Power Industry Applications

The Power & Energy
Applications
industry
Competence in Power & Energy
Flow
Uwe Wagner
Slide 2
Steam generator / inside view

Top-view
into the
vessel
Flow
Level
Analysis
Pressure
Evaporato
r pipes
Temperature
Gamma
Recorder
View from
below into
the vessel
Opening for
start up
burner
Discharge opening
for flyash
Monitoring the start-up/support

burner
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
To initiate combustion and/or support coal firing of the

boiler, oil is used for the booster and supporting burner
A precise mass measurement installed in the oil flow line
is required for the exact batching and control of the
combustion process
Monitoring the start-up/support

burner
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Coriolis mass flow: Promass

Compact device for direct,
precise mass measurement
(kg/h) no additional
instruments required
Replaces mechanical
systems that can obstruct
and block the furnace oil
flow line
No moving parts for
unimpeded flow and
operation of the furnace
(highest available)
Safe measurement, even
with poor quality oil
Oil massflow to the start-up

burners in steam generator
Flow
Level
Analysis
Coriolis mass flow meter PROMASS
Advantages of PROMASS in comparison to positive displac
Pressure
Temperature
Gamma
Recorder
References PROMASS

Flow
Coriolis mass flow meter PROMASS
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Advantages of PROMASS
Direct massflow measurement
in kg/h
No moving parts
High accuracy
High dynamic 1000:1
No inlet- and outlet lengh
necessary
Simple installation (compact)
Devices are available for
temperatures up to 200 C and
Positive displacers versus Coriolis flow meters

Flow
Application at the start-up burners of the steam generator
Level
Analysis
Pressure
Temperature
Gamma
Recorder
BEFORE
Positive displacers with a
major effort from the
instrumentation and a
danger of blocking
AFTER
Promass without moving
parts. Direct mass flow
signal and open system
without danger of
blocking

Flow
Advantages of PROMASS in comparison to positive displa
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Disadvantages of politive
displacers
Accuracy and calibration
depents on constant viscosity

High pressure loss e.g. filter
Conversion of volume to
massflow =>kg/h
Sensitive against dirt; therefore
higher risk of blockage and
danger of breakdown
Moving parts reduce the
Advantages - Promass
Accuracy is independent of oil
characteristics like density and
viscosity
Low pressure loss
Measuring of oil mass flow
direct without conversion
Promass can not blockage,
because the sensor is an open
pipe without built in
No moving parts ensures a high
lifetime and a maintenance-free

Flow
Level
References
(Heated oil circuit to the different levels of the vessel)
Analysis
Pressure
Temperature
Gamma
Recorder
Oil supply system with various Promass flow meters
Reference Power Station La Colette

(England)
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Power station La
Colette in England:
12 pcs. Promass
together with
Siemens Power
Generation
Reference Power Station

Braunschweig
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Power Station
Braunschweig/Ger
many:
16 pcs Promass at
the steam
generator
Reference Power Station Weiher

Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Power Station
Weiher,
Saarenergie/Ger
many
24 pcs Promass
at differnet levels
at the boiler
Reference E.ON Power Station

Wilhelmshaven
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Power Station
Wilhelmshaven,
E.ON:
Promass at
different levels at
the boiler
Main cooling water system

Flow
Round
treatment
basin
Level
Analysis
Pressure
Temperature
Air intake in
the lower
part of the
cooling
tower
Kohle-
Gamma
Recorder
lagerpla
tz
140 m high
cooling
towers
Cut view of a
main
condenser
Water volumes in the main cooling

water system
Flow
Large volumes of cooling water flow through the main

condenser, helping to create a high degree of efficiency in
the power plant
Level
Analysis
In order to measure cooling water volumes, a measuring

device is required which supplies reliable values even with
Steam from
large pipe diameters
turbine-mean
Pressure
Temperature
Cooling tower
Gamma
Cooling water
circuit
pressure section
Low pressure turbine part
Recorder Drop collector

Trickling
system
Main-condenser
Cooling waterpump
Discharge
Return to the
water/steamcircuit
Water volumes in the main cooling

water system
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Ultrasonic flow: Prosonic Flow

Installed directly on pipelines
via detecting sensors with
transmitter mounted
separately
External installation allowing
easy retrofit with no
intrusion into the pipe
Maintenance free with no
moving parts
No obstructions in the
pipeline and no pressure loss
Economical alternative for
large diameters up to 4000
mm
Desalination
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
View of a
desalination
plant
Volume measurement in
desalination
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Full desalination requires the production of pure water

necessary for the operation of steam boilers
Volumetric flow meters are required for the measuring of
deionized water in the water/steam circuit
desalination
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Vortex flow: Prowirl

