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TLY Energy

Level Measurement in Steam Boilers

ENERGY GENERATION: Level Measurement in Steam Boilers

Level measurement in high-pressure and low-pressure steam boilers at power plants is of vital importance to ensure the safe and efficient operation of the facility. As TLY Energy, among the turnkey application projects we offer to our customers, we would like to highlight a project focused on improving the level measurement systems of steam boilers. This project solved a significant problem faced by power plants, enabling facilities to operate more safely and economically.

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Project Summary

In this special project designed and executed by the TLY Energy team, advanced technologies were utilized for level measurement in high-pressure and low-pressure steam boilers at power plants. The customer had previously performed level measurements using differential pressure transmitters; however, steam condensation within the capillary tubes caused water accumulation, leading to inaccurate measurements. To eliminate this problem, VegaFlex 86 guided radar level sensors and Kobold magnetic level indicators were implemented within the project.

Project Features

  • Technology Used: A total of 6 VegaFlex 86 guided radar level sensors and 6 Kobold magnetic level indicators were installed. These instruments are SIL2 certified, demonstrating their suitability for high-safety applications.

  • Quality and Safety Standards: All welding operations carried out during the mechanical modifications were tested by TÜV Austria using NDT (Non-Destructive Testing) methods, ensuring compliance with high safety and quality standards.

  • Technical Documentation: All required technical drawings, Procedure Qualification Records (PQR), and Welding Procedure Specifications (WPS) were prepared by the TLY Energy team. This documentation serves as proof that every stage of the project was completed according to the highest standards.

  • Innovative Solution: Through mechanical modifications and the creation of bypass lines on both high-pressure (100 bar) and low-pressure (15 bar) steam boilers, the sensors were configured to perform measurements from the bypass lines rather than directly from the boilers. This approach enabled reliable measurements with an accuracy of ±2 mm.

  • Economic and Safety Benefits: Due to inaccurate level measurements, the power plant previously experienced a minimum of three emergency shutdowns and restarts per year, resulting in significant economic losses. The implemented improvements completely eliminated this issue, increased energy efficiency, and provided substantial economic benefits.

  • Project Location and Capacity: The application was carried out at a 450 MW Natural Gas Combined Cycle Power Plant.

Result

As TLY Energy, through our technical expertise and practical experience, we significantly improved our customer’s operational safety and economic efficiency. The success of this project once again demonstrated how the use of advanced level measurement technologies can effectively overcome the challenges faced by power plants. TLY Energy will continue to provide innovative solutions that meet customer needs and remain a reliable partner in the energy sector.01-02-2024_TLY_VEGA_KOBOLD_8.png

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