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Explore how industrial measurement solutions are used across industries and processes
Showing 460 use cases
Transportation & Logistics
Know the exact location of every vehicle in your fleet at all times. Real-time GPS tracking provides live positions, speed, heading, and ignition status on a single dashboard, enabling dispatchers to make informed decisions and customers to receive accurate ETAs.
Transportation & Logistics
Monitor harsh braking, rapid acceleration, sharp cornering, and speeding events across your fleet. Assign driver safety scores, identify high-risk drivers, and reduce accidents through data-driven coaching programs.
Transportation & Logistics
Monitor fuel consumption in real time, detect unauthorized drainage events, and reduce fuel costs by connecting precision fuel sensors to GPS trackers. Correlate fuel usage with routes, drivers, and driving behavior to identify waste.
Food & Beverage (Cold Chain)
Ensure perishable goods maintain the required temperature throughout transit. Connect temperature sensors to GPS trackers to monitor refrigerated compartments in real time, receive alerts on threshold violations, and generate compliance reports for SFDA and HACCP audits.
School Bus & Education
Track school buses in real time, monitor driver behavior on school routes, enforce speed limits near schools, and give parents live visibility of bus location and estimated arrival. Driver identification via iButton or RFID ensures only authorized personnel operate school vehicles.
Transportation & Logistics
Combine GPS tracking with AI-powered dashcams to detect risky driving in real time, capture incident evidence, and reduce insurance costs. Dual-facing cameras record road conditions and driver behavior simultaneously, providing context for every safety event.
Construction
Define virtual boundaries around job sites, warehouses, customer locations, and restricted zones. Receive instant alerts when vehicles enter or exit designated areas, track time spent at each location, and enforce operational boundaries automatically.
Government & Public Safety
Meet Saudi Arabia IVMS (In-Vehicle Monitoring System) requirements with certified GPS tracking devices. Automatically transmit vehicle location, speed, and driver behavior data to regulatory platforms. Generate compliance reports and maintain audit-ready records.
Construction
Track the location and utilization of high-value assets — generators, heavy equipment, containers, and trailers — across remote job sites. Battery-powered GPS trackers with long standby life provide positions even where no power is available, while satellite connectivity covers areas beyond cellular range.
Distribution & Delivery
Reduce mileage, fuel costs, and delivery times by optimizing routes based on real-time traffic, vehicle locations, and delivery priorities. Dispatchers assign jobs to the nearest available driver, track progress in real time, and adjust routes dynamically as conditions change.
Field Services
Schedule preventive maintenance based on actual vehicle data — mileage, engine hours, DTC codes, and battery voltage. OBD-connected trackers read engine diagnostics in real time, alerting fleet managers before breakdowns occur and reducing unplanned downtime.
Transportation & Logistics
AI-powered dashcams detect drowsiness, yawning, phone usage, and smoking in real time. Audible in-cab alerts warn the driver immediately while the fleet manager receives event footage for review and coaching.
Government & Public Safety
When an accident occurs, access detailed event data within minutes — GPS coordinates, speed at impact, g-force readings, dashcam footage, and driver behavior in the moments before the incident. Protect your organization from false claims and accelerate insurance processing.
Car Rental
Locate and recover stolen or unauthorized vehicles using concealed GPS trackers with backup battery power. Remote engine immobilization, tamper detection alerts, and real-time location sharing with authorities enable rapid recovery and minimize losses.
Transportation & Logistics
Lower fleet insurance premiums by providing insurers with verified safety data — driver scores, incident rates, dashcam footage, and IVMS compliance records. Telematics data turns safety investment into measurable insurance savings.
Transportation & Logistics
Access live video feeds from any vehicle in your fleet through a web dashboard or mobile app. Multi-channel MDVR systems support up to 8 cameras per vehicle — road-facing, driver-facing, cargo area, and blind spots — enabling remote supervision and incident response.
Government & Public Safety
Protect high-value cash transport vehicles with multi-layer security: real-time tracking, route deviation alerts, panic buttons, smart door locks, and video surveillance. Any deviation from the planned route triggers instant alerts to the control room.
Mining and Metal Production
Track heavy mining vehicles, dump trucks, and personnel carriers across remote mine sites. Monitor speed limits in hazardous zones, enforce proximity warnings, track equipment operating hours, and ensure compliance with mine safety regulations.
Public Transit
Dispatch the closest available emergency vehicle to any incident location using real-time GPS positions. Track response times, monitor ambulance and fire truck routes, and generate detailed response analytics for service improvement.
Environment and Recycling
Monitor fleet carbon emissions based on fuel consumption, mileage, idling time, and vehicle type. Generate sustainability reports aligned with Vision 2030 environmental goals and identify opportunities to reduce your fleet carbon footprint through route optimization and driver training.
Public Transit
Count passengers boarding and alighting public transit buses using video-based AI or infrared sensors integrated with GPS trackers. Correlate ridership data with routes, stops, and time of day to optimize schedules and capacity planning.
Car Rental
Manage shared company vehicle pools with GPS tracking, smart lock access control, and automated booking integration. Track who used which vehicle, for how long, and which routes were driven — enabling fair cost allocation across departments.
Utilities
Monitor electric vehicle battery levels, charging status, and range estimates alongside conventional fleet tracking. Plan routes that account for charging station locations and battery capacity, ensuring EVs complete their assignments without running out of charge.
Transportation & Logistics
Monitor tire pressure and temperature across all wheels in real time using wireless TPMS sensors connected to GPS trackers. Under-inflated tires increase fuel consumption by 3-5% and are a leading cause of tire blowouts — early detection prevents both.
Oil and Gas Offshore
Track vehicles, equipment, and personnel in areas without cellular coverage using satellite-based GPS trackers. Oil and gas operations, desert logistics, and remote construction sites rely on satellite connectivity for location updates, emergency alerts, and check-in verification.
Energy
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.
Energy
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.
Refining and Petrochemicals
Acid slurries in the alkylation unit create an aggressive environment that requires robust, highly resistant level measurement instrumentation to withstand the conditions. Accurately reporting the process levels ensures that there is ample acid available for proper execution of the alkylation process.
Mining and Metal Production
Depending on the manufacturing process and the type of metal being produced, various additives such as lime are required. The products are stored in silos or concrete bunkers and usually fed to the process via conveyor belts. For cost-effective storage of these materials, level measurement in the silo contents is essential.
Energy
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.
Pharmaceutical Industry
In the pharmaceutical industry, numerous liquids with widely different properties are required. Liquid intermediate products must be made available and held ready for further processes. To ensure smooth, continuous production, reliable level measurement and point level detection are essential.
Energy
Level measurement with guided radar for regulating the electrolyte level and the water intake Pressure sensor for pressure monitoring in an electrolyte tank Differential pressure measurement between the two electrolyte tanks.
Refining and Petrochemicals
In an alkylation unit the acid settler is fed from the reactor vessel which is used to remove acid for recycling back into the reactor. The layers created in the separation process form interfaces that must be tracked to manage the output of the material from the unit. Reporting density on a horizontal plane enables accurate control of the process and maximizes throughput, therefore controlling the acid levels for optimal processing.
Mining and Metal Production
The alumina powder is kept ready in storage and day silos for subsequent smelting. Aluminium smelting is carried out in the fused salt electrolysis process, where pure liquid aluminium is extracted from aluminium oxide. Optimal storage is ensured by level measurement and point level detection.
Mining and Metal Production
The extraction of Aluminium from natural deposits of bauxite requires complex and expensive processes. In the ‘Bayer process, the bauxite is first mixed with sodium hydroxide, autoclaved and then stirred. After that, it is fed into the calciner (high temperature kiln), where it dehydrates to a fine white powder, aluminium oxide (Al2O3). Level measurement in this tank ensures optimal operation of the process.
Refining and Petrochemicals
Amine contactors introduce amine solutions to the incoming natural gas from the inlet separator to remove acidic components, such as H2S and CO2, from the process stream. The operator must accurately monitor the amine collecting at the bottom of the contactor to ensure that the process is running efficiently.
Energy
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.
Chemical Industry
In the ammonia reactor, nitrogen reacts with hydrogen to form ammonia. The temperature in the reactor can be anywhere up to 500 °C at pressures of 200 bar. To monitor the system pressure, the measurement itself does not take place in the interior of the reactor, but in the cooler inlet pipe of the reactor.
Chemical Industry
In the ammonia separator, the reaction gas mixture (ammonia, hydrogen, nitrogen, traces of methane) is cooled to the boiling point of ammonia (-33 °C). This condenses the ammonia gas. A bypass tube is typically used for measuring the level of the condensed ammonia. In addition, a limit switch is also installed directly in the vessel as a redundant measurement.
Chemical Industry
The diffusion behaviour of ammonia is extreme, which means it can eventually pass through any conventional process fitting or elastomer seal. To avoid any long term leaks and unwanted outages, gas-tight process sealing and special safety configurations are therefore mandatory, which considerably restricts the choice of instrumentation. The high risk potential and tough environmental restrictions also make reliable control of the level absolutely necessary when handling ammonia.
Refining and Petrochemicals
During the sulfur removal process, nitrogen is converted into ammonia through a water wash process to be sold for fertilizer production. Stringent environmental restrictions and the high hazard potential make secure control of the levels in ammonia handling processes absolutely necessary.
Food Industry
In the agricultural industry, animal feed is usually stored in tall, slim silos. To ensure that there is always enough animal feed in stock, a reliable level measurement combined with wireless data transmission is a great business asset. A fully automatic notification of resupply requirement can trigger the sending of an order to the animal feed supplier.
Ship and Yacht Building
Ship heeling caused by high winds, uneven cargo loading or the forces of sharp turns is counteracted by anti-heeling systems. To counter these conditions, ballast tanks are connected to each other by means of pipe systems. Depending on the attitude of the ship, the tanks are either blown out or flooded by means of compressed air blowers or pumps. Reliable level measurement is needed to control this system.
Food Industry
A wide variety of aromas and flavourings are used in the food industry. The containers which store these ingredients until further processing often have small dimensions and internal obstructions. They are cleaned several times a day during batch changes. Level measurement is essential for cost-effective stocking of these ingredients.
Paper Industry
Large quantities of fibre waste are produced during paper production. These are dried and burned and the energy released during combustion is used as process heat or to generate electricity. The ash is stored in high silos to be later used as an additive in the building materials industry. When the ash silo is filled, a great amount of noise and dust is generated and the material forms large angles of repose and overhangs. Filling, emptying and transportation logistics are controlled through the level measurement system.
Food Industry
The aluminium cans are sterilised with steam at a temperature of 120 °C and a pressure of 3 bar in an autoclave. Then, while the cans are still in the autoclave, they are cooled down with water to a temperature between 35 °C and 40 °C. They are dried and further cooled before being stacked in the warehouse. To enable a safe, optimal autoclaving process, pressure and limit level are measured.
Pharmaceutical Industry
In the production of medical consumables, autoclaves are commonly used for sterilization. Every autoclave has 4 chambers where medical products are sterilized. They work with dry, saturated steam at 2.7 bar pressure and 130 °C. To regulate the water level in the condensate sump, a reliable level measurement is required. The overpressure is also measured to ensure an optimal and safe autoclaving process.
Refining and Petrochemicals
Precise interface monitoring in refinery separators is critical to product quality because it confirms there is complete separation. For liquid-liquid interface in a BTX (benzene, toluene, xylene) separator, an accurate measurement helps control the quality of the separator’s output and thus helps to extend equipment life in downstream units by avoiding potentially expensive operating issues.
Oil and Gas Offshore
Floating drilling or pumping assets such as platforms or FPSOs are stabilized by filling or emptying ballast tanks with seawater. This enables operators to critically and safely manage the ballast and trim of a vessel according to operational needs, deck loading and sea conditions. For trouble-free operation of the ballast system and the safety of personnel and equipment on board, reliable level measurement and point level detection are absolutely essential.
Ship and Yacht Building
The ballast water measurements in the wing and double bottom tanks go directly into the control system for the ship trim, draught and list. Since these measuring points are virtually inaccessible during operation on board, reliability and stability are an absolute must. Pressure shocks, abrasive sand particles and seawater place additional heavy demands on the instrumentation.
Water and Wastewater
Water obtained from wells adjacent to lakes and rivers is called bank filtration. The flowing water constantly seeps through the riverbed and mixes with the ground water. The level of water must be constantly monitored for an optimum extraction of water. The pump pressure is also monitored in the delivery line.
Food Industry
The small batch filler vessels around 1 m high and 60 cm diameter alongside the production facility supply the filler heads of the tank. The products vary from conserve to peanut butter to chocolate spread, with varying viscosity and temperatures. The product density is also changing from each batch. The level system is required to enable an optimal filling of jars.
Pharmaceutical Industry
Pharmaceutical products such as drugs and vaccines are held in batch filling holding tanks ready to be filled into injection vials under absolutely sterile conditions. After each batch, the holding tank has to be totally sterilized using an autoclaving procedure. During this process, the sensor is exposed to a pressure of 2.5 bar and a temperature of 130 °C for at least half an hour. The rapidly changing levels of the aqueous liquids are continuously monitored. The rapidly changing levels of the aqueous liquids require continuous and precise monitoring.
Paper Industry
The press rolls are cleaned during product changes or shutdowns of the paper machine and then treated with a special coating agent. This protects them from adhesions and deposits that could cause the paper web to tear or split in the machine. The coating agent is mixed with hot water in a batching tank at a temperature of 50 °C, and pumped to various points in the machine. To maintain automatic operation, the level in the batching tank must be measured and the filter status monitored continuously.
Food Industry
The production of dairy cultures is a process characterised by heat treatment, cooling, inoculation, incubation and storage. Exact timing and temperatures must be maintained throughout all phases of production. In addition, contamination from outside must be avoided. Reliable level measurement and point level detection are important for maintaining an optimal process.
Pharmaceutical Industry
Many different ointments and creams are produced in batching tanks. The process conditions in batch production are typically characterized by high temperatures and vacuum. After each batch run, the tank needs to be cleaned quickly and effectively with chemically aggressive cleaning agents ready for the next batch. Contamination of the products during the mixing or reaction process is prevented by the use of a protective gas atmosphere. To ensure a safe, reliable process, both the level and the gas head pressure must be continuously monitored.
Food Industry
During the brewing process, a thick layer of foam is always present in the beer tanks. Therefore usually two pressure transmitters are used for level measurement. One transmitter measures the head pressure, while the other at the bottom measures the total pressure. The level is precisely calculated from the differential between these two pressures. Hygienic process fittings are absolutely necessary for these sensors.
Energy
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.
Ship and Yacht Building
Every ship has ‘bilges’ – this is space at the lowest point of the vessel between the floor of the engine room and the bottom of the ship. A water/oil mixture collects in this bilge area, where the mixture is pumped out and recovered and separated into water and oil by an on-board skimmer and demulsifying unit. The bilge de-oiling equipment is normally controlled by level switches. The oil sumps of the main engine and any auxiliary systems must also be monitored continuously for safety and environmental reasons.
Water and Wastewater
The methane gas extracted from the digestion tank is temporarily stored in a gas reservoir. Depending on the design of the gas storage facility, either a flexible diaphragm of plastic or a floating roof is used for volume equalization. The gas volume and gas pressure are measured continuously to ensure reliable and safe operation.
