instrumentation around utilities - endress+hauser

08/16/2019

Products Solutions Services

Instrumentation around utilities

Water, Steam, Natural Gas & Compressed Air

Slide 1 Seou Wei

08/16/2019

The Industrial Production Process – W.A.G.E.S

Steam Across Industries - GIM Workshop

Oliver SeifertSlide 2

Raw Materials

Labor

Wat

er

Products

Emissions/Effluents

Air

Gas

Elec

tric

ity

Stea

m

08/16/2019

First thing first….


Slide 3 Seou Wei

08/16/2019


Steam

Slide 4 Seou Wei

08/16/2019

Efficiency Safety

Quality Availability

Steam Across Industries / ALN Mtg 2014 Malaysia

Hot Topics in Steam

Slide 5 Uwe Wagner

08/16/2019

Condensate (V, T)

Steam

make up water (V,T)

feed water (V,T)

Fuel (M,T )

flue gas (V,P,T)

Blow down

(V,P,T)

Air (V,P,T)

Steam Boiler (direct) efficiency calculation

Boiler Efficiency % =Heat provided by fuel combustion

Heat exported by steam

Heat exported by steam = Steam mass * (steam enthalpy – feed water enthalpy)

*100

Steam Systems - Engineering Know How

Slide 6 Wöhrle S.

08/16/2019

Prowirl 200 - the next step in vortex technology

Prowirl 200 is optimized for steam measurement

IAPWS-IF97 Table

• Mass and energy compensation for wet/saturated and superheated steam

• Compensation with temperature and pressure (fixed or dynamic)

The International Association for the Properties of Water and Steam

Slide 7 Seou Wei

08/16/2019

Temperature-Enthalpy diagram for Steam

To achieve dry saturated steam (100% steam quality) at all times is close to impossible!!! Think of these scenarios: • If heat loss along steam distribution line due to poor insulation, dry saturated steam will

falls into wet steam area. • Pressure change after pressure reducing valve, dry saturated steam further heat to

superheated steam area

Steam Tools Guideline

Slide 8 Seou Wei

08/16/2019

Wet Steam Detection – Prowirl F 200 (Size: DN25 – DN300)

Wet steam detection

80% steam quality

100% steam quality

Slide 9 Product Marketing

08/16/2019

Proline Prowirl 200

Why Steam Detection for Plant Safety

• Water hammer - water carry over from boiler to steam pipeline, poor insulation or malfunction of steam traps

Slide 10 Seou Wei

08/16/2019

Steam Training

Visible steam quality discharging to ambient

Oliver Seifert, Endress + HauserSlide 11

• Good steam quality: almost invisible

• Poor steam quality: liquid droplets visible

• Poor steam quality: liquid droplets visible

08/16/2019

Impact of Steam Quality to Energy Efficiency

• Saturated steam at 100% dryness fraction at 11 bar A has 2,000.3 kJ/kg latent heat of steam.

• 97% dryness fraction – 3% wet hasonly 1,940.3 kJ/kg – 3% less energy!

• 93% dryness fraction – 7% Wet hasonly 1,860.3 kJ/kg – 7% less energy!

• 90% dryness fraction – 10% wet hasonly 1,800.3 kJ/kg – 10% less energy!

Slide 12 Seou Wei

08/16/2019

Gas/ Steam Application - Saving time and cost with multivariable measurement

Prowirl 200 Customer Presentation

Slide 13 Seou Wei

Prowirl F/R/O 200 with integrated pressure and temperature measurement

Traditional measuring point with separate measuring devices

Flowmeter $$$ $$

Pressure sensor - $

Temperature sensor - $

Flow computer - $

Installation (mechanical) $ $$$

Wiring (electrical) $ $$

Configuration costs Low High

Max. measured error ±1.5% o.r. ±2 to 5% o.r.

08/16/2019

Saturated Steam in Palm Oil Mill

Slide 14 Seou Wei

• Saturated steam measurement • Prowirl F 200 with pressure and

temperature compensation

08/16/2019

Leakage - Visible steam loss

Energy Efficiency Manual; Wulfinghoff, Energy Institute Press, 1999

Steam leaks have got one advantage: in case steam is leaking, you will immediately see it.


Slide 15 Wöhrle S.

