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8/20/2019 Advance Boiler Control System
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GESTRA Steam SystemsGESTRA
Intermittent blowdown valve MPA / PA up to PN250
IntermittentIntermittent BlowdownBlowdown ValveValve Special Design
-Radial Multi-stages Nozzle--Spring Closing Force
Fail Safe Function Boiler Pressure closes Valve Pneumatic Actuator Possible
. .
PN 40-250 DN 20-50
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Boiler water discharge of different valves
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 31 of 74
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GESTRA Steam SystemsGESTRA
Automated intermittend blowdown system conventional
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Bottom Blowdown Range up to PN250
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 32 of 74
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GESTRA Steam SystemsGESTRA
The Benefits of the New GESTRA Intermittent Blowdown Valves
Improved blowdown effectiveness through integrated pressure chamber in the outletsection of the body rea er g ness roug a ona w per r ngs e ween e pac ng sea s Longer service life and availability through radial stage nozzle downstream of the valveseat Insensitive to waterhammer through absence of large body cover Reduced wear through new arrangement of the seals on the low pressure side ons s en mp emen a on o e wor sa e y regu a ons roug nove s ance u e Quick and easy installation thanks to multifunction parts Reduced maintenance and service effort throu h additional cu s rin s actin on the
compression spring and through the possibility of tensioning the seals from outside Better checking functionally through relief vent for leak detection from outside
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Blowdown receiver
Cooling Water
Cooling Water
Mixed cooled water
Drain
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 33 of 74
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GESTRA Steam SystemsGESTRA
Boiler blow down with sample cooler
For Safety
[Result of Lab test from sampling
high TDS, resulting in the excessive
to atmosphere]
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
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 = 0.0035
Sample water from 10 barg to ATM will flash by 16%so wa er rom , , g w e , g o as s eamTDS / water new = 3,500 / 840,000 = 0.0042
ev a on = . - . x . ~ g er an e ac
boiler is by 2,916 ppm excessive blowdown Energy Loss
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 34 of 74
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Flash vessel
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 35 of 74
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GESTRA Steam SystemsGESTRA
Flash vessel
GESTRA Steam SystemsGESTRA
GESTRA Flash Vessel Design
Velocity of evaporation rate is. - . m s o avo carry over.
Condensate inlet over a
Large diameter
the impact to the vessel.
condensate inlet over
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 36 of 74
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GESTRA Steam SystemsGESTRA
Heat Recovery Skid
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 37 of 74
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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.0-2721-3860Page 38 of 74
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GESTRA Steam SystemsGESTRA
BA(E) 46 PN40 Surface blow down valve discharge capacity
GESTRA Steam SystemsGESTRA
(M)PA46 PN40 Bottom blow down valve discharge capacity
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 39 of 74
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
261.82 x (781.66-450.51)/2236.86
= . g
= 38.76x 24 x 300 kg/year
= 279.07 ton/ ear
279,072 x4.18 x (107.434 - 30) kJ/year
= 90,328,384 kJ/year
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
= , , . = . on year
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
223.06 x 4.18 x (107.434 - 40) kJ/h
= 62,874.41 kJ/h
62,874.41/2236.86 kg/h
= 28.11 kg/h
= 28.11 x 24 x 300 kg/year = 202,382.7 kg/year
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 40 of 74
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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.0-2721-3860Page 41 of 74
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
Sensible heat of blowdown water = 261.82 x 781.66 = 204,654.22 kJ/h
at 10 barg (781.66 kJ/kg)Sensible heat of drain point of = 261.82 x 4.18 x 40 = 43,776.3 kJ/h
‘ (specific heat of water (C) ~ 4.18 kJ/kg)
= - = , . , . , .
Equivalent to 0.3 barg steam = 160,877.92 /2,236.86 = 71.92 kg/h= . , .
Equivalent steam saving per year= 71.92 x 300 x 24 = 517,824 kg/year (steam cost = 985.12 B/t) = . x .
~ 510, 118 Baht + Water treatment cost
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Level Level Control Control
Monitor Monitor
Page 42 of 74
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GESTRA Steam SystemsGESTRA
Water Level Controls
The regulations concerning the control of Boilers vary from
.regulations require the Boiler to be fitted with :-
• Two independent low water alarms
• A device to control the boilerwater level
os regu a ons a so requ re e o er arms o e
tested daily.