Pharmaceutical Industry
Some pharmaceutical companies use bioreactor vessels to cultivate particular cells or microorganisms required for certain treatments. The very high level of hygiene required means the vessels and all associated parts must be easy to thoroughly clean, because even the slightest contamination with other organisms can lead to an aborted production run. These reactors are mainly "batch-fed", where they are completely filled at the start and not emptied again until the process is completed. The pressure and level in the reactor have to be monitored continuously during process in order to obtain a high-quality yield.
Building Materials
Bitumen is an important ingredient in asphalt production. It binds stone aggregates together to form the finished asphalt. To enable cost-effective asphalt production, reliable level measurement and overfill protection in the storage tank is required.
Mining and Metal Production
Burden (iron-bearing materials) and coke are transported from the bunker to the top of the blast furnace. The charging of the furnace is done via conveyor belts or small aggregate wagons. To ensure an optimal distribution of the burden and coke layers, exact level measurement is required.
Paper Industry
In order to achieve the desired degree of whiteness, the pulp must be bleached. For this it is filled into the 25 meter high bleaching tower. The bleaching process runs continuously at temperatures up to 95 °C, with using chemicals such as oxygen, ozone or peroxide. The bleached pulp is discharged via screw conveyors. Due to its size, the bleaching tower is never emptied. Continuous level measurement enables a smooth process flow.
Cement Industry
To attain high quality and uniform material consistency in the finished cement, the raw material is homogenized in a so-called blending bed. The rock is distributed evenly over the blending bed with a stacker. Material is removed with a scraper. To ensure that the incoming material is distributed as evenly as possible, the level must be continuously measured.
Refining and Petrochemicals
The blowdown drum is designed to allow the refinery to release any process or byproduct liquids including hydrocarbons, in a safe and controlled way that protects plant equipment and personnel. The blowdown drum can see rapid filling at high pressures and temperatures. Because of the mixture of products, density and viscosity can also fluctuate, so the level must be measured quickly and reliably.
Food Industry
Before they are filled with beer, the bottles are thoroughly cleaned. The bottles are fed into the system and filled with caustic water in the basin of the washing facility, which removes all coarse dirt and contamination. Water at different temperatures is then sprayed into the bottles via high-pressure nozzles in order to remove any remaining dirt and the caustic solution. To ensure optimal system operation, the level in the basin is hydrostatically monitored. In addition, the pressure in the supply line to the basin and in the water pipeline to the rinsing nozzles is measured.
Building Materials
After crushing and screening, the different aggregates are transported via conveyor belts and distributed among the silos. Before further processing, the stones, gravel or rock flour are stored in buffer and production silos. To ensure optimal material storage, a precise level measurement is required.
Energy
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.
Mining and Metal Production
In the smelter, above the fused salt electrolysis bath there are small buffer tanks that are pneumatically fed via pipelines. The alumina powder is dispensed into the melt bath in small quantities from these tanks. The filling of the buffer tank is controlled by the feed pressure. Full and empty alarms ensure optimal charging of the powder.
Energy
Continuous level measurement with radar in the buffer tank for potash lye.
Building Materials
After being crushed, screened and sorted into different grain sizes, the gravel and sand are transported on conveyors and stored in large stockpiles. To automate the stockpiling levels and enable the optimum area to be filled, a reliable level measurement is essential.
Chemical Industry
Dependable storage is not only the basis for reliable production and supply, it also protects against raw material shortages and price volatility. In addition to regulations on the use of overfill protection or safety instrumented systems, large storage tanks are also often subject to hazardous area codes of practice in conjunction with level measurement.
Mining and Metal Production
Dependable storage is not only the basis for reliable production and supply, it also protects against raw material shortages and price volatility. In addition to regulations on the use of overfill protection or safety instrumented systems, large storage tanks are also often subject to hazardous area codes of practice in conjunction with level measurement.
Pharmaceutical Industry
In the pharmaceutical industry, cleaning of process equipment takes place within the framework of a validated "Clean in Place (CIP)" process to ensure aseptic conditions are maintained in production equipment, tanks and pipelines. Sodium hydroxide or concentrated acids are frequently used as cleaning agents, which are held in storage tanks within the CIP system. They are diluted in a premix vessel prior to use. Level measurement enables safe storage and optimal usage of these cleaning agents. Point level detection serves as overfill and dry run protection.
Food Industry
CO2 is produced during the fermentation process in the fermentation tank. It is captured to increase efficiency and used later in the filling process. To this end, CO2 recirculation systems are integrated in the brewing process. In whats known as a foam trap, the CO2 is fed into a small container and passed through a tank filled with water, in order to filter out any residues in the gas generated in fermentation. Foam is produced during this process. If too much foam accumulates, it has to be flushed out at an early stage. For this purpose, a fine spray of water is introduced via a spray ball to 'kill the foam'. A point level detection system ensures a reliable and efficient flushing process and reduces water consumption.
Pharmaceutical Industry
The empty raw capsules and the active ingredient pellets are stored above the filling machine. Reliable level measurement is required here to ensure a continuous supply to the process. The capsules are only lightly stuck together and can be easily sucked apart by a vacuum, so that the upper part separates from the lower part. The pellets are then filled into the lower part of the capsule. After filling, the capsules are transported to the collecting vessels via a hose system. A level detection system serves as overfill protection in these containers.
Ship and Yacht Building
The levels in storage tanks, especially those on board chemical tankers must be continuously measured. This is especially important to monitor during loading and unloading operations, because of strict safety and environmental requirements. Any overfilling or product discharge on deck or into the sea could have devastating consequences for human life as well as the wider environment. Also, to prevent damage to the tanks caused via external temperature fluctuations, or overpressure and underpressure created by charging and discharging procedures, the internal tank pressures require continuous monitoring.
Ship and Yacht Building
Bitumen is transported at temperatures of around 170 °C to 190 °C. The heating is supplied via an array of multi-layered heating tubes mounted on the floor and sides of the tanks. To ensure efficient utilisation of the tanks as well as a safe ship attitude, the levels in the bitumen tanks require accurate monitoring, particularly during loading and unloading.
Ship and Yacht Building
Liquefied gas is transported in insulated cargo tanks on LNG carriers at temperatures of -162 °C. The instrumentation used must be specially designed for these extreme temperatures. Pressure, level and point level of LNG in the cargo tanks must be reliably measured for the transport.
Ship and Yacht Building
To extend the duration of stay at sea, every cubic centimetre of space on navy and research vessels is utilised. All available spaces and any inaccessible places on the ship are used as additional tanks for drinking water, diesel or aviation fuel. The tank shape and dimensions are completely different from familiar standard tanks. Depending on the type and size of the ship, they can also extend over several decks. A reliable level measurement is indispensable for the operation of these ships.
Building Materials
Before further processing, the cement is stored in tall silos. The cement is transported both in and out of the silo via pneumatic conveying. Efficient storage and transport of the product is ensured by accurate level measurement and point level detection, as well as also monitoring the pneumatic conveying system pressure.
Cement Industry
Before further processing, the cement is stored in tall silos. The cement is transported both in and out of the silo via pneumatic conveying. Efficient storage and transport of the product is ensured by accurate level measurement and point level detection, as well as also monitoring the pneumatic conveying system pressure.
Food Industry
The milk is mixed with the cultures and the rennet and fed into the cheese vat. The milk is then coagulated at a constant temperature of +35 °C. After it has solidified, the curd is cut. The whey is then pumped out through a pipeline. The curd is removed for further processing. Reliable point level detection prevents dry run.
Water and Wastewater
Chemical tanks guarantee the supply of raw materials for ongoing processes. The plant operator needs exact level readings from the containers at all times to be able to ensure punctual replenishment. An additional level switch protects against overfilling.
Water and Wastewater
Through the addition of chemicals, phosphates in the wastewater are precipitated out, for example in primary sedimentation, in aeration systems or in special precipitation and secondary clarifiers. Precipitants like ferric chloride bind the phosphate chemically and deposit it in the sludge. In the storage tanks for these chemicals, a level measurement and point level detection system is deployed for continuous inventory control and optimal dosage.
Chemical Industry
Chlorine production and storage places high demands on the chemical and the diffusion resistance of the materials in the production equipment. Extensive process knowledge and experience is required when selecting the sealing materials. In fact it is decisive for the long-term, safe and profitable operation of the plant. Since the processes can only be interrupted at great expense and plant disruption, the reliability of the instrumentation is a top priority.
Food Industry
After the “conching” process the liquid chocolate is kept in large tanks for further processing. An agitator stirs the chocolate “mass” to maintain a uniform consistency and temperature in the vessel. A reliable level measurement is required in both the chocolate tank and the downstream filler hoppers to control the production process.
Paper Industry
Cleaners remove contaminating materials that are specifically heavier than fibres. In waste paper processing, these contaminants are, for example, sand, glass, stones or staples. The feed through the inlet is tangential in order to set the flow of material in rotation. The heavier particles migrate outwards due to the centrifugal forces and are precipitated downwards, while the lighter fibres in the middle of the vortex rise upwards and are passed on as accepted material. Pressure measurements in the inlet, outlet and overflow are required to regulate the process and ensure that it stays at the optimal operating point.
Food Industry
The cleaning of process equipment in the food industry takes place within the framework of validated "Cleaning in Place (CIP)" processes that ensure aseptic conditions in production tanks. Sodium hydroxide or concentrated acid are frequently used as cleaning agents, which are stored in the storage tank of the CIP system and diluted in the production vessel. Level measurement enables optimal storage of these cleaning agents. Point level detection serves as overfill and dry run protection.
Cement Industry
To produce cement, the raw meal is burned to clinker in a long rotary kiln. After leaving the rotary kiln, the clinker has a temperature of up to +1300 °C and must be cooled down to a temperature of about +200 °C for further storage. To achieve this, the clinker bed is cooled with a continuous stream of air. Pressure monitoring is required in the lower part of the clinker cooler to make the cooling as effective as possible. The material height of the hot clinker, at over 1000 °C on the conveyor belt, also has to be reliably measured.
Cement Industry
After the raw meal is burned, the emerging clinker of varying consistency is stored for further processing. The silos are filled and emptied through different openings. Continuous operation of the subsequent production processes is ensured by level measurement and point level detection.
Energy
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.
Energy
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.
Energy
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.
Energy
Mechanical cleaning removes entrained floating matter with screens or sieves. This protects the downstream process stages from buildup, clogging and abrasion. Solids with diameters greater than 25 mm are trapped in the coarse screens, compressed in a press and then disposed of. Finer secondary screens remove smaller residual materials. Measurement of the difference in water level between the front and the back of the screen determines the degree of contamination and initiates the cleaning of the screen when necessary.
Water and Wastewater
Mechanical cleaning removes entrained floating matter with screens or sieves. This protects the downstream process stages from buildup, clogging and abrasion. Solids with diameters greater than 25 mm are trapped in the coarse screens, compressed in a press and then disposed of. Finer secondary screens remove smaller residual materials. Measurement of the difference in water level between the front and the back of the screen determines the degree of contamination and initiates the cleaning of the screen when necessary.
Refining and Petrochemicals
Delayed coking units are a critical step in the refining process - this is where downtime, inefficiency, and overfill are not an option. They generate extreme heat during operation and are very large vessels. By monitoring upper vapour phase density, operators can reduce antifoam carry-over and improve continuous productivity with accurate level measurement.
Mining and Metal Production
Coke provides the necessary process heat, serves as a metal reducing agent and is a supporting matrix in the blast furnace. To achieve a high quality coke, the pressures in each of the separate ovens of a coking plant are individually regulated.
Refining and Petrochemicals
Coke is often stored in very tall silos. Coke product is also susceptible to plugging the chute as the vessel empties. To accurately measure and monitor the level in these silos, especially during fill/empty stages, the instrumentation must be able to perform reliably, even under these conditions.
Refining and Petrochemicals
After the coke is extracted from the drums it is stored in silos or stockpiles. Reliable level measurement is an absolute must for automating the stockpiling process and ensuring optimal levels.
Chemical Industry
Accurate level control of the distillation unit ensures product quality of the hydrocarbon at the different cuts, but this is made difficult due to hot liquids flashing, buildup and high temperature. Even through process changes reliable level measurement and point level detection are required.
Refining and Petrochemicals
Accurate level control of the distillation unit ensures product quality of the hydrocarbon at the different cuts, but this is made difficult due to hot liquids flashing, buildup and high temperature. Even through process changes reliable level measurement and point level detection are required.
Water and Wastewater
Large Combined Sewer Overflows (CSOs) protect the wastewater treatment plant from a capacity overload during heavy rain. The precipitation is temporarily stored and then delivered to the treatment plant at a reduced rate. If the stormwater basin cannot hold the accumulating quantities of water, part of it is discharged. Due to legal requirements, such operational events and discharged water quantities must be measured and documented. A level sensor provides the required measurement data.
Energy
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.
Energy
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.
Cement Industry
The air compressor system generates the necessary compressed air to transport the material from the silos via the network of feed pipes. To ensure a smooth, steady flow of material, reliable pressure monitoring in the compressors and conveying channels is required.
Refining and Petrochemicals
The vapour liquid separation that occurs in a knockout drum protects the waste or cooling stream from process vapours and compressors from water. This crucial measurement point means it requires constant, reliable level monitoring without being influenced by the high volume of vapour inside the vessel. A reliable instrument ensures that there is no water carry-over into the compressor, avoiding the extremely expensive downtime that results from an upset.
Food Industry
The so-called Brix value (expressed in Brix degrees) is controlled in a concentrator. This value indicates the proportion of solids in a liquid (density). A certain Brix value is required, for example, to produce an optimal tomato concentrate. The liquid circulates in a spiral tube, from which the concentrate is obtained. The liquid content is extracted via evaporation in a special chamber. Electronic differential pressure measurement ensures accurate density measurement.
Refining and Petrochemicals
Throughout the different process units, there are storage vessels that collect clean, reusable condensate. This condensate accumulates from the steam system that is used to heat the various hydrocarbon processes. The condensate tanks routinely have extremely high process temperatures, so a level measurement and point level detection are necessary that can withstand this environment.
Food Industry
In the condenser, potable water evaporated as steam and condensed to form pure, clean water . Inside the condenser there is a cooling system that cools the steam to make it condense. The feed of cooling liquid is monitored in the pipeline. Point level detection ensures that sufficient condensate is present to prevent steam from directly entering the circulation reservoir.
Pharmaceutical Industry
The so-called aqua purificata evaporated in the steam separator is condensed to high purity water (WFI) in the condenser. Inside the condenser there is a cooling system that cools the steam to make it condense. The feed of cooling liquid is monitored in the pipeline. Point level detection ensures that sufficient condensate is present to prevent steam from entering the WFI reservoir directly via the feed pipe.
Water and Wastewater
The applied chemicals and precipitants are suitably conditioned to ensure that they reach the wastewater in an optimal, low concentration. They are metered out according to the degree of pollution and mixed with the wastewater. Continuous level measurement is employed to ensure optimal metering control.
Water and Wastewater
After coarse/fine screening, sorted solids such as waste, plastics, sand and sludge are transported to special containers via conveyor belt. Reliable level measurement enables automatic notification to change over these containers.
Refining and Petrochemicals
Platformers and reformers, both catalyst-based processes, require “fresh” catalyst at a given point in their cycle. To provide fresh catalyst without shutting down the process, a continuous catalyst regeneration unit can be installed. This unit regenerates the spent catalyst so that it can be used again. Maintaining the proper level in the vessel ensures that the expensive catalyst is used at the highest level of efficiency without waste.
