Energy

In all areas of energy production, security of supply and reliability have top priority. IPTech has the right sensors for level, switching and pressure in the various applications.

Coal power plant

IPTech is an experienced supplier of measuring instruments for coal power plants. The sensors for level and pressure measurement are optimized and certified for use in the energy sector. Their longevity reduces operating costs and contributes to the safety of the processes.

Coal surge bin I

Level measurement and point level detection in the coal surge bin

Application

In a typical coal power plant, lignite (soft coal) and anthracite (hard coal) are stored temporarily in bins up to 15 meters high. To ensure that the coal belts are continuously loaded without interruption, a robust and reliable level measuring system is required. Additional point level detectors are used to prevent any overfilling of the bins.

Your benefit

Reliable
Consistent measurement even during filling
Cost effective
Efficient use of the entire container capacity
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Surge bin
Measuring range up to:
15 m
Medium:
Soft coal and hard coal
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Large measuring ranges, dust exposure and intense filling noise

Coal surge bin II

Level measurement and point level detection in the coal surge bin

Application

In a typical coal power plant, lignite (soft coal) and anthracite (hard coal) are stored temporarily in bins up to 30 meters high. To ensure that the coal belts are continuously loaded without interruption, a robust and reliable level measuring system is required. Additional point level detectors are used to prevent any overfilling of the bins.

Your benefit

Reliable
Dependable measurement even during filling
Cost effective
Efficient use of the entire container capacity
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Surge bin
Measuring range up to:
30 m
Medium:
Soft coal and hard coal
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Large measuring ranges, dust exposure and intense filling noise

Belt transfer station

Level measurement at the belt transfer station

Application

In a coal power plant, either hard coal or brown coal is burned as the main fuel source. The coal is transported on conveyor belts to the furnace. To avoid backup or overfilling at the belt transfer stations, level controls are necessary. Because only a reliable level measurement at these belt transfer stations can ensure uninterrupted feeding of the furnaces with coal. Additional point level detectors are installed to prevent overfilling.

Your benefit

Reliable
Reliable under all operating conditions
Cost effective
Maintenance-free operation in the plant
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
Belt transfer station
Measuring range up to:
3 m
Medium:
Soft coal and hard coal
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust exposure and intense filling noise

Coal stockpile

Height measurement of the coal stockpile

Application

After being unloaded from rail cars or ships, the coal is stored in stockpiles. Here, reliable measuring systems that function properly in any kind of weather are essential for level monitoring and belt positioning.

Your benefit

Reliable
Consistent measuring results in any weather
Cost effective
Simple installation on existing infrastructure
User friendly
Maintenance-free operation

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Stockpile
Measuring range up to:
20 m
Medium:
Soft coal and hard coal
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Rain, snow, wind, dust and noise

Wet deslagger

Level measurement in the wet deslagger

Application

In a coal fired power station, either hard coal or brown coal is burned as the main energy source. Most plants have a so-called “wet deslagger” for removing the bottom ash (slag) from the combustion chamber. Level control in the wet deslagger fulfils two important functions: First and foremost, it controls the water level, which cools and removes the hot slag. Secondly, it maintains a hermetic seal on the furnace chamber – a reliable level measurement avoids unwanted air that would otherwise get sucked into the combustion chamber.

Your benefit

Reliable
Reliable water level measurement ensures optimal operation of the process
Cost effective
Maintenance-free measurement with high accuracy
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
Wet deslagger
Measuring range up to:
2 m
Medium:
Coal slag
Process temperature:
+30 … +80 °C
Process pressure:
0 … 0 bar
Special challenges:
Buildup

Fly ash silo, ash bunker

Level measurement and point level detection in the fly ash silo or bunker

Application

The burning of coal creates huge quantities of ash. It is collected in a silo or bunker and then dumped into an open pit. To determine the filling height, radar transmitters and level detectors are deployed in the respective vessels.

Your benefit

Reliable
Reliable content measurement in the fly ash silo
Cost effective
Maintenance-free operation through non-contact measurement
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Silo, bunker
Measuring range up to:
40 m
Medium:
Ash
Process temperature:
-40 … +150 °C
Process pressure:
0 … 0 bar
Special challenges:
Extreme dust generation

Silo for filter dust

Level measurement and point level detection in the filter dust silo

Application

In power plants, the flue gases are cleaned in several ways. One of them is electrostatic filtering, which efficiently extracts large amounts of dust from the gases. This material is collected in a silo and further processed. Level measuring instruments and level detectors are used to monitor the silo.

Your benefit

Reliable
Reliable measurement even during filling
Cost effective
Reliable measurement of the entire vessel volume
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Silo
Measuring range up to:
40 m
Medium:
Filter dust
Process temperature:
-40 … +100 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust generation

Oil feed tank

Turbine oil feed tank level measurement

Application

Turbines are highly complex systems in which lubricating oil plays an important role. The oil is used to ensure proper operation, to reduce maintenance costs to a minimum and to prevent turbine failure. Turbine oils are produced from high quality mineral oils that have special properties to reduce demulsification (separation of water) and air release. The level in the feed tank must be monitored to ensure that there is always enough oil available for lubrication.

