Energy Use Cases
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36 use cases
Coal Power Plant
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.
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