Advance Boiler Control System

GESTRA
GESTRA Steam Systems
Intermittent blowdown valve MPA / PA up to PN250

z Intermittent Blowdown Valve
z Special Design
-Radial Multi-stages Nozzle
-Large Opening Area
-Spring Closing Force
z Fail Safe Function
z Boiler Pressure closes Valve
z Pneumatic Actuator Possible
z Function max
max. 3 Sec.
Sec
z PN 40-250
z DN 20-50
ENERGY TECHNOLOGY CO., LTD. 0-2721-3860
GESTRA
Boiler water discharge of different valves
Page 31 of 74
GESTRA
Automated intermittend blowdown system conventional
GESTRA
Bottom Blowdown Range up to PN250
Page 32 of 74
GESTRA
The Benefits of the New GESTRA Intermittent Blowdown Valves

Improved blowdown effectiveness through integrated pressure chamber in the outlet
section of the body
Greater
G t titightness
ht
th
throughh additional
dditi l wiper
i rings
i
between
b t
the
th packing
ki seals
l
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
Consistent
C i t t implementation
i l
t ti off th
the workk safety
f t regulations
l ti
th
throughh novell di
distance
t
ttube
b
Quick and easy installation thanks to multifunction parts
g additional cupp springs
p g actingg on the
Reduced maintenance and service effort through
compression 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
GESTRA
Blowdown receiver
Flash steam discharge/vent
Cooling Water
Hot waste water

Cooling Water
Mixed cooled water
Drain
Page 33 of 74
GESTRA
Boiler blow down with sample cooler
For Safety
For Accurate Measurement
[Result of Lab test from sampling
without sample cooler leads to too
high TDS, resulting in the excessive
blowdown due to loss of flash steam
to atmosphere]
GESTRA
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 water
t ffrom 1,000,000
1 000 000 kg
k will
ill bbe 160,000
160 000 kg
k off flflashh steam
t
TDS / water new = 3,500 / 840,000 = 0.0042
D i ti = [0
Deviation
[0.0042-0.0035]x100
0042 0 0035] 100 / 0.0035
0 0035 ~ 20% hi
higher
h th
than the
th fact
f t
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
Page 34 of 74
GESTRA
Heat Recovery from Surface Blowdown
GESTRA
Flash vessel
Page 35 of 74
GESTRA
Flash vessel
GESTRA
GESTRA Flash Vessel Design
Large diameter
Velocity of evaporation rate is

0 6 0 8 m/s
0.6-0.8
/ tto avoid
id carry over.
Condensate inlet over a
tangential pipe helps reduce
the impact to the vessel.
condensate inlet over

a tangential pipe
Page 36 of 74
GESTRA
Heat Recovery Skid
GESTRA
Page 37 of 74
GESTRA
GESTRA
Or conductivity (uS/cm)
Page 38 of 74
GESTRA
BA(E) 46 PN40 Surface blow down valve discharge capacity
GESTRA
(M)PA46 PN40 Bottom blow down valve discharge capacity
Page 39 of 74
GESTRA
261.82 x (781.66-450.51)/2236.86
= 38.76
38 76 kg/h
= 38.76x 24 x 300 kg/year
y
= 279.07 ton/year
279,072 x4.18 x (107.434 - 30) kJ/year
= 90,328,384 kJ/year
= 90,328,384
90 328 384 /2236.86
/2236 86 = 40.38
40 38 ton/year
GESTRA
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
28 11 x 24 x 300 kg/year
k /
= 202,382.7 kg/year
Page 40 of 74
GESTRA
GESTRA
Page 41 of 74
GESTRA

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
blowdown water at 40
40C
C
(specific heat of water (C) ~ 4.18 kJ/kg)
Energy Recovery
Equivalent to 0.3 barg steam
= 204,654.22
204 654 22-43
43,776.3
776 3 = 160,877.92
160 877 92 kJ/h
= 160,877.92 /2,236.86 = 71.92 kg/h
(latent heat of steam (r) at 0.3

0 3 barg = 2,236.86
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
517 824 x 985.12
985 12
~ 510, 118 Baht + Water treatment cost
GESTRA
Level
Control
Monitor
Page 42 of 74
GESTRA
Water Level Controls

The regulations concerning the control of Boilers vary from
Country to Country.
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 limits
Mostt regulations
M
l ti
also
l require
i th
the B
Boiler
il Al
Alarms tto bbe
tested daily.
GESTRA
Extracted from Transaction Volume

