Energy Use Cases
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Coal Power
Absorber
Energy
The lime milk sprayed into the flue gas desulphurization system collects at the bottom of the absorber. The level has to be monitored to ensure that the absorber pumps do not run dry.
Absorber pump
Energy
Before the flue gas enters the absorber (scrubbing tower), its pollutant content (sulphur) is measured. If the degree of pollution of the flue gas requires it, the absorber pumps are switched on and a quantity of lime milk corresponding to the pollutant content is blown in. To monitor the absorber pumps, pressure transmitters are installed in the pipelines immediately upstream and downstream of the pumps.
Adipic acid mixing tank
Energy
Adding adipic acid to the lime milk increases the effectiveness of the desulfurization process in the absorber. This is done by mixing adipic powder with water in the mixing tank. This acid lowers operating costs because it reduces the amount of lime milk required. Various measurement systems ensure optimal control of the mixing ratio.
Ammonia feed tank
Energy
To protect the environment, the nitrogen oxide content in the flue gas is reduced as much as possible. This is accomplished by adding air and ammonia to the flue gas. Through a chemical reaction, the nitrogen oxides (NOx) are transformed into water and nitrogen. The required ammonia (NH3) is supplied from feed tanks. Level measurement in the feed tank ensures a reliable process.
Belt transfer station
Energy
In a coal power plant, either hard coal or brown coal is burned as the main fuel source. The coal is transported on conveyor belts to the furnace. To avoid backup or overfilling at the belt transfer stations, level controls are necessary. Because only a reliable level measurement at these belt transfer stations can ensure uninterrupted feeding of the furnaces with coal. Additional point level detectors are installed to prevent overfilling.
Coal stockpile
Energy
After being unloaded from rail cars or ships, the coal is stored in stockpiles. Here, reliable measuring systems that function properly in any kind of weather are essential for level monitoring and belt positioning.
Coal surge bin I
Energy
In a typical coal power plant, lignite (soft coal) and anthracite (hard coal) are stored temporarily in bins up to 15 meters high. To ensure that the coal belts are continuously loaded without interruption, a robust and reliable level measuring system is required. Additional point level detectors are used to prevent any overfilling of the bins.
Coal surge bin II
Energy
In a typical coal power plant, lignite (soft coal) and anthracite (hard coal) are stored temporarily in bins up to 30 meters high. To ensure that the coal belts are continuously loaded without interruption, a robust and reliable level measuring system is required. Additional point level detectors are used to prevent any overfilling of the bins.
Combustion air pipe
Energy
To ensure an optimum combustion process in a coal-fired power plant, the amount of air flowing in the pipes leading to the furnace must be carefully monitored. A Venturi section of the air pipe is a defined constriction in which the pressure drops a few millibars proportional to flow rate. Differential pressure transmitter measures the pressure drop across the measuring section very accurately and calculates the air flow rate.
Conveyor belts for coal
Energy
For optimal quantity measurement of the coal being conveyed to the power plant or to the individual boilers, a continuous flow of material must be ensured. Throughput measurement on the conveyor belts accurately determines the amount of coal transported.
Cooling tower basin
Energy
At the bottom of the cooling tower there are nozzles for atomizing and cooling incoming hot water. As the heated water is sprayed up inside the cooling tower, it warms the air, which expands, flows upward creating updraft which pulls fresh cold air up through the slatted bottom. Draft eliminators inside the cooling tower cause the cooled water to form droplets and rain back down into the cooling tower basin. The water level in the cooling tower basin must be monitored continuously to optimise use of the circulation pumps and the cooling process.
Cooling water intake
Energy
Coal fired power stations use huge amounts of cooling water. This water is usually taken from rivers, with the help of specially built intake structures. At these extraction points, reliable level measurement in all weathers and surface conditions is needed to ensure an ample supply of cooling water for the operation of the plant.
Cooling water pumps
Energy
A considerable amount of cooling water is required for a coal power plant. Large, powerful pumps are needed to keep the huge quantities of water circulating. Robust and adjustment-free sensors ensure that the pumps never run dry.
