulting in less wear and tear
GESTRA Steam SystemsGESTRA
Conductivity measurement 4 electrode system-Scale Compensationp
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GESTRA Steam SystemsGESTRA
Why don‘t we use direct current to clean electrode tip? Creating Hydrogen and Oxygen on the tip Creating Hydrogen and Oxygen on the tip
itself and at the boiler shell Creating an anode and cathode by Creating an anode and cathode by
applying direct current to a TDS electrode. Depending on where we apply the plus pole, either the boiler or the electrode tip will be the anodeIn any case the anode will be destroyed In any case, the anode will be destroyed after a certain while. Electrode or Boiler?
Generating a fluctuating cell constant, as g g ,the electrode tip will vary in shape and surface area after each cleaning cycle
Electrolysis of water
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GESTRA Steam SystemsGESTRA
Automatic intermittent blowdown system conventional
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GESTRA Steam SystemsGESTRA
Boiler water discharge of different valves
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GESTRA Steam SystemsGESTRA
Intermittent blowdown valve MPA / PA up to PN250
Intermittent Intermittent BlowdownBlowdown Valve Valve Special Design
-Radial Multi-stages Nozzle-Large Opening Area-Spring Closing Forcep g g
Fail Safe Function Boiler Pressure closes Valve Pneumatic Actuator Possible Pneumatic Actuator Possible Function max. 3 Sec. PN 40-250 DN 20 50 DN 20-50
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Flash steam discharge/ventBlowdown receiver
Cooling Waterg
Cooling WaterHot waste water
Mixed cooled water
Drain
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GESTRA Steam SystemsGESTRA
Boiler blow down with sample cooler
For SafetyFor Safety For Accurate Measurement[Result of Lab test from sampling [Result of Lab test from sampling without sample cooler leads to too high TDS, resulting in the excessive g gblowdown due to loss of flash steam to atmosphere]
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GESTRA Steam SystemsGESTRA
Excessive Blowdown from sampling without sample cooler
Ex : Boiler Pressure 10 barg with boiler TDS = 3500 ppm (mg/l)or TDS / water = 3,500 / 1,000,000 = 0.0035Sample water from 10 barg to ATM will flash by 16%so water from 1,000,000 kg will be 160,000 kg of flash steam
TDS / t 3 500 / 840 000 0 0042TDS / water new = 3,500 / 840,000 = 0.0042Deviation = [0.0042-0.0035]x100 / 0.0035 ~ 20% higher than the fact
So if we calibrate TDS from this lab value then the exact value in the boiler is by 2,916 ppm excessive blowdown Energy Loss
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
Or conductivity (uS/cm)
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
261 82 x (781 66 450 51)/2236 86261.82 x (781.66-450.51)/2236.86= 38.76 kg/h= 38.76x 24 x 300 kg/year
279 07 t /= 279.07 ton/year279,072 x4.18 x (107.434 - 30) kJ/year= 90,328,384 kJ/year
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= 90,328,384 /2236.86 = 40.38 ton/year
GESTRA Steam SystemsGESTRA
H R f S f Bl dHeat Recovery from Surface Blowdown
223.06 x 4.18 x (107.434 - 40) kJ/h 62 874 41 kJ/h= 62,874.41 kJ/h
62,874.41/2236.86 kg/h= 28 11 kg/h 28.11 kg/h= 28.11 x 24 x 300 kg/year= 202,382.7 kg/year
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
H R f S f Bl dHeat Recovery from Surface Blowdown
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
H R f S f Bl dHeat Recovery from Surface Blowdown
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
H R f S f Bl d
Sensible heat of blowdown water = 261 82 x 781 66 = 204 654 22 kJ/h
Heat Recovery from Surface Blowdown
Sensible heat of blowdown water 261.82 x 781.66 204,654.22 kJ/hat 10 barg (781.66 kJ/kg)
Sensible heat of drain point of = 261 82 x 4 18 x 40 = 43 776 3 kJ/hSensible heat of drain point of 261.82 x 4.18 x 40 43,776.3 kJ/hblowdown water at 40‘C(specific heat of water (C) ~ 4.18 kJ/kg)(specific heat of water (C) 4.18 kJ/kg)
Energy Recovery = 204,654.22-43,776.3 = 160,877.92 kJ/hEquivalent to 0.3 barg steam = 160,877.92 /2,236.86 = 71.92 kg/hEquivalent to 0.3 barg steam 160,877.92 /2,236.86 71.92 kg/h(latent heat of steam (r) at 0.3 barg = 2,236.86 kJ/kg)
Equivalent steam saving per year= 71.92 x 300 x 24 = 517,824 kg/year(steam cost = 985.12 B/t) = 517.824 x 985.12
~ 510, 118 Baht + Water treatment cost
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA Steam SystemsGESTRA
Condensate Monitoring/ Savings with Turbidity & Conductivity ControlsConductivity Controls
GESTRA Steam SystemsGESTRA
Diffuse or stray light in water
90° Streulicht Scattering light
Lichtempfänger15° Streulicht
LichtempfängerDurchlicht
Opto reciverOpto reciver
LichtsenderDurchlicht Opto reciver
Opto transmitter
Streuung von Feststoffen, daherScattering of solids 90° Hauptanwendungsgebiet in derTrinkwasser-Aufbereitung / -Versorgung
Streuung von Öltropfen, daher Anwendung des
Scattering of solids 90
Scattering of oil 15° Streuung von Öltropfen, daher Anwendung des15° Steulichtverfahrens zur Ölerkennung
Scattering of oil 15
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GESTRA Steam SystemsGESTRA
Functional principle of the ORA t ti h K ti Stö öß i A t ti l ti f Automatische Kompensation von Störgrößen wie:
Verfärbung Lampenalterung Verschmutzung der Gläser
Automaticly compansation of Variable disturbance
AlarmTV AlarmVentil
UmschaltungValve switch over
IstwertX
3 – 12 V
Actual value
SollwertW Setpoint
Lampenspannung12 V Voltage 12 V
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GESTRA Steam SystemsGESTRA
Saving from Condensate Return Condition : Condensate 1 t/h P1 = 5 barg P2 = 0 3 bargCondition : Condensate 1 t/h, P1 5 barg, P2 0.3 bargSensible heat of blowdown water = 1,000 x 671 = 671,000 kJ/hat 5 barg (671 kJ/kg)at 5 barg (671 kJ/kg)
Feed water temp 30’C = 1,000 x 4.18 x 30 = 125,400 kJ/h(specific heat of water (C) ~ 4.18 kJ/kg)(specific heat of water (C) 4.18 kJ/kg)
Energy Recovery = 671,000-125,400 = 545,600 kJ/hEquivalent to 0.3 barg steam = 545,600 /2,236.86 ~ 244 kg/hEquivalent to 0.3 barg steam 545,600 /2,236.86 244 kg/h(latent heat of steam (r) at 0.3 barg = 2,236.86 kJ/kg)
Equivalent steam saving per year= 244 x 300 x 24 = 1,756,800 kg/year(if steam cost = 1,000 B/t) = 1,756.8 x 1,000
~ 1,756, 800 Baht + Water treatment cost
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860