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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


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

ENERGY TECHNOLOGY CO., LTD. 0-2721-3860


Steam Boiler Equipment– up to PN320

Analog Digital - Bus



SPECTOR - The right system makes all the difference



New Installation with busConventional Installation - Point to point - Analog



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


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


SPECTORcontrol - Wir verbinden Welten !Büro-PC / Laptop Servicepartner / LieferantProzeß-Leitwarte

EthernetIntranet

GSM-NetzFestnetz via Modem

Profibus DP


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



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




Condensate Turbidity or TDS Alarm


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.




Temperature Limiter for Superheater


• One Temperature gauge on every superheater stage

Automatic Temperature Control for superheated steam

Automatic pressure control (Burner control)




If national laws allows a operation without constant supervision, the


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



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%)


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 %


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



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.


y


Extracted from Transaction Volume 4


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



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


W t li it M h i l Fl tWater limiter – Mechanical Float


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



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


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



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



หลกการนาไฟฟา - Conductive : Simple level alarm

Isolatorinsulator

MeßspitzeProbe tip

MeßgefäßMeasuring chamber



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



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



Selection of Controller

extracted from “National Board BULLETIN“ Issue : winter 1999

Spacer to lock electrode tips



Water level limiter ”special design” self monitoring

monitoring electrode

first insulator

g

d i l tsecond insulator

Monitoring electrodeinsulatorprobe tip

insulator

Probe tip



State of the Art Technology - Self Monitoring Level Limiter

Device StatusWh t t b idStatus(Alarm,Configuration,Watch Dog)

Wheatstone bridge



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



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”



Safety Integrity Level (SIL) Overview


Safety Integrity Level (SIL) of GESTRA low water limiter



ON-OFF LEVEL CONTROL APPLICATION

Pump on/off

Pump off

Low Alarm 2Pump on


Multiple tip electrode


On- Off level control with self monitoring low level alarm



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


Principle capacitance measurement



Capacitance level probe

Measuring pipe20 mA

Measuring pipe

insulator4-20 mA adjustable for the whole probe

Measuring chamber

length

4 mAplug



Principle capacitance level measurement


Principle capacitance level measurement

Capacitive Reactance XC



Modulating level control with Control Valve or Pump c/w Invertor

Frequency driven feedwater control

Steam4...20 mA

Speise-wasser


wasser


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.



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



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 ????



Three element control

TICDD

NLIC

Boiler

W



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



Protection tube - Movie


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


Blowdown System



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.)



Steam boiler blow down

High TDSDilution of boiler water

t ll bl lLow TDS

to max, allowable value



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


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


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



Why Blowdown?

Boiler Tube Blocked with Sludge Caused by Insufficient Blowdown

Boiler Feedwater Line Blocked with Sludge from Feed tank.



Why Blowdown?

Break-down of hardness insideThe Boiler



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



Former Accidents Caused from Poor BlowdownWhy Blowdown?

Former Accidents Caused from Poor Blowdown

23mm scale



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


Scale and Sludge due to Poor Blowdown

Pitures extracted from other Safety Technology Bureau/ DIW


Fuel losses because of deposits in the boiler



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



Temperature influence on conductivity

actual = 25 ( 1 + / 100 (Tactual -25°C)) = 2-3 %/ C 2 3 %/ C



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.



Concept Design of Conductivity Electrode



Permissible Salt Content or TDS Limit



Max. TDS fire tube(shell) boiler ,feed water >30uS/cm

6000


Max.TDS water tube boiler,TDS feed water>30uS/cm

6000


Max.TDS water tube boiler,TDS feed water ≤ 30uS/cm


American Boiler Manufacturer Association (ABMA)



How much to Blowdown and How to Blowdown in order to Save Energy?in order to Save Energy?


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:



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 : 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



Blowdown Methods

Continuous Blowdown- Surface Intermittent Blowdown - Bottom


Continuous Blowdown- Surface Intermittent Blowdown - Bottom


Conductivity Control Characteristic



Surface Blowdown System – Modulating Control



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



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


Deposits at Conductivity Electrode


Conductivity measurement 4 electrode system-Scale Compensationp



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



Automatic intermittent blowdown system conventional



Boiler water discharge of different valves



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



Flash steam discharge/ventBlowdown receiver

Cooling Waterg

Cooling WaterHot waste water

Mixed cooled water

Drain



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]



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



Heat Recovery from Surface Blowdown



Or conductivity (uS/cm)




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


= 90,328,384 /2236.86 = 40.38 ton/year


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



H R f S f Bl dHeat Recovery from Surface Blowdown



H R f S f Bl d

Sensible heat of blowdown water = 261 82 x 781 66 = 204 654 22 kJ/h


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



Condensate Monitoring/ Savings with Turbidity & Conductivity ControlsConductivity Controls


Condensate Monitoring



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



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



Functional principle of the OR



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


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