Building Materials
Bulk aggregates are fed into production processes via conveyor belts or screw conveyors. For effective feed control to and from these processes, or inter-production unit billing, the mass flow of the conveyed bulk material must be measured. A reliable belt-weighing scale system and mass flow rate ensures accurate measurement and smooth operation of the plant.
Cement Industry
Bulk aggregates are fed into production processes via conveyor belts or screw conveyors. For effective feed control to and from these processes, or inter-production unit billing, the mass flow of the conveyed bulk material must be measured. A reliable belt-weighing scale system and mass flow rate ensures accurate measurement and smooth operation of the plant.
Mining and Metal Production
Bulk aggregates are fed into production processes via conveyor belts or screw conveyors. For effective feed control to and from these processes, or inter-production unit billing, the mass flow of the conveyed bulk material must be measured. A reliable belt-weighing scale system and mass flow rate ensures accurate measurement and smooth operation of the plant.
Food Industry
The delivered sugar beets are poured from trucks onto conveyor belts that transfer it to the washing and shredding facility. Multiple level sensors are required to monitor the loading of the beet as it goes on the conveyor belt to optimise the feed rate and energy usage.
Building Materials
The transport of coarse and fine bulk solids within a stone processing facility takes place in most cases via conveyor belts. To achieve an even throughput and compensate for volume fluctuations during transport, belt transfer points are integrated in the conveyor line. The incoming bulk material is briefly stored in a buffer silo to prevent belt overfilling. This is the point where the level and the point level must be monitored.
Cement Industry
The transport of coarse and fine bulk solids within a stone processing facility takes place in most cases via conveyor belts. To achieve an even throughput and compensate for volume fluctuations during transport, belt transfer points are integrated in the conveyor line. The incoming bulk material is briefly stored in a buffer silo to prevent belt overfilling. This is the point where the level and the point level must be monitored.
Energy
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.
Mining and Metal Production
The cooling water is collected in tanks. Pressure pumps provide the water for cooling the manufacturing process. Level measurement in the coolant tanks ensures that there is always sufficient water available.
Energy
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.
Refining and Petrochemicals
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.
Energy
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.
Energy
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.
Chemical Industry
The main reaction in colour pigment production takes place in the ‘coupling’ vessel. So named as a type of coupling reaction occurs here to form a synthetic ‘azo dye’, which is then converted into different colour pigments in subsequent process steps. An agitator in the tank ensures constant mixing of the azo dye. Additionally, ice is added for cooling, as otherwise the individual components of the reaction would decompose. Level measurement is required to ensure a smooth process flow.
Ship and Yacht Building
Crude oil is pumped directly into the cargo tanks on board in order to separate gas, oil and water from each other using gravity. To ensure profitable utilisation of the loading capacities as well as effective control of the pumps, the level is measured continuously and the point levels are monitored.
Building Materials
Large boulders are loosened from the solid bedrock through blasting. Further steps are then required to process the rock into basic building materials such as crushed rock, gravel or sand. The large stones are crushed into different grain sizes by jaw and roller crushers. To enable economic operation and keep wear and tear on the crusher to a minimum, level measurement and limit level detection are required.
Cement Industry
The large boulders are extracted from the solid bedrock with blasting. This very first stage in the process is needed to enable these very large rocks to be crushed by smaller, secondary jaw and roller crushers, which create the smaller sizes for screening to produce the basic building materials like gravel, grit or sand. To enable efficient, continuous operation and keep wear on the crusher as low as possible, level measurement and point level detection are required.
Mining and Metal Production
To be able to transport and further process the largest possible production volumes, the ore must have an optimal size. To achieve this, the ore is crushed to the correct size in two stages, in a primary and then a secondary crusher. In order to enable an optimum throughput, and avoid choking or damaging the crusher, a reliable level measurement is required.
Cement Industry
In clinker production, cyclones are used to preheat the raw meal. Before the raw meal enters the rotary kiln it is preheated to +900 °C in the cyclone. Constant monitoring of the buildup thickness on the walls ensures a continuous process.
Energy
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.
Paper Industry
The approach flow system connects the stock preparation facility with the paper machine. Here, the pulp for the paper machine is diluted to the required consistency. Additionally, the approach flow system ensures a smooth flow of stock. A particularly important element is the stock deaerator upstream of the headbox. It removes any entrained air under vacuum to ensure a constant, smoothly running process. For effective performance, the stock deaerator always has to be filled to a predefined, millimetre-exact level.
Refining and Petrochemicals
Accurate level control of the debutanizer ensures product quality of the obtained hydrocarbons, but this is made difficult due to hot liquids flashing, buildup and high temperature. Even through quick process changes reliable level measurement and point level detection are required to ensure a smooth operation of the plant.
Water and Wastewater
Ground water from deep wells is pumped to the surface with the help of submersible pumps. It must be ensured, however, that the amount of water extracted is balanced to the amount that seeps back in. Reliable, maintenance-free level measurement is necessary for smooth operation of the well.
Refining and Petrochemicals
Accurate level control of the deethanizer ensures product quality of the obtained hydrocarbons, but this is made difficult due to hot liquids flashing, buildup and high temperature. Even through quick process changes reliable level measurement and point level detection are required to ensure a smooth operation of the plant.
Aquaculture
One of the major challenges for fish farms around the world is lice infestation, which can force farmers to pull their fish out early. In addition to the use of cleaner fish, a thermo-mechanical treatment has proven successful. In this process, pressure is used to lift the lice off the fish before they can be removed by low-pressure flushing. Pressure sensors control the process and ensure that it runs safely and efficiently.
Refining and Petrochemicals
Accurate level control of the depropanizer ensures product quality of the obtained hydrocarbons, but this is made difficult due to hot liquids flashing, buildup and high temperature. Even through quick process changes reliable level measurement and point level detection are required to ensure a smooth operation of the plant.
Environment and Recycling
The waste oil is heated to a temperature of 105 °C in the lower section of the column. Here, the water evaporates and is pumped away after it condenses. After reaching the appropriate temperature, the oil is transported through pipes to the upper part of the column, where the remaining water vaporises. For optimal dewatering, a defined level is required in the column. As the oil surface is very turbulent due to the action of pumps and heating, making level measurement directly inside the column practically impossible. For that reason it is done in a bypass tube.
Environment and Recycling
In open cast mining, the groundwater levels must be continuously reduced to protect the mining area from flooding and the excavation walls from instability due to water pressure. A large number of dewatering wells with submersible pumps are kept in operation for this purpose. A continuous water flow prevents the pump shaft from blocking due to the effects of hardening clay/iron oxide deposits. To regulate the pump output, precise level measurement is required in each of the up to 750 m deep wells.
Food Industry
After a large part of the yeast has already been filtered out in the separator, the brew leaves the green beer storage tank and is pumped into the diatomaceous earth filter for filtration. Here, the remaining yeast cells and other substances causing turbidity are removed with the help of diatomaceous earth, which clarifies the beer. The limit level is detected in the diatomaceous earth storage tank. If necessary, diatomaceous earth is added to the diatomaceous earth filter via water inflow. The degree of contamination of the diatomaceous earth filter is monitored by an electronic differential pressure measuring system.
Chemical Industry
In the diazotization process, the individual raw materials for colour pigment production are prepared so that they will react to become diazonium compounds ready for the subsequent ‘coupling’ vessel where they form the final crude pigment or ‘azo dye’. The basic starting materials for these compounds are hydrochloric acid, water, sodium nitrite and the diazo component (usually aniline). To preserve the material quality during formulation, the mixture is kept cool by adding ice or via a cooling jacket. During this process, the level must be carefully monitored and kept constant.
Paper Industry
In the digester, the action of chemical dissolution removes the lignin binder, thereby exposing and freeing the cellulose fibres. During the cooking process according to the alkaline sulphate method, the fibres are fed into the digester by means of steam pressure. To enable fully automatic operation of the digester, a point level detection of the filling is required. The vessel pressure also needs to be carefully monitored throughout this process.
Water and Wastewater
The organic components of sewage sludge are decomposed under anaerobic conditions in heated, closed digestion tanks. In the process, combustible gases such as methane are released from the sludge. These are collected in a biogas tank and then converted into electricity and heat in cogeneration (CHP) plants. A level sensor controls the filling of the digester. To ensure that no foam gets into the gas system along with the collected gas, a point level sensor is used for monitoring.
Chemical Industry
The final, still wet pigment cake is heated on a belt dryer. At the end of the belt dryer, the dried coarse pigment powder is discharged into a silo ready for final milling and grinding into a fine powder. The feed through the belt dryer is controlled both by the flow through the chute and level in the silo.
Pharmaceutical Industry
When very small product batches are produced in the pharmaceutical industry, disposable plastic containers are often used. These are essentially polymer bags in which a fermentation process takes place or which contain a certain medium or buffer. Continuous level measurement is required to ensure high process efficiency.
Chemical Industry
The precursors for the manufacture of colour pigments are dissolved in the dissolving tank. These precursors are mainly Naphtha based, and, depending on the formulation, water and sodium hydroxide solution are added as solvents for the production of the basic pigment solution. An agitator ensures uniform mixing of substances as they are added. The level measuring system is needed to ensure reliable values that are delivered to the control system.
Chemical Industry
The process temperatures in a distillation column place high demands on the measurement technologies deployed. The boiling point of the distillate frequently exceeds 400 °C. The aim is to achieve the highest possible product throughput for cost-effective operation of the plant. This means the raw material replenishments need to be optimally controlled by level and process pressure measurement in the column.
Refining and Petrochemicals
The heavy, highly viscous process material and extreme temperature are located in the bottom part of the distillation. For level control of residual feeds, a non-contact measurement is essential for reliability. Monitoring head space pressure at the upper end of refinery columns is important to ensure that the process is operating under ideal conditions.
Pharmaceutical Industry
Solvents are used in the pharmaceutical industry for extracting active ingredients. They are then recovered via evaporation in a high-vacuum distillation vessel. After the solvent has been removed from the pharmaceutical product by evaporation, it is further processed. Reliable level measurement is required in the distillation vessel for process control.
Water and Wastewater
To transport drinking water even to the remotest drinking water storage facilities, pumping stations generate the required water pressure, which is constantly monitored by a pressure transmitter. A level switch serves as dry run protection for the pumps.
Pharmaceutical Industry
In the pharmaceutical industry, tablets are coated with colouring agents or active ingredients in a drum coater. This coating in the form of a liquid suspension, contains colouring or solids and is stored in a storage tank next to the drum. Itis sprayed into the drum via nozzles for even distribution on the surface of the tablets. Reliable level measurement in the storage tank is required to ensure that there is always enough of the liquid suspension for tablet coating. Overflow and dry run protection is provided by a reliable level switch.
Energy
Point level detection with capacitive level switch at the charging point of the belt dryer.
Paper Industry
The residual moisture content of the paper web is removed by steam-heated cylinders in the drying section of the paper machine. The drying process removes heat from the steam, which then forms a thin layer of condensate on the inner walls of the cylinder. This layer influences the transfer of heat to the paper and has to be skimmed off continuously by siphoning. The correct level of heat transfer from the drying cylinder to the paper is monitored by pressure measurements both at the inlet and at the outlet.
Paper Industry
The fibre suspension created in the pulper is first drawn off into a dump chest. There it is temporarily stored for the further stages of the stock preparation process. Typical process challenges in the dump chest are fast filling from above and high stock densities. A slow-running lateral agitator ensures a homogeneous, pumpable consistency of the fibres in suspension. Level measurement in the dump chest determines when it is filled to capacity and ready for emptying and the next process step. The measurement is carried out hydrostatically via a side-mounted pressure transmitter with a ball valve fitting. This allows removal for maintenance or cleaning purposes, even when the dump chest is full.
Water and Wastewater
Elevated water tanks are reservoirs located at high places that act as a buffer during periods of peak demand. They compensate for delivery fluctuations and enable efficient plant operation. Reliable level measurement is therefore indispensable.
Water and Wastewater
In thermal seawater desalination, the drinking water is produced in multi-stage evaporation processes. By connecting the various stages in series with ever lower temperatures, the system’s coefficient of performance is significantly increased and its overall efficiency enhanced. Reliable monitoring of the pressures and levels in the various stages is an important prerequisite for optimal operation of the plant.
Aquaculture
Fish waste is one of the highest quality raw materials for the production of oils. These oils are, among other things, the source of omega-3 oil. The distillation-based production of the oil requires careful control in high temperatures and vacuum. In the oil vapour condensation process, reliable limit level detection must ensure the accurate switching on and off for the dependable operation of the pumps.
Food Industry
In the production of spices, the spices are first mixed with water and oil to form a slurry. This is fed into an evaporator, where water is removed to turn it into a kind of syrup. The thickened spice syrup must have exactly the right density - so that it can be spread thinly onto metal sheets for oven drying, ready to be ground into powder. To ensure the optimal density of the spice syrup, it requires a continuous measurement during manufacture. The pressure in the feed pipe leading to the evaporator also requires careful monitoring to ensure a smooth-running production process.
Energy
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.
Energy
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.
Aquaculture
When rearing fish larvae to the young adult stage in onshore systems, the optimal amount of oxygen in the water is a necessary criterion for growth. To reliably and cost-efficiently monitor the compressors required for this, the feed lines carrying the oxygen-enriched water must be monitored for correct pressure. This way, the system can detect a malfunction or a drop in pressure immediately. Reliable operation allows the young fish to grow up healthily and stress-free.
Aquaculture
As well as the type of fish being farmed, it is the feed coefficient, the so-called "fish in – fish out" ratio, that determines the required quantity and appropriate composition of feed. To ensure on-time availability and optimal feed composition, reliable stock level monitoring is necessary. The feed stocks, from production to delivery and distribution, are visualised and reliably managed. Automatic ordering processes are triggered by VEGA Inventory System.
Aquaculture
To feed the fish, automatic systems distribute feed pellets from the storage containers. In floating facilities, there are several storage containers located next to the "grow-out tanks" for this purpose. These are continuously monitored in order to reliably measure the amount of feed extracted. In this way, evenly distributed feed quantities can be ensured over the entire lifetime of the fish.
Energy
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.
Food Industry
After the wort has been cooled down to the appropriate temperature in the wort cooler, it is pumped into the fermentation tanks. The fermentation process is then started by adding in yeast. The yeast converts the malt sugar dissolved in the wort into carbonic acid and alcohol. To ensure optimal fermentation in the tank, the following key parameters are measured: hydrostatic pressure for determining the level, overpressure for CO2 content monitoring and limit level for overfill or dry run protection.
Chemical Industry
In the last production step, the finished pigment powders are pneumatically conveyed into packing silos. The conveying system generates very high dust levels and air movement inside the silos. To control the filling process, the levels in the silos need continuous monitoring. A high level detection switch is used for safety shutdown in case of overfilling. The pigment powder is then filled into sacks via the bottom outlet.
Water and Wastewater
The raw water is pumped from the lake into a tank. It is then filtered via a drum filter. In this process the water is separated and purified from any suspended matter and coarse impurities. An electronic differential pressure measuring instrument monitors the level of contamination of the filter. Cleaning of the filter is automatically triggered as soon as the threshold contamination is exceeded.
Pharmaceutical Industry
Often, in the manufacture of pharmaceuticals, substances need to be separated from one another or perhaps some cell components precipitated. One method of doing this is using special filtration systems. When the filter is working properly, the quality and yield of the products are at their optimum. So continuous differential pressure monitoring of the filters ensures the filters are running at their most efficient at all times.
