Opportunities to garner profits through application of accurate measurement instrumentation to steam production and condensate recovery by eliminating inefficiencies in operation.
Thermoelectric generators convert heat directly into electricity using a fuel source for heat, a hermetically sealed thermopile, and cooling fins. These generators are a positive and cost effective solution for remote power requirements, having operational and cost benefits over batteries and solar sources for many applications.
Hydraulic power units (HPU’s) complement Rotork's extensive offering of rotary and linear actuators. The company has over three decades of experience in their manufacture, with units in service in a variety of plants and pipelines in locations spanning the globe. Although the HPU’s are primarily intended to power hydraulic actuators they are of course suitable for other applications as well. And, in order to provide a complete range of options to best meet the requirements of any application, RFS also has the Skilmatic range of self-contained electro-hydraulic actuators.
The use of LNG is a proven, reliable, and safe process, and natural gas is quickly becoming the world’s cleanest burning fossil fuel as it emerges as the environmentally preferred fuel of choice. It is for this reason that LNG facilities are put under more pressure than ever to meet the world’s natural gas demand. Keeping your plants running at an efficient pace is vital to production and condition monitoring plays a critical part in this process. Condition monitoring provides a proactive approach so that maintenance can be planned, eliminating unscheduled outages and optimizing machine performance. In addition, condition monitoring helps to avoid breakdowns with subsequent secondary damage and loss of production revenue meaning that today’s LNG facilities simply can’t afford to not have a reliable condition monitoring solution.
The technology and thermal efficiencies of the coal-fired
cycle have improved dramatically, and the basic idea
of converting the stored energy of coal into electricity
accounts for more than 40% of the world’s power.
This document discusses GE Energy's HydroXTM expert system for online monitoring of hydro-generators. Key points:
1. HydroXTM was developed over 5 years with New York Power Authority to interpret data from complex sensors using expert knowledge in rules.
2. It relies on available affordable online monitors for critical components and expertise documenting diagnostic rules.
3. The system runs on the commercial System 1 software, which interfaces with sensors and uses a rule engine and tools to develop custom interfaces and visualize data.
4. An initial prototype was evaluated successfully on two 60MVA generators at NYPA's St. Lawrence Power Project.
This document discusses GE's asset condition monitoring solutions for combined cycle power plants. It begins by providing background on the history and importance of gas turbine power plants. It then describes GE's portfolio of condition monitoring systems that can monitor various assets across a combined cycle plant, such as gas turbines, steam turbines, pumps, fans and more. It discusses how these systems help customers minimize downtime, reduce costs, protect critical equipment, and optimize maintenance through predictive analytics. Customers can see returns through increased availability, reduced maintenance durations and costs, and extended time between outages. The document provides an overview of how GE's solutions can be applied across a combined cycle plant.
The document discusses a waste water treatment plant that installed a Heat Recovery Steam Generator (HRSG) and Steam Turbine Generator to increase efficiency and reduce costs. Utility Plant Solutions provided start-up, commissioning, and operation services during the project. They have since taken over plant operations and maintenance. The document also announces that Utility Plant Solutions is now an authorized distributor for Gem Steam Traps and VAF Filtration Systems.
The document describes a water-cooled dual-circuit screw chiller that uses R134a refrigerant. It has a cooling capacity ranging from 600-1200kW and features screw compressors with slider control for capacity modulation between 25-100%. The chiller offers high efficiency with an EER up to 5.58, low operating costs, and proven reliability.
Thermoelectric generators convert heat directly into electricity using a fuel source for heat, a hermetically sealed thermopile, and cooling fins. These generators are a positive and cost effective solution for remote power requirements, having operational and cost benefits over batteries and solar sources for many applications.
Hydraulic power units (HPU’s) complement Rotork's extensive offering of rotary and linear actuators. The company has over three decades of experience in their manufacture, with units in service in a variety of plants and pipelines in locations spanning the globe. Although the HPU’s are primarily intended to power hydraulic actuators they are of course suitable for other applications as well. And, in order to provide a complete range of options to best meet the requirements of any application, RFS also has the Skilmatic range of self-contained electro-hydraulic actuators.
The use of LNG is a proven, reliable, and safe process, and natural gas is quickly becoming the world’s cleanest burning fossil fuel as it emerges as the environmentally preferred fuel of choice. It is for this reason that LNG facilities are put under more pressure than ever to meet the world’s natural gas demand. Keeping your plants running at an efficient pace is vital to production and condition monitoring plays a critical part in this process. Condition monitoring provides a proactive approach so that maintenance can be planned, eliminating unscheduled outages and optimizing machine performance. In addition, condition monitoring helps to avoid breakdowns with subsequent secondary damage and loss of production revenue meaning that today’s LNG facilities simply can’t afford to not have a reliable condition monitoring solution.
The technology and thermal efficiencies of the coal-fired
cycle have improved dramatically, and the basic idea
of converting the stored energy of coal into electricity
accounts for more than 40% of the world’s power.
This document discusses GE Energy's HydroXTM expert system for online monitoring of hydro-generators. Key points:
1. HydroXTM was developed over 5 years with New York Power Authority to interpret data from complex sensors using expert knowledge in rules.
2. It relies on available affordable online monitors for critical components and expertise documenting diagnostic rules.
3. The system runs on the commercial System 1 software, which interfaces with sensors and uses a rule engine and tools to develop custom interfaces and visualize data.
4. An initial prototype was evaluated successfully on two 60MVA generators at NYPA's St. Lawrence Power Project.
This document discusses GE's asset condition monitoring solutions for combined cycle power plants. It begins by providing background on the history and importance of gas turbine power plants. It then describes GE's portfolio of condition monitoring systems that can monitor various assets across a combined cycle plant, such as gas turbines, steam turbines, pumps, fans and more. It discusses how these systems help customers minimize downtime, reduce costs, protect critical equipment, and optimize maintenance through predictive analytics. Customers can see returns through increased availability, reduced maintenance durations and costs, and extended time between outages. The document provides an overview of how GE's solutions can be applied across a combined cycle plant.
The document discusses a waste water treatment plant that installed a Heat Recovery Steam Generator (HRSG) and Steam Turbine Generator to increase efficiency and reduce costs. Utility Plant Solutions provided start-up, commissioning, and operation services during the project. They have since taken over plant operations and maintenance. The document also announces that Utility Plant Solutions is now an authorized distributor for Gem Steam Traps and VAF Filtration Systems.
The document describes a water-cooled dual-circuit screw chiller that uses R134a refrigerant. It has a cooling capacity ranging from 600-1200kW and features screw compressors with slider control for capacity modulation between 25-100%. The chiller offers high efficiency with an EER up to 5.58, low operating costs, and proven reliability.
This document discusses Turbo Oil-Free Compressors for chillers. It notes that magnetic bearings allow for extremely high speeds of up to 200 m/s without lubrication. This results in reliable, low maintenance systems with high efficiency. Applications include replacing old centrifugal chillers or adding backup chillers. The compressors come in a range of sizes from 265-1055 KWc and can be used for both water-cooled and air-cooled systems. Installation involves removing an old compressor and installing the new one along with any necessary piping or electrical work.
This document provides a summary of a sourcebook about improving steam system performance in industry. It includes:
1) An overview of steam systems, including generation, distribution, end use, and recovery. It describes common components like boilers, traps, heat exchangers and discusses opportunities for improvement.
2) A discussion of using a systems approach to identify performance improvement opportunities across generation, distribution and recovery. It also introduces DOE tools to help analyze steam systems.
3) Contact information for organizations that can provide resources and assistance to improve steam systems. It acknowledges their contributions to the sourcebook.
الطريق لتقديم خدمات بنكية مستدامة عن طريق التكنولوجيا الخضراء أصبح ممكنا بما يضمن رفع كفاءة المبانى القائمة بنسبة 20%-30% حتى 50% فى بغض المبانى
The road to provide green banking is GREEN
Cooling Strategies for Efficiency – Techniques that Reduces YourEnergy Bill by 20-30% up to 50%
The Bently Nevada Trendmaster system was installed at a large petrochemical facility to monitor hundreds of pumps and prevent catastrophic failures after a pump failure caused a $12 million fire. Before the system was fully commissioned, it detected a pump with high vibration levels that was about to fail imminently, saving the plant. It then detected issues with two other pumps that required replacement. The system also identified pumps needing additional coolers or piping repairs. It proved more effective than manual monitoring by catching developing problems sooner to prevent failures.