Your benefit

Reliable
Reliable measurement of the level
Cost effective
Maintenance-free measurement with high accuracy
User friendly
Reliable, continuous operation

Process data

Measuring task:
Level measurement
Measuring point:
Oil sump in the turbine
Measuring range up to:
3 m
Medium:
Lubricating oil
Process temperature:
+50 … +80 °C
Process pressure:
0 … 0 bar
Special challenges:
Low dielectric constants

Ammonia feed tank

Level measurement in the feed tank

Application

To protect the environment, the nitrogen oxide content in the flue gas is reduced as much as possible. This is accomplished by adding air and ammonia to the flue gas. Through a chemical reaction, the nitrogen oxides (NOx) are transformed into water and nitrogen. The required ammonia (NH3) is supplied from feed tanks. Level measurement in the feed tank ensures a reliable process.

Your benefit

Reliable
Optimum protection against diffusion of NH3
Cost effective
Maintenance-free measurement with high accuracy
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
Feed tank
Measuring range up to:
4 m
Medium:
Ammonia
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Strong diffusion of the product

Lime milk pipeline

Density measurement in lime milk

Application

The flue gas enters the scrubbing tower (absorber) and cools down further. Here the lime milk (gypsum suspension) is sprayed into the flue gas to wash out the SO2 gas component. The sulphur dioxide is converted into calcium sulphite, which then falls into the absorber sump. To ensure effective flue gas desulfurization, the lime milk (gypsum suspension) must always have a certain density. Radiation-based measurement is used to ensure this.

Your benefit

Reliable
Maximum safety through approvals according to SIL
Cost effective
Reliable density measurement ensures high plant availability
User friendly
Maintenance-free through non-contact measurement

Process data

Measuring task:
Density measurement
Measuring point:
Pipeline
Measuring range up to:
0.3 m
Medium:
Lime milk
Process temperature:
-40 … +50 °C
Process pressure:
+1 … +3 bar
Special challenges:
Determining exact density of lime milk

Level measurement in the raw water basin

Water treatment

Application

The raw water facility, is extracted mostly from rivers, it is conditioned for use in the steam and condensate loops. Reliable level measurement in the raw water basin ensures that there is always an adequate supply of water.

Your benefit

Reliable
Reliable measurement of the level
Cost effective
Maintenance-free operation of the measuring point
User friendly
Simple installation and adjustment

Process data

Measuring task:
Level measurement
Measuring point:
Open basin
Measuring range up to:
3 m
Medium:
Raw water
Process temperature:
+10 … +30 °C
Process pressure:
0 … 0 bar
Special challenges:
Contaminants and abrasion

Wet gypsum storage hall I

Level measurement in the wet gypsum storage hall

Application

The gypsum extracted from the exhaust gases in the flue gas desulphurisation unit is stored in the wet gypsum storage hall ready for further transport. Level sensors are needed to determine the stockpile height of the gypsum and quantity of the stock to optimise transportation management.

Your benefit

Reliable
Reliable function under all operating conditions
Cost effective
Simple installation on existing infrastructure
User friendly
Maintenance-free operation

Process data

Measuring task:
Level measurement
Measuring point:
Wet gypsum storage hall
Measuring range up to:
15 m
Medium:
Gypsum
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust generation

Wet gypsum storage hall II

Height measurement on the gypsum scraper

Application

The stored gypsum is pushed onto a conveyor belt with a scraper arm which is then conveyed out for loading and onward transportation. The radar sensor measures the height of the gypsum stockpile, and in turn is controlling the position of the gypsum scraper to optimise the gypsum loading and shipments.

Your benefit

Reliable
Reliable function under all operating conditions
Cost effective
Simple installation on existing infrastructure
User friendly
Maintenance-free operation

Process data

Measuring task:
Level measurement
Measuring point:
Wet gypsum storage hall
Measuring range up to:
15 m
Medium:
Gypsum
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust generation

Reversing conveyor

Level measurement in the discharge area of the gypsum conveyor

Application

The gypsum extracted from the exhaust gases in the flue gas desulphurisation unit is transported by conveyor belts to the wet gypsum storage hall. The stockpile loading is carried out by a reversing conveyor, which is able to, when a desired filling height is reached, traverse forward or back to another discharge position. For safety reasons, there are two redundant radar sensors at the end of the reverse conveyor belt to monitor the stockpile filling height during discharge.

Your benefit

Reliable
Reliable function, even during discharge/filling
Cost effective
Simple installation onto the existing infrastructure
User friendly
Maintenance-free operation

Process data

Measuring task:
Level measurement
Measuring point:
Wet gypsum storage hall
Measuring range up to:
15 m
Medium:
Gypsum
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust generation

Turbine steam line

Pressure measurement in the water steam line

Application

The pressure in the steam loop has to be monitored at various points in the process. Reliable measurement is required especially at the inlets of the various pressure stages of the turbine. Pressure transmitters detect even the smallest changes in the steam loop in any state of operation.

Your benefit

Reliable
Reliable operation under all operating conditions
Cost effective
Optimal plant operation
User friendly
Simple installation and adjustment

Process data

Measuring task:
Pressure measurement
Measuring point:
Steam line in the medium pressure range
Measuring range up to:
20 bar
Medium:
Steam
Process temperature:
+100 … +210 °C
Process pressure:
+6 … +20 bar
Special challenges:
High pressure and high temperatures

Receiving tank for feed water

Level detection in the receiving tank for feed water

Application

The process water, which is usually extracted from a river, cannot be fed directly into the turbine loop until it has been treated. It has to undergo cleansing through filtering systems and ionizers. The raw water has contaminants that can cause long-term buildup. Level detectors need to work reliably to protect against overfilling the tank or dry running of the pump.

