Facility conversion as a turnkey project

Measurement campaigns

Key Takeaways

Measurement campaigns provide reliable operating and process data for the evaluation, optimization and further development of industrial systems.
The CONENGA Group plans and accompanies measurement campaigns to analyze energy flows, emissions, process conditions and plant behavior.
Structured data collection allows weak points, inefficiencies and unstable operating states to be identified.
Measurement campaigns form the basis for balancing, simulations, optimization measures and technical decision-making processes.
The CONENGA Group combines measurement technology, data analysis and process engineering know-how for the sound evaluation of complex industrial processes.

Understanding real operating conditions instead of updating assumptions

In many existing systems, DCS data, operating measurements or original design assumptions do not provide a complete picture of the actual process conditions. Temperatures deviate greatly locally, volume flows are not plausible or system balances do not close properly. At the same time, optimization measures are often based on individual values or empirical values without a reliable data basis.

Measurement campaigns are used to record real operating conditions directly on the system and to classify them technically. The focus is not on individual measured values, but on understanding temperature distributions, flow conditions, boundary zones, measurement deviations and process engineering correlations.

The combination of measurement technology, system understanding and process engineering interpretation creates a reliable basis for optimizations, conversions and investment decisions.

Installation of temperature measuring lances in the superheater of a boiler system

Typical occasions for measurement campaigns

Measurement campaigns are particularly useful when existing operating data does not appear plausible or technical decisions need to be validated.

Typical questions are:

Temperature profiles in boilers and flue gas ducts
Checking SNCR temperature windows
Validation of air and flue gas volume flows
Evaluation of false air components
Comparison between DCS values and real measured values
Root cause analysis for balance sheet variances

The measurement campaign is always tailored to the specific problem and the actual system geometry.

What can be measured

The focus is on measurements in thermal industrial plants, especially in:

Boilers and furnaces
Flues
Air and flue gas ducts
Flue gas cleaning
Combustion air systems

Among other things, temperatures, volume flows, flow velocities, pressure ratios and additional gas parameters such as oxygen are recorded.

Depending on the task, point measurements, traverses or network measurements are carried out across the system cross-section. This makes it possible to visualize spatial distributions and real flow effects that are often not detected with individual operating measuring points.

Data recording via PC and corresponding interfaces

Methodology and implementation

If possible, the measurements are carried out during ongoing system operation and using existing infrastructure such as measuring nozzles, flanges or inspection openings. Depending on the temperature range and task, suitable measuring lances, thermocouples, dynamic pressure measurements or supplementary mobile measuring methods are used.

The measurement campaign includes:

Preliminary clarification and measurement concept
Definition of suitable measuring points
Implementation in the company
Plausibility check of the measured values
Comparison with existing operating data
Technical raw data evaluation

The measuring positions are selected in such a way that a meaningful picture of the cross-section, height, depth and flow direction is obtained.

Evaluation and technical interpretation

The actual added value comes from the technical evaluation of the measurement data. The results are not viewed in isolation, but are compared with DCS data, operating states, system geometry and existing measuring points and interpreted in terms of process engineering.

This results in reliable statements on:

Temperature distributions
Flow centers
Marginal zones and inhomogeneities
Measurement deviations
Sensor quality
technical optimization potential

The results are presented in graphical and tabular form and documented in a comprehensible manner. This includes cross-sectional views, temperature profiles and comparisons between operating data and real measured values.

Volume flow net measurement using Prandtl pipe

Benefits for operators

Measurement campaigns create a reliable data basis for operation, maintenance and technical decisions.

Typical advantages:

Less trial-and-error with optimizations
Better evaluation of existing measuring points
sound basis for conversion decisions
More targeted action planning
Technical protection of investments
Higher operational reliability

This is particularly relevant for emission reduction, SNCR optimization, performance increases and the evaluation of air and flue gas systems.

Result of a measurement campaign

The result is comprehensible technical documentation with a measuring concept, measuring points, operating conditions, raw data, diagrams, tables and technical interpretation.

The report typically includes:

Graphical and tabular evaluation
Comparison with DCS and operating measured values
Plausibility check
Technical conclusions
concrete recommendations for action

If necessary, further engineering or optimization measures are derived from this.

Temperature measuring lance in the combustion chamber

FAQ on measurement campaigns

What are measurement campaigns?

Measurement campaigns comprise the structured recording and evaluation of technical operating and process data in industrial and energy plants. The aim is to analyze plant states, energy flows, emissions and process behaviour under real operating conditions. The data obtained serves as a basis for optimization, balancing and technical decisions. The CONENGA Group supports companies in the planning, implementation and evaluation of complex measurement campaigns and in the interpretation of the results.

Why are measurement campaigns in industrial plants important?

Many optimization and engineering projects require reliable operating data as a basis for technical evaluations. Measurement campaigns enable the analysis of real system conditions and help to identify weak points, losses or unstable operating modes. This enables more informed technical decisions to be made.

How does the CONENGA Group support measurement campaigns?

The CONENGA Group accompanies measurement campaigns from planning to data acquisition and technical evaluation. This combines measurement technology, balancing, data analysis and process engineering evaluation. The aim is to develop a reliable basis for decisions on optimization, conversion or operational management.

What role does measurement data play in optimization projects?

Measurement data forms the basis for simulations, balancing and technical modeling. Energy consumption, emissions and process behavior can only be reliably evaluated with real operating data. This allows optimization potential to be specifically identified and evaluated.

Why are measurement campaigns particularly relevant for existing systems?

Existing systems often have incomplete or outdated operating data. Measurement campaigns create transparency about actual process conditions and enable a well-founded evaluation of existing systems. This is particularly important for conversions, efficiency increases or decarbonization projects.

We are here for you!

Dominik Gappmaier and Jakob Hirsch are your experts when it comes to measurement campaigns!

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The CONENGA Group uses measurement campaigns and data-based analyses for the well-founded evaluation and optimization of industrial plants and processes.