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-Large Opening Area-Spring Closing Force
� Fail Safe Function� Boiler Pressure closes Valve� Pneumatic Actuator Possible� Function max 3 Sec� Function max. 3 Sec.� PN 40-250� DN 20-50
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GESTRA Steam SystemsGESTRA
Boiler water discharge of different valves
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GESTRA Steam SystemsGESTRA
Automated intermittend blowdown system conventional
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GESTRA Steam SystemsGESTRA
Bottom Blowdown Range up to PN250
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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 outlet section of the body
G t ti ht th h dditi l i i b t th ki l� Greater tightness through additional wiper rings between the packing seals� Longer service life and availability through radial stage nozzle downstream of the valve seat� Insensitive to waterhammer through absence of large body cover� Reduced wear through new arrangement of the seals on the low pressure side
C i t t i l t ti f th k f t l ti th h l di t t b� Consistent implementation of the work safety regulations through novel distance tube� Quick and easy installation thanks to multifunction parts� Reduced maintenance and service effort through additional cup springs acting on the g p p g gcompression spring and through the possibility of tensioning the seals from outside� Better checking functionally through relief vent for leak detection from outside� Greater convenience through innovative clip fastening of the hand lever PA 46/47� Greater convenience through innovative clip fastening of the hand lever PA 46/47
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GESTRA Steam SystemsGESTRA
Flash steam discharge/ventBlowdown receiver
Flash steam discharge/vent
Cooling Water
Hot waste waterCooling Water
Hot waste water
Mixed cooled water
Drain
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GESTRA Steam SystemsGESTRA
Boiler blow down with sample cooler
� For Safety� For Accurate MeasurementFor Accurate Measurement[Result of Lab test from sampling without sample cooler leads to toowithout sample cooler leads to too high TDS, resulting in the excessive blowdown due to loss of flash steamblowdown 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%
t f 1 000 000 k ill b 160 000 k f fl h tso water from 1,000,000 kg will be 160,000 kg of flash steamTDS / water new = 3,500 / 840,000 = 0.0042
D i ti [0 0042 0 0035] 100 / 0 0035 20% hi h th th f tDeviation = [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 theSo 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 Page 34 of 74
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
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GESTRA Steam SystemsGESTRA
Flash vessel
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GESTRA Steam SystemsGESTRA
Flash vessel
GESTRA Steam SystemsGESTRA
GESTRA Flash Vessel Design
� Velocity of evaporation rate is 0 6 0 8 / t id0.6-0.8 m/s to avoid carry over.
� Condensate inlet over a tangential pipe helps reduce
Large diametertangential pipe helps reduce the impact to the vessel.
condensate inlet over a tangential pipea tangential pipe
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GESTRA Steam SystemsGESTRA
Heat Recovery Skid
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
Or conductivity (uS/cm)
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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
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
261.82 x (781.66-450.51)/2236.86= 38 76 kg/h= 38.76 kg/h= 38.76x 24 x 300 kg/year= 279.07 ton/yeary279,072 x4.18 x (107.434 - 30) kJ/year= 90,328,384 kJ/year
90 328 384 /2236 86 40 38 ton/year
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= 90,328,384 /2236.86 = 40.38 ton/year
GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
223.06 x 4.18 x (107.434 - 40) kJ/h= 62,874.41 kJ/h62,874.41/2236.86 kg/h= 28.11 kg/h
28 11 24 300 k /= 28.11 x 24 x 300 kg/year= 202,382.7 kg/year
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
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GESTRA Steam SystemsGESTRA
Heat Recovery from Surface Blowdown
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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/hat 10 barg (781.66 kJ/kg)
Sensible heat of drain point of = 261.82 x 4.18 x 40 = 43,776.3 kJ/hblowdown water at 40‘Cblowdown water at 40 C(specific heat of water (C) ~ 4.18 kJ/kg)
Energy Recovery = 204 654 22-43 776 3 = 160 877 92 kJ/hEnergy 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/h(latent heat of steam (r) at 0 3 barg = 2 236 86 kJ/kg)(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/year517 824 985 12(steam cost = 985.12 B/t) = 517.824 x 985.12
~ 510, 118 Baht + Water treatment cost
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GESTRA Steam SystemsGESTRA
LevelLevelControlControlMonitorMonitor
Page 42 of 74
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 Country to Country. In general however we can say that most regulations require the Boiler to be fitted with :-
• Two independent low water alarms
• A device to control the boilerwater level within specified limitswithin specified limits
M t l ti l i th B il Al t b Most regulations also require the Boiler Alarms to betested daily.