Alternative to dp flow with
orifice plates
Compact device for volume
measurement in deionized
water
Reliable measurement
independent of deionate
conductivity
Large measuring dynamics,
i.e. high turndown
Minimal pressure loss
desalination
Flow
Level
Analysis
Pressure
Ultrasonic flow: Prosonic Flow

inline
Ideally suited for applications in
process control and utility
measurement in energy
production
Temperature
Gamma
Recorder
Short inlet and outlet length

reducing the space required for
installation in comparison to
orifice plates and Vortex meters
Loop powered transmitter with
accuracy up to 0.3%
Measures the flow of conductive
and especially non-conductive
liquids
Control of raw water supply

Flow
Level
Additional water is required as replacement for the

condensate loss in the cooling system and feedwater in
the steam circuit
Analysis
Pressure
Temperature
Gamma
Recorder
The extraction flow rate must be measured in order to

control the chemical cleaning process
Control of raw water supply

Flow
Electromagnetic flow:
Promag
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Compact device especially

designed for raw water
usage with sizes from
15mm to 2000mm
Simple commissioning with
user-friendly quick setup via
large display and plain
language text
Relay outputs can be
configured for error
indication, material and
limit value monitoring
Pulse and analog outputs
are fitted as standard and
are freely configurable
Level
Uwe Wagner
Slide 24
Water-/Steam system
Water-/Steam
system with
pipes and
vessels
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Steam
turbine
with
Steam turbine
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Steam
turbine
Generato
r
Turbinehigh
pressure
section
middle
pressure
section
low pressure
section
Innovation of Level in the

Water/Steam system
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Boiler
drum
High
pressure
preheater
Feedwater
tank
Low
pressure
preheater
Main
condenser
Innovation of Level in the

Water/Steam system
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Guided radar: Levelflex M

Alternative to displacer/dp
level
Shutdowns avoided due to
independence of vacuum
(hotwell)
Automatic gas phase
compensation for large
measuring errors that can
occur due to high
temperatures and high
pressures (boiler/steam drum)
Independent of density
fluctuations, changing
dielectric numbers, gas
covering steam and vacuum
Levelflex vs. traditional dp-level

LEVELFLEX
Flow
Differential pressure
Problem 1: different densities

Problem 2: vacuum
Level
P (bar) = h x x g
Analysis
Gamma
Recorder
Density
P (bar) in
the
container
Solution:
LEVELFLEX shows
the correct level
???
Wrong level indication
Temperature
Direct, exact level measurement
Pressure
1>2
An incorrect and reduced

level is shown, because the
transmitter does not take
the fluctuating densities
caused by changing loads
into account (1 2)
Levelflex - THE newcomer in power plants

Flow
Application
Level
Analysis
Pressure
Temperature
Gamma
Recorder
To main
condenser
Levelflex
Bypass pipes
(2 out of 3)
Level measurement of the

condensed steam in front
of the turbine in the main
condenser (Hotwell)
Process: 0.1 bar, max. 40 oC
Measuring range: ca. 2.5 m
Benefits
Measurement with
Levelflex is not influenced
by vacuum => better
solution than differential
More reliable
pressure
measurement
Increased safety
E.ON Power plant Wilhelmshaven
Easier installation
Level measurement with radar technology

Flow
Applications in the power plant => example of low

pressure preheater
Measuring technology
Power station Jiangsu Guohua Taichang in China
Level-transmitter (radar
instrument)
LEVELFLEX FMP40
Level
Analysis
Process
Pressure
Temperature
Control the level of the

condensed extraction steam to
protect the steam turbine from
damage.
Medium: Condensate (demiwater)
Operation: 7 bar, 180 oC
Measuring range : 2100 mm
Gamma
Levelflex
FMP40
Recorder
3 bypasses
Features
(2of3 selection)
Signal of
condensate levelLEVELFLEX is installed in a
LP-Preheater
Envelope curve
redundant installation with

three bypasses (2 of 3
selection) to implement the
safety concept of the power
station
The measurement is not
influenced by fluctuations in the
process or fluctuations in
density (pressure, temp.)

