GESTRA

Equipment for Energy Supply Centres

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

PRO_810689_06_AusrEnergie_en.ind2 2 08.08.2007 13:54:08 Uhr

 Equipment for Energy Supply Centres

Electrical pressure control

Contents
Controlled from
Steam flow measurement the condensate side
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
Steam Boiler Equipment with BUS Technology . . . . . . . . . . . . . . 6–7
Electrical
temperature Steam Boiler Equipment with SPECTORcontrol
control
– Controlling, Monitoring and Visualizing . . . . . . . . . . 8–9
Mechanical Steam Boiler Equipment with BUS Technology
Heat
temperature
control
exchanger Spectorcontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12
SPECTORcom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steam Boiler Equipment – Conventional –
for 24 Hours of Unmanned Operation . . . . . . . . . . . 14–15
Steam Boiler Equipment – Conventional –
for Operation with Limited Supervision . . . . . . . . . . 16 –17
Steam Boiler Equipment
for Plants Requiring No Supervision . . . . . . . . . . . . 18–19
Equipment for Pressurized Hot-Water Plants
– BUS Technology – . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Equipment for Pressurized Hot-Water Plants
– Conventional – . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Low-Level Limiters (LW) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–23
Monitoring High-Level Alarm (HW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
of turbidity
Level Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–27
Boiler Water Quality Monitoring . . . . . . . . . . . . . . . . . . . . . . 28–31
Temperature Controller/Limiter . . . . . . . . . . . . . . . . . . . . . . . 32–33
Monitoring of Sample Cooler PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
conductivity Portable Digital Meter VRM-2/VRM-3 . . . . . . . . . . . . . . . . . . . . 35
Energy Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Condensate Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36–39
Equipment for Steam Generators – Marine Boilers – . . . . . . . 40–41

Flash
vessel

Sight glass
Steam trap
Non-return valve
3
Overview
Reliability, availability and economy have always
enjoyed top priority in boiler operation. To an
increasing extent, another aspect is being added:
plant automation and visualization.
To implement these fundamental principles,
GESTRA AG has for decades now been working
exclusively with electrode systems that are low in
maintenance and wear; in contrast to other sys-
tems, they function entirely without moving parts.
Over and above the boiler house equipment itself,
these systems have now conquered the peripheral
vessels, such as feedwater and condensate tanks,
pumpless and pump-driven return installations
4
etc., since the entire energy supply centre is only
as effective as its weakest element. Many of our
customers therefore do not enter into any com-
promises in this area too.
Another step forward was taken for the GESTRA
equipment components through the introduction
of the SPECTOR family, consisting of the Compact
and the BUS technology variants, which not only
permit easy integration into automation concepts
but also provide many technical innovations that
simplify plant construction and commissioning
considerably.
The motto here is: “With GESTRA into the Future”.
We stand by what we say! For each safety-related
requirement, we offer the right concept, and that
all over the globe. From simple systems to units
of “high-integrity design”; for landbased and
shipboard boilers in the pressure ratings PN 6 to
PN 320. Installations with high demands on tech-
nical safety, e.g. in unmanned boiler operation or in
power station engineering, are fitted with GESTRA
components of “high-integrity design”.
These units work with constant self-monitoring
and routine self-testing for loss of redundancy,
which means that malfunctions in the system
are detected immediately. Based on the positive
experience gained over decades, GESTRA equip-
ment components have been granted not only the
German TÜV type approval but also approvals in
Austria, Switzerland, Holland, England, Hungary,
France, the Czech Republic, Slovakia as well as by
many classification societies for the marine boiler
sector. And of course, GESTRA AG also meets
the requirements of the new European Pressure
Equipment Directive.
 Equipment for Energy Supply Centres

GESTRA SPECTORbus Less is more!

The benefits in detail From little acorns big oaks grow. With the BUS
technology by GESTRA, a new era has begun in
1. No risk of overheating: ◗ Reduced cost for control cabinets the measurement and control of boiler systems:
◗ Patented thermal barrier in cylindrical body ◗ Cabling connection male/female, ready-made
above electrode flange cable ◗ Less cabling
◗ Electronic temperature protection in the ◗ Only five input terminals ◗ Less installation work
terminal box ◗ Only one cable in the control cabinet for all ◗ Less space needed in control cabinets
◗ Patented connection arrangement sensing units ◗ Fewer control units
◗ Minimization of thermal effects ◗ Optimum system integration without additional ◗ Less wear and tear
cable installations ◗ Less maintenance
2. Easy installation and maintenance: ◗ Fewer production outages
◗ Freely accessible connecting terminals at the 4. Increased safety: ◗ Lower costs
control units ◗ Active cable monitoring with more than twice
◗ Large terminal box makes for easy installation the previous maximum cable length ◗ More control
◗ Easy to integrate into visual display and auto- ◗ Better process overview
3. Reduced cost: mation systems ◗ Higher availability
◗ Minimized inventory and spares levels ◗ More reliability
◗ Only a single cable needed between boiler ◗ Greater plant efficiency
and control cabinet ◗ Better utilization of energy
◗ Low installation and material costs ◗ Longer plant operation times

GESTRA Performance Spectrum

System PN25 PN40 PN63 PN160 PN250 PN320 Konv Bus

Low-level limiters of “high-integrity design” • • • • • •

High-level alarms of “high-integrity design” • • • • •
Level controllers • • • • • •
Low-level limiters/controllers (compact units) • • •
Safety temperature limiters • • • • •
Conductivity measurement
◗ with autom. temperature compensation • • • •
◗ without autom. temperature compensation • • • •
Continuous blowdown valves • • • • • • •
Intermittent blowdown valves • • • • •

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GESTRA Steam Boiler Equipment with BUS Technology
For operation e.g. according to TRD 604 (72 h) or EN 12953 (24 h)

The future has already begun!

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 Equipment for Energy Supply Centres

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

level electrode NRG 16-40, level switch NRS 1-40.1 1) . . . . . . . . . . . . . . . p. 22, 23 The benefits in detail
bt Modulating level controller with integrated 2nd water level and
No risk of overheating
conductivity indicator: level probe NRG 26-40, level controller NRR 2-40,
control terminal and display unit URB 1 (URB 2) . . . . . . . . . . . . . . . . . . p. 25–27 • Patented thermal barrier in cylindrical body
above electrode flange
c High-level alarm of “high-integrity design”:
• Electronic temperature protection in the
level electrode NRG 16-41, level switch NRS 1-41 2) . . . . . . . . . . . . . . . . . . . p. 24
terminal box
de Conductivity measurement and continuous/intermittent blowdown: • Minimization of thermal effects
conductivity electrode LRG 16-41, continuous blowdown controller
LRR 1-40, continuous blowdown valve BAE, intermittent blowdown Easy installation and maintenance
valve MPA, 3/2-way pilot valve, strainer . . . . . . . . . . . . . . . . . . . . . . . . . p. 30, 31 • Freely accessible connecting terminals
f Sample cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 34 at the control units
• Large terminal box for easy installation
g Blowdown flash vessel
h Residual blowdown cooler Reduced cost
• Minimized inventory and spares levels
j Blowdown receiver
• Only a single cable needed between boiler
k Safety temperature limiter: resistance thermometer TRG 5-65, and control cabinet
temperature preamplifier TRV 5-40, level switch NRS 1-40.1 1) . . . . . . . . p. 32, 33
• Only one cable in the control cabinet for
m Safety valve GSV all sensing units
n Pressure limiter DSF • Optimum system integration without
o Pressure controller/transmitter additional cable installations