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GESTRA Steam SystemsGESTRA
Extracted from Transaction Volume 4 Page 43 of 74
GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
body
magnetmagnet switch
g
11
rod
measuring chamber
float
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GESTRA Steam SystemsGESTRA
Routine test by pressure or magnetic force Water limiter – Mechanical FloatRoutine test by pressure or magnetic force
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GESTRA Steam SystemsGESTRA
P bl t l f th i t b tWater limiter – Mechanical Float
Problem not only from the moving part but also the boiler water quality
� Float get struck from scale and dirt� Pitting (not cause boiler explosion)� Pitting (not cause boiler explosion)
Pitures extracted from other Safety Technology Bureau/ DIWENERGY TECHNOLOGY CO., LTD. �0-2721-3860
GESTRA Steam SystemsGESTRA
Former German RegulationWater limiter – Mechanical Float
body
magnetmagnet switch
Former German Regulation
g
Owing to the physical measurement principle and the experience obtained in practice, which i l fl t d i th TÜV d d t fil
11
rodis also reflected in the TÜV damage data files, additional requirements for the operation were issued in the later development of the technical
measuring chamberp
rules; these included a reduction of the maximum permissible boiler-water conductivity f 8 000 t 300 S/ l l t
floatfrom 8,000 to 300 �S/cm, regular replacement of the magnetic switches etc. – measures which were intended to prevent boiler damage p gbut at the same time in-creased the operating costs
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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
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GESTRA Steam SystemsGESTRA
Water limiter – Mechanical Float
extracted from “National Board BULLETIN“ Issue : winter 1999
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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 mmOutside 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
19992010
NRG 161999NRG 261981
ER 961978 ER 551977
ER 7719721969
1980ER 83-3First Capacitance
NRG 16 SIL3
ER 77MR 16First self monitoring
1969ER 14
First Capacitance
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GESTRA Steam SystemsGESTRA
Measuring Principals
� Conductive: For level detection/Control� Conductive: For level detection/Control� Low level limiters� Multiple tip electrodes� Multiple tip electrodes � Conductivity Control
� C it F d l ti L l C t l� Capacitance: For modulating Level Control� Level control� I t t d Hi h l l Al� Integrated High level Alarm
ENERGY TECHNOLOGY CO., LTD. �0-2721-3860 Page 48 of 74
GESTRA Steam SystemsGESTRA
Pressure temperature range of Conductive Electrode
The conductive probes are available for:
Pressure temperature range of Conductive Electrode
The conductive probes are available for:� 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� PN 63 T : 275°C / 527°F P : 60 bar� PN 63 Tmax: 275 C / 527 F Pmax: 60 bar� PN 160 Tmax: 311°C / 592°F Pmax: 100 bar� PN 320 Tmax:: 400°C /752°F P max 183 barmax:: max
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GESTRA Steam SystemsGESTRA
Conductive - Simple low level alarm
Isolator
ß
insulator
Probe tipMeßspitze
Meßgefäß
Probe tip
Measuring chamberMeßgefäßMeasuring chamber
ENERGY TECHNOLOGY CO., LTD. �0-2721-3860 Page 49 of 74
GESTRA Steam SystemsGESTRA
Concept Design of Conductivity Electrode
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GESTRA Steam SystemsGESTRA
Possible danger of limiter with ‘‘conventional design“
22
insulator
11
Probe tip
M i h bMeasuring chamber
Short curcuit by means of deposits1
condensation after steam penetration2
ENERGY TECHNOLOGY CO., LTD. �0-2721-3860 Page 50 of 74
GESTRA Steam SystemsGESTRA
Simple low level alarm
Isolator
ß
insulator
Probe tipMeßspitze
Meßgefäß
Probe tip
Measuring chamber
� Electrode rod is covered by PTFE to protect the short circuit
MeßgefäßMeasuring chamber**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
fi t i l t
monitoring electrode
first insulator
second insulator
probe tip
Monitoring electrodeinsulatorprobe tip
Probe tip
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GESTRA Steam SystemsGESTRA
State of the Art Technology - Self Monitoring Level LimiterMeasuredMeasuredValue
Device Status(Alarm,ConfigurationConfiguration,Watch Dog)
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GESTRA Steam SystemsGESTRA
Basic of Self Monitoring : Wheatstone bridge
R1/R2 = R3/RxRST = R of insulation across monitoring electrode
R1/R2 = R3/RxIG => 0
and boiler shell => insulation checkRK = R across monitoring electrode and boiler shell
=> scale checkRP1, RP2 = Fixed R of the design circuit
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GESTRA Steam SystemsGESTRA
