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GESTRA Equipment for Energy Supply Centres Conventional or BUS technology for Land & Marine Applications

GESTRA

Equipment for Energy Supply Centres

Conventional or BUS technology for Land & Marine Applications

GESTRA Equipment for Energy Supply Centres Conventional or BUS technology for Land & Marine Applications
GESTRA Equipment for Energy Supply Centres Conventional or BUS technology for Land & Marine Applications
GESTRA Equipment for Energy Supply Centres Conventional or BUS technology for Land & Marine Applications
GESTRA Equipment for Energy Supply Centres Conventional or BUS technology for Land & Marine Applications
GESTRA Equipment for Energy Supply Centres Conventional or BUS technology for Land & Marine Applications
Steam and condensate systems with one-stop sophistication 2 Energy supply centre

Steam and condensate systems with one-stop sophistication

2 Energy supply centre
2
Energy supply centre
Equipment for Energy Supply Centres Electrical pressure control Steam flow measurement Controlled from the condensate
Equipment for Energy Supply Centres Electrical pressure control Steam flow measurement Controlled from the condensate

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres Electrical pressure control Steam flow measurement Controlled from the condensate
Equipment for Energy Supply Centres Electrical pressure control Steam flow measurement Controlled from the condensate
Electrical pressure control Steam flow measurement Controlled from the condensate side Electrical temperature
Electrical pressure control
Steam flow measurement
Controlled from
the condensate side
Electrical
temperature
control
Mechanical
Heat
temperature
exchanger
control
Monitoring
of turbidity
Monitoring of
conductivity
Flash
vessel
Sight glass
Steam trap
Non-return valve

Contents

Overview

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4–5

Steam Boiler Equipment with BUS Technology

 

6–7

Steam Boiler Equipment with SPECTORcontrol

 

Controlling, Monitoring and Visualizing

Steam Boiler Equipment with BUS Technology

 

8–9

 

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Spectorcontrol

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10–12

. Steam Boiler Equipment – Conventional – for 24 Hours of Unmanned Operation

SPECTORcom

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14–15

Steam Boiler Equipment – Conventional – for Operation with Limited Supervision

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16 –17

Steam Boiler Equipment for Plants Requiring No Supervision

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18–19

Equipment for Pressurized Hot-Water Plants

 

BUS Technology –

 

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Equipment for Pressurized Hot-Water Plants

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Conventional –

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Low-Level Limiters (LW)

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22–23

High-Level Alarm (HW)

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24

Level Controller

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25–27

Boiler Water Quality Monitoring

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28–31

Temperature Controller/Limiter

 

32–33

Sample Cooler PK

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34

Portable Digital Meter VRM-2/VRM-3

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35

Energy Recovery

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35

. Equipment for Steam Generators – Marine Boilers –

Condensate Monitoring

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36–39

40–41

3

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Overview Reliability, availability and economy have always enjoyed top priority in boiler operation. To an

Overview

Reliability, availability and economy have always enjoyed top priority in boiler operation. To an increasing extent, another aspect is being added:

plant automation and visualization.

To implement these fundamental principles, GESTRA AG has for decades now been working exclusively with electrode systems that are low in maintenance and wear; in contrast to other sys- tems, they function entirely without moving parts.

Over and above the boiler house equipment itself, these systems have now conquered the peripheral vessels, such as feedwater and condensate tanks, pumpless and pump-driven return installations

etc., since the entire energy supply centre is only as effective as its weakest element. Many of our customers therefore do not enter into any com- promises in this area too.

Another step forward was taken for the GESTRA equipment components through the introduction of the SPECTOR family, consisting of the Compact and the BUS technology variants, which not only permit easy integration into automation concepts but also provide many technical innovations that simplify plant construction and commissioning considerably.

The motto here is: “With GESTRA into the Future”.

The motto here is: “With GESTRA into the Future”. 4 We stand by what we say!

4

The motto here is: “With GESTRA into the Future”. 4 We stand by what we say!

We stand by what we say! For each safety-related requirement, we offer the right concept, and that all over the globe. From simple systems to units of “high-integrity design”; for landbased and shipboard boilers in the pressure ratings PN 6 to PN 320. Installations with high demands on tech- nical safety, e.g. in unmanned boiler operation or in power station engineering, are fitted with GESTRA components of “high-integrity design”.

These units work with constant self-monitoring and routine self-testing for loss of redundancy, which means that malfunctions in the system are detected immediately. Based on the positive experience gained over decades, GESTRA equip- ment components have been granted not only the German TÜV type approval but also approvals in Austria, Switzerland, Holland, England, Hungary, France, the Czech Republic, Slovakia as well as by many classification societies for the marine boiler sector. And of course, GESTRA AG also meets the requirements of the new European Pressure Equipment Directive.

