Conductivity measurement equipment for steam boilers and condensate systems

GESTRA
Special
b hea
, ter
ter before it is

Conductivity Measurement Equipment

for Steam Boilers and Condensate Systems

From absolute measurement to BUS-capable

4-electrode measurement compensated for
temperature, fouling and polarity with TV approval
as per VdTV bulletin Water Monitoring 100

GESTRA AG
Mnchener Strasse 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

818748-00/407 EMA 2007 GESTRA AG Bremen Printed in Germany With Energy into the Future
 Conductivity measurement equipment for steam boilers and condensate systems

SPECTORbus of the measurement, since the influence of

the temperature on the conductivity (rising
2 Conductivity measurement with
manual temperature compensation

One System for All approx. 2-5 %/K, depending on the medium)
completely clouded the measurement results. If,
Requirements! for instance, the technical codes stipulated con
ductivity values of 10,000 S/cm, the devices
On the basis of the experience gained in practical
operation and with the aim of being able to offer
improved measurement systems, the next step
had to be set to 50,000 S/cm or more, to
With the bus-capable four-electrode conductivity was taken equipment with manual tempe-
account for the influence of temperature.
system of the SPECTOR family, GESTRA AG rature compensation. Here too, the familiar
This situation repeatedly led to errors in inter-
is already offering the fourth generation of two-electrode measurement procedure was
pretation.
components for safety equipment. used. With the introduction of manual tempe-
With the increasing modernization and auto rature compensation, there was now the added
History of the development: advantage that the conductivity was referred to
mation of boiler systems as well as the develop-
With the introduction of automatic continuous ment of new boiler plants, there were increased the working point of the boiler plant at 25 C.
blowdown control at boiler plants and the demands on the precision of the monitoring This was a basis for the demands expressed in
conductivity monitoring in pressurized hot- equipment. In following the progress in boiler the codes. Now the boiler attendant was in a
water and condensate systems, the equipment construction, the codes demanded ever lower position to set the desired conductivity, referred
initially used was of a type that evaluated the conductivities in the boiler water together with to 25 C. A prerequisite for this is, however,
absolute conductivity. A particular drawback improved quality in the measurement systems. proper calibration for the influence of tempe
for the operators of the plants lay in the quality rature on the measurement result, by means of a
comparison measurement using a sample cooler
What developmental steps were taken? (e. g. PK 45).
This advance was rapidly accepted by the
market and implemented in numerous boiler
1 Conductivity measurements without plants. It is still widely in use today. The devices
temperature compensation were extended with a 4-20 mA current output,
which was used for a remote indicator or for
In the early days of conductivity measurements the additional connection of limit detectors
for steam and condensate systems, the con (min./max.) in monitoring the entire control
ductive measurement approach was applied, circuit for continuous blowdown and conductivity
as had already become common for level measurement (electrode, cable and valve).
measurement.
With the advancement of boiler house automa-
The basis for this approach was provided by tion, the more stringent demands on the boiler
Ohms Law (R = U/I). water quality (with the limit of 6,000 S/cm as
In conductive measurement, the resistance is per EN standard) and the need for optimized
a function of the particular liquid to be moni measurement systems, the limits of this tech
tored, the distance between the measurement nology were reached. The question that had
surfaces, and the measurement area. been posed more and more frequently was:
Continuous blowdown controller LRR 11 of the first what happens in the case of
In contrast to level measurement, the influence
generation without temperature compensation w pressure fluctuations and the associated
of surface area is entirely unwelcome, i. e. the
With this unit, only a very coarse setting was electrode must be designed so that only a clearly temperature variations
possible, i.e. the selector switch was varied from defined sensing area is used for the measure- w temperature variations in condensate lines
right to left until the indicator light went dark, then ment result. Solution: the electrode rods are
adjusted 2 steps higher to give some leeway for the insulated, except for the desired measurement w plants in which the service pressure is
concentration of the boiler water. area (cell constant). reduced temporarily, and so on.
Such questions always addressed the influence
of the temperature on the conductivity measure-
ment.
U voltage s conductivity
U I I current a temperature factor
R resistance C salt concentration
S area T temperature
D distance Tx temperature at
working point
s S
U = R x I
R = D : (S x s)
s = f (C, T) S / cm
s = s 25 (1+ a / 100 (Tx 25 C))
a = 2 3 % / K
Continuous blowdown controller LRR 1-5 of the
D a = 1 / R [S / D = 1]
second generation with manual temperature
compensation
 Conductivity measurement equipment for steam boilers and condensate systems