Your benefit

Reliable
Reliable switching even when heavily soiled
Cost effective
Low maintenance costs
User friendly
Simple mounting and setup

Process data

Measuring task:
Point level detection
Measuring point:
Receiving tank
Measuring range up to:
5 m
Medium:
Demineralized water
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Aggressive medium

Water vapour line

Flow measurement in the steam line

Application

The pressure in the steam circuit has to be monitored at various points in the process. A reliable flow measurement is required especially at the inlets of the various pressure stages of the turbine. With a differential pressure transmitter, the flow rate can be accurately measured by means of the pressure drop across an orifice plate.

Your benefit

Reliable
Reliable function under all operating conditions
Cost effective
Optimal plant operation
User friendly
Simple installation and adjustment

Process data

Measuring task:
Flow rate measurement
Measuring point:
Pipeline
Measuring range up to:
20 bar
Medium:
Steam
Process temperature:
+100 … +210 °C
Process pressure:
+6 … +20 bar
Special challenges:
High pressure and high temperatures

Absorber pump

Pressure measurement at the absorber pump

Application

Before the flue gas enters the absorber (scrubbing tower), its pollutant content (sulphur) is measured. If the degree of pollution of the flue gas requires it, the absorber pumps are switched on and a quantity of lime milk corresponding to the pollutant content is blown in. To monitor the absorber pumps, pressure transmitters are installed in the pipelines immediately upstream and downstream of the pumps.

Your benefit

Reliable
Ceramic measuring cell is resistant to abrasion
Cost effective
Optimal operation of the pumps
User friendly
Reliable, low-maintenance operation

Process data

Measuring task:
Pressure measurement
Measuring point:
Absorber pump
Measuring range up to:
1 m
Medium:
Lime milk
Process temperature:
-40 … +50 °C
Process pressure:
+1 … +3 bar
Special challenges:
Abrasive and aggressive medium

Lime milk storage tank

Level measurement and point level detection in the lime milk storage tank

Application

The sulphur in the flue gas is chemically bound by injecting lime milk into the scrubbing tower. To ensure that there is always enough lime milk available for the scrubbing tower, sensors are required to regulate the level and reliably prevent an overfilling of the tank.

Your benefit

Reliable
Reliable level measurement and overfill protection
Cost effective
High chemical resistance
User friendly
Maintenance-free, reliable operation of the system

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Lime milk storage tank
Measuring range up to:
8 m
Medium:
Lime milk
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Abrasive and aggressive medium

Storage tanks for acids

Level measurement and point level detection in storage tanks for acids

Application

The raw water, which is usually extracted from a river, cannot be fed untreated directly into the turbine circuit of the plant. It has to be treated first. To neutralize the water, either sodium hydroxide (NaOH) or hydrochloric acid (HCl) is added. Level sensors supply the measurement data required to ensure a high availability of these chemicals and others used to treat the feed water.

Your benefit

Reliable
High operational reliability through the use of chemically resistant materials
Cost effective
Yearly WHG test can be carried out by pressing a button
User friendly
Reliable, maintenance-free measurement

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
4 m
Medium:
Lime milSulphuric or hydrochloric acid
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Aggressive media

Wastewater basin

Level measurement in the wastewater basin

Application

The wastewater created in the power plant is collected in a basin and fed into a treatment system. This is where wastewater from the chemical treatment, the slag cooling, the sanitary facilities as well as surface water and oil contaminated fluids are neutralised and treated. Immersion proof sensors are needed to measure the levels of these large amounts of water in the basins reliably and accurately.

Your benefit

Reliable
Reliable measurement despite strong foam generation
Cost effective
Simple mounting and reliable readings
User friendly
Maintenance-free and universally applicable

Process data

Measuring task:
Level measurement
Measuring point:
Open basin
Measuring range up to:
3 m
Medium:
Wastewater
Process temperature:
+10 … +30 °C
Process pressure:
0 … 0 bar
Special challenges:
Aggressive media

Storage tanks for fire water

Level measurement in storage tanks for fire water

Application

To ensure fire safety, power plants are required to have an adequate supply of extinguishing water on hand for the fire brigade. The water is usually provided through a central fire water main. To make sure there is always a minimum supply on site, trustworthy level measuring instruments are deployed in the fire water

Your benefit

Reliable
Reliable content measurement in the fire water tank
Cost effective
Maintenance-free operation through non-contact measurement
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
Storage tank, storage container and basin
Measuring range up to:
30 m
Medium:
Extinguishing water
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Large measuring ranges

Cooling tower basin

Cooling tower basin level measurement

Application

At the bottom of the cooling tower there are nozzles for atomizing and cooling incoming hot water. As the heated water is sprayed up inside the cooling tower, it warms the air, which expands, flows upward creating updraft which pulls fresh cold air up through the slatted bottom. Draft eliminators inside the cooling tower cause the cooled water to form droplets and rain back down into the cooling tower basin. The water level in the cooling tower basin must be monitored continuously to optimise use of the circulation pumps and the cooling process.

