Application Case of Remote-Type Vortex Flow Meter in Steam Measurement Systems of Chemical Plants

A large-scale chemical enterprise required precise measurement of its steam network to optimize energy management and control production costs. The steam network spans multiple workshops, with main pipeline temperatures reaching up to 220°C. Some pipelines are located in elevated or confined spaces, where traditional integrated flow meters faced challenges due to inconvenient installation, insufficient temperature resistance of electronic components, leading to significant data discrepancies and maintenance difficulties. The company urgently needed a high-precision, high-temperature resistant, and flexibly installable steam flow measurement solution.

Issues and Challenges

• Poor stability in high-temperature environments: The electronic components of integrated flow meters are prone to aging and failure when exposed to high-temperature steam over long periods.

• Limited installation conditions: Elevated pipelines and confined spaces make it difficult to meet the straight pipe segment and operational space requirements of traditional flow meters.

• Large data fluctuations: Variations in steam humidity and pressure lead to measurement errors, affecting the accuracy of cost accounting.

• High maintenance costs: Frequent disassembly and maintenance of integrated instruments affect the continuity of production.

Solution: Split-Type Vortex Flow Meter

To address the above issues, the technical team selected a remote type vortex flow meter, with core advantages including:

• Split design: The sensor and signal converter are separated, with the sensor installed directly on the high-temperature pipeline and the converter placed on the ground or in the control room, preventing damage to electronic components from high temperatures.

• High-temperature resistance: The sensor is made of 316L stainless steel, with a temperature tolerance range of -40°C to 350°C.

• Anti-vibration interference: Built-in digital filtering technology effectively eliminates the impact of pipeline vibration on vortex signals.

• Flexible installation: Supports horizontal, vertical, and inclined installations in various directions,  adapting to complex conditions.

• Remote data transmission: Equipped with 4-20mA/HART output, integrated into the plant's DCS system for real-time monitoring and historical data analysis.

• Check the detail: Oem Air Flow Meter Manufacturer, Steam Vortex Flow Meter | Sure

Implementation Process

• Site survey: Conducted thermodynamic calculations on the steam network to determine the flow range and selected a DN200 diameter flow meter.

• Custom installation bracket: Designed an adjustable bracket for elevated pipelines to ensure stable sensor installation, with the converter connected to the control cabinet via a 10-meter dedicated cable.

• Humidity compensation calibration: Adjusted the flow meter parameters based on steam dryness (85%~90%) to reduce measurement errors caused by two-phase flow.

• System integration: Connected flow data to the enterprise's energy management platform to achieve statistical functions for steam consumption by workshop and threshold alert feature.

Application Effects

• Improved accuracy: Measurement error reduced from ±3% to ±1.5%, with an annual reduction in steam loss of about 800 tons, saving costs of over 500,000 yuan.

• Convenient maintenance: Remote adjustment and fault diagnosis of the converter reduced maintenance frequency by 70%, avoiding downtime losses.

• Data transparency: Real-time monitoring of peak steam usage in each workshop, optimizing boiler load distribution, and increasing steam utilization by 12%.

• Long-term stability: Operated for 18 months without failure, with customer feedback stating, "It completely solved the measurement pain point in high-temperature environments."

The remote type vortex flow meter, through its "high-temperature separation design + intelligent signal processing," has overcome the stubborn problems in chemical steam measurement, providing a cost-effective solution for high-parameter fluid measurement, helping enterprises achieve:

• Accurate energy auditing

• Cost reduction and efficiency enhancement

• Intelligent upgrading