Bulletin B-950 3D TRASAR ® Boiler Technology Detects, Determines and Delivers the Next Dimension of Boiler Water Management 3D TRASAR automation and control is now available for boiler water treatment. 3D TRASAR boiler automation continues to build on the Nalco 3D TRASAR platform, advancing the premiere technology in control capabilities. The 3D TRASAR boiler system uses the Nalco patented fluores- cence technology program for boiler scale control, and introduces a unique, patented Nalco Corrosion Stress Monitor ™ (NCSM) for preboiler corrosion control. Boiler scale control is achieved with an updated version of the tried- and-true 3D TRASAR controller coupled with the most advanced boiler internal treatment programs to protect your boiler from scale and deposits. The 3D TRASAR program detects system variations, then determines and adjusts the correct program dosage. Nalco continues to improve 3D TRASAR technology, making it the industry standard for monitoring and control that delivers measurable results. The NCSM minimizes preboiler corrosion by measuring and reacting to the net oxidation/ reduction potential of the bulk feedwater, at the actual boiler operating temperatures and pressures. The NCSM detects changes in oxidation/reduction stress, determines the corrective action and responds in real-time by changing oxygen scavenger or metal passivator feed to protect the system. It is now possible to detect and react to the conditions inside the preboiler system under Table 1 – 3D TRASAR boiler technology can be customized and upgraded to ensure your system has the amount of desired control when and where you want it. 3D TRASAR Boiler Technology Model Model Model Feature Descriptions BLx54xx BLx55xx BLx53xx 3D TRASAR Controller & Configurator Software S S S Communication for Remote Monitoring & Alarming C C C Web Reporting & Data Management C C C 3D TRASAR Fluorometer for Scale Control S S U Nalco Corrosion Stress Monitor (NCSM) for Preboiler Corrosion Control U* S, U* S, U* Maximum pressure 1500 psi (103 bar) S S Maximum pressure 2800 psi (193 bar) S Conductivity – Based Blowdown Control U** U** U** Feedwater pH & Conductivity Monitoring U*** U*** U*** S = Standard feature C = Customized U = Upgrade available *can have 2 total **up to 4 boilers ***High purity and low purity water options Note: See global part numbering system on page 9.
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1 Bulletin B-950
3D TRASAR® Boiler Technology Detects,Determines and Delivers the NextDimension of Boiler Water Management
3D TRASAR automation and control
is now available for boiler water
treatment. 3D TRASAR boiler
automation continues to build on
the Nalco 3D TRASAR platform,
advancing the premiere technology
in control capabilities.
The 3D TRASAR boiler system
uses the Nalco patented fluores-
cence technology program for boiler
scale control, and introduces a
unique, patented Nalco Corrosion
Stress Monitor™ (NCSM) for
preboiler corrosion control.
Boiler scale control is achieved
with an updated version of the tried-
and-true 3D TRASAR controller
coupled with the most advanced
boiler internal treatment programs to
protect your boiler from scale and
deposits. The 3D TRASAR program
detects system variations, then
determines and adjusts the
correct program dosage. Nalco
continues to improve 3D TRASAR
technology, making it the industry
standard for monitoring and
control that delivers measurable
results.
The NCSM minimizes preboiler
corrosion by measuring and
reacting to the net oxidation/
reduction potential of the bulk
feedwater, at the actual boiler
operating temperatures and
pressures. The NCSM detects
changes in oxidation/reduction
stress, determines the corrective
action and responds in real-time
by changing oxygen scavenger or
metal passivator feed to protect
the system. It is now possible to
detect and react to the conditions
inside the preboiler system under
Table 1 – 3D TRASAR boiler technology can be customized and upgraded to ensure your
system has the amount of desired control when and where you want it.
3D TRASAR Boiler Technology
Model Model Model
Feature Descriptions BLx54xx BLx55xx BLx53xx
3D TRASAR Controller & Configurator Software S S S
Communication for Remote Monitoring & Alarming C C C
S = Standard feature C = Customized U = Upgrade available *can have 2 total**up to 4 boilers ***High purity and low purity water options
Note: See global part numbering system on page 9.