Building owners have more questions and requests on how to integrate renewable power into their buildings. And as the Smart Grid evolves, integration of renewable energy sources is increasing. Possible renewable power technologies include solar, wind, geothermal, and biomass. As the technologies that support increasing use of renewable energy mature, the codes and standards that define their use, interconnection, and interoperability with the grid must keep pace with them. Engineers involved with integrating renewable power into buildings must be aware of the applicable energy codes and standards and how to properly implement them into the building design. They must also evaluate the design objectives, materials, systems, and construction from all perspectives. It’s critical for designers to assess the design for cost, quality of life, expansion capabilities, efficiencies, impact on environment, creativity, and productivity.
This document summarizes Sebastian Arriaga's engineering experience since graduating with a Bachelor's degree in electrical engineering in 1998. It outlines his positions at Eficar Electronica and Tecnología, Servicios y Equipos, as well as projects he worked on including designing an automotive gas analyzer, electronic cards for an injector cleaner machine, and an opacity meter for measuring truck exhaust. It also discusses his participation in updating Venezuela's industrial standards for automotive emissions testing.
11 Things to Know When Owning and Operating a Standby GeneratorJessicaSharpee
This document outlines 11 key considerations for sizing, owning, and operating a standby generator system. It discusses factors like identifying load requirements and peak needs for proper sizing, selecting a reliable manufacturer, choosing an indoor or outdoor placement, determining fuel sources like natural gas or diesel, and ensuring routine maintenance and testing. Proper monitoring and having backup redundancy plans are also covered to help ensure power is always available from the standby system. Taking all these implementation and ongoing operational factors into account is necessary to find the right reliable solution.
During commissioning of a large petrochemical plant in the UK, two electric motor-driven pumps were damaged overnight. Data from continuous online monitoring systems linked to GE's System 1 software showed the pumps had run at extremely high speeds in the reverse direction, likely caused by backwards fluid flow due to faulty check valves. Without this data, the pumps would have been replaced without identifying the root cause, risking further damage costing $40,000. Continuous monitoring helped identify the issue and avoid unnecessary costs and downtime.
This brochure presents Vacon NXP liquid cooled AC drives. As no air ducts are required, these high power density AC drives are suitable for locations where air-cooling is difficult, expensive or impractical or where installation space is at a premium such as in heavy industries with harsh operating conditions like marine & offshore, pulp & paper, renewable energy and mining & metal. These AC drives have been exclusively designed for liquid-cooling and are available in the power range from 7.5 to 5300 kW and at 380-690 VAC supply voltages for both induction motors and permanent magnet motors.
Immersion Cooling solutions enabling net zero and resiliencyIrene de Groot
Presented by Asperitas and Shell, we hereby invite you to view our presentation at DCD Towards Net-Zero Summit on Wed 24th February, 2021. The talk will explore how the modern datacentre fits into a zero-carbon future.
Asperitas and Shell have partnered up once again to address the most urgent challenges for the datacentre landscape to enable sustainable and high performance datacentres at a time where carbon neutrality is more important than ever. The talk will identify where datacentres need to be and what they should be capable of in terms of innovation and performance.
Our Green Mission أهدافنا خضراء تقليل هدر الطاقة فى منظومتي التكييف والتهوية و تجويد أجواء الحياة الداخلية تقديرا لقيمة أمنا «الأرض»
To efficiently reduce energy wastage in HVAC Industry and improve the quality of indoor environment with high regards to our mother “Earth”.
Instantaneous hot water generation, distribution and precision temperature control for industrial applications. Learn how to avoid scaling, improve efficiency and safety, and increase your production and yield. A full range of individual state-of-the-art products, including: water heaters, water temperature controls, hose stations, variable frequency drive (VFD) pump assemblies and ancillary accessories such as storage tanks, and pressure-reducing valves.
Introduction to an innovative electrochemical ammonia wastewater treatment system. The system is compared to traditional biological treatment plants (biological nitrification-denitrification, ammonia strippers, and Annamox). The "Ammonia Splitter" provides reliable, adjustable, temperature and salinity insensitive ammonia wastewater treatment.
Project results are presented from two pilot projects treating municipal wastewater treatment plant (WWTP) centrate and landfill leachate. WWTP centrate is the concentrated reject stream from the biological treatment process.
This 2015 Environmental Leader “Top Project of the Year” award winner uses wireless gateways to integrate a historical science building into its campus-wide building management system to monitor and manage energy use and reduce costs.
OCP Tech Week Immersion Cooling Optimized IT platformsIrene de Groot
This session is focused on explaining the practicalities of several server developments with different OEM's which are focused on OCP equipment and which are following OCP immersion guidelines. This session showcases several actual server platforms which are created using the Open Cassette specifications and how the principles are followed which are outlined in the "Guidelines for Immersion-Cooled IT equipment" whitepaper. This session covers work and equipment by Asperitas, OEMs and system integrators from the OCP ecosystem.
What can you expect to learn?
The practical implications of optimizing IT equipment for immersion. It covers the challenges which are faced with retrofitting IT equipment, opportunities for different applications and the way in which collaboration works to achieve common goals. This session will also cover the value of data collection and material compatibility studies as part of a certification process.
Aldi widiartono gis eco efficient switchgearHariSantoso20
This document discusses ABB's Gas Insulated Switchgear (GIS) portfolio, focusing on their ELK-04 170kV GIS. It provides an overview of ABB's GIS factories globally, the benefits of GIS systems such as compact design and reliability. Details are given on the technical specifications and modular design of the ELK-04 170kV GIS. Application examples shown include integration into buildings, offshore wind farms, and use in tropical climates and container substations.
Energy saving in cooling towers by using variable frequency drivesIAEME Publication
This document discusses energy savings in cooling towers by using variable frequency drives (VFDs). It finds that using VFDs to adjust the speed of cooling tower fans based on water temperature can achieve energy savings of 25% annually. A case study is presented of a cooling tower that provides process cooling water to five production plants. Currently the fans operate at a fixed speed all year. Installing VFDs would allow the fan speed to vary to better maintain a constant cooling water temperature despite changing weather conditions and partial loading, improving plant operations. Simulation results are presented showing the cooling water temperature impact of running the fans at full versus zero speed with VFD control.
BARTON 7000 Series liquid turbine meters are designed for a broad range of precise liquid measurement applications. Based on more than 40 years of turbine manufacturing experience, this built-to-order series features a range of sizes, materials, bearing systems, and options.
Electronic displacer level transmitter technology operates by detecting changes in buoyancy force caused by liquid level change. These forces act upon the spring supported displacer causing vertical motion of the core within a linear variable differential transformer.
As the core position changes with liquid level, voltages are induced across the secondary windings of the LVDT. These signals are processed in the electronic circuitry and used to control the current in the 4-20 mA current loop. The enclosing tube acts as a static isolation barrier between the LVDT and the process media.
The document discusses a new product launch for a company. It outlines key details of the product such as its features and target market. It also provides a timeline for rolling out marketing and shipping the product over the next few months.
This document discusses Turbo Oil-Free Compressors for chillers. It notes that magnetic bearings allow for extremely high speeds of up to 200 m/s without lubrication. This results in reliable, low maintenance systems with high efficiency. Applications include replacing old centrifugal chillers or adding backup chillers. The compressors come in a range of sizes from 265-1055 KWc and can be used for both water-cooled and air-cooled systems. Installation involves removing an old compressor and installing the new one along with any necessary piping or electrical work.
This document provides a summary of a sourcebook about improving steam system performance in industry. It includes:
1) An overview of steam systems, including generation, distribution, end use, and recovery. It describes common components like boilers, traps, heat exchangers and discusses opportunities for improvement.
2) A discussion of using a systems approach to identify performance improvement opportunities across generation, distribution and recovery. It also introduces DOE tools to help analyze steam systems.
3) Contact information for organizations that can provide resources and assistance to improve steam systems. It acknowledges their contributions to the sourcebook.