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Extracted from Transaction Volume 4Page 43 of 74
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GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
body
magnet
magnet switch
11
rod
measuring chamber
float
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 44 of 74
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GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
ro em no on y rom e mov ng par ualso the boiler water quality
Float get struck from scale and dirt
Pitures extracted from other Safety Technology Bureau/ DIW
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Former German Re ulationWater limiter – Mechanical Float
body
ma netmagnet switch
Owing to the physical measurement principle
and the experience obtained in practice, which
11
rods a so re ec e n e amage a a es,additional requirements for the operation wereissued in the later develo ment of the technical
measuring chamber rules; these included a reduction of themaximum permissible boiler-water conductivity
floatrom , o cm, regu ar rep acemenof the magnetic switches etc. – measureswhich were intended to revent boiler dama e
but at the same time in-creased the operatingcosts
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 45 of 74
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GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
extracted from “National Board BULLETIN“ Issue : winter 1999
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 46 of 74
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GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
extracted from “National Board BULLETIN“ Issue : winter 1999
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
Test Requirement EN 1295-9 for Mechanical Float in EU
Float Movement : min 250,000 test cyclesElectromechanical switches : min 100,000 cycleOutside float and inside chamber : min 10 mm
No float switches for LW in EU
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 47 of 74
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GESTRA Steam SystemsGESTRA
Developement of GESTRA boiler control equipment
2010
NRG 261981
ER 961978ER 55
19771972
1980ER 83-3
SIL3
MR 16First self monitoring
ER 14
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Measuring Principals
Low level limiters
Conductivity Control
apac ance: or mo u a ng eve on ro Level control
n egra e g eve arm
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 48 of 74
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GESTRA Steam SystemsGESTRA
PN 6 Tmax: 156°C / 313°F Pmax: 6 bar
PN 10 Tmax: 180°C / 356°F Pmax: 10 bar
PN 40 Tmax: 238°C / 460°F Pmax: 32 bar
° ° max max
PN 160 Tmax: 311°C / 592°F Pmax: 100 bar
PN 320 T 400°C /752°F P 183 bar
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Conductive - Simple low level alarm
Isolator insulator
Meßspitze
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 49 of 74
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GESTRA Steam SystemsGESTRA
Concept Design of Conductivity Electrode
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Possible danger of limiter with ‘‘conventional design“
insulator
11
Probe tip
easur ng c am er
Short curcuit by means of deposits1
condensationafter steam penetration2
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 50 of 74
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GESTRA Steam SystemsGESTRA
Simple low level alarm
Isolator insulator
Meßspitze Electrode rod is covered byPTFE to protect the short circuit
**spacer to lock for multipleElectrode tip
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Selection of Controller
extracted from “National Board BULLETIN“ Issue : winter 1999
Spacer to lock electrode tips
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 51 of 74
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GESTRA Steam SystemsGESTRA
Water level limiter ”special design” self monitoring
monitoring electrode
rs nsu a or
second insulator
Monitoring electrodeinsulator
Probe tip
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
State of the Art Technology - Self Monitoring Level Limiter
Value
DeviceStatus(Alarm,
,
Watch Dog)
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 52 of 74
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GESTRA Steam SystemsGESTRA
Basic of Self Monitoring : Wheatstone bridge
RST = R of insulation across monitoring electrode
IG => 0and boiler shell => insulation checkRK = R across monitoring electrode and boiler shell=> scale check
RP1, RP2 = Fixed R of the design circuit
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Failure Dianogsis of Periodic Self-Checking Controller
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 53 of 74
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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 toTRD602(max. 2 hrs) only one self-monitoring low-level limiter is necessary
Boiler Equipment acc.to PED, EN 12952 and EN12953
e -mon or ng equ pmen w per o c-se c ec ng s requ re or o erswith temperature/pressure rating > 1 bar and > 120’C and a volume > 50 l
- -
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Function Safety acc.to PED, EN 12952 and EN12953
Since the international standards IEC 61508 and IEC 61511 for functionalsafet came into effect there has been an ever-increasin demand foranalysing equipment and process instruments that meet the requirements
accordin to SIL Safet Inte rit Level classification. The Euro ean directivesEN12952 and 12953 demand that a hazard analysis shall be carried out foreach limiting device function and appropriate levels of functional safety beImplemented.Note 1 states :” Typical Safety Integrity Level (SIL) requirements for boilerprotective systems are not less than 2”
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 54 of 74
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GESTRA Steam SystemsGESTRA
Safety Integrity Level (SIL) Overview
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Safety Integrity Level (SIL) Overview
Page 55 of 74
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GESTRA Steam SystemsGESTRA
Safety Integrity Level (SIL) Overview
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Safety Integrity Level (SIL) of GESTRA low water limiter
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 56 of 74
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GESTRA Steam SystemsGESTRA
ON-OFF LEVEL CONTROL APPLICATION
Pump on/off
Pump off
Low Alarm 2
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Inside the Spector Compact NRGS 16-2
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 57 of 74
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GESTRA Steam SystemsGESTRA
On- Off level control with self monitoring low level alarm
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
On/Off Level ControlAdvantages
Sim le suitable for low ca acit boiler
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GESTRA Steam SystemsGESTRA
Comparison: Intermittend / Continous
Intermittend with fixed switch points Continuous with variable switch points
High level -Alarm
Pump Off
High level-Alarm
Pump OnSet point
Low level -Alarm Low level - alarm
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Capacitance level probe
Measuring pipe20 mA
insulator 4-20 mA adjustablefor the whole probelength
Measuring chamber
4 mA
plug
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 59 of 74
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GESTRA Steam SystemsGESTRA
Principle capacitance measurement
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Principle capacitance level measurement
Page 60 of 74
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GESTRA Steam SystemsGESTRA
Principle capacitance level measurement
Capacitive Reactance XC
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Measurement with Capacitance Probes
Low Voltage
AC Supply
CurrentFlowsInsulated
Probe
Less CurrentFlows
Rod
Liquid
in a
Metal
Vessel
Probe Deeply Immersed Lower Water Level
between Probe rod and Water Less Current Flows
Page 61 of 74
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GESTRA Steam SystemsGESTRA
Level Calibration of Capacitance Probe
D
= Dielectric
W
T
L
W = Water
T = Teflon
L = Air
Probe tip cannot be cutD
Durch den Einfluß des Druckes wird derLuftspalt zwischen Teflonisolation undMeßrohr verdrängt
W
Durch den Einfluß der Temperatur längtsich der Teflonschlauch und wird somitdünner
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Modulating level control-conventional
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 62 of 74
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GESTRA Steam SystemsGESTRA
Pump speed control with compact probe NRGT 26-1
Frequency driven feedwater control
4...20 mA
Speise-wasser Feed water
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Modulating Level Control
van ages
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 consuption
Disadvantages
Less suitable for ‘stand b ’ o eration.
