ECOTHERM Austrias Steam System Turnkey Solution

PGTECH, the representative of ECOTHERM (Austria) in Vietnam, provides a diverse range of heat transfer solutions for steam systems, hot water systems, and solar energy systems. In this article, we would like to present the complete turnkey steam system solution from ECOTHERM so you can understand it and choose the appropriate technology solution for your project.

ECOTHERM Steam Solutions

The complex topic of steam plants requires highly qualified and experienced engineering staff. As a turnkey supplier ECOTHERM is providing a whole functional, well-engineered, efficient and space saving system, including steam boilers with highly efficient and low NOx firing systems, feed water tanks and pumps with water treatment, condensate management systems, headers, armatures, piping, wiring and of course a master control panel with latest PLC technology ensuring high efficiency and safe operation of all components in the boiler-room.

For steam systems much more components are required than for hot water systems. The spectrum ranges from oil or gas burners over feed water tanks, water treatment, clean steam generators, condensate recovery systems, steam separators up to the control panel with a touch panel. Therefore ECOTHERM already plans 80 to 90 percent of all details for a system in the design stage. This ensures that the suggested time schedule really works, that the costs for the project suit the suggested budget and that the desired performance can be achieved by the system. ECOTHERM steam systems are mainly installed in hotels (e. g. for the laundry), in hospitals (especially clean steam generators for e. g. cleaning the surgical instruments) or in industry.

ECOTHERM steam systems consist of high quality components. Clean steam generators are made of high quality stainless steel. This high capacity products are manufactured at the ECOTHERM headquarters in Austria. The quality management system of ECOTHERM is certified according to ISO 9001 : 2008 for sizing, design, production and distribution of solar, hot water and steam systems as well as of pressure vessels and heat exchangers. The products are manufactured in high quality stainless steel according to the highest European standards as e. g. ISO 3834-2 and therefore guarantee long life time and perfect hygiene. ECOTHERM's test bench assures the highest quality and reliability.

Components of the ECOTHERM Steam System Solution

1. Industrial Steam Boiler (steam, hot steam, central steam)
2. Economizers / Feed Water Heaters
3. Chimneys
4. Burners
5. Feed Water Tanks
6. Blowdown Coolers & Flash Vessels
7. Water Treatment
8. Control Panels
9. Condensate Return Stations
10. Pressure Reducing Stations
11. Automatic Blowdown Systems
12. Automatic TDS Control Units
13. Level Control for Steam Boilers
14. Valves, Instruments & Accessories for steam systems
15. Steam Flow Metering
16. Feed Water Pumps
17. Steam Headers
18. Industrial Steam Separators
19. Sample Coolers

Individual Turnkey Steam Solutions

Steam systems are complex and individual. On the one hand a lot of different components have to be used. All these components need to be optimally coordinated with each other to ensure functionality and perfect efficiency right from day one. On the other hand steam systems operate with high pressures. Thus a failure can really be very dangerous for the staff operating the system as well as for the complete building.

Therefore ECOTHERM offers complete individual turnkey solutions. The services range from design, 3D visualization, project management, over manufacture, pre-assembly, pre-wiring and testing to shipping, commissioning, supervision and maintenance. Experienced ECOTHERM engineers ensure that your system operates stable, save, reaches the desired output and they train your staff how to monitor and control the most important parameters of the system. Premium quality of the products and premium service during the whole project is the minimum you should claim for your individual steam system.

Following these three stages:

• Stage 1: Design & Pre-production
• Stage 2: Production
• Stage 3: Post-production

Find the products and services included in an ECOTHERM turnkey system on the following pages.

(Pre-)Wiring

Turnkey system from ECOTHERM meet highest quality demands. Therefore the system is pre-assembled and pre-wired in the headquarters in Austria. The complete system is fully tested and approved according to European standards. After shipping the pre-wired components can be installed very quickly. Small systems usually can go into operation within a couple of days.

(Pre-)Piping

Small systems are delivered including pre-piping as a standard. For larger turnkey systems ECOTHERM offers the option to individually manufacture all necessary pipes, to pre-assemble and test the complete system including the piping in the production facility in Austria and then to ship the piping in units which can easily be mounted at construction site. The complete piping is 3d visualized with CAD design prior to manufacture. The welding is done accordining to ISO 3834-2 : 2005 certification.

