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GESTRA Equipment for Energy Supply Centres. SPECTORbus, SPECTORmodule or conventional technology for land and marine applications

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GESTRA Equipment fo Enegy Supply Centes SPECTORbus, SPECTORmodule o conventional technology fo land and maine applications Steam and condensate systems with one-stop sophistication Pocess steam Steam die/
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GESTRA Equipment fo Enegy Supply Centes SPECTORbus, SPECTORmodule o conventional technology fo land and maine applications Steam and condensate systems with one-stop sophistication Pocess steam Steam die/ puifie Flash steam/gas Enegy supply cente Steam flow measuement Stack Economize Boile automation as pe TRD 604 SPECTORcontol Measuement data fom boile house Poduction measuement data Deaeating unit Condensate tank Blowdown Flash vessel Intemittent boile blowdown Heat exchange Fesh/soft wate Cooling wate Fuel Cooling wate 2 Blowdown eceive Equipment fo Enegy Supply Centes Electical pessue contol Steam flow measuement Electical tempeatue contol Monitoing of conductivity Mechanical tempeatue contol Flash vessel Heat exchange Monitoing of tubidity Contolled fom the condensate side Contents Oveview Steam Boile Equipment with BUS Technology Steam Boile Equipment with SPECTORcontol Contolling, Monitoing and Visualizing Steam Boile Equipment with BUS Technology SPECTORcontol SPECTORcom GESTRA SPECTORmodule Steam Boile Equipment SPECTORmodule fo 24 Hous of Unmanned Opeation fo Opeation with Limited Supevision Steam Boile Equipment fo Plants Requiing No Supevision Equipment fo Pessuized Hot-Wate Plants BUS Technology Conventional Low-Level Limites (LW) SPECTORbus SPECTORmodule High-Level Alam (HW) SPECTORbus und SPECTORmodule Level Contolle On/Off Conventional Boile Wate Quality Monitoing Tempeatue Contolle/Limite Sample Coole PK Potable Digital Mete VRM-2/VRM Enegy Recovey Condensate Monitoing Equipment fo Steam Geneatos Maine Boiles Sightglass Steam tap Non-etun valve 3 Oveview Reliability, availability and economy have always enjoyed top pioity in boile opeation. To an inceasing extent, anothe aspect is being added: plant automation and visualization. To implement these fundamental pinciples, GESTRA AG has fo decades now been woking exclusively with electode systems that ae low in maintenance and wea; in contast to othe systems, they function entiely without moving pats. Ove and above the boile house equipment itself, these systems have now conqueed the peipheal units, such as feedwate and condensate tanks, pumpless and pump-diven etun installations etc., since the entie enegy supply cente is only as effective as its weakest element. Many of ou customes theefoe do not ente into any compomises in this aea too. Anothe step fowad was taken fo the GESTRA equipment components though the intoduction of the SPECTOR family, consisting of SPECTORcompact, SPECTORbus and SPECTORmodule. SPECTORbus not only allows easy integation into automation concepts but also offes many technical innovations that simplify plant constuction and commissioning consideably. SPECTORmodule epesents a logical advancement of the conventional technology. Following the state of the at, it uses the latest electonic components and, as egads the limites, is based on the EN standads. These units wee developed and manufactued with consideation fo functional safety as pe IEC and cetified accoding to SIL3. GESTRA Pefomance Spectum GESTRA GESTRA System PN25 PN40 PN63 PN160 PN250 PN320 module bus Low-level limites of high-integity design High-level alams of high-integity design Level contolles Low-level limites/contolles (compact units) Safety tempeatue limites Conductivity measuement with autom. tempeatue compensation without autom. tempeatue compensation Continuous blowdown valves Intemittent blowdown valves 4 Equipment fo Enegy Supply Centes GESTRA SPECTORbus Less is moe! The Benefits in Detail 1. No isk of oveheating: Patented themal baie in cylindical body above electode flange Electonic