Failure Dianogsis of Periodic Self-Checking Controller
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GESTRA Steam SystemsGESTRA
Boiler Equipment acc. TRD
For boiler operation acc.to TRD 604 (max. 72 hrs without supervision) t lf it i l l l li it i d d f b il ti ttwo 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 S lf it i i t ith i di lf h ki i i d f b ilSelf-monitoring equipment with periodic-self checking is required for boilers with temperature/pressure rating > 1 bar and > 120’C and a volume > 50 lTwo self monitoring low level for 24 hrs without supervisionTwo 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
Since the international standards IEC 61508 and IEC 61511 for functional safety came into effect there has been an ever-increasing demand for sa e y ca e o e ec e e as bee a e e c eas g de a d oanalysing equipment and process instruments that meet the requirementsaccording to SIL (Safety Integrity Level) classification. The European directivesg ( y g y ) pEN12952 and 12953 demand that a hazard analysis shall be carried out for each limiting device function and appropriate levels of functional safety beg yImplemented.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) Overview
Page 55 of 74
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 onPump offPump on
Multiple tip electrodeLow Alarm 2
Multiple tip electrode
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GESTRA Steam SystemsGESTRA
Inside the Spector Compact NRGS 16-2
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GESTRA Steam SystemsGESTRA
On- Off level control with self monitoring low level alarm
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GESTRA Steam SystemsGESTRA
On/Off Level ControlAdvantages
� Simple, suitable for low capacity boiler(<3-5 t/h), condensate and feed tankp , p y ( ),
� Inexpensive for investment
� Good for ‘stand by’ boilers� Good for ‘stand by’ boilers.
Disadvantages
� Intense thermal shock stress in the boiler
� Leads to strongly modulating operation of burnerg y g p
� Integration into a heat recovery concept or exhaust gas cooling using the economizer principle is not possiblep p p
� More wear and tear on the feed pump and control gear and burner
� Variable steam pressure and flow rate� Variable steam pressure and flow rate.
� More boiler water carry over. ENERGY TECHNOLOGY CO., LTD. �0-2721-3860 Page 58 of 74
GESTRA Steam SystemsGESTRA
Comparison: Intermittend / ContinousIntermittend 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
�
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GESTRA Steam SystemsGESTRA
Capacitance level probe
Measuring pipe20 mA
insulator4-20 mA adjustable for the whole probe length
Measuring chamber4 mA
plug
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GESTRA Steam SystemsGESTRA
Principle capacitance measurement
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GESTRA Steam SystemsGESTRA
Principle capacitance level measurement
Page 60 of 74
GESTRA Steam SystemsGESTRA
Principle capacitance level measurement
Capacitive Reactance XC
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GESTRA Steam SystemsGESTRA
Measurement with Capacitance ProbesLow Voltage AC Supply
Current FlowsInsulated
Probe
Less Current Flows
Rod
Liquid in a Metal Vessel
Probe Deeply ImmersedCurrent flows due to Capacitance
Lower Water LevelCurrent flows due to Capacitance between Probe rod and Water
Less Current Flows
Page 61 of 74
GESTRA Steam SystemsGESTRA
Level Calibration of Capacitance Probe�D
��= Dielectric
�D = Steam
�W
�TL
�D = Steam
W = Water
T = Teflon
L = Air
�
Probe tip cannot be cutD
�
��
Durch den Einfluß des Druckes wird der Luftspalt zwischen Teflonisolation und Meßrohr verdrängt
p
W
��
g
Durch den Einfluß der Temperatur längt sich der Teflonschlauch und wird somit dünner
�
�
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GESTRA Steam SystemsGESTRA
Modulating level control-conventional
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GESTRA Steam SystemsGESTRA
Pump speed control with compact probe NRGT 26-1
Frequency driven feedwater control
Steam4...20 mA
Steam
Speise-wasserFeed water
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GESTRA Steam SystemsGESTRA
Modulating Level ControlAdvantagesAdvantages� 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 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 valveLow level limiter Low level limiter
Steam area Steam area
Combustion tube
Fire tube
Shell boiler without steam production Shell boiler with steam productionp p
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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� 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� Water level decreases partial below low level
� Boiler is shut down due to low level alarm !
