Installation for collecting and pumping condensate from steam consumers, phase separation to the boiler room ART-Economy CRP-5.5.
The condensate collection and pumping unit consists of 3 modules (blocks).
For this project, we have developed and implemented solutions for collecting condensate from the PK-2 production site, condensate / steam phase separation, pumping condensate to the boiler house and reusing flash steam by consumers at the boiler house.
Block number 1.
ART-Economy CRP-5.5 is a unit for collecting and pumping condensate from steam consumers, phase separation and pumping condensate to a boiler room.
This block is made entirely on mechanical units without the use of automation elements. It is installed in the production area in close proximity to the existing condensate tank.
The condensate is fed to the deaerator by means of mechanical pumps. It is also supplied to the boiler room and secondary steam, which was previously lost. Block 1 is fully designed and manufactured at the own production site of Artezia LLC using modern steam condensate equipment from well-known global manufacturers (MIYAWAKI, SCA, etc.)
Block number 2.
A bubbling element is installed in the condensate tank, to which secondary flash steam is supplied, formed on the ART-Economy CRP-5.5 modular unit.
The amount of steam per bubbling is regulated by a control valve using a temperature sensor, which is additionally mounted in the condensate tank. In addition, the condensate tank is additionally equipped with a circulation pump and a level sensor. The pump helps to equalize the temperature field in the condensate tank, and the level sensor prevents the pump from running dry and makes it possible to limit the bubbling operation in conditions of low condensate level in the tank.
Secondary steam is additionally (in parallel) supplied to the steam cushion of the deaerator tank, using a separate control valve and pressure sensor.
Excess steam, if necessary, is vented to the atmosphere using a separate control valve and pressure sensor on the secondary steam line.
To obtain data on savings, a secondary boiling steam flow meter is installed.
Works on Block 2 were carried out directly at the customer's boiler house.
To transport the secondary boiling steam for production to the boiler house of the Sandora LLC enterprise, the Artesia company laid steam pipelines and insulated them, according to the requirements of the customer.
Block number 3.
To control the system for receiving steam at the boiler house from the ART-Economy CRP-5.5 unit for collecting condensate, phase separation and pumping condensate to the boiler house, Artesia developed software and used a control panel based on a Schneider Electric controller.
For more comfortable monitoring of the parameters of the condensate return system to the boiler, Artesia has developed a solution that makes it possible to display the system control panel on the monitor of an operator or other specialist who will be in the network.
To control the steam intake system at the boiler house and the steam metering system, Artezia performed cable laying and connection of off-panel control and management elements.
- Accounting for hourly expenses;
- Accounting for total consumption (meter);
- Display of instant consumption;
- Display of graphs of changes in consumption;
- Automatic conversion of volumetric steam flow into mass;
- indication, registration of emergencies and response to them;
- Ability to transfer data over an industrial network for dispatching (common industrial protocol Modbus-TCP, Ethernet interface);
- Access to the archive of readings through a regular web browser;
- Ability to store archives on flash drives;
- Various access levels for system settings protected by passwords;
- Multiple flow measurement channels with independent settings (up to 3 mass flow measurement channels).