Enhancing Boiler Efficiency with Electromagnetic Flow Meters in Feedwater Measurement

A large thermal power plant sought to optimize its boiler feedwater system to improve operational efficiency and energy management. The existing mechanical flow meters faced critical challenges:

• Low accuracy (±2% error), causing unstable steam production due to uneven feedwater control.

• Poor media compatibility: Feedwater contained trace minerals (conductivity ≥5μS/cm), leading to corrosion and scaling in traditional meters.

• High maintenance: Frequent downtime due to mechanical wear, impacting productivity.

Solution

After thorough evaluation, Sure Instrument's LDG-B Electromagnetic Flow Meter was deployed. Key features aligned with the plant's needs:

• Why LDG-B?

• Precision: Faraday's Law-based measurement with no moving parts ensured long-term stability.

• Corrosion resistance: PTFE liner and SS316L electrode withstood chloride ions and weak acidity in feedwater.

• Robust design: IP68 rating for high humidity/temperature environments.

• Bidirectional measurement: Enabled real-time monitoring for system diagnostics.

Installation & Integration

1. Positioning:

• Installed at the discharge end of the feedwater pump (horizontal pipeline), ensuring ≥10D upstream and ≥5D downstream straight pipe sections (per installation guidelines).

• Added 316 stainless steel grounding rings to eliminate static interference in non-conductive PPR pipes.

      2. System Connectivity:

• 4-20mA output integrated with DCS for automated feedwater control.

• Modbus RS485 communication enabled data logging on the energy management platform.

Results

• Accuracy boost: Measurement error reduced from ±2% to ±0.5%, stabilizing steam output by 30%.

• Lower OPEX: Zero mechanical wear eliminated maintenance for 2+ years, saving $10K annually.

• Enhanced reliability: IP68 and wide temperature range (-20°C to 120°C) ensured 90% fewer failures in harsh conditions.

• Sustainability: Optimized water usage saved 5,000 tons/year, reducing thermal waste.

Sure Instrument's LDG-B electromagnetic flow meter proved to be a game-changer in boiler feedwater management, delivering precision, durability, and cost efficiency. This success paves the way for broader applications in cooling cycles, steam monitoring, and beyond!