الطريق لتقديم خدمات بنكية مستدامة عن طريق التكنولوجيا الخضراء أصبح ممكنا بما يضمن رفع كفاءة المبانى القائمة بنسبة 20%-30% حتى 50% فى بغض المبانى
The road to provide green banking is GREEN
Cooling Strategies for Efficiency – Techniques that Reduces YourEnergy Bill by 20-30% up to 50%
The Bently Nevada Trendmaster system was installed at a large petrochemical facility to monitor hundreds of pumps and prevent catastrophic failures after a pump failure caused a $12 million fire. Before the system was fully commissioned, it detected a pump with high vibration levels that was about to fail imminently, saving the plant. It then detected issues with two other pumps that required replacement. The system also identified pumps needing additional coolers or piping repairs. It proved more effective than manual monitoring by catching developing problems sooner to prevent failures.
Building owners have more questions and requests on how to integrate renewable power into their buildings. And as the Smart Grid evolves, integration of renewable energy sources is increasing. Possible renewable power technologies include solar, wind, geothermal, and biomass. As the technologies that support increasing use of renewable energy mature, the codes and standards that define their use, interconnection, and interoperability with the grid must keep pace with them. Engineers involved with integrating renewable power into buildings must be aware of the applicable energy codes and standards and how to properly implement them into the building design. They must also evaluate the design objectives, materials, systems, and construction from all perspectives. It’s critical for designers to assess the design for cost, quality of life, expansion capabilities, efficiencies, impact on environment, creativity, and productivity.
This document summarizes Sebastian Arriaga's engineering experience since graduating with a Bachelor's degree in electrical engineering in 1998. It outlines his positions at Eficar Electronica and Tecnología, Servicios y Equipos, as well as projects he worked on including designing an automotive gas analyzer, electronic cards for an injector cleaner machine, and an opacity meter for measuring truck exhaust. It also discusses his participation in updating Venezuela's industrial standards for automotive emissions testing.
11 Things to Know When Owning and Operating a Standby GeneratorJessicaSharpee
This document outlines 11 key considerations for sizing, owning, and operating a standby generator system. It discusses factors like identifying load requirements and peak needs for proper sizing, selecting a reliable manufacturer, choosing an indoor or outdoor placement, determining fuel sources like natural gas or diesel, and ensuring routine maintenance and testing. Proper monitoring and having backup redundancy plans are also covered to help ensure power is always available from the standby system. Taking all these implementation and ongoing operational factors into account is necessary to find the right reliable solution.
During commissioning of a large petrochemical plant in the UK, two electric motor-driven pumps were damaged overnight. Data from continuous online monitoring systems linked to GE's System 1 software showed the pumps had run at extremely high speeds in the reverse direction, likely caused by backwards fluid flow due to faulty check valves. Without this data, the pumps would have been replaced without identifying the root cause, risking further damage costing $40,000. Continuous monitoring helped identify the issue and avoid unnecessary costs and downtime.
This brochure presents Vacon NXP liquid cooled AC drives. As no air ducts are required, these high power density AC drives are suitable for locations where air-cooling is difficult, expensive or impractical or where installation space is at a premium such as in heavy industries with harsh operating conditions like marine & offshore, pulp & paper, renewable energy and mining & metal. These AC drives have been exclusively designed for liquid-cooling and are available in the power range from 7.5 to 5300 kW and at 380-690 VAC supply voltages for both induction motors and permanent magnet motors.
Immersion Cooling solutions enabling net zero and resiliencyIrene de Groot
Presented by Asperitas and Shell, we hereby invite you to view our presentation at DCD Towards Net-Zero Summit on Wed 24th February, 2021. The talk will explore how the modern datacentre fits into a zero-carbon future.
Asperitas and Shell have partnered up once again to address the most urgent challenges for the datacentre landscape to enable sustainable and high performance datacentres at a time where carbon neutrality is more important than ever. The talk will identify where datacentres need to be and what they should be capable of in terms of innovation and performance.
Our Green Mission أهدافنا خضراء تقليل هدر الطاقة فى منظومتي التكييف والتهوية و تجويد أجواء الحياة الداخلية تقديرا لقيمة أمنا «الأرض»
To efficiently reduce energy wastage in HVAC Industry and improve the quality of indoor environment with high regards to our mother “Earth”.
Instantaneous hot water generation, distribution and precision temperature control for industrial applications. Learn how to avoid scaling, improve efficiency and safety, and increase your production and yield. A full range of individual state-of-the-art products, including: water heaters, water temperature controls, hose stations, variable frequency drive (VFD) pump assemblies and ancillary accessories such as storage tanks, and pressure-reducing valves.
Introduction to an innovative electrochemical ammonia wastewater treatment system. The system is compared to traditional biological treatment plants (biological nitrification-denitrification, ammonia strippers, and Annamox). The "Ammonia Splitter" provides reliable, adjustable, temperature and salinity insensitive ammonia wastewater treatment.
Project results are presented from two pilot projects treating municipal wastewater treatment plant (WWTP) centrate and landfill leachate. WWTP centrate is the concentrated reject stream from the biological treatment process.
This 2015 Environmental Leader “Top Project of the Year” award winner uses wireless gateways to integrate a historical science building into its campus-wide building management system to monitor and manage energy use and reduce costs.
OCP Tech Week Immersion Cooling Optimized IT platformsIrene de Groot
This session is focused on explaining the practicalities of several server developments with different OEM's which are focused on OCP equipment and which are following OCP immersion guidelines. This session showcases several actual server platforms which are created using the Open Cassette specifications and how the principles are followed which are outlined in the "Guidelines for Immersion-Cooled IT equipment" whitepaper. This session covers work and equipment by Asperitas, OEMs and system integrators from the OCP ecosystem.
What can you expect to learn?
The practical implications of optimizing IT equipment for immersion. It covers the challenges which are faced with retrofitting IT equipment, opportunities for different applications and the way in which collaboration works to achieve common goals. This session will also cover the value of data collection and material compatibility studies as part of a certification process.
Aldi widiartono gis eco efficient switchgearHariSantoso20
This document discusses ABB's Gas Insulated Switchgear (GIS) portfolio, focusing on their ELK-04 170kV GIS. It provides an overview of ABB's GIS factories globally, the benefits of GIS systems such as compact design and reliability. Details are given on the technical specifications and modular design of the ELK-04 170kV GIS. Application examples shown include integration into buildings, offshore wind farms, and use in tropical climates and container substations.
Energy saving in cooling towers by using variable frequency drivesIAEME Publication
This document discusses energy savings in cooling towers by using variable frequency drives (VFDs). It finds that using VFDs to adjust the speed of cooling tower fans based on water temperature can achieve energy savings of 25% annually. A case study is presented of a cooling tower that provides process cooling water to five production plants. Currently the fans operate at a fixed speed all year. Installing VFDs would allow the fan speed to vary to better maintain a constant cooling water temperature despite changing weather conditions and partial loading, improving plant operations. Simulation results are presented showing the cooling water temperature impact of running the fans at full versus zero speed with VFD control.
BARTON 7000 Series liquid turbine meters are designed for a broad range of precise liquid measurement applications. Based on more than 40 years of turbine manufacturing experience, this built-to-order series features a range of sizes, materials, bearing systems, and options.
Electronic displacer level transmitter technology operates by detecting changes in buoyancy force caused by liquid level change. These forces act upon the spring supported displacer causing vertical motion of the core within a linear variable differential transformer.
As the core position changes with liquid level, voltages are induced across the secondary windings of the LVDT. These signals are processed in the electronic circuitry and used to control the current in the 4-20 mA current loop. The enclosing tube acts as a static isolation barrier between the LVDT and the process media.
The document discusses a new product launch for a company. It outlines key details of the product such as its features and target market. It also provides a timeline for rolling out marketing and shipping the product over the next few months.
Industrial process control employs measuring devices for determining the level of fluids in containers. This comprehensive guide to magnetic level gauges, switches, transmitters, and related products delivers an understandable and clear description of the technology and principals of operation behind magnetic level gauges and instruments. The guide also assists the reader in properly specifying and selecting the best instrument configuration for an application.