Pipe Supports

Pipe shoes and supports from Sikla in Austria have become the widely recognized “state-of-the-art” in plant engineering’s pipe installations. A modular kit gives all the freedom at the installation in the plant room. You will capitalize on simplified stock logistics. Through the combination of base unit (skid) with a set, only one type is stocked and the variations can instantly be generated depending on demand. All pipe supports and pipe shoes have a safety-relevant function within an operating plant.

Vapour Heat Exchangers

The ECOTHERM vapour heat exchanger is used for:

• Pre-heating of boiler feed water
• Condensate relief
• Degasification of fresh softened water and condensate
• Flash steam heat recovery

For this process, thermal degasification, steam is used which deaerates the gases (N2 , O2 , CO2 ) out of building. Hence there is energy lost on deaerator. This “lost energy” can be used for pre-heating of cold softened water or domestic cold water.

ECOTHERM High Capacity Water Heaters

Description

High capacity water heater for steam/ water operation. External heat exchanger with patented free floating turbulator rods for increased efficiency and self cleaning effect. Perforated stainless steel safety cover. Fibre-fleece insulated hot water storage tank, upright standing. All parts in contact with water are made entirely of stainless steel AISI-316Ti / duplex. “Anti-Legio” design fully compliant with European anti-legionella recommendations.

Microprocessor controlled modulating 2 way condensate control valve on primary circuit return line, secondary circuit circulating pump, 4 temperature sensors for pre-heat start-up, heating cycle start, heating cycle stop and anti-fouling cooling cycle. Microprocessor control unit mounted on gantry with volt free output signals for boiler request and alarm. Input signal for remote operation. All components are preassembled and wired. Simple on-site assembly.

Storage tank insulation

Fibre-fleece insulation with a robust PP exterior shell, patented aluminum closure strips and patented self-fixing covering rossettes, fire protection class B2 (B1 upon request).

High Capacity Clean Steam Generators

Clean steam generators are used wherever plant steam, generated in fired steam boilers is not suitable. Due to the necessity of chemical dosing and the black material of the fired steam boilers, plant steam is not applicable for hygienic purposes. The ECOTHERM clean steam generator is entirely made of stainless steel to suit hygienic purposes like sterilizer units in hospitals or cleaning the stainless steel pipes of beverage & food industries. It is a compact, skid mounted unit ready for easy installation at site.

Standard equipment

• Clean Steam vessel made of AISI 316 Ti or duplex stainless steel
• Pressure / temperature controlled
• Steam trap set with ball float valve
• Centrifugal feed water pump
• Fully automatically control panel
• Blow down vessel, stainless steel
• Sample cooler, stainless steel
• Safety and control utilities
• Design and manufacturing according to PED 97/23/EC

Steam generation:

• by heat exchanger (plant steam / clean steam)
• by electric heating bundle

Description:

The clean steam is generated by plant steam or by electrical energy. The clean steam generator is loaded with softened and heated water (without lime, PH-neutral conductivity, 0–30 μS). This water will become clean steam. The level control guarantees an optimized level of water and causes an alarm if the water level falls below the alarm switch. The pressure of the clean steam is controlled according to the requirement by regulation valve.

A conductivity measuring unit regulates the level of minerals in the water to protect the vessel. To avoid any dirt inside the clean steam generator and to guarantee a high quality of water and a long life of the vessel is installed a blow down valve which is controlled automatically.

The blow down cooler cools the hot water of the blow down to 40°C to drain the water and to avoid burnings. The clean steam generators can be manufactured completely pre-piped and wired, mounted on a stainless steel support frame.