2
actual operating temperatures and
pressures, allowing 3D TRASAR
technology to deliver superior boiler
system performance.
3D TRASAR boiler technology can
be customized and upgraded to
ensure your system has the amount
of desired control when you want it.
3D TRASAR boiler automation
continuously measures key param-
eters, detects system variability and
upsets, determines and executes
appropriate corrective action and
delivers measurable results. It has
web accessibility and easy reporting
capabilities in one, easy to install
package.
The controller, equipped with the
optional relay box, can operate up
to four blowdown control valves.
A conductivity probe assembly,
motorized valve and flow control
valve are needed for each boiler to
be controlled.
3D TRASAR boiler technology is
just one more example of how
Nalco innovation protects your
boiler systems, saves water and
energy and increases efficiency.
3D TRASAR technology detects,
determines and delivers the
next dimension in boiler water
management.
3D TRASAR boiler technology can
also help keep the boiler water
conductivity in the correct range by
automatically blowing down water
at high solids levels so it can be
replaced with low-conductivity
make-up water. The controller can
be set up for either intermittent or
continuous sampling. A variety of
control, sampling and measurement
options provides the flexibility to
optimize system operation.
High pressure sample point (preferred installation) Low pressure sample point
3
Steamdrum
Mainsteam
Boiler 1” piping• Electrode should NOT
be mounted at the highest point in th piping run where steam can collect• Bushing up piping at or before electrode will cause flashing
1” piping
Minimum 2’ horizontal pipe runto reduce turbulence in sample line
3/4” Electrode cross
High conductivityblowdown to
drain
1/2” flushing valve(to clean electrodes
and chamber)
1” gate valvefull – port
for isolation
3/4” or 1/2”piping
12” to 18”electrode toflow control
valve
Electrodeleakagesafetydrain line
1”- 3/4” reducer
Conductivity sensor
To drain
120 VAC valve control
Low voltageelectrode signal
Mount within 12”-18” ofmotorized ball valve toavoid water hammer
Mount away from heatof boiler and below the
level of the boilerclose to the floor
Sensor and control valvewired to
®3D TRASAR Controller
Motorized
ball valve Main flow
control valve
}
1/2” piping
Pipe runabovesensor
to ensurepipe remains
full atsensor cross
1” gate valve full-port for isolation
Maximum 10’ distance – boiler toelectrode with minimal unions, valvesand elbows that can cause flashing.
Skimmer (surface) blowdown line4-6” below minimum water levelto ensure sample does notcontain steam
Intermittent boiler blowdown sampling
Continuous boiler blowdown sampling
Steamdrum
Mainsteam
Feed
Muddrum
Boiler
Maximum 10’ distance – boiler toelectrode with minimal unions, valvesand elbows that can cause flashing.
Skimmer (surface) blowdown line4-6” below minimum water levelto ensure sample does notcontain steam
1” piping• Electrode should NOT
be mounted at the highest point in th piping run where steam can collect• Bushing up piping at or before electrode will cause flashing
1” piping
1” piping
Minimum 2’ horizontalpipe run to reduce
turbulence in sample line
3/4” Electrode cross
Electrodeleakagesafetydrain line
1/2” piping
Pipe runabovesensor
to ensurepipe remains
full atsensor cross
Continuousblowdownto drain
120 VAC valve control
High conductivityblowdown to drain
Continuousflow control
valve
Low voltageelectrode signal
Mount within 12”-18” ofmotorized ball valve toavoid water hammer
Mount away from heatof boiler and below the
level of the boilerclose to the floor
Sensor and control valvewired to
®3D TRASAR Controller
Note: Steam in the boiler blowdown linewill result in erratic conductivity readings,drifting, poor control and greatly reducethe life of sensors and valves.
1/2” flushing valve(to clean electrodes
and chamber)
1” gate valvefull-port
for isolation
1” gate valve full-port for isolation
1”- 3/4”reducer
To drain
3/4” or 1/2”piping
12” to 18”electrode toflow control
valve
Motorized
ball valve Main flow
control valve
Continuous blowdownContinuous blowdown (Sampling) is recommended for boilers with blowdown requirements of over5,000 lb/hr. This system allows for continuous monitoring and control of boiler water conductivity.