Aquaculture
In on-shore facilities, reliable filtration ensures the required water quality. This is achieved through the use of mechanical drum and disc filters. They form a multi-stage system, where automatic flushing via jet nozzles is controlled by the water level in the tank. Besides a high water quality, the fish also need the right amount of oxygen in the water. After the water has been cleaned, the correct amount of oxygen is added to it via compressors. Throughout the entire process, a guaranteed flow of water with sufficient oxygen enrichment is essential and therefore ensured by reliable differential pressure measurement and limit level detection.
Refining and Petrochemicals
Reliable level measurement of crude and bulk liquids storage tanks in a refinery is necessary for inventory management and overspill protection. Multiple measurement devices can fit into a single process fitting.
Aquaculture
Under ideal conditions, a wide variety of fish species can live in indoor and outdoor tanks, either in or near the sea. It is extremely important that the tanks are reliably monitored against leakage and always adequately supplied with fresh water. Reliable pump monitoring when emptying and filling the tanks is also important. All three factors increase the efficiency of fish production and make a significant contribution to the overall success of the facility.
Refining and Petrochemicals
Level measurement of crude and bulk liquids storage tanks in a refinery is necessary for inventory management and overspill protection. Multiple measurement devices can fit into a single process fitting.
Chemical Industry
The unrecoverable residues of oil and gas production are collected in the flare knockout drum and liquefied at high pressure. The recovered liquid, the condensate, collects at the bottom of the vessel and is disposed of. The non-liquefied gases are decompressed and burned in the flare system. To ensure efficient and safe operation of the vessel, the level inside must be very reliably measured.
Oil and Gas Offshore
The unrecoverable residues of oil and gas production are collected in the flare knockout drum and liquefied at high pressure. The recovered liquid, the condensate, collects at the bottom of the vessel and is disposed of. The non-liquefied gases are decompressed and burned in the flare system. To ensure efficient and safe operation of the vessel, the level inside must be very reliably measured.
Refining and Petrochemicals
The flare knockout drum requires continuous, accurate level monitoring to keep liquids from reaching the flare and creating a potential fire hazard. In order to ensure safety of process by performing this critical measurement, the total process level over the span of the drum needs to be tracked and continuously reported to the operator for proper control. For measurement in the sump of the flare knockout drum, the sensor provides exact position of interface.
Pharmaceutical Industry
Granular raw materials are delivered and stored in Flexible Intermediate Bulk Containers (FIBC) also known as ‘Bulk Bags’ or ‘BigBags’. The raw materials are fed to the various process stages via conveyor belts or pneumatic lines. To ensure reliable supply to production, the levels in these FIBC’s need to be continuously monitored.
Water and Wastewater
To filter suspended matter out of the water, precipitants are added to the water. When small air bubbles are injected into the liquid, suspended matter is bound to the rising bubbles and drawn off at the water surface. In order to achieve the best possible bubble formation, the pressure in the air supply is regulated to stay within narrow limits. Reliable and accurate level measurement is necessary to achieve efficient removal of the suspended matter.
Food Industry
The different varieties of flour are most often stored in tall silos with very narrow chambers. Filling takes place regularly and is done pneumatically from the top. In order to produce the desired blend of different varieties at any time, a reliable level measurement in the individual silos is essential, even during filling. The process challenges include dust generation, strong air movement and a poorly reflecting product surface.
Environment and Recycling
Flue gas from waste incineration must be cleaned before it is released into the environment. Flue gas scrubbers do this by removing acidic gas components such as sulphur dioxide. Lime water is used as the washing solution and it is sprayed in against the flow of the gas. The lime deposits filtered out of the washing water are used as gypsum, e.g. for the production of plasterboard. To ensure a continuous scrubbing process, a constant level in the scrubbing tower is required.
Refining and Petrochemicals
Fluid Catalytic Cracking (FCC) is one of the most important conversion processes used in petroleum refineries. As with many other refining applications, the vessels in the reactor system need to be operated and controlled at their optimum levels, as this is critical for the process productivity. Maintaining the proper levels also ensures that the expensive catalyst is used at maximum efficiency, with no waste.
Pharmaceutical Industry
One method for producing and drying granulates is the fluidized bed process. A uniform stream of air is fed up through a distributor plate at the bottom of the fluidized bed reactor. A liquid granule suspension is sprayed in from above, in the air stream it turns into solid granulate and collects on the top of distributor plate and the exhaust air flows through a filter for cleaning. To ensure a high-quality process, both the granulate quantity on the distributor plate and the condition of the filter must be permanently monitored. The measurement technology must also fulfil the most stringent hygienic requirements in order to guarantee a consistently high granulate quality.
Energy
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.
Refining and Petrochemicals
Accurate level control of the fractionator ensures product quality of the obtained hydrocarbons, but this is made difficult due to hot liquids flashing, buildup and high temperature. Even through quick process changes reliable level measurement and point level detection are required to ensure a smooth operation of the plant.
Ship and Yacht Building
Every yacht has different tanks on board for storing hot water, pool water and drinking water. For drinking water, an especially hygienic measuring system is required.
Mining and Metal Production
To work efficiently, flotation cells depend on continuous froth formation. If the froth layer is too thin, it cannot transport the sufficient amount of dispersed or suspended particles to the surface. On the other hand, froth that is too thick indicates that the reaction time of the chemicals is too long. This has the consequence that too little of the medium gets processed. A density-compensated level measurement is the reliable solution in this process: this ensures that the density of the liquid remains constant and optimizes the process yields over a long period.
Energy
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.
Water and Wastewater
Backup generators are a common safeguard at lift stations to maintain operation during power outages. Day tanks at each lift station and a main tank at the plant are used to store the fuel. To make sure there is sufficient fuel when needed, the level in the tanks is continuously measured.
Ship and Yacht Building
The fuel tanks are some of the most important on board. They store a variety of fuels; diesel for the main engine and power generators, petrol for jet skis and dinghies, even aviation fuel for the helicopter. Level measurement ensures optimum availability of fuel at all times. An additional overfill protection system also ensures maximum safety for the environment.
Water and Wastewater
The biogas generated from sewage sludge is used for environmentally friendly production of heat and electricity. It is transported to the storage tanks through a gas pipeline.
Chemical Industry
Carbon dioxide is separated from a gas mixture via two scrubbing columns. The gas mixture consisting of nitrogen, hydrogen and carbon dioxide passes through a gas pipeline into the first stage gas scrubber. An added solvent, usually aniline, binds with the carbon dioxide, which is then forwarded in liquid form to a gas scrubber or ‘desorber’ where it is “washed” out of the liquid. The process pressure is monitored during the absorption process, which takes place at high pressure and low temperature. The actual separation of the carbon dioxide from the liquid, however, is carried out under low pressure and high temperature, where the level of the liquid needs to be kept as constant as possible.
Oil and Gas Offshore
Extracted natural gas and gas residues from oil production are contaminated with water and are therefore collected in gas separators (scrubbers) for separation. Pressures of up to +150 bar keep the gas in the liquid state. Exact pressure and level measurement enable optimal utilization of the gas separator and effective control of the gas drying process. The separation of gas from water is carried out by chemically binding the water to glycol and separating it mechanically. Accurate measurement of the gas/water interface determines the quality of the gas.
Energy
Continuous level measurement with radar for permanent gas volume measurement Monitoring of the gas pressure in the gas reservoir Separator (supply isolator) for optimal power supply to connected sensors.
Environment and Recycling
Accurate monitoring of the river level is an important prerequisite to be able to react quickly and correctly in the event of a flood. Visual, on-site level monitoring requires great effort, particularly for facilities in remote areas.
Water and Wastewater
Accurate monitoring of the river level is an important prerequisite to be able to react quickly and correctly in the event of a flood. Data recording and transmission via radio link is the optimal solution for getting level information on rivers in remote areas without power.
Water and Wastewater
Precise monitoring of the river level is an important requirement for sustainable extraction of river water for use as drinking water. The measurement sites are often in exposed locations and sensors are subjected to all weathers and surface conditions.
Energy
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.
Food Industry
Barley is stored in malt houses in silos up to 20 metres high before it is processed into malt for production of beer. Filling the silos generates a lot of dust and the material cone geometry constantly changes during the filling and emptying process. A reliable indication of the level ensures the smooth operation by sending signals corresponding to the level or possible limit levels of the grain.
Water and Wastewater
The suspended matter is filtered out of the water via the sand and gravel filled filter tank. Pressure is applied to pump water through the filter bed. Dirt particles are retained in the filter material. The electronic differential pressure measurement monitors the level of contamination in the filter. As soon as the threshold contamination is exceeded, an automatic cleaning cycle of the filter is triggered.
Food Industry
After fermentation and after a large part of the yeast has already been removed in the separator, the green beer is placed in storage. Here it is continuously cooled. The green beer is then pumped into the filtration system. In the green beer storage tank, the overpressure, the limit level and the actual level are continuously monitored.
Ship and Yacht Building
Wastewater accumulated on board is stored in grey or black water tanks up until its final disposal on land. The tanks are equipped with continuous level monitoring as well as point level detection to avoid overfilling.
Water and Wastewater
Through circulation and aeration of the wastewater, mineral substances such as grit and sand settle to the bottom of the settling basin. Point level detection of settled sand under water prevents equipment malfunction and damage and controls the cleaning cycle in the grit trap.
Water and Wastewater
Before the settled out sand can be used as recycled material, it is cleansed of organic matter in the sand washing plant. The washed sand is then dewatered in a screw press and discharged into a storage vessel. The discharge of the washed sand is controlled by a pressure transmitter.
Water and Wastewater
Buildup and deposits accumulate in gullies and raise the water level there. Since this can lead to blockages, gullies must be cleaned regularly. Reliable level measurement ensures that blockages are recognized quickly. The level data is transmitted wirelessly to the control centre. This makes certain that gully cleaning is carried out as required.
Ship and Yacht Building
To ensure fuel feed to the main engine, heavy fuel oil (HFO) is separated though first being pumped into a settling (buffer) tank. The following service tank or day tank, which is filled via a continuous overflow from the settling tank, directly supplies fuel into the main engine. Heating coils in both of these tanks maintain an even temperature between +75° C and +90° C. A reliable level measurement in these tanks guarantees continuous manoeuvrability of the ships.
Paper Industry
The paper suspension is pumped into the headbox of the paper machine. Via the hydraulically pressurized headbox it passes through a tapered cross-flow distributor and manifold, through the rectangular discharge opening, or slice, onto the screen. The outflow speed of the suspension is adjusted to match the speed of the screen by adjusting the pressure of the headbox feed pump. This means an accurate pressure measurement, with minimal turbulence created in the headbox is vital at this part of the process.
Food Industry
In a plate heat exchanger, the milk is heated up to +85 °C, depending on the process, so that all germs are killed. The milk is heated in multiple sections, kept hot and cooled down again by cold, inflowing milk. This in turn warms up the inflowing milk. Reliable pressure measurement is required to maintain an optimal process in the heat exchanger.
Chemical Industry
In the heat recovery boiler, hot process gas is passed through heating pipes. This means the gas is cooled and the necessary process heat for the plant recovered to be reused. To prevent the heat recovery boiler from running dry and thus overheating, reliable monitoring of the water level in the boiler is required. For maximum safety, the measurement is carried out redundantly with diverse instrument technology.
Energy
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.
Ship and Yacht Building
Flo-Flo (Float On/Float Off) ships are characterised by their large number of ballast water tanks. These make it possible to lower the ship until the main deck is below the waterline. This allows large floating loads to be loaded. The cargo is lifted out of the water and balanced by pumping out or blowing out the ballast water tanks. To avoid damage to the ballast water tanks from overpressure or underpressure, the internal tank pressures and levels require continuous monitoring.
Pharmaceutical Industry
In pharmaceutical production, Hexane is a commonly used solvent and reaction medium, as well as an agent for oil and grease extraction. This colourless liquid has a slight petrol odour and is highly volatile light hydrocarbon, readily forming highly flammable vapour-air mixtures. When the tank is emptied, no residues may remain inside. Reliable level measurement and overfill protection is an absolute necessity for safe storage and handling.
Refining and Petrochemicals
Exact interface measurement in high temperature separators is important for ensuring the quality of the separation process. Continuous control of the interface between oil and water ensures that oil is not inadvertently withdrawn instead of water. This saves costs and increases the efficiency of the plant. A vibrating level switch serves as an additional overfill protection mechanism.
Refining and Petrochemicals
Buffer and storage tanks are needed at numerous places in refineries for storing the input and output materials of the various process steps. The containers have different geometries, ranging from horizontal or vertical spherical tanks to horizontal cylindrical tanks to portable plastic containers. To run the refining processes effectively, which includes ensuring the availability of the media, it is crucial to know the exact levels in these storage tanks at all times.
Food Industry
In order to prevent the milk fat from settling on top of the milk, either just the cream or the whole milk is homogenised in the next step. This is where the cream or milk is pushed through micro-sized nozzles, which reduces the size of the fat globules and distributes them evenly in the liquid. The homogenised cream is then returned to the skimmed milk. Pressure in the feed line is monitored to control the homogenisation process. At the same time, pressure monitoring of the hydraulic oil ensures optimal control of the pistons.
Ship and Yacht Building
The hopper contains a mixture of sand, gravel and water. This mixture is collected by one or two suction pipes and drag heads that move over the seabed. The water flows out through so-called overflows and sand and gravel remain and are transported to an end destination for creating new land, or to be used as a supplementary material or building material. Accurate measurement of filling height, to determine the exact volume of displaced material, is important for smooth operation.
Oil and Gas Offshore
The hydraulic oil used to transmit power circulates in a closed system. However, it is gradually lost due to lubrication points and leakages in the power equipment. To ensure optimum operation of the power equipment, the level in every hydraulic oil reservoir tank must be monitored for replenishment.
Ship and Yacht Building
The hydraulic oil used to transmit power circulates in a closed system. However, it is gradually lost due to lubrication points and leakages in the power equipment. To ensure optimum operation of the power equipment, the level in every hydraulic oil reservoir tank must be monitored for replenishment.
Paper Industry
In the press section of a paper machine, very high pressures are needed for dewatering the stock. Hydraulic oil stations provide the supply to the various parts of the machine as well as filtering and cooling the recirculating lubrication system. Integrated pumps provide oil to the required locations and to enable fully automatic operation of the station, the flow rate and the level in the supply tanks must be measured.
Refining and Petrochemicals
Heavy oil residues are processed in the hydrocracker, such as atmospheric and vacuum residue. Fresh catalyst is continuously added and used catalyst is withdrawn, enabling product quality over time. To promote safe and efficient heavy oil processing, a reliable measurement and density profiling is needed for control of critical process stages.
Energy
Pressure sensor for pressure measurement in the compression chamber Pressure measurement in the compressor pipelines.
Energy
Pressure monitoring in the hydrogen pipeline.
Energy
Level measurement via differential pressure in a tank holding liquid hydrogen Level measurement with radar in a tank holding liquid hydrogen.
Ship and Yacht Building
If energy-rich hydrogen has to be transported over long distances, special tanker ships are used. To minimise losses, the hydrogen is cooled down to -253 °C at 1 bar pressure so that it can be stored in liquid form. The level can be measured either by means of thin impulse lines and conventional differential pressure or free-radiating radar. An elaborate standpipe, which would also lead to increased heat input, is not required.
Paper Industry
Various chemicals are used in paper manufacturing to achieve the desired properties in the end product. The media are supplied directly to the production areas in IBC containers and added to the paper suspension via metering pumps. Level measurement ensures the supply for the ongoing processes. The stocks are continuously monitored, which allows a dwindling level to automatically trigger an order for replenishment from the chemicals distributor.