Smart Steam Generators (160 - 560 kg/h)

In contrast to a steam generator (with heating-coil and piston pump), the system works as follows:

• Controlled by the water level measured inside of the evaporation system, the centrifugal pump refills the feed water via the economizer.
• The burner is controlled by steam pressure.
• A multiplepass pipe transfers the burnt-gas heat through the evaporation system and to the water inside.
• Additionally, the economizer transfers residual heat from the exhaust air to the feed water stream.
• The special inner structure of the evaporation system provides best dry steam results.
• Oil or gas fired
• Vertical evaporation system
• Without coil / with centrifugal pump
• Particulary low-maintenance and energy-efficent

High energy efficiency

• Up to 97% combustion efficiency
• Condensing heating technology (More than 100% efficiency possible with optional use of second economizer)
• Minimal loss of heat in stand-by-mode
• High steam quality (little entrainment of water)
• 3- to 5-pass boiler technology

Robust and low-maintenance

• Robust pressure vessel with up to 8mm wall thickness
• Integreated maintenance-free centrifugal pump
• State-of-the-art, interchangeable standard burner
• Gentle heating procedure within 8 minutes
• Safety-related equipment exceeding the requirements of PED 97/24/EC
• Components mainly serial products of established suppliers

Easy

• Menu-driven, easy operation by full-text touchscreen
• Simple start / stop procedure by remote control, timer or manual
• Parallel management of multiple boilers possible as an option
• Operating pressure up to 11 bar(g).

Multiple Steam Boiler Plants (up to 2,240 kg/h) & Electric Clean Steam Generators for low capacities

Advantages of using ECOTHERM Austrias Steam system turnkey solution

ECOTHERM steam solutions offer premium service and high quality products with several advantages:

• Provides high efficiency
• 3D/VR design in advance
• Delivers custom-tailored solutions
• Offers premium quality
• Maximizes savings
• Easy to operate and control
• Premium after-sales service
• Training courses from the ECOTHERM Academy
• Continuous research and development for improvements
• Abundant experience and skills
• Certified and multi-certified solutions
• Experience from thousands of installations worldwide

Notable Turnkey Hot Water System Projects by Ecotherm

1. Sheikh Jaber Al-Ahmad Al-Jaber Al-Sabah Hospital – Kuwait

Since 2009 the construction of the expected largest health center in Kuwait has been running. ECOTHERM components have been installed and mounted in 2016. The hospital, which provides 1,168 beds, includes also 36 major and minor operating rooms, 4 cardiac cath labs, 4 MRI labs, 4 CT labs and the largest Trauma Centre in the whole Middle East. With these facilities Kuwait wants to offer its inhabitants the best health services, which ever existed. The overall costs of this project amount about 1.16 billion US dollars.

ECOTHERM Installations:

• Turnkey Steam System with 12 m3 Feed Water Tank
• 3x Steam Boilers, each 7,000 kg/h
• 3x Clean Steam Generators, each 4,500 kg/h
• 5x Hot Water Boilers, each 6,000 kW
• 31x High Capacity Water Heaters (Total Capacity: 6,920 kW)
• 15x Drinking Water Cooler Stations
• Installation, Supervision, Commissioning

2. King Abdullah Specialized Hospital for Children

This hospital specializes in the treatment of sick children. It is the first hospital of the kind in Saudi Arabia and has 85,000 m² of floor space. The building has a capacity of 350 beds, and makes available concentrated paediatric medical care. Each hospital ward has its own classrooms, play rooms, storage areas and other support services.

ECOTHERM supplied a turnkey facility for hot water and steam production consisting of:

• 5x Steam boilers (6.820 kg/hour, 12 bar)
• 1x Feed storage water tank (25,200 litres)
• 4x Clean steam generator (3,550 kg/h at 10 bar)
• 11x High-performance stainless steel instantaneous water heaters

Conclusion

With the long-standing experience of its leadership team and a commitment to passion in every product, ECOTHERM has affirmed its position as a leading brand for customized hot water, steam, and solar energy systems for hotels and hospitals, as well as for commercial & industrial applications. With distributors in over 50 countries, thousands of references, and premium quality and support, ECOTHERM is always a preferred partner. ECOTHERM develops, designs, manufactures, and supplies stainless steel components such as commercial high-capacity hot water tanks, heat exchangers, industrial hot water storage tanks, industrial boilers, insulation materials, as well as providing all-in-one, energy- and space-saving services for hot water, steam, and solar energy systems—"turnkey solutions."

 

PGTECH GROUP LIMITED – Authorized Distributor of HVAC System Products in Vietnam and Regional Markets

News Editorial Board: PGTECH

Engineer: Tuan Quang

PGTECH GROUP LIMITED

Business Office: 3rd Floor, Bac Ha Building C14-CT1, To Huu Street, Dai Mo Ward, Hanoi City, Vietnam

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