4
Page 43 of 74
GESTRA
Water limiter Mechanical Float

body
magnet switch
magnet
g
rod
1 1
measuring chamber
float
GESTRA

Routine test by pressure or magnetic force
Page 44 of 74
GESTRA

Problem
P
bl nott only
l ffrom th
the moving
i partt bbutt
also the boiler water quality
Float get struck from scale and dirt
Pitting (not cause boiler explosion)
Pitures extracted from other Safety Technology Bureau/ DIW
GESTRA
Former German Regulation
body
magnet switch
magnet
g
rod
1 1
measuring chamber
float
Owing to the physical measurement principle

and the experience obtained in practice, which
i also
is
l reflected
fl t d in
i the
th TV ddamage ddata
t fil
files,
additional requirements for the operation were
p
of the technical
issued in the later development
rules; these included a reduction of the
maximum permissible boiler-water conductivity
f
from
8 000 to
8,000
t 300 S/cm,
S/
regular
l replacement
l
t
of the magnetic switches etc. measures
which were intended to pprevent boiler damage
g
but at the same time in-creased the operating
costs
Page 45 of 74
GESTRA
GESTRA
extracted from National Board BULLETIN Issue : winter 1999
Page 46 of 74
GESTRA
GESTRA

Test Requirement EN 1295-9 for Mechanical Float in EU
Float Movement : min 250,000 test cycles

Electromechanical switches : min 100,000 cycle
Outside float and inside chamber : min 10 mm
No float switches for LW in EU
Page 47 of 74
GESTRA
Developement of GESTRA boiler control equipment
1969
ER 14
1977
1972
ER 77
MR 16
First self monitoring
1978
ER 55
1981
1980
ER 96
ER 83-3
First Capacitance
1999
NRG 26
2010
NRG 16
SIL3
GESTRA
Measuring Principals
z Conductive:
For level detection/Control
z Low level limiters

z Multiple tip electrodes
z Conductivity Control
z Capacitance:
C
it
F modulating
For
d l ti LLevell C
Control
t l
z Level control
z Integrated
I t
t d Hi
Highh llevell Al
Alarm
Page 48 of 74
GESTRA
Pressure temperature range of Conductive Electrode

The conductive probes are available for:
z PN 6
Tmax: 156C / 313F
Pmax: 6 bar
z
z
z
z
z
Tmax: 180C / 356F

Tmax: 238C / 460F
Tmax: 275
275C
C / 527
527F
F
Tmax: 311C / 592F
Tmax:: 400C /752F
Pmax: 10 bar
Pmax: 32 bar
Pmax: 60 bar
Pmax: 100 bar
P max 183 bar
PN 10
PN 40
PN 63
PN 160
PN 320
GESTRA
Conductive - Simple low level alarm
insulator
Isolator
Probe tip
Mespitze
Megef
egef
Measuring chamberM
Page 49 of 74
GESTRA
Concept Design of Conductivity Electrode
GESTRA
Possible danger of limiter with conventional design

2
insulator
1 1
Probe tip
M
Measuring
i chamber
h b
1
Short curcuit by means of deposits
condensation
after steam penetration
Page 50 of 74
GESTRA
Simple low level alarm
insulator
Isolator
Probe tip
Mespitze
Electrode rod is covered by

PTFE to protect the short circuit
Measuring chamberMegef
**spacer to lock for multiple

Electrode tip
GESTRA
Selection of Controller
Spacer to lock electrode tips
Page 51 of 74
GESTRA
Water level limiter special design self monitoring
monitoring electrode
fi t iinsulator
first
l t
second insulator
insulator
Monitoring electrode
probe tip
Probe tip
GESTRA
State of the Art Technology - Self Monitoring Level Limiter

Measured
Value
Device
Status
(Alarm,
Configuration,
Configuration
Watch Dog)
Page 52 of 74
GESTRA
Basic of Self Monitoring : Wheatstone bridge
RST = R of insulation across monitoring electrode

and boiler shell => insulation check
RK = R across monitoring electrode and boiler shell
=> scale check
RP1, RP2 = Fixed R of the design circuit
R1/R2 = R3/Rx
IG => 0
GESTRA
Failure Dianogsis of Periodic Self-Checking Controller
Page 53 of 74
GESTRA
Boiler Equipment acc. TRD

For boiler operation acc.to TRD 604 (max. 72 hrs without supervision)
t self-monitoring
two
lf
it i low
l level
l l lilimiters
it are required
i d andd ffor bboiler
il operation
ti tto
TRD602(max. 2 hrs) only one self-monitoring low-level limiter is necessary
Boiler Equipment acc.to PED, EN 12952 and EN12953