3 Conductivity measurement with auto 4 SPECTOR

matic temperature compensation the future has already begun

In pursuing the objective of always offering the With the latest product of the SPECTOR family,
GESTRA AG again blazed a new trail in boiler 1
right measurement system to suit both the needs s=
of our customers and the advanced require- equipment, strengthening its position as a R + coating
ments of the technical codes, we considered, market and technology leader.
during the development of the SPECTOR family, Through the continuous surveillance of our prod
the simultaneous advances in the VdTV bulletin ucts by the quality assurance section and our
Water Monitoring (W 100) and incorporated laboratory, it was found that there were repeated
them into the products. This resulted in systems complaints about the quality of the measurement
which have a Pt1000 temperature sensor results yielded by the systems described above.
integrated into the electrodes and hence con- Investigations showed that, as had already been
tinuously sense the temperature to integrate it the case in the past, the quality of the water
into the result of the conductivity measurement. treatment or the handling of the plant and the
In this way, it became possible to ensure that the resulting water quality are the decisive factors
affecting the quality of measurement. Electrodes
displayed and the evaluated conductivity values
exhibiting various kinds of damage and impair-
were always referred to 25 C independently of ment were submitted as part of the complaints.
any temperature fluctuations. In the previous
electrode configurations, the wall of the boiler, If the diagram shown alongside is considered in
vessel or pipe served as the reference electrode. view of the principle of conductive measurement, Coating
Because of the integrated protection tube, it rapidly becomes clear that the deposits will
the new electrodes had a defined reference increase the resistance, i. e. the conductivity will
appear to decrease.
electrode, which led to a further improvement in
the measurement accuracy. This enhancement These results and our desire to achieve reliable
prompted an application for a type examination and accurate measurement convinced us that
of the conductivity measurement systems of the we had to optimize the measurement system for
SPECTOR family. The basis of the examination the conductivity range from 500 S/cm, as is
was provided by the draft of the now-published required in industrial steam boilers, for example.
VdTV bulletin W 100 *), issue date 07/2006.
The approval number was already granted in
2001. From the viewpoint of many external
experts, this was one of the foundations for 72h
operation according to TRD 604.

*) Water Monitoring 100

Insulating layer of phosphate

Conductivity controller
Conductivity electrode KS 90
LRGT 16-1

Continuous blowdown valve

BAE 46 Max.
limit contact

Automatic continuous blowdown control with signalling of max. limit value Magnetite deposits
 The result provided by our Design and
Development Department is the new
four-electrode measurement method.

For this system, the conductivity sensing
electrode consists of two current and two
~ I
voltage electrodes. The current electrodes
are used to apply a measurement current U
ucts b (UI ) with a fixed frequency to the medium;

la tory, it was f ted a potential difference then arises between

complaints about the quality of the measurement these electrodes 1.
y the systems described above.
Investiga t, as had already been This potential difference is sensed by the
the case in the past, the quality of the water voltage electrodes 2 and evaluated as the
trea measurement voltage UU. The relationship
resulting water quality are the decisive factors between current and voltage is proportional
af Electrodes 1 2 2 1
to the conductance. Any line resistances, R = 1 /s
exhibiting various kinds of dama -
polarization effects or fouling of the
ment were submitted as part of the complaints.
electrodes are compensated.
If the diagram shown alongside is considered in
Moreover, the electrical conductivity varies
it rapidly becomes clear that the deposits will with temperature. In order to relate the
increase the resistance, i. e. the conductivity will measurement values to a reference tempe-
a rature, a Pt1000 resistance thermometer
integrated into the electrode rod is used to
These results and our desire to achieve reliable
measure the fluid temperature.
and accurate measurement convinced us that f = 1 kHz
we had to optimize the measurement system for The electrical conductivity is then calculated
as is from the measurement values UU and UI
required in industrial steam boilers, for example. and, depending on the set temperature
coefficient Tk, is referred linearly to the
reference temperature of 25 C. After
conversion into a current signal that is UI
proportional to the conductivity, the output
is available as a current of 4-20 mA (LRGT
16-2) or as the corresponding signal on the
bus (LRG 1x-41).
O
The lines to the measuring electrode and
resistance thermometer are checked for
interruptions and short circuits; moreover, the
electronic circuit board is protected against
excessive temperatures in the terminal box. UU

