Steam and Pressure Transmitter
Steam, as an important energy medium in the industrial field, is widely used in industries such as power, chemical, pharmaceutical, and food processing. The pressure stability of a steam pipeline system directly affects production efficiency, equipment safety, and energy utilization. If the steam pressure is too low, it will lead to a decrease in heating efficiency, a longer production cycle, and even incomplete reaction. If the pressure is too high, exceeding the pressure limit of the pipeline, it may cause safety accidents such as pipeline rupture and steam leakage. Therefore, accurate measurement of steam pipeline pressure is one of the core requirements for production and operation in the industry.
Industrial Pain Points
1.Steam temperatures often reach 150-400°C, and pressure ranges from 0.5-10MPa. Excessive pressure and temperature can easily lead to measurement errors or damage to sensors with ordinary structures.
2.As steam flows through the pipeline, it is easy to condense into liquid water near the measurement point. If the pressure transmitter is not installed properly, the condensate will seep into the sensor chamber, causing fluctuations in the measurement data and even damaging the core components of the sensor.
3.Changes in some production processes can cause frequent changes in steam pipeline pressure (such as rapid changes within the range of 0.5-3MPa). Traditional manufacturers' response time (usually >500ms) cannot capture the pressure in time, resulting in a lag in the control system and affecting the stability of the production process.
4.Traditional pressure measurement equipment requires regular disassembly and calibration, and components wear out quickly in high-temperature environments, requiring frequent maintenance. This not only increases labor costs but also affects production continuity, resulting in economic losses.
Product Recommendation
For steam pipeline pressure measurement, we recommend that customers use the GPT220 pressure transmitter. The GPT220 high-temperature pressure transmitter is a dedicated device developed by GAMICOS for high-temperature medium pressure measurement scenarios, with its core positioning as "a high-precision pressure monitoring solution adapted to harsh high-temperature working conditions". The product uses a high-temperature resistant pressure sensor as the core of signal measurement, and is equipped with an optimized heat dissipation structure and a stainless steel protective housing, which can accurately convert the pressure of the measured medium into a standard output signal. From component selection and semi-finished product testing to finished product aging verification, the entire process is strictly controlled to ensure long-term stable operation in scenarios such as steam pipelines and high-temperature equipment, effectively solving problems such as accuracy drift and short lifespan of traditional pressure measurement equipment in high-temperature environments.
Core advantages：Targeted solutions to the pain points of high temperature measurement
1.Strong temperature resistance, suitable for high-temperature media.
Employing imported high-temperature resistant chips and a dedicated heat dissipation structure design, the GPT220 can measure media temperatures up to 350℃, allowing direct contact measurement of steam, high-temperature liquids/gases, and other media without the need for additional cooling devices. In contrast to traditional mechanical pressure gauges that are prone to deformation above 150℃, the GPT220 maintains stable measurements in high-temperature pipelines in industries such as chemical engineering and power generation, avoiding reading drift caused by high temperatures.
2.High stability, reduced maintenance costs
It possesses excellent anti-interference capabilities and long-term stability. Utilizing a 316L stainless steel diaphragm structure, it is compatible with various corrosive high-temperature media (such as high-temperature fluids containing trace amounts of acids and alkalis in the chemical industry), reducing component wear.
3.High precision + fast response, meeting the needs of dynamic monitoring
With a standard accuracy of ±0.5% FS and a high-precision model reaching ±0.1% FS, it can accurately capture minute pressure changes, and supports direct contact measurement, which greatly improves the pressure response frequency and is suitable for the dynamic pressure monitoring needs of steam pipelines in batch reaction processes (such as fluctuation range of 0.5-3MPa), providing real-time data support for the control system and avoiding production fluctuations caused by response lag.
Customer Case
Customer Background
In the ethyl acetate production workshop of a medium-sized chemical enterprise, steam pipelines are used to supply saturated steam at 1.2-1.8 MPa and 200-220℃ to the reactor jacket to control the esterification reaction temperature. Previously, traditional Bourdon tube pressure gauges were used to measure the pipeline pressure, which presented the following problems:
1.The pressure reading drifts approximately 1.5% per month and needs to be adjusted periodically.
2.Condensation caused pressure fluctuations of ±0.1 MPa, reactor temperature deviations of ±5℃, and a product qualification rate of only 92%.
3.The pressure gauge needs to be replaced every 3 months, and each shutdown results in a production loss of about 50,000 yuan.
Customer Requirements
Pressure accuracy should be controlled within 0.5%, and annual temperature drift within 0.5%. Improving temperature, controlling accuracy and increasing product yield.
Solution
1.Equipment selection: Select GPT220 high temperature pressure transmitter with a range of 0-2.5MPa, suitable for steam pipeline pressure range, equipped with DN25 stainless steel condenser elbow for connection to pipeline flange.
2.Installation location: Select a location 1.5 times the pipe diameter downstream of the horizontal section of the steam pipeline, avoiding turbulent areas such as pipe bends and valves to reduce the impact of fluid disturbance on the measurement. The transmitter should be installed 10cm above the centerline of the pipeline to further prevent condensate buildup.
3.System Integration: Connect the transmitter's 4-20mA signal to the workshop's DCS system, set the upper limit alarm value (2.0MPa) and lower limit alarm value (1.0MPa), and automatically trigger valve adjustment when the pressure exceeds the range to maintain pressure stability.
Solution Affects
1.Improved measurement accuracy: After the upgrade, the pressure measurement error is controlled within ±0.02MPa, the temperature deviation of the reactor is reduced to ±1℃, the product qualification rate is increased to 98.5%, and the monthly loss from defective products is reduced by approximately 80,000 yuan.
2.Reduced maintenance costs: Transmitters do not require frequent calibration, the maintenance cycle is extended to 15 months, reducing the number of downtime maintenance by 4 times per year and avoiding production losses of approximately 200,000 yuan. At the same time, the cost of pressure gauge replacement is reduced, saving approximately 12,000 yuan in consumable costs per year.
3.Enhanced safety and stability: Through real-time monitoring and automatic alarms by the DCS system, steam pipeline pressure fluctuations can be captured and adjusted within 100ms, eliminating safety hazards caused by abnormal pressure and significantly improving the stability of workshop production.