08/16/2019

Insulate piping

U.S. DOE: Steam System Opportunity Assessment; 2002

Heat loss every 100 ft/30m of steam pipe without isolation (US-$/year // €/year)*DN ANSI/EN

Steam pressure (psi/bar)

15/1 150/10 300/20 600/40

1in/25 1120/896 2280/1824 3000/2400 3960/3168

2in/50 1880/1504 3840/3072 5040/4032 6720/5376

4in/100 3320/2656 6800/5440 8960/7168 12000/9600

8in/200 5920/4736 12320/9856 16240/12992 21800/17440

12in/300 8440/6752 17600/14080 23280/18624 31360/25088


Slide 16 Wöhrle S.

08/16/2019

Avoid leakage

Steam pressure Hole diameter Steam loss lbs/h / kg/h

Annual loss in US-$/€*

115 psi/7.9 bar115 psi/7.9 bar115 psi/7.9 bar115 psi/7.9 bar115 psi/7.9 bar415 psi/28.6 bar415 psi/28.6 bar415 psi/28.6 bar415 psi/28.6 bar415 psi/28.6 bar

1/16 in/0.16 cm1/8 in/0.32 cm¼ in/0.64 cm½ in/1.27 cm1 in/2.54 cm1/16 in/0.16 cm1/8 in/0.32 cm¼ in/0.64 cm½ in/1.27 cm1 in/2.54 cm

15/6.860/27.2240/108.91010/458.13900/176955/24.9220/99.8880/399.23520/159714080/6387

400/3201600/12806400/512027000/21600104000/832001450/11605800/464023200/1856092800/74240372000/297600

Canadian Industry Programme for Energy Conservation: Energy Efficiency and Management Guide; 2002


Slide 17 Wöhrle S.

08/16/2019

Natural gas feeding boiler using t-mass

Best Demonstrated Practices Steam

INTERNAL - Oliver Seifert, E+HSlide 18

• Thermal mass flowmeter, t-mass 65 installed on natural gas feeding shell boiler

• Direct mass flow measurement • Low pressure drop• High turndown (100:1) • t-mass 65 calculates calorific value • The calorific value sometimes called the heating value

or energy value of a fuel is the amount of heat released during the combustion of a specified amount of it.

• The calorific value for fuels is expressed either as Gross Calorific Value or Net Calorific Value

08/16/2019

Steam/ Water Analysis System (SWAS)

SWAS - Status 2017

Slide 19 Lukas Graf, MPS

Steam/ Water Analysis System (SWAS) is a system dedicated to monitor steam and water cycles in power plants, utilities, and all industries with steam demands. It is used to analyze the water quality, aiming to ensure that there are no impurities which can cause damage to boiler, heat exchanger and turbine.

08/16/2019

SWAS - Status 2017

Why analyze steam?

Lukas Graf, MPSSlide 20

Let’s compare producing steam for industrial purpose with your kitchen at home. Over the time water impurities like calcium and magnesium cause a lime layer in your water boiler. This layer can lead to loss of efficiency, corrosion and in the worst case to overheating or other damages.

→ Imagine this impact in big boiler applications

Lime layers reduce the efficiency of the heat transfer thus increase the operational cost

08/16/2019

Steam & Water analysis system

Jeff LowSlide 21

ASME Guidelines for Water Quality in Firetube boilers

ASME: Consensus Operating Practices for Control of Feedwater/ Boiler Water Chemistry in Modern Industrial Boilers

• Boiler water requires chemical treatment.

• Re-use of condensate minimize (energy) and water treatment costs!

DOFeCuHapH

08/16/2019


Which analytical parameters should you measure?

• pH - should be 8.5…9.5 in feedwater and 10.5…12.0 in boiler to reduce corrosion and foaming• Conductivity/TDS/hardness - boiler feedwater and boiler water, reduce foaming)• Dissolved oxygen - reduce corrosion• Silica - automated regeneration of base softener

Several parameters at several points required! Ideal choice: CM44x with respective sensors!

Slide 22 Uwe Wagner

08/16/2019

Application : Boiler Blowdown

• Feed water is treated with chemicals tocondition pH, cond & DO to avoid corrosion and scaling.

• The chemicals do not boil off and will concentrate in the form of suspended solids (sludge) & dissolved solids (TDS)

• Boiler water blowdown is required to avoid concentration of chemicals.

• continuous or intermittent

• Bottom blowdown

• TDS blowdown


Slide 23 Wöhrle S.

Conductivity (high T)

CLS12 CLS13

08/16/2019

Application : Boiler Blowdown

Slide 24

• “blowdown” or “blowoff”. - removing solids from the water while controlling boiler water levels.