Your benefit

Reliable
Reliable operation under all operating conditions
Cost effective
Maintenance-free operation of the plant
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
Cooling tower basin
Measuring range up to:
5 m
Medium:
Water
Process temperature:
+20 … +40 °C
Process pressure:
0 … 0 bar
Special challenges:
High humidity and steam

Steam drum

Level measurement and point level detection in the steam drum

Application

Process heat in a power plant is provided by steam at different pressures. The required process temperature is regulated via the steam pressure. Depending on the process temperatures there can be pressures up to 160 bar, at temperatures up to 400 °C in the steam drums. Reliable control of water levels and fail safe limit of high and low water in the steam vessels are crucial for the safe operation of the plant.

Your benefit

Reliable
Reliable measurement through automatic measurement correction
Cost effective
Optimal operation of the facility
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Steam drum
Measuring range up to:
3 m
Medium:
Condensate
Process temperature:
+180 … +400 °C
Process pressure:
+40 … +160 bar
Special challenges:
High pressures and temperatures, steam

Heating condenser

Level measurement in the heat condenser

Application

In the heating condenser, steam is used to provide energy for a district heating network. The outgoing temperature of the heating water is controlled by the prevailing weather conditions. As part of this system, level sensor mounted in a bypass tube measures level of the condensate.

Your benefit

Reliable
Reliable measurement of process water volume
Cost effective
Maintenance-free measurement with high accuracy
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Steam drum
Measuring range up to:
3 m
Medium:
Condensate
Process temperature:
+180 … +400 °C
Process pressure:
+40 … +160 bar
Special challenges:
High pressures and temperatures, steam

Fuel oil storage tanks

Level measurement in fuel oil storage tanks

Application

To start up the combustion process in a coal power plant, fuel oil is required. Then later the plant switches over to its proper fuel, coal. The fuel oil is stored in large storage tanks equipped with state-of-the-art level measurement technology.

Your benefit

Reliable
Reliable content measurement in the fuel oil tank
Cost effective
Maintenance-free operation through non-contact measurement
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
Tank
Measuring range up to:
30 m
Medium:
Fuel oil
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Large measuring ranges and the weak reflectivity of the medium

Cooling water pumps

Dry run protection in the cooling water system

Application

A considerable amount of cooling water is required for a coal power plant. Large, powerful pumps are needed to keep the huge quantities of water circulating. Robust and adjustment-free sensors ensure that the pumps never run dry.

Your benefit

Reliable
Reliable dry run protection for the pumps
Cost effective
Simple mounting and dependable function
User friendly
Maintenance-free operation

Process data

Measuring task:
Point level detection
Measuring point:
Closed pipe system
Measuring range up to:
Switching contact
Medium:
Water
Process temperature:
+10 … +40 °C
Process pressure:
0 … +6 bar
Special challenges:
Strong pressure fluctuation

Lime silo I

Level measurement and point level detection in the lime silo

Application

For flue gas desulfurization a continuous production of the lime milk is required, the lime is kept on hand in sufficient quantities in large silos. Lime tends to readily adhere to more or less anything, depending on its type and consistency, interfering with equipment like the operation of instruments. A robust, non-susceptible level measurement is therefore absolutely necessary for reliable lime logistics and stocking. That’s why a non-contact measuring instrument that also works well in the very dusty environment is essential here.

Your benefit

Reliable
Reliable measurement even during filling
Cost effective
Accurate measurement of the entire container volume
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Silo
Measuring range up to:
30 m
Medium:
Lime
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Strong dust generation and possible condensation

Lime silo II

Level measurement and point level detection in the lime silo

Application

For flue gas desulfurization a continuous production of the lime milk is required, the lime is kept on hand in sufficient quantities in large silos. Lime tends to readily adhere to more or less anything, depending on its type and consistency, interfering with equipment like the operation of instruments. A robust, non-susceptible level measurement is therefore absolutely necessary for reliable lime logistics and stocking. That’s why a non-contact measuring instrument that also works well in the very dusty environment is essential here.

Your benefit

Reliable
Reliable measurement even during filling
Cost effective
Accurate measurement of the entire container volume
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Silo
Measuring range up to:
30 m
Medium:
Lime
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Strong dust generation and possible condensation

Combustion air pipe

Combustion air flow and volume measurement

Application

To ensure an optimum combustion process in a coal-fired power plant, the amount of air flowing in the pipes leading to the furnace must be carefully monitored. A Venturi section of the air pipe is a defined constriction in which the pressure drops a few millibars proportional to flow rate. Differential pressure transmitter measures the pressure drop across the measuring section very accurately and calculates the air flow rate.

Your benefit

Reliable
Reliable flow measurement of combustion air
Cost effective
Exact volume control possible for optimal combustion process
User friendly
Easy setup

Process data

Measuring task:
Differential pressure measurement
Measuring point:
Pipeline
Measuring range up to:
30 mbar
Medium:
Air and coal dust
Process temperature:
+200 … +400 °C
Process pressure:
0 … +1 bar
Special challenges:
Very small measuring ranges, high temperatures

Feed belt to the coal mill

Quantity measurement on the feed belt to the coal mill

Application

To fuel the power plant boilers, chain conveyors must first bring raw coal from the bunkers. Feed belts (distributors) then transport the coal to the coal mill, where it is ground into dust and blown into the boiler. In order to ensure the fuel supply to the boiler in periods of full load, and especially low load, three redundant measuring systems are employed per feed belt.