This document outlines design standards for a highway project. It discusses standards for road capacity, geometric design, intersections, bridges and culverts, pavements, and other road elements. The standards are sourced from Indian Road Congress codes and Ministry of Road Transport & Highways guidelines. Tables summarizing the adopted standards are presented for various elements, including minimum median widths, carriageway widths, shoulder widths, slopes, sight distances, and more. Pavement designs will follow IRC standards and consider a 20-year performance period. Bridge and culvert designs will be based on the latest IRC and IS codes.
One day, I was walking in the woods when I had a run in with bobcat. What I saw change my whole life. After that, my interest of animals grew. No matter what I decided to do in life, I decided that it would have something to do with animals. They can't tell their stories, so I want to tell it for them. I want to be A.J. Roberts. "The Voice of Animal Tribulations."
A short presentation over innovation within your business.
I'll walk you through several options.
This presentation has bin given on 13-04-2016 Business Open Lelystad
Available in sizes from 3/4" npt to 2" npt for differential pressures up to 125 psig saturated steam service with supply pressures limited to 250 psig at temperatures not to exceed 406 deg. F.
El documento explica los requisitos para elaborar un Programa de Seguridad y Salud Laboral en concordancia con la Ley Orgánica de Prevención, Condiciones y Medio Ambiente de Trabajo de Venezuela. Detalla los puntos que debe contener el programa, como la descripción del proceso de trabajo, identificación de riesgos, planes de capacitación, inspecciones, atención médica y planes de emergencia. Además, enfatiza la importancia de contar con un programa de seguridad certificado para cumplir con la ley y evitar sanciones.
Dans le cadre du Meet-Up French Video Game Analyst, Ingrid Florin Muller, Acquisition Manager chez Ankama, vient partager ses méthodes et bonnes pratiques sur l'acquisition avec un focus les jeux en ligne. On parlera parcours client, funnel de conversion, test AB, KPIs (ARPU, CPA, CTR, ROI), automatisation des bilans de campagne, modèle d'attribution et retargeting.
Inline and Insertion models of the Azbil Multivariable Vortex Mass Flow Meters employ three sensing elements in a single meter; a vortex shedding velocity sensor, an RTD temperature sensor, and a solid state pressure transducer. This unique combination allows accurate mass flow measurements of gases, liquids and steam.
Cyber Defense - Annunciators as watcher for critical process applicationsM.S. Jacobs & Associates
DCS/PLC and SCADA control systems, though they provide immense capability, share a common weakness. Both are subject to cyber attack from external sources. The potential impact of this vulnerability should not be dismissed. An annunciator system can be put in place that will monitor critical process elements and provide notification of abnormalities. The systems, whether hardwired or software based, are isolated, allowing them to act as a failsafe or backup to the main control and monitoring system.
This document discusses monitoring genset systems in standby mode to ensure reliable backup power. It describes using microBlox I/O modules to monitor inputs like battery voltage, fuel level, and temperature to transmit conditions over Ethernet to be displayed at an instrument shop for continuous monitoring during standby mode from remote locations. The solution features products like microBlox modules configurable via Bluetooth, Ethernet I/O modules to map analog and alarm signals, and the Agility mobile app.
An intelligent boiler cleaning system can significantly improve plant profitability by increasing boiler efficiency and reducing operating costs. The document discusses several case studies where intelligent cleaning systems, using sensors and controls to optimize cleaning, increased profits by 30-50% with payback periods of less than 6 months. It also provides guidance on evaluating if a plant is a good candidate for an intelligent cleaning system based on factors like fuel changes, burner retrofits, and slagging issues.
The document summarizes an energy audit conducted on a thermal power plant in Jordan. The power plant produces 14.36 MW through a Rankine cycle using natural gas. A preliminary energy audit evaluated the performance of the plant's components, including the boiler, turbine, condenser, and pumps. The results showed deviations in efficiency for all components compared to their design specifications. Specifically, the boiler had the largest deviation of 4.9% efficiency, likely due to poor water and fuel quality and heat loss. Several solutions were proposed to improve the plant's efficiency.
The document discusses how power plant efficiency can be improved by analyzing key performance indicators defined in the original heat balance and design, such as flue gas exit temperatures, feedwater flow ratio, and circulating water system performance. Comparing actual operating data to design specifications can help identify areas for improvement, such as reducing stack losses, blade path losses, or circulating water losses. The circulating water system often offers the greatest potential for gains since small reductions in backpressure can significantly boost output. Regular coal sampling and analysis is also important for accurate efficiency calculations.
General Water Treatment For Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CHOICE OF COOLING SYSTEM
4.1 ‘Once through' Cooling Systems
4.2 Open Evaporative Recirculating Systems
4.3 Closed Recirculating Systems
4.4 Comparison of Cooling Systems
5 MAKE-UP WATER QUALITY
6 FOULING PROCESSES
6.1 Deposition
6.2 Scaling
6.3 Corrosion
6.4 Biological Growth
7 CONTROL OF THE COOLING SYSTEM
7.1 ‘Once through' Cooling Systems
7.2 Closed Recirculating Systems
7.3 Open Evaporative Cooling Systems
TABLES
1 RELATIVE IMPORTANCE OF FOULING PROCESSES AND INSTALLED COSTS
2 WATER QUALITY PARAMETERS
FIGURES
1 PREDICTION OF CALCIUM CARBONATE SCALING
2 CALCIUM SULFATE SOLUBILITY
3 CALCIUM PHOSPHATE SCALING INDEX
Review on Boiler Control Automation for Sugar IndustriesIRJET Journal
This document discusses boiler automation systems for sugar industries. It begins with an abstract that outlines controlling boiler parameters like steam generation and drum water level using PID controllers and SCADA systems. It then discusses several key boiler parameters that are controlled like drum level, pressures, temperatures, and flows. Upgrading to advanced automation controls is recommended to improve efficiency by minimizing excess air, allowing tighter emissions control, and improving combustion characterization. Automating the control of critical parameters can help ensure efficient and reliable plant operation.
This document summarizes research applying particle swarm optimization (PSO) and flower pollination algorithm (FPA) techniques to solve hydrothermal scheduling problems. Hydrothermal scheduling involves optimally coordinating hydroelectric and thermal power generation to minimize fuel costs while meeting demand and accounting for water availability constraints. Previous methods for solving these problems, such as simulated annealing and genetic algorithms, have drawbacks like long computation times. The document describes applying PSO and FPA to minimize fuel costs for 3-unit and 6-unit test systems, showing they can find near-optimal solutions faster than other methods while satisfying constraints. FPA, based on pollination in plants, is a new metaheuristic that effectively solves the optimization problem with better
This document provides an overview of the goals and purpose of power plant chemistry, with a focus on the water/steam cycle. It discusses how the chemist supports safe and economical plant operation by maintaining water quality, diagnosing issues, and proposing remedies. The chemist is responsible for routine monitoring and control of various systems, as well as strategic planning and troubleshooting. Their work aims to prevent corrosion and scaling to protect assets and ensure long equipment life. It also outlines the complex interactions within the water/steam cycle that the chemist must understand to fulfill these responsibilities.
OVERVIEW OF COGENERATION OPPORTUNITIES IN NEPALESE SUGAR SECTOR eecfncci
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- How performance monitoring systems work and the types of information they can provide.
- The factors that can affect gas turbine performance, both naturally from ambient conditions and loads, as well as from equipment degradation.
- The importance of differentiating between performance changes from natural causes versus degradation when analyzing data from monitoring systems.
- The distinction between recoverable and non-recoverable degradation, and how performance and mechanical condition monitoring can be used together to better diagnose issues.
