the future of steam generation - willbanksinc.com · contents company history 1 our references 2...

THE FUTURE OF

STEAM GENERATION

Contents

C O m pa n y H i s T O R y 1

O U R R E F E R E n C E s 2

H O w i T w O R k s 3

J U n i O R T C 4

U n i v E R s a l T C 6

C v E – C E R T U s s v E R i F i E d E q U i p m E n T 8

C v E a d va n Ta g E s 9

E C O n O m i z E R 10

C O n Ta i n E R 12

a d va n Ta g E s aT a g l a n C E 14

C H E C k l i s T 15

C E R T i F i C aT E s 16

i n s Ta l l aT i O n s 17

The content of this publication is not legally binding and is provided as information only.

1

CERTUSS Company History

Introduction steam generators CvE Economizer Container advantages Checklist Certificates installations

w H O w E A R E sCERTUss was established in 1957 in krefeld, germany when Hans Joachim schroder set himself the goal ofmanufacturing reliable, low-noise, compact steam generators. These generators were designed to be easyto maintain and applicable for continuous operation. Today CERTUss are satisfying customers all around theglobe with the help of sustainable, long-term partnerships. Trained and exclusive service partners in 35countries are ready to assist you anytime from everywhere. we are market leader with more than 60%market share in germany, offering high quality “made in Germany” products.

Our next project was to establish ourselves in the north american market. CERTUss america lp was foundedin 2014 with its headquarters located in Philadelphia. we chose this location for various historical and strategicreasons. krefeld and philadelphia’s history is entwined by 13 german families, the Original 13, who travelledto philadelphia by ship in 1683 and chose “germantown” as their new home. Further, philadelphia provides astrategically advantageous infrastructure with a focus on “green economy” which fits our energy efficientproducts and mentality.

Our companies focus lies on a clearly defined product line, systematic R&D and a team of highlytrained professionals enabling equipment production of the highest standards complying with asmE andUl regulations, as well as isO 9001-2008 and pEd.

CERTUss offers generators requiring little space with capacities ranging from 5.1 BHp to 127.8 BHp andoperating pressures of up to 421 psi. To complete the generator system, we offer our CVE, CERTUSS VerifiedEquipment, package plant module where all associated ancillary items are pre-piped, pre-wired and factorytested. all generators are equipped with a touchscreen simplifying control and operation. The thermalefficiency of CERTUss steam generators ranges from 83% to 85%*. we offer various fuel types, including lpg,natural gas, #2 oil or a duel fuel burner for natural gas and #2 oil for units above 31.95 BHp. Full spare partssupport is provided for each generator for up to 20 years after commissioning and we hold electronicdocumentation of every generator manufactured over the past 30 years.

why you should chose CERTUss? Check out all our advantages on page 14.

“Our history is the cornerstone that supports our current success, continue growth and allows us to pushinnovation in the future” Mathias K. Brauner, CEO, CERTUSS Germany

* ng = 1004 BTU/f3, Feedwater = 68 °F, steam = 212 °F. subject to be changed.

2

Our References

Introduction steam generators CvE Economizer Container advantages Checklist Certificates installations

w H O w E W O R K w i T H sThanks to our long company history we have had the privilege of working with many large and well-knowncompanies and establishments from various industries.

CERTUss steam generators have the advantage of being applicable in nearly all industries. we choose tokeep our product line clearly defined and scalable.

we have gathered experience in over 80 different sectors, some of which are listed below, and haveworked with diverse applications.

we have many customers in service and hospitality who use our generators for chemical cleaning,disinfecting, laundering and other service purposes. For example we have installed generators in many Hyatt,Kempinski, Four Seasons and Holiday Inn Hotels.

another major sector we serve is the healthcare sector, including the chemical and pharmaceuticalindustry. CERTUss generators are applied in hospitals, cosmetics, plastics, mineral oil processing, pharmacies,and other chemical processes. Besides hospitals we have also worked with chemical and pharmaceuticalcompanies, for example B.Braun, Evonik, BASF, Merck, Procter & Gamble or Unilever.

additionally the food and beverage industry offers many applications for our steam generators.Examples are meat, milk, mineral water, soft drink, flavor, oils and sugar processes as well as alcoholic beverage,juice, coffee, tea productions or luxury food goods like candy, tobacco products or pralines. in this sectorCERTUss generators are used by, for example, Coca-Cola Companies, Dr. Oetker Frozen Foods as well asNestle Group.