Your benefit

Reliable
Reliable monitoring of chain conveyor loading
Cost effective
Optimal plant operation
User friendly
Simple installation without mounting system

Process data

Measuring task:
Level measurement
Measuring point:
Feed belt
Measuring range up to:
1 m
Medium:
Hard coal and brown coal
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Small measuring ranges, dust, belt speed

Steam pipe

Condensate detection in the water-steam cycle

Application

To warm up the water for the boiler, steam is bled from the power plant turbine and delivered into a preheater. As the steam cools and condenses, it is removed from the preheater with pumps. Any condensate gathering in steam pipes has to be reliably detected to prevent it from entering the turbine. Vibrating level switches, mounted at low points in the system, reliably detect any water accumulation.

Your benefit

Reliable
Optimum protection of the turbine against condensation
Cost effective
Simple mounting and dependable function
User friendly
Function test via test button

Process data

Measuring task:
Point level detection
Measuring point:
Closed pipe system
Measuring range up to:
Switching contact
Medium:
Steam/condensate
Process temperature:
+150 … +320 °C
Process pressure:
+60 … +100 bar
Special challenges:
High pressures and temperatures

Conveyor belts for coal

Mass flow measurement on conveyor belts

Application

For optimal quantity measurement of the coal being conveyed to the power plant or to the individual boilers, a continuous flow of material must be ensured. Throughput measurement on the conveyor belts accurately determines the amount of coal transported.

Your benefit

Reliable
Reliable mass flow measurement, unaffected by environmental influences
Cost effective
Long service life thanks to robust measuring system
User friendly
Simple installation on existing conveyors

Process data

Measuring task:
Throughput measurement
Measuring point:
Coal conveyor belt
Measuring range up to:
2.80 m
Medium:
Coal
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust exposure and fast belt speed, vibration

Adipic acid mixing tank

Level measurement and point level detection in adipic acid mixing tank

Application

Adding adipic acid to the lime milk increases the effectiveness of the desulfurization process in the absorber. This is done by mixing adipic powder with water in the mixing tank. This acid lowers operating costs because it reduces the amount of lime milk required. Various measurement systems ensure optimal control of the mixing ratio.

Your benefit

Reliable
Reliable, service-proven technology
Cost effective
Minimal costs for maintenance and servicing
User friendly
Simple setup and commissioning

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Mixing tank
Measuring range up to:
2 m
Medium:
Adipic acid
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Aggressive medium

Absorber

Level measurement in the absorber

Application

The lime milk sprayed into the flue gas desulphurization system collects at the bottom of the absorber. The level has to be monitored to ensure that the absorber pumps do not run dry.

Your benefit

Reliable
Abrasion and overload resistant ceramic measuring cell ensures high reliability
Cost effective
Minimal costs for servicing and maintenance
User friendly
Simple stocking

Process data

Measuring task:
Level measurement
Measuring point:
Absorber bottom
Measuring range up to:
4 m
Medium:
Lime milk suspension
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Aggressive and abrasive medium

Cooling water intake

Water level gauging in the cooling water intake structure

Application

Coal fired power stations use huge amounts of cooling water. This water is usually taken from rivers, with the help of specially built intake structures. At these extraction points, reliable level measurement in all weathers and surface conditions is needed to ensure an ample supply of cooling water for the operation of the plant.

Your benefit

Reliable
Reliable measurement and pump control
Cost effective
Maintenance-free operation and non-contact measurement technology
User friendly
Reliable function in any weather

Process data

Measuring task:
Level measurement
Measuring point:
Open water
Measuring range up to:
15 m
Medium:
Water
Process temperature:
+10 … +30 °C
Process pressure:
0 … 0 bar
Special challenges:
Extreme weather conditions

Hydropower

Dam of the hydroelectric power plant

Flow measurement at the dam

Application

The seepage water in the dam of the hydroelectric plant is collected in pipes or channels. The quantity of seepage water provides information on the condition of the dam (another indicator of the condition of the dam is the clouding of the seepage water which is also assessed). The quantity of water flowing in an open channel is measured via water head height as it passes through a ‘V’ notch, flume or weir structure, which is then calculated into flow rate.

Your benefit

Reliable
Reliable flow measurement allows reliable detection of leaks in the dam
Cost effective
Sensor with high protection rating for long service life, even under extremely humid conditions
User friendly
Easy setup via external display and adjustment unit

Process data

Measuring task:
Flow
Measuring point:
Channel
Measuring range up to:
0.5 m
Medium:
Seepage water
Process temperature:
+5 … +10 °C
Process pressure:
0 … 0 bar
Special challenges:
Very humid atmosphere, condensation

Reservoir at the pumped storage power plant

Level measurement at the reservoir

Application

Pumped storage power plants store a large amount of energy and feed it into the grid very quickly when necessary. One important parameter is the height of the water level in the reservoir. It allows calculations to be made about the amount of energy available and the existing storage volume in pump operation mode. High reliability is required from the measurement technology deployed, because the sensors are often mounted at very remote locations.

