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….
Instrumentation around utilities
Slide 3 Seou Wei
08/16/2019
Products Solutions Services
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.
Steam Systems - Engineering Know How
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-$/year // €/year)*DN ANSI/EN
Steam pressure (psi/bar)
15/1 150/10 300/20 600/40
1in/25 1120/896 2280/1824 3000/2400 3960/3168
2in/50 1880/1504 3840/3072 5040/4032 6720/5376
4in/100 3320/2656 6800/5440 8960/7168 12000/9600
8in/200 5920/4736 12320/9856 16240/12992 21800/17440
12in/300 8440/6752 17600/14080 23280/18624 31360/25088
Steam Systems - Engineering Know How
Slide 16 Wöhrle S.
08/16/2019
Avoid leakage
Steam pressure Hole diameter Steam loss lbs/h / kg/h
Annual loss in US-$/€*
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
Steam Systems - Engineering Know How
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
Steam Across Industries / ALN Mtg 2014 Malaysia
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
Steam Systems - Engineering Know How
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
Best Demonstrated Practices Steam
• 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.
INTERNAL - Oliver Seifert, E+HSlide 25
08/16/2019
Analytical Skid for boiler feedwater
Best Demonstrated Practices Steam
• Analytical skid for boiler feedwater in a Steam Assisted Gravity Drainage application
• Turbidty, hardness, Dissolved Oxygen
INTERNAL - Oliver Seifert, E+HSlide 26
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
Steam Across Industries / ALN Mtg 2014 Malaysia
08/16/2019
Steam Across Industries / ALN Mtg 2014 Malaysia
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
Steam Across Industries / ALN Mtg 2014 Malaysia
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!
Steam Across Industries / ALN Mtg 2014 Malaysia
• 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
Products Solutions Services
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
Detected Leakage at Our Production Center: ~13% Losses!
Consumption decreases before weekend and about at 9 p.m. production stops…
Thermal mass t-mass
Slide 45 SW Lim
08/16/2019
Detected Leakage at Our Production Center: ~13% Losses!
…although there is no production “consumption” at Saturday still about 100 kg/h…??
Thermal mass t-mass
Slide 46 SW Lim
08/16/2019
Detected Leakage at Our Production Center: ~13% Losses!
…as well on Sunday…
Thermal mass t-mass
Slide 47 SW Lim
08/16/2019
Detected Leakage at Our Production Center: ~13% Losses!
…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
Products Solutions Services
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
Instrumentation around utilities
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
Heartbeat Technology
Slide 56 SW Lim
08/16/2019
Heartbeat Technology – a practical example
Heartbeat Technology
Diagnostics Verification Monitoring
Permanent process and device diagnostics
Documented verification without process interruption
Information for predictive maintenance
Slide 57 SW Lim
08/16/2019
Heartbeat Technology –Diagnostics (NAMUR recommendation NE107)
Heartbeat Technology
Diagnostics
Permanent process and device diagnostics
Increased plant availability …
… 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
Heartbeat Technology
Verification
Documented verification without process interruption
Increased plant availability …
… 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
Products Solutions Services
Thank you for your attention
Questions?
Slide 65 Seou Wei