1. Project Background: The challenge of localizing large gas generator sets

A power plant in Guangdong, Huadian, is a major project in the domestic energy sector. Its boiler system uses large gas-fired generator sets, characterized by few domestic cases, complex industrial development, and large unit scale. Such units have extremely strict requirements for boiler steamwater quality; any fluctuations in water quality can cause equipment corrosion, scaling, or even shutdown accidents. Traditional water quality monitoring and dosing systems struggle to adapt to complex working conditions, urgently requiring a high-precision, stable, and intelligent solution.

Relying on its deep experience in industrial automatic control systems, Mozhidao Measurement & Control undertook the equipment supply task for the boiler steam-water quality intelligent control system at a power plant in Guangdong, successfully overcoming the following challenges:

Adaptability of Large Gas Units: Customized monitoring and dosing equipment is developed to meet the large size and complex operating conditions of the units to ensure stable system operation.

Domestic Substitution: Breaking foreign technology monopolies, providing fully localized equipment throughout the process, reducing operation and maintenance costs, and enhancing supply chain security.

High-precision water quality control: Meets the extreme requirements for soda and water quality of gas units, ensuring power generation efficiency and equipment lifespan.

2. Core Project Solution: Full-process intelligent management and control system

Modao Measurement & Control has tailored an intelligent boiler steam-water quality control system for a power plant in Guangdong, covering four core modules: boiler steam-water monitoring system, chemical water dosing system, boiler dosing system, and circulating water dosing system, achieving full-process automation and intelligence from water quality monitoring to chemical dosing.

(1) Boiler steam-water monitoring system: high precision and real-time feedback

Dedicated monitoring instruments: Uses hydrogen conductivity measurement technology and high-precision dissolved oxygen sensors, capable of detecting trace impurities as low as μg/L, with a temperature compensation range covering 0-100°C, suitable for complex boiler feedwater system conditions.

Multi-parameter real-time monitoring: Real-time monitoring of key indicators such as conductivity, dissolved oxygen, pH, hardness, silicon dioxide, sodium ions, alkalinity, and chloride ions, with detection accuracy reaching ±5% and data error rate below 0.5%.

Intelligent data transmission: Supports RS485, TCP/IP, and 4~20mA communication interfaces, allowing seamless integration with DCS systems for real-time data upload and automatic control.

(2) Chemical and chemical dosing system: precise regulation, energy saving, and consumption reduction

Intelligent dosing control: The PLC module controls the opening and closing of solenoid valves, automatically adding scale inhibitors and corrosion inhibitors based on influent water quality, reducing chemical waste by over 30%.

Multi-stage stirring assembly: Uses pneumatic stirring and multi-stage mixing technology to improve chemical mixing efficiency and ensure uniform distribution of chemicals.

Remote monitoring and adjustment: Supports remote real-time data viewing and remote control (customization), making it easy for operation and maintenance personnel to adjust dosing parameters at any time.

(3) Boiler dosing system: dynamic balancing and equipment protection

Dynamic dosing algorithm: Combines online pH and conductivity data to dynamically calculate the type and dosage of chemicals currently needed, ensuring stable furnace water quality.

High-efficiency dosing equipment: Made from corrosion-resistant and high-temperature resistant materials, suitable for boiler system high-temperature and high-pressure environments, with a lifespan of over 10 years.

Safety protection mechanism: Equipped with power-off protection and over-temperature and over-voltage protection functions to ensure safe system operation.

(4) Circulating water dosing system: adapts to seawater, reduces consumption and increases efficiency

Seawater corrosion resistance design: optimized chemical formulation for the high chloride ion characteristics of seawater replenishment, reducing dosage by 25%, while using a thermal deaerator to lower oxygen content and extend equipment lifespan.

Intelligent linkage control: Linked with the circulating water monitoring system, it automatically adjusts dosage based on water quality changes, preventing chemical waste and equipment corrosion.

3. Project Highlights: Technological Leadership and Experience Empowerment

(1) Full-process localization to break foreign monopolies

Mozhidao Measurement & Control's intelligent boiler steam and water quality management and control system has achieved independent research and production from sensors to control modules, with equipment performance reaching a leading domestic level and some indicators surpassing imported products. The system supports seamless integration with domestic DCS systems, promoting the domestic replacement of core equipment for large gas generator sets.

(2) High precision and high stability, suitable for complex working conditions

The system uses high-precision sensors and industrial-grade programmable controllers, featuring strong anti-interference capability and high data stability, enabling long-term stable operation under complex conditions such as high temperature, high pressure, and high salinity. Equipment calibration cycles can reach up to 3 months, reducing operation and maintenance frequency and lowering labor costs.

(3) An experienced on-site commissioning team to ensure smooth project implementation

Modaodao Measurement & Control has a professional on-site commissioning team with extensive experience in commissioning large gas turbine units. The team developed a standardized debugging process (SOP), covering ten key steps: planning first, complete tools, knowledge preview, clarifying relationships, effective communication, executing according to plan, standard recording, timely assistance, process solidification, and problem closed-loop, ensuring efficient and professional debugging work.

Case Reference: In a supercritical unit project, the Modaodao team achieved a scientific adjustment to raise the boiler soda water quality pass rate to 99.8%.

4. Project Outcomes: Triple benefits of safety, economy, and environmental protection

(1) Stable water quality to ensure safe operation of the unit

After the system was put into operation, the quality of boiler steam water at a power plant in Guangdong has remained stable for a long time, with key indicators such as hydrogen conductivity and pH value exceeding industry standards, and no shutdowns caused by water quality issues occurred.

(2) Cost optimization to improve economic efficiency

Reduced chemical costs: Through precise dosing control, dosing volume is reduced by 20%-30%, saving over one million yuan in annual chemical costs.

Reduced operation and maintenance costs: equipment failure rate dropped by 40%, maintenance frequency decreased by 50%, saving over 2 million yuan in annual operation and maintenance costs.

Improved power generation efficiency: After water quality improvement, boiler thermal efficiency increased by 2%, unit power generation efficiency increased by 5%, and annual power generation increased by over ten million kilowatt-hours.

(3) Demonstration effect, promoting the localization process of the industry

The Huadian Guangdong power plant project, as a benchmark case for intelligent water quality control of large gas generator units in China, has been replicated in multiple provinces, providing a referable solution for similar projects and promoting the localization of the industry.

5. Customer Evaluation

A person in charge of a power plant in Guangdong said: "Mozhidao Measurement and Control System solves the 'bottleneck' problem in water quality control for large gas units. The equipment performance is stable, and the commissioning team is professional and efficient." After project implementation, the operational safety and economic efficiency of the units have significantly improved, creating significant comprehensive benefits for the power plant. ”

Mozhidao Measurement & Control—Breaking boundaries through innovation, defining the future with intelligence