As the core equipment of the thermal power generation system, the accuracy of the water level measurement of the boiler drum directly affects the safety and efficiency of the unit operation. In industrial practice, traditional measurement methods generally have measurement deviations caused by interference factors such as medium temperature and pressure fluctuations and blurred steam-water interface. The magnetic level switch UHC-EBK has shown significant advantages in solving the differences in multi-source measurement systems through its unique mechanical structure and signal processing mechanism, providing a reliable solution for modern industrial process control.

1. Analysis of the causes of differences in boiler drum water level measurement

The dynamic characteristics of steam-water two-phase flow are the root cause of measurement deviations. During the operation of the boiler, the medium temperature can reach above 350°C and the pressure exceeds 10MPa. This extreme working condition makes the traditional differential pressure level gauge susceptible to changes in steam density. At the same time, the turbulence and bubble entrainment inside the drum may cause sensors at different installation positions to obtain contradictory data.

The differences in the principles between the measurement systems exacerbate the data contradictions. Non-contact measurement methods such as capacitive and ultrasonic are greatly affected by changes in dielectric constant and sound velocity parameters of the medium, while connected-vessel mechanical instruments have thermal expansion errors. When measuring devices based on multiple principles are used in parallel, data coordination between systems becomes a technical difficulty.

The performance degradation of equipment during long-term operation cannot be ignored. Progressive faults such as electrode scaling, float jamming, and magnet demagnetization can cause measurement characteristic deviations. This change is often hidden and can easily cause misjudgment of the control system.

2. Technical features of differential coordination of UHC-EBK

The liquid level switch UHC-EBK adopts a magnetic float-reed switch coupling structure. The built-in permanent magnet in the float triggers the reed switches at different positions as the liquid level rises and falls. Different from traditional mechanical limit switches, its non-contact triggering method eliminates the reliability problems caused by mechanical wear. The two-color magnetic flap indicator works synchronously with the switch output, realizing the real-time correspondence between mechanical indication and electrical signal.

The multi-level redundant design effectively improves the fault tolerance of the system. Each measuring point is equipped with three sets of independent reed switches, and the “two-out-of-one” voting logic is used to output the signal. This design enables the device to maintain normal function when a single component fails, significantly reducing the probability of false operation. The waveguide structure set inside the shell effectively suppresses the influence of medium disturbance on the movement of the float.

Environmental adaptability enhances measurement stability. The limit switch UHC-EBK uses Hastelloy float and 316L stainless steel conduit, with a temperature tolerance of 450°C and a pressure level covering the range of PN16 to PN40. The built-in temperature compensation module can automatically correct the measurement deviation caused by the change of medium density to ensure the measurement consistency in the full range of working conditions.

3. System-level coordinated control strategy

Establishing a hierarchical calibration system is the basis for coordinating differences. The liquid level control switch UHC-EBK is used as a primary reference device, and its switch output is used to calibrate the zero point and full scale of the continuous measuring instrument. During the automatic calibration process of each cycle, the control system compares the readings of each device under steady-state conditions and automatically generates a deviation compensation coefficient.

Dynamic compensation algorithm improves the system response accuracy. When it is detected that the discreteness of multi-source measurement data exceeds the set threshold, the system automatically switches to the reference value provided by the liquid level switch UHC-EBK, and performs weighted processing in combination with the historical data trend. This mechanism is particularly important under transient conditions such as starting and stopping the furnace, and can avoid control errors caused by the failure of a single sensor.

The fault diagnosis system realizes intelligent maintenance. By analyzing parameters such as the switch action frequency and contact resistance change, potential faults such as magnet attenuation and guide tube scaling can be predicted in advance. Maintenance personnel can perform preventive maintenance according to system prompts to increase the equipment availability to more than 99.9%.

When looking for high-quality, reliable boiler level switches, YOYIK is undoubtedly a choice worth considering. The company specializes in providing a variety of power equipment including steam turbine accessories, and has won wide acclaim for its high-quality products and services. For more information or inquiries, please contact the customer service below:

E-mail: sales@yoyik.com
Tel: +86-838-2226655
Whatsapp: +86-13618105229

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