Feed belt to the coal mill
Energy
To fuel the power plant boilers, chain conveyors must first bring raw coal from the bunkers. Feed belts (distributors) then transport the coal to the coal mill, where it is ground into dust and blown into the boiler. In order to ensure the fuel supply to the boiler in periods of full load, and especially low load, three redundant measuring systems are employed per feed belt.
Fly ash silo, ash bunker
Energy
The burning of coal creates huge quantities of ash. It is collected in a silo or bunker and then dumped into an open pit. To determine the filling height, radar transmitters and level detectors are deployed in the respective vessels.
Fuel oil storage tanks
Energy
To start up the combustion process in a coal power plant, fuel oil is required. Then later the plant switches over to its proper fuel, coal. The fuel oil is stored in large storage tanks equipped with state-of-the-art level measurement technology.
Heating condenser
Energy
In the heating condenser, steam is used to provide energy for a district heating network. The outgoing temperature of the heating water is controlled by the prevailing weather conditions. As part of this system, level sensor mounted in a bypass tube measures level of the condensate.
Level measurement in the raw water basin
Energy
The raw water facility, is extracted mostly from rivers, it is conditioned for use in the steam and condensate loops. Reliable level measurement in the raw water basin ensures that there is always an adequate supply of water.
Lime milk pipeline
Energy
The flue gas enters the scrubbing tower (absorber) and cools down further. Here the lime milk (gypsum suspension) is sprayed into the flue gas to wash out the SO2 gas component. The sulphur dioxide is converted into calcium sulphite, which then falls into the absorber sump. To ensure effective flue gas desulfurization, the lime milk (gypsum suspension) must always have a certain density. Radiation-based measurement is used to ensure this.
Lime milk storage tank
Energy
The sulphur in the flue gas is chemically bound by injecting lime milk into the scrubbing tower. To ensure that there is always enough lime milk available for the scrubbing tower, sensors are required to regulate the level and reliably prevent an overfilling of the tank.
Lime silo I
Energy
For flue gas desulfurization a continuous production of the lime milk is required, the lime is kept on hand in sufficient quantities in large silos. Lime tends to readily adhere to more or less anything, depending on its type and consistency, interfering with equipment like the operation of instruments. A robust, non-susceptible level measurement is therefore absolutely necessary for reliable lime logistics and stocking. That’s why a non-contact measuring instrument that also works well in the very dusty environment is essential here.
Lime silo II
Energy
For flue gas desulfurization a continuous production of the lime milk is required, the lime is kept on hand in sufficient quantities in large silos. Lime tends to readily adhere to more or less anything, depending on its type and consistency, interfering with equipment like the operation of instruments. A robust, non-susceptible level measurement is therefore absolutely necessary for reliable lime logistics and stocking. That’s why a non-contact measuring instrument that also works well in the very dusty environment is essential here.
Oil feed tank
Energy
Turbines are highly complex systems in which lubricating oil plays an important role. The oil is used to ensure proper operation, to reduce maintenance costs to a minimum and to prevent turbine failure. Turbine oils are produced from high quality mineral oils that have special properties to reduce demulsification (separation of water) and air release. The level in the feed tank must be monitored to ensure that there is always enough oil available for lubrication.
Receiving tank for feed water
Energy
The process water, which is usually extracted from a river, cannot be fed directly into the turbine loop until it has been treated. It has to undergo cleansing through filtering systems and ionizers. The raw water has contaminants that can cause long-term buildup. Level detectors need to work reliably to protect against overfilling the tank or dry running of the pump.
Reversing conveyor
Energy
The gypsum extracted from the exhaust gases in the flue gas desulphurisation unit is transported by conveyor belts to the wet gypsum storage hall. The stockpile loading is carried out by a reversing conveyor, which is able to, when a desired filling height is reached, traverse forward or back to another discharge position. For safety reasons, there are two redundant radar sensors at the end of the reverse conveyor belt to monitor the stockpile filling height during discharge.
Silo for filter dust
Energy
In power plants, the flue gases are cleaned in several ways. One of them is electrostatic filtering, which efficiently extracts large amounts of dust from the gases. This material is collected in a silo and further processed. Level measuring instruments and level detectors are used to monitor the silo.