Your benefit

Reliable
Ensures reliable efficient, optimal operation of the hydroelectric plant
Cost effective
Maintenance-free measurement
User friendly
Simple installation on existing structures

Process data

Measuring task:
Level measurement
Measuring point:
Basin, reservoir
Measuring range up to:
70 m
Medium:
Water
Process temperature:
0 … +25 °C
Process pressure:
0 … 0 bar
Special challenges:
Wind, weather, temperature changes, ice formation

Turbine building in the hydroelectric power plant

Level measurement and point level detection in a seepage water shaft

Application

A large number of sensors are deployed to ensure reliable operation of the generators and turbines in the hydroelectric power plant. They monitor the pressure in the hydraulic lines, the lubricant supply for turbine bearings, vibration, temperatures and many other parameters. At the lowest point of the plant, cooling water from the generators and any leakage water from the Kaplan or Francis turbines is collected in a seepage water shaft, pit or sump. To prevent a flooding of the shaft and thus of the turbine building, with disastrous results for equipment, the sensors are often installed redundantly. As additional protection, the maximum water level is monitored with a point level switch.

Your benefit

Reliable
Protection against flooding of the turbine building with high reliability water level detection of the seepage shaft
Cost effective
Optimal operation and monitoring of the pumps
User friendly
Easy installation, even in tight spaces

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Shaft
Measuring range up to:
3 m
Medium:
Water
Process temperature:
+5 … +30 °C
Process pressure:
0 … 0 bar
Special challenges:
High safety and security requirements

Water inlet at the reservoir

Level measurement and point level detection of stones and sand in the water basin

Application

If the natural flow of water into a reservoir is not sufficient for optimal energy production, additional water is fed into the reservoir via ducts or tunnels from water catchments that can be up to several kilometres distant. Coarse debris is held back by massive grids at the main water inlet. Smaller stones, grit and sand can accumulate in the transfer basin in front of the tunnel. Constant monitoring of the level of stones and sand in the basin ensures that no debris gets into the tunnel system.

Your benefit

Reliable
Reliable level switch protects the tunnel system from rocks and sand
Cost effective
Flushing only on demand
User friendly
Automatic operation

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Basin
Measuring range up to:
10 m
Medium:
Water, sand, rocks
Process temperature:
-20 … +30 °C
Process pressure:
0 … 0 bar
Special challenges:
Mechanical loads and abrasion due to water pressure, sand and stones

Pressure line in a hydroelectric power plant

Breakage and leak detection in a pressure line in a hydroelectric power plant

Application

In hydroelectric power plants, water is transported from the dam to the turbine via a pressure pipe. A partial or complete rupture of the pressure line leads to an increase in flow rate in the pipe that is higher than the maximum permissible flow expected. Undetected leaks lead to flooding and destruction of the power plant, resulting in a loss of energy production. For that reason it is important to measure the flow rate reliably in order to detect a pipe break and thus trigger the necessary remedial action, such as closing the pressure valve.

Your benefit

Reliable
Accurate flow measurement in the pipeline ensures timely leak detection in the pressure line
Cost effective
Long-term stability of the differential pressure transmitter
User friendly
Simple commissioning setup without medium

Process data

Measuring task:
Flow rate measurement
Measuring point:
Pressure line
Measuring range up to:
500 mbar
Medium:
Water
Process temperature:
0 … +20 °C
Process pressure:
0 … +500 mbar
Special challenges:
Pressure shocks

Wind power

Gearbox oil tank in a wind turbine

Oil tank point level detection in the rotor gearbox

Application

In wind turbines, efficiency has top priority: the higher the availability of a turbine, the higher the profitability and the faster the investment pays off. Wind power is transferred from the turbine to the generator via a rotor gearbox. Full lubrication of all moving parts ensures a long service life and high availability of the wind turbine, thus making it essential for the oil level in the rotor gearbox to be constantly and reliably monitored.

Your benefit

Reliable
Media-independent switching point
Cost effective
Protection against wear through continuous oil lubrication
User friendly
Compact dimensions allow easy integration into any system

Process data

Measuring task:
Point level detection
Measuring point:
Tank
Measuring range up to:
1 m
Medium:
Machine oil
Process temperature:
-10 … +80 °C
Process pressure:
0 … 0 bar
Special challenges:
Vibration, changing outdoor temperatures

Wind turbine in an offshore wind farm

Measurement of water level

Application

Wind turbines in offshore wind farms operate in an extremely harsh environment. Besides the buffeting of constant waves and often exceedingly strong winds, they have to withstand the corrosive effects of salt water. Due to the way the turbines are constructed and their location, it is inevitable that some seawater will enter the turbine tower. The water level inside the tower must be continuously monitored in order to detect any leaks at an early stage that can cause corrosion. To determine the mechanical loads and the generating capability of a wind power array, the tidal and wave height measurements on the outside are also required.

Your benefit

Reliable
Detection of leaks, corrosion prevention and safe operation
Cost effective
High-resistance materials for uninterrupted operation
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
In a tower
Measuring range up to:
15 m
Medium:
Sea water
Process temperature:
+5 … +25 °C
Process pressure:
0 … 0 bar
Special challenges:
Aggressive saline atmosphere

Solar energy

Expansion tank in a thermal solar plant

Level and pressure measurement of heat transfer fluid(HTF) in expansion tanks

Application

The solar heat captured in the mirror system of a thermal solar plant is transported via a heat transfer fluid (HTF) to the steam generator at the central turbine. The HTF normally has a temperature between 300 °C and 400 °C. There are different containers for the fluid across the plant and the varying temperatures cause volume changes to the HTF that need to be accurately measured to operate the plant safely and profitably.