GESTRA SPECTOR bus The benefits in detail 1. No risk of overheating: ◗ Patented thermal
GESTRA SPECTOR bus The benefits in detail 1. No risk of overheating: ◗ Patented thermal

GESTRA SPECTORbus

The benefits in detail

1. No risk of overheating:

Patented thermal barrier in cylindrical body above electrode flange

Electronic temperature protection in the terminal box

Patented connection arrangement

Minimization of thermal effects

2. Easy installation and maintenance:

Freely accessible connecting terminals at the control units

Large terminal box makes for easy installation

3. Reduced cost:

Minimized inventory and spares levels

Only a single cable needed between boiler and control cabinet

Low installation and material costs

GESTRA Performance Spectrum

System

Equipment for Energy Supply Centres

Spectrum System Equipment for Energy Supply Centres ◗ Reduced cost for control cabinets ◗ Cabling
Spectrum System Equipment for Energy Supply Centres ◗ Reduced cost for control cabinets ◗ Cabling

Reduced cost for control cabinets

Cabling connection male/female, ready-made cable

Only five input terminals

Only one cable in the control cabinet for all sensing units

Optimum system integration without additional cable installations

4. Increased safety:

Active cable monitoring with more than twice the previous maximum cable length

Easy to integrate into visual display and auto- mation systems

PN25

PN40

PN63

PN160

Less is more!

From little acorns big oaks grow. With the BUS technology by GESTRA, a new era has begun in the measurement and control of boiler systems:

Less cabling

Less installation work

Less space needed in control cabinets

Fewer control units

Less wear and tear

Less maintenance

Fewer production outages

Lower costs

More control

Better process overview

Higher availability

More reliability

Greater plant efficiency

Better utilization of energy

Longer plant operation times

PN250

PN320

Konv

Bus

Low-level limiters of “high-integrity design”

 

High-level alarms of “high-integrity design”

 

Level controllers Low-level limiters/controllers (compact units)

Safety temperature limiters Conductivity measurement

with autom. temperature compensation

without autom. temperature compensation

Continuous blowdown valves

 

Intermittent blowdown valves

www.gestra.de

• • • • • • Intermittent blowdown valves • • • • • www.gestra.de 5

5

GESTRA Steam Boiler Equipment with BUS Technology For operation e.g. according to TRD 604 (72

GESTRA Steam Boiler Equipment with BUS Technology

For operation e.g. according to TRD 604 (72 h) or EN 12953 (24 h)

For operation e.g. according to TRD 604 (72 h) or EN 12953 (24 h)

The future has already begun!

The future has already begun!

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Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”: level electrode NRG 16-40,
Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”: level electrode NRG 16-40,

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”: level electrode NRG 16-40, level
Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”: level electrode NRG 16-40, level
a Low-level limiter of “high-integrity design”: level electrode NRG 16-40, level switch NRS 1-40.1 1
a
Low-level limiter of “high-integrity design”:
level electrode NRG 16-40, level switch NRS 1-40.1 1 )
p. 22, 23
bt
Modulating level controller with integrated 2nd water level and
conductivity indicator: level probe NRG 26-40, level controller NRR 2-40,
control terminal and display unit URB 1 (URB 2)
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p. 25–27
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High-level alarm of “high-integrity design”:
level electrode NRG 16-41, level switch NRS 1-41 2 )
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p. 24
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Conductivity measurement and continuous/intermittent blowdown:
conductivity electrode LRG 16-41, continuous blowdown controller
LRR 1-40, continuous blowdown valve BAE, intermittent blowdown
valve MPA, 3/2-way pilot valve, strainer
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Sample cooler
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p. 34
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Blowdown flash vessel
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Residual blowdown cooler
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Blowdown receiver
k
Safety temperature limiter: resistance thermometer TRG 5-65,
temperature preamplifier TRV 5-40, level switch NRS 1-40.1 1 )
p. 32, 33
m
Safety valve GSV
n
Pressure limiter DSF
o
Pressure controller/transmitter
p
Disco non-return valve RK 86
q
Strainer GSF
r
Stop valve GAV
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Electrical/pneumatic control valve V 725
t
Control terminal and display unit URB 1 (URB 2)
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Process data acquisition SPECTORcontrol with interfaces:
CAN, MODbus, Ethernet, modem, Profibus (optional)
v
Burner control unit
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Monitoring of the fresh water:

Demineralization equipment – using conductivity monitoring

Partial demineralization equipment: by monitoring residual hardness (not part of our product range)

1 ) Only one electronic control unit is needed. 2 ) Not required by EN.

control unit is needed. 2 ) Not required by EN. The benefits in detail The benefits

The benefits in detail

The benefits in detail

No risk of overheating

No risk of overheating

• •

Patented thermal barrier in cylindrical body

Patented thermal barrier in cylindrical body

above electrode flange

above electrode flange

• •

Electronic temperature protection in the

Electronic temperature protection in the

terminal box

terminal box

• •

Minimization of thermal effects

Minimization of thermal effects

Easy installation and maintenance

Easy installation and maintenance

• •

Freely accessible connecting terminals

Freely accessible connecting terminals

at the control units

at the control units

• •

Large terminal box for easy installation

Large terminal box for easy installation

Reduced cost

Reduced cost

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• •

Minimized inventory and spares levels

Minimized inventory and spares levels

Only a single cable needed between boiler

Only a single cable needed between boiler

and control cabinet

and control cabinet

• •

Only one cable in the control cabinet for

Only one cable in the control cabinet for

all sensing units

all sensing units

• •

Optimum system integration without

Optimum system integration without

additional cable installations

additional cable installations

Increased safety

Increased safety

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• •

Active cable monitoring

Active cable monitoring

Easy integration into visual display and

Easy integration into visual display and

automation systems

automation systems

Get a technical lead with the first and

Get a technical lead with the first and

only control package for energy supply

only control package for energy supply

centres using an open CAN-bus system.

centres using an open CAN-bus system.