Flow
Application in power plant => example of feedwater

tank
Level transmitter LEVELFLEX
FMP40
Level
Process
Analysis
Level measurement of
feedwater in the feedwater tank
of water/steam circuit
Pressure
Temperature
Gamma
Recorder
Levelflex
FMP40
3 bypasses
(2of3 selection)
Feedwater
tank
Medium: Feedwater
Operation: app. 10 bar, app. 170
o
C
Measuring range: app. 1600 mm
Features
LEVELFLEX has no moving

parts, therefore no wear and
tear
LEVELFLEX has no mechanical
moving parts, therefore no wear
LEVELFEX is suited for pressure
up to 400 bar or 400 C
SOTEC Waste-to-Energy Power Station TREA Freiburg

Flow
Application in power plant => example high

pressure preheater
Power station Anhui Datang Huaibei in China
Level
Process
Analysis
Pressure
Temperature
Gamma
Recorder

FMP45 Installation bypass at
HP Preheater
High Pressure
Preheater
Levelflex
FMP45
Bypass pipe
Envelope curve

condensed extraction steam
(auxiliary condensate) in the
High Pressure preheater.
Medium: Condensate (DemiWater)
Operation: 42,4 bar / 300 oC
Features
LEVELFEX is suited very well for

high pressure and temperature
parameters in high pressure
preheaters
Analysis of the signal via the
envelope curve of the
transmitter, that can be viewed
on the display or with a laptop

Flow
Applications in the power plant => example low

pressure preheater
Power station Jiangsu Guohua Taichang in China
instrument)
LEVELFLEX FMP40
Level
Analysis
Process
Pressure
Temperature

protect the steam turbine form
damage.
Gamma
Levelflex
FMP40
Recorder
3 bypasses
Features
(2of3 selection)
Signal of
condensate levelLEVELFEX is installed in a
LP-Preheater
Envelope curve
redundant installation with

three bypasses (2 of 3
selection) to implement the
safety concept of the power
station

Flow

pressure preheater
Power station Guizhou Qianxi in China
Level
LP-Preheater
Analysis
instrument)
LEVELFLEX FMP45
Process
Pressure
Temperature
Gamma
Levelflex
FMP45
Recorder
Redundant
installation

protect the steam turbine form
damage
Features
For safety reasons the

Signal of
condensate level LEVELFEX is installed in a
Envelope curve
redundant installation
density. (pressure, temp.)
For operating the application
with the envelope curve you can
use the display or the E+H
software TOF-Tool, together
with a laptop
Low pressure preheater Today

radar technology
Flow
Level
level-transmitter (radar
instrument)
LEVELFLEX FMP40/45
Analysis
Process
level measurement of the

(auxiliary condensate) in
preheater (low pressure/high
medium:
pressure)main condenser
operation: max. 4 bar, max. 120
o
C
MB: to ca. 2 m
Pressure
Temperature
Radar device
Gamma
Recorder
Bypass pipe
Features
Pre heater
Old
measurem
ent
RWE power plant Niederaussem

up to 400 bar and 400 degrees
C. This ensures great safety.
the instrument works without
moving parts; no wear.
the measurement is not
density. (pressure, temp.).

Flow

pressure preheater
instrument)
LEVELFLEX FMP40/45
Level
Analysis
Process

(auxiliary condensate) in the
Low Pressure preheater
Medium: condensate (demiwater)
Operation: max. 4 bar, max. 120
o
C
Measuring range : app. 1500 m
Features
Pressure
Temperature
Instrument
Gamma
Recorder
Bypass pipe
LP-Preheater
Old
device
RWE Power Station Niederaussem

up to 400 bar or 400 degrees C.
This ensures great safety
The instrument works without
moving parts; no wear =>
better than replacer
density. (pressure, temp.)

Flow
Applications in the power plant => example, main

condenser (2v3 selection)
installation in the bypass pipe
(2v3 - selection)
Level
Process
Analysis
Pressure
Temperature
Gamma
Recorder
Condenser
(Hotwell)
Levelflex
Bypass pipes
(2of3-choice)

condensed steam in front of the
turbine in the main condenser
(Hotwell)
Operation: ca. 0,2 bar, max. 40
o
C
Measuring range: app. 2,5 m
Features
Measurement with LEVELFLEX is
not influenced by vacuum; =>
better solution than differential
pressure
Installation is carried out easily
in the bypass
E.ON Power Station Wilhelmshaven
LEVELFLEX has no mechnically


Flow
Application in power plant => example main

condenser (separate version)
FMP40 installation as separate
version
Level
Process
Analysis
Pressure
Temperature
Gamma
Recorder
Condenser
(Hotwell)
Levelflex
(remote
electronics)
Bypass pipe
RWE Power plant Wachtberg

condensed steam below the
turbine in the main condenser
(Hotwell)
Operation: ca. 0,2 bar, max. 40
o
C
Measuring range: app. 2,0 m
Features
The measurement with
LEVELFLEX is not influenced by
vacuum; => better solution
than differential pressure
parts, therefore no wear
Installation is easy in a bypass
pipe. With the separate version,
interfering vibration is not
passed on to the transmitter