Your benefit

Reliable
Highly overload-resistant measuring systems
Cost effective
Accurate level measurement for optimal utilization of the container volumes
User friendly
Easy instrument selection: one sensor version fits all tank sizes

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Tank
Measuring range up to:
5 m
Medium:
Heat transfer fluid
Process temperature:
+300 … +400 °C
Process pressure:
8 … 12 bar
Special challenges:
High temperatures, pressure surges and volume changes

Molten salt storage in a thermal solar plant

Level measurement in the molten salt storage tank

Application

The important criterion for the location a thermal solar plant is gaining the optimal amount of sunlight energy available at that site over the year. Molten salt is used to store this thermal energy produced on the days when there is abundant sunshine, this enables the production of electricity even on days with little or no direct sunlight via a heat exchange process. This molten salt is usually stored in two large vessels. One vessel contains salt at a lower temperature (approx. 300° C), the other contains salt at a higher temperature (approx. 400° C). Accurate level measurement is essential to monitor the system capacity.

Your benefit

Reliable
Reliable level measurement ensures smooth operation
Cost effective
Large storage reserves available through optimal utilization of tank volume
User friendly
Maintenance-free through non-contact measuring method

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Tank
Measuring range up to:
5 m
Medium:
Heat transfer fluid
Process temperature:
+300 … +400 °C
Process pressure:
8 … 12 bar
Special challenges:
High temperatures, pressure surges and volume changes

Wood

Drying facility for wood pellets

Point level detection in front of the wood pellet drying facility

Application

For economical production of wood pellets, highly automated manufacturing facility operation is necessary. In this process, the wood is chipped, dried and pressed into small pellets under high pressure. Reliable level sensors guarantee automated, efficient production and ensure supplies of quality wood fuel for customers.

Your benefit

Reliable
Automated production ensured by trustworthy level sensors
Cost effective
Always optimum filling of the drying facility
User friendly
Measurement unaffected by build up

Process data

Measuring task:
Point level detection
Measuring point:
Buffer tank
Measuring range up to:
Switching point
Medium:
Fine wood chips
Process temperature:
+20 … +60 °C
Process pressure:
0 … 0 bar
Special challenges:
Build up, mechanical loading

Storage silo for wood pellets

Level measurement and point level detection in a corrugated metal silo

Application

The finished pellets are stored ready for delivery in corrugated metal silos up to and over 30 m high. Larger storage volumes allow the supplier to better respond to the increased demand during the heating season and utilize the production equipment continuously throughout the year. For optimal planning of material logistics, a reliable measurement of silo contents is a must.

Your benefit

Reliable
Highly dependable and accurate level measurement, even during filling
Cost effective
By optimising silo volumes, it results in better utilization of production capacity
User friendly
Simple mounting, installation from top

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Silo
Measuring range up to:
30 m
Medium:
Wood pellets
Process temperature:
-20 … +40 °C
Process pressure:
0 … 0 bar
Special challenges:
High dust levels, temperature fluctuations and highly corrugated container walls

Mobile wood pellet silos

Level measurement and point level detection in a corrugated metal silo

Application

Pellet silos are ideal storage containers for mobile heating. Mobile wood pellet silos are used, for example, for construction and temporary heating, for drying buildings or for heating marquees or halls. The pellets are fed into the furnace and burned as required. To ensure continuous heat generation, reliable monitoring of the level in the pellet silo is necessary. The silo level data is transmitted wirelessly to the central office to ensure timely replenishment of the fuel.

Your benefit

Reliable
Reliable measurement ensures continuous heat generation
Cost effective
Optimal resupply of silos through inventory monitoring
User friendly
Simple mounting and setup

Process data

Measuring task:
Level measurement
Measuring point:
Silo
Measuring range up to:
10 m
Medium:
Pellets
Process temperature:
-30 … +35 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust generation, condensation

Biogas

Compact slurry tanks in biogas plants

Level measurement in energy production from waste

Application

Biogas plants convert a mixture of organic waste and renewable raw materials into valuable energy through fermentation using a largely CO2 neutral process. Optimal consumption of the resources and maintenance-free operation require the use of highly reliable measurement technology. In all production steps – from the delivery of raw materials and waste to the removal of residues – the levels must be closely and accurately monitored.

Your benefit

Reliable
Trouble-free operation of the fermenter with technology
Cost effective
Long service life ensured through non-contact measuring method
User friendly
Easy installation and retrofit, through external vessel mounting

Process data

Measuring task:
Level measurement
Measuring point:
Fermenter
Measuring range up to:
5 m
Medium:
Liquid manure, organic waste, corn silage
Process temperature:
+35 … +38 °C
Process pressure:
0 … 5 mbar
Special challenges:
Aggressive medium, gas overlay, measurement through closed container ceiling

Slurry tanks in biogas plants

Point level and pressure measurement in energy production from liquid manure

Application

Semi-liquid manure, or slurry, in biogas plants is often stored in closed, large-volume slurry tanks. Through fermentation, a valuable energy carrier is extracted from the mixture of organic waste and renewable raw materials. Level and pressure are monitored in the tank, as well as in the delivery and removal systems handling the raw materials and waste.

