Congo 25MW Energy Power Center Project – Power Plant Instrumentation Package Supply

Project Facts

1. Project Overview

The project involved the supply of a complete instrumentation package for the Congo 25MW Energy Power Center, a captive thermal power plant built to secure stable electricity supply for mining operations in the Democratic Republic of the Congo.

The facility is designed as a 1×25MW high-temperature, high-pressure condensing steam turbine generator set, paired with 2×120t/h high-temperature, high-pressure circulating fluidized bed (CFB) boilers. Anhui Tiankang Group served as the instrumentation package supplier for this EPC project, providing temperature, pressure, flow, and level measurement instruments, along with valves, fittings, and installation accessories. The supplied package supported reliable process monitoring and control under demanding thermal power plant operating conditions, including high-temperature steam service, high-pressure feedwater systems, and high-altitude operating conditions at elevations of 1,360–1,380m.

The plant was successfully commissioned in April 2026 and has been operating stably, providing critical power supply to the Kasompe mining operations.

2. Power Plant Instrumentation Package Supply Scope

We delivered a comprehensive instrumentation package tailored to the specific requirements of the 25MW thermal power plant. Our scope included:

Temperature Measurement:

• Bimetallic thermometers (WSS-581 series, 0-350°C / 0-80°C, 150mm dial, IP65) with thermowells

• High-temperature, high-pressure thermocouples (WRN2-72, Class I, dual-element K-type, 12Cr1MoVG sheath) for main steam and feedwater services

• Sheathed thermocouples (WRN2-630, Class I, dual-element K-type, 304SS sheath) for extraction steam services

• Sheathed RTDs (WZP2-630, Class A, dual-element Pt100, 3-wire) for condensate and cooling water services

Pressure Measurement – Power Plant Pressure Transmitters:

• Smart pressure transmitters (EJA530E series, 0-0.4MPa to 0-25MPa, 4-20mA with HART, LCD display, 0.075% accuracy)

• Smart differential pressure transmitters (EJA110E series, 0-6KPa to 0-250KPa, 4-20mA with HART, LCD display)

• Stainless steel pressure gauges (YNB-150, 1.6级, IP65, glycerin-filled for vibration resistance)

• Stainless steel diaphragm pressure gauges (YENB-150, 0-16KPa, for low-pressure air services)

• Differential pressure gauges (YCE-150, 0-40KPa, with manifold valves)

Flow Measurement:

• Long-neck nozzles (LGJJ series) for high-pressure feedwater and main steam flow measurement

• Venturi tubes (LGWG series) for feedwater flow measurement

• Standard orifice plates (LGFK series) for circulating water flow measurement

• Oval gear flowmeters (LC-B series, Ex d IIC T6) for diesel fuel oil measurement

• Annubar-type flowmeters for air flow measurement

Level Measurement – Boiler Drum Level Measurement & Coal Bunker Level:

• Radar level transmitters (TKWL-1403, 0-10,000mm, 4-20mA with HART, 80GHz FMCW, lens antenna) for coal bunker level monitoring

• Ultrasonic level transmitters (TKWL-1600, 0-4m, PTFE probe, 4-20mA) for water tank level monitoring

• Magnetic flap level transmitters (UHZ/50C, 0-1,700mm, 4-20mA with HART, side-mounted) with stop valves and drain valves

• Differential pressure level transmitters (EJA110E series) for drum level measurement

Valves & Accessories:

• 2-valve manifolds and 3-valve manifolds (304SS, for EJA transmitters)

• Instrument stop valves (304SS, 14×2mm tubing connection)

• Condensing pots for steam flow measurement

• 2-inch standpipe mounting brackets and U-bolts

Instrumentation Tools & Documentation:

• HART communicator (475 handheld terminal) for field configuration and diagnostics

• Material test certificates (MTCs)

• Calibration certificates for all instruments

• FAT reports and test documentation

• Installation manuals and maintenance guides

3. CFB Boiler Instrumentation Technical Requirements

The Congo power plant project demanded strict adherence to Chinese national standards (GB), power industry standards (DL), and international standards (IEC) due to the critical nature of power generation and the harsh operating environment. The key technical requirements included:

• High Temperature & High Pressure Service: Main steam service at 535°C and 9.2MPa (design pressure 10.6MPa) required thermocouples with 12Cr1MoVG sheaths and welded process connections. Feedwater service at 246°C and 13.8MPa required heavy-wall thermowells and high-pressure rated instruments.

• High-Altitude Environment: The plant is located at 1,360-1,380m elevation, requiring all instruments and control equipment to operate reliably under high-altitude conditions.

• Corrosion Resistance: Equipment must withstand high humidity, seasonal rainfall (800-1,000mm annually), and tropical climate conditions (temperatures ranging from 6°C to 35°C).