Conductivity sensor
}
Timed blowdownTimed blowdown (Sampling) is recommended for smaller boilerswith blowdown requirements of less than 5,000 lb/hr. The boilerwater is periodically sampled for conductivity. This is done in orderto maintain the boiler water level and not ‘over blow’ the boiler.
NoteSteam in the boiler blowdown line will result in erraticconductivity readings, drifting and poor control and greatlyreduce the life of sensors and valves.
4
Feed and Control MethodsFeed and Control MethodsFeed and Control MethodsFeed and Control MethodsFeed and Control MethodsChemical Feed – Scale Inhibitor
SpecificationsSpecificationsSpecificationsSpecificationsSpecificationsThe 3D TRASAR boiler systems consist of a number of modules. The modules are factory-assembled
on either wall-mountable back plate or on a free-standing frame. This modular design provides a broad
• (4) Analog inputs, non-isolated, 4-20 mA or 0-10 V
(user-selectable), powered or non-powered
• (1) Interlock input (contact closure)
• (4) Digital inputs (contact closure or transistor)
discrete or low frequency water meter counts
• (2) pH/NCSM user selectable, individually isolated
• (6) Contacting conductivity inputs (2 or 4 wire)
• (3) Temperature (RTD, PT1000) inputs (4 wire)
• (2) Fluorometer inputs (Modbus)
• Modbus RS-232 or RS-485 (choose one) RTU
SCADA port
Outputs
• (5) control relay outputs rated 2.0 amps each
(larger loads require external motor starters)
• (8) 4-20 mA outputs, powered, non-isolated,
600 ohms
Alarms
• (1) Alarm output relay (rated 1.0 amp max)
Enclosure
Nema 4X
Ambient temperature
40-120°F (4-50°C)
Relative Humidity
0-95% non-condensing
Display/Keypad
Numeric keypad plus specialty keys
Security
Password protected (user assignable)
Communications
• (2) Ethernet port for direct PC connection, network
or wireless gateway
• USB memory stick (approved devices only)
• Built-in modem for direct remote connection or
access to 3D TRASAR Web via Internet
(requires ISP)
• Optional wireless gateway with monthly service
package.
Approvals
CE, UL (pending), CUL (pending)
Software
• 3D TRASAR Configurator for system configuration
and data transfer
• Optional Vantage® 100 SPC software for comprehen-
sive data management and analysis.
System DimensionsSystem DimensionsSystem DimensionsSystem DimensionsSystem DimensionsWall Mount Controller & Sensor Panel:
Dimensions: 12” D x 33” W x 42” H
(31 cm x 84 cm x 107 cm)
Material: PVC back panel
Mounting Holes: 7/16” diameter
Sample Conditioning System:
Dimensions: 8” D x 33” W x 22” H
(21 cm x 84 cm x 56 cm)
Material: PVC back panel
Mounting Holes: 7/16” diameter
Frame Mounted System:
Dimensions: 29” D x 33” W x 66” H
(74 cm x 84 cm x 168 cm)
Material: PVC back panel on SS frame
Note: The Sample Conditioning System must be field
mounted 1-1/2” (3.8 cm) below the Control and Sensor
Panel for all Wall Mount installations.
SupportSupportSupportSupportSupportPlease contact your local Nalco Sales Engineer if you
have any questions. In North America, you can also
contact the Nalco Equipment Solutions Technical
Support Group at 1-800-323-8483.
3D TRASAR System Diagrams3D TRASAR System Diagrams3D TRASAR System Diagrams3D TRASAR System Diagrams3D TRASAR System DiagramsThe following diagrams are representative of the
systems in each model series. They have been selected
to illustrate the broad variety of possible configurations.
The actual equipment included in each system is
dependent on the specific model number.