Self-monitoring
S
lf
it i equipment
i
t with
ith periodic-self
i di
lf checking
h ki iis required
i d ffor bboilers
il
with temperature/pressure rating > 1 bar and > 120C and a volume > 50 l
Two self-monitoring
self monitoring low
low-level
level for 24 hrs without supervision
GESTRA
Function Safety acc.to PED, EN 12952 and EN12953

Since the international standards IEC 61508 and IEC 61511 for functional
safety
sa
e y came
ca e intoo eeffect
ec there
e e has
as been
bee an
a ever-increasing
e e c eas g demand
de a d for
o
analysing equipment and process instruments that meet the requirements
accordingg to SIL ((Safetyy Integrity
g y Level)) classification. The European
p
directives
EN12952 and 12953 demand that a hazard analysis shall be carried out for
each limitingg device function and appropriate levels of functional safetyy be
Implemented.
Note 1 states : Typical Safety Integrity Level (SIL) requirements for boiler
protective systems are not less than 2
Page 54 of 74
GESTRA
Safety Integrity Level (SIL) Overview
GESTRA
Page 55 of 74
GESTRA
GESTRA
Safety Integrity Level (SIL) of GESTRA low water limiter
Page 56 of 74
GESTRA
ON-OFF LEVEL CONTROL APPLICATION
Pump on/off
Pump off
Pump on
Low Alarm 2
Multiple tip electrode
GESTRA
Inside the Spector Compact NRGS 16-2
Page 57 of 74
GESTRA
On- Off level control with self monitoring low level alarm
GESTRA
On/Off Level Control

Advantages
p , suitable for low capacity
p y boiler(<3-5
(
t/h),
), condensate and feed tank
Simple,
Inexpensive for investment
Good for stand by boilers
boilers.
Disadvantages
Intense thermal shock stress in the boiler
Leads to strongly
g y modulating
g operation
p
of burner
Integration into a heat recovery concept or exhaust gas cooling using the
principle
p is not p
possible
economizer p
More wear and tear on the feed pump and control gear and burner
Variable steam pressure and flow rate
rate.
More boiler water carry over.
Page 58 of 74
GESTRA
Comparison: Intermittend / Continous

Intermittend with fixed switch points
Continuous with variable switch points
High level -Alarm
High level-Alarm
Pump Off
9
Set point
Pump On
Low level - alarm
Low level -Alarm
GESTRA
Capacitance level probe
Measuring pipe
insulator
20 mA
4-20 mA adjustable
for the whole probe
length
Measuring chamber
4 mA
plug
Page 59 of 74
GESTRA
Principle capacitance measurement
GESTRA
Principle capacitance level measurement
Page 60 of 74
GESTRA
Principle capacitance level measurement
Capacitive Reactance XC
GESTRA
Measurement with Capacitance Probes

Low Voltage
AC Supply
Current
Flows
Insulated
Probe
Rod
Less Current
Flows
Liquid
in a
Metal
Vessel
Probe Deeply Immersed

Current flows due to Capacitance
between Probe rod and Water
Lower Water Level

Less Current Flows
Page 61 of 74
GESTRA
Level Calibration of Capacitance Probe

HD
H=HDielectric
HD = Steam
HT
HW
W = Water
T = Teflon
L = Air
HD
Probe tipp cannot be cut
Durch den Einflu des Druckes wird der

Luftspalt zwischen Teflonisolation und
g
Merohr verdrngt
Durch den Einflu der Temperatur lngt

sich der Teflonschlauch und wird somit
dnner
GESTRA
Modulating level control-conventional
Page 62 of 74
GESTRA
Pump speed control with compact probe NRGT 26-1

Frequency driven feedwater control
4...20 mA
Steam
SpeiseFeed water
wasser
GESTRA
Modulating Level Control

Advantages
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
stand by
by operation.
Page 63 of 74
GESTRA
Influence of the boiler capacity on the low level switchpoint
Main steam valve
Low level limiter
Main steam valve
Steam area
Low level limiter
Steam area
Combustion tube
Fire tube
Shell boiler without steam p

production
Shell boiler with steam p

production
GESTRA
Sudden increasing steam consumption in the boiler leads to :

z Pressure drop in the boiler
z Extension of steam bubbles
z Increasing water level
z Closure of the control valve
z Pressure drop leads to increasing burner output
z Steam bubbles are compressed
z Water level decreases partial below low level
z Boiler is shut down due to low level alarm !
z Remedy ????
Page 64 of 74
GESTRA
Mode of Boiler Operation

Sudden increase in steam consumption
Boiler performance during feedwater filling without
economizer
design
Operation at higher level or lower pressure of boiler design.
Three elements control for sudden change of steam
consuption
GESTRA
Three element control