Only GESTRA permits easy interfacing to

Only GESTRA permits easy interfacing to

other open bus systems.

other open bus systems.

7

GESTRA Steam Boiler Equipment with SPECTOR control – Controlling, Monitoring and Visualizing – Boiler equipment

GESTRA Steam Boiler Equipment with SPECTORcontrol – Controlling, Monitoring and Visualizing –

Boiler equipment according to TRD 604 (72 h) or European guidelines, e.g. EN 12953 Part 6

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Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”:   level electrode NRG
Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”:   level electrode NRG

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”:   level electrode NRG
Equipment for Energy Supply Centres a Low-level limiter of “high-integrity design”:   level electrode NRG

a

Low-level limiter of “high-integrity design”:

 

level electrode NRG 16-40, level switch NRS 1-40.1

 

p. 22, 23

b

Modulating level controller:

 

level probe NRG 26-40

 

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High-level alarm of “high-integrity design”:

 

level electrode NRG 16-41*)

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Conductivity measurement and continuous/intermittent blowdown:

 

conductivity electrode LRG 16-40, continuous blowdown controller LRR 1-40, continuous blowdown valve BAE, intermittent blowdown

valve MPA, 3/2-way pilot valve, strainer

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p. 30, 31

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Sample cooler

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p. 34

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Blowdown flash vessel

 

h

Residual blowdown cooler

 

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Blowdown receiver

 

k

Safety temperature limiter at the superheater:

 

resistance thermometer TRG 5-65, temperature preamplifier TRV 5-40

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Safety valve GSV

 

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Pressure limiter DSF

 

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Pressure controller/transmitter

 

p

Disco non-return valve RK 86

 

q

Strainer GSF

r

Stop valve GAV

s

Electrical/pneumatic control valve V 725

 

u

Process data acquisition SPECTORcontrol with interfaces:

 

CAN, MODbus, Ethernet, modem, Profibus (optional

 

w

Monitoring of the fresh water:

 

Demineralization equipment – using conductivity monitoring

Partial demineralization equipment: by monitoring residual hardness (not part of our product range)

*) If the high-level alarm does not act on the safety chain, the level switch NRS 1-41 is required.

on the safety chain, the level switch NRS 1-41 is required. The benefits in detail Better

The benefits in detail

Better overview of the process

Better overview of the process through centralized process display

Actual values indicated as bar chart

Trend plot of the measurement values

Prioritized display of faults

List of maintenance intervals

Totalizing of consumption

Increased safety

Designations of the measurement quantities, input/output signals, and logging/alarms can be configured by the plant operator

All signals, limits and warning levels can be logically linked (NAND, NOR, RS-FF etc.); the result is available as a switching output/ logging signal

Environmental protection through active monitoring of waste water and exhaust gases

Reduced cost

Better utilization of fuel

Integrated control circuits, i.e. separate elec- tronic control units are no longer needed.

Easily integrated and expanded

Easily integrated and expanded

Modular structure, therefore extendable and suitable for all plant sizes

Existing input and output signals are easy to integrate

9

GESTRA SPECTOR bus boiler equipment GESTRA SPECTOR control Controlling and Monitoring Low-level High-level alarm alarm

GESTRA SPECTORbus boiler equipment GESTRA SPECTORcontrol

Controlling and Monitoring

Low-level High-level alarm alarm
Low-level
High-level
alarm
alarm

Burner Control

GESTRA SPECTOR control Controlling and Monitoring Low-level High-level alarm alarm Burner Control I/O-module 10

I/O-module

GESTRA SPECTOR control Controlling and Monitoring Low-level High-level alarm alarm Burner Control I/O-module 10
GESTRA SPECTOR control Controlling and Monitoring Low-level High-level alarm alarm Burner Control I/O-module 10
GESTRA SPECTOR control Controlling and Monitoring Low-level High-level alarm alarm Burner Control I/O-module 10
GESTRA SPECTOR control Controlling and Monitoring Low-level High-level alarm alarm Burner Control I/O-module 10

10

GESTRA SPECTOR control Controlling and Monitoring Low-level High-level alarm alarm Burner Control I/O-module 10
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.
Visualizing the Process Data The gateway between different worlds for an optimized flow of information.

Visualizing the Process Data

The gateway between different worlds for an optimized flow of information.

If you need to hand your boiler data up to a higher-ranking control system, you need the SPECTORcontrol system by GESTRA. It registers all measurement values via electronic signal trans- ducers and passes them on to the control centre. There they are combined to form higher-level statements and presented on a colour monitor. Pressure, temperature, conductivity etc. are regu- lated automatically.