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060-BLx54xxxx.88 Series
Part Number 060-BL5421BH.88 Part Number 060-BL5420BH.88
Part Number 060-BL5521BH.88 Part Number 060-BL5522BH.88
060-BLx55xxxx.88 Series
8
060-BLx52xxxx.88 Series
Part Number 060-BL5223.88
Part Number 060-BDC100.88
060-BLx53xxxx.88 Series
Part Number 060-BL5321.88 Part Number 060-BL5302.88
060-BDCx100.88 Series
9
3D TRASAR Technology for Pre-Boiler ControlScale Control and Corrosion Stress Control
Lexan
Shield
SS
Enclosure
High
Pressure
Low
PressureNone Wall Frame High Purity Low Purity None USA Part Number
Y Y Y Y Y Y 060-BL5520.88
Y Y Y Y Y Y 060-BL55200L.88
Y Y Y Y Y Y 060-BL55200H.88
Y Y Y Y Y Y Y 060-BL5520B0.88
Y Y Y Y Y Y Y 060-BL5520BL.88
Y Y Y Y Y Y Y 060-BL5520BH.88
Y Y Y Y Y Y 060-BL5521.88
Y Y Y Y Y Y 060-BL55210L.88
Y Y Y Y Y Y 060-BL55210H.88
Y Y Y Y Y Y Y 060-BL5521B0.88
Y Y Y Y Y Y Y 060-BL5521BL.88
Y Y Y Y Y Y Y 060-BL5521BH.88
Y Y Y Y Y Y 060-BL5522.88
Y Y Y Y Y Y 060-BL55220L.88
Y Y Y Y Y Y 060-BL55220H.88
Y Y Y Y Y Y Y 060-BL5522B0.88
Y Y Y Y Y Y Y 060-BL5522BL.88
Y Y Y Y Y Y Y 060-BL5522BH.88
Y Y Y Y Y Y 060-BL5523.88
Y Y Y Y Y Y 060-BL55230L.88
Y Y Y Y Y Y 060-BL55230H.88
Y Y Y Y Y Y Y 060-BL5523B0.88
Y Y Y Y Y Y Y 060-BL5523BL.88
Y Y Y Y Y Y Y 060-BL5523BH.88
Y Y Y Y Y Y 060-BL5510.88
Y Y Y Y Y Y 060-BL55100L.88
Y Y Y Y Y Y 060-BL55100H.88
Y Y Y Y Y Y Y 060-BL5510B0.88
Y Y Y Y Y Y Y 060-BL5510BL.88
Y Y Y Y Y Y Y 060-BL5510BH.88
Y Y Y Y Y Y 060-BL5511.88
Y Y Y Y Y Y 060-BL55110L.88
Y Y Y Y Y Y 060-BL55110H.88
Y Y Y Y Y Y Y 060-BL5511B0.88
Y Y Y Y Y Y Y 060-BL5511BL.88
Y Y Y Y Y Y Y 060-BL5511BH.88
Y Y Y Y Y Y 060-BL5512.88
Y Y Y Y Y Y 060-BL55120L.88
Y Y Y Y Y Y 060-BL55120H.88
Y Y Y Y Y Y Y 060-BL5512B0.88
Y Y Y Y Y Y Y 060-BL5512BL.88
Y Y Y Y Y Y Y 060-BL5512BH.88
Y Y Y Y Y Y 060-BL5513.88
Y Y Y Y Y Y 060-BL55130L.88
Y Y Y Y Y Y 060-BL55130H.88
Y Y Y Y Y Y Y 060-BL5513B0.88
Y Y Y Y Y Y Y 060-BL5513BL.88
Y Y Y Y Y Y Y 060-BL5513BH.88
Mounting Feedwater pH & ConductivityBlowdown
Relay BoxController Fluorometer
Corrosion Stress
MonitorSample Conditioning System
3D TRASAR Boiler System Numbering Convention
Model Region
Series USA Canada Europe Latin America Asia-Pacific
North America: Headquarters –1601 West Diehl Road • Naperville, Illinois 60563 • USA Energy Services Division – 7705 Highway 90-A • Sugar Land, Texas 77487 • USA
Europe: Ir.G.Tjalmaweg 1 • 2342 BV Oegstgeest • The NetherlandsAsia Pacific: 2 International Business Park • #02-20 The Strategy Tower 2 • Singapore 609930Latin America: Av. das Nações Unidas 17.891 • 6° Andar 04795-100 • São Paulo • SP • Brazil