III. Industrial Application Scenarios and Cases
3.1 Petrochemical Industry: High Differential Pressure Pipeline Flow Measurement
Application Scenario: A hydrocracking unit in a refinery required differential pressure measurement for reactor feed and product streams. The operating pressure reached 16MPa, with frequent water hammer impacts caused by startup and shutdown cycles.
Pain Points of Traditional Solutions: Using diffused silicon differential pressure transmitters, diaphragm rupture and zero drift occurred repeatedly after water hammer impacts, leading to measurement failure and frequent shutdowns for maintenance, with annual maintenance costs exceeding 500,000 RMB.
Monocrystalline Silicon High Overload Sensor Solution:
- Selected a monocrystalline silicon differential pressure sensor with a range of 0~1.6MPa and an overload capacity of 10 times the range.
- Isolation diaphragm made of Hastelloy alloy to suit strongly corrosive media.
- Special center diaphragm material and overload protection structure capable of withstanding instantaneous water hammer impacts up to 42MPa.
Application Results:
- Continuous operation for 36 months without zero drift, measurement accuracy stable at ±0.075% FS.
- No overload damage incidents occurred; annual maintenance costs reduced to below 80,000 RMB.
- Ensured continuous and stable operation of the hydrocracking unit, avoiding losses from unplanned shutdowns.
3.2 Electric Power Industry: Boiler Drum Water Level Measurement
Application Scenario: A 600MW unit boiler drum water level measurement in a thermal power plant. Operating conditions: temperature 350°C, pressure 16.7MPa, with instantaneous overpressure events during safety valve lifting.
Pain Points of Traditional Solutions: Metal capacitance transmitters experienced deformation of capacitor plates after overpressure, causing measurement error to expand to ±5%, requiring regular calibration and affecting the stability of boiler combustion control.
Monocrystalline Silicon High Overload Sensor Solution:
- Adopted a monocrystalline silicon differential pressure sensor with a range of 0~40kPa and overload capacity of 8 times the range.
- High-temperature resistant oil filling system suitable for high-temperature media up to 200°C.
- Built-in temperature compensation algorithm ensures stable accuracy across a wide temperature range.
Application Results:
- No measurement deviation after safety valve lifting; no recalibration required.
- Water level measurement accuracy stable at ±0.075% FS.
- Reduced water level control risks during unit startup and shutdown, ensuring power grid stability.
3.3 Metallurgical Industry: Blast Furnace Gas Differential Pressure Measurement
Application Scenario: A steel plant's blast furnace gas pipeline required differential pressure measurement for gas flow. The medium contained dust and corrosive gases, with sudden pressure changes due to furnace condition fluctuations.
Pain Points of Traditional Solutions: Diffused silicon transmitters were susceptible to dust blockage and corrosion; diaphragm failure occurred after overload, with an average service life of only 12 months.
Monocrystalline Silicon High Overload Sensor Solution:
- Isolation diaphragm made of 316L stainless steel with Teflon coating for corrosion resistance and anti-blocking properties.
- High overload design capable of withstanding pressure fluctuations up to 8 times the range.
- Chip encapsulation using silicone oil immersion prevents medium penetration while ensuring lossless pressure transmission.
Application Results:
- Continuous operation for 24 months without failure; long-term stability ±0.1% FS/10 years.
- Reduced blast furnace gas venting losses, generating annual economic benefits exceeding 2 million RMB.
- Adapted to harsh operating conditions, significantly improving the automation level of metallurgical production.