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Before applying Fermsept-S, the STP was not meeting pollution control board limits for various parameters like BOD, COD and TSS. It also faced high operational costs including electricity costs to run aerators, costs of sludge removal and aerator repairs. After applying Fermsept-S, the plant was able to maintain parameters within legal limits and significantly reduce electricity costs by switching off aerators at
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Design of Heat Exchanger Network for VCM Distillation Unit Using Pinch Techno...IJERA Editor
In process industries, heat exchanger networks represent an important part of the plant structure. The purpose of the networks is to maximize heat recovery, thereby lowering the overall plant costs. In process industries, during operation of any heat exchanger network (HEN), the major aim is to focus on the best performance of the network As in present condition of fuel crises is one of the major problem faced by many country & industrial utility is majorly depend on this. There is technique called process integration which is used for integrate heat within loop so optimize the given process and minimize the heating load and cooling load .In the present study of heat integration on VCM (vinyl chloride monomer) distillation unit, Heat exchanger network (HEN) is designed by using Aspen energy analyzer V8.0 software. This software implements a methodology for HEN synthesis with the use of pinch technology. Several heat integration networks are designed with different ΔT min and total annualized cost compared to obtain the optimal design. The network with a ΔT min of 90C is the most optimal where the largest energy savings are obtained with the appropriate use of utilities (Save 15.3764% for hot utilities and 47.52% for cold utilities compared with the current plant configuration). Percentage reduction in total operating cost is 18.333%. From calculation Payback Period for new design is 3.15 year. This save could be done through a plant revamp, with the addition of two heat exchangers. This improvement are done in the process associated with this technique are not due to the use of advance unit operation, but to the generation of heat integration scheme. The Pinch Design Method can be employed to give good designs in rapid time and with minimum data.
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Electric Process Heaters
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 ADVANTAGES OF ELECTRIC HEATERS
4.1 Safety
4.2 Environment
4.3 Location of Equipment
4.4 Low Temperature Applications
4.5 Cross Contamination
4.6 Control
5 DISADVANTAGES OF ELECTRIC HEATERS
6 POTENTIAL APPLICATIONS FOR ELECTRIC
PROCESS HEATERS
7 GENERAL DESIGN AND OPERATING CONSIDERATIONS
8 TYPES OF PROCESS ELECTRIC HEATERS
8.1 Pipeline Immersion Heaters
8.2 Tank Heaters and Boilers
8.3 Indirect (Fluid Bath) Heaters
8.4 Radiant Furnaces
8.5 Induction Heaters
8.6 Hot Block Heaters
9 CONTROL
10 REFERENCES
FIGURES
1 ELECTRIC HEAT EXCHANGER CONSTRUCTION
2 SHEATHED HEATING ELEMENTS
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Energy saving in cooling towers by using variable frequency drives (1)IAEME Publication
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Energy saving in cooling towers by using variable frequency drivesIAEME Publication
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The document discusses monitoring programs for critical equipment in ammonia plants to improve reliability and uptime. It outlines key performance indicators to monitor for various units, such as the primary reformer, secondary reformer, and shift converters. Monitoring parameters like temperatures, pressures, emissions and efficiencies can help identify problems early before catastrophic failures and keep the plant running optimally.
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This document discusses performance monitoring for gas turbines. It begins by explaining that performance monitoring is important for maximizing efficiency and minimizing costs, though it is less common than mechanical condition monitoring. It then discusses:
- How a performance monitoring system works and the types of information it can provide
- The business case for monitoring performance based on potential fuel cost savings
- Examples of how customers are obtaining value from performance monitoring systems
It describes the various performance monitoring solutions available from GE Energy. It also explains key concepts regarding gas turbine thermodynamics and the factors that can affect performance. These include ambient conditions, load, fuel properties, and degradation. It emphasizes the importance of differentiating between "natural" causes of performance changes
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Optimizing the Steam Generation Cycle and Condensate Recovery Process
1. 1
“The U.S. pulp and paper industry—defined as
facilities engaged in the manufacture of pulp, paper,
and paperboard—consumes over $7 billion worth
of purchased fuels and electricity per year. Energy
efficiency improvement is an important way to reduce
these costs and to increase predictable earnings,
especially in times of high energy price volatility.”
Berkeley National Laboratory
Environmental Energy Technologies Division, October 2009.
Objective
To identify key areas in the steam generation cycle, condensate
recovery system and waste heat recovery process where cost-effective
instrumentation solutions offer a tangible return on investment over
the short term. The goal is to reduce heat rate, environmental impact,
fuel and water consumption, water treatment and maintenance costs in
commercial and heavy industries where steam generation is essential to
the production processes.
Overview
• Why control?
• Steam generation
Boiler/steam drum
Deaeration
Blowdown
• Condensate and waste heat recovery
Cost benefits of condensate recovery
Condensate receiver tanks
Pump protection
Flash tanks and heat exchangers/condensers
• Water chemistry and treatment
Chemical storage monitoring
• Energy management
Combustion air, fuel flow & compressed air
Why Control?
Although the pulp and paper industry is one of the largest producers
of steam outside power generation, the primary metals, petroleum
refining, chemical process, and food processing industries also allocate
significant portions of their total energy consumption, anywhere from
10% to 60%, to the production of steam. Instrumentation plays an
importantroleinkeyapplicationsthroughoutthesteamgenerationcycle.
As a consequence, the performance of any level technology relative to
instrument induced errors, calibration nuances, and vulnerabilities to
process dynamics can have an immediate and adverse impact on fuel
consumptionwhilecontributingnegativelyinotheraspectsoftheprocess
be it makeup water requirements, excessive boiler blowdown, energy
transfer, etc. Unfortunately, these other aspects of the process indirectly
contribute to the inefficient use of fuel and hinder production throughput
and product quality. Adding to this burden is the potential for damage
to expensive hardware resulting in forced outages, unscheduled, costly
maintenance, and production downtime.
It is not an uncommon practice in this day and age to employ a waste
heat and/or condensate recovery process to reduce energy losses and
capture valuable condensate. The use of instrumentation technology
that cannot adequately or reliably address the control aspects of these
processes can inhibit the effectiveness and overall return on investment
in these systems or expose hardware to unnecessary damage.
Furthermore, processes where electricity consumption and steam
generation represent a disproportionate amount of the fuel cost can be
plagued with inefficiencies simply due to a technology’s shortcomings
Donald Hite, Business Development Manager
Magnetrol®
International and Orion Instruments®
Optimizing the Steam Generation
Cycle and Condensate
Recovery Process for Profit
2. 2
on critical applications which adversely affect heat rate. Of course, this
depends on the fuel type as well as other factors. Nonetheless, when
properly addressed, these areas have an immediate and positive impact
on costs.
An overview of the processes involved, along with the unique
instrumentation requirements for each component, offers insight into
the significance of maintaining proper level control and protective
measures to realize potential savings in steam generation, waste heat
and condensate recovery and water treatment systems common in
heavy industry.
In essence, it is not a one-size-fits-all scenario; rather by providing
the proper level technology to enhance performance in specific areas
throughout the process to maintain market share in a highly competitive
global arena. This paper will highlight the individual areas where the
application of specific level control technologies can improve overall
performance. As price is usually a key consideration, severe service
applications leverage technologies where the cost benefits are realized
over the short and long terms and are linked directly to efficiency. More
consideration is typically given to the front-end cost on applications
having the least effect on efficiency of the process; but, in reality,
reliable measurement is a key factor in normal operation of the process.
Steam Generation
Steam generation and condensate recovery systems can vary in
complexitydependingonthesteamendusageandprocessrequirements,
e.g., steam for electricity generation or to support a paper mill operation
versus that for a small to mid-size specialty chemical process operation.
Figure 1 is a simplified diagram depicting a basic steam generation
cycle, scalable to virtually any plant requirement whether incorporating
a fire tube or larger water tube type boiler. It should suffice to highlight
critical areas in the cycle where addressing level control concerns can
have a profound impact on efficiency, reliability and maintenance.
At the heart of the system is the boiler/steam drum. Regardless of
size, its primary functions are as follows: to provide ample surface
area (based on steam needs) for the efficient separation of water
and steam; provide storage capacity to meet immediate boiler feed
water requirements or minimize the effects of the introduction of boiler
feed water on the steam generation process; and, to facilitate the
introduction of chemicals for treatment purposes as well as the removal
(blowdown) of impurities.
A boiler, fire or water tube, presents an extremely dynamic environment
with respect to level control regardless of the control strategy—
single-, two-, or three-element. The common denominator in each of
these strategies is the level measurement itself. Applying a technology
that improves on this portion of the equation will most certainly aid in
allowing the boiler/steam drum to better serve its primary purpose
of efficiently separating water and steam. This becomes more
pronounced when fluctuations in demand can have dramatic effects on
an instrument’s performance due to “shrink” and “swell” issues as a
result of pressure changes. In larger-scale steam production such as
that required for commercial power generation (water tube boilers),
disruptions in boiler/steam drum level control can have adverse affects
on the natural circulation of the process and a plant’s ability to respond
to market demand.