The benefits for you

1. Better process overview:

Enhanced overview of the process, through centralized process display

Actual values indicated as bar chart

Trend plot of the measurement values

Prioritized display of faults

List of maintenance intervals

Designations of the measurement quantities, input/output signals, and logging of alarms. Can be configured by the plant operator

All signals, limits and warning values can be logically interlinked

The results are available as a report

2. Greater efficiency:

Better utilization of fuel

Totalizing of consumption

Improved environmen tal protection through monitoring of wastewater and exhaust gases

Modular, expandable architecture for all plant sizes

Separate electronic control units no longer needed, thanks to the integrated control circuitry

Input and output signals are easy to integrate

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units no longer needed, thanks to the integrated control circuitry ◗ Input and output signals are
units no longer needed, thanks to the integrated control circuitry ◗ Input and output signals are
units no longer needed, thanks to the integrated control circuitry ◗ Input and output signals are
units no longer needed, thanks to the integrated control circuitry ◗ Input and output signals are
units no longer needed, thanks to the integrated control circuitry ◗ Input and output signals are
Equipment for Energy Supply Centres Process control level Office PC, laptop OPC Profibus Ethernet DP
Equipment for Energy Supply Centres Process control level Office PC, laptop OPC Profibus Ethernet DP

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres Process control level Office PC, laptop OPC Profibus Ethernet DP (optional)

Process control level

Office PC, laptop

OPC Profibus Ethernet DP (optional) GSM network, land lines via modem Service partner Supplier Modbus
OPC
Profibus
Ethernet
DP (optional)
GSM network,
land lines via modem
Service partner
Supplier
Modbus RTU
CANopen
CAN
I/O-modul
partner Supplier Modbus RTU CANopen CAN I/O-modul The benefits … from the viewpoint of burner attendance

The benefits

… from the viewpoint of burner attendance

Dynamic status indication

• Maintenance log

• Flowrate log Y/M/D

• Dynamic sequencing for start-up / shut-down

• Trend plot

• Fault/alarm list

… from the viewpoint of boiler attendance

Dynamic status indication

• Maintenance log

• Trend plot M/D/H

• Flowrate log Y/M/D

• Optimized parametrization of the BUS sub- scribers; analog/digital inputs and outputs

• Integrated software controller

… from the viewpoint of the service partner

Online commissioning support

• Targeted maintenance planning

• Remote diagnosis

• Remote parametrization

• Full remote control

• Individual parametrization can be stored

12

Equipment for Energy Supply Centres SPECTOR com Process control level Office PC, laptop OPC Profibus

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres SPECTOR com Process control level Office PC, laptop OPC Profibus Ethernet
Equipment for Energy Supply Centres SPECTOR com Process control level Office PC, laptop OPC Profibus Ethernet

SPECTORcom

Process control level

Office PC, laptop

OPC Profibus Ethernet DP (optional) GSM network, land lines via modem Modbus RTU CANopen CAN
OPC
Profibus
Ethernet
DP (optional)
GSM network,
land lines via modem
Modbus RTU
CANopen
CAN
Service partner
Supplier
I/O-modul

13

RTU CANopen CAN Service partner Supplier I/O-modul 13 The benefits … from the viewpoint of burner

The benefits

… from the viewpoint of burner attendance

Dynamic status indication

• Maintenance log

• Flowrate log Y/M/D

• Dynamic sequencing for start-up / shut-down

• Trend plot

• Fault/alarm list

… from the viewpoint of boiler attendance

Dynamic status indication

• Maintenance log

• Trend plot M/D/H

• Flowrate log Y/M/D

• Optimized parametrization of the BUS sub- scribers; analog/digital inputs and outputs

• Integrated software controller

… from the viewpoint of the service partner

Online commissioning support

• Targeted maintenance planning

• Remote diagnosis

• Remote parametrization

• Full remote control

• Individual parametrization can be stored

GESTRA Steam Boiler Equipment – Conventional – For 24 hours of unmanned operation as per

GESTRA Steam Boiler Equipment – Conventional –

For 24 hours of unmanned operation as per TRD 604 (72 h) or EN 12953 Part 6

Safety, reliability and the certainty of components working together optimally

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of components working together optimally d 14 s c r q r a a n r
2 a 3 1 3 4 Equipment for Energy Supply Centres a Low-level limiter of
2 a 3 1 3 4 Equipment for Energy Supply Centres a Low-level limiter of
2 a 3 1 3 4
2 a
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1
3
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Equipment for Energy Supply Centres

2 a 3 1 3 4 Equipment for Energy Supply Centres a Low-level limiter of “high-integrity
2 a 3 1 3 4 Equipment for Energy Supply Centres a Low-level limiter of “high-integrity
a Low-level limiter of “high-integrity design”: level electrode NRG 16-11, level switch NRS 1-7 p.
a
Low-level limiter of “high-integrity design”:
level electrode NRG 16-11, level switch NRS 1-7
p. 22, 23
bc
Modulating level controller with integrated high-level alarm
and second water level gauge:
level probe NRG 26-21, level controller NRR 2-2,
bar-chart indicator URA 2
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Conductivity measurement and continuous blowdown/
conductivity limitation:
conductivity electrode LRGT 16-1, blowdown controller KS 90,
continuous blowdown valve BAE
p. 30, 31
e
Intermittent blowdown:
cycling timer TA 5
intermittent blowdown valve MPA
p. 30, 31
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Blowdown flash vessel
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Residual blowdown cooler
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Blowdown receiver
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Safety valve GSV
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Pressure limiter DSF
o
Pressure controller/transmitter
p
Disco non-return valve RK 86
q
Strainer GSF
r
Stop valve GAV
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Electrical/pneumatic control valve V 725
t
Economizer (ECO)
1
Measuring pot
2
Monitoring unit SRL 63 24h / 72h
3
Shut-off valve with two limit switches
4
Drain valve with one limit switch
2 Monitoring unit SRL 63 24h / 72h 3 Shut-off valve with two limit switches 4