p Disco non-return valve RK 86 Increased safety

q Strainer GSF • Active cable monitoring
• Easy integration into visual display and
r Stop valve GAV
automation systems
s Electrical/pneumatic control valve V 725
t Control terminal and display unit URB 1 (URB 2) Get a technical lead with the first and
u Process data acquisition SPECTORcontrol with interfaces: only control package for energy supply
CAN, MODbus, Ethernet, modem, Profibus (optional) centres using an open CAN-bus system.
Only GESTRA permits easy interfacing to
v Burner control unit
other open bus systems.
w Monitoring of the fresh water:
◗ Demineralization equipment – using conductivity monitoring
◗ Partial demineralization equipment: by monitoring residual hardness
(not part of our product range)

1
) Only one electronic control unit is needed.
2
) Not required by EN. 7
GESTRA Steam Boiler Equipment with SPECTORcontrol
– Controlling, Monitoring and Visualizing –
Boiler equipment according to TRD 604 (72 h) or European guidelines, e.g. EN 12953 Part 6

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 Equipment for Energy Supply Centres

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

level electrode NRG 16-40, level switch NRS 1-40.1 . . . . . . . . . . . . . . . . p. 22, 23 The benefits in detail
b Modulating level controller:
Better overview of the process
level probe NRG 26-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 25, 26
• Better overview of the process through
c High-level alarm of “high-integrity design”: centralized process display
level electrode NRG 16-41*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 24
• Actual values indicated as bar chart
de Conductivity measurement and continuous/intermittent blowdown: • Trend plot of the measurement values
conductivity electrode LRG 16-40, continuous blowdown controller • Prioritized display of faults
LRR 1-40, continuous blowdown valve BAE, intermittent blowdown • List of maintenance intervals
valve MPA, 3/2-way pilot valve, strainer . . . . . . . . . . . . . . . . . . . . . . . . . p. 30, 31
• Totalizing of consumption
f Sample cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 34
Increased safety
g Blowdown flash vessel
• Designations of the measurement quantities,
h Residual blowdown cooler input/output signals, and logging/alarms
j Blowdown receiver can be configured by the plant operator
k Safety temperature limiter at the superheater: • All signals, limits and warning levels can be
resistance thermometer TRG 5-65, logically linked (NAND, NOR, RS-FF etc.);
temperature preamplifier TRV 5-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 32, 33 the result is available as a switching output/
m Safety valve GSV logging signal
• Environmental protection through active
n Pressure limiter DSF
monitoring of waste water and exhaust gases
o Pressure controller/transmitter
Reduced cost
p Disco non-return valve RK 86
• Better utilization of fuel
q Strainer GSF • Integrated control circuits, i.e. separate elec-
r Stop valve GAV tronic control units are no longer needed.
s Electrical/pneumatic control valve V 725 Easily integrated and expanded
u Process data acquisition SPECTORcontrol with interfaces: • Modular structure, therefore extendable and
CAN, MODbus, Ethernet, modem, Profibus (optional suitable for all plant sizes
w Monitoring of the fresh water: • Existing input and output signals are easy to
integrate
◗ Demineralization equipment – using conductivity monitoring
◗ Partial demineralization equipment: by monitoring residual hardness
(not part of our product range)

*) If the high-level alarm does not act on the safety chain,

the level switch NRS 1-41 is required.

9
GESTRA SPECTORbus boiler equipment
GESTRA SPECTORcontrol
Controlling and Monitoring

Low-level High-level
alarm alarm

I/O-module

Burner Control

10
Visualizing the Process Data
The gateway between different
worlds for an optimized flow of
information.
If you need to hand your boiler data up to a
higher-ranking control system, you need the
SPECTORcontrol system by GESTRA. It registers
all measurement values via electronic signal trans-
ducers and passes them on to the control centre.
There they are combined to form higher-level
statements and presented on a colour monitor.
Pressure, temperature, conductivity etc. are regu-
lated automatically.
11
The benefits for you
1. Better process overview:
◗ Enhanced overview of the process, through
centralized process display
◗ Actual values indicated as bar chart
◗ Trend plot of the measurement values
◗ Prioritized display of faults
◗ List of maintenance intervals
◗ Designations of the measurement quantities,
input/output signals, and logging of alarms.
Can be configured by the plant operator
◗ All signals, limits and warning values can be
logically interlinked
◗ The results are available as a report
2. Greater efficiency:
◗ Better utilization of fuel
◗ Totalizing of consumption
◗ Improved environmental protection through
monitoring of wastewater and exhaust gases
◗ Modular, expandable architecture for all
plant sizes
◗ Separate electronic control units no longer
needed, thanks to the integrated control
circuitry
◗ Input and output signals are easy to integrate
 Equipment for Energy Supply Centres

Process control level Office PC, laptop

The benefits
… from the viewpoint of burner attendance
• Dynamic status indication
• Maintenance log
OPC Profibus Ethernet • Flowrate log Y/M/D
DP (optional)
• Dynamic sequencing for start-up / shut-down
GSM network, • Trend plot
land lines via modem
• Fault/alarm list

… from the viewpoint of boiler attendance

• Dynamic status indication
• Maintenance log
• Trend plot M/D/H
• Flowrate log Y/M/D
• Optimized parametrization of the BUS sub-
Service partner scribers; analog/digital inputs and outputs
Supplier
• Integrated software controller
Modbus RTU CANopen
CAN … from the viewpoint of the service partner
• Online commissioning support
• Targeted maintenance planning
• Remote diagnosis
• Remote parametrization
• Full remote control
• Individual parametrization can be stored

I/O-module

12
 Equipment for Energy Supply Centres

SPECTORcom

Process control level Office PC, laptop

The benefits
… from the viewpoint of burner attendance
• Dynamic status indication
• Maintenance log
OPC Profibus Ethernet
DP (optional) • Flowrate log Y/M/D
• Dynamic sequencing for start-up / shut-down
GSM network,
land lines via modem • Trend plot
• Fault/alarm list

… from the viewpoint of boiler attendance

• Dynamic status indication
• Maintenance log
• Trend plot M/D/H
Modbus RTU CANopen
CAN • Flowrate log Y/M/D
• Optimized parametrization of the BUS sub-
Service partner
Supplier scribers; analog/digital inputs and outputs
• Integrated software controller

