In this text you will see how level control with a guided wave radar, such as the Magnetrol Eclipse 706, has the potential to bring considerable savings to your industrial plant.
For most power plants, between 70 and 80% of production costs correspond to fuel expenses. Therefore, any improvement in fuel use efficiency can have a significant impact on plant profitability. By improving the final temperature of the feedwater heater through more precise level control, power plants can reduce the heat rate and achieve substantial savings.
For example, in a 500-megawatt power plant, an improvement of just 1% in the thermal rate can generate a annual savings of approximately US$500.000.
The thermal rate is a measure of how efficiently a plant uses thermal energy. The higher the thermal rate, the lower the efficiency. This metric has a significant impact on a company's profitability and its ability to compete in unregulated markets.
The benefits of an improved thermal rate go far beyond consumption and cost: the plant can reduce emissions simply by decreasing the amount of fuel needed to generate a given amount of energy. In many cases, this can be achieved economically simply by improving the level control of the feedwater heater.
Reducing the thermal rate also increases the boiler's lifespan by preventing thermal overload. Furthermore, there is significant value in terms of institutional image and environmental responsibility when the plant demonstrates a commitment to minimizing its environmental impact.
Level control throughout the energy cycle.
Maintaining precise and reliable level control throughout the entire energy cycle is essential.
The condenser is the starting point of the feedwater heater process, where condensed steam from the heater drains and high, medium, and low-pressure turbines is routed through successive heaters. Simultaneously, steam extracted from the turbines reaches the appropriate heaters, thus enabling energy transfer.
Reliable and precise level control is essential to achieving the final temperatures required by this cycle.
Operation of the feedwater heater
Feedwater heaters utilize the heat from condensation to preheat the water to the appropriate temperature for the boiler. During this process, shell-and-tube heat exchangers allow feedwater to pass through the tube side, while steam extracted from the turbine passes through the shell side.
When operated correctly, feedwater heaters reduce fuel consumption by using extraction steam to preheat the water instead of expensive hot fuel.
Achieving the ideal water level in the heater reduces the heating rate and lowers fuel costs. Investing in an efficient level control system helps achieve optimal thermal performance.
Instrumentation for controlling the feedwater heater level.
O Eclipse® Model 706The guided radar transmitter, manufactured by Magnetrol®, is a smart choice for monitoring the level in feedwater heaters.
This transmitter guided wave radar (GWR) helps plant operators optimize the condensation zone, provide precise level control, maximize energy transfer, and minimize premature equipment wear.
Although older technologies—such as differential pressure, magnetostrictive, RF capacitance, and torque tube—are still used to measure the level in heaters, these instruments can present operational challenges. These technologies are subject to process variations, induced errors, changes in specific gravity, and mechanical or electronic drift.
Guided wave radar (GWR) is the most reliable measurement solution for level control of feedwater heaters because it is immune to process conditions, requires no calibration or gravity corrections, and offers a superior signal-to-noise ratio. By adopting the Eclipse® Model 706 transmitter, plants can reduce heat transfer and significantly lower fuel costs.