Aquaculture
Water and cleaning agents are used to efficiently clean the feed pellet containers. These media are stored on site, for example on a feeding barge or on a supply ship. Reliable level measurement ensures that the required amount of cleaning agent is available at all times. And this in turn guarantees that the feed pellet containers are cleaned quickly in the time between complete emptying and the next filling.
Chemical Industry
In many of the production processes in the chemical industry, small quantities of various chemicals are needed in order to improve the characteristics of certain products. The media are often provided directly to the production areas in small, transport containers. Accurate level measurement ensures a continuous supply of materials for production.
Chemical Industry
In many of the production processes in the chemical industry, small quantities of various chemicals are needed in order to improve the characteristics of certain products. The media are often provided directly to the production areas in small, transport containers. Accurate level measurement ensures a continuous supply of materials for production.
Food Industry
The ingredients for making ice cream are accurately weighed and fed into a mixing tank, where the "premix" is made. Afterwards, the premix is passed through the homogenizer at a pressure of about 140 bar and then pasteurized at 80 °C. The level in the premix vessel and the pressure in the pipeline leading to the homogenizer need to be continuously monitored to ensure continuous ice cream production.
Environment and Recycling
To ensure that the waste burns completely, temperatures up to 1000 °C must be maintained. For this purpose, large amounts of primary air from below and secondary air from above are blown in. Air quantity and air pressure must be precisely measured. Also an optimum waste layer thickness on the combustion grate is required for uniform combustion.
Environment and Recycling
After the crane system lifts the waste from the waste bunker and drops it to the feed chute, in the lower part of the chute, a hydraulic piston pushes the waste onto the combustion grate. It is important that waste in the chute is always at an optimal level and uniformly distributed. This prevents air from leaking into the furnace and ensures a constant supply of fuel for combustion. For that reason the minimum level in the feed chute has to be monitored and the resulting data displayed to the crane operator.
Water and Wastewater
Sewage and rainwater are often transported to the treatment plant in open collection channels or flumes. The flow rate is measured at various points in these channels. Measurement of the water flow at the inlet and outlet of the treatment plant is the basis for the calculation of tariffs and operating costs.
Ship and Yacht Building
Separation tanks on the deck of an FPSOs contain oil and water as well as other products. Mixing hydrocarbons with water can form an emulsified layer that makes it extremely difficult for operators to detect and control the water level. This can lead to loss of hydrocarbons when the water is drained or even damage to the electrostatic grids in desalination tanks due to the salty feed water. Multi phase density profiling is required to identify the different layers, including sand, for reliable, efficient process control. Level measurement is also required to ensure redundancy.
Water and Wastewater
In many processes, small amounts of various additives are required to improve the properties of certain end products. The media are supplied in small, transportable containers. Level measurement ensures the supply for the ongoing processes.
Environment and Recycling
Both chemical and thermal processes are used to treat hazardous waste. For efficient processing, the flow rate through the processing facility must be kept constant. To facilitate this, hazardous wastes such as varnishes, paints and thinners are buffered in tanks. Agitators prevent clumping and settling of the solids contained in the mixture. Reliable level measurement ensures continuous waste processing is maintained.
Aquaculture
Since the fish scraps left over from filleting still contain a lot of usable substances, they are processed further. To enable simple, mechanical processing, these leftovers are pre-processed for the mill and stored in an intermediate tank. Depending on the feedstock, different consistencies can form in this tank. Reliable point level detection prevents overfilling or dry run.
Food Industry
Deseeded fruits and other ingredients for the production of jam are weighed and placed in a cooking vessel and gently heated. The cooking process takes place in a closed vacuum boiler at a temperature of 65 °C to 85 °C, in order to maintain the product quality and preserve the fruits’ flavours and colours. Pressure transmitters are deployed to closely monitor the vessel pressure and jam cooking process to ensure the setting point for the conserve is reached. One transmitter measures the head pressure, the other at the bottom of the tank measures the total pressure. The difference between the two is used to calculate the level with great precision.
Refining and Petrochemicals
LPG tanks are usually only accessible for service and maintenance work every few years during shut-down periods. In addition, the containers are mostly installed underground or covered with earth. The solution is a process independent measuring system that delivers safe and reliable readings despite low dielectric constants and low temperatures.
Building Materials
To ensure continuous production, even if material production is interrupted, the raw materials are stored in large bunkers with heights of over 30 m and diameters of up to 20 m. The large dimensions of the silos require the filling and emptying to take place at multiple points. Uniform filling and emptying of the bunkers is achieved through level measurement at various points in the bunker.
Environment and Recycling
Pollutants contained in the waste are partly washed out over time by rainwater, posing a significant threat to groundwater and surface water. For that reason, leachate is caught in drains within the ground seal or liner, collected in wells and fed to a multistage treatment plant. To control the submersible drainage pumps, a level measuring system is needed inside the leachate well.
Energy
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.
Building Materials
A lime kiln is used to produce quicklime through the calcination of limestone. Here the furnace is filled from the top and the calcined limestone (quicklime) is collected at the bottom of the furnace. Accurate level measurement ensures optimal charging and hence efficient operation of the furnace.
Energy
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.
Energy
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.
Building Materials
After the calcined lime is cooled, it is sorted into different sizes and stored for further processing. Most of the lime is further processed to lime powder. For optimum production planning, a reliable level measurement is a must.
Water and Wastewater
In the nitrogen and phosphorus removal stage, lime is used to stabilize the pH value. Stored in silos, the lime is added to the wastewater as a solid or as an aqueous suspension. The silo content is measured by a radar sensor and a point level sensor detects the maximum level and transmits a full signal.
Energy
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.
Energy
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.
Energy
Level measurement with differential pressure in the liquid hydrogen storage tank.
Pharmaceutical Industry
In preparation for proper disposal, liquid wastes that arise in the production of pharmaceuticals are temporarily stored in buffer tanks. These potentially hazardous mixtures consist of diverse media with very different properties including dielectric conductivity (dielectric constant) and density. For optimal storage, reliable and accurate level measurement is required. Point level detection ensures overfill and dry run protection.
Food Industry
The malt is prepared for mashing in the malt mill. Wet or dry malt mills are used depending on which brewing process is being used. During the milling process it is important to have a continuous flow of malt. If the mill is operated without malt, wear increases, which can lead to breakdowns and outages. To prevent the mill from running empty, the limit level is monitored.
Ship and Yacht Building
Hose connecting stations, also known as manifolds, connect the pipes and hoses that are required for cargo loading and offloading on tankers. To ensure the safety of facilities on shore and on board, and to control the pumps, the pipeline pressures need to be closely monitored on the manifold. Reliable pressure transmitters are required to ensure safe loading or unloading operations.
Food Industry
Elderberries are first mashed up in order to produce a concentrate, from which food dyes are then made. The elderberry mash is refrigerated to maintain the product quality. Accurate level measurement and exact records of the process temperatures ensure hygienic operation.
Food Industry
The crushed malt is mixed with brewing water to create the mash. The mixture is heated in the mash tun and the natural enzymes convert the insoluble grain starch into soluble malt sugar. During the process, all the malt ingredients important for the beer are transferred to the brewing liquor. The end product is then clarified, separating the enriched brewing liquor from the solids. Continuous level measurement is required during the cooking process.
Food Industry
The finished meat pellets and kibbles are fed onto a conveyor belt ready for packaging to be sold as pet foods. In order to ensure a continuous supply of meatballs, the conveyor belt requires careful monitoring.
Chemical Industry
Many different kinds of bulk solids are produced or used as raw materials in the chemical industry. To ensure reliable measurement of the silo contents, several factors must be considered: different bulk densities, abrasive properties, dust generation and the requirements of explosion protection. Application of the right level sensors ensures optimal production planning and reliable logistics for the finished products.
Water and Wastewater
Various methods are used to replenish the demineralised water with the minerals required in healthy drinking water. One method is to pass the water through a container filled with limestone, enriching it with mineral substances. The filling of the container is monitored with the help of a point level switch.
Food Industry
Foods often consist of a mixture of different raw materials. Mixers are used, for example, to mix solids into liquids. The resulting mixture is then further processed or used in downstream processes, if required, or directly packaged. The level switches are used to control the inlet valve and protect the vacuum pump from running dry.
Pharmaceutical Industry
Mixing vessels are applied for preparation, storage and transfer of a wide range of pharmaceutical products. These vessels are used for the manufacture of antibiotics, blood plasma products, and injection and infusion solutions. Following preparation, substances are transferred to a filling station. To ensure a reliable process, the liquid level in the mixing vessel must be reliably and continuously monitored.
Water and Wastewater
These open pools even out peak loads and strong volume fluctuations. During periods of decreased load, the wastewater is pumped from the buffer pool into downstream biological treatment basins. A level sensor monitors and controls the pumps and cleaning units in the buffer pool.
Food Industry
In the production of soft cheeses, various types of cheese are mixed and melted in a mixing tank. The cheese collects on the walls of the tank and is scraped off again by large spatulas. To ensure efficient production of the soft cheese, reliable level measurement is required.
Building Materials
Materials such as concrete and mortar are needed in widely different compositions depending on the application. The various raw materials are stored in segmented towers, which then blend cement, lime and other aggregates according to specific requirements. In each individual segment, reliable level measurement and point level detection ensure the constant availability of the raw materials and cost-effective operation of the plant.
Building Materials
Diesel is stored in tanks on construction sites to supply the construction vehicles with fuel directly on site. A sufficient supply of diesel fuel is essential for optimal construction site operation. Exact level measurement, in combination with wireless data transmission to a central location, ensures automatic, optimal provisioning of mobile containers at all times.
Cement Industry
Diesel is stored in tanks on construction sites to supply the construction vehicles with fuel directly on site. A sufficient supply of diesel fuel is essential for optimal construction site operation. Exact level measurement, in combination with wireless data transmission to a central location, ensures automatic, optimal provisioning of mobile containers at all times.
Building Materials
Safe filling and timely routing of tanker trucks is essential for reliable bitumen supply. The medium is hot and viscous and places high demands on both handling and safety. Accurate level measurement, in combination with wireless data transmission to a central location, guarantees optimal automatic refilling of these mobile containers.
Energy
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.
Oil and Gas Offshore
The drilling mud flowing back from the drilling contains large amounts of solids. To avoid clogging in these pipes and the associated damage to the drill head and loss of production, a reliable monitoring of the entire mud return system is essential.
Oil and Gas Offshore
In the mud tanks, agitators or jet nozzles stir and mix the mud to ensure a homogeneous mixture. To enable a continuous process, the level measurement must be reliable and independent of the composition of the drilling mud.
Oil and Gas Offshore
Prior to, and during pumping into the well, the density of the mud needs continuous monitoring. Density is an important criteria for determining the correct composition of the drilling mud. The correct mud formulation ensures smooth forward propulsion, wear-free drilling and excellent sealing of the borehole is ensured through density monitoring.
Energy
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.
Oil and Gas Offshore
The separator vessel contains a mixture of crude oil, gas, water and sand extracted from the subsea well. Precise monitoring of these multiple separation interfaces and emulsions play a vital role in ensuring the quality of the oil separator for separation. Exact control of interfaces, level and pressure allows optimum utilization of the oil separator and increases the effectiveness of the entire asset.
Refining and Petrochemicals
Accurate measurement in oil skim and separation tanks is critical to product quality because there is complete separation of oil and gas possible. For liquid-liquid interface monitoring an accurate measurement helps control the quality of the separator’s output and thus helps to extend equipment life in downstream units by avoiding any potentially expensive impurity problems.
Mining and Metal Production
Mined ore is transported via conveyor systems to large above ground or underground silos and stored there until it is used in production. A reliable level measurement is required to determine the contents of the silos.
Mining and Metal Production
Extracted minerals are fed to the thickener as a slurry via a trough. The solids are settled out into the bottom of the tank, in a process accelerated through the addition of flocculants. Precise density measurement of the slurry underflow is necessary for effective control of the ore thickener.
Energy
Differential pressure transmitter for measuring filter contamination External display and adjustment unit for 4 … 20 mA/HART sensors Mounting bracket for differential pressure transmitter.
Water and Wastewater
Sea water is pressed through a semi-permeable membrane under high pressure. The semi-permeable membrane allows only water molecules to seep through. Salts, bacteria and viruses are retained in the filter. The finished product is almost the same as distilled water. A differential pressure measurement is needed to monitor the level of contamination across the filter.
Water and Wastewater
Ozone is used for the disinfection of drinking water. It is produced from oxygen in a hyperbaric reactor by means of electrical energy. The gas produced then flows into the ozone gas collection pipe. Reliable pressure measurement is mandatory in order to keep the pressure in the pipeline constant and monitor the process integrity.
Energy
Pressure measurement in the inlet and outlet of the PEM electrolyser Level measurement with radar for regulation of water quantities Level measurement with guided radar for water volume control.
Paper Industry
The black liquor resulting from pulp cooking is regenerated and fed back into the digester. Liquor regeneration comprises several process steps. The processes take place at high temperatures and pressures; the media are aggressive and sometimes abrasive. Density measurement of the liquor in the pipelines is required for eco-friendly and energy-efficient process control.
Environment and Recycling
Complete plastic windows can be recycled by means of a special process. The recycling process results in a final product of high-quality, pure-grade PVC granules, which serve as a raw material for new windows. It is stored in large silos that are fitted with tubes for uniform colour mixing. For optimal control of production and supply, the contents of the silo have to be determined, which is usually via level measurement.
Food Industry
Sodium chloride and calcium salts are stored in small plastic tanks. When necessary, these substances are added to the food as additives to regulate the pH value and consistency. The plant operator needs exact level readings from the tanks at all times to ensure timely replenishment.
Chemical Industry
In a pool condenser, ammonium carbamate is produced from a mixture of carbon dioxide and ammonia under high pressure. The ammonium carbamate, in turn, is the starting material for the subsequent main reaction in the production of urea. To ensure safe operation of this high-pressure application, a continuous, dependable level measurement solution is needed.
Chemical Industry
In the preflash drum, the medium is heated before it is fed into the distillation column. Accurate and reliable level control is a critical factor in ensuring efficient operation of the distillation column. Reliable measurement of the level prevents overfilling of the vessel and also keeps the pumps from running dry.
Refining and Petrochemicals
In the preflash drum, the medium is heated before it is fed into the distillation column. Accurate and reliable level control is a critical factor in ensuring efficient operation of the distillation column. Reliable measurement of the level prevents overfilling of the vessel and also keeps the pumps from running dry.
Food Industry
After the raw milk has been delivered and stored, it is first preheated to approx. +55 °C in the preheater before being passed on for separation. To ensure an optimal heating process, both the cool and hot water need to be monitored by a reliable pressure measuring system.
Food Industry
A hot caustic solution is required for fast cleaning. It is heated in the storage tank and then flushed into the production equipment. The tank is wrapped in a steam heating jacket that serves to control the temperature inside the tank. The level measuring system is used to control filling and discharge. Level detection prevents the tank from overfilling or running empty.
Pharmaceutical Industry
The various solvents and intermediate carrier materials have to be first prepared before they proceed onto further production steps. This is usually carried out in bioreactors and fermentation tanks. These vessels are enclosed with a steam heating jacket to regulate the temperature inside the mixing process. The level measuring system is needed to control filling and discharge as well as monitor during the process. Level detection prevents the tank from overfilling or running empty.
Energy
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.