15

GESTRA Steam Boiler Equipment – Conventional – For operation with limited supervision, e.g. as per

GESTRA Steam Boiler Equipment – Conventional –

For operation with limited supervision, e.g. as per TRD 602 (2 h)

d

16

n a bc m k o d d r e g h r f r
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Equipment for Energy Supply Centres a b c Low-level limiter of “high-integrity design” incl. on-off
Equipment for Energy Supply Centres a b c Low-level limiter of “high-integrity design” incl. on-off

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres a b c Low-level limiter of “high-integrity design” incl. on-off level
Equipment for Energy Supply Centres a b c Low-level limiter of “high-integrity design” incl. on-off level

abc

Low-level limiter of “high-integrity design” incl. on-off level controller and high-level alarm:

 

level electrode NRG 16-36, level switch NRS 1-9

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Conductivity measurement and continuous blowdown:

 

compact conductivity electrode LRGT 16-1, blowdown controller KS 90, continuous blowdown valve BAE

 

p. 29–31

e

Intermittent blowdown:

 

cycling timer TA 5 Intermittent blowdown valve MPA

 

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Blowdown flash vessel

 

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Residual blowdown cooler

 

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Blowdown receiver

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Safety temperature limiter:

 

resistance thermometer TRG 5-55,

 

temperature switch TRS 5-6

 

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Safety valve GSV

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Pressure limiter DSF

 

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Pressure controller/transmitter

 

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Disco non-return valve RK

 

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Stop valve GAV

www.gestra.de

controller/transmitter   p Disco non-return valve RK   r Stop valve GAV www.gestra.de 17

17

GESTRA Steam Boiler Equipment SPECTOR compact steam boiler plants requiring no supervision, e.g. in non-EU

GESTRA Steam Boiler Equipment

SPECTORcompact steam boiler plants requiring no supervision, e.g. in non-EU states

d

18

n ab m o r e g h r p f r e
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ab
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compact steam boiler plants requiring no supervision, e.g. in non-EU states d 18 n ab m
Equipment for Energy Supply Centres ab Low-level limiter of “standard design” (with test button) incl.
Equipment for Energy Supply Centres ab Low-level limiter of “standard design” (with test button) incl.

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres ab Low-level limiter of “standard design” (with test button) incl. on-off
Equipment for Energy Supply Centres ab Low-level limiter of “standard design” (with test button) incl. on-off
ab Low-level limiter of “standard design” (with test button) incl. on-off level controller: compact system
ab
Low-level limiter of “standard design” (with test button)
incl. on-off level controller:
compact system NRGS 15-1 (PN 25)
with integrated test and reset buttons
p. 22, 23, 25–27
d
Conductivity measurement and continuous blowdown:
compact conductivity electrode LRGS 15-1,
continuous blowdown valve BAE
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Intermittent blowdown:
compact system TA 7 with intermittent blowdown valve MPA
p. 29–31
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Blowdown flash vessel
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Residual blowdown cooler
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Blowdown receiver
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Safety valve GSV
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Pressure limiter DSF
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Pressure controller/transmitter
p
Disco non-return valve RK 86
r
Stop valve GAV

www.gestra.de

non-return valve RK 86 r Stop valve GAV www.gestra.de The benefits in detail More safety •

The benefits in detail

More safety

Patented thermal barrier in cylindrical body above electrode flange

Electronic temperature protection in the terminal box

Less effort

Optimum system adaptation, thanks to the modular design

No mounting of component parts in the control cabinet => No space requirements => No installation => No wiring

Easy planning

No special cable required for wiring the sensing unit to the control cabinet

Simplified logistics

19

GESTRA Equipment for Hot-Water Boilers – BUS technology – for high-pressure hot-water generation with separate

GESTRA Equipment for Hot-Water Boilers

– BUS technology – for high-pressure hot-water generation with separate pressurizing vessel

c a b bc c * b a y y a k l pp pp
c a
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bc
c *
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Steam boiler 2
m
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v Steam boiler 1
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*) 72 h operation only

a

Low-level limiter of “high-integrity design”:

 

level electrode NRG 16-40/level switch NRS 1-40.1 or level electrode NRG 16-11/level switch NRS 1-7

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p. 22, 23

 

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On-off level controller with separate high-level alarm:

 
 

level electrode NRG 16-42/level switch NRS 1-42 or level probe ER 56/level switch NRS 1-5, NRS 1-2

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blowdown: intermittent blowdown valve PA . . . . . . . . . . .
Equipment for Energy Supply Centres GESTRA Equipment for Hot-Water Boilers – Conventional – for high-pressure
Equipment for Energy Supply Centres GESTRA Equipment for Hot-Water Boilers – Conventional – for high-pressure
Equipment for Energy Supply Centres GESTRA Equipment for Hot-Water Boilers – Conventional – for high-pressure
Equipment for Energy Supply Centres GESTRA Equipment for Hot-Water Boilers – Conventional – for high-pressure

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres GESTRA Equipment for Hot-Water Boilers – Conventional – for high-pressure
Equipment for Energy Supply Centres GESTRA Equipment for Hot-Water Boilers – Conventional – for high-pressure

