Custom gas flow meter factory for industry

A large-scale thermal power plant, in response to the national Emission Standard of Air Pollutants for Thermal Power Plants (GB 13223-2011), has launched an ultra-low emission retrofit project for its 2×660MW units. The goal is to achieve real-time monitoring and data reporting of pollutants such as SO₂, NOx, and particulate matter. The focus of this project is to upgrade the flue gas flow monitoring unit. The traditional differential pressure instruments were replaced with the SURE Vortex Flow Meter LUGB-A Series to address the measurement challenges in high-dust and wide-temperature-variation conditions, meeting the regulatory requirements of the Ministry of Ecology and Environment for "installation, display, and connectivity".Operating Conditions1. High Temperature and Thermal ShockThe flue gas temperature in the primary air duct reaches up to 400°C (with an instantaneous peak of 450°C), and there are severe temperature fluctuations during start-up and shutdown phases.2. Dust InterferenceThe flue gas contains dust with a concentration of ≤1000mg/m³ and a wide particle size distribution (0.1-100μm), which can easily cause instrument wear and signal distortion.3. Wide Flow Rate RangeDuring load adjustment, the flow rate varies rapidly from 15m/s to 50m/s, requiring a turndown ratio of ≥33:1.4. Low Pressure MeasurementThe flue operates under negative pressure (-70mbar), necessitating high sensitivity for signal capture.5. Data ComplianceThe flow measurement accuracy must reach ±0.5%, and support hourly average exceedance warnings in accordance with the HJ 75-2017 standard.SURE Vortex Flow Meter LUGB-A Series Technical Solution1. High Temperature and Structural ReinforcementMaterial and Heat ResistanceThe LUGB-A Series features a high-temperature design with a vortex generator made of SS316L stainless steel. The sensor is encapsulated in an insulated chamber for heat dissipation, supporting long-term operation at temperatures ranging from -40°C to +420°C.Vibration ResistanceThe fully welded structure has passed a 10g vibration test (IEC 60068-2-6), making it suitable for the shock during boiler start-up and shutdown.2. Adaptation to Dusty EnvironmentsNo Moving Parts DesignThe absence of mechanical moving parts eliminates the risk of dust jamming.Redundant Signal ProcessingThe digital filter amplifier automatically filters out noise signals caused by particle collisions.Blow-off InterfaceA reserved compressed air blow-off interface (custom option) is available for DCS-triggered timed cleaning.3. Wide Turndown Ratio and Low Pressure MeasurementWide Turndown RatioThe turndown ratio reaches 33:1, covering flow rates from 0.5m/s to 60m/s.Low Pressure Loss DesignThe optimized vortex generator shape results in a pressure loss of less than 0.5kPa (one-third of the traditional Venturi tube).Multi-parameter CompensationThe built-in temperature and pressure sensors (T&P compensation model) convert actual flow to standard dry flue gas flow in real-time with an accuracy of ±0.5%.4. System Integration and ComplianceData OutputSupports 4-20mA + HART V7.0, which can be connected to the CEMS control computer.CertificationsCertified with CE, SIL2, and Exd II CT6 Gb explosion-proof certification, meeting the data validity review requirements of HJ 75-2017.Implementation ResultsMeasurement AccuracyAt a typical flow rate of 30m/s, the comparison error with the reference method (grid method) is ≤0.5% (accuracy of the A Series).Reliability ImprovementZero failures in a 2-year operation cycle, with maintenance costs reduced by 60% compared to the original system.Emission ControlFlow data supports the calculation of SO₂/NOx emissions, helping the power plant reduce pollutant emission intensity to 15mg/m³ (better than the national standard of 35mg/m³).Regulatory ComplianceCEMS data is directly connected to the provincial ecological cloud platform, with no exceedance warnings in the past 12 months.Features1. High Temperature AdaptabilityThe +420°C temperature resistance covers the full load conditions of coal-fired units (according to the T4 code).2. Economic OptimizationThe wide turndown ratio (33:1) reduces redundant instrument configurations, lowering overall costs by 40%.3. Support for Carbon Neutrality StrategyAccurate emission data provides a reliable basis for carbon quota trading.    