• Vibration Resistance: Instruments installed on fans, pumps, and other rotating equipment required vibration-resistant designs with glycerin-filled gauges and ruggedized transmitters.

• Hazardous Area Compliance: Oval gear flowmeters for diesel fuel service required Ex d IIC T6 explosion-proof certification.

• Control System Compatibility: All field instruments were supplied with standard 4-20mA output signals with HART protocol, compatible with the plant's DCS and control systems.

• Ingress Protection: Indoor instruments: IP54 minimum; outdoor instruments: IP65 minimum.

• Material Selection: Wetted parts material selected to match or exceed the process pipe material. Stainless steel components at minimum 304SS. High-temperature services used 12Cr1MoVG or 20G materials.

• Process Connections: Pressure instruments supplied with M20×1.5 connections and integral manifold valves (2-valve for pressure, 3-valve for differential pressure). Electrical connections: 1/2" NPT(F).

4. CFB Boiler Instrumentation Engineering Solution

Our engineering approach was based on the client's P&IDs, instrument datasheets and I/O requirements. Beyond material supply, our engineering team provided comprehensive technical support throughout the project lifecycle:

• High-Temperature Thermocouple Engineering: For main steam service at 535°C and 9.2MPa, we selected WRN2-72 thermocouples with 12Cr1MoVG sheaths and welded process connections, ensuring reliable temperature measurement under extreme conditions. The thermowell design included frequency calculation per ASME PTC 19.3TW to prevent vibration-induced failure.

• Flow Element Sizing & Calculation: We provided complete flow calculation sheets for all primary flow elements, including long-neck nozzles for feedwater and main steam, Venturi tubes for feedwater bypass, and orifice plates for circulating water. Each element was sized based on actual process conditions (pressure, temperature, flow rates, media characteristics) provided by the EPC team.

• Power Plant Pressure Transmitters Selection: For high-pressure feedwater service (13.8MPa, 246°C), we selected EJA530E transmitters with 0-25MPa range and 316SS wetted parts. For main steam pressure (9.2MPa, 535°C), we provided transmitters with appropriate temperature compensation and high-temperature diaphragm seals where required.

• Boiler Drum Level Measurement Configuration: For the boiler drum, we provided differential pressure level transmitters with condensation pots and 3-valve manifolds for reliable water level indication. For coal bunker level monitoring, we configured 80GHz FMCW radar level transmitters with lens antennas to overcome dust accumulation and provide reliable measurement in the challenging coal handling environment.

• Manifold Valve Integration: All pressure and differential pressure transmitters were supplied with factory-integrated manifold valves (2-valve or 3-valve, 304SS). The complete assemblies were pressure-tested at the factory to ensure leak-free performance and simplify field installation.

• HART Configuration Support: We provided a HART 475 handheld terminal for field configuration, allowing on-site range adjustment, diagnostics, and parameter setting without interrupting the 4-20mA signal loop.

5. Key Challenges & Solutions

Challenge 1: High-Temperature, High-Pressure Steam Service
The main steam and feedwater systems operated at 535°C / 9.2MPa and 246°C / 13.8MPa respectively, requiring instruments capable of withstanding extreme thermal and mechanical stress.

Solution: We selected thermocouples with 12Cr1MoVG sheaths (matching the main steam pipe material) and welded process connections to eliminate leak paths. All temperature sensors were supplied with thermowell frequency calculation reports per ASME PTC 19.3TW to ensure mechanical integrity under high-velocity steam flow. Pressure transmitters were selected with appropriate pressure ratings (up to 25MPa for feedwater service) and 316SS wetted parts.

Challenge 2: High-Altitude Environmental Conditions
The plant site at 1,360-1,380m elevation required instruments to maintain accuracy and reliability under reduced atmospheric pressure and temperature variations (6°C to 35°C).

Solution: All instruments were selected with operating temperature ranges covering the full ambient spectrum. Pressure transmitters were configured with absolute pressure options where required, and all outdoor instruments were supplied with IP65-rated enclosures to withstand the tropical climate conditions, including heavy seasonal rainfall (800-1,000mm annually) and high humidity.

Challenge 3: Complex Logistics & Tight Schedule
The project was executed under challenging logistics conditions in the DRC, with long supply chains and a tight construction schedule.

Solution: We implemented a phased delivery plan aligned with the EPC contractor's installation schedule. Dedicated production slots were allocated to ensure timely manufacturing, and all documentation (MTCs, calibration certificates, FAT reports) was compiled and submitted with each shipment to streamline site acceptance.

Challenge 4: Coal Bunker Level Measurement
Coal dust accumulation and the angle of repose in bunkers presented challenges for reliable level measurement.

Solution: We selected 80GHz FMCW radar level transmitters with lens antennas, which are less susceptible to dust accumulation compared to traditional horn antennas. The high-frequency radar provides reliable echo processing even in dusty environments, ensuring continuous level monitoring for the coal feed system.