Finally, diverse companies from the automotive, construction and mechanicalengineering sector have purchased CERTUss generators for use in sanitation, ceramics and glass, cementproduction, heating, and woodworking. Samsung Germany, Siemens, Philips Components are customerswe have served to this day.

with all the german car manufacturers located in our home country CERTUss has had the possibility to workfor Volkswagen, Mercedes Benz and BMW.

all that is left to say now is that if you like german cars, you’ll love our generators!

3

How it works

introduction Steam Generators CvE Economizer Container advantages Checklist Certificates installations

The touch screen control panel simplifiesoperation and control of the generator. allconfigurations and settings of steam pressure aremade here.

The pre-heated feed water is delivered to thegenerator at approx. 194 to 203 °F. The heat freesthe oxygen from water and reduces the risk ofoxygen corrosion.

The heat exchanger coil is supplied with waterthrough the feed water inlet. The change ofphase from water to steam begins.

The modulating, integral burner with the fastestresponse time, provides precise steam pressurecontrol down to ¼ psi.

insulation material is made obsolete by guidingthe combustion air from the top of the gene -rator through an outer shell, and from there intoan inner, secondary shell.

The combustion air intake & fan draw in warmair through the triplex system to preheat thecombustion air and keep the outer jacket cool.

when the steam has been produced, it leaves thegenerator through the steam outlet and is thenready for use.

The flue gas outlet connects to the chimney withor without an Economizer.

sediment is flushed out through the steamgenerator coil blowdown valve.

The safety relief valve opens automatically todischarge excess steam when the pressure is toohigh.

1

2

3

4

5A

6

7

8

9

5B

F E a T U R E s sBy using the water tube boiler principle, the CERTUss technology for generating steam offers

maximum safety, reliability and instant availability of high quality steam.

5A

6

9

74

3

8

1

2

5B

4

Junior TC


F E a T U R E s s• space saving

• installation without foundation support

• Robust steel construction

• Triplex air insulation creates good air circulationwithin the generator and preheats the com -bustion air

• integrated, 1st stage CERTUss burner system (ng, lpg)

• noise and vibration reduction, anti-vibrationmoun tings

• Economical fast energy transfer reducing radia -tion losses

• vertical expansion free centrally suspended heat -ing coil with bottom blowdown

• Replaceable evaporation section

• Easy and quick cleaning of the heating system,without removal

• Fully automated operation

• Exemplary customer service and spare parts avail -ability 24 / 7 / 365

• Thermal Efficiency from 83% to 85%* (withoutEconomizer)

• Full adjustable output of steam

• Bms compatibility with profibus/Canbus, mod -bus, BaCnet etc.,

• 7“ Touch Control (TC) screen

The Junior TC series includes the smaller sized generators for customers who require low amounts of steam.all Junior TC generators are equipped with an easy to use touchscreen panel that simplifies operation.They are our most space saving steam solutions. They can serve constant and fluctuating demands in steam,with steam available in under 5 minutes.

Junior TC 80 – 400


5

Specifications


1. Junior TC steam generator2. CvE Utility Unit3. pre pressure pump4. Feed water pump5. Feed water Tank6. Blowdown vessel7. Chemical dosing8. water softening plant9. Brine Tank10. Control panel11. steam separator12. water Filter

da. steam Connectionwa. water Connectionsl. Tank vent (To atmos)sv. safety valve (To atmos)ka. drain Connectionkd. Condensate ConnectionBa. Fuel Connection

Model Junior

Capacities Pressures Consumption Dimensions (~ inch)Weight (~ lb

)

