Precision Steam & Feedwater Measurement in Boiler Systems with Electromagnetic & Vortex Flow Meters

A chemical plant aimed to optimize boiler efficiency by upgrading its steam and feedwater measurement systems. Key challenges included:

• High steam measurement errors (±3%) due to extreme conditions (1.6MPa, 204°C).

• Unstable feedwater control caused by scaling and corrosion in traditional meters.

• Excessive maintenance costs from vibration-induced mechanical wear.

Integrated Solution

Tianjin Sure Instrument's dual-technology approach addressed both steam and feedwater needs:

    1. Steam Measurement: LUGB Vortex Flow Meter (T&P compensation):

• Key Features:

• High-temperature resilience: Withstands up to 420°C and 4MPa pressure.

• Density compensation: Integrated sensors for real-time adjustments, achieving ±0.5% accuracy.

• Vibration resistance: No moving parts + IP67 rating for harsh environments.

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

    2. Feedwater Measurement: LDG-B Electromagnetic Flow Meter (DN80, PTFE liner, Hastelloy electrode):

• Key Features:

• Corrosion resistance: PTFE and Hastelloy combat chlorides (≤200ppm) and alkaline media.

• Ultra-high precision: Faraday's Law-based measurement with ±0.2% accuracy.

• Bidirectional monitoring: Detects backflow for data integrity.

• Check the detail: Electromagnetic Flow Meter Manufacturer, Seawater Flow Meter

Installation & Integration

1. Steam Pipeline (Vortex Meter):

• Installed 20D upstream of pump discharge (horizontal section) with ANSI 300# flanges and Monel grounding rings.

• HART + 4-20mA output linked to PLC for real-time steam heat value calculation.

2. Feedwater Line (Electromagnetic Meter):

• Mounted vertically at tank outlet with full-pipe design, IP68-rated for humid conditions.

• Modbus RS485 integration enabled auto-adjustment via DCS.

3. System Synergy:

• Vortex data optimized steam generation; electromagnetic feedback balanced feedwater supply.

Results

• Accuracy leap:

• Steam error reduced to ±0.7%, saving 8,000 tons/year in losses.

• Feedwater error cut to ±0.2%, boosting boiler efficiency by 12%.

• Cost savings:

• Zero mechanical wear slashed maintenance costs by 60% ($120K/year saved).

• Self-diagnostic features halved troubleshooting time.

• Sustainability wins:

• Dynamic system adjustments lowered annual energy consumption by 15%.

• Precise carbon tracking reduced CO₂ emissions by 2,500 tons/year.

By combining electromagnetic and vortex flow meters, Tianjin Sure Instrument delivered a holistic measurement solution:

• Vortex technology mastered high-pressure steam challenges.

• Electromagnetic precision ensured corrosion-resistant feedwater control.

This synergy paves the way for smarter energy management in heat recovery, condensate monitoring, and beyond!