Paper Industry
Pressure screens are used to filter out impurities and separate fibres in stock preparation. A rotating screen basket inside the filter does the actual filtering. Pressure screens have an inlet for the suspension, an outlet for accepted stock and a discharge for rejected stock and contaminants. The process conditions are characterized by pressure surges as well as abrasion and contaminants in the stock. Efficient screening requires a controlled pressure difference between inlet and outlet, which therefore requires continuous, reliable measurement.
Oil and Gas Offshore
It is important that a desalter unit runs efficiently to prevent corrosion to downstream equipment. When the crude oil mixes with the emulsifying chemicals and water, the resulting emulsion layer makes it difficult for standard level measurement technologies to reliably track the interface. Radiation-based measuring instruments are not affected by this and allow to track the interface even with thick emulsion layers present in the tank to make sure that the desalting process can be controlled efficiently at maximum throughput.
Refining and Petrochemicals
It is important that a desalter unit runs efficiently to prevent corrosion to downstream equipment. When the crude oil mixes with the emulsifying chemicals and water, the resulting emulsion layer makes it difficult for standard level measurement technologies to reliably track the interface. Radiation-based measuring instruments are not affected by this and allow to track the interface even with thick emulsion layers present in the tank to make sure that the desalting process can be controlled efficiently at maximum throughput.
Chemical Industry
In the primary reformer, methane gas and water vapour react into hydrogen, oxygen, carbon monoxide and carbon dioxide at a pressure of around 30 bar and a temperature of 870 °C. Since the temperature in the reformer is very high, pressure is measured at the inlet via a temperature adapter. The temperature also needs to be measured in order to regulate the process.
Energy
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.
Water and Wastewater
The process water is collected in tanks or open basins. Pressure pumps deliver the water for cleaning and rinsing purposes to various locations in the wastewater treatment plant. To ensure an optimal supply of water, the level in the process water tank is measured continuously.
Refining and Petrochemicals
Propane, a flammable, colourless and odourless gas, is one of the many types of liquefied petroleum gases (LPG) that exist. It is produced from natural gas via a special refining process. Propane is compressed, liquefied and stored in pressure vessels so that it does not return to a gaseous state. To ensure optimal storage, reliable level measurement is required.
Chemical Industry
Propane, a flammable, colourless and odourless gas, is one of the many types of liquefied petroleum gases (LPG) that exist. It is produced from natural gas via a special refining process. Propane is compressed, liquefied and stored in pressure vessels so that it does not return to a gaseous state. To ensure optimal storage, reliable level measurement is required.
Paper Industry
Waste paper or pulp bales are transported on a conveyor belt to the pulper, where they are broken down by adding process water. A stirrer speeds up to separate fibers. Difficult process conditions exist in the pulper: falling bales cause severe pressure shocks, the stirrer creates vortexes. Besides that, foreign substances like wire, glass or sand enter the process along with the waste paper and have an extremely abrasive effect on the interior of the vessel. To ensure an automatic process flow, the level measuring system must establish the ratio of waste paper/pulp to process water. In addition, a possible jamming of the bales on the conveyor belt must be detected.
Aquaculture
Recirculation aquaculture systems (RAS) score points with their low water consumption. In such systems, water is treated and reused in a way that conserves resources. This is facilitated by circulating the water in a closed loop. The necessary pump technology is monitored with pressure sensors in order to detect any malfunction immediately.
Water and Wastewater
To protect the process pumps, any leakage water, e.g. arising from a faulty pump seal, is detected and an alarm triggered. The pressure in the pipe is measured directly at the pump and displayed in the control system of the WWTP. Any malfunctions are detected quickly.
Mining and Metal Production
Bauxite, lime and sodium hydroxide are ground and mixed in a ball mill – the mixture turns into a red slurry, which is then conveyed into the pumping tank. Some of the balls from the mill can potentially enter the tank along with the slurry. To prevent this from happening, the balls are collected in a weir arrangement, which overflows into the main tank. Level measurement in the tank avoids dry running of the pump and ensures a continuous process.
Water and Wastewater
Wastewater from households and businesses, together with surface water, is carried to the wastewater treatment plant via an extensive sewer network. If the natural gradient is not steep enough, numerous pumping stations are required to create a sufficient height difference. The level measurement in the inlet shaft is used for cost-effective control of the pumps.
Paper Industry
Wet strength agents are polymeric additives that enhance water resistance properties, especially in sanitary and specialty papers. They are applied in the paper machine via a size press or spraying device. Because of their high pH value, these substances are stored in double-walled GRP (glass reinforced plastic) tanks. The high viscosity of the medium requires the use of a pneumatic conveyor system and special eccentric pumps for filling and emptying. With these pump types, dry run protection and pressure monitoring is a necessity.
Ship and Yacht Building
Ballast water is taken on board seagoing vessels to ensure the stability of the ship when sailing with little or no cargo. The water is stored in ballast water tanks. To monitor the function of the pumps, appropriate pressure measurements are employed – pump failure can thus be detected immediately.
Water and Wastewater
Pure water tanks are important storage facilities for periods of peak demand. They compensate for delivery fluctuations and enable efficient plant operation. The pure water tank is therefore not only a means of storage, it also serves as an equalizing tank. Reliable level measurement is therefore essential.
Environment and Recycling
Waste incineration converts domestic and commercial waste into combustible gases and ash. Pyrolysis is carried out in the absence of air at temperatures up to 500 °C. The intermediate product, charcoal, is then further burned by adding air. Ash and synthesis gas with high thermal content are the end products. For continuous operation, the vessel must be loaded and emptied automatically. To this end, the level of material in the pyrolysis chamber and in the ash pan has to be measured.
Paper Industry
Quicklime is an important substance for the recovery of lye in pulp production. It is produced in the lime kiln through the combustion of lime sludge from causticisation. The quicklime is conveyed via a bucket elevator into the quicklime silo, where it is temporarily stored, and then discharged via screw conveyors into the lime dosing feeder for the causticising process. Continuous level measurement in the quicklime silo is required to ensure a reliable supply is readily available.
Food Industry
Hops, malt and raw fruit sugar are required as raw materials for the brewing process. The raw materials are stored in large silos. To ensure continuous supplies for production are maintained, the level must be constantly monitored.
Energy
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.
Cement Industry
Before being burned in the rotary kiln, the material from the blending bed and the aggregates are ground to a fine raw meal in large mills. The powdery material is then transported to the silo by a pneumatic conveyor system. Reliable monitoring of the level is essential for optimal raw material storage.
Food Industry
The incoming raw milk is stored at a temperature of about 4 °C and stirred gently at all times to ensure it is kept until it is forwarded for further processing. As well as measuring the level in the vessel, the milk is protected against contamination with an overpressure. Point level detection prevents any overfilling of the raw milk tank.
Chemical Industry
Changing media, as well as process pressures and temperatures, characterize the typical reaction processes in a reaction vessel. This is a big engineering challenge, because any sensors used to control the process need to deliver reliable measurements under these conditions. To meet the diverse conditions found in reaction vessels, level measurement and point level detection instrumentation must cover a broad spectrum of applications.
Pharmaceutical Industry
The measuring conditions inside a reaction vessel in a multi-product, multi-line production facility are characterized by changing media as well as widely fluctuating temperatures and pressures. Depending on the properties of the raw materials, either alloy, stainless steel or enamel lined vessels are used. Different components like stirrers, dryers and centrifuges also vary in each process. To ensure reliable operation and high productivity, both level and pressure have to be continuously measured and monitored.
Food Industry
Creatine is a naturally occurring substance in the body, but it is also produced synthetically. The ingredients are filled into an agitated reaction vessel. Mixing the ingredients generates an exothermic reaction during which the creatine is separated out. Continuous level monitoring ensures a reliable reaction process in the vessel.
Food Industry
Production of polyvinyl acetate – the base material for chewing gum – is carried out in a reaction vessel with a four stage agitator. The various raw materials begin to react when they are mixed by the agitator. To ensure smooth production, accurate level measurement is required.
Pharmaceutical Industry
The key component in the manufacture of pharmaceutical products is the reactor. Different raw materials are mixed with solvents and made to react by applying heat and pressure. During this process, the pressure, temperature and consistency of the medium are changing constantly. A stirrer ensures homogeneous mixing of the product, and can also cause an agitated surface and heavy foaming. To ensure a reliable process, the liquid level in the reaction vessel must be reliably and continuously monitored.
Chemical Industry
High temperatures, pressures and vacuums are techniques usually employed to make reaction processes more efficient and economical. This is a big challenge for engineering, because the sensors used have to deliver reliable measurements under these conditions. To be able to meet the diverse requirements of reaction vessels, sensors for level measurement have to meet a very wide range of application conditions.
Environment and Recycling
In a recycling company, oil sludge, oil/water mixtures and emulsions from many industrial processes are collected and treated. The objective is to separate the oil and water for recovery, purification and reuse. This process takes place in several steps. Firstly the oil/water mixture is centrifuged, hydrogen peroxide is added and mixed in a stirring reactor, then finally it is centrifuged again. Continuous level measurement is required in the reactor stage to enable automated operation. It’s very important for there to be an absolutely reliable and accurate measurement even at low liquid levels, right down to the vessel bottom.
Mining and Metal Production
Aluminium powder suspension is an intermediate for titanium sponge production. In the reactor, vanadium oxide trichloride is removed from the aluminium powder suspension. When the aluminium powder suspension is fed into the reactor, strong turbulence arises on the product surface. To optimize the process, the level in the reactor must be accurately measured and monitored.
Food Industry
The reactor is filled with concentrated fruit juice and heated. In order to achieve a higher density, the water content is reduced through evaporation. As soon as the required Brix (density) value is reached, the syrupy fruit juice concentrate is pumped out. The concentrate is then pumped over to a filling machine to be stored in barrels or to a cooling machine where it is hardened and granulated. Reliable density measurement is used to monitor quality in the production process.
Chemical Industry
Evaporators are heat exchangers that are deployed at the bottom of distillation columns. In the evaporator, the residue is boiled up from the sump and fed back into the distillation process. Precise control of the level in the evaporator ensures efficient operation of the plant. A reliable measurement also ensures that the heating coils are always covered with liquid, to prevent any overheating incidents.
Refining and Petrochemicals
Evaporators are heat exchangers that are deployed at the bottom of distillation columns. In the evaporator, the residue is boiled up from the sump and fed back into the distillation process. Precise control of the level in the evaporator ensures efficient operation of the plant. A reliable measurement also ensures that the heating coils are always covered with liquid, to prevent any overheating incidents.
Energy
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.
Environment and Recycling
Hazardous waste can include lacquers, paints and thinners, as well as acids, alkalis and mixtures. At hazardous waste treatment facilities, environmentally harmful substances are converted into environmentally safe ones. Before treatment, the liquid hazardous waste is collected in receiving tanks. Level measuring systems ensure the automated, monitored operation of the facility, thereby protecting human health and the environment.
Water and Wastewater
After the wastewater has been treated, it is discharged into bodies of water through a drainage system. The local municiple water organisation requires measurement of the amount of wastewater being discharged into the receiving watercourse in order to determine how it affects the water quality downstream.
Paper Industry
Refiners are used in paper production to grind up pulp. The main objective of the process is to impart certain properties to the pulp. Every refiner has a grinding set consisting of both fixed and rotating parts. The pressures at the input and output have to be measured for monitoring the loading and release of the grinding set as well as for display of performance.
Chemical Industry
The efficiency of a distillation column is increased with the help of return flow. The return flow in this case is that portion of the condensed liquid head product that is fed back to the upper part of the column. Reliable level measurement in the reflux tank is required to ensure that the return flow is accurate and continuous.
Refining and Petrochemicals
The efficiency of a distillation column is increased with the help of return flow. The return flow in this case is that portion of the condensed liquid head product that is fed back to the upper part of the column. Reliable level measurement in the reflux tank is required to ensure that the return flow is accurate and continuous.
Energy
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.
Aquaculture
When transporting live fish, the operators of aqua farms do everything in their power to carry out the task as efficiently, gently and stress-free (for the fish) as possible, usually with the help of special ships. Large amounts of water are required to maintain the water quality in the tanks during transport. The seawater is forced through a semi-permeable diaphragm under high pressure. Only pure water molecules can pass through. Differential pressure measurement monitors the level of contamination of the filter.
Water and Wastewater
The seawater is forced through a semi-permeable diaphragm under high pressure. Only pure water molecules can pass through. Salts, bacteria and viruses are retained in the filter. The resulting water is almost like distilled water. Differential pressure measurement monitors the level of contamination of the filter.
Energy
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.
Food Industry
The selected, peeled tomatoes are packed in metal cans with a capacity of up to 10 kg. The telescopic filler automatically feeds the tomatoes into the cans. The level of the tomatoes on the turntable must be measured so that there are enough tomatoes to fill the cans.
Building Materials
During the winter season the highways and road maintenance departments safeguard the roads, public squares and pedestrian paths by clearing off snow and ice. The quantities of road salt required are stored in silos and when needed, loaded onto snowploughs. Reliable level measurement is necessary for the optimal and adequate stocking of the salt. The stock level information is transmitted to the central control centre.
Water and Wastewater
The seawater is fed into large buffer basins for further processing, sometimes these can be several hundred metres from the coast. Level measurement in the basins controls the extraction pumps and thus enables reliable operation of the plant.
Oil and Gas Offshore
To maximize efficiency of the electrostatic grid as it removes contaminants within second and third stage desalters, a crucial point of control is to maintain the oil and water interface just below this grid. Reliable measurement of this level protects the grid from shorting out on the water as well as increasing efficiency of the unit, which ensures the quality of the feed moving into the next process unit.
Refining and Petrochemicals
To maximize efficiency of the electrostatic grid as it removes contaminants within second and third stage desalters, a crucial point of control is to maintain the oil and water interface just below this grid. Reliable measurement of this level protects the grid from shorting out on the water as well as increasing efficiency of the unit, which ensures the quality of the feed moving into the next process unit.
Chemical Industry
These processes often involve the separation of water-based media from hydrocarbons. In most applications, the upper, lighter medium is electrically non-conductive. Guided radar level measurement makes use of the effect that non-conductive media allow some of the radar energy to pass through, thus enabling a measurement of the interface between the water-based lower medium and the hydrocarbons.
Food Industry
After the raw milk has been heat treated, it is cleaned in the separator and separated into the components cream and skimmed milk. The raw milk and cream are brought back together again in mixtures that depend on the desired fat content. To ensure a continuous supply of raw milk to the separator, the pressure in the raw milk supply line is monitored. The pressure in the skimmed milk and cream outlets is also regulated to ensure uniformity and standardisation. A point level detection system monitors the separated solid particles, such as the dirt or bacteria that settle to the bottom of the separator, and controls the cleaning processes.
Refining and Petrochemicals
Exact interface measurement in separators is important for ensuring the quality of the separation process. Continuous control of the interface between oil and water ensures that oil is not inadvertently withdrawn instead of water. This saves costs and increases the efficiency of the plant. A vibrating level switch serves as an additional overfill protection mechanism.
Ship and Yacht Building
Drinking water is an essential commodity on a ship. It is stored separately in dedicated tanks. Depending on the type and size of the ship, different amounts of fresh water are required for drinking, personal hygiene and cleaning. Direct electrical measuring principles are mandatory for level measurement.
Ship and Yacht Building
Waste water, known as grey/black water on ships, is treated on board larger vessels using ship-board clarification plants or it may be stored in special grey/black water tanks to await final disposal. Direct electrical measuring principles are mandatory for level measurement.
