PROCESS ANALYTICS

Breakthrough Detection for Heat Exchangers

Heat exchangers are used when liquid process media need to be cooled and/or dissipated heat needs to be recovered for other processes. Typical areas of application are steam generators and cooling towers in power plants (air as the cooling medium), as well as process areas in which plate heat exchangers and tubular heat exchangers are cooled with high efficiency by liquid cooling media.

Conductivity Changes in the Cooling Water Indicate Breakthroughs in the Process

In heat exchangers, temperature exchange between material flows with different temperatures is realized using chamber or tube walls that are typically made of metal. They separate the flows but are permeable to heat. As a result of wear and corrosion, leaks in the partitions or tubes occur that may contaminate the cooling medium and cause significant damage to the plant. Contaminated cooling water could also enter the local water supply, leading to health hazards and severe penalties for system operators.

When steam is cooled down, it precipitates as condensation with a high degree of purity and in turn, very low conductivity. Since increased conductivity indicates contamination, conductivity measurement of condensate is a reliable method for checking that plants are functioning properly and detecting process breakthroughs.

As a rule, the measuring loops used here contain various conductivity sensors that are connected to multiple industrial transmitters in the enclosure. However, this setup requires extensive wiring and takes up lots of installation space in the enclosure.

Memosens digital sensor technology offers a space-saving, maintenance-free solution: With the Memosens SE615 conductivity sensor, contamination in the condensate can be established in the wide range of 10 µS/cm – 20 mS. The very narrow sensor with a PG 13.5 connection thread can be easily connected to the process inline in a matching fitting (e.g., ARI106) downstream to the heat exchanger where the temperature is no longer high.

For more stringent pressure and temperature requirements, Knick recommends using the SE604 (for the smallest measuring ranges from 0.001 – 1000 µS/cm) or SE630 (for larger measuring ranges up to 50 mS/cm) sensor with direct process connection via a G 1" or NPT thread.

All sensors have an integrated temperature detector for correct temperature compensation. When connecting the measuring loops to the control system, streamlined MemoRail transmitters (12 mm) significantly reduce the amount of space and cables needed in the enclosure for mounting on DIN rails. Moreover, two standard signal current outputs ensure the floating transfer of process-measured values and temperatures to the programmable logic controller.

Return on Investment

Reliable monitoring of cooling water quality ensures plant efficiency and reduces the costs of repairs and water consumption.
With precise conductivity measurement, leakage can be detected and remedied in time before it causes expensive damage to plants and the environment.
Using MemoRail transmitters to transmit measured values and temperature values to the control system makes room in the enclosure and minimizes wiring complexity.

Associated Products

SE615 Conductivity Sensor | 2 Graphite electrodes | Memosens | 120 mm | For water and wastewater treatment

Product number:

SE615/1-MS

SE604 2-Electrode Conductivity Sensor | Memosens | Measuring range from ultrapure water to 500 μS/cm

Product number:

SE604-MS

Product number:

SE630X-MS

ARI106 (H) Inline Fitting | Modular | Stainless steel or highly resistant plastic | For 12-mm sensors | For chemical and hygienic applications

Product number:

ARI106

Associated Industries and Applications

Energy

In power plants, water is used in many processes with completely different requirements: for example, for steam generation, cooling, and flue gas scrubbing.

Chemistry

The chemicals industry is characterized by an extremely wide variety of applications, often in toxic and explosive environments.

Monitoring Steam Generators

Since steam generators fulfill application-critical functions and the cost of their downtime or replacement is extremely high, damage caused by wear should be prevented by monitoring water quality.

Boiler Feed Water Circuits

Measurement of pH values, dissolved oxygen, and conductivity as key parameters in the boiler feed water circuit.

Combined Cycle Power Plants

Measurement of pH values, dissolved oxygen, and conductivity in boiler feed water, steam, and condensate in combined gas turbines in power plants.

Pulp and Paper Production

Many measuring loops in pulp production are located in environments in which technical personnel must spend as little time as possible.

pH Measurements in the Dye Synthesis of Azo Dyes

In terms of numbers, azo dyes are the largest group of synthetic dyes. They are used as food dyes, paint dyes, primary colors for 4-color printing (yellow and magenta), and on a massive scale, as textile dyes.

Cooling Tower Monitoring

In a wide range of industrial sectors, cooling towers are used to dissipate process heat from cooling circuits. Mineral deposits and corrosion reduce their efficiency and lead to premature wear on plant parts.

Ion Exchanger Systems

Measurement of pH values, dissolved oxygen, and conductivity in boiler feed water, steam, and condensate in combined gas turbines in power plants.

Cooling Water Systems

Measurement of pH value, redox potential, and conductivity in cooling water, which has to be continuously treated with acid and biocides.

Flue Gas Desulfurization

pH value measurement in the pre-scrubber, the neutralization phase, and the lime scrubber as part of the flue gas desulfurization process in power plants.

Water Treatment Systems

Measurement of pH value, dissolved oxygen, and redox potential in various applications during the water treatment process of power plant wastewater.

Reverse Osmosis Systems

Reverse osmosis systems are used for water treatment in a wide range of industrial applications. The main application is industrial saltwater desalination.

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