Flow
Application in power plant => example feedwater

tank
FMP40
Level
Process
Analysis
Level measurement of
feedwater in the feedwater tank
of water/steam circuit
Pressure
Temperature
Gamma
Recorder
Levelflex
FMP40
3 bypasses
(2of3 selection)
Feedwater
tank
Medium: Feedwater
Operation: app. 10 bar, app. 170
o
C
Features

parts, therefore no wear
LEVELFLEX has no mechnically
up to 400 bar or 400 degrees C
SOTEC Waste-to-Energy Power Station TREA Freiburg
Level measurement in the

ammonia tank
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Guided microwave level:

Levelflex M
Low frequency guided
microwaves are proven to deliver
very reliable measurement in
ammonia tanks
Mounted in the tank or in a
bypass
Independent of density,
temperature or dielectric
constant
Measurement possible with foam
on the surface
Level measurement in the

ammonia tank
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Level limit switch: Liquiphant S

Unaffected by flow, turbulence, bubbles,
foam, vibration, solids content or build up
No calibration required: quick, low-cost
startup
No mechanical moving parts: no
maintenance, no wear and tear, long
operation life
Self monitoring of fork for damage
increases plant safety
Leakage detection at the

generator
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Because of heat build up, generators in a power plant must be

cooled. This is usually done with hydrogen cooling gas.
Discharge lines are located at the generator housing. If
lubricants reach the housing due to leakage in the thrust
bearings, the rise in liquid is detected by the Liquiphant limit
switch at the end of the discharge lines. The problem is then
recognized and can be eliminated.
Leakage detection at the

generator
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Level limit detection:

Liquiphant
Compact instrument for level
limit detection in liquids using the
vibration principle
Ideal solution for applications
where space is limited
Leakage detection to protect
generator and protects pump
against running dry
Ex version for use in hazardous
areas where hydrogen may be
present
Maintenance free no moving
parts
Pressure
Uwe Wagner
Slide 45
References: Coal power

stations
Flow
Power Station Voerde
Level
Analysis
Pressure
Power Station Bergkamen
Temperature
Gamma
Power Station Herne
Recorder
Power Station Lnen
Differential Pressure in the

Water/Steam system
Flow
Level
Analysis
Pressure
Temperature
Gamma
Recorder
Deltabar S
Very good
reproducibility and longterm stability
Used for flow, level and
differential pressure
monitoring to SIL2
Flow measurement
together with orifice
plates, pitot tubes and
other primary elements
Function-monitored
from the measuring cell
to the electronics Installation via impulse pipes (2oo3)

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The Power & Energy

Competence in Power & Energy

Competence in Power & Energy

Steam generator / inside view

Competence in Power & Energy

Monitoring the start-up/support

To initiate combustion and/or support coal firing of the

Competence in Power & Energy

Monitoring the start-up/support

Coriolis mass flow: Promass

Competence in Power & Energy

Oil massflow to the start-up

Coriolis mass flow meter PROMASS

Advantages of PROMASS in comparison to positive displac

Competence in Power & Energy

Oil massflow to the start-up

Coriolis mass flow meter PROMASS

Competence in Power & Energy

Positive displacers versus Coriolis flow meters

Application at the start-up burners of the steam generator

Competence in Power & Energy

Oil massflow to the start-up

Advantages of PROMASS in comparison to positive displa

depents on constant viscosity

Competence in Power & Energy

Oil massflow to the start-up

Oil supply system with various Promass flow meters

Competence in Power & Energy

Reference Power Station La Colette

Competence in Power & Energy

Reference Power Station

Competence in Power & Energy

Reference Power Station Weiher

Competence in Power & Energy

Reference E.ON Power Station

Competence in Power & Energy

Main cooling water system

Competence in Power & Energy

Water volumes in the main cooling

Large volumes of cooling water flow through the main

In order to measure cooling water volumes, a measuring

Low pressure turbine part

Recorder Drop collector

Competence in Power & Energy

Water volumes in the main cooling

Ultrasonic flow: Prosonic Flow

Competence in Power & Energy

Competence in Power & Energy

Full desalination requires the production of pure water

Competence in Power & Energy

Vortex flow: Prowirl

Competence in Power & Energy

Ultrasonic flow: Prosonic Flow

Short inlet and outlet length

Competence in Power & Energy

Control of raw water supply

Additional water is required as replacement for the

The extraction flow rate must be measured in order to

Competence in Power & Energy

Control of raw water supply

Compact device especially

Competence in Power & Energy

Competence in Power & Energy

Competence in Power & Energy