Case Study

Panametrics Ultrasonic Flow Meters
monitor steam flow measurement in boilers
at Alcoa-San CiprianBenefits• Energy savings with nopressure drop
• Reliability• Accuracy• Drift free solution

A global leader in lightweight metals technology, engineering and manufacturing,Alcoa innovates multi-material solutions that advance the world. Its technologies
enhance transportation, from automotive and commercial transport to air andspace travel, and improve industrial and consumer electronics products. A pioneerin the aluminum industry for over 125 years, today Alcoa employs approximately
15,000 people in 15 countries to deliver value-add products made of aluminum,and produce best-in-class bauxite, alumina and primary aluminum products.

Problem
Alcoa used three steam boilers, operated in parallel, to provide the production units
with steam to support the production process. In order to measure the steam flow,
Alcoa initially installed flow nozzles, which is a type of flow measurement based on
differential pressure methodology. Each flow nozzle provides a flow measurementthat is used to control the load of a boiler. With three boilers, one may have ahigher load (meaning more work) than the other boilers depending on the steam
demand. The customer suspected that flow nozzles were measuring in excess
because the yield of the system had been too high since installation, and the flow
measurement was not sensitive to any process actions taken to reduceenergy usage.

Solution

Benefits

Alcoa needed to improve the flow measurement to:

Panametrics GS868 ultrasonic steam flow meters quickly
detect any change or problem in the steam generation,either in quantity or quality. The ultrasonic technology
provides accurate and repeatable flow measurements
across a wide flow range of 1-200 T/h (high turndown),
cause no pressure loss, have no moving parts, no drift andno maintenance. With pressure and temperature inputs, theGS868 also provides a direct mass flow measurement, whichsimplified Alcoa’s overall system installation and wiring
requirements, resulting in lower overall installation costs
and on-going operating costs. Alcoa commented that the“repeatability and lack of drift over the years is amazing.”• Understand the current efficiency of the boilers toproduce steam• Measure improvements in boiler efficiency and control,
based on process actions• Control and improve steam quality
They ultimately decided to install Panametrics, a Baker
Hughes business, GS868 ultrasonic steam flow meter withFTPA buffers and BWT transducers in a flowcell. With thenew meters in place to monitor steam flow measurement
in boilers, Alcoa was able to get the actual yield of thesteam production and monitor the impact of the flow
measurements taken to improve steam production.

Payback
After installing GS868 Flow Meter, Alcoa confirmed that theflow nozzles were measuring flow rates 6-10% higher than theactual flow. Using the ultrasonic flow solution, Alcoa began
to improve the yield of steam production and monitor theimpact of improvements. With the use of the ultrasonic flow
meter, Alcoa reported a yield increase of 2-3.5% in steam
production. With this 2.5% improvement in steam yield
results, Alcoa realized a total yearly savings of over $220,000
for the three boilers:• Annual steam generation: 110T/h*20h/day*300day/
year=660kT/year• Approximate steam cost: $4.5/T• 2.5% yield improvement = 16,500T additional
steam produced• 16500T*$4.5/T= $74.25k per boiler per year.- $222k/ysavings for three boilers

Panametrics, a Baker Hughes Business, provides solutions in the toughest
applications and environments for moisture, oxygen, liquid and gas flow
measurement. Experts in flare management, Panametrics technology also
reduces flare emissions and optimizes performance.
With a reach that extends across the globe, Panametrics’ criticalmeasurement solutions and flare emissions management are enablingcustomers to drive efficiency and achieve carbon reduction targets acrosscritical industries including: Oil & Gas; Energy; Healthcare; Water andWastewater; Chemical Processing; Food & Beverage and many others.
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