Your benefit

Reliable
Reliable operation of the fermenter through overflow protection
Cost effective
Universally applicable and modular sensors across the biogas plant, thus very cost-effective spare parts stocking
User friendly
Maintenance-free operation using build up-insensitive technologies

Process data

Measuring task:
Pressure measurement and point level detection
Measuring point:
Tank in biogas plant
Measuring range up to:
10 m
Medium:
Liquid manure, organic agricultural refuse, corn silage
Process temperature:
+35 … +38 °C
Process pressure:
0 … 5 mbar
Special challenges:
Changing media with varying properties, build up

Raw material silo in the ethanol plant

Level measurement and point level detection in the grain silo

Application

Ethanol is an additive used in gasoline. Through the use of renewable resources, the CO2 emission of fuels is significantly improved and the consumption of crude oil reduced. In modern ethanol plants, raw materials such as grain, sugar cane or sugar beet are processed into alcohol and ethanol. The resulting by-products and residues are also completely utilized. The different types of grain used for ethanol production are stored in silos more than 20 m high. Reliable silo level measurement is essential to ensure continuous production supply is maintained.

Your benefit

Reliable
Reliable level measurement for trouble-free operation of the raw material stocks
Cost effective
Complete utilising of the silo without mechanical overload
User friendly
Easy installation in the container roof with exact alignment for optimum measurement accuracy

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Silo
Measuring range up to:
20 m
Medium:
Grain, sugar cane, sugar beet
Process temperature:
0 … +40 °C
Process pressure:
0 … 0 bar
Special challenges:
Dust and noise during filling, material cone (angle of repose), changing measurement characteristics of the product

Buffer silo for raw materials in the ethanol plant

Level measurement and point level detection in buffer silos

Application

In order to always have enough material available for downstream processes in the ethanol plant, the crushed raw materials are held ready to use in buffer silos. The ground-up grain ‘flour’ for the production of ethanol is transported directly from the mill into a silo, where it is temporarily stored. The vast material throughput can lead to extreme mechanical loading of the silos and the associated equipment and high levels of dust are generated in the process. Level sensors are deployed to optimise the throughput, reduce overloading and ensure continuous, economical production and operation of the plant.

Your benefit

Reliable
The measuring systems protect against mechanical overload, thereby ensuring smooth, trouble-free operation
Cost effective
Enabling smoother continuous production guarantees economical operation
User friendly
In case of extreme dust build up on the sensor, automatic cleaning can be enabled via the air purge connections on the sensor

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Silo
Measuring range up to:
15 m
Medium:
Flour
Process temperature:
-20 … +40 °C
Process pressure:
0 … 0 bar
Special challenges:
Extreme mechanical loading of all components, high dust generation, continuous operation

Process vessels in the ethanol plant

Process vessel level and pressure measurement and point level detection

Application

To ensure the best possible fermentation of the ingeredients, optimal process conditions must prevail, control of pH value and temperature of the medium play important roles. The pH is adjusted by adding acids or alkalis, and sodium hydroxide is used to clean the vessel under absolute sanitary conditions. The levels of the process vessels have to be monitored at all times, to ensure continuous operation of the system. The measured media place very high demands on the chemical resistance of the sensors. To be totally reliable, the instruments need to be equally resistant to both acids and alkalis.

Your benefit

Reliable
Reliable long term performance and operation of the process vessels through reliable level measurement
Cost effective
High-resistance materials for long term measurement in all media
User friendly
No adjustment required for changing media

Process data

Measuring task:
Level and pressure measurement, point level detection
Measuring point:
Tank
Measuring range up to:
5 m
Medium:
Acids and alkalis
Process temperature:
+20 … +40 °C
Process pressure:
0 … 0 bar
Special challenges:
Aggressive media with different measurement properties

Fermentation in the ethanol plant

Level, switching and pressure measurement in the conversion process for alcohol production

Application

The heart of the ethanol plant is the fermentation process. This is where the sugars in the mash are converted into alcohol, which, in the subsequent distillation process, is then concentrated to a strength of 99.9 %. The CO2 gas given off by the fermentation is captured and used for carbonation in the beverage industry. To keep the fermenter vessel operating in its optimal range, reliable monitoring of the process parameters including the vessel level and overall pressure is required.

Your benefit

Reliable
Accurate readings under all process conditions in the fermenter
Cost effective
Level and pressure measurement using electronic differential pressure provides all relevant measurement data

Process data

Measuring task:
Pressure and level measurement, point level detection
Measuring point:
Tank
Measuring range up to:
5 m
Medium:
Mash
Process temperature:
+20 … +40 °C
Process pressure:
0 … 5 mbar
Special challenges:
Fluctuating gauge pressure, foaming
User friendly
Simple mounting and setup

Storage tank in an ethanol plant

Level measurement and point level detection in the ethanol storage tank

Application

After going through all process steps, the bioethanol is stored in a tank ready for delivery to the consumer. Accurate measurement of the tank contents is an important prerequisite for fiscal inventory, reliable logistics planning and ensures a sufficient supply for customers. Since the tanks can often not be emptied after an initial filling, maintenance-free operation and setup without product are crucial considerations for the measurement technology.

Your benefit

Reliable
Reliable level measurement ensures safe operation of the ethanol depot
Cost effective
High-precision measurement allows optimal utilization of the tank volume
User friendly
Installation from top, offers easy mounting and simple adjustment, even when tank is full

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
15 m
Medium:
Bioethanol
Process temperature:
-10 … +40 °C
Process pressure:
0 … 5 mbar
Special challenges:
Vapours, temperature fluctuations

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