• Boiler Blowdown may be continuous or intermittent, and may be a surface blow or a bottom blow.

• Continuous blowdown is normally a surface blowdown, and is defined as a method where a portion (between 1 and 10 percent) of the boiler water is continuously removed by skimming the surface of the water in the steam drum to remove the entrained solids.

• A bottom blowdown is normally an intermittent blowdown (e.g.,once per day), which lowers the water level by a few inches. Discharge point is the bottom of the boiler, or in the case of a two-drum system, the lower “mud” drum.

08/16/2019

Conducivity of returned condensate


• Cargill Cedar Rapids• Liquisys CLM253 + CLS15 conductivity

system• Based on the conductivity, this

customer decides if condensate can bere-used (boiler feedwater) or has to bedumped.


08/16/2019

Analytical Skid for boiler feedwater


• Analytical skid for boiler feedwater in a Steam Assisted Gravity Drainage application

• Turbidty, hardness, Dissolved Oxygen


08/16/2019

The firetubes may never fall dry!

Oliver Seifert, Endress + HauserSlide 27

This is the control band for level!

Source: Bosch Industrial

08/16/2019


08/16/2019


Foam inside a boiler – which Level device to use?

• Capacitance : affected by foam!• DP Level : OK• Guided radar : OK

Slide 29 Uwe Wagner

Keep in mind: Foam may lead to

shut-down!

08/16/2019

Continuous Level in boilers: Levelflex M vs. DP


Result of level measurement with LevelflexThe correct level is shown because Levelflex worksindependently of density fluctuations whilemeasuring precisely up to the liquid surface

Result of the DP measurement:An incorrect and reduced level is shown, because thetransmitter does not take the fluctuating densities intoaccount (ρ1 ≠ ρ2)

AND: Lower DP measurement issubject to clogging because of sludge!

Density: ρ 1 > ρ 2 P (bar) = h x ρ x gρ 1

ρ 2???

P (bar) in thecontainer

Differential pressure

Levelflex

Slide 30 Uwe Wagner

08/16/2019

Measuring in a bypass is better!


• Level forms a „hill“ toward the outlet of the boiler through thecrown valve

• This will fool level measurements inside the boiler!

Slide 31 Uwe Wagner

08/16/2019


Compressed Air

Slide 32 Seou Wei

08/16/2019

Typical Compressed Air System

Thermal mass t-mass

Slide 33 SW Lim

08/16/2019

Gas Attributes

Gas molecules are moving freely in the tank. When they bounce against the wall they put a force on it. The number and intensity of the molecule impacts are responsible for the amount of the Gas pressure.

By compressing a gas the pressure increases and the temperature rises!

p V = n R Tor …and more accurate

The relationship of V, P and T is described using gas equations

P2, V2 ,T2

P1, V1, T1

Gas - Engineering Know How

2

22

1

11

T

VP

T

VP

Ideal gas equation

p V = n R T Z or

Real gas equation

212

22

1

11Z

T

VPZ

T

VP

Slide 34 Wöhrle S.

08/16/2019

Measuring unit for gas

• Normal cubic meter (Nm3) and Standard cubic meter (Sm3) both are corrected volume term

𝑣𝑟𝑒𝑓𝑚𝜌𝑟𝑒𝑓

• Corrected volume is NOT a volume term, but a mass term • They refer to the same reference pressure but to different reference temperatures

1m

1m

P=1013mbarT= 0ºC 1m

1m

P=14.696psiT= 70ºF

1 Nm3 1 Sm3

Examples:

Air = 1.293 kgHydrogen= 0.089 kgChlorine= 3.220 kg

Examples:

Air = 1.199 kgHydrogen= 0.083 kgChlorine= 2.936 kg

Deviation 6-8%!!!!

Thermal mass t-mass

Slide 35 SW Lim

08/16/2019

Compressed Air: Volume or Corrected Volume?

Consumption

Counter1

Counter2

CompressorSuction/ Free Air Delivered

Volume changes as a function of p/T, corrected volume is constant!

