1. Core principle: How can pressure difference be used to judge pipeline blockage

When the medium in the circulating water system pipeline flows at a constant speed, a stable and minimally fluctuating pressure difference will form between the upstream and downstream sections of the pipeline. Once scaling, debris accumulation, or filter blockage occurs on the inner wall of the pipeline, the fluid flow cross-section narrows, and the resistance to medium passage increases significantly. Consequently, the pressure difference between the front and rear ends of the same monitoring point will continue to increase.

The degree of blockage is positively correlated with the pressure difference: slight blockage leads to a slight increase in pressure difference, while severe blockage causes a sharp rise in pressure difference. By relying on a differential pressure transmitter to collect real-time pressure difference values at both ends, and setting a pressure difference alarm threshold in conjunction with a control system, it is possible to detect potential pipeline blockage hazards in advance, enabling early warning of blockages. This eliminates the need to wait until the water circulation becomes obstructed or equipment cooling fails before carrying out maintenance.

II. Advantages of Longlv PTL801 Differential Pressure Transmitter in Monitoring Circulating Water Blockage

 Strong adaptability to working conditions

 Circulating water is mostly industrial cooling water, containing sediment, scale, and other impurities. The temperature and humidity of the pipeline undergo significant changes throughout the year. PTL801 is optimized for fluid pressure difference measurement, capable of stably collecting pressure difference signals at both the inlet and return ends, without being slightly disturbed by conventional water impurities. It provides stable long-term online monitoring data, making it suitable for long-term uninterrupted duty monitoring in factory areas.

 Convenient early warning linkage

 The transmitter outputs standard universal signals, which can be directly connected to PLCs, control cabinets, and remote monitoring platforms. Operation and maintenance personnel can view real-time changes in pipeline pressure difference in the central control room. An early warning range is set based on the normal operating pressure difference of the circulating water pipelines in the plant area. When the value exceeds the limit, an automatic pop-up window, audible and visual alarms will be triggered, and a blockage reminder will be sent immediately.

 Simple installation and maintenance

 Simply take pressure measurements upstream and downstream of the circulating water monitoring section, standardize the wiring and debugging process, and there is no need for complex modifications to the existing pipelines. The equipment is resistant to vibration and pipeline water hammer impact, and pressure fluctuations caused by the start and stop of industrial circulating water pumps will not cause data drift. The frequency of subsequent inspection and calibration is low, reducing the workload of operation and maintenance.

 Multi-scenario coverage

 Whether it's closed-loop water for central air conditioning, cooling water for chemical processes, cooling water pipelines in power plants, or supporting filters and front-end pipelines of heat exchangers, this differential pressure transmitter can be relied upon for blockage monitoring. It can effectively identify and provide early warnings for three common blockage issues: plate blockage in heat exchangers, dirt accumulation on pre-filters, and scaling in long-distance pipelines.

III. Implementation Plan for Complete Blockage Early Warning and Monitoring

 Point layout

 Install pressure taps at the easily clogged pipe sections, inlet and outlet of the heat exchanger, and both ends of the pipeline pre-filter, and connect them to the Longlv PTL801 differential pressure transmitter. Each device synchronously collects data on high pressure at the front end and low pressure at the rear end, and directly outputs the measured pressure difference value.

 Threshold level setting

 Level 1 Warning (Mild Blockage): When the pressure difference exceeds the daily benchmark value by 30%, the system will send a reminder and arrange a scheduled inspection and cleaning;

 Level 2 alarm (severe blockage): When the pressure difference exceeds 60% of the reference value, the pipeline flow capacity drops significantly, triggering an emergency maintenance notification to prevent high-temperature failure of the heat exchange equipment.

 Long-term operation and maintenance value

 Traditional inspection methods require regular downtime for dismantling pipes to check for blockages, which is inefficient and affects production line operations. With the help of differential pressure transmitters for online real-time monitoring, it is possible to predict blockages without stopping the machine, arrange pipeline cleaning as needed, reduce unplanned downtime, extend the service life of circulating water pipelines and heat exchangers, and save costs on water treatment and pipeline maintenance.