… from the viewpoint of the service partner

• Online commissioning support
• Targeted maintenance planning
• Remote diagnosis
• Remote parametrization
I/O-module • Full remote control
• Individual parametrization can be stored

13
GESTRA Steam Boiler Equipment – Conventional –
For 24 hours of unmanned operation as per TRD 604 (72 h) or EN 12953 Part 6

Safety, reliability and the certainty of components working together optimally

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 Equipment for Energy Supply Centres

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

level electrode NRG 16-11, level switch NRS 1-7 . . . . . . . . . . . . . . . . . . . p. 22, 23
bc Modulating level controller with integrated high-level alarm
and second water level gauge:
level probe NRG 26-21, level controller NRR 2-2,
bar-chart indicator URA 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 24, 27
d Conductivity measurement and continuous blowdown/
conductivity limitation:
conductivity electrode LRGT 16-1, blowdown controller KS 90,
continuous blowdown valve BAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 30, 31
2 a e Intermittent blowdown:
cycling timer TA 5
intermittent blowdown valve MPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 30, 31
f Sample cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 34
g Blowdown flash vessel
h Residual blowdown cooler
3 j Blowdown receiver
m Safety valve GSV
n Pressure limiter DSF
1 o Pressure controller/transmitter
p Disco non-return valve RK 86
q Strainer GSF
3 r Stop valve GAV
s Electrical/pneumatic control valve V 725
t Economizer (ECO)
4

1 Measuring pot
2 Monitoring unit SRL 63 24h / 72h
3 Shut-off valve with two limit switches
4 Drain valve with one limit switch

15
GESTRA Steam Boiler Equipment – Conventional –
For operation with limited supervision, e.g. as per TRD 602 (2 h)

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 Equipment for Energy Supply Centres

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

incl. on-off level controller and high-level alarm:
level electrode NRG 16-36, level switch NRS 1-9 . . . . . . . . . . . . . . . . p. 22–27
d Conductivity measurement and continuous blowdown:
compact conductivity electrode LRGT 16-1,
blowdown controller KS 90, continuous blowdown valve BAE . . . . . . . p. 29–31
e Intermittent blowdown:
cycling timer TA 5
Intermittent blowdown valve MPA . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 29–31
f Sample cooler PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 34
g Blowdown flash vessel
h Residual blowdown cooler
j Blowdown receiver
k Safety temperature limiter:
resistance thermometer TRG 5-55,
temperature switch TRS 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 32, 33
m Safety valve GSV
n Pressure limiter DSF
o Pressure controller/transmitter
p Disco non-return valve RK
r Stop valve GAV

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

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 Equipment for Energy Supply Centres

ab Low-level limiter of “standard design” (with test button)

incl. on-off level controller: The benefits in detail
compact system NRGS 15-1 (PN 25)
with integrated test and reset buttons . . . . . . . . . . . . . . . . . . . . p. 22, 23, 25–27 More safety
d Conductivity measurement and continuous blowdown: • Patented thermal barrier in cylindrical body
compact conductivity electrode LRGS 15-1, above electrode flange
continuous blowdown valve BAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 29–31 • Electronic temperature protection in the
terminal box
e Intermittent blowdown:
compact system TA 7 with intermittent blowdown valve MPA . . . . . . . . . p. 29–31 Less effort
f Sample cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 34 • Optimum system adaptation, thanks to
g Blowdown flash vessel the modular design
• No mounting of component parts in the
h Residual blowdown cooler
control cabinet
j Blowdown receiver => No space requirements
m Safety valve GSV => No installation
n Pressure limiter DSF => No wiring
• Easy planning
o Pressure controller/transmitter
• No special cable required for wiring the
p Disco non-return valve RK 86 sensing unit to the control cabinet
r Stop valve GAV • Simplified logistics

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

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*) 72 h operation only a Low-level limiter of “high-integrity design”:

level electrode NRG 16-40/level switch NRS 1-40.1
or level electrode NRG 16-11/level switch NRS 1-7 . . . . . . . . . . . . . . . p. 22, 23
bc On-off level controller with separate high-level alarm:
level electrode NRG 16-42/level switch NRS 1-42
or level probe ER 56/level switch NRS 1-5, NRS 1-2 . . . . . . . . . . . . . . p. 24, 27
20 e Intermittent blowdown: intermittent blowdown valve PA . . . . . . . . . . . . p. 30, 31
 Equipment for Energy Supply Centres

GESTRA Equipment for Hot-Water Boilers

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

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Steam boiler 1 Steam boiler 2

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k Safety temperature limiter: n Pressure limiters DSL (MIN) and DSH (MAX)
resistance thermometer TRG 5-63/TRV 5-40/NRS 1-40.2 p Disco non-return valve RK 86
or resistance thermometer TRG 5-53/TRS 5-6 . . . . . . . . . . . . . p. 32, 33
v Burner control unit
l Temperature controller for elevating the return temperature:
resistance thermometer TRG 5-63/TRS 5-40/URB 2 x Monitoring of the return flow for ingress of foreign matter
or resistance thermometer TRG 5-53/TRS 5-8 y Temperature controller
m Safety valve GSV

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a GESTRA Low-Level Limiter (LW)

Level limiter Limiter system Externally mounted level limiters of

of “high-integrity design” of “high-integrity design” “high-integrity design”

It consists of a level electrode and level switch,
and was developed from a concept proven over
many years of service. The GESTRA systems NRG
16-40, 17-40, 19-40, NRG 111-40, NRS 1-40 and
NRS 1-40.1 (PN 40–320) offer the highest state
of the art.
With the electronic control unit NRS 1-40.1, it is
possible to connect not only the level limiter but
also a high-level alarm and/or safety temperature
limiter.
To safeguard the high safety standard of the level
limiters even when mounted outside the boiler, it
is imperative that the regular, controlled purging of
the measuring pot be monitored properly. The logic
unit SRL 6-40 is used for monitoring the flushing
procedure.

The electronic control unit NRS 1-40.1/2 is suitab-

le for up to four limiters in any configuration; e.g.
NRG 16-40 (LW), NRG 16-41.1, TRV 5-40 (STB).