Thermal mass t-mass

Slide 36 SW Lim

Volume 10m3/min 1.50m3/min 1.46m3/minTemperature 20°C 35°C 20°CPressure 1 bar a 7 bar a 6.8 bar aDensity 1.2 kg/m3 7.92 kg/m3 8.1kg/m3

Corrected Volume (Reference Condition:0°C; 1.013 bar a)

9.19 Nm3/min 9.19 Nm3/min 9.19 Nm3/min

08/16/2019

Wrong sizing for compressed air application

Slide 37 SW Lim

Air Compressor Name Plate

• DO NOT enter the free air delivery flowrate on flowmeter requested flow as stated on the air compressor name plate Wrong sizing t-mass 65F DN100

• Click on the requested flow (FAD) button and enter the flowrate of free air delivery

08/16/2019

Flowrate on compressor name plate ≠ Flowrate for flowmeter

Slide 38 SW Lim

Correct Size: t-mass 65F DN40

08/16/2019

Compressed Air - Facts & Figures

Thermal mass t-mass

• 10% of all electricity is consumed to create compressed air.• Over long term calculation, 75% of the cost of a compressor due to energy use• >30% of all compressed air generated is never used (leakage, wastage).

Energy Cost, 75%

Capital, 15%

Maintenance, 10%

Source: OIT/Department of Energy: Assessment of the Market for Compressed Air Efficiency Services; 2001

Slide 39 SW Lim

08/16/2019

Did you know…… ???

*Tariff: 28.8sen/kWh

Hole Diameter (mm)

Quantity of air lost in leaks (L/s)

Annual energy waste (kWh)

Annual cost of leaks *(RM)

0.4 0.2 133 38

0.8 0.8 532 153

1.6 3.2 2128 613

3.2 12.8 8512 2,451

6.4 51.2 34040 9,804

12.7 204.8 136192 39,223

Example:

50 leaks with 0.8mm hole diameter = RM 7,650/year

80 leaks with 0.8mm hole diameter = RM 12,240/year

$$$$$ $$

Thermal mass t-mass

Slide 40 SW Lim

08/16/2019

Measurement is a Must

Oliver SeifertSlide 41

Filter supervision

Manometer Differential Pressure

08/16/2019

Why measure differential pressure across filters?

Filer element costs, Fraunhofer ISI; 2003

Filtering leads to Pressure drop=> Energy costs

Gas - Engineering Know How

Slide 42 Wöhrle S.

08/16/2019

Detect Air Leakage with thermal

• Switch off all consumers (pressurized system!) e.g. during weekend and leave compressor running.

• If the thermal meter is still reading flow this will indicate the amount of leakage!

Slide 43 SW Lim

08/16/2019

Detected Leakage at Our Production Center: ~13% Losses!

Consumption of compressed air at our production center on a beautiful sunny Friday…

Thermal mass t-mass

Slide 44 SW Lim

08/16/2019


Consumption decreases before weekend and about at 9 p.m. production stops…

Thermal mass t-mass

Slide 45 SW Lim

08/16/2019


…although there is no production “consumption” at Saturday still about 100 kg/h…??

Thermal mass t-mass

Slide 46 SW Lim

08/16/2019


…as well on Sunday…

Thermal mass t-mass

Slide 47 SW Lim

08/16/2019


…production starts on Monday morning at 5 a.m…..

Mean consumption

Thermal mass t-mass

Slide 48 SW Lim

08/16/2019

Compressor

• Promass F and t-mass 65 within 0.5% of each other for 2 years

• Departmental allocation of compressed air monitored

• 10% savings made to date (leakage)

• Production management now focused on where, when and why

• Optimization of consumption by pinpointing problem areasfor further potential savings

• Not for mass balance confirmation

Slide 49 SW Lim

Sub metering example at our production center

08/16/2019

0

200

400

600

800

1000

1200

1400

kg/h

t-mass 65F sub - meter 1 + sub - meter 2Compressed Air to Production

• Promass F and t-mass 65 within 0.5% over 2 year period

t-mass 65 vs sum of t-mass 150 sub-meters

Thermal mass t-mass

Slide 50 SW Lim

08/16/2019

t-mass 65I - Low Pressure Factory Air

Thermal mass t-mass

Gas: Air

Temp: 25°C

Press: Atm

Flow: 30000 Nm3/h

Size: 800 *1400mm

Slide 51 SW Lim

08/16/2019

t-mass: Industrial Gases and Compressed Air Measurement •Optimal process monitoring - Multivariable measuring device: mass flow, gas temperature & corrected volume flow

•Industry-optimized measuring device – robust with versatile connection for piping and rectangular ducts

•Cost efficient - easy installation and operation, low pressure drop (<2mbar) and maintenance friendly with self diagnostic function

•High turndown (100:1)

•Reliable – measures accurately even at low flow condition (as low as 0.5 kg/h), calibrated according to ISO/IEC 17025

t-mass 150

t-mass 65

•Integrated Gas Engine with list of 20 gases. Specific gas mixtures can be programmed up to 8 components

•Measuring accuracy up to ± 1.5% o.r.