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 63 of 74
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GESTRA Steam SystemsGESTRA
Influence of the boiler capacity on the low level switchpoint
Main 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 production
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Sudden increasing steam consumption in the boiler leads to :
Pressure drop in the boiler
Increasing water level
Closure of the control valve
Pressure drop leads to increasing burner output
Steam bubbles are compressed
Boiler is shut down due to low level alarm !
Remedy ????
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 64 of 74
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GESTRA Steam SystemsGESTRA
Mode of Boiler Operation
Sudden increase in steam consumption
economizer
.
Three elements control for sudden change of steam
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Three element control
D
NLIC
Boiler
W
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 65 of 74
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GESTRA Steam SystemsGESTRA
Boiler equipment with SPECTORbus
GESTRA Steam SystemsGESTRA
Recommendation for installation 40 mm
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 66 of 74
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GESTRA Steam SystemsGESTRA
Recommendation for installation 40 mm
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
„Self monitoring“ External Low Level Limiter
Risks with externalmeasuring pots :
• Sto -valve blockin
• Mud inside level pot
• a ure n c ang ng evedetection
Page 67 of 74
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GESTRA Steam SystemsGESTRA
Level probe installed in an external measuring pot with SRL
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Level probe installed in an external measuring pot with SRL
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 68 of 74
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GESTRA Steam SystemsGESTRA
Compact Design and compatible to conventional systemsEasily accessible connection terminalsCompact Design and compatible to conventional systemsSupply voltage 24 VDC, improved EMC control (other voltages with separate power unit)Switchable sensitivity : 0.5 or 10 µS/cm
Intuitive operating using rotary pushbutton or color touch displaySPECTORmodule Touch with separate control unit and greatly extended
functionalityNow also as modulating controller and three-element controlAll limiter systems with SIL3 certification
GESTRA Steam SystemsGESTRA
SPECTORmodul TOUCHContinous level controller
-
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 69 of 74
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GESTRA Steam SystemsGESTRA
Screen shots of NRR 2-52 operating unit URB 50
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Screen shots of NRR 2-52 operating unit URB 50
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 70 of 74
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GESTRA Steam SystemsGESTRA
Condensate Monitoring
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Diffuse or stray light in water
90° Streulicht Scattering light
Lichtempfänger
15° Streulicht O to reciver
Lichtsender
Lichtempfänger Durchlicht Opto reciver
O to transmitter
Streuung von Fe ststoffen, daher Hauptanwend ungsgebiet in der Scattering of solids 90°Trinkwasser-Aufbereitung / -Versorgun g
Streuung von Öltropfen, daher Anwendung desScatterin of oil 15° teu c tver a rens zur er ennung
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 71 of 74
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GESTRA Steam SystemsGESTRA
Functional principle of the OR
Automatische Kompensation von Störgrößen wie: Verfärbung
Lam enalterun
Automaticly compansation of
Variable disturbance Verschmutzung der Gläser
VentilUmschaltung
AlarmTV AlarmValve switch over
3 – 12 V
X Actual valueSollwert
W Setpoint
Lampenspannung12 V Voltage 12 V
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Saving from Condensate Return
Condition : Condensate 1 t/h, P1 = 5 barg, P2 = 0.3 barg
Sensible heat of blowdown water = 1,000 x 671 = 671,000 kJ/h
at 5 barg (671 kJ/kg)
Feed water tem 30’C = 1 000 x 4.18 x 30 = 125 400 kJ/h (specific heat of water (C) ~ 4.18 kJ/kg)
= - = , , ,
Equivalent to 0.3 barg steam = 545,600 /2,236.86 ~ 244 kg/h . , .
Equivalent steam saving per year= 244 x 300 x 24 = 1,756,800 kg/year
(if steam cost = 1,000 B/t) = , . x ,~ 1,756, 800 Baht + Water treatment cost
ENERGY TECHNOLOGY CO., LTD.0-2721-3860Page 72 of 74
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GESTRA Steam SystemsGESTRA
Example of saving from condensate return
ENERGY TECHNOLOGY CO., LTD.0-2721-3860
GESTRA Steam SystemsGESTRA
Example of saving from condensate return
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GESTRA Steam SystemsGESTRA