The benefits for you

1. Savings:
◗ One control unit for two electrodes
◗ Lower inventory costs

2. Easy maintenance:
◗ Separate undelayed signal output for exchange
of electrode
◗ Autonomous functional test, including the relay
output contacts
◗ Definite detection of the signal state within the
system
◗ Active test of the cable connection

3. Approved safety:
◗ All systems comply with the new Pressure
Equipment Directive (PED) and have EU type
approval.

NRS 1-40 2 x NRG 16-40 SRL 6-40

NRS 1-40.1 / NRS 1-40.2

22

Technical Information
a Low-Level Limiter (LW) up to PN 320
The limiters consist of a combination of level
electrode and level switch. In general, a distinc-
tion must be made between units of “standard
design” and of “high-integrity design” (i.e. with
self-monitoring). The corresponding applications
for the units are defined in the technical rules
and depend mainly on the hazard potential of the
plant. A basis for these considerations can be the
maximum allowable working pressure (TRD 701:
1 bar; PED: 0.5 bar) or the boiler water content
(TRD 802).
For areas covered by these rules and the compar-
able regulations of non-EU states, such as limited
supervision (2 h, 4 h or 8 h operation), the com-
pact units NRGS 11-2 (PN 6), NRGS 16-2 (PN
40) and NRGS 15-1 (PN 25, non-EU states) were
developed. With this design, the level electrode
and level switch form a single unit. In addition,
the test and reset buttons were integrated into the
terminal box. As a special feature, the redundancy
(2-channel design) was extended right up to the
electrode tip, which leads to a clear increase in
safety.
With the self-monitoring limiters, the concept
proven over decades for the systems MR/2VR8,
ER 86/NRS 1-4 and NRG 16-, 17-, 19-, 111-40/
NRS 1-7 was advanced further and now offers the
current state of safety and automation technology
with the system NRG 16-, 17-, 19-, 111-40/NRS
1-40.1. As a supplement to the previous systems,
the safety functions, including the routine self-test,
was designed directly into the electrode, with the
advantage that two electrodes but only one level
switch are needed for the limiter system. The level
switch NRS 1-40.1 represents an extension of the
limiter system. In addition to the low-level elec-
trodes, the high-level alarm NRG 1-41.1 and/or the
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Equipment for Energy Supply Centres
safety temperature limiter can also be connected.
Based on the experience of the last decades,
further optimization was introduced for the benefit
of the planner, operator, commissioning technician
and boiler inspector.
◗ Response threshold always from 0.5 µS/cm
◗ Separate undelayed signal output for
emerging of the electrode
◗ Autonomous functional test, including the
relay output contacts
◗ Definite detection of the signal state within
the system
◗ Flashing indicator = electrode emerged
◗ Steady light = electrode emerged and time
delay elapsed
◗ Active test of the cable connection between
electrode and switch
e 23
Of course, the self-monitoring limiters also comply
with the PED (Pressure Equipment Directive) and
have EU type approval.
If particularly high demands are made on the
availability of boiler plants (power stations, chemi-
cal industry etc.), the “2-out-of-3” circuit is often
used.
With this arrangement, the safety chain is only
interrupted when at least two limiters give the
signal for low-water or fault. If the self-monitoring
triggers for one of these units, the plant remains
available, and the malfunctioning unit can be
checked during planned downtime.
As in the past, GESTRA is again offering with the
systems NRG 17-40 or NRG 19-40 the entire
palette up to the pressure rating PN 160 (100 bar /
311 °C). For application parameters going beyond
this, the NRG 211/NRS/URN systems proven in the
power station sector have repeatedly been used
with success in the 2-out-of-3 circuit (230 bar /
550 °C). Nowadays, the NRG 111-11/NRS 1-7 or
NRG 111-40/NRS 1-40 systems are used for the
PN 320 range (183 bar / 400 °C).
The following systems are available:
Conventional technology
◗ NRG 1.-11/NRS 1-7
BUS-technology
◗ NRG 1.-40/NRS 1-40
◗ NRG 1.-40/NRS 1-40.1
c GESTRA
High-Level Alarm (HW)
The right system for every
application.
1. Units of “high-integrity design”:
These are always used when the require-
ment is for a separate device.
◗ NRG 16-41, NRG 17-41, NRG 19-41
(PN40–160)
◗ NRS 1-41
or
◗ NRG 16-41.1, NRG 17-41.1, NRG 19-41.1
◗ NRS 1-40.1
2. Units of “standard design”:
These are used wherever entrained boiler
water cannot cause any damage.
◗ NRG 16-42 + NRS 1-42 with fixed
switchpoints
◗ NRG 26-40 + NRS 2-40 or NRR 2-40
with adjustable switchpoints
NRS 1-41
NRG 16-41 or NRG 16-41.1
(in conjunction with NRS 1-40.1)
24
Technical Information
c High-Level Alarm (HW)
For the high-level alarm, there are also various requirement is made for a separate unit and the
systems available whose area of application is safety or product-related viewpoint calls for it.
primarily determined not by the technical literature Several reasons are possible:
but by the downstream consumers of the steam.
◗ Products heated directly by steam
Of the diverse standards, only the TRD 604 (e.g. rubber industry)
(72 h operation) poses the requirement that the ◗ Turbine operation
high-level alarm must be a unit separate from the ◗ etc.
controller and limiter. In the other codes, including
EN, this requirement is not expressed. As a unit of “high-integrity design”, the system
NRG 16-41/NRS 1-41 from the Bus family is used.
The units of “standard design” are especially
applied wherever no direct damage can occur at With this system, the requirement profiles are the
downstream heating sur faces, installations, steam- same as for the low-level limiters of “high-integrity
heated products etc. as a result of carry-over. design”.
Here the Spector family offers solutions within the
area of the Compact version (NRGS 11-1 or NRGS
16-1) and also in the BUS technology with fixed
switchpoints (NRG 16-42/NRS 1-42) or contin-
uously adjustable switchpoints (NRG 26-40/NRS
2-40 or NRR 2-40). All of the above systems have
the high-level alarm integrated into the controller
block.
The high-level alarm of “high-integrity design”
(with self-monitoring) is always used when the
The following systems are available:
Conventional technology
◗ NRG 1.-12/NRS 1-8
BUS-technology
◗ NRG 1.-41/NRS 1-41
◗ NRG 1.-41.1/NRS 1-40.1
 Equipment for Energy Supply Centres

b Level Controllers

Depending on the parameters of boiler capacity, The palette of possibilities includes:

required steam quality, plant economy and
degree of automation, the make-up arrangement
is differentiated into the on-off and modulating
control modes. Within the on-off controls, these
are subdivided further into those with fixed switch-
points and those with continuously adjustable
switchpoints.
◗ Switch-selectable response sensitivities
> 0.5 / > 10 µS/cm
◗ Continuously adjustable delays for each
contact and contact position in the range
1–25 sec.
◗ Variable switchpoint adjustment (NRS 2-40)

On-Off Systems (Pump ON/OFF)