Water and Wastewater
The heavily soiled, greasy wastewater from households and commercial enterprises flows into the sewage lifting station. The dirty water and floating debris contained therein are raised to a higher level with screw pumps and then flow into the treatment plant along a natural downward gradient. Level measurement in the inlet shaft controls the cost-effective use of the pumps.
Water and Wastewater
Wastewater from households and industrial operations is carried through a sewerage system to the clarification plant. In large sewer systems, the water levels are monitored at key points in the network. Level measurement in the sewer allows an accurate assessment of the degree of utilization of the conduit system.
Oil and Gas Offshore
Through the effects of strong vibration in the shaker, the liquid and solid components of the drilling mud returning from the borehole are separated from each other. The drilled rock and the sand are disposed of and the valuable drilling mud is fed back into the continuous drilling process. Level measurement and point level detection are absolutely necessary for effective processing of the drilling mud in the shaker.
Ship and Yacht Building
Among the most important measurements on board ships are those for determining draught, trim and list. In general, one measuring point is placed on the bow and another is used in the aft. On larger ships, two additional measuring points are installed on both the port and on the starboard. Accurate level measurements are required to determine the exact values of ship position and draught.
Aquaculture
After mixing with acid, the ground fish scraps are mixed and ground again. Pressure sensors are used to monitor the mill. They enable immediate detection of any malfunction of the mill. This ensures uniform processing of the fish scraps over the long term.
Aquaculture
Fish waste and scraps are the valuable raw material for fish silage, which in turn is a protein-rich raw material for the production of fish meal and dry fish feed. The acids used during production enable controlled growth of bacteria. The levels in the storage tanks must be carefully and reliably monitored. The visualisation of current process and storage status is handled by VEGA Inventory System.
Environment and Recycling
Glass is made of quartz sand, lime and soda, which are melted together at extremely high temperatures up to 1600 °C. This melting process is very energy intensive and for that reason, more easily melted waste glass is also often added into the mix. After delivery, the waste glass is first crushed and freed from impurities. The material, known as cullet, is then transported and filled into a silo, where it is fed to the melting process. To ensure a continuous supply of material to the furnace, a reliable level measurement in the cullet silo is required.
Energy
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.
Building Materials
Different qualities are required from the asphalt depending on the usage and climatic conditions, so every asphalt mixture varies depending on the application. Asphalt is always extremely viscous, hot and highly adhesive. Due to these properties and the numerous different asphalt mixtures, reliable level measurement and point level detection methods are essential.
Cement Industry
Large amounts of energy are needed to burn clinker in rotary kilns. Apart from conventional energy sources such as gas, oil and coal, solid substitute fuels such as dried sewage sludge, old tires or meat and bone meal are increasingly being used. Since the required amounts of energy represent a significant cost factor in cement production, exact level measurement of the solid fuels is essential.
Chemical Industry
In the chemical industry, many different kinds of bulk solids are produced or used as raw materials. To ensure reliable measurement of silo contents, many factors must be considered: different bulk densities, abrasive properties, dust generation and the requirements of explosion protection. Implementation of the most suitable level sensors ensures optimal production planning and reliable logistics for the finished products.
Mining and Metal Production
After sintering, the hot material is cooled down to a temperature of about 150 °C in the sintering cooler. The feed rate of the sintering belt is controlled to ensure that the material is thrown off at the end of the sintering belt. To achieve effective cooling, the thickness of the material on the sintering belt has to be continuously and precisely measured.
Ship and Yacht Building
Usually a ship has two slop tanks, portside and starboard. This tank contains the water from the cleaning processes on a ship. Especially after sailing the procedure of tank cleaning is processed and the slob tanks are filled with wash water. It includes chemicals, edible oils or other products. A level measurement is important to ensure a reliable cleaning process.
Water and Wastewater
The digested sludge is dewatered prior to drying in centrifuges or filter presses. The sludge liquor thus obtained passes through the cleaning process of the WWTP once again. A level detector controls the pumps in the filter water tank to prevent overfilling. The discharge of the dewatered sludge is controlled by a point level sensor.
Water and Wastewater
Through drying, the weight and volume of the sludge is further reduced. In the thermal drying unit, which is equipped with a belt drier and a hot (+80 to +130 °C) air stream, water is removed from the sludge through evaporation. The continuous monitoring of belt loading is done by means of radiometric, i.e. radiation-based, measurement - this technique allows optimal, cost-effective dryer control.
Water and Wastewater
After thermal drying, the sludge is stored in silos for further use. The granulated product is deposed of in landfills, used in agriculture or burned for energy generation. The level measurement and point level detection ensure that the container volume is optimally utilized.
Water and Wastewater
Sewage sludge from small decentralized sewage treatment plants or sewer cleaning operations is delivered in special vehicles. It is collected in a receiving tank and then gradually fed into the main sewage treatment plant for processing. Continuous level measurement determines the content of the receiving tank and controls the input to the plant.
Water and Wastewater
The digested sewage sludge is pumped into a sludge storage tank. This tank serves as an intermediate storage facility before the sludge is fed to the centrifuge or pressed for mechanical dewatering. To ensure optimal feeding, the sludge volume is monitored by a level measuring instrument.
Water and Wastewater
Before the sludge enters the digestion tower, it is stored in large vessels. During storage, the sludge is dewatered and thickened sometimes scrapers and agitators are used to accelerate the process.
Energy
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.
Food Industry
Small vessels and hoppers are used as intermediate storage containers in which ingredients such as flour, yeast and salt are there, ready for manufacture into baked goods. Level measurement and point level detection ensure that the ingredients required have high levels of availability and replenish when needed to meet production demand.
Refining and Petrochemicals
Safe and reliable measurement of the separation layers in the sour water stripper is extremely important in preventing sour water from accidentally getting into other parts of the plant. Sour water is highly corrosive and can cause serious damage over time, leading to safety problems in other process vessels and pipes. The sour water discharged from the stripper is delivered to the desulphurisation plant for further processing.
Cement Industry
To maintain a high quality and uniform material consistency in the finished cement, the raw materials are homogenized in a blending bed. To achieve this the rock is distributed evenly over the blending bed with a stacker. Material is reclaimed in reverse order with the help of a scraper. In order to optimally control the conveyor systems, their positions must be determined as precisely as possible.
Paper Industry
Starch is an important additive to increase the strength of the paper. The raw starch is stored in tall, narrow silos. Filling is carried out pneumatically, generating large amounts of dust. They are discharged into the starch slurry production system beneath the silo and the resulting slurry is pumped into the starch cookers by eccentric pumps. For optimal control of the silo filling process, a reliable level measurement is required. To prevent the eccentric pump from running dry, an in-line switch is needed upstream of the pump.
Chemical Industry
High process pressures and a highly compressed vapour phase are the normal operating conditions inside boilers. The size of the steam generator is what determines the quantity of saturated steam that can be fed into a heat exchanger. Reliable control of the water level and limitation of high and low water levels are therefore extremely important. In power plants boilers are governed by the steam pressure and the process temperature.
Pharmaceutical Industry
High process pressures and a highly compressed vapour phase are the normal operating conditions inside boilers. The size of the steam generator is what determines the quantity of saturated steam that can be fed into a heat exchanger. Reliable control of the water level and limitation of high and low water levels are therefore extremely important.
Energy
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.
Refining and Petrochemicals
High pressure steam is critical for the operation of the refinery. For the production and reliable supply of steam, accurate level measurement is required that allows efficient operation of the steam boiler. In addition to level measurement, high and low water limit detectors are also extremely important. As safety devices, they ensure that the water level neither exceeds the upper limit nor falls below the lower limit.
Energy
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.
Paper Industry
Steam is needed in the drying section of the paper machine. There it is used to heat the drying cylinders for drying the paper web. The steam is usually generated in the company's own power plant and fed in via an insulated supply line. To ensure optimal consumption and demand planning, the flow rate is continuously measured via an orifice plate with a built-in differential pressure transmitter.
Food Industry
The washed tomatoes are fed into the steam drum on a conveyor belt. They are first heated to about 115 °C. In the next process step, the tomatoes are cooled in a vacuum, which separates the skin from the tomato. The skins are transported to a container via a special conveyor belt and the peeled tomatoes go to the next process step. Pressure sensors measure the steam as well as the vacuum in the pipelines. Level detection is required to monitor the level in the waste container.
Food Industry
In the production of purified water, the process begins with tap water being fed into the steam separator. The tap water evaporates there and is fed into the condenser. Evaporation is effected by a heat exchanger supplied with saturated steam. To ensure that the heat exchanger is always covered with tap water, reliable level detection is required. The pressure inside the steam separator must be kept constant in order to achieve maximum efficiency.
Pharmaceutical Industry
In the production of ultrapure water (WFI), the process begins with aqua purificata being fed into the steam separator. The aqua purificata evaporates there and is fed into the condenser. Evaporation is effected by a heat exchanger supplied with saturated steam. To ensure that the heat exchanger is always covered with aqua purificata, reliable level detection is required. The pressure inside the steam separator must be kept constant in order to achieve maximum efficiency.
Food Industry
The milk lactose is converted to lactic acid under controlled heating in stirring and batching tanks. This process thickens the milk to yoghurt and gives it its sourish taste. The resulting product is then cooled down. In further processing into a fruit based yoghurt, berries, nuts or grains are added and stirred in. The level and point level detection must be reliably detected to enable optimal filling of the vessel.
Chemical Industry
Storage and buffer tanks enable a reliable material supply for various ongoing processes. The plant operators need to have exact level data from these tanks at all times to ensure timely replenishment and facilitate continuous production. In addition, the measured values form the basis of the statistical consumption analysis for validation and quality monitoring.
Refining and Petrochemicals
Storage and buffer tanks enable a reliable material supply for various ongoing processes. The plant operators need to have exact level data from these tanks at all times to ensure timely replenishment and facilitate continuous production. In addition, the measured values form the basis of the statistical consumption analysis for validation and quality monitoring.
Food Industry
The rennet is needed to coagulate the milk when making cheese. It is stored in a storage container and metered out into the cheese vat as needed. Reliable level and point Level detection are essential to ensure that sufficient rennet is on hand for continuous cheese production.
Food Industry
The yeast is grown and stored in small storage tanks at an optimal temperature, then added to the fermentation tanks as required. To ensure ideal storage, the minimum and maximum limit levels as well as the pressure in the tank are monitored.
Food Industry
Flour and sugar are the basic ingredients for many food products and stored in silos up to 20 metres high. The filling and emptying is often performed by pneumatic systems that transport the media from the large external silos and deposit them in smaller holding vessels for further processing. The filling and emptying processes are controlled by reliable level measurement. Pressure monitoring is also needed in the pneumatic conveying pipelines.
Chemical Industry
In the production of pigments, aggressive raw materials such as chlorobenzene, hydrochloric acid and sodium hydroxide are used. They are stored in horizontal cylindrical tanks and filled through a dip pipe to reduce splashing and fume generation. A reliable level measurement ensures safe handling and continuous material availability for optimum productivity.
Food Industry
Beer is continuously delivered into the filler supply tank of the bottling machine. Reliable level measurement is important for an optimal filling process. A point level sensor is used to also prevent dry run.
Water and Wastewater
The finest impurities in the water are bound together through flocculation. This allows the coagulated materials to be removed from the water by sedimentation or filtration. The flocculant required for such operation is stored in a reserve tank. A continuous level measurement ensures a sufficient supply of flocculants. The point level detection serves as overflow protection in the tank.
Food Industry
In the food industry, liquid media such as glucose, fruit juice or syrup must always be kept in stock. To get them ready for the production process, some liquids must be either pre-cooled or pre-heated, while still in the storage tanks. This is done by means of a water-filled ‘jacketed’ container wall that can be either cooled or heated. To ensure uninterrupted production, a reliable level measurement is essential.
Oil and Gas Offshore
Oils and alkaline solutions are among the liquid raw materials for the mud mixtures. These additives are stored on the drilling platform in special storage tanks. To ensure the continuous production of drilling mud, the level of raw materials in the storage tanks must be exactly monitored.
Food Industry
Milk and milk-based products such as cream, standard and pasteurized milk have to be stored in the correct quantities depending on production requirements. Since whole milk tends to separate into milk and cream even at low temperatures, it has to be circulated during storage. The quality of the milk must not be affected by stirring. To ensure that the circulation does not begin until the agitator is completely covered with product, a reliable measurement is required.
Food Industry
Purified water is used for the CIP cleaning of the production equipment. This water is produced through filtration and distillation and then stored temporarily in tanks. Absolute sterility and cleanability are essential criteria for all device components that have direct contact to the medium. This also applies to the instruments for level and pressure measurement in the tank.
Oil and Gas Offshore
The solid raw materials such as gravel, clay, barite, cement and binders are essential for creating the different properties of the drilling mud. These materials are stored for mud production in storage tanks. To ensure optimal storage, reliable level measurement and point level detection are required.
Paper Industry
Wet strength agents are polymeric additives that increase the water resistance particularly of hygienic and specialty papers. These are applied in the paper machine via a size press or spraying device. Because of their high pH value, these substances are stored in double-walled GRP (glass reinforced plastic) tanks. For safety and operational reasons, multiple level measurements are needed in these tanks.
Energy
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.
Energy
Pressure sensor for pressure measurement in a storage tank with gaseous hydrogen.
Energy
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.
Mining and Metal Production
For many processes, additives such as sulfuric or hydrochloric acid are required. These are kept ready for use in storage tanks. Level measurement is needed here to ensure availability of the additives.
Food Industry
Alcohol storage tanks are considered potentially explosive and are therefore kept in special rooms. When the alcohol is needed, it is pumped directly to the appropriate production vessel through a ”ring main” supply system. Reliable measuring instruments are required for dependable measurement of the level in the tank and for monitoring the feed pressure in the pipeline.
Paper Industry
The targeted addition of chemicals and auxiliary substances influences the properties and quality of the paper. Common additives are hydrogen peroxide as well as alkalis, acids and fillers. These chemicals and additives are sometimes aggressive, produce vapours and are at temperatures of up to 95 °C. This means they are often stored in stainless steel or glass fibre reinforced plastic containers. Level and pressure measurements are essential for the safe filling and emptying of the storage tanks and for dry run protection of pumps.
Energy
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
Chemical Industry
For extremely toxic substances such as phosgene, absolute control over the process is a necessity. In industrial applications, these products are only used in hermetically closed circuits. To minimize the inherent risks, independent protection devices form an integral part of the tank equipment. Moreover, it is important to keep the number of tank openings as small as possible. An external level measuring system that includes point level detection is ideal for such situations.
Pharmaceutical Industry
Many different liquids with widely varying properties are required in pharmaceutical production. Products, at all stages have to be stored and held ready for subsequent processing. These are used as catalysts for the decomposition of compounds and stored in a wide variety of concentrations, some of these products are acids. For smooth production and optimal storage, reliable level measurement and point level detection are absolutely necessary.
Chemical Industry
Some chemical processes generate extremely toxic intermediates that have to be stored under the most stringent security measures. In order to be used in this application, the measurement technology must meet specific requirements in terms of design and functional reliability. A redundant sealing concept, an optional glass feedthrough (Second Line of Defense) and highly resistant materials provide the necessary security for the storage and processing of toxic media.
Mining and Metal Production
Some processes generate toxic intermediates that have to be stored in compliance with strict safety regulations. In order to be used in this area, the measurement technology deployed must meet special safety requirements when it comes to design and functional reliability. A trustworthy level measurement is critical for the storage of these toxic materials.