Blowdown
Flash Tank
Process Steam
Process Condensate (from condensate receiver tanks)
Deaeration Steam
Heating
Steam
Boiler Feed Water
Makeup Water
Makeup Water-
Treatment
Makeup Water
Chemical Feed System
Plant
Steam
Usage
Boiler/Steam Drum
Boiler Feed Water
Boiler/Steam Drum
MainCondensate Tank
Heat Exchanger
Deaeration and Storage
Figure 1
2
3. 3
Level technologies historically used on boilers rely on inference or
buoyancy to determine the level. This in itself leaves them vulnerable to
process dynamics (specific gravity, pressure, temperature, etc.) or limits
their ability to precisely manage the level for improved fuel economy.
Although corrections can be applied to mitigate the effects, the variables
that need to be accounted for increase the level control’s installation,
hardware and calibration complexity, which has the unintended
consequence of introducing new avenues for error. Eliminating potential
sources of error (including human error) as related to an instrument’s
fundamental technology is the first step in optimizing boiler/steam
drum level control.
A quick peek at various technologies reveals their shortfalls as related to
boiler/steam drum level control:
• Differential Pressure – a complex system of tubing, condensate
pot and transmitter(s) based on inference requiring up to 12 process
parameters to properly calibrate. External inputs and corrections are
applied to ensure accuracy.
• Buoyancy (displacer) – accuracy from startup to operational
temperatures is not achievable due to displacer being designed for the
specific gravity at operational conditions. Calibration and mechanical
wear may introduce errors over time.
• Buoyancy (mechanical switch for on/off control) – a low-cost
solution for smaller boilers; however, introduction of larger volumes
of sub-cooled liquid could affect performance and increase fuel
consumption as compared to a continuous type measurement.
• RF Capacitance – based on the dielectric constant of the process
medium. The dielectric constant of water/condensate changes as a
function of temperature, introducing unnecessary errors. Requires in-
situ callibration.
• Conductivity–highupfrontandprobemaintenancecostsascompared
to other technologies. Not a continuous measurement. Resolution is
contingent on the proximity of adjacent conductivity probes across
the measurement span; Vulnerable to scale accumulation and fouling.
Guided Wave Radar (GWR), on the other hand, is a continuous
measurement technology that has the distinct advantage of not
being vulnerable to changes in process conditions that affect the
aforementioned measurement techniques. Since its performance and
accuracy are not contingent on the specific gravity and/or inference, it
excels in measuring the actual liquid level in all conditions encountered
in the boiler/steam drum. Furthermore, GWR does not require external
inputs or calibration to achieve specified performance — accuracy is
inherent to the technology. This effectively eliminates the introduction
of errors during the calibration process or from external sources, i.e.,
pressure and temperature. A reduction in the number of variables
affecting the measurement provides a high degree of data certainty
allowing operators to better maintain the Normal Water Level (NWL) in
the boiler/steam drum for optimal water/steam separation throughout
a variety of process conditions.
Key benefits of GWR for
boiler/steam drum level
• Three-element control strategy: feedwater flow, main steam
flow and boiler/steam drum level – actual versus inferred
level. Continuous versus discrete indication.
• No calibration or external compensation: data certainty
when implementing control strategy during normal operations
and “shrink swell” conditions. Prevents over/under carry
conditions.
• Maintaining NWL in all process conditions improves steam/
water separation and overall steam quality.
• Eliminates waste energy due to excessive blowdown to
manage level.
• Responsiveness to changes in demand.
• Steam specific process isolation seal for corrosive high
temperature/high pressure applications.
• Automatic steam/vapor space compensation.
• Simplified trouble analysis and lower maintenance costs.
The hardware and calibration complexity and vulnerability to process conditions introduce
additional costs and potential errors in any given level measurement technology.
Boiler/Steam Drum
Process Steam
Swell
Shrink
Boiler/Steam Drum
Thermal Dispersion
Flow Switch for boiler
feed pump protection
Eclipse®
GWR
Transmitter meets all requirements
of ASME Boiler Code Section 1
Boiler Blowdown/
Blowdown Flash Tank
Boiler
Feed Water
3
Figure 2
4. 4
An aside to the discussion on optimizing level control for improved
operational efficiency of the boiler/steam drums is the sight/gauge
glass requirement delineated in Section 1 of the ASME Boiler Code.
Sight gauges serve a very important role as a backup to boiler/steam
drum level controls so their presence cannot be understated. However,
in continuous service they come with the burden of ongoing, expensive
maintenance costs, along with potential safety concerns.
Eliminating one of the two required sight gauges as provided in
Section 1 of the ASME Boiler Code (above) can substantially reduce
maintenance costs while allowing the remaining sight gauge to be
isolated during day-to-day operation. Oftentimes, the costs associated
with repairing sight gauges on boilers/steam drums as well as other
applications (feedwater heaters/heat exchangers) incorporating these
gauges offset the expense of the new instrument. Significantly reducing
the number of leak points in comparison to a sight glass/gauge is a
bonus when it comes to the safety of plant personnel.
Deaerator
Another key level application, oftentimes, overlooked when discussing
efficiency is the deaerator with its primary functions being the removal
of oxygen and other corrosive gases from the boiler feed water to
reduce damage to hardware while ensuring sufficient boiler feed water
heater inventory to meet the demand for steam. However, a deaerator
also serves as an “open” type or deaerating feedwater heater not too
dissimilar to a “closed” type or shell and tube feedwater heater. In this
respect, the deaerator performs its function of deaeration while at the
same time using steam, which can give up about 970 Btu per pound, to
preheat the boiler feed water prior to entry into the boiler.
As with any feedwater heater, the level is critical in maintaining a
consistent condensing zone to maximize the transfer of energy from
the steam to the boiler feed water while ensuring adequate boiler feed
water reserves are available. Of course, any appreciable gains in boiler
feed water that can be achieved in the deaerator reduces the amount of
energy (fuel) required at the boiler – every 10.8°F (6°C) rise in boiler
feed water amounts to a one percent savings in fuel cost.
PG−60.1.1 Boilers having a maximum allowable working
pressure exceeding 400 psi (3 MPa) shall have two gauge
glasses.
Instead of one of the two required gauge glasses, two
independent remote water level indicators (two discrete systems
that continuously measure, transmit, and display water level)
may be provided.
PG−60.1.1.2 When two independent remote water level
indicators are in reliable operation (continuously indicating water
level), the one required gauge glass may be shut off, but shall be
maintained in the serviceable condition.
Optimizing the heat exchanger aspects of the deaerator with
enhanced level technologies can improve energy transfer. Every
10.8°F (6°C) rise in boiler feedwater amounts to a 1 percent
savings in fuel.
Aurora®
:
Magnetic Level Indicator with Integral Guided Wave Radar
Makeup Water
Deaeration Steam
from Boiler or
Blowdown Flash Tank
Heating Steam
from Boiler or
Blowdown
Flash Tank
Feed Water to Boiler
Deaeration and Storage
Boiler Feed Water
Common Sight/Gauge Glass Issues
• Steam cuts
• Integral valve failure
• Gasket/seal leakage
• Glass erosion/fatigue
Repair Kit
Seals/Gaskets
Kit with Glass
$660.00
$1,600.00
Shop Time
4 hrs @ $35/hr (est.) $140.00
Installation Time
4 hrs @ $35/hr (est.) $140.00
Vessel/Process
Downtime
1 Day at $$$
4
Figure 3
5. 5
In addition to the “open” or deaerating feedwater heater, the more
common shell and tube or “closed” feedwater heaters can be found
in larger scale steam generation cycles where their costs are offset
by gains in thermal efficiency. How effective a feedwater heater is in
transferring thermal energy is contingent, barring hardware anomalies,
on accurate level control. For more information, consult Magnetrol®
bulletin 41‑296, Heat Rate and Feedwater Heater Level Control.
The same attributes making GWR technology uniquely suited for a
boiler/steam drum application can also be leveraged on the deaerator
and feedwater heaters to provide improvements in thermal efficiency.