Steam drum
Energy
Process heat in a power plant is provided by steam at different pressures. The required process temperature is regulated via the steam pressure. Depending on the process temperatures there can be pressures up to 160 bar, at temperatures up to 400 °C in the steam drums. Reliable control of water levels and fail safe limit of high and low water in the steam vessels are crucial for the safe operation of the plant.
Steam pipe
Energy
To warm up the water for the boiler, steam is bled from the power plant turbine and delivered into a preheater. As the steam cools and condenses, it is removed from the preheater with pumps. Any condensate gathering in steam pipes has to be reliably detected to prevent it from entering the turbine. Vibrating level switches, mounted at low points in the system, reliably detect any water accumulation.
Storage tanks for acids
Energy
The raw water, which is usually extracted from a river, cannot be fed untreated directly into the turbine circuit of the plant. It has to be treated first. To neutralize the water, either sodium hydroxide (NaOH) or hydrochloric acid (HCl) is added. Level sensors supply the measurement data required to ensure a high availability of these chemicals and others used to treat the feed water.
Storage tanks for fire water
Energy
To ensure fire safety, power plants are required to have an adequate supply of extinguishing water on hand for the fire brigade. The water is usually provided through a central fire water main. To make sure there is always a minimum supply on site, trustworthy level measuring instruments are deployed in the fire water
Turbine steam line
Energy
The pressure in the steam loop has to be monitored at various points in the process. Reliable measurement is required especially at the inlets of the various pressure stages of the turbine. Pressure transmitters detect even the smallest changes in the steam loop in any state of operation.
Wastewater basin
Energy
The wastewater created in the power plant is collected in a basin and fed into a treatment system. This is where wastewater from the chemical treatment, the slag cooling, the sanitary facilities as well as surface water and oil contaminated fluids are neutralised and treated. Immersion proof sensors are needed to measure the levels of these large amounts of water in the basins reliably and accurately.
Water vapour line
Energy
The pressure in the steam circuit has to be monitored at various points in the process. A reliable flow measurement is required especially at the inlets of the various pressure stages of the turbine. With a differential pressure transmitter, the flow rate can be accurately measured by means of the pressure drop across an orifice plate.
Wet deslagger
Energy
In a coal fired power station, either hard coal or brown coal is burned as the main energy source. Most plants have a so-called "wet deslagger" for removing the bottom ash (slag) from the combustion chamber. Level control in the wet deslagger fulfils two important functions: First and foremost, it controls the water level, which cools and removes the hot slag. Secondly, it maintains a hermetic seal on the furnace chamber - a reliable level measurement avoids unwanted air that would otherwise get sucked into the combustion chamber.
Wet gypsum storage hall I
Energy
The gypsum extracted from the exhaust gases in the flue gas desulphurisation unit is stored in the wet gypsum storage hall ready for further transport. Level sensors are needed to determine the stockpile height of the gypsum and quantity of the stock to optimise transportation management.
Wet gypsum storage hall II
Energy
The stored gypsum is pushed onto a conveyor belt with a scraper arm which is then conveyed out for loading and onward transportation. The radar sensor measures the height of the gypsum stockpile, and in turn is controlling the position of the gypsum scraper to optimise the gypsum loading and shipments.
Wind Power
Gearbox oil tank in a wind turbine
Energy
In wind turbines, efficiency has top priority: the higher the availability of a turbine, the higher the profitability and the faster the investment pays off. Wind power is transferred from the turbine to the generator via a rotor gearbox. Full lubrication of all moving parts ensures a long service life and high availability of the wind turbine, thus making it essential for the oil level in the rotor gearbox to be constantly and reliably monitored.
Wind turbine in an offshore wind farm
Energy
Wind turbines in offshore wind farms operate in an extremely harsh environment. Besides the buffeting of constant waves and often exceedingly strong winds, they have to withstand the corrosive effects of salt water. Due to the way the turbines are constructed and their location, it is inevitable that some seawater will enter the turbine tower. The water level inside the tower must be continuously monitored in order to detect any leaks at an early stage that can cause corrosion. To determine the mechanical loads and the generating capability of a wind power array, the tidal and wave height measurements on the outside are also required.