tempeatue potection in the teminal box Patented connection aangement Minimization of themal effects 2. Easy installation and maintenance: Feely accessible connecting teminals at the contol units Lage teminal box makes fo easy installation 3. Reduced cost: Minimized inventoy and spaes levels Only a single cable needed between boile and contol cabinet Low installation and mateial costs Reduced cost fo contol cabinets Cabling connection male/female, peassembled cables Only five input teminals Only one cable in the contol cabinet fo all sensing units Optimum system integation without additional cable installations 4. Inceased safety: Active cable monitoing with moe than twice the pevious maximum cable length Easy to integate into visual display and automation systems Fom little acons big oaks gow. With the BUS technology by GESTRA, a new ea has begun in the measuement and contol of boile systems: Less cabling Less installation wok Less space needed in contol cabinets Fewe contol units Less wea and tea Less maintenance Fewe poduction outages Lowe costs Moe contol Bette pocess oveview Highe availability Moe eliability Geate plant efficiency Bette utilization of enegy Longe plant opeation times w w w. g e s t a. d e 5 6 d d n c a b a a b c d t m o g h f p q e k s w e j GESTRA Steam Boile Equipment with BUS Technology Fo opeation e.g. accoding to TRD 604 (72 h) o EN (24 h) The futue has aleady begun! Equipment fo Enegy Supply Centes a Low-level limite of high-integity design : level electode NRG 16-40, level switch NRS ) p. 22, 23 bt Modulating level contolle with integated 2nd wate level and conductivity indicato: level pobe NRG 26-40, level contolle NRR 2-40, contol teminal and display unit URB 1 (URB 2) p. 29 c High-level alam of high-integity design : level electode NRG 16-41, level switch NRS ) p. 25 de Conductivity measuement and continuous/intemittent blowdown: conductivity electode LRG 16-41, continuous blowdown contolle LRR 1-40, continuous blowdown valve BAE, intemittent blowdown valve MPA, 3/2-way pilot valve, staine p. 32, 33 f Sample coole p. 36 g Blowdown flash vessel h Residual blowdown coole j Blowdown eceive k Safety tempeatue limite: esistance themomete TRG 5-65, tempeatue peamplifie TRV 5-40, level switch NRS ) p. 34, 35 m n o Safety valve GSV Pessue limite DSF Pessue contolle/tansmitte p Disco non-etun valve RK 86 q Staine GSF Stop valve GAV s Electical/pneumatic contol valve V 725 t Contol teminal and display unit URB Monitoing of the fesh wate: w Deminealization equipment using conductivity monitoing Patial deminealization equipment: by monitoing esidual hadness (not pat of ou poduct ange) The benefits in detail No isk of oveheating Patented themal baie in cylindical body above electode flange Electonic tempeatue potection in the teminal box Minimization of themal effects Easy installation and maintenance Feely accessible connecting teminals at the contol units Lage teminal box fo easy installation Reduced cost Minimized inventoy and spaes levels Only a single cable needed between boile and contol cabinet Only one cable in the contol cabinet fo all sensing units Optimum system integation without additional cable installations Inceased safety Active cable monitoing Easy integation into visual display and automation systems Get a technical lead with the fist and only contol package fo enegy supply centes using an open CAN-bus system. Only GESTRA pemits easy intefacing to othe open bus systems. 1 ) Only one electonic contol unit is needed. 