The four-electrode measurement system

was type-approved in 2007, also on the
basis of the VdTV bulletin W 100 *) Conductivity (25 C) = UI / UU x MB / (1 + Tk / 100 x Top 25 C)
(issue date 07/2006), in the combinations
SPECTORcompact (LRGT 1x-2** / KS 90) and
SPECTORbus (LRG 1x-41** / LRR 1-40).
In conjunction with the system enhance-
w an adjustable repetition rate for the Thanks to the three-position stepping control,
ments in the control unit, such as:
intermittent blowdown pulses there is the possibility of controlling the actual
w the possibility of selecting the tempe TDS value of the boiler water as close as
w temperature-compensated display of the
rature compensation mode as Tk-Manu, possible to the limiting value specified by
actual value, and
Tk-Norm or Tk-Auto for optimized the EN/TRD codes or to the requirements of
adaptation to the water treatment w the capability of choosing between the boiler manufacturers. The result of this
three-position control (closed / operation / operation mode is an increase in the concen-
w 24h purging pulse for the blowdown open) and three-position stepping control tration factor (the relationship between the
line / valve etc. quality of the feedwater to that of the boiler
w integrated program-controlled intermit- measurement systems of a much higher water ) and, associated with that, a reduction
tent blowdown with pulse repetition level of sophistication are achieved. in the ensuing continuous blowdown losses.
 Conductivity measurement equipment for steam boilers and condensate systems

Continued: Conductivity [S/cm]

SPECTOR
the future has already begun

A reduction in the continuous blowdown

losses will also help to cut costs, because
less fresh water will have to produced
by the water treatment plant, heated up Set point according to TRD 611 / EN 12953 (6000 S/cm)
in the deaerator or boiler, and then later
cooled down by cooling water before it is Conductivity with continuous control
discharged to the sewerage system. Conductivity with control of operation / open position

With the continuous blowdown valve Conductivity with manual blowdown

BAE 46-40, we now offer to supplement
the measurement functions a valve which
Reducing energy losses by optimizing the continuous blowdown control
has a CANopen interface in conjunction
with the actuator EF 1-40. The signals for
communication, driving and feedback (such
as valve position, temperature in the body, / year
blockage detection etc.) are sent directly 400,000
via the CANbus.
300,000

You too can benefit from the possibilities

of modern and reliable boiler safety
200,000 From absolute measurement to BUS-capable
technology. Why settle for anything less?
100,000 4-electrode measurement compensated for
temperature, fouling and polarity with TV approval
0
GESTRA with Energy into the Future 5 10 15 20 25 as per VdTV bulletin Water Monitoring 100
Concentration 20 bar, 12.5 to/h
Reducing energy losses by increasing the concentration factor

LRG 16-41 LRR 1-40

URB 2

Pt1000
MAX.
4-20 mA module Control terminal and display
(actual value) 230 V,
unit with remote level indicator
50 Hz

Intermittent Continuous
blowdown blowdown
valve MPA 46 valve BAE 46-40




Automatic monitoring of the boiler water quality with automatic temperature compensation,
signalling of max. limit level, continuous blowdown and integrated intermittent blowdown
 Conductivity measurement equipment for steam boilers and condensate systems

GESTRA
Special
b hea
, ter
ter before it is

Conductivity Measurement Equipment

for Steam Boilers and Condensate Systems

From absolute measurement to BUS-capable

4-electrode measurement compensated for
temperature, fouling and polarity with TV approval
as per VdTV bulletin Water Monitoring 100

GESTRA AG
Mnchener Strasse 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

818748-00/407 EMA 2007 GESTRA AG Bremen Printed in Germany With Energy into the Future