Solar
Expansion tank in a thermal solar plant
Energy
The solar heat captured in the mirror system of a thermal solar plant is transported via a heat transfer fluid (HTF) to the steam generator at the central turbine. The HTF normally has a temperature between 300 °C and 400 °C. There are different containers for the fluid across the plant and the varying temperatures cause volume changes to the HTF that need to be accurately measured to operate the plant safely and profitably.
Molten salt storage in a thermal solar plant
Energy
The important criterion for the location a thermal solar plant is gaining the optimal amount of sunlight energy available at that site over the year. Molten salt is used to store this thermal energy produced on the days when there is abundant sunshine, this enables the production of electricity even on days with little or no direct sunlight via a heat exchange process. This molten salt is usually stored in two large vessels. One vessel contains salt at a lower temperature (approx. 300° C), the other contains salt at a higher temperature (approx. 400° C). Accurate level measurement is essential to monitor the system capacity.
Hydropower
Coarse and fine screens
Energy
Mechanical cleaning removes entrained floating matter with screens or sieves. This protects the downstream process stages from buildup, clogging and abrasion. Solids with diameters greater than 25 mm are trapped in the coarse screens, compressed in a press and then disposed of. Finer secondary screens remove smaller residual materials. Measurement of the difference in water level between the front and the back of the screen determines the degree of contamination and initiates the cleaning of the screen when necessary.
Dam of the hydroelectric power plant
Energy
The seepage water in the dam of the hydroelectric plant is collected in pipes or channels. The quantity of seepage water provides information on the condition of the dam (another indicator of the condition of the dam is the clouding of the seepage water which is also assessed). The quantity of water flowing in an open channel is measured via water head height as it passes through a ‘V’ notch, flume or weir structure, which is then calculated into flow rate.
Pressure line in a hydroelectric power plant
Energy
In hydroelectric power plants, water is transported from the dam to the turbine via a pressure pipe. A partial or complete rupture of the pressure line leads to an increase in flow rate in the pipe that is higher than the maximum permissible flow expected. Undetected leaks lead to flooding and destruction of the power plant, resulting in a loss of energy production. For that reason it is important to measure the flow rate reliably in order to detect a pipe break and thus trigger the necessary remedial action, such as closing the pressure valve.
Reservoir at the pumped storage power plant
Energy
Pumped storage power plants store a large amount of energy and feed it into the grid very quickly when necessary. One important parameter is the height of the water level in the reservoir. It allows calculations to be made about the amount of energy available and the existing storage volume in pump operation mode. High reliability is required from the measurement technology deployed, because the sensors are often mounted at very remote locations.
Turbine building in the hydroelectric power plant
Energy
A large number of sensors are deployed to ensure reliable operation of the generators and turbines in the hydroelectric power plant. They monitor the pressure in the hydraulic lines, the lubricant supply for turbine bearings, vibration, temperatures and many other parameters. At the lowest point of the plant, cooling water from the generators and any leakage water from the Kaplan or Francis turbines is collected in a seepage water shaft, pit or sump. To prevent a flooding of the shaft and thus of the turbine building, with disastrous results for equipment, the sensors are often installed redundantly. As additional protection, the maximum water level is monitored with a point level switch.
Water inlet at the reservoir
Energy
If the natural flow of water into a reservoir is not sufficient for optimal energy production, additional water is fed into the reservoir via ducts or tunnels from water catchments that can be up to several kilometres distant. Coarse debris is held back by massive grids at the main water inlet. Smaller stones, grit and sand can accumulate in the transfer basin in front of the tunnel. Constant monitoring of the level of stones and sand in the basin ensures that no debris gets into the tunnel system.
Biogas
Buffer silo for raw materials in the ethanol plant
Energy
In order to always have enough material available for downstream processes in the ethanol plant, the crushed raw materials are held ready to use in buffer silos. The ground-up grain ‘flour’ for the production of ethanol is transported directly from the mill into a silo, where it is temporarily stored. The vast material throughput can lead to extreme mechanical loading of the silos and the associated equipment and high levels of dust are generated in the process. Level sensors are deployed to optimise the throughput, reduce overloading and ensure continuous, economical production and operation of the plant.