Blowdown Flash
Blowdown Tanks
Maintaining water quality in the boiler within design parameters
maximizes heat transfer while minimizing blowdown of the boiler; both
of which allow better management of fuel and water consumption.
Continuous or manual blowdown of the boiler minimizes scale
accumulation and corrosion resulting from impurities in the water.
The blowdown and blowdown flash tanks provide a means of
accommodating liquid and impurities from the boiler with the latter
facilitating energy recovery through the use of flash steam. Estimates
of up to 49 percent of the energy can be recovered through the use
of flash steam routed to heat exchangers or the deaerator to preheat
boiler makeup water or support the deaeration process, respectively.
Additionally, better level control technology at the boiler side eliminates
energy losses resulting from unnecessary blowdown to prevent false
carryover conditions.
Taking advantage of a specific technology’s ability to reliably address
the level in either of these vessels, especially the blowdown flash
tank, in a plug-and-play type installation and commissioning format
(foregoing calibration, external hardware or inputs) is an easy way to
ensure optimal performance.
Optimizing boiler, deaerator, feedwater heater (heat exchanger/
condenser) and blowdown usage relative to level control primarily
affects fuel economy (heat rate) by better managing the amount of
energy required to produce high quality steam for any given task.
Seamless response to changes in demand and reducing maintenance
associated with the instrumentation or damage to hardware are residual
benefits that have their own financial ramifications; hence, should
also be considered when implementing any technology. The return
on investment time frame can vary depending on the scale of the
operation as well as the time spent maintaining aging instrumentation.
Condensate Recovery
The benefits of any condensate recovery system are well documented in
industries relying on steam generation for their processes. Condensate
hasrealvalueinthateverygallonrecoveredsparesthecostofadditional
makeup water, makeup water treatment and/or wasteful discharge to
municipal or other systems. Oftentimes, it is the instrumentation, or
lack thereof, that limits the performance of the overall system causing
the recovery process to fall short of financial expectations.
Three areas of particular interest relative to efficiency when it comes to
level controls are the condensate receiver and main condensate tanks,
condensate pumps and associated valves as well as any shell and tube
heat exchangers/condensers (Figure 4, next page).
The condensate receiver tanks accept blow-through steam and
condensate from various steam process groups throughout a plant.
Condensate is later pumped to the main condensate tank where it is
stored pending reintroduction into the steam generation cycle. The shell
and tube heat exchanger/condenser allows what would otherwise be
waste energy to be recovered in the form of flash steam from the
receiver tank to preheat makeup water or other process fluids through
the heat of condensation. The resulting condensate drains back to the
condensate or condensate receiver tank.
The level transmitter on the condensate receiver tank facilitates the
automatic management of the condensate level to ensure adequate
capacity is available to accommodate (recover) condensate from
various plant processes as well as maintaining sufficient headspace in
the vessel for the creation of flash steam. Aside from being a critical
asset for the plant, the condensate in the condensate receiver tank also
protects valves and condensate pump seals from direct exposure to
high temperature steam while maintaining a minimum head pressure
on the pump. This prevents hardware damage; expensive maintenance
and downtime of the receiver tank; and subsequent ripple effects on
the steam generation cycle and makeup water requirements. Lastly,
the level transmitter provides the control signals for the valves and
condensate pump necessary to transfer condensate from the receiver
to the main condensate tank, ensuring approximately 15 percent
level retention for the aforementioned reasons. At this point, the main
condensate tank level transmitters take over to manage boiler feed
water supply to service steam generation demand.
5
6. 6 6
Magnetic Level Indicator
with integrated Eclipse®
GWR or standalone GWR
in a chamber/water
column
Heat Exchanger/Condenser
Condensate
Receiver
Tank(s)
Main Condensate Tank
Flash Steam
Process Condensate – Plant Processes
Pumped Condensate
Preheated Makeup
Water to Deaerator
Boiler Feed Water
to Deaerator
Makeup Water
Steam to other Plant Processes
Atlas™
and Jupiter®
Magnetic Level Indicator
with externally attached
magnetostrictive
transmitter
Thermal Dispersion
Aurora®
Protects pumps from
dead head, run out,
overheating and
cavitation
Figure 4
Condensate Recovery
Process Level
• Protect valves pump seals from
exposure to high temperature steam
• Maintain minimum head pressure on
condensate pump
• Ensure sufficient headspace for flash
steam creation
• Allow capacity to accommodate
condensate from various process
groups
• Manage boiler feedwater supply chain
to meet demand
GWR/MLI Technology
Benefits
• Redundant and diverse level
technologies
• Unaffected by process conditions
• No calibration required
• No moving parts – eliminates
instrument induced errors (GWR)
• Setup wizard and full diagnostics –
fast startup and fault isolation
• Designed for high temperature steam
applications
• Simplifies instrumentation hardware
Case Study
• Pump Seal - $1,000.00
• Labor - two person for ½ day @
$75.00/hr equals $600.00
• Discharged condensate
$3.65/1000 gallons
• Condensate receiver out-of-service for
maintenance $$$
• 1 to 3 pump seal replacements per
week reduced to 1 to 3 per year:
“Pulp Paper Plant”
• Maintenance cost of poor level control:
$78K to $244K per year
Eliminating Hidden Maintenance Costs
7. 7
Makeup Water Treatment
Makeup water treatment is a critical component of steam generation
in that it is the means to resupply the system with water suitable
for boiler and other operations that, for whatever reason, was lost
in the cycle. Unlike the previous applications discussed in the steam
generation cycle, level control for the water treatment process is not
necessarily about efficiency, but rather, accuracy, reliability and safety
while providing proper inventory management to ensure chemical and
makeup water supply meets demand.
Here the focus is on the chemical component of the water treatment
sinceitpresentsdifficultiesforleveltechnologiesthatmayworkperfectly
on non-chemical applications related to the water treatment process or
those with limited variations in the contents of the vessel’s vapor space.
Although important measurements such as ammonia, acid, caustic and
other chemical storage tanks are not difficult level applications by any
stretch, small nuances in how the vessels are monitored relative to level
technology can have a dramatic effect on the day-to-day practicality
and reliability of the type of instrument(s) used. Additionally, there
are safety considerations when replenishing chemicals as well as long-
term maintenance costs, which can be addressed simultaneously with
inventory monitoring by implementing a few simple, cost-effective
modifications to the instrumentation package.
Chemical storage, demineralization and water header tanks come in
a variety of shapes and sizes, usually, horizontal or vertical vessels
six to ten feet in diameter/height, with the ammonia storage and
demineralizer tanks being the largest. It is not uncommon to see some
type of level transmitter (ultrasonic being the most prevalent) installed
to provide level indication to the control room with a local display at the
base of the tank, either in series with the 4–20 mA transmitter output
or repeated from the control room. The signal to the control room tracks
inventory, acts as a high alarm for overfill protection and establishes the
resupply interval. The local display facilitates monitoring the offload of
chemicals from the supplier’s truck.
Accuracy, reliability and visibility in dynamic vessel environments and
operational scenarios are a level technology’s best attributes when
addressing chemical storage applications. Cost is always an upfront
consideration on these seemingly less complicated measurements.
Nonetheless, performance in these two areas can have a measurable
impact on the “real” cost of ownership for a plant. There is also a
good argument for selecting the appropriate level technology during
the Front End Engineering Design (FEED) phase of a project, as this will
eliminate potential installation and commissioning issues by taking into
consideration the technology in the vessel design — another area of
potential savings.
Any number of level technologies can and have been used to address
chemical storage. Adhering to the principles of minimizing the number of
variables (e.g., vulnerability to process dynamics, calibration, hardware
complexity, etc.) that can affect a technology’s ability to perform as
intended is a key step in reducing the total cost of ownership. Again,
Guided Wave (contact) Radar as well as its Through-Air (non-contact)
Radar counterpart excel in these areas. Magnetic Level Indicators
(MLI) operating in conjunction with either type of radar technology or
coupled with a magnetostrictive level transmitter offer redundancy and
technology diversity while enhancing visibility for improved safety during
resupply operations. There is also the added benefit of redundancy
when verifying the primary transmitter’s performance during periodic
inspections on scheduled outages or while troubleshooting.