Steamcapa

city

lb/h

Heating capacity

BHP

Nom

inal lo

adMMBtu/h

Max. o

peratin

gpressure psi

Max. p

ermissible

overpressure psi

# 2 oil

GPH

Natural gas

CFH

Liqu

idga

s LPG

CFH

Heigh

t A

Width

B

Dep

th

C

Boiler Ø

D

Flue

gas pipe Ø

E

Flue

gas (cen

ter)

F

80120

176265

68

197.9296.8

116 –421

145 –464

1.512.27

205307

78120

59 28 48 20 7 41 705

150200

331441

1013

372.0495.0

116 –421

145 –464

2.833.78

385512

148198

69 29 54 22 8 44 926

250300350400

551661772882

16202326

621.0744.0870.1993.0

116 –421

145 –464

4.705.656.607.53

6437709011028

251297350399

73 33 59 25 10 53 1146

specifications subject to be changed

6 introduction Steam Generators CvE Economizer Container advantages Checklist Certificates installations

Universal TC

F E a T U R E s s• space saving

• installation without foundation support

• Robust steel construction

• Triplex air insulation creates good air circulationwithin the generator and preheats the com -bustion air

• integrated, 1st stage CERTUss burner system (ng, lpg)

• noise and vibration reduction, anti-vibrationmountings

• Economical fast energy transfer reducing radia -tion losses

• vertical expansion free centrally suspended heat -ing coil with bottom blowdown

• Replaceable evaporation section

• Easy and quick cleaning of the heating system,with out removal

• Fully automatic operation

• Exemplary customer service and spare parts avail -ability 24 / 7 / 365

• Thermal Efficiency from 83% to 85%* (withoutEconomizer)

• Full modulation from 50% to 100% (ng, lpg)

• Bms compatibility with profibus/Canbus, mod -bus, BaCnet etc.,

• 7“ Touch Control (TC) screen

The Universal TC series is equipped to serve constant, as well as fluctuating, high steam demands makingthese generators our most high performing solutions. due to an extremely short heat up time, steam isavailable after less than 5 minutes. The touch screen control panel facilitates operation and gives abundled overview of current pressures and configurations. additionally the generator can easily be operatedremotely.

Universal TC 500 – 2000


7

Specifications


Model Universal

Capacities

Levels

Pressures Consumption Dimensions (~ inch)

Weight (~ lb

)

Steamcapa

city

lb/h

Heating capacity

BHP

Nom

inal lo

adMMBtu/h

Max. o

peratin

gpressure psi

Max. p

ermissible

overpressure psi

# 2 oil

GPH

Natural gas

CFH

Liqu

idga

s LPG

CFH

Heigh

tA

Width

B

Dep

th

C

Boiler Ø

D

Flue

gas pipe Ø

E

Flue

gas (cen

ter)

F

500600

11021322

3238

1,2421,488

2116 –421

145 –464

9.4011.30

12851540

498597

78 37 63 28 10 57 2094

700850

15431874

4554

1,7402,112

2116 –421

145 –464

13.1816.00

17972182

696847

90 46 73 34 12 69 2425

10001300

22052866

6483

2,4843,231

2116 –421

145 –464

18.8324.51

25673340

9961296

100 50 84 39 14 76 3307

150018002000

330739684409

96115128

3,7294,4734,971

2116 –421

145 –464

28.2633.9137.78

385246225145

149417941995

105 54 91 43 20 80 5070

1. Universal TC steam generator2. CvE Utility Unit3. pre pressure pump4. Feed water pump5. Feed water Tank6. Blowdown vessel7. Chemical dosing8. water softening plant9. Brine Tank10. Control panel11. steam separator12. water filter

ga. Fuelsv. safety valveda. steamsl. Tank ventka. drainwa. waterkd. Condensate


8

CVE

introduction steam generators CVE Economizer Container advantages Checklist Certificates installations

F E a T U R E s s• duplex water softening plant

including automatic dosing

• Brine tank

• Feed water tank with pre-heater

• steam separator

• Blow-down vessel with automatic after cooler

• Control panel

• Blowdown heat recovery system

• pre -pressure pump

• Testomat; conductivity monitor

CERTUss Verified Equipment for Junior & Universal TCThe CVE supply unit combines all components needed to supply the steam generator in one compact body.instead of having to combine many single parts, our CvE offers all necessary add-on’s for supply andwater treatment in one. Thereby complex on-site installations are obsolete and factory-tested functionalreliability is assured.

supply Unit CVE

9

CVE Advantages

introduction steam generators CVE Economizer Container advantages Checklist Certificates installations

• all supply and water treatment com po -nents for CERTUss steam generators aresupplied as a single unit and are CERTUssverified.