A large-scale thermal power plant, in response to the national Emission Standard of Air Pollutants for Thermal Power Plants (GB 13223-2011), has launched an ultra-low emission retrofit project for its 2×660MW units. The goal is to achieve real-time monitoring and data reporting of pollutants such as SO₂, NOx, and particulate matter. The focus of this project is to upgrade the flue gas flow monitoring unit. The traditional differential pressure instruments were replaced with the SURE Vortex Flow Meter LUGB-A Series to address the measurement challenges in high-dust and wide-temperature-variation conditions, meeting the regulatory requirements of the Ministry of Ecology and Environment for "installation, display, and connectivity".Operating Conditions1. High Temperature and Thermal ShockThe flue gas temperature in the primary air duct reaches up to 400°C (with an instantaneous peak of 450°C), and there are severe temperature fluctuations during start-up and shutdown phases.2. Dust InterferenceThe flue gas contains dust with a concentration of ≤1000mg/m³ and a wide particle size distribution (0.1-100μm), which can easily cause instrument wear and signal distortion.3. Wide Flow Rate RangeDuring load adjustment, the flow rate varies rapidly from 15m/s to 50m/s, requiring a turndown ratio of ≥33:1.4. Low Pressure MeasurementThe flue operates under negative pressure (-70mbar), necessitating high sensitivity for signal capture.5. Data ComplianceThe flow measurement accuracy must reach ±0.5%, and support hourly average exceedance warnings in accordance with the HJ 75-2017 standard.SURE Vortex Flow Meter LUGB-A Series Technical Solution1. High Temperature and Structural ReinforcementMaterial and Heat ResistanceThe LUGB-A Series features a high-temperature design with a vortex generator made of SS316L stainless steel. The sensor is encapsulated in an insulated chamber for heat dissipation, supporting long-term operation at temperatures ranging from -40°C to +420°C.Vibration ResistanceThe fully welded structure has passed a 10g vibration test (IEC 60068-2-6), making it suitable for the shock during boiler start-up and shutdown.2. Adaptation to Dusty EnvironmentsNo Moving Parts DesignThe absence of mechanical moving parts eliminates the risk of dust jamming.Redundant Signal ProcessingThe digital filter amplifier automatically filters out noise signals caused by particle collisions.Blow-off InterfaceA reserved compressed air blow-off interface (custom option) is available for DCS-triggered timed cleaning.3. Wide Turndown Ratio and Low Pressure MeasurementWide Turndown RatioThe turndown ratio reaches 33:1, covering flow rates from 0.5m/s to 60m/s.Low Pressure Loss DesignThe optimized vortex generator shape results in a pressure loss of less than 0.5kPa (one-third of the traditional Venturi tube).Multi-parameter CompensationThe built-in temperature and pressure sensors (T&P compensation model) convert actual flow to standard dry flue gas flow in real-time with an accuracy of ±0.5%.4. System Integration and ComplianceData OutputSupports 4-20mA + HART V7.0, which can be connected to the CEMS control computer.CertificationsCertified with CE, SIL2, and Exd II CT6 Gb explosion-proof certification, meeting the data validity review requirements of HJ 75-2017.Implementation ResultsMeasurement AccuracyAt a typical flow rate of 30m/s, the comparison error with the reference method (grid method) is ≤0.5% (accuracy of the A Series).Reliability ImprovementZero failures in a 2-year operation cycle, with maintenance costs reduced by 60% compared to the original system.Emission ControlFlow data supports the calculation of SO₂/NOx emissions, helping the power plant reduce pollutant emission intensity to 15mg/m³ (better than the national standard of 35mg/m³).Regulatory ComplianceCEMS data is directly connected to the provincial ecological cloud platform, with no exceedance warnings in the past 12 months.Features1. High Temperature AdaptabilityThe +420°C temperature resistance covers the full load conditions of coal-fired units (according to the T4 code).2. Economic OptimizationThe wide turndown ratio (33:1) reduces redundant instrument configurations, lowering overall costs by 40%.3. Support for Carbon Neutrality StrategyAccurate emission data provides a reliable basis for carbon quota trading.    

