Core Challenges in High-temperature Operating Condition Level Measurement

In industrial fields such as petrochemicals, metallurgy, and electric power, level monitoring of high-temperature media above 300℃ has long faced three major technical bottlenecks: zero drift caused by thermal expansion of sensor materials, crystallization clogging of impulse tubes by high-temperature media, and failure risks of cable sealing structures under thermal cycling. The TK-HB high-temperature impulse-guided level transmitter developed by Xi'an Shenghongchuang Instrument Co., Ltd. adopts an integrated 316L stainless steel cable-barrel structure. Through a patented thermal isolation design, the sensitive elements are physically isolated from the high-temperature medium. Actual testing shows that it can still maintain a measurement accuracy of ±0.25%FS in a 450℃ environment, far exceeding the basic requirements for industrial transmitters under IEC 60770-1.

Case 1: Level Control in a Molten Salt Thermal Energy Storage System

A solar thermal power generation project required continuous level monitoring of a 565℃ molten salt storage tank, but traditional capacitive sensors produced distorted data due to changes in the dielectric constant. The project adopted the TK-HB paired with the BYR-ZP high-temperature isolation diaphragm, reducing the actual operating temperature to below 125℃ through a dual capillary impulse-guiding structure. Operating data show that under working conditions with a day-night temperature difference of up to 200℃, the transmitter's annual zero drift was only 0.3% of full scale, a 67% reduction compared with similar SE600 models. The mechanical sealing structure of this stainless steel cable-barrel level sensor effectively blocks corrosion of electrical components by molten salt vapor, increasing MTBF (mean time between failures) to 80,000 hours.

Technical Comparison Table: Key Parameters of High-temperature Level Transmitters

Case 2: Reliability Verification in a Petrochemical Delayed Coking Unit

A refinery's delayed coking unit needed to monitor the interface position in a 380℃ high-temperature oil-gas separator, and the original AP203 transmitter suffered flange seal leakage due to thermal stress. After replacement with the TK-HB, its CS20LG heat sink fin design kept the housing temperature consistently below 80℃, and when combined with the BOS-H208-C special cable, achieved intrinsically safe explosion protection. Comparative data show that in media containing solid particles, the impulse-guided structure reduced measurement fluctuation amplitude by 82% compared with non-contact radar level gauges such as the STB-618, and eliminated the need for periodic shutdowns to clean coke buildup on the antenna.

Five Key Technical Considerations for Procurement Decisions

1. Thermal compensation range: Competing products such as YKKT-1D usually compensate only for 0-200℃, while the TK-HB has a built-in three-stage temperature compensation algorithm
2. Sealing rating: Dual protection with IP68 protection and EN 10204-3.1 material certification
3. Dynamic response: The impulse tube diameter is optimized to Φ6mm, increasing response speed by 30% compared with conventional models
4. Installation compatibility: Multiple process connection options are available, including flange/thread/clamp connections
5. Lifecycle cost: A 5-year warranty period reduces maintenance costs by 30%

Why Choose Shenghongchuang Instrument

As a national high-tech enterprise, we hold 12 patents related to high-temperature measurement, and all TK-HB series products have completed 1000 thermal cycle tests in the Siemens industrial-grade EMC laboratory. To address the ROI concerns of commercial evaluators, we provide full lifecycle service solutions covering installation and commissioning, regular calibration, and spare parts reserves. Contact a technical consultant now to obtain the High-temperature Level Measurement White Paper and a customized selection report. Call 029-XXXXXXX or visit www.sensor-tech.cn to submit your requirements online.