2 ) Not equied by EN. w w w. g e s t a. d e 7 8 GESTRA Steam Boile Equipment with SPECTORcontol Boile equipment accoding to TRD 604 (72 h) o Euopean guidelines, e.g. EN Pat 6 d d n c a b a u d m o g h f p q e k s w e j k ac* Contolling, Monitoing and Visualizing v Sevice patne Contol oom Equipment fo Enegy Supply Centes a b Low-level limite of high-integity design : level electode NRG 16-40, level switch NRS p. 22, 23 Modulating level contolle: level pobe NRG p. 29 c High-level alam of high-integity design : level electode NRG 16-41*) p. 25 de Conductivity measuement and continuous/intemittent blowdown: conductivity electode LRG 16-41, continuous blowdown contolle LRR 1-40, continuous blowdown valve BAE, intemittent blowdown valve MPA, 3/2-way pilot valve, staine p. 32, 33 f Sample coole p. 36 g Blowdown flash vessel h Residual blowdown coole j Blowdown eceive k m n o Safety tempeatue limite at the supeheate: esistance themomete TRG 5-65, tempeatue peamplifie TRV p. 34, 35 Safety valve GSV Pessue limite DSF Pessue contolle/tansmitte p Disco non-etun valve RK 86 q Staine GSF Stop valve GAV s Electical/pneumatic contol valve V 725 u v w Pocess data acquisition SPECTORcontol with intefaces: CAN, MODbus, Ethenet, modem, Pofibus (optional Bune contol via MODbus RTU intefacew Monitoing of the fesh wate: Deminealization equipment: using conductivity monitoing Patial deminealization equipment: by monitoing esidual hadness (not pat of ou poduct ange) The benefits in detail Bette oveview of the pocess Bette oveview of the pocess though centalized pocess display Actual values indicated as ba chat Tend plot of the measuement values Pioitized display of faults List of maintenance intevals Totalizing of consumption Inceased safety Designations of the measuement quantities, input/output signals, and logging/alams can be configued by the plant opeato All signals, limits and waning levels can be logically linked (NAND, NOR, RS-FF etc.); the esult is available as a switching output/ logging signal Envionmental potection though active monitoing of waste wate and exhaust gases Reduced cost Bette utilization of fuel Integated contol cicuits, i.e. sepaate electonic contol units ae no longe needed. Easily integated and expanded Modula stuctue, theefoe extendable and suitable fo all plant sizes Existing input and output signals ae easy to integate *) If the high-level alam does not act on the safety chain, the level switch NRS 1-41 is equied. w w w. g e s t a. d e 9 GESTRA Steam Boile Equipment with BUS Technology GESTRA SPECTORcontol Contolling and Monitoing Low-level alam High-level alam I/O module Bune contol 10 Equipment fo Enegy Supply Centes Visualizing the Pocess Data The gateway between diffeent wolds fo an optimized flow of infomation. If you need to hand you boile data up to a highe-anking contol system, you need the SPECTORcontol system by GESTRA. It egistes all measuement values via electonic signal tansduces and passes them on to the contol cente. Thee they ae combined to fom highe-level statements and pesented on a colou monito. Pessue, tempeatue, conductivity etc. ae egulated automatically. The benefits fo you 1. Bette pocess oveview: Enhanced oveview of the pocess, though centalized pocess display Actual values indicated as ba chat Tend plot of the measuement values Pioitized display of faults List of maintenance intevals Designations of the measuement quantities, input/output signals, and logging of alams. Can be configued by the plant opeato All signals, limits and waning values can be logically intelinked The esults ae available as a epot 2. Geate efficiency: Bette utilization of fuel Totalizing of consumption Impoved envionmental potection though monitoing of waste wate and exhaust gases Modula, expandable achitectue fo all plant sizes Sepaate electonic contol units no longe needed, thanks to the integated contol cicuity Input and output signals ae easy to integate w w w. g e s t a. d e 11 GESTRA SPECTORcontol GESTRA SPECTORcom Pocess contol level Office PC, laptop Pocess contol level Office PC, laptop OPC Pofibus DP (optional) Ethenet OPC Pofibus DP (optional) Ethenet Land lines via modem Land lines via modem Sevice patne Supplie Modbus RTU CAN CANopen Sevice patne Supplie Modbus RTU CAN CANopen I/O module I/O module The benefits fom the viewpoint of bune attendance Dynamic status indication Maintenance log Flowate log Y/M/D Dynamic sequencing fo stat-up / shut-down Tend plot Fault/alam list fom the viewpoint of boile attendance Dynamic status indication Maintenance log Tend plot M/D/H Flowate log Y/M/D Optimized paametization of the BUS subscibes; analog/digital inputs and outputs Integated softwae contolle fom the viewpoint