A large-scale thermal power plant, in response to the national Emission Standard of Air Pollutants for Thermal Power Plants (GB 13223-2011), has launched an ultra-low emission retrofit project for its 2×660MW units. The goal is to achieve real-time monitoring and data reporting of pollutants such as SO₂, NOx, and particulate matter. The focus of this project is to upgrade the flue gas flow monitoring unit. The traditional differential pressure instruments were replaced with the SURE Vortex Flow Meter LUGB-A Series to address the measurement challenges in high-dust and wide-temperature-variation conditions, meeting the regulatory requirements of the Ministry of Ecology and Environment for "installation, display, and connectivity".Operating Conditions1. High Temperature and Thermal ShockThe flue gas temperature in the primary air duct reaches up to 400°C (with an instantaneous peak of 450°C), and there are severe temperature fluctuations during start-up and shutdown phases.2. Dust InterferenceThe flue gas contains dust with a concentration of ≤1000mg/m³ and a wide particle size distribution (0.1-100μm), which can easily cause instrument wear and signal distortion.3. Wide Flow Rate RangeDuring load adjustment, the flow rate varies rapidly from 15m/s to 50m/s, requiring a turndown ratio of ≥33:1.4. Low Pressure MeasurementThe flue operates under negative pressure (-70mbar), necessitating high sensitivity for signal capture.5. Data ComplianceThe flow measurement accuracy must reach ±0.5%, and support hourly average exceedance warnings in accordance with the HJ 75-2017 standard.SURE Vortex Flow Meter LUGB-A Series Technical Solution1. High Temperature and Structural ReinforcementMaterial and Heat ResistanceThe LUGB-A Series features a high-temperature design with a vortex generator made of SS316L stainless steel. The sensor is encapsulated in an insulated chamber for heat dissipation, supporting long-term operation at temperatures ranging from -40°C to +420°C.Vibration ResistanceThe fully welded structure has passed a 10g vibration test (IEC 60068-2-6), making it suitable for the shock during boiler start-up and shutdown.2. Adaptation to Dusty EnvironmentsNo Moving Parts DesignThe absence of mechanical moving parts eliminates the risk of dust jamming.Redundant Signal ProcessingThe digital filter amplifier automatically filters out noise signals caused by particle collisions.Blow-off InterfaceA reserved compressed air blow-off interface (custom option) is available for DCS-triggered timed cleaning.3. Wide Turndown Ratio and Low Pressure MeasurementWide Turndown RatioThe turndown ratio reaches 33:1, covering flow rates from 0.5m/s to 60m/s.Low Pressure Loss DesignThe optimized vortex generator shape results in a pressure loss of less than 0.5kPa (one-third of the traditional Venturi tube).Multi-parameter CompensationThe built-in temperature and pressure sensors (T&P compensation model) convert actual flow to standard dry flue gas flow in real-time with an accuracy of ±0.5%.4. System Integration and ComplianceData OutputSupports 4-20mA + HART V7.0, which can be connected to the CEMS control computer.CertificationsCertified with CE, SIL2, and Exd II CT6 Gb explosion-proof certification, meeting the data validity review requirements of HJ 75-2017.Implementation ResultsMeasurement AccuracyAt a typical flow rate of 30m/s, the comparison error with the reference method (grid method) is ≤0.5% (accuracy of the A Series).Reliability ImprovementZero failures in a 2-year operation cycle, with maintenance costs reduced by 60% compared to the original system.Emission ControlFlow data supports the calculation of SO₂/NOx emissions, helping the power plant reduce pollutant emission intensity to 15mg/m³ (better than the national standard of 35mg/m³).Regulatory ComplianceCEMS data is directly connected to the provincial ecological cloud platform, with no exceedance warnings in the past 12 months.Features1. High Temperature AdaptabilityThe +420°C temperature resistance covers the full load conditions of coal-fired units (according to the T4 code).2. Economic OptimizationThe wide turndown ratio (33:1) reduces redundant instrument configurations, lowering overall costs by 40%.3. Support for Carbon Neutrality StrategyAccurate emission data provides a reliable basis for carbon quota trading.    