Paper Industry
Large quantities of prepared stock are needed to keep a paper mill running continuously. This material is stored in high storage towers. They are characterised by their large material throughput and agitators that ensure the homogeneity of the stock. Inside, the warm stock generates lots of steam and the pumping and stirring processes make the surface very turbulent. Reliable level measurement ensures a continuous supply of stock and prevents the agitator from running dry.
Water and Wastewater
In case of heavy precipitation, excess rainwater is temporarily stored in open, artificial reservoirs. The water reservoir buffers the drainage and the water is pre-cleaned through natural settlement. Continuous level data are the basis for calculating the flow through the sewer system and thus protecting against flooding.
Chemical Industry
Impurities are separated from urea in a special process tank, the so-called stripper. The unwanted substances are removed from the urea by means of a counter current of carbon dioxide to the flow from the urea solution leaving the reactor. The urea itself collects at the bottom of the stripper. The filling height in the urea sump must be monitored and kept constant.
Environment and Recycling
In the stripping column process, the nitrogen and carbon compounds are decomposed by various microorganisms. Special carrier materials are packed in the central part of the reactor, which improve the biochemical reaction processes. To ensure an optimal operating point inside the stripping column, an exact level measurement at the base of the column is required. Because the surface of the medium in the reactor is very turbulent due to air flowing in from below, the level measurement has to be carried out in a bypass tube.
Building Materials
In the manufacture of stucco with special insulating properties, Styrofoam is also added to the traditional sand, lime and cement mixture. With a bulk density of only a few grams per litre, Styrofoam balls are extremely light and therefore very difficult to measure. For cost-effective storage, reliable level measurement and point level detection are required.
Food Industry
In beet sugar refining the raw sugar is heated and dissolved in water into liquor. There are typically several interconnected agitated vessels in this process, each one with a weir allowing the liquor to flow from vessel to vessel. During the dissolving process, sugar byproducts from the downstream refining process are reintroduced to enable sugars to be recovered. To ensure a continuous process, a reliable level measurement is required.
Food Industry
The process in a vacuum pan is designed to ensure the growth of sugar crystals. The syrup is cooked in a closed boiler with steam-heated tubes and the liquid is extracted. The intermediate product is magma, a mixture of crystal sugar and syrup. This mixture is then poured into a holding tank, the crystallizer. In the holding tank, the cooling and drying process creates a substance called massecuite, from which the sugar crystallizes. The level in the tank must remain constant, so a reliable level measurement is required here.
Refining and Petrochemicals
In a sulphur decanter, the operator must manually verify the interface level of the sulphur deposits as they slowly build up under the water. An instrument that can automate the measurement and enable continuous operation of the process ensures availability of the vessel and minimal impact on the downstream process.
Refining and Petrochemicals
The level in the sumps around a refinery must be reliably monitored to prevent overfilling and subsequent pollution, or pump overload. Balanced pump utilization is possible thanks to a pump control rotation system integrated into the controller.
Food Industry
Yoghurt is stored in the supply tank of the filling machine. Reliable level measurement and point level detection are important for maintaining the filling process. A point level sensor is also used to prevent dry running of the supply to the machine.
Food Industry
Tomatoes are stored in the supply tank of the filling machine. Reliable level measurement is important for an optimal filling process. A point level sensor is used to also prevent dry run.
Water and Wastewater
In the central drinking water supply system, air-bladder chambers are used to compensate for pressure fluctuations in the supply line. They are used primarily to stabilize smaller water networks, where, for economic reasons, a water tower is not an option. A pressure transmitter is deployed to monitor the tank and control the pumps. A low level switch detects the minimum water level in the tank and thus prevents air from entering the water supply network.
Aquaculture
The pipes installed above the fish tanks enable demand-oriented, automatic feeding at any time of day. To this end, the storage tanks are continuously monitored to make sure they contain sufficient fish pellets and always get refilled on time. The tanks vary in size, depending on whether young fish or adult fish are involved.
Cement Industry
Large amounts of energy are needed to burn clinker in rotary kilns. Substitute liquid fuels such as spent oils or recovered solvents are often used for this purpose. The fuel storage tanks often contain a mixture of solvents, which can produce fumes and vapours in the air space. Due to the large amount of energy needed in cement production, the fuel inputs represent a significant cost factor, so accurate level measurement is essential.
Food Industry
When correcting the pH value and adding ingredients; salt, sugar or citric acid are dissolved in water. Depending on the product, acids or bases are added to obtain the desired pH value in the final product. To ensure a continuous production process, reliable level measurement is required.
Chemical Industry
Low viscosity solvents can degrade many types of plastics. This places increased demands on the process instrumentation. A separate level detection system is required for protection against overfilling. It increases plant safety and ensures protection of human health and the environment.
Food Industry
The thin juice extracted from sugar beet is thickened by the reduction of excess water in multiple stages at the evaporator station. This evaporation process is carried out under vacuum and heat. The liquid in the evaporator boils so violently that great amounts of vapour are formed. A level sensor is needed to monitor and control the thickening process.
Food Industry
The empty cans enter the filling machine on a conveyor belt. As soon as an individual can reaches the appropriate position for filling, it is pulled in with the help of a pneumatic cylinder and filled under vacuum with natural tomato juice. The level of juice in the supply tank is monitored by a radar sensor. In each filling cycle, the same amount of tomato juice is sucked out of the supply tank. Reliable point level detection ensures that all cans are filled equally.
Food Industry
In the plate heat exchanger, the tomatoes are heated up to about +85 °C, depending on the product, so that all germs are killed. The tomatoes are heated in multiple sections, kept hot for a time and then cooled down again. This process is suitable for thermal treatment of tomato concentrate, pulp and juice. Reliable pressure measurement is required to maintain an optimal process in the heat exchanger.
Food Industry
In the pulper, the cores and skins are separated from the pulp of the tomatoes by means of centrifugal force. To ensure that this process runs efficiently and that there is no downtime, it is important to monitor the level precisely. Limit level detection in the waste container prevents overfilling.
Mining and Metal Production
After the blast furnace is tapped, the molten pig iron flows into torpedo cars at a temperature of over 1400 °C, then transported to the foundry or converter for further processing. A reliable level measurement is a must for the safe, reliable filling of these torpedo cars.
Building Materials
In order to process building materials such as mortar, plaster or grout effectively, they are delivered directly to the construction site in transport silos. There, water is added as required and the building material is processed immediately. Level measurement ensures that there is enough material in the silos.
Pharmaceutical Industry
In many of the production processes in the pharmaceutical industry, small quantities of various chemicals are needed in order to improve the characteristics of certain products. The media are often provided directly to the production areas in small, transport containers. Accurate level measurement ensures a continuous supply of materials for production.
Oil and Gas Offshore
The drilling mud flowing back under high pressure from the drilling well is held and monitored in the trip tank. This drilling mud is contaminated with sea water, rocks and sand. In addition to materials like rocks and sand, residues of oil and gas are also present. The built-in level measuring system provides feedback about down-well conditions, basic data for comparing the quantity of drilling mud fed into the wellbore with that returned, as well as regulating mud production.
Building Materials
Dust-free, closed loading systems are needed for fine aggregates and finished products such as cement. Automated loading of trucks is preferred in the industry and, while the load quantity is determined with a weighing system, it must be ensured that the truck is in the correct place and not overfilled. Reliable point level detection and vehicle positioning shortens loading times, increases throughput and improves the efficiency of the entire system.
Cement Industry
Dust-free, closed loading systems are needed for fine aggregates and finished products such as cement. Automated loading of trucks is preferred in the industry and, while the load quantity is determined with a weighing system, it must be ensured that the truck is in the correct place and not overfilled. Reliable point level detection and vehicle positioning shortens loading times, increases throughput and improves the efficiency of the entire system.
Environment and Recycling
Tsunamis travel quickly and cause great damage when they hit land. So it is vital that tsunami warnings are issued early. Tsunami information centres continuously evaluate simultaneous data from seismic and sea level measuring stations. Such a sea level measuring station is operated by an oceanographic centre in a ferry and cargo-ship terminal. The measurement has to reliably and accurately detect the sea level and forward the data directly to the central monitoring system.
Energy
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.
Energy
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.
Water and Wastewater
During seawater desalination, substances often have to be removed or separated from each other. One method for separation or precipitation is filtration. Superior product quality results only when the filter functions properly. For that reason it must be ensured at all times that the filter is performing adequately. This requires continuous monitoring of the filter.
Pharmaceutical Industry
High-purity water (WFI) is required for pharmaceutical products that are injected directly into the bloodstream or administered as eye or nose drops. This water is produced through filtration and distillation, then stored temporarily in tanks. Absolute sterility and cleanability are essential criteria for all process components that have direct contact with the medium. This also applies to the instruments for level and pressure measurement in the tank.
Chemical Industry
In a Urea reactor, ammonium carbonate is decomposed into urea and water. Nearly pure urea is discharged from the reactor via the long pipe, which projects into the upper part of the vessel from the bottom. During the reaction process, the level in the reactor must be kept as constant as possible to maximise the purity and productivity of the process.
Chemical Industry
In the production of urea from ammonia, high process temperatures and the urea itself limit any sensor material selection considerably. The thick container walls further complicate the installation of measurement technology. A reliable monitoring of the level is essential to enable the cost-effective production of urea.
Pharmaceutical Industry
A thickening vessel fitted with a scraper is used to increase the concentration of extracted solutions by means of evaporation under vacuum. Extremely precise level measurement is required in this process because the concentration is determined by the filling height. The evaporation system operates according to meeting specified levels. As soon as they reach the correct value, the evaporation process is stopped and the concentrated solution is discharged out of the tank.
Water and Wastewater
When new building zones are opened up, it is often quite expensive to build a sewerage network with the necessary downward slope. In such cases, a vacuum sewerage network offers an interesting alternative to traditional sewer systems. The wastewater is transported to the pumping station under vacuum, which allows significantly smaller pipes to be used and stretches of upward slope spanned. A central vacuum pumping unit conveys the wastewater from households via a central sewage discharge into the public sewer system. To effectively control the system the level in the vacuum tank must be continuously monitored.
Paper Industry
A vacuum system is used to perform dewatering on the high-speed paper machines. The required high vacuum is generated by a single or multi-stage centrifugal blower. The strength of the vacuum is regulated by the rotational speed of the electric drives. For this purpose, the vacuum must be continuously measured. It is also necessary to monitor the bearing lubrication system to ensure reliable operation of the vacuum blower itself. To achieve this, the pressure in the lubricating lines and the level in the lube oil supply tank need to be measured.
Food Industry
Tomatoes are unloaded from the truck into the basin and, with the help of water, pumped through the washing line. Heavy materials such as stones and mud sink to the bottom and are caught by a flow in the opposite direction. The tomatoes are washed with high-pressure air blowers. The radar sensor enables accurate level measurement, ensuring an optimal flow of tomatoes.
Environment and Recycling
The waste storage bunker in the reception hall is an important part of the EFW incineration plant. Its purpose is to provide a place to store, buffer and uniformly mix the delivered waste and ensure a continuous supply of waste to the incinerator. A grab crane transports the waste to the feed chute of the furnace. To ensure efficient operation of the plant, a reliable and accurate level measuring system is required in the waste storage bunker. In addition, the level in the feed chute must be monitored to protect against a blowback of flue gas.
Energy
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.
Oil and Gas Offshore
Rain run-off on board of oil platforms and ships is polluted with production residues and contaminants such as oil, sand and dirt. The rainwater with these contaminants must be collected in special tanks and properly disposed of. A reliable level measurement in the tank protects against overflow of the open drain removing the possibility of subsequent marine pollution.
Energy
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.
Paper Industry
The paper web is dewatered in the press and wire section of the paper machine. As the resulting water is removed via vacuum pipelines which are monitored by pressure transmitters to control the vacuum pump. It is also very important to prevent water from getting into the vacuum pump. To achieve this, water separators are built into the feed lines and the separated water is drawn off by a water pump. A continuous level measurement is used to control the level and the pump.
Water and Wastewater
Spring water originates from surface water, which passes down through layers of porous rock on its way down into the earth. It then flows horizontally along a layer of clay or rock and thus forms a spring. To obtain drinking water, the spring is impounded in some type of structure and protected against contamination. The spring water flows into a settling pond and then into a reservoir. A reliable level measurement is critical in ensuring a sufficient supply of drinking water.
Energy
Vibrating level switch as overfill protection in water storage tanks Non-contact level measurement with radar in water storage tanks.
Water and Wastewater
Water storage tanks are especially important in times of peak demand. They compensate for delivery fluctuations and enable efficient plant operation. The water storage tanks are therefore not just storage tanks, they also serve as equalising tanks. Reliable level and point level measurement are thus indispensable here.
Water and Wastewater
To operate drinking water storage reliably, precise information about the water level of the inflow as well as the dam itself is required. The level of water in the dam can be continuously monitored by a hydrostatic level measurement. Since infrastructure at these remote sites at the dam wall, is often lacking, wireless mobile data transmission units are often used for sending the measured values.
Water and Wastewater
Water towers are used as storage facilities for drinking water and as pressure balancing tanks in the network of water supply pipelines. In order to keep the water level and thus the network pressure constant, the level in the water tower needs to be constantly maintained. The level of water is monitored by a pressure transmitter.
Energy
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.
Oil and Gas Offshore
The height of floating drilling or pumping assets like platforms or FPSOs must be precisely maintained, even in the roughest seas with waves up to 30 m high. Environmental influences such as wind and waves must be measured quickly and accurately, then evaluated with GPS navigation data. Furthermore, quick and exact measurement of wave heights is needed should there be an evacuation, where "freefall lifeboats" need to be released to meet waves at their highest point.
Ship and Yacht Building
Container ships can cause enormous damage to the quay if they dock improperly. When a container ship approaches, a giant wave, the so-called "swell", shoots between the columns and floods the chamber. Radar sensors measure the distance to the ship repeatedly and thus determine its speed. The reliable radar measurement detects deviations from the berthing plan in good time. This allows the ship's crew to be informed at an early stage so that countermeasures can be taken.
Energy
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.
Environment and Recycling
The hot, burned-out slag falls into the water quenching bath of the deslagger. A mechanical discharge mechanism pushes the slag out and, while doing so, presses out most of the entrained water. Evaporation and slag removal cause a steady loss of water. For that reason the water level in the deslagger has to be measured and replenished as required.
Energy
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.
Energy
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.
Energy
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.
Paper Industry
The wood chips are transferred via conveyor belts to storage silos up to 25 m high and stored there temporarily for further processing. The silos are filled and emptied in batches. During the process, large amounts of dust are generated, material cones and bridges form, which collapse during emptying. Reliable level measurement is needed here to ensure supplies for downstream processes and facilitate logistics planning.
Food Industry
In the wort cooler, the wort is cooled down from approx. +100 °C to 8 - 15 °C. The yeast is added in a subsequent process. Reliable pressure measurement is required to maintain an optimal process in the wort cooler.
Food Industry
Hops give beer its typical beer aroma. Proper dosage of the hops is therefore enormously important for the flavour of the finished product. Wort and hops are mixed together and cooked in the wort kettle. To ensure reliable control of the hops dosage and cooking process, level and pressure measurements are integrated in the process.
Food Industry
After leaving the fermentation tank, the green beer is fed to the separator. There, a large part of the yeast is removed before filtration. To ensure a continuous supply to the separator, the pressure in the green beer supply line is monitored. A level detection system monitors the separated yeast, which settles in the lower part of the separator, and controls the cleaning process.