GESTRA Equipment for Hot-Water Boilers

– Conventional – for high-pressure hot-water generation with separate pressurizing vessel

bc a y y p i p i p l l x a k k
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Steam boiler 1
Steam boiler 2
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akk

k Safety temperature limiter:

resistance thermometer TRG 5-63/TRV 5-40/NRS 1-40.2 or resistance thermometer TRG 5-53/TRS 5-6

p. 32, 33

l Temperature controller for elevating the return temperature:

resistance thermometer TRG 5-63/TRS 5-40/URB 2 or resistance thermometer TRG 5-53/TRS 5-8

m Safety valve GSV

n

Pressure limiters DSL (MIN) and DSH (MAX)

p

Disco non-return valve RK 86

v

Burner control unit

x

Monitoring of the return flow for ingress of foreign matter

y

Temperature controller

www.gestra.de

unit x Monitoring of the return flow for ingress of foreign matter y Temperature controller www.gestra.de

21

a GESTRA Low-Level Limiter (LW) Level limiter of “high-integrity design” It consists of a level

a GESTRA Low-Level Limiter (LW)

Level limiter of “high-integrity design”

It consists of a level electrode and level switch, and was developed from a concept proven over many years of service. The GESTRA systems NRG 16-40, 17-40, 19-40, NRG 111-40, NRS 1-40 and NRS 1-40.1 (PN 40–320) offer the highest state of the art.

The electronic control unit NRS 1-40.1/2 is suitab- le for up to four limiters in any configuration; e.g. NRG 16-40 (LW), NRG 16-41.1, TRV 5-40 (STB).

The benefits for you

1. Savings:

One control unit for two electrodes

Lower inventory costs

2. Easy maintenance:

Separate undelayed signal output for exchange of electrode

Autonomous functional test, including the relay output contacts

Definite detection of the signal state within the system

Active test of the cable connection

3. Approved safety:

All systems comply with the new Pressure Equipment Directive (PED) and have EU type approval.

22

Limiter system of “high-integrity design”

With the electronic control unit NRS 1-40.1, it is possible to connect not only the level limiter but also a high-level alarm and/or safety temperature limiter.

NRS 1-40 NRS 1-40.1 / NRS 1-40.2
NRS 1-40
NRS 1-40.1 / NRS 1-40.2
temperature limiter. NRS 1-40 NRS 1-40.1 / NRS 1-40.2 Externally mounted level limiters of “high-integrity

Externally mounted level limiters of “high-integrity design”

To safeguard the high safety standard of the level limiters even when mounted outside the boiler, it is imperative that the regular, controlled purging of the measuring pot be monitored properly. The logic unit SRL 6-40 is used for monitoring the flushing procedure.

2 x NRG 16-40

pot be monitored properly. The logic unit SRL 6-40 is used for monitoring the flushing procedure.

SRL 6-40

Equipment for Energy Supply Centres Technical Information a Low-Level Limiter (LW) up to PN 320
Equipment for Energy Supply Centres Technical Information a Low-Level Limiter (LW) up to PN 320
Equipment for Energy Supply Centres Technical Information a Low-Level Limiter (LW) up to PN 320
Equipment for Energy Supply Centres Technical Information a Low-Level Limiter (LW) up to PN 320

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres Technical Information a Low-Level Limiter (LW) up to PN 320 The
Equipment for Energy Supply Centres Technical Information a Low-Level Limiter (LW) up to PN 320 The

Technical Information

a Low-Level Limiter (LW) up to PN 320

The limiters consist of a combination of level electrode and level switch. In general, a distinc- tion must be made between units of “standard design” and of “high-integrity design” (i.e. with self-monitoring). The corresponding applications for the units are defined in the technical rules and depend mainly on the hazard potential of the plant. A basis for these considerations can be the maximum allowable working pressure (TRD 701:

1 bar; PED: 0.5 bar) or the boiler water content (TRD 802).

For areas covered by these rules and the compar- able regulations of non-EU states, such as limited supervision (2 h, 4 h or 8 h operation), the com- pact units NRGS 11-2 (PN 6), NRGS 16-2 (PN 40) and NRGS 15-1 (PN 25, non-EU states) were developed. With this design, the level electrode and level switch form a single unit. In addition, the test and reset buttons were integrated into the terminal box. As a special feature, the redundancy (2-channel design) was extended right up to the electrode tip, which leads to a clear increase in safety.

With the self-monitoring limiters, the concept proven over decades for the systems MR/2VR8, ER 86/NRS 1-4 and NRG 16-, 17-, 19-, 111-40/ NRS 1-7 was advanced further and now offers the current state of safety and automation technology with the system NRG 16-, 17-, 19-, 111-40/NRS 1-40.1. As a supplement to the previous systems, the safety functions, including the routine self-test, was designed directly into the electrode, with the advantage that two electrodes but only one level switch are needed for the limiter system. The level switch NRS 1-40.1 represents an extension of the limiter system. In addition to the low-level elec- trodes, the high-level alarm NRG 1-41.1 and/or the

www.gestra.de

safety temperature limiter can also be connected. Based on the experience of the last decades, further optimization was introduced for the benefit of the planner, operator, commissioning technician and boiler inspector.

