Flow, level & control A


large coal-fired power plant serving Colorado and Wyoming, produces just under 1,500 MW of power across three sepa- rate phases. Each of the three isolated phases, or power generation units,


can be turned on and off for maintenance or as needed with power grid concerns. Each phase features multiple measurements on a steam- heated dryer system to alert plant operators of maintenance issues, a critical part of the power generation process. Before reliable sensors were in place, inaccurate pressure measurements trans- lated to excessive back pressure and warnings at inconvenient times.


WARNINGS, BACKPRESSURE, AND UNEXPECTED CLEANINGS In this facility, the exhaust pre-heater and dryer system dries the exhaust before entering the baghouse to remove moisture before it gets to process filters and causes them to become blocked. The pressure transmitter, located at the base of the system tower, gave poor and insuf- ficient alerts for filter blockages, causing excess back pressure and system safety warnings. This required unexpected shutdowns for cleaning, inter- rupting service to the surrounding area. As a result, workers had to go through sensor recalibration and recommissioning processes, which prevented the team from getting accu- rate pressure information critical to their power plant operations.


A CLEVER AND COST-EFFECTIVE SOLUTION


With repeated issues, plant operators started seeking out measurement alternatives. Originally, workers spoke with VEGA about potentially using a competitor’s conventional differential pressure sensor, mounted on two independent pressure used to gauge filter status. However, after a lunch and learn focused on an electronic differential pressure (EDP) setup without capillary lines, the professionals purchased VEGABAR 82s set up for EDP, for all three main filter rooms. Plant personnel were grateful that they didn’t have to purchase a fixed length of capillary tube, and the Bluetooth connectivity to the sensor enabled easy setup, calibration, and adjustments from a distance. The abrasion-resistant ceramic measuring cell prevents measurement drift, can easily withstand the demands of the pre-heater and dryer system, and provides operators with consistent and maintenance-free measurements. After the install was complete, the maintenance and electrical team loved how they can now communicate with the master devices from their catwalk without using safety harnesses and two-man crews to access.


20 January 2025 Instrumentation Monthly


FILTERING OUT POWER PLANT PRESSURE PROBLEMS


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