This solution is mainly used in steam boiler plants

of low capacity (< 5 t/h), in condensate and feed-
water tanks, and is frequently also rounded off with
the implementation of the entire pump control. The
intermittent make-up of relatively cool feedwater
(103 °C) naturally leads to strongly modulating
operation of the burner and to intense thermal-
shock stresses. Through the intermittent feedwater
flow, integration into a heat recovery concept using
the economizer principle is not possible. For this In the area of systems with fixed switchpoints:
task, there are several systems from the SPECTOR Compact system Function
family, so that we can offer customer-oriented ◗ NRGS 11-1 or NRGS 16-1 First low alarm/pump ON/OFF/HW alarm
solutions. As a result of our operational experience, ◗ NRGS 11-2 or NRGS 16-2 First low alarm/pump ON/OFF
numerous innovations in the area of the BUS Conventional technology
technology have been introduced to considerably ◗ ER 5./NRS 1-.
simplify commissioning, and to reduce the effort BUS system
of time and the water loss to a minimum. By using
◗ NRG 16-42/NRS 1-42 First low alarm/pump ON/OFF/HW alarm
the control terminal and display unit URB, features
which were previously impossible are now within
In the area of systems with continuously adjustable switchpoints:
grasp.
Compact system Function
◗ NRGT 26-1 4–20 mA output as an input signal for PLC controls
Regulator KS 92-1
Conventional technology
◗ NRG 26-21/NRS 2-1
BUS system
◗ NRG 26-40/NRS 2-40 First low alarm/pump ON/OFF/HW alarm

w w w . g e s t r a . d e 25
Technical Information – continued –
b Level Controllers
Modulating Systems
(control valves, frequency-controlled pumps)
With modulating control, one thinks first of the
economical operation, higher steam quality and the
capability of adapting to difficult situations regard-
ing the controlled systems, e.g. those caused by
strong fluctuations or sudden changes in steam
consumption, as is the case for process-related
reasons in the rubber, foodstuff and building-mate-
rials industries. The greater operational economy of
the boiler and the higher steam quality are naturally
an aspect of the controlled, demand-oriented
make-up of the boiler water. On the one hand, this
mode ensures continuous burner operation and, on
the other, the boiler water level is not elevated as
high as with the two-position control, which then
reduces the danger of carry-over appreciably.
In practice, two systems have established
themselves :
◗ Compact system NRGT 26-1
◗ BUS system NRG 26-40/
NRR 2-40/URB 1
The compact system is preferred for applications
where the control is to be realized via an external
general-purpose controller, a PLC (programmable
logic controller) or a frequency-controlled pump.
The compact probe NRGT 26-1 supplies a level-
proportional output signal (4–20 mA), which
can be switched to one of the above-mentioned
electronic units.
In the area of the BUS technology, the experience
of the last three decades was evaluated and inte-
grated here to optimize the established systems.
26
The level controller NRR 2-40 also offers, as an
option to the 3-position stepping output, the possi-
bility of using 4–20 mA modules for the manipu-
lated variable and/or the actual value. As already
described with the on-off controllers, delays can
also be programmed here. Furthermore, by using
the control terminal and display unit URB, consider-
able savings are possible in commissioning, since,
thanks to the modern technology, the calibration
of the 100% measuring range of the probe can
already be performed at the 50 % level. The pleas-
ing result: less time lost, lower water losses and
lower resource requirements. What is more, after
coordination with the boiler inspector, the control
terminal and display unit can be used as a second
water level indicator, which means that a water-
level gauge glass according to TRD 401, section
8.1; prEN 12952-7 section 5.4.1; prEN 12953-6
section 5.1.1 is no longer needed. Another advan-
tage of this technology is the fact that the entire
“output stage” of the controller remains on the
mounting panel, i.e. elaborate cable harnesses
in the control cabinet door can be omitted and at
the same time the control terminal can be used
for parametrizing the continuous/intermittent
blowdown control. As mentioned already, with
modulating control there is also the possibility of
catering for difficult controlled systems through the
use of steam and feedwater flow measurement.
In such cases, the so-called two- or three-element
controls are implemented.
In the areas > PN 40, we use the intelligent
buoyancy transmitter 144 LD, which covers the
range up to PN 250. Like the compact system
NRGT 26-1, this system has a level-proportional
4–20 mA current output.
 Equipment for Energy Supply Centres

b GESTRA Level Controller

Universal control terminal

Everything is easier The benefits for you and display unit URB

For level control too, a large number of innovations
have been introduced to make operation much
easier. Continuous control reduces the time nee-
ded and the loss of water to a minimum.
BUS
1. Savings:
◗ Reduction of time and feedwater requirement
during measurement, through 100 % calibration
at 50 % level
◗ The control terminal can also be used as a
second water level indicator, which does away
with the need for a water gauge glass
2. Systemoptimierung:
◗ Omission of an additional time-lag relay, thanks
to the integrated, adjustable time delays
◗ Preset switchpoints
Conventional
A single control terminal for all systems.
With the URB 1, you can now control all the stan-
dard functions of the CAN bus systems. And the
switchpoints etc. can be adjusted with the aid of
the keypad, regardless of the actual level. What
is more, this control terminal can be used as a
second water level indicator, which saves the need
for a water gauge glass.
In accordance with WÜ 100 requirements, the
current conductivity value is shown continuously.
With the URB 2, GESTRA offers the
following advantages:
◗ Integration of further units, e.g. TRV, TRS
◗ Clear start page with the present operating data
◗ New rotary selector with button function
◗ Quick navigation
◗ Easy alteration of numerical values

NRR 2-40

NRGT 26-1 NRGT 26-1 KS 92-1

URB

URZ 40a

V 725 V 725 URB 1 URB 2

w w w . g e s t r a . d e 27
GESTRA Boiler Water Quality Monitoring

r
e

d
g
h
r
f e

d Conductivity measurement and continuous blowdown: e Intermittent blowdown: cycling timer TA 5,

compact conductivity electrode LRGT 16-1, blowdown Intermittent blowdown valve MPA . . . . . . . . . . . . . . . . . . . . p. 30, 31
controller KS 90, blowdown valve BAE . . . . . . . . . . . . . . . . . . p. 30, 31 f Sample cooler PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 34
g Blowdown flash vessel
h Residual blowdown cooler
28 r Stop valve GAV
 Equipment for Energy Supply Centres

Technical Information
de Boiler Water Monitoring

Safe operation of steam boilers at high availability
necessitates:
1. Modern treatment of the boiler water, designed
to meet economic criteria and operational
conditions in accordance with TRD 611 (TRD =
German Technical Rules for Steam Boilers)
or EN 12952 Part 12; EN 12953 Part 10
2. The corresponding care and monitoring of the
boiler water through constant measurement of
the conductivity, continuous top blowdown and
periodic bottom blowdown.
Continuous and intermittent blowdown com-
plement each other. Both processes are usually
needed for proper boiler operation. This also
applies for boiler types with demineralization
plants.
Separate monitoring of the boiler water density
(TDS level) provides additional safety, and is
required by TRD 604 for 72h unmanned operation.
In plants which are fitted with manually operated
continuous/intermittent blowdown valves, it is
absolutely necessary for signalling when the limit
values have been exceeded.

Depending on the type of treatment, a certain

amount of salts passes into the water cycle all the
time. Some of these salts (mainly calcium and
magnesium salts), together with other impurities,
remain in the water as hardening constituents.

As a result of the evaporation process, the salt

content in the boiler tends to rise. To prevent de-
posits or the risk of an excessive dissolved-solids
content in the downstream plant components
with “foaming and priming” (the result of a salt
concentration that is too high), the TDS level must
be kept within the admissible limits. This is done
in a simple and reliable manner by continuous top
blowdown.

