However, this sensitive process only runs reliably when the heat exchanger remains consistently covered with water. This is where UWT sensor technology delivers decisive advantages. With continuous level measurement, precise limit detection, and intelligent inlet monitoring, UWT sensors ensure stable steam production – and with it, a consistent flow of energy and heat.
Flow Control: Keeping the heat exchanger under control
To maintain a stable process, the water feed into the steam separator must be regulated precisely. UWT point level detection ensures the heat exchanger never runs dry and always remains reliably cooled.
This is critical for several reasons:
- Avoid overheating: Without water coverage, the heat exchanger is exposed to hot steam, risking overheating and damage.
- Ensure efficient heat transfer: Saturated steam can only release its energy effectively the exchanger is covered with water.
- Maintain stable pressure: A constant water level keeps pressure and evaporation rate consistent for smooth operation.
Beyond Level Monitoring: Flow Measurement for total process stability
Steam separator performance depends on more than just level monitoring. UWT sensors enable accurate measurement of:
- Water inflow through the feed line
- Continuous energy transfer from saturated steam
- Consistent removal of pure steam into the condenser
Together, these parameters form a closed loop – stabilized and safeguarded by UWT sensor technology.
The Challenge: Extreme Conditions
Steam separator environments push components to their limits, with
- Process temperatures up to 150 °C
- Pressures up to 40 bar
- Condensing steam atmospheres that demand absolute reliability
UWT Solution
UWT provides robust, pressure- and temperature-resistant sensors with hermetically sealed designs that maintain performance even in steam and condensate environments.
Sensors in Action
Continuous level measurement – NivoRadar® NR 8200
A compact radar sensor that continuously monitors the water level, even under extreme conditions up to 250 °C and 40 bar. Its robust stainless-steel threaded antenna ensures precise readings despite steam, condensate, and fluctuating surfaces.
Limit level detection for maximum and minimum levels – Vibranivo® VN 7120
At the top of the tank, a vibrating fork detects the maximum fill level to prevent water from entering the condenser. A second fork monitors the minimum level just above the heat exchanger, ensuring it always remains covered with water. Both sensors are reliable up to 150 °C and remain unaffected by steam, turbulence, or air bubbles.
Precision in the water inlet – Capanivo® CN 7120
Installed in the inlet pipe, this capacitive sensor monitors the feed water supply. Its compact stainless-steel design is ideal for small pipelines, while EHEDG-compliant construction meets the highest hygiene standards. IO-Link connectivity enables instant digital data access for optimized process control.
Ultra-compact Vibranivo® VN 7120 inside the heat exchanger
Designed for tight installation spaces within the heat exchanger, an ultra-compact version of the Vibranivo® is used. It directly monitors the saturated steam feed in the heating section and requires minimal installation space, yet withstands up to 150 °C with reliable switching accuracy.
Stable Steam Processes with UWT
With this tailored sensor solution from UWT, the heat exchanger remains constantly covered, overheating is prevented, and process pressure remains stable. The result is safe, efficient, and continuous steam generation – a decisive contribution to flow control and measurement in the food industry.