In-line version

Insertion version with optional ‘Hot Tap’ mounting toolFor inserting or removing the device under process condition

Insertion versionCost-efficient gas flow measurement in large diameter pipes up DN1500 (60”)

•Measures Compressed Air, Nitrogen, Carbon Dioxide & Argon

•Measuring accuracy up to ± 3.0% o.r.

Fits everywhere

Thermal mass t-mass

Slide 52 SW Lim

08/16/2019


Water

Slide 53 Seou Wei

08/16/2019

Electromagnetic flowmeter for Water/ Waste Water

Promag L• Available in various type of process connection: Flanged, Lap-joint

flanged • Process temperature up to +90ºC• Liners: Polyurethane, Hard Rubber, PTFE• Nominal diameters: DN 50 to 2400 (2” to 96")

Promag W• Process temperature up to +80ºC• Liners: Polyurethane, Hard Rubber • Nominal diameters: DN 25 to 2000 (1” to 80")

Promag D• Compact design with wafer version process connections• Process Temperature: 0 to +60ºC• Liners: Polyamide• Nominal diameters: DN 25 to 100 (1” to 4")

Slide 54 SW Lim

08/16/2019

EMF selection consideration for water/ waste water measurement

• Select suitable liner and measuring electrode that are direct in contact with fluid

• Measuring flowrate and temperature range• Sufficient straight pipe before and after

flowmeter


Slide 55 Seou Wei

5 x NB

5 x NB

5 x NB

2 x NB

Electromagnetic flowmeter (EMF) sensor design

08/16/2019

Heartbeat Technology

Diagnostics Verification Monitoring

Permanent process and device diagnostics

Documented verification without process interruption

Information for predictive maintenance

Increased plant availability …

… safe processes … reduced verification effort … optimization of processes and maintenance


Slide 56 SW Lim

08/16/2019

Heartbeat Technology – a practical example


Diagnostics Verification Monitoring



Information for predictive maintenance

Slide 57 SW Lim

08/16/2019

Heartbeat Technology –Diagnostics (NAMUR recommendation NE107)


Diagnostics



… safe processes

Slide 58 SW Lim

08/16/2019

Operation with standard web browser

• Integrated web server is a standard feature for all Proline four-wire devices (Proline 100, 300, 400, 500)

• Fast and easy connection to the devicevia standard LAN cable (RJ45 connectors)

• Full device access without specialtools or interfaces

No special tools or interfaces required Saves time

OR

Slide 59 SW Lim

08/16/2019

Heartbeat Technology – Verification

Pass or Fail report:Layout is separated to …• Device information• Mainboard module• I/O Module• Sensor modul

…to assist with failure identification and spare part management


Verification



… reduced verification effort

Slide 60 SW Lim

08/16/2019

Sample of Heartbeat Verification Report

Slide 61 SW Lim

08/16/2019

Challenges in Water/ Wastewater treatment plants

• Periodic inspection of flow measuring points is a recurring obligation

• While it is technically feasible to recalibrate an electromagnetic flowmeter on an accredited calibration rig, in reality this is only a theoretical option

• It is usually ruled out due to the cost and effort involved in removing and shipping devices, often with very large pipe diameters, and also due to the demand for 24/7

Slide 62 SW Lim

08/16/2019

Micropilot FMR20 at a glance Micropilot FMR20

• Level and Flow measurement (with open channels or weirs; via linearization table)

• 4 to 20mA / HART output• Commissioning via HART or optionally wireless via app

using Bluetooth® • Optional with RIA15 – remote display for commissioning• Measuring range of 10m or 20m• Gas Ex approvals• ±2mm accuracy• Ambient/process temperature -40 to +80°C• Ingress protection IP 66, IP 68/NEMA4x/6P• Cable lengths up to 300m

• Sales channel: Face to face sales via E+H

Launch Micropilot FMR10/FMR20

Slide 63 MTF

08/16/2019

Micropilot FMR10/20

11 – Wastewater treatment plant Steinen – DE #122757

Application • Rain overflow basin• Measurement range: 7.7 m• Medium: water

• Order code:FMR20-AA P BM WDE WFE 2

Slide 64 MVS/B. Vogt

08/16/2019


Thank you for your attention

Questions?

Slide 65 Seou Wei

instrumentation around utilities - endress+hauser

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