Response threshold always from 0.5 µS/cm

Separate undelayed signal output for emerging of the electrode

Autonomous functional test, including the relay output contacts

Definite detection of the signal state within the system

Flashing indicator = electrode emerged

Steady light = electrode emerged and time delay elapsed

Active test of the cable connection between electrode and switch

test of the cable connection between electrode and switch Of course, the self-monitoring limiters also comply

Of course, the self-monitoring limiters also comply with the PED (Pressure Equipment Directive) and have EU type approval.

If particularly high demands are made on the availability of boiler plants (power stations, chemi- cal industry etc.), the “2-out-of-3” circuit is often used.

With this arrangement, the safety chain is only interrupted when at least two limiters give the signal for low-water or fault. If the self-monitoring triggers for one of these units, the plant remains available, and the malfunctioning unit can be checked during planned downtime.

As in the past, GESTRA is again offering with the systems NRG 17-40 or NRG 19-40 the entire

palette up to the pressure rating PN 160 (100 bar /

311 °C). For application parameters going beyond

this, the NRG 211/NRS/URN systems proven in the

power station sector have repeatedly been used with success in the 2-out-of-3 circuit (230 bar /

550 °C). Nowadays, the NRG 111-11/NRS 1-7 or

NRG 111-40/NRS 1-40 systems are used for the

PN 320 range (183 bar / 400 °C).

The following systems are available:

Conventional technology

NRG 1.-11/NRS 1-7

BUS-technology

NRG 1.-40/NRS 1-40

NRG 1.-40/NRS 1-40.1

23

c GESTRA High-Level Alarm (HW) The right system for every application. 1. Units of “high-integrity

c GESTRA

High-Level Alarm (HW)

The right system for every application.

1. Units of “high-integrity design”:

These are always used when the require- ment is for a separate device.

NRG 16-41, NRG 17-41, NRG 19-41

(PN40–160)

NRS 1-41

or

NRG 16-41.1, NRG 17-41.1, NRG 19-41.1

NRS 1-40.1

2. Units of “standard design”:

These are used wherever entrained boiler

water cannot cause any damage.

NRG 16-42 + NRS 1-42 with fixed switchpoints

NRG 26-40 + NRS 2-40 or NRR 2-40 with adjustable switchpoints

NRS 1-41 NRG 16-41 or NRG 16-41.1 (in conjunction with NRS 1-40.1)
NRS 1-41
NRG 16-41 or NRG 16-41.1
(in conjunction with NRS 1-40.1)

24

Technical Information

c High-Level Alarm (HW)

For the high-level alarm, there are also various systems available whose area of application is primarily determined not by the technical literature but by the downstream consumers of the steam.

Of the diverse standards, only the TRD 604 (72 h operation) poses the requirement that the high-level alarm must be a unit separate from the controller and limiter. In the other codes, including EN, this requirement is not expressed.

The units of “standard design” are especially applied wherever no direct damage can occur at downstream heating surfaces, installations, steam- heated products etc. as a result of carry-over.

Here the Spector family offers solutions within the area of the Compact version (NRGS 11-1 or NRGS 16-1) and also in the BUS technology with fixed switchpoints (NRG 16-42/NRS 1-42) or contin- uously adjustable switchpoints (NRG 26-40/NRS 2-40 or NRR 2-40). All of the above systems have the high-level alarm integrated into the controller block. The high-level alarm of “high-integrity design” (with self-monitoring) is always used when the

The following systems are available:

Conventional technology

NRG 1.-12/NRS 1-8

BUS-technology

NRG 1.-41/NRS 1-41

NRG 1.-41.1/NRS 1-40.1

◗ NRG 1.-41/NRS 1-41 ◗ NRG 1.-41.1/NRS 1-40.1 requirement is made for a separate unit and

requirement is made for a separate unit and the safety or product-related viewpoint calls for it. Several reasons are possible:

Products heated directly by steam (e.g. rubber industry)

Turbine operation

etc.

As a unit of “high-integrity design”, the system NRG 16-41/NRS 1-41 from the Bus family is used.

With this system, the requirement profiles are the same as for the low-level limiters of “high-integrity design”.

With this system, the requirement profiles are the same as for the low-level limiters of “high-integrity
b Level Controllers Depending on the parameters of boiler capacity, required steam quality, plant economy
b Level Controllers Depending on the parameters of boiler capacity, required steam quality, plant economy
b Level Controllers Depending on the parameters of boiler capacity, required steam quality, plant economy
b Level Controllers Depending on the parameters of boiler capacity, required steam quality, plant economy

b Level Controllers

Depending on the parameters of boiler capacity, required steam quality, plant economy and degree of automation, the make-up arrangement is differentiated into the on-off and modulating control modes. Within the on-off controls, these are subdivided further into those with fixed switch- points and those with continuously adjustable switchpoints.

On-Off Systems (Pump ON/OFF)

This solution is mainly used in steam boiler plants of low capacity (< 5 t/h), in condensate and feed- water tanks, and is frequently also rounded off with the implementation of the entire pump control. The intermittent make-up of relatively cool feedwater (103 °C) naturally leads to strongly modulating operation of the burner and to intense thermal- shock stresses. Through the intermittent feedwater flow, integration into a heat recovery concept using the economizer principle is not possible. For this task, there are several systems from the SPECTOR family, so that we can offer customer-oriented solutions. As a result of our operational experience, numerous innovations in the area of the BUS technology have been introduced to considerably simplify commissioning, and to reduce the effort of time and the water loss to a minimum. By using the control terminal and display unit URB, features which were previously impossible are now within grasp.

www.gestra.de

Equipment for Energy Supply Centres

grasp. www.gestra.de Equipment for Energy Supply Centres The palette of possibilities includes: ◗
grasp. www.gestra.de Equipment for Energy Supply Centres The palette of possibilities includes: ◗

The palette of possibilities includes:

Switch-selectable response sensitivities > 0.5 / > 10 µS/cm

Continuously adjustable delays for each contact and contact position in the range 1–25 sec.