Compact slurry tanks in biogas plants
Energy
Biogas plants convert a mixture of organic waste and renewable raw materials into valuable energy through fermentation using a largely CO2 neutral process. Optimal consumption of the resources and maintenance-free operation require the use of highly reliable measurement technology. In all production steps – from the delivery of raw materials and waste to the removal of residues – the levels must be closely and accurately monitored.
Fermentation in the ethanol plant
Energy
The heart of the ethanol plant is the fermentation process. This is where the sugars in the mash are converted into alcohol, which, in the subsequent distillation process, is then concentrated to a strength of 99.9 %. The CO2 gas given off by the fermentation is captured and used for carbonation in the beverage industry. To keep the fermenter vessel operating in its optimal range, reliable monitoring of the process parameters including the vessel level and overall pressure is required.
Process vessels in the ethanol plant
Energy
To ensure the best possible fermentation of the ingeredients, optimal process conditions must prevail, control of pH value and temperature of the medium play important roles. The pH is adjusted by adding acids or alkalis, and sodium hydroxide is used to clean the vessel under absolute sanitary conditions. The levels of the process vessels have to be monitored at all times, to ensure continuous operation of the system. The measured media place very high demands on the chemical resistance of the sensors. To be totally reliable, the instruments need to be equally resistant to both acids and alkalis.
Raw material silo in the ethanol plant
Energy
Ethanol is an additive used in gasoline. Through the use of renewable resources, the CO2 emission of fuels is significantly improved and the consumption of crude oil reduced. In modern ethanol plants, raw materials such as grain, sugar cane or sugar beet are processed into alcohol and ethanol. The resulting by-products and residues are also completely utilized. The different types of grain used for ethanol production are stored in silos more than 20 m high. Reliable silo level measurement is essential to ensure continuous production supply is maintained.
Slurry tanks in biogas plants
Energy
Semi-liquid manure, or slurry, in biogas plants is often stored in closed, large-volume slurry tanks. Through fermentation, a valuable energy carrier is extracted from the mixture of organic waste and renewable raw materials. Level and pressure are monitored in the tank, as well as in the delivery and removal systems handling the raw materials and waste.
Storage tank in an ethanol plant
Energy
After going through all process steps, the bioethanol is stored in a tank ready for delivery to the consumer. Accurate measurement of the tank contents is an important prerequisite for fiscal inventory, reliable logistics planning and ensures a sufficient supply for customers. Since the tanks can often not be emptied after an initial filling, maintenance-free operation and setup without product are crucial considerations for the measurement technology.
Hydrogen
Alkaline electrolyser (AEL)
Energy
Level measurement with guided radar for regulating the electrolyte level and the water intake Pressure sensor for pressure monitoring in an electrolyte tank Differential pressure measurement between the two electrolyte tanks.
Buffer tank for potash lye
Energy
Continuous level measurement with radar in the buffer tank for potash lye.
Gas storage tank
Energy
Continuous level measurement with radar for permanent gas volume measurement Monitoring of the gas pressure in the gas reservoir Separator (supply isolator) for optimal power supply to connected sensors.
Hydrogen compressor
Energy
Pressure sensor for pressure measurement in the compression chamber Pressure measurement in the compressor pipelines.
Hydrogen pipeline
Energy
Pressure monitoring in the hydrogen pipeline.
Hydrogen tanker with liquid hydrogen
Energy
Level measurement via differential pressure in a tank holding liquid hydrogen Level measurement with radar in a tank holding liquid hydrogen.
Liquid hydrogen storage tank
Energy
Level measurement with differential pressure in the liquid hydrogen storage tank.
Osmosis filter
Energy
Differential pressure transmitter for measuring filter contamination External display and adjustment unit for 4 … 20 mA/HART sensors Mounting bracket for differential pressure transmitter.
PEM electrolyser
Energy
Pressure measurement in the inlet and outlet of the PEM electrolyser Level measurement with radar for regulation of water quantities Level measurement with guided radar for water volume control.
Storage tank with hydrogen gas
Energy
Pressure sensor for pressure measurement in a storage tank with gaseous hydrogen.
Water storage tank
Energy
Vibrating level switch as overfill protection in water storage tanks Non-contact level measurement with radar in water storage tanks.
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