Some hardening constituents can contain sedi-

ments which pass into the bottom zone of the
boiler. Together with the other foreign matter, a
sludge layer is produced there which must be
discharged with a view to preventing corrosion,
poor heat transfer etc. Intermittent bottom blow-
down is the proven method.

GESTRA intermittent blowdown valves MPA 26 ensure trouble-free

w w w . g e s t r a . d e production for autoclaves in a sand-lime brick works. 29
de GESTRA Boiler Water Monitoring

More safety The benefits for you

Separate monitoring of the boiler-water density 1. Less effort: 2. Longer lifetime:

is prescribed for 72 h operation without constant
supervision. In plants with manually operated
continuous and intermittent blowdown valves, it is
actually mandatory – and consists of the conducti-
vity probe LRG 16-40, the controller LRR 1-40,
a control terminal URB 1, the continuous blow-
down valve BAE and the intermittent blowdown
valve MPA 46. If the control terminal is already
intended for the level measurement, an additional
URB is not needed.
◗ Operating personnel are relieved of routine tasks ◗ The specified boiler-water density is maintained
◗ Automatic temperature compensation ◗ High reliability and enhanced boiler care
◗ Automatic ranging for the measurement
◗ One controller for both continuous and inter-
mittent blowdown
◗ Simple operating procedures
◗ Savings in energy
◗ Can be used for all boiler types

BUS Conventional

URB 2 LRR 1-40 KS 90

LRG 16-41 LRGT 16-2

BAE 46-40 MPA 46 BAE 46-3

30
 Equipment for Energy Supply Centres

Technical Information
GESTRA Boiler Water Monitoring

The aim for modern boiler plants is to achieve not
only safe but above all economical operation. To
optimize the operational economy, energy losses
must be kept as low as possible, i.e. by recovering
the exhaust heat (for preheating the feedwater or
burner air), utilizing the flash steam downstream
of the continuous blowdown, saving energy with
speed-controlled motors in the feedwater and
combustion air control systems etc. An important
objective here is, of course, also to reduce the
continuous blowdown losses. Optimum continuous
blowdown of the boiler plant can be measured
on the basis of the “concentration factor”, i.e. the
relationship between the quality of the feedwater to
that of the boiler water. Two main factors play a role
in achieving a high concentration factor:
1. The choice of water treatment process, and
2. Optimized continuous blowdown control,
with which it is possible to operate the boiler
as closely as possible to the limits of the plant,
hence reducing the continuous blowdown
rates.
Benefits
◗ Reliable maintenance of the specified boiler
water density, and thus a high level of safety
with simultaneous boiler care and extended
service life
◗ No manual intervention, relieving the person-
nel of routine tasks and also saving power
◗ Can be used for all types and designs of
boilers
◗ Robust units proven in thousands of instal-
lations
Just as in the previous topics, the SPECTOR family
offers system solutions to suit the customer’s
needs. Like the NRGT (compact probe operating
continuously), the LRGT 16-2 is also used where
the continuous blowdown valve is driven by a
general-purpose controller or a PLC. The LRGT
supplies a temperature-compensated, conduc-
tivity-proportional 4–20 mA signal, which is then
routed to one of the above-mentioned electronic
control units. The boiler monitoring and care is
rounded off with the intermittent blowdown system
TA 5/7/MPA.
level, in accordance with WÜ 100.
In the output stage of the continuous blowdown
controller LRR 1-40, the MAX limit value and the
driver for the intermittent blowdown valve (MPA
plus control valve) are also integrated, in addition
to the driving circuit for the continuous blowdown
valve. As an option, we offer a 4–20 mA current
module as an actual-value output. With this system,
the same technical features apply as described
under level control.
The overall palette covers the pressure range from
PN 10 to PN 320, with electrodes mounted directly
in the boiler and the sampling stations with down-
stream measurement chamber.
Further systems for continuous/intermittent blow-
down are given in the Technical Information.
Automatic intermittent blowdown with the GESTRA MPA

As explained in the section on level control, the

BUS technology includes many technical innova-
tions which are the result of our wide-ranging
experience with diverse systems over the past
decades.

The system consists of the components

LRG 16-41/LRR 1-40/URB 1/BAE. The URB 1 can
already be part of the level control and need only
be installed once. This is not only a clear benefit
in terms of cost, but also makes commissioning
much easier. In the URB 1, the present conductivity
is constantly displayed together with the water

w w w . g e s t r a . d e 31
k GESTRA Temperature Controller
Elevating the Return Temperature

NRS 1-40.1
NRS 1-40. 2 Circulating pumps
TRV 5-40

TW/TR

TRV 5-40

URB

2x

WB STB

TW TR TRG 5-63/64

WB = Water-level limiter
STB = Safety-temperature limiter
TW = Temperature monitor
TR = Temperature controller
TRS 5-40

32
 Equipment for Energy Supply Centres

Technical Information
k Safety Temperature Limiter/Temperature Controller

Safety temperature limiters and controllers are
used for steam boilers with superheaters and in
the inlet flow of hot-water generating plants. Tem-
perature controllers are used in the return line of
hot-water plants and serve to elevate the tempera-
ture from the inlet flow when the return flow has
cooled down too far. As with the systems for level
detection, here GESTRA also uses exclusively
electronic systems that distinguish themselves
particularly through high accuracy, low drift and
time-saving commissioning. Based on the high
demands GESTRA makes of its safety-related
equipment components, the limiter system has
a periodic self-check for loss of redundancy, with
the result that this system requires no periodic
tests besides the annual external examination
by the boiler inspector. A large spectrum of appli-
cations is covered by various sensors (Pt100,
thermocouple).
Through the use of resistance thermometers with
a dual Pt100 probe, costs can be saved through
the reduction in the number of sensors to be
installed.
TRV 5-40

NRS 1-40.1 TRS 5-40

URB 2

The following systems are available:

Conventional technology:
◗ Resistance thermometer/temperature switch
TRG 5-5.../TRS 5-6 PN 40–160 Max. temperature 540 °C
TRG 5-5.../TRS 5-8 PN 40–160 Max. temperature 540 °C
◗ Thermocouple type K/temperature switch
TRG 5-11,...-41/TRS 5-7 PN 1–160 Max. temperature 1.000 °C
BUS technology:
◗ Resistance thermometer/safety temperature limiter
TRG 5-65/TRG 5-66 TRG 5-63/-64 TRG 5-6.../TRV 5-40/NRS 1-40.1 PN 40–160 Max. temperature 650 °C
◗ Resistance thermometer / temperature controller
TRG 5-6.../TRV 5-40/NRS 1-40.1/TRS 5-40/URB 2

w w w . g e s t r a . d e 33
Technical Information
f Sample Cooler PK

Apart from the continuous blowdown, sampling

is also of special importance for the smooth oper-
ation of steam generating units.

Each GESTRA continuous blowdown valve is fitted

with a sample valve, with which boiler water can be
removed for analysis.