• Fast, economical commissioning, ready foroperation

• Easy maintenance access

• Enhanced safety due to factory pre-installation of water, steam and electricalconnections

• less space required due to compact design

• simple on site single point installation

• Complete with electrical sub distribution

• durable galvanized base frame

• Use of approved, high quality materials

• 3d drawings available for easy design andlayout

a d v a n T a g E s s

*incl. connected load of steam generators specifications subject to be changed

Model

For SteamGenerators withsteam output

lb/h

Dimensions (inch) Connections

Height Width Depth Raw Water NPTWaste Water

NPTRinsing Water(softening) NPT

Ventilation (feedwater tank) NPT

Condensate NPT

Jun

ior 176 – 265

77 51 33 1“ 2“ 1/2“ 2“ 1 1/4“331 – 400

551 – 882

Un

iver

sal

1102 – 1322

91 67 47 1“ 2“ 1/2“4“

(dn 100)1 1/2“

1543 – 1874

2204 – 2866

3307 – 4409

Mu

ltip

le U

nit

s 2 x 176 – 265

91 87 47 1“ 2“ 1/2“ 2“ 1 1/4“2 x 331 – 400

2 x 551 – 882

2 x 1102 – 1322

1 0

CERTUSS Economizer

introduction steam generators CvE Economizer Container advantages Checklist Certificates installations

CERTUss Economizer CERTECON for Junior TC 80 – 400an innovative solution for saving energy during operation of the oil- or gas-heated CERTUss steam generatorsof the Junior 80 – 400 series.

depending on the output level, operating pressure and utilization of the steam generator, the combustion-specific degrees of thermal efficiency increases to up to 5%.

A B D

E

F

C

G

CERTECON Junior 80 – 120 150 – 200 250 – 400

A Flue gas inlet Ø internal inch 7 8 10

B Flue gas outlet Ø external inch 7 8 10

C Connecting piece distance inch 8.5 10.5 14

D Height inch 10 11 14.5

E Widht inch 23 25 29

F Water inlet / outlet NPT 1/2“ 1/2“ 3/4“

G Drain flue gas condensate 1/2“ 1/2“ 1/2“

Heat output at full load up to BHP 0.09 – 0.15 0.09 – 0.41 0.37 – 0.56

Weight without water lb 53 73 145

Water capacity gal 0.24 0.53 1.02

Operating overpressure max. psi 580 580 580

Economizer for Junior TC


1 1

CERTUSS Economizer


CERTUss Economizer CERTECON for Universal TC 500 – 2000The CERTUss Economizer increases the degree of generator efficiency and reduces CO2 emissions for generatorsystems fired by natural gas or #2 oil. as flue gas heat exchanger, it uses exhaust gas heat to increase thetemperature of the boiler feed water and reduces fuel use by up to 5% and gains efficiency up to 5%.

CERTECON Universal 500 – 600 700 – 850 1000 – 1300 1500 – 1800

A Flue gas inlet Ø internal inch 10 12 14 20

B Flue gas outlet Ø external inch 7 12 13.5 19.5

C Connecting piece distance inch 29 33.5 35.5 37

D Distance floor / connecting piece inch 14

E Height inch 48.5 52 54.5 57

F Diameter inch 31 35.5 40 43

G Water inlet / outlet NPT 1“ 1 1/4“

H Blowdown NPT 1/2“ 1“

I Dewatering flue gas condensate 3/4“

Heat output at full load up to BHP 0.6 – 0.9 1.2 – 1.5 1.8 – 2.5 2.8 – 4.4

Weight without water lb 502 705 853 974

Water capacity gal 6.31 11.39 13.63 18.91

Operating overpressure max. psi 580 580 580 580

Economizer for Universal TC

AF

E

B

G

GD

C

H


1 2

Container


F E a T U R E s s• steam generator(s)