� Remedy ????
ENERGY TECHNOLOGY CO., LTD. �0-2721-3860 Page 64 of 74
GESTRA Steam SystemsGESTRA
Mode of Boiler Operation
� Sudden increase in steam consumption� Boiler performance during feedwater filling without� Boiler performance during feedwater filling without
economizer� Operation at higher level or lower pressure of boiler designOperation at higher level or lower pressure of boiler design.� Three elements control for sudden change of steam
consuptionconsuption
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GESTRA Steam SystemsGESTRA
Three element control
TICTICD
NLIC
Boiler
W
ENERGY TECHNOLOGY CO., LTD. �0-2721-3860 Page 65 of 74
GESTRA Steam SystemsGESTRA
Boiler equipment with SPECTORbus
GESTRA Steam SystemsGESTRA
Recommendation for installation 40 mm
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GESTRA Steam SystemsGESTRA
Recommendation for installation 40 mm
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GESTRA Steam SystemsGESTRA
„Self monitoring“ External Low Level Limiter
Risks with external measuring pots :
• Stop-valve blockingStop valve blocking
• Mud inside level pot
F il i h i l l• Failure in changing level detection
Page 67 of 74
GESTRA Steam SystemsGESTRA
Level probe installed in an external measuring pot with SRL
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GESTRA Steam SystemsGESTRA
Level probe installed in an external measuring pot with SRL
ENERGY TECHNOLOGY CO., LTD. �0-2721-3860 Page 68 of 74
GESTRA Steam SystemsGESTRA
� Compact Design and compatible to conventional systems�Easily accessible connection terminals�Compact Design and compatible to conventional systems�Supply voltage 24 VDC, improved EMC control (other voltages with separate power unit)�Switchable sensitivity : 0.5 or 10 μS/cm�Supply via reliable networks possible without additional component (inverters)�Supply via reliable networks possible without additional component (inverters)�Intuitive operating using rotary pushbutton or color touch display�SPECTORmodule Touch with separate control unit and greatly extended
functionality�Now also as modulating controller and three-element control �All limiter systems with SIL3 certification
GESTRA Steam SystemsGESTRA
SPECTORmodul TOUCHContinous level controller
NRR 2 52NRR 2-52
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GESTRA Steam SystemsGESTRA
Screen shots of NRR 2-52 operating unit URB 50
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GESTRA Steam SystemsGESTRA
Screen shots of NRR 2-52 operating unit URB 50
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GESTRA Steam SystemsGESTRA
Condensate Monitoring
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GESTRA Steam SystemsGESTRA
Diffuse or stray light in water
90° Streulicht Scattering light
Lichtempfänger15° Streulicht Opto reciver
Lichtsender
LichtempfängerDurchlicht
pOpto reciver
Opto transmitterp
Streuung von Feststoffen, daherHauptanwendungsgebiet in derScattering of solids 90°Trinkwasser-Aufbereitung / -Versorgung
Streuung von Öltropfen, daher Anwendung des15° St li ht f h Öl k
Scattering of oil 15°15° Steulichtverfahrens zur Ölerkennung
g
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GESTRA Steam SystemsGESTRA
Functional principle of the ORAutomatische Kompensation von Störgrößen wie:
� Verfärbung� Lampenalterung
Automaticly compansation of Variable disturbancep g
� Verschmutzung der GläserVariable disturbance
VentilUmschaltung
AlarmTV AlarmValve switch over
Istwert3 – 12 V
IstwertX 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 bargSensible heat of blowdown water = 1,000 x 671 = 671,000 kJ/hat 5 barg (671 kJ/kg)
Feed water temp 30’C = 1,000 x 4.18 x 30 = 125,400 kJ/hFeed water temp 30 C 1,000 x 4.18 x 30 125,400 kJ/h(specific heat of water (C) ~ 4.18 kJ/kg)
Energy Recovery = 671 000-125 400 = 545 600 kJ/hEnergy Recovery 671,000 125,400 545,600 kJ/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)(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/year1 756 8 1 000(if steam cost = 1,000 B/t) = 1,756.8 x 1,000
~ 1,756, 800 Baht + Water treatment cost
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GESTRA Steam SystemsGESTRA
Example of saving from condensate return
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GESTRA Steam SystemsGESTRA
Example of saving from condensate return
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