However, proper and uncorrupted analysis values

require the right sampling procedure and analysis
devices that function correctly.

Direct sampling of hot boiler water from pressur-

ized lines always involves the danger of scalding
and the risk that the samples do not represent
the true TDS content (salinity). Flashing losses
within the sampling line or in the sample container
cause an increase in the density of the boiler water
sample; corruption of the analysis result is thus
unavoidable.

The perfect solution is to use the GESTRA sample

cooler PK. The boiler water sample is cooled down
to the reference temperature of 25 °C and thus
fulfils the basic requirements for precise water
analysis.

The GESTRA sample cooler PK can be fit ted down-

stream of the sample valve, thus enhancing the
technical standard of your energy supply centre.

34
 Equipment for Energy Supply Centres

Energy Recovery
Portable Digital Meter VRM-2 / VRM-3 Energy Recovery
after Continuous Blowdown

In addition to the chemical reagents needed for
analysing the boiler water and condensate, elec-
tronic analysis units are indispensable tools for
modern steam and hot-water generating plants.
Here
GESTRA has the conductivity testing case VRM-2
to offer. The case contains the conductivity meter
and electrode.
With the testing case VRM-3, the test devices
measure not only the conductivity but also the
temperature and the pH value. The testing case
contains a measuring device for the conductivity,
including electrode, and a measuring device for the
pH value and temperature, together with acces-
sories such as: pH probe, Pt100, 5 capsules each
for the calibrating solutions pH 4.01; 7.01; 10.01;
1 bottle of 3 mol/L KCl solution, and 1 bottle of
Pepsin cleaning solution. The measuring devices
operate independently of the mains supply, using
a 9 V battery.
After the continuous blowdown, irrespective of
whether automatically controlled or manually set,
it is easily possible to utilize the dissipated heat.
For example, in a GESTRA blowdown flash vessel,
the energy generated by the continuous blowdown
in the boiler blowdown is recuperated to a large
degree by flashing. In a residual blowdown cooler
located downstream, the heat remaining in the
flash vessel can also be used to preheat the feed-
water. Flash steam coolers offer another way for
heat recovery. They can be used for preheating the
make-up water by utilizing the flash steam of the
feedwater deaerator. Experienced specialists in
industrial systems engineering are available to you
for individual advice.
In Germany and many other countries, the heat
recovery plants made by GESTRA are eligible for
an investment subsidy.

VRM-2

Measuring ranges:

Conductivity 0 – 200 µS/cm

0 – 2,000 µS/cm
0 – 20 mS/cm
0 – 200 mS/cm
pH value 0.00 – 14.0
Temperature -50 – +250 °C
VRM-3

w w w . g e s t r a . d e 35
GESTRA Condensate Monitoring
According to TRD 604 (72 h) or EN 12953 Part 6 – Steam and Condensate System

3 4

2 5 5
6 6
7 7

12

13

1 11

7 10 7

9 9

*)

1 Steam generating unit
2 Steam flow measurement
3 Steam drier
4 Pressure-reducing valve
5 Sight glass
6 Steam trap
7 Disco non-return valve RK 86 10
8 Monitoring for ingress of foreign substances,
such as acids and blowdown: conductivity elec- 11
trode LRG 12-1, conductivity transmitter LRT 1-6, 12
max.-min. limit switch URS 2
9 Monitoring for ingress of foreign substances, such 13
as oil and grease: oil and turbidity detector OR
Electrical/pneumatic three-way valve for dis-
charging the contaminated condensate
Condensate tank
Condensate sequence control: compact level
electrode NRGS 11-1, pump control unit NRSP
Feedwater tank

36 *) not required by EN
 Equipment for Energy Supply Centres

Technical Information
3 4 GESTRA Condensate Monitoring

In any heat exchanger that is operated with steam, In practice, fitting a three-way control valve down-
condensate is produced. Since the condensate stream has proven to be ef fective, i.e. the impure
contains an appreciable quantity of heat, it would condensate is discharged and then disposed of.
economically unwise to discharge this condensate This disposal takes place via oil separation sys-
unused from the boiler water cycle. Nonetheless, tems, for instance, since the contaminated conden-
the condensate is often dumped because of fears sate is not allowed to pass into the sewage system.
that it might be contaminated by product ingress.
Indeed, the possibility that hydrocarbons, acids, When planning boiler plants according to TRD 604
alkalis, dyebaths or other substances may pass – 72 hour operation – it is additionally necessary
through leaky heat-exchanger surfaces into the to observe that in this case the oil and turbidity
condensate, thus endangering the boiler opera- detector is required twofold.
tion, cannot be excluded. As a rule, however, the
condensate will not be contaminated constantly, Experience shows that in these cases it is advis-
i.e. it is generally feasible to include the returning able to install the second monitoring unit down-
condensate in the boiler water cycle. If the plants stream of the three-way control valve, because only
are operated according to TRD 604 or prEN in this way is the function of the valve monitored
12952/12953, the standard requires constant properly.
monitoring of the condensate quality if there is any
risk of ingress by the products mentioned above.
For this monitoring, a distinction is made between
substances which affect the electrical conductivity
of the condensate and those which cause turbidity
or refraction. The former is sensed by means of
conductivity electrodes and evaluated by the asso-
ciated control units. For the detection of oil, grease
and similar substances, oil and turbidity detectors
are used.

According to TRD 604, the boiler plant must be

shut down on detection of foreign matter ingress,
if the contaminated condensate can pass into
the boiler water cycle. Since the availability of the
boiler plant has the highest priority, measures must
be taken to prevent such an ingress into the boiler
water cycle.

w w w . g e s t r a . d e 37
w GESTRA Condensate Monitoring

Please do not disturb!

Since the availability of your boiler plant enjoys hig-

hest priority, nothing must be allowed to penetrate
the boiler water cycle.

For this monitoring, the GESTRA systems dis-

criminate between substances which affect the
electrical conductivity of the condensate and those
which cause turbidity or refraction. The former is 7
sensed by means of conductivity electrodes and
evaluated by control units.

With GESTRA oil and turbidity detectors, you

obtain automatic compensation of disturbances
such as: 3
1 2
5
◗ Discolouration
◗ Lamp ageing 2
◗ Soiling of the glasses
6
The ingress of conductive substances, such as
blowdown and untreated water, is rapidly detected
and signalled by the systems LRG 12-1/LRT 1-6 /
URS 2 or the SPECTORcompact system LRGT/
URS 2.

