In the power generation industry, reliability and efficiency are critical. This case study examines a Combined Cycle Power Plant (CCPP) that supplies electricity to approximately two million households daily with a total production capacity of 1,410 megawatts. The plant operates with three Combined Cycle Units (CCUs), each comprising a steam generator with heat recovery, a gas turbine, a steam turbine, and a generator. To ensure seamless operation, the plant integrated SIL Certified AMETEK LMS Magnetrol branded Guided Wave Radar (GWR) transmitters as a key component of their level measurement strategy.
THE CHALLENGE:
Steam drum level measurement is a critical process in power generation, where inaccuracies can lead to operational inefficiencies, equipment damage, or even complete shutdowns. Each of the three CCUs in this facility consists of three steam drums—Low Pressure (LP), Intermediate Pressure (IP), and High Pressure (HP)—each with three side-mounted chambers containing two GWR probes per chamber. This sophisticated setup forms a 2oo3 (two-out-of-three) system for both control and safety functions. The plant required a solution that could ensure highly accurate level measurements while reducing maintenance complexity and risks associated with traditional measurement methods.
THE SOLUTION:
The facility operates at an efficiency of approximately 58%, making it one of the most advanced of its kind. However, any failure in level measurement could result in turbine damage, compromised pipe connections, or safety hazards for plant personnel. Moreover, a trip in the safety system would trigger a complete CCU shutdown, leading to significant downtime and loss of power supply.
The implementation of 2oo3 systems is a standard approach in many industries, including Oil & Gas (O&G). However, this plant uniquely applied the setup for both control and safety purposes. The use of GWR technology presented a more robust, accurate, and maintenance-friendly alternative to conventional Differential Pressure (DP) transmitters.
One of the key benefits of GWR technology is its ability to provide highly reliable level measurement without being affected by changing media characteristics. In contrast, conventional DP transmitters often struggle in extreme environments, particularly in cases where freezing conditions could lead to system failures. With no moving parts, the less complex nature of GWR technology also means reduced maintenance efforts and lower operational costs over time.
RESULTS & BENEFITS:
Understanding facility requirements for accuracy and efficiency, a redundant 2oo3 GWR system was implemented. Each double GWR device, equipped with vapor compensation measurement, was strategically installed within dedicated chambers. This configuration ensured precise level control while reducing complexity and minimizing failure risks. Fortunately, this approach was designed from the ground up as part of the new installation, making it a seamless fit for the plant’s operational framework.
The results of integrating our Magnetrol branded GWR technology have been overwhelmingly positive:
- Enhanced reliability in steam drum level measurement: reducing operational risks.
- Substantially lower maintenance requirements: compared to DP transmitters, reducing both production and servicing costs.
- Improved plant safety: through reliable, precise level control, minimizing the likelihood of equipment failure and hazardous conditions.
- Optimized uptime and efficiency: ensuring stable electricity generation for millions of households.
CONCLUSION:
With the ability to provide unparalleled accuracy, reduced maintenance, and enhanced safety, AMETEK LMS GWR technology has proven to be the ideal solution for this power plant. By addressing the unique challenges of steam drum level measurement, the plant has ensured uninterrupted operation, safeguarded equipment, and maximized efficiency. This case study showcases how innovative measurement technology can drive better outcomes in the energy sector, setting a precedent for future projects.