Gas Turbine Flow Meter in New Energy Vehicle Production Combustion Units

In the quest to expand production capabilities, a leading new energy vehicle (NEV) manufacturer faced significant challenges in the paint shop's drying process. The combustion units used for drying vehicle bodies required precise control of gas flow to ensure efficient and safe operation. However, traditional gas flow monitoring methods were plagued by inaccuracies and slow response times, leading to excessive energy consumption, inconsistent product quality, and potential safety hazards.

Problem Analysis

1. Inaccurate Measurement: Traditional flow meters exhibited significant errors in measuring gas flow, resulting in unstable combustion efficiency and compromised drying quality.

2. High Energy Consumption: The inability to precisely control gas flow led to unnecessary gas waste, increasing production costs.

3. Safety Risks: Inaccurate gas flow monitoring could cause gas leaks or incomplete combustion, posing serious safety risks.

4. Inefficient Data Management: Traditional monitoring methods lacked automated data collection and remote monitoring capabilities, making it difficult to optimize production processes and prevent failures.

Solution

To address these challenges, the NEV manufacturer adopted the Sure Instrument LWQ Series Gas Turbine Flow Meter, a high-precision solution for monitoring gas supply in combustion units. The key features of the LWQ Series include:

1. High Precision Measurement: The LWQ Series flow meters offer an accuracy of ±1.0%, ensuring stable combustion efficiency and product quality.

2. Fast Response: With rapid response capabilities, the flow meters can adjust in real-time to changes in gas flow, optimizing the combustion process.

3. Energy Efficiency and Environmental Benefits: By precisely controlling gas flow, the flow meters reduce gas consumption and minimize exhaust emissions, aligning with environmental standards.

4. Automated Data Management: Integration with the factory's intelligent monitoring system enables automated data collection, real-time analysis, and remote monitoring, facilitating production optimization and preventive maintenance.

5. Wide Rangeability: The LWQ Series flow meters have a wide measurement range, such as the DN100 model covering 20-400 m³/h, accommodating significant gas flow fluctuations during production.

6. Low Pressure Loss: Designed for minimal pressure loss (e.g., 1.0 kPa for DN100 at maximum flow), the flow meters enhance energy efficiency and reduce operational costs.

Implementation Process

1. Equipment Selection and Installation: The DN100 model was chosen for its suitability to the gas flow requirements of the combustion units. The flow meter was carefully installed to ensure proper alignment with the gas pipeline, minimizing measurement errors.

2. System Integration: The flow meter was seamlessly integrated with the factory's intelligent monitoring system via an RS485 communication interface, enabling real-time data transmission and remote monitoring. The flow meter's temperature and pressure compensation features ensured accurate measurements under varying conditions.

3. Commissioning and Optimization: After installation, the flow meter was calibrated to ensure accurate data. The gas supply to the combustion units was optimized based on real-time flow data, enhancing combustion efficiency.

4. Personnel Training: Factory operators were trained on the operation and maintenance of the flow meters, ensuring smooth and reliable operation.

Results

1. Significant Energy Savings: The introduction of the LWQ Series flow meters reduced gas consumption by 20%, saving approximately $500,000 in annual gas costs. The low pressure loss design of the flow meters further enhanced energy efficiency.

2. Improved Quality: Precise gas flow control stabilized the drying process, increasing the first-pass quality rate from 90% to 95%.

3. Enhanced Safety: The flow meters' high precision and fast response capabilities minimized the risk of gas leaks and incomplete combustion, significantly improving production safety.

4. Optimized Data Management: Integration with the intelligent monitoring system enabled real-time data access and remote adjustments, reducing failure rates by 30% and enhancing production management efficiency.

The adoption of the Sure Instrument LWQ Series Gas Turbine Flow Meter has transformed the combustion unit operations at the NEV manufacturing plant. By delivering precise gas flow control, the flow meters have enhanced production efficiency, reduced energy consumption, and improved safety. The integration with automated data management systems has also supported the plant's digital transformation. As the NEV industry continues to grow, the application of advanced flow metering technology will play a crucial role in achieving sustainable and efficient production processes.