Boiler Steam Drum Level Measurement: Application of JWrada®-35 Radar and Ring-11 Vibrating Fork Switch
In thermal power generation and industrial steam systems, the boiler steam drum plays a vital role in steam-water separation and energy conversion. Maintaining a stable drum level is essential for ensuring steam quality, improving operational efficiency, and safeguarding overall system reliability.
However, under harsh operating conditions—such as high temperature, high pressure, and severe steam interference—achieving accurate and reliable level measurement becomes highly challenging. This makes continuous level monitoring combined with high and low level point detection a critical component in modern boiler automation systems.
Project Background and Operating Conditions
During a boiler system upgrade at a large thermal power plant, stricter requirements were introduced for steam drum level measurement. The application involves continuous level monitoring alongside safety alarm functions within a measurement range of 0–3 meters. The process medium consists of condensate water in the presence of saturated steam, with operating temperatures ranging from 180°C up to 400°C and high pressures.
Such extreme conditions present multiple technical challenges. High temperature and pressure demand robust instrument construction, reliable sealing, and long-term electronic stability. Meanwhile, steam turbulence and liquid level fluctuations can lead to unstable signals, while foam formation, condensation, and pressure variations further impact measurement accuracy. In addition, strict safety regulations require highly reliable high and low level protection mechanisms to prevent hazardous operating conditions.
Solution Design for Reliable Measurement and Safety Protection
To address these challenges, a combined measurement solution was developed based on Jiwei’s expertise in harsh industrial environments. The system integrates different measurement technologies to achieve both precise continuous monitoring and independent safety protection.
For continuous level measurement, the JWrada®-35 radar level transmitter is deployed as the primary instrument. Utilizing 80 GHz millimeter-wave radar technology, it delivers high-resolution measurements with excellent resistance to steam interference. Even in conditions with heavy turbulence, foam, and complex reflections, the device provides stable and accurate level readings. Its advanced self-learning echo processing algorithm automatically identifies and suppresses false signals, ensuring long-term measurement reliability and delivering high-quality data to the DCS system.
For safety protection, the Ring-11 ultra-high temperature vibrating fork level switch is installed as an independent point level device. Designed with an innovative cooling structure, it operates reliably in temperatures exceeding 280°C, with a maximum resistance of up to 400°C. Based on vibration detection principles, it is unaffected by steam, foam, or variations in medium properties. This ensures fast and dependable switching signals for critical high-high and low-low level alarms, enabling effective safety interlock functions and preventing risks such as overfilling or dry firing.
By combining the JWrada®-35 radar transmitter with the Ring-11 vibrating fork switch, the system establishes a dual-layer architecture of continuous measurement and independent protection. The radar device provides accurate real-time level data for process control, while the vibrating fork switch ensures safety redundancy. This design significantly reduces the risk of single-point failure and enhances overall system reliability.
Advantages of JWrada®-35 Radar Level Transmitter
1. High-Precision Radar Level Measurement with Strong Anti-Interference Performance
The JWrada®-35 radar level transmitter adopts advanced 80 GHz millimeter-wave radar technology and is equipped with a 76 mm large-diameter lens antenna, enabling a maximum measuring range of up to 150 meters. Even within the confined space of a boiler steam drum, this radar level measurement device delivers high-resolution and highly accurate level data.
Its core advantage lies in the built-in self-learning intelligent echo processing algorithm, which can automatically identify false echoes, enabling multi-echo separation and dynamic target tracking. In challenging conditions such as dense steam, turbulence, and fluctuating liquid levels, the system maintains stable output, significantly improving the reliability of steam drum level measurement in industrial applications.
2. Reliable Performance in High-Temperature Steam Drum Environments
The JWrada®-35 radar level transmitter is specifically designed for high-temperature steam applications and can operate continuously and stably at temperatures up to 220°C. It is certified for hazardous areas with gas and dust explosion protection (Ex db, Ex ia, Ex tb, etc.), making it suitable for demanding industrial environments.
Its specially engineered corrosion-resistant sealing structure effectively prevents high-temperature steam and moisture ingress, ensuring long-term operational reliability in harsh boiler and steam drum conditions. This makes it an ideal solution for boiler level measurement in power plants and process industries.
3. Smart Radar Level Transmitter with Easy Maintenance and Remote Monitoring
The JWrada®-35 supports the HART communication protocol and integrates Bluetooth 5.0 technology, enabling seamless wireless configuration and remote monitoring. Through the “Jiwei Smart Control” mobile platform, users can perform parameter setup and diagnostics without opening the device enclosure.
This smart level measurement solution significantly reduces maintenance workload and downtime, while improving operational efficiency. It is especially suitable for modern digital plants requiring remote access, intelligent diagnostics, and efficient boiler level control systems.
Role of Ring-11 Vibrating Fork Level Switch
1. Ultra-High Temperature Performance for Steam Drum Applications
The Ring-11 vibrating fork level switch features an innovative cooling structure, enabling continuous operation above 280°C and up to 400°C. It is fully suited for extreme boiler steam drum conditions and provides a reliable alternative to imported high-temperature level switches.
2. Reliable Point Level Detection with Strong Anti-Interference
Based on vibration technology, the device is unaffected by dielectric constant changes and offers strong resistance to steam, foam, and pressure fluctuations. It ensures fast and stable switching signals for high-high (HH) and low-low (LL) level alarms in steam drum level measurement.
3. Redundant Safety Design for Boiler Level Measurement Systems
Two Ring-11 switches are typically installed for HH and LL protection, forming an independent safety interlock system with the radar level transmitter. This redundancy minimizes single-point failure risks and improves overall system safety.
Operational Performance and Customer Benefits
1. Proven Performance in Harsh Operating Conditions
After commissioning, the combined measurement system demonstrated stable and reliable performance under high temperature, high pressure, and strong steam interference conditions. The application highlights Jiwei’s capability in delivering advanced solutions for extreme process environments.
2. Enhanced Measurement Accuracy and Reliability
Measurement reliability has been significantly improved through accurate identification of true level signals and effective suppression of false echoes. The system provides stable, continuous, and high-precision level data, enhancing confidence in critical process measurements.
3. Improved Safety with Redundant Protection
Operational safety has also been greatly strengthened. The independent vibrating fork switches provide fast and reliable responses to abnormal conditions, ensuring effective protection against overfill and low-level risks.
4. Optimized Efficiency and Process Control
In terms of efficiency, precise level control enables optimized boiler feedwater regulation, reducing level fluctuations and preventing steam carryover. This results in improved steam quality and enhanced thermal efficiency.
5. Reduced Maintenance Costs and Downtime
Maintenance costs have been reduced due to the maintenance-free design and remote diagnostic capabilities. The integration of wireless configuration and high device reliability minimizes unplanned downtime and lowers overall operational expenses.
Support for Digitalization and Smart Plant Operations
Furthermore, the system supports digitalization and smart plant initiatives. With remote monitoring, easy installation, and intuitive operation, it enhances user experience and facilitates modern plant management.
Conclusion
In boiler steam drum applications characterized by high temperature, high pressure, and strong interference, traditional measurement methods often fail to meet both accuracy and reliability requirements.
The combined solution of the JWrada®-35 radar level transmitter and the Ring-11 ultra-high temperature vibrating fork level switch provides a robust and effective approach. By integrating advanced measurement technology with a redundant safety design, it ensures precise level control and reliable protection under extreme conditions.
This solution not only improves safety and operational efficiency but also serves as a benchmark for level measurement in thermal power, petrochemical, and other demanding industrial applications.