Variable switchpoint adjustment (NRS 2-40)

In the area of systems with fixed switchpoints:

Compact system

NRGS 11-1 or NRGS 16-1

NRGS 11-2 or NRGS 16-2

Conventional technology

ER 5./NRS 1-.

BUS system

NRG 16-42/NRS 1-42

Function

First low alarm/pump ON/OFF/HW alarm

First low alarm/pump ON/OFF

First low alarm/pump ON/OFF/HW alarm

In the area of systems with continuously adjustable switchpoints:

Compact system

NRGT 26-1

Function

4–20 mA output as an input signal for PLC controls Regulator KS 92-1

Conventional technology

NRG 26-21/NRS 2-1

BUS system

NRG 26-40/NRS 2-40

First low alarm/pump ON/OFF/HW alarm

Conventional technology ◗ NRG 26-21/NRS 2-1 BUS system ◗ NRG 26-40/NRS 2-40 First low alarm/pump ON/OFF/HW

25

Technical Information – continued – b Level Controllers Modulating Systems (control valves, frequency-controlled

Technical Information – continued –

b Level Controllers

Modulating Systems (control valves, frequency-controlled pumps)

With modulating control, one thinks first of the economical operation, higher steam quality and the capability of adapting to difficult situations regard- ing the controlled systems, e.g. those caused by strong fluctuations or sudden changes in steam consumption, as is the case for process-related reasons in the rubber, foodstuff and building-mate- rials industries. The greater operational economy of the boiler and the higher steam quality are naturally an aspect of the controlled, demand-oriented make-up of the boiler water. On the one hand, this mode ensures continuous burner operation and, on the other, the boiler water level is not elevated as high as with the two-position control, which then reduces the danger of carry-over appreciably.

In practice, two systems have established themselves:

Compact system NRGT 26-1

BUS system NRG 26-40/ NRR 2-40/URB 1

The compact system is preferred for applications where the control is to be realized via an external general-purpose controller, a PLC (programmable logic controller) or a frequency-controlled pump. The compact probe NRGT 26-1 supplies a level- proportional output signal (4–20 mA), which can be switched to one of the above-mentioned electronic units.

In the area of the BUS technology, the experience of the last three decades was evaluated and inte- grated here to optimize the established systems.

26

The level controller NRR 2-40 also offers, as an option to the 3-position stepping output, the possi- bility of using 4–20 mA modules for the manipu- lated variable and/or the actual value. As already described with the on-off controllers, delays can also be programmed here. Furthermore, by using the control terminal and display unit URB, consider- able savings are possible in commissioning, since, thanks to the modern technology, the calibration of the 100% measuring range of the probe can already be performed at the 50 % level. The pleas- ing result: less time lost, lower water losses and lower resource requirements. What is more, after coordination with the boiler inspector, the control terminal and display unit can be used as a second water level indicator, which means that a water- level gauge glass according to TRD 401, section 8.1; prEN 12952-7 section 5.4.1; prEN 12953-6 section 5.1.1 is no longer needed. Another advan- tage of this technology is the fact that the entire “output stage” of the controller remains on the mounting panel, i.e. elaborate cable harnesses in the control cabinet door can be omitted and at the same time the control terminal can be used for parametrizing the continuous/intermittent blowdown control. As mentioned already, with modulating control there is also the possibility of catering for difficult controlled systems through the use of steam and feedwater flow measurement. In such cases, the so-called two- or three-element controls are implemented.

In the areas > PN 40, we use the intelligent buoyancy transmitter 144 LD, which covers the range up to PN 250. Like the compact system NRGT 26-1, this system has a level-proportional 4–20 mA current output.

the range up to PN 250. Like the compact system NRGT 26-1, this system has a
Equipment for Energy Supply Centres b GESTRA Level Controller Everything is easier For level control
Equipment for Energy Supply Centres b GESTRA Level Controller Everything is easier For level control
Equipment for Energy Supply Centres b GESTRA Level Controller Everything is easier For level control
Equipment for Energy Supply Centres b GESTRA Level Controller Everything is easier For level control

Equipment for Energy Supply Centres

Equipment for Energy Supply Centres b GESTRA Level Controller Everything is easier For level control too,
Equipment for Energy Supply Centres b GESTRA Level Controller Everything is easier For level control too,

b GESTRA Level Controller

Everything is easier

For level control too, a large number of innovations have been introduced to make operation much easier. Continuous control reduces the time nee- ded and the loss of water to a minimum.

The benefits for you

1. Savings:

Reduction of time and feedwater requirement during measurement, through 100 % calibration at 50 % level

The control terminal can also be used as a second water level indicator, which does away with the need for a water gauge glass

2. Systemoptimierung:

Omission of an additional time-lag relay, thanks to the integrated, adjustable time delays

Preset switchpoints

BUS

NRGT 26-1
NRGT 26-1