of the sevice patne Online commissioning suppot Tageted maintenance planning Remote diagnosis Remote paametization Full emote contol Individual paametization can be stoed 12 Equipment fo Enegy Supply Centes GESTRA SPECTORmodule Safety at its best! Building on the poven conventional technology, this new membe of the SPECTOR family was developed to meet the optimization equiements of ou customes, the plant opeatos and design enginees, as well as the evised Euopean standads. SPECTORmodule stands fo a new geneation of GESTRA equipment. The benefits Supply voltage 24 V DC, i.e. independent of national mains voltages Modula stuctue Feely accessible connection teminals Geat flexibility Functional safety is the pat of the oveall safety that depends on the coect opeation of the safety-elated systems o subsystems and of extenal isk eduction facilities. As a consequence, the aea of functional safety only coves the oveall safety to a limited extent, i.e. it does not include electical safety, fie potection, adiation potection etc. Because safety functions ae inceasingly being implemented in moden systems by electonic modules, especially pogammable ones, the fundamental challenge elating to functional safety lies in ensuing the coect function of complex pogammable systems. Suitable methods must theefoe be applied to pevent systemic faults (usually esulting fom human eo in the specification, implementation etc.) and to contol possible failues and malfunctions (usually esulting fom phenomena of the opeational envionment). In this connection, one also efes to the safety integity of the potection o safety function. The elevant aspects of functional safety fo electical o electonic (pogammable) systems ae descibed in the standad IEC Functional safety of electical/electonic/pogammable electonic safety-elated systems. w w w. g e s t a. d e 13 d d d n a a a b c m o g h f p q e s e j t 14 GESTRA Steam Boile Equipment SPECTORmodule Fo 24 hous of unmanned opeation as pe TRD 604 (24 h) o EN Pat 6 Safety, eliability and the cetainty of components woking togethe optimally Equipment fo Enegy Supply Centes a 1 a Low-level limite of high-integity design, cetified to SIL 3: level electode NRG 16-50, level switch NRS p. 22, 23 bc Modulating level contolle with integated high-level alam and second wate level gauge: level pobe NRGT 26-1, level contolle KS p. 29 d e Conductivity measuement and continuous blowdown/conductivity limitation: conductivity electode LRGT 16-2, blowdown contolle KS 90, continuous blowdown valve BAE p. 32, 33 Intemittent blowdown: cycling time TA 5 intemittent blowdown valve MPA p. 32, 33 f Sample coole p. 36 g Blowdown flash vessel h Residual blowdown coole j Blowdown eceive m Safety valve GSV n Pessue limite DSF o Pessue contolle/tansmitte p Disco non-etun valve RK 86 q Staine GSF Stop valve GAV s Electical/pneumatic contol valve V 725 t Economize (ECO) Measuing pot Monitoing unit SRL 6-50 (24 h/72 h) Shut-off valve with two limit switches Dain valve with one limit switch w w w. g e s t a. d e 15 GESTRA Steam Boile Equipment SPECTORmodule Fo opeation with limited supevision, e.g. as pe TRD 602 (2 h) n a bc m o k d d e d g h f e j p 16 Equipment fo Enegy Supply Centes abc Level limite of high-integity design incl. on-off level contolle and high-level alam: level electode NRG 16-36, level switch NRS p d Conductivity measuement and continuous blowdown: compact conductivity electode LRGT 16-2, blowdown contolle KS 90, continuous blowdown valve BAE p e Intemittent blowdown: cycling time TA 5 intemittent blowdown valve MPA p. 32, 33 f Sample coole PK p. 36 g Blowdown flash vessel h Residual blowdown coole j Blowdown eceive k Safety tempeatue limite: esistance themomete TRG 5-55, tempeatue switch TRS p. 32, 33 m Safety valve GSV n Pessue limite DSF o Pessue contolle/tansmitte p Disco non-etun valve RK Stop valve GAV w w w. g e s t a. d e 17 GESTRA Steam Boile Equipment SPECTORcompact steam boile plants equiing no supevision, e.g. in non-eu states n o a b m d e g h f e j p 18 Equipment fo Enegy Supply Centes ab Low-level limite of conventional design (with test button) incl. on-off level contolle: compact system NRGS 15-1 (PN 25) with integated test and eset buttons p. 22, 23, 26, 27 d Conductivity measuement and continuous blowdown: compact conductivity electode LRGS 15-1 with continuous blowdown valve BAE p. 32, 33 e Intemittent blowdown: compact system TA 7 with intemittent blowdown valve MPA p. 32, 33 f Sample coole p. 36 g Blowdown flash vessel h Residual blowdown coole j Blowdown eceive m Safety valve GSV n Pessue limite DSF o p Disco non-etun valve RK 86 Stop valve GAV Pessue contolle/tansmitte The benefits in detail Moe safety Patented themal baie in cylindical body above electode flange Tempeatue potection in the teminal box Less effot Optimum system adaptation, thanks to the modula design No mounting of component pats in the contol cabinet: = No space equiements = No installation = No wiing Easy planning No special cable equied fo wiing the sensing unit to the contol cabinet Simplified logistics w w w. g e s t a. d e 19 GESTRA Equipment fo Pessuized Hot-Wate Plants BUS technology fo high-pessue hot-wate geneation with sepaate pessuizing vessel b c a bc c* b a y a k l t p p p p p y k l k a l n m n Steam boile 2 x bc a v Steam boile 1 e *) 72 h opeation only a Low-level limite of high-integity design : level electode NRG 16-40/level switch NRS o level electode NRG 16-50/level switch NRS p. 22, 23 bc On-off level contolle with sepaate high-level alam: level electode NRG 16-42/level switch NRS 1-42 o level pobe ER 56/level switch NRS 1-5, NRS p e Intemittent blowdown: intemittent blowdown valve PA p. 30, 31 20 Equipment fo Enegy Supply Centes GESTRA Equipment fo Pessuized Hot-Wate Plants Conventional fo high-pessue hot-wate geneation with sepaate pessuizing vessel bc a y y l p p l p p p a k k n a m n k k n m n x bc a Steam boile 1 Steam boile 2 e e k l m Safety tempeatue limite: esistance themomete TRG 5-63/TRV 5-40/NRS o esistance themomete TRG 5-53/TRS p. 32, 33 Tempeatue contolle fo elevating the etun tempeatue: esistance themomete TRG 5-63/TRS 5-40/URB 2 o esistance themomete TRG 5-53/TRS 5-8 Safety valve GSV n Pessue limites DSL (MIN) and DSH (MAX) p Disco non-etun valve RK 86 t v x y Contol teminal and display unit URB Bune contol via MODbus inteface Monitoing of the etun flow fo ingess of foeign matte Tempeatue contolle w w w. g e s t a. d e 21 a Low-Level Limite (LW) up to PN 320 Technical Infomation The limites consist of a combination of level electode and level switch. In geneal, a distinction must be made between units of conventional design and those of high-integity design (i.e. with self-monitoing). The coesponding applications fo the units ae defined in the technical ules and depend mainly on the hazad potential of the plant. A basis fo these consideations can be the maximum allowable woking pessue (TRD 701: 1 ba; PED: 0.5 ba) o the boile wate content (TRD 802). Fo aeas coveed by these ules and the compaable egulations of non-eu states, such as limited supevision (2 h, 4 h o 8 h opeation), the compact units NRGS 11-2 (PN 6) and NRGS 16-2 (PN 40) wee developed. With this design, the level electode and level switch fom a single unit. In addition, the test and eset buttons wee integated into the teminal box. As a special featue, the edundancy (2-channel design) was extended ight up to the electode tip, which leads to a clea incease in safety. With the self-monitoing limites, the concept poven ove decades fo the systems MR/2VR8, ER 86/NRS 1-4/VR 18 and NRG 16-, 17-, 19-, /NRS 1-7 and SPECTORbus NRG 16-, 17-, 19-, o NRS was advanced futhe and now offes the the cuent state of safety and automation technology with the system SPECTORmodule NRG 16-, 17-, 19-, /NRS On the basis of the applicable EN standads, the units wee developed and manufactued accoding to IEC Functional safety and cetified to SIL 3. Building on the expeience of the last decades, futhe optimization was intoduced fo the benefit of the design enginee, plant opeato, commis- soning technician and boile inspecto. A distinction must be made between
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