TIC
D
N
LIC
Boiler
Page 65 of 74
GESTRA
Boiler equipment with SPECTORbus
GESTRA
Recommendation for installation 40 mm
Page 66 of 74
GESTRA
Recommendation for installation 40 mm
GESTRA
Self monitoring External Low Level Limiter

Risks with external
measuring pots :
Stop
Stop-valve
valve blocking
Mud inside level pot
F
Failure
il
in
i changing
h
i
level
l
l
detection
Page 67 of 74
GESTRA
Level probe installed in an external measuring pot with SRL
GESTRA
Level probe installed in an external measuring pot with SRL
Page 68 of 74
GESTRA
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 S/cm
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
SPECTORmodul TOUCH
Continous level controller
NRR 2-52
2 52
Page 69 of 74
GESTRA
Screen shots of NRR 2-52 operating unit URB 50
GESTRA
Screen shots of NRR 2-52 operating unit URB 50
Page 70 of 74
GESTRA
Condensate Monitoring
GESTRA
Diffuse or stray light in water

90 Streulicht
Scattering light
Lichtem pfnger
15 Streulicht
Lichtem pfnger
Durchlic ht
Opto
p transmitter
Opto
p reciver
Opto reciver
Lichtsender
Scattering of solids 90
Streuung von Feststoffen, daher

H auptanw endungsgebiet in der
Trinkw asser-A ufbereitung / -Versorgung
Scatteringg of oil 15
Streuung von ltropfen, daher A nw endung des

15 S tteulichtverfahrens
li ht
f h
zur lerkennung
l k
Page 71 of 74
GESTRA
Functional principle of the OR

Automatische Kompensation von Strgren wie:
) Verfrbung
) Lampenalterung
p
g
) Verschmutzung der Glser
Automaticly compansation of
Variable disturbance
TV
Alarm
Ventil
Umschaltung
Alarm
Valve switch over
3 12 V
Istwert
X
Sollwert
W
Lampenspannung
12 V
Actual value
Setpoint
Voltage 12 V
GESTRA
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 temp 30
30C
C
= 1,000 x 4.18 x 30 = 125,400 kJ/h
(specific heat of water (C) ~ 4.18 kJ/kg)
Energy Recovery
Equivalent to 0.3 barg steam
= 671,000
671 000-125
125,400
400 = 545,600
545 600 kJ/h
= 545,600 /2,236.86 ~ 244 kg/h
(latent heat of steam (r) at 0.3

0 3 barg = 2,236.86
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
1 756 8 x 1,000
1 000
~ 1,756, 800 Baht + Water treatment cost
Page 72 of 74
GESTRA
Example of saving from condensate return
GESTRA
Example of saving from condensate return
Page 73 of 74
GESTRA
Page 74 of 74

Advance Boiler Control System

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Advance Boiler Control System

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GESTRA

GESTRA Steam Systems

Intermittent blowdown valve MPA / PA up to PN250

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

GESTRA Steam Systems

Boiler water discharge of different valves

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

GESTRA Steam Systems

Automated intermittend blowdown system conventional

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

GESTRA Steam Systems

Bottom Blowdown Range up to PN250

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

GESTRA Steam Systems

The Benefits of the New GESTRA Intermittent Blowdown Valves

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

GESTRA Steam Systems

Flash steam discharge/vent

Hot waste water

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

GESTRA Steam Systems

Boiler blow down with sample cooler

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

GESTRA Steam Systems

Excessive Blowdown from sampling without sample cooler

Boiler Pressure 10 barg with boiler TDS = 3500 ppm (mg/l)

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

GESTRA Steam Systems

Heat Recovery from Surface Blowdown

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

GESTRA Steam Systems

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

GESTRA Steam Systems

GESTRA Steam Systems

GESTRA Flash Vessel Design

Velocity of evaporation rate is

condensate inlet over

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

GESTRA Steam Systems

Heat Recovery Skid

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

GESTRA Steam Systems

Heat Recovery from Surface Blowdown

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

GESTRA Steam Systems

Heat Recovery from Surface Blowdown

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

GESTRA Steam Systems

Heat Recovery from Surface Blowdown

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

GESTRA Steam Systems

BA(E) 46 PN40 Surface blow down valve discharge capacity

GESTRA Steam Systems

(M)PA46 PN40 Bottom blow down valve discharge capacity

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

GESTRA Steam Systems

Heat Recovery from Surface Blowdown

GESTRA Steam Systems

Heat Recovery from Surface Blowdown

223.06 x 4.18 x (107.434 - 40) kJ/h

GESTRA Steam Systems

Heat Recovery from Surface Blowdown

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

GESTRA Steam Systems