6. Project Execution & Delivery

Execution was driven by strict adherence to the EPC master timeline and the quality requirements of Hangzhou Turbine New Energy Co., Ltd. Anhui Tiankang Group established a dedicated project management team to handle order processing, manufacturing, quality control, and logistics.

• Phased Delivery: Materials were dispatched in batches corresponding to the installation schedule. The main instrumentation package was delivered in accordance with the project timeline, with the plant achieving first fire and grid connection on schedule.

• Documentation & Compliance: Every shipment was accompanied by comprehensive technical documentation, including material test certificates (MTCs), calibration reports, FAT reports, pressure test certificates, and installation manuals. All documentation was provided in Chinese with bilingual support as required.

• Factory Acceptance Testing: All instruments underwent comprehensive FAT prior to shipment, including pressure testing, leakage testing, calibration verification, and functional testing. Test reports were compiled and submitted with the final documentation package.

• Third-Party Inspection: Equipment was subject to inspection by the EPC contractor's quality team. All items met the inspection criteria and were accepted for installation.

• Installation Support: Our project team remained available for technical consultation during installation, ensuring that any on-site questions were resolved promptly.

7. Application Areas

The instrumentation package supplied to the Congo 25MW Energy Power Center is utilized across the following critical process domains:

• CFB Boiler Systems (2×120t/h): Drum level measurement, main steam temperature and pressure monitoring, feedwater flow and temperature measurement, air and flue gas pressure monitoring

• Steam Turbine Generator (1×25MW): Main steam temperature and pressure at turbine inlet, extraction steam temperature and pressure monitoring (4 stages), condensate temperature and pressure monitoring, lube oil pressure monitoring

• Feedwater Systems (2×110% capacity electric feedwater pumps, one duty/one standby): High-pressure feedwater flow measurement (long-neck nozzles), feedwater temperature and pressure monitoring

• Condensate Systems: Condensate flow measurement, condensate temperature monitoring, condensate pump discharge pressure

• Cooling Water Systems: Circulating water flow measurement (orifice plate), cooling water temperature and pressure monitoring

• Fuel Oil Systems: Diesel fuel flow measurement (oval gear flowmeter, Ex d IIC T6), fuel oil pressure monitoring

• Coal Handling: Coal bunker level monitoring (radar level transmitters)

• Compressed Air Systems: Compressed air flow measurement (Venturi tube), pressure monitoring

8. Products Supplied

9. Project Outcome

The instrumentation package for the Congo 25MW Energy Power Center was executed successfully, meeting all quality and delivery requirements.

Key Results:

• ✓ 100% of instruments delivered on schedule – all shipments completed in alignment with EPC construction milestones

• ✓ 100% inspection acceptance rate – all equipment passed third-party inspection on first attempt upon arrival

• ✓ Successful 72+24-hour trial operation completed in April 2026

• ✓ Stable operation since April 2026 – no instrument-related issues reported during initial production phase

All supplied equipment met the project inspection requirements and was accepted for installation. The supplied field instruments and valves were integrated successfully into the plant's DCS and control systems. The plant achieved first fire, turbine roll, and grid connection on schedule, with the power unit successfully completing performance testing in April 2026. The instrumentation package has demonstrated stable performance during commissioning and initial operation, providing reliable measurement data for boiler combustion control, steam turbine monitoring, and auxiliary systems.

The successful completion of this project further strengthened Anhui Tiankang's capability in delivering complete instrumentation solutions for thermal power generation and mining infrastructure projects in Africa.

10. Need a Complete Instrumentation Package for Your Power Plant Project?

From individual transmitters to complete EPC instrumentation packages, we help contractors reduce engineering workload and shorten procurement cycles.

Send us your P&ID, instrument datasheet or I/O list.

Our engineering team can provide:

✓ Instrument selection based on process conditions and engineering standards
✓ Flow element sizing and calculation with complete calculation sheets
✓ Thermowell design and frequency calculation per ASME PTC 19.3TW
✓ Full EPC technical documentation and I/O wiring assistance
✓ Factory Acceptance Testing (FAT) and third-party inspection coordination
✓ Fast quotation – typically within 24 hours

We provide complete solutions for:

• ✔ Thermal Power Plants (Coal-fired, Biomass, Waste-to-Energy)

• ✔ Gas Turbine and Combined Cycle Power Plants

• ✔ Mining and Mineral Processing Facilities

• ✔ Oil & Gas Refineries and Petrochemicals

• ✔ Industrial Boiler and Utility Systems

• ✔ Large-Scale Tank Farm and Pipeline Projects

Contact Our Engineering Team

Yin Shuangjie
International Sales Manager
📧 Email: [email protected]
📱 WhatsApp / Zalo: +86 17856068126
🌐 Website: www.tiankang-global.com

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The information presented in this case study is for reference only and is based on project delivery records and publicly available sources.