• CvE supply unit

• softening plant

• pressure reducing station

• steam distribution header

• Blowdown vessel with automatic after cooler

• steam separator

• Condensate header

• Emergency stopswitch

• …and more

The CERTUss fully equipped container unit is our solution in case isolation from the rest of yourplant is required. it contains all components necessary to operate an entire plant.

after connecting the main services and commissioning, steam is at your disposal in less than 5minutes. The self contained unit is flexible, allowing permanent, as well as temporary positioning.

On inquiry we can take over full or partial installation of the steam system. if you choose to contract out to othercompanies, we can carry out consultation and supervision for your containerized unit.

Containerized packageplant

1 3

Container Advantages


a d v a n T a g E s s• Customizable

• space saving

• Complete installation of both mechanical andElectrical components, leaving only site serviceconnections to be made

• Fully insulated walls for protection of equipmentagainst adverse weather conditions

• High grade steel walls internally and externally

• European standard paint finish to customerspecification

• Fully insulated pipe services internally of thecontainer

• Optional steel door or UpvC door to suit customerspecification

• Full internal lighting

• Full internal heating

• Flexible for temporary or permanent locationpositioning; mobileunit

• Removes requirementfor separate boiler-house

• allows customer fullusage of valuableprocess floor space

• access space formaintenance work isfixed

• Reduced costs for siteinstallation work

1 4

All Advantages at a glance

introduction steam generators CvE Economizer Container Advantages Checklist Certificates installations

a d v a n T a g E s s• start-up time of 3-5 minutes with steam available

• Minimal floor requirement• Up to 85% thermal efficiency*

• Reduced corrosion due to vertical orientation

• low water carrier equals safe operations

• Fully automated, unmanned operationavailable

• silent operation, less than 75 dBa sound pressure

• Reduction of piping costs due to decentralized plants

• 7” Touchscreen display

• Remote access via Ethernet, Wi-Fi or GSM (Cellular)

• Remote maintenance and control possible with iPad oriPhone

• predictive maintenance: informing of potential issuesbefore they occur

• Redundancy with multiple plant solution

• mildly warm operating generator due to triplex air insulation vessel

• minimal and easy maintenance with spare parts available up to 20 years

• 24/7/365 aftersales support

• Less pollution through low waterdrainage


1 5introduction steam generators CvE Economizer Container advantages Checklist Certificates installations

Checklist

C H E C k l i s T s

1. do you want quick start-up times and steam almost instantaneously?

2. do you have a boiler constantly in hot standby mode?

3. do you want to be more environmentally friendly?

4. do you experience fluctuations in steam demand?

5. do you have limitations in space or want to use your space more efficiently?

6. do you want to operate your generator remotely without having an operator on site all thetime?

7. do you currently have an aging boiler?

8. do you face difficulties obtaining replacement and spare parts for your boiler?

9. do you experience efficiency losses due to long distances between the production and the useof steam?

10. do you prefer a point of use steam source?

11. do you have maintenance issues with your current boiler?

12. do you have confidence in the quality and reliability of your existing boiler?

if you checked 4 or more of these questions you should consider buying anew, high efficiency steam generator by CERTUSS!

1 6

Certificates


Customer Installations

Food & Beverage

Healthcare

mechanical Engineering service industry

laboratories

1 7introduction steam generators CvE Economizer Container advantages Checklist Certificates Installations

CERTUSS America L.P.The Center for Building Energy science (Building 661)

4960 south 12th street, philadelphia | pa 19112, Usa

phone: +1-215-320-0021 | www.certuss-america.com | [email protected] 28.0

01.0

2.19

98.0

3 U

s

the future of steam generation - willbanksinc.com · contents company history 1 our references 2...

Documents