BUS interface BUS interface

(optional) (optional)

Steam and condensate system

1 Steam trap 4 Monitoring for ingress of foreign substances such as oil and
2 Disco non-return valve RK 86 grease: oil and turbidity detector OR
3 Monitoring for ingress of foreign substances such as acids
5 Electrical/pneumatic three-way valve for discharging the con-
and blowdown: conductivity electrode LRG 12-1, conductivity taminated condensate
transmitter LRT 1-6, limit switch URS 2 6 Main condensate tank
7 Boiler protection
38

Technical Information
GESTRA Condensate Monitoring
If the downstream oil and turbidity detector senses
an impurity, there is the possibility of shutting
down the condensate pumps in order to ensure the
plant’s availability. This step prevents the passage
of impure condensate into the boiler water cycle.
In this case, the shutdown should be coupled to
an alarm annunciation, so that the operating per-
sonnel can intervene appropriately.
Regarding the question as to when monitoring of
the return condensate is necessary, a clear rule is
given in TRD 604 and EN 12952/12953:
Whenever there is a risk of ingress by
foreign substances, but only then!
In the majority of the boiler plants already installed,
the condensate is collected in condensate tanks.
This is frequently done decentrally in the various
production zones, and the condensate is then con-
veyed to the main condensate tank in the energy
supply centre by means of recirculation units work-
ing with or without pumps.
For such extended systems, the most suitable
location for the condensate monitoring equipment
must of course be considered carefully.
Owing to the increasing pressure of costs with
the planning and construction of the plant, the
principle frequently applied is to cut the costs as
far as possible by reducing the number of units,
which often means that the monitoring devices are
installed downstream of the condensate tanks.
Unfortunately, this approach also signifies that,
if there is any ingress of foreign substances, the
entire condensate system is contaminated and
w w w . g e s t r a . d
Equipment for Energy Supply Centres
therefore the entire condensate must be dumped,
not to mention the cleaning and disposal costs.
The following rule should be applied:
Mount the monitoring unit as close as
possible to the potential source of trouble.
If there are several potential trouble-spots in a
facility, it may be necessary to group several con-
densate lines together before the monitoring point.
But even for this solution, the scope of the grouped
lines should be kept within clear limits, so that the
source of a fault can be localized quickly.
Monitoring for grease and oil ingress
in two separate condensate return lines
e 39
3 Conductivity Monitoring
The ingress of conductive substances – such
as blowdown, acids, untreated water, dyebaths
etc. – is rapidly detected and signalled by the
systems LRG 12-1/LRT 1-6/URS 2 or the compact
system LRGT/URS 2, and the necessary measures
are initiated automatically. As explained for boiler
water monitoring, these systems function with
automatic temperature compensation, i.e. fluctua-
tions in temperature do not lead to a fault indication
or initiation of automatic discharge.
4 Oil and Turbidity Detection
As described above, this monitoring system is
used to cover the risk of ingress by hydrocarbons,
whey products etc. Because of the various con-
densates, a system is needed to differentiate, after
calibration of the zero point, between soiling and
impurities resulting from the condensate system
itself and contamination by hydrocarbons, for
instance. With the oil and turbidity detector OR,
we have developed a system which can make this
distinction through a combination of transmitted
and scattered light. False alarms are reduced to a
minimum, and system malfunctions are detected
automatically.
The requirements described for the condensate
system must be applied to the same extent for the
return flow of hot-water plants. An essential differ-
ence lies in the signal processing, since discharge
is not possible or not permissible for hot-water
systems.
GESTRA Equipment for Steam Generators – Marine Boilers –

Burner/furnace OFF Feedwater control valve

n o a a b

s
p
Steam drum

r r q r
w

r r
Water tubes

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

level electrode NRG 16-40/level switch NRS 1-40.1
b Level electrode NRGT 26-1S, universal controller KS 92-1
e Conductivity measurement and continuous/intermittent blow
down: conductivity electrode LRG 16-40, continuous blowdown
controller LRR 1-40, continuous blowdown valve BAE,
intermittent blowdown valve MPA, 3/2-way pilot valve, strainer
n Pressure limiter DSF
o Pressure controller/transmitter
p Disco non-return valve RK 86
q Strainer GSF
e
r Stop valve GAV
s Electrical/pneumatic control valve V 725
w Monitoring of the fresh water:
◗ Demineralization equipment – using conductivity monitoring
◗ Partial demineralization equipment: by monitoring residual
hardness (not part of our product range)

40
 Equipment for Energy Supply Centres

Technical Information

By making just a few technical modifications
we were able to adapt our well-proven boiler
equipment to the special requirements (such as
vibrations, air conditioning, EMC etc.) of various
classification societies. We can provide our custo-
mers with a great number of acceptance inspec-
tions such as GL, LR, SeeBG, RINA; NKK, ABS,
KR, BV, DNV, which guarantee that the GESTRA
equipment range meets the requirements of the
international market.
We can offer the following equipment packages:
Steam boiler
Water-level limiter of
„high-integrity design“:
◗ NRG 16-11S/NRS 1-7 see page 22
Water level controller,
intermittent control
◗ NRGS 16-1S (fixed switchpoints)
◗ NRGT 26-1/NRS 2-3 (variable switchpoints)
modulating control
◗ NRGT 26-1/KS 90-21 see page 25
Condensate monitoring
◗ OR 52-5
The system OR 52-5. consists of the sensor ORG,
which is installed in a bypass, and the electronic
control unit ORT. The photometric measuring
system can detect traces of oil with a sensitivity of
2 ppm. This method yields qualitative measuring
results and is mainly used in open systems, e. g.
for condensate monitoring, the monitoring of open
cooling systems coming from / leading to public
stretches of water, and the monitoring of oil sepa-
rators for bilge water (OR 52-7) etc. These TÜV
approved systems can automatically compensate:
◗ dirty glass cylinders in the sensor
◗ aging of the lamp filament
◗ change of colour in the medium
and they feature self-checking routines for sys-
tem defects of the light emitter, light receiver
and the electronic control unit.
Cooling water monitoring
◗ ORGS 11-2
The ORGS 11-2 features a measuring pot that is
installed in a bypass and uses gravity to separate
oil droplets from water. When approx. 50 ml oil
have accumulated in the „dome“ of the measuring
pot, the conductivity electrode and the associated
electronic control unit will raise an alarm. Due to
the qualitative measuring result the system is parti-
cularly suitable for closed systems, such as cooling
water systems for engines etc.
Monitoring of oil separators for bilge water
(IMO)
◗ OR 52-7
Marine boiler

Combination equipment
◗ NRG 16-38S/1 x NRS 1-7
(NRG 16-11 + NRGT 26-1)
◗ NRG 16-39S/2 x NRS 1-7
(2 x NRG 16-11 + NRGT 26-1)

Safety temperature limiter of

„high-integrity design“
◗ TRG 5-.. /TRS 5-6 see page 33

Feedwater monitoring
◗ LRGT 16-1 see page 28

w w w . g e s t r a . d e 41
GESTRA AG
Münchener Str. 77, D-28215 Bremen
P.O. Box 10 54 60, D-28054 Bremen
Telephone +49 (0) 421-35 03-0
Telefax +49 (0) 421-35 03-393
E-mail gestra.ag@flowserve.com
Internet www.gestra.de

810689-06/807 EMA · © 2007 · GESTRA AG · Bremen · Printed in Germany With Energy into the Future