There is a leading domestic manufacturer of new energy materials in China, specializing in the research and development and production of nickel cobalt manganese (NCM) lithium battery precursors and cathode materials. With the rapid growth of the new energy vehicle market, the company urgently needed to enhance the automation level of its production lines to ensure precise measurement of parameters such as medium flow rate, liquid level, and pressure during the production process, thereby improving product quality and production efficiency.Project Requirements1. Precision Measurement Needs: The production of lithium battery materials involves highly corrosive media such as nickel sulfate and cobalt sulfate, requiring flow meters with high precision and corrosion resistance.2. Multi-Scenario Adaptability: The production line covers complex process links such as batching, reaction, and centrifugal washing, necessitating a variety of instruments to match different media (liquids, gases, steam).3. Quick Delivery and After-Sales Service: The project schedule was tight, demanding that the supplier have the capability for rapid delivery and timely technical support.SolutionSure Instrument designed a comprehensive solution for the complex conditions of the customer's production line, focusing on technical adaptability, environmental tolerance, and system integration, as follows:1. Electromagnetic Flow Meter (LDG Series) - Precision Measurement of Corrosive MediaTechnical Adaptability:PTFE Lining and Hastelloy C276 Electrodes: The use of PTFE lining and Hastelloy C276 electrodes ensures resistance to highly corrosive liquids such as nickel sulfate and cobalt sulfate (pH value ≤2), preventing measurement deviations caused by electrode corrosion.Dual-Frequency Excitation Technology: By alternating high and low-frequency excitation, this technology suppresses slurry noise interference, allowing stable output even at low flow rates of 0.3 m/s, with a precision of 0.2 grade, ensuring that the batching ratio error is ≤0.3%.Configuration Options:Integral Threaded Connection Type: Suitable for feed pipes of small reactors (DN15~DN50) with compact installation space.Split Insertion Type: Designed for large liquid storage tanks (DN300~DN1200), supporting remote display and control.2. Liquid Turbine Flow Meter (LWGY Series) - Quantitative Control of High-Pressure Pure Water and Liquid AlkaliEnvironmental Tolerance:High-Pressure Clamp Design: The sensor's no-opening structure can withstand pressures up to 42 MPa, matching high-pressure liquid alkali conveying pipelines (DN25~DN100) and eliminating leakage risks.Sanitary 316L Stainless Steel Material: Used in pure water circulation systems, it meets GMP cleanliness standards, preventing medium contamination.Functional Advantages:Pulse Frequency Signal Output: Linked with the customer's PLC system, it enables automatic quantitative injection (e.g., pure water addition within ±0.5L), enhancing batch consistency.High Repeatability of 0.02%: Long-term operation without drift, reducing calibration frequency and lowering annual maintenance costs by 25%.3. Steam Vortex Flow Meter (LUGB Series) - High-Temperature Steam Flow MonitoringHigh-Temperature and Anti-Vibration Design:Temperature and Pressure Flange Structure: Made of high-temperature alloy materials (withstanding up to 350℃), it matches steam heating pipelines for reactors (DN50~DN200) and withstands saturated steam pressure of 1.6 MPa.Anti-Vibration Software Algorithm: The digital chip filters mechanical vibration signals in real-time (with anti-vibration capability up to 1.0g), preventing measurement fluctuations caused by production line vibrations.Precision Measurement:Standard Nozzle Design: Extends the lower flow rate limit to 2.5 m/s, covering low-load steam conditions, with a precision of 1.0 grade and steam usage statistics error of ≤1.5%.4. Pressure Transmitter - Full-Process Pressure MonitoringMulti-Scenario Adaptability:Diffused Silicon Sensor: With a precision of 0.1%, it is used for absolute pressure monitoring of reactors (010 MPa) and pipeline gauge pressure control (-0.12.5 MPa), with real-time feedback to the DCS system.Explosion-Proof Design (Ex d IIC T6): Suitable for flammable gas environments (e.g., ammonia pipelines), certified by ATEX to ensure safe production.Intelligent Functions:HART Protocol Communication: Supports remote parameter adjustment and fault diagnosis, reducing manual inspection frequency by 30%.5. System Integration and Auxiliary InstrumentsRadar Level Meter:80GHz High-Frequency Millimeter-Wave Radar: With a blind zone of only 0.05m, it accurately monitors liquid levels in storage tanks (precision ±2mm), preventing overflow or empty tank risks.pH Meter:Membrane-Free Three-Electrode Method: Online monitoring of reactor pH values (range 0~14) with a precision of ±0.02pH, linked to the dosing system via a 4-20mA signal to ensure stable reaction processes.Data Interoperability:RS485/Modbus Protocol: All instrument data is integrated into the customer's central control platform, enabling full-process production visualization and abnormal alarm response in less than 1 second.Highlights of the SolutionCustomized Selection: Matching different materials and models for corrosive, high-temperature, and high-pressure scenarios, extending equipment life to over 8 years.Quick Delivery: Leveraging the automated production line in Qingxian Base (with a weekly capacity of 2,000 units), 300 instruments were delivered within 3 days to meet the urgent project needs.Achievements and BenefitsPrecision Improvement: Flow measurement error ≤0.5%, significantly improving production batching consistency and increasing product pass rate by 15%.Efficiency Optimization: Automated instruments reduce manual intervention, enhancing overall production line efficiency by 20%.Cost Savings: Corrosion-resistant design extends instrument life, reducing maintenance costs by 30%.Project Expansion: Building on the successful experience of the first phase, Sure Instrument consecutively won bids for the second and third phases, delivering a total of 350 electromagnetic flow meters and 180 liquid turbine flow meters.Sure Instrument's Core AdvantagesTechnical Leadership: Patent technologies + in-house R&D laboratory to ensure product adaptability to complex industrial scenarios.Intelligent Manufacturing: Annual production capacity of 100,000 instruments, supporting rapid customization and bulk delivery.