This does not imply non-contact ultrasonic level transmitters or other
technologies are not up to the task. Simply put, radar is indifferent to
the changes in the contents of the vapor space of these vessels occurring
throughout the course of the day. Oftentimes, these changes affect a
technology causing what can be referred to as nuisance alarms, e.g.,
intermittent signal loss or when the level indication becomes erratic only
7
High-visibility magnetic level indicator with magnetostrictive transmitter
supports the offloading of ammonia at a combined cycle power plant
Key Components to
Chemical Storage Monitoring
• Inventory Management (accuracy)
• Resistance to chemical attack (reliability maintenance)
• Utilize a technology that is unaffected by changes in the vapor
space of the vessel (reliability)
• Performance verification (maintenance)
• Visibility during product transfer (safety)
8. 8
to recover about the time a technician arrives on the scene. These types
of issues are difficult to isolate due to their intermittent nature and the
fact they cannot be linked to an installation, configuration or hardware
anomaly.
When discussing the water treatment process supporting any steam
cycle, large or small, it is not a one-size-fits-all concept that provides the
most benefit as related to performance. For as simple as some of these
level applications appear, there is no shortage of instances where they
contribute disproportionately to the commissioning and maintenance
budgets simply because they cannot accommodate the full breadth
of the application dynamics. Opting for a technology-centric versus a
one-size-fits-all approach to applications throughout the water treatment
process reduces both short- and long-term cost of ownership. This allows
for the implementation and realization of the cost benefit of entry-level
technologies for less strenuous applications, while minimizing cost
on those with variations in the vapor space (e.g., steam, chemical
composition, excessive condensation, etc.). All of which can wreck
havoc on an instrument’s performance as well as a plant’s maintenance
budget.
Energy Management
The thrust of this discussion, regardless of the scale of an operation,
centers on identifying key areas of the plant where leveraging the
attributes of a technology in any given scenario has the most profound
effect on efficiency with a quantifiable return on investment falling in
the one- to two-year time frame.
As noted earlier, purchased fuel and electricity consumption are areas
where any improvements in efficiency drop directly to a company’s
bottom line. It makes sense that having the ability to monitor the end-
use location of fuel throughout a facility as well as the consumption
specifics for individual applications — predominately the boiler — can
offer insight to potential areas of improvement. A similar statement can
be made for electricity consumption; whereby reductions can be realized
by simply identifying where the energy is being lost.
In the energy management arena the ability to better monitor
combustion air, fuel gas flow and compressed air can help identify losses
that over short periods of time can affect a plant’s profitability. The two
key phrases when discussing instrumentation for the aforementioned
are “cost effective” and “return on investment.” Without question, any
situation can be resolved if enough financial resources are thrown in its
direction. The idea is to realize the benefit in the shortest time frame
possible at the most reasonable cost. Thermal dispersion mass flow
meters meet these criteria.
Chemical Storage Water
Treatment Level Technologies
• Radar – Guided Wave (GWR) and Non-Contact for
simplified installation, commissioning and maintenance while
tolerant to a changing vapor space
• Magnetic Level Indicator (MLI) for improved visibility
during resupply; periodic maintenance or performance
verification. Can stand alone or work in conjunction with
other level transmitters to provide redundancy and technology
diversity to critical measurement
• Magnetostrictive transmitter coupled with MLI offers an
alternative to top-mounted level transmitter technologies while
being isolated from vessel contents
• Ultrasonic (non-contact) excellent level solution for
non-chemical or less critical applications in the water treatment
process with limited variations in the vapor space
8
9. 9
Combustion air flow measurement to a boiler is important to
maintain a stoichiometric ratio with the amount of fuel being supplied.
Too little air flow can result in incomplete combustion along with
additional carbon monoxide or pollutants depending on the fuel being
burned. On the other hand, too much air flow can cool the furnace and
waste heat out of the stack. The repeatability of the air measurement is
essential to obtaining the most efficient air-fuel ratio (AFR).
Measuring fuel gas flow (natural gas or propane) usage to individual
combustion sources compared to the output (steam/hot water) can
help optimize boiler efficiency and better manage energy consumption.
Knowingindividualboilerperformancemayalsoassistinoperatingthose
offering the best efficiency. Lowering fuel consumption is one of the
easiest methods to reduce cost and improve market competitiveness.
A key role in energy and facilities management is making compressed
air systems more reliable and efficient. Valuable resources are wasted
when a leak goes unnoticed or cannot be easily isolated.
The Department of Energy estimates that 20–30% of compressor
output goes to leaks accounting for thousands of dollars in electrical
consumption for wasted air. More extreme cases are the purchase cost
of additional/larger compressors to fulfill compressed air needs. The
first step to reducing utility costs is to measure the usage. Thermal
dispersion technology can be used in branch lines for determining
consumption in different sections of the plant or as a relative indication
of leakage.
• Repeatability of ±0.5% of reading
• Direct mass flow measurement
• Easy to install in an air duct
• No on-site or in-situ calibration
• Strong signal at low flow rates with high turndown
• Verify calibration in the field
• Easy installation with low pressure drop
• Direct mass flow measurement without the need for pressure
or temperature compensation
• Easy installation with use of an insertion probe with
compression fitting
• Accurate flow measurement under varying pressures
• High turndown and good sensitivity at low flow rates
Thermal Dispersion Mass Flow Meter
Thermal mass flow meters are primarily used in air and gas flow measurement
applications. The meters consist of a transmitter and probe with temperature
sensors (RTDs) located in the pins at the bottom of the probe. The reference sensor
measures the process temperature and the other sensor is heated to a specific
temperature above the reference. As the flow rate increases, heat gets taken
away from the heated sensor. More power is then applied to the heated sensor to
maintain the temperature difference. The relationship between power and mass
flow rate is established during factory calibration.
9
10. 10
Case Study 1*
Steam System Efficiency Optimized
J.R. Simplot Fertilizer Plant
Benefits:
Total annual cost savings: $335,000
Energy savings: 75,000 MMBtu
• Improved Boiler Operation • Recycled Steam
• Increase Condensate Recovery • Steam Trap Repairs
• Improved Insulation
Project costs: $180,000.00/ROI 6.5 months
Case Study 2*
Improving Steam System Efficiency
Goodyear Tire Plant
Benefits:
Total annual cost savings: $875,000
Energy savings: 93,000 MMBtu
• Optimize Boiler Operation – tune boilers to reduce excess 02, reduce fuel consumption
• Recover Process Waste Heat – installed heat exchanger to raise makeup water temperature using energy in condensate
• Insulate Process Equipment – lower steam system energy consumption
Total Implementation Project Costs: $180,000/ROI 2.5 months * U.S. Department of Energy
10
Summary: Process Optimization through Instrumentation
Although plausible, it is rare to identify a single source of inefficiency
related to poor level controls that impacts a company’s bottom line in the
double digit percentile. More so than not, it is these small incremental
opportunities for improvement across various aspects of the steam
generation cycle, condensate recovery system and waste heat recovery
process that ultimately equate to substantial savings.
• Reduced water consumption, treatment, discharge and
inventory management
• Improved boiler/steam drum control – energy savings and
steam quality
• Reduced fuel consumption – waste heat recovery
• Energy Management – fuel gas, combustion air and
compressed air flow
• Hardware protection maintenance – pumps and pump seals
Oftentimes, the hidden maintenance costs and inefficiencies associated
with a technology’s vulnerabilities (sustained operation in high pressure
and temperature steam environments; exposure to chemical and other
process conditions; and errors due to the complexity of the measurement
itself and subsequent calibration requirements) are overshadowed by the
day-to-day operation of these processes.
Regardless of the scale of an operation – commercial power generation
or small scale boiler system, leveraging the inherent attributes of
an instrument’s fundamental technology in both the short-term
(engineering, upfront cost, installation and commissioning) and long-
term (maintenance, day-to-day practicality and energy management)
present simple and cost-effective approaches to maximizing the return
on investment in the system itself.
11. 11
Magnetrol®
Instrumentation
See the full product line at:
magnetrol.com
11
Guided Wave Radar Non-Contact Radar
Ultrasonic Buoyancy
Thermal Dispersion Magnetic Level Indication/
Magnetostrictive