Solving High Static Pressure & Low Range Measurement Challenges: WIKA Solution Deployed

In the complex working conditions of gas power generation and sintering production in the steel industry, reliable pressure measurement is critical to production safety and operational efficiency. For core measurement requirements of a gas power plant affiliated with a well-known steel enterprise in Henan, the combined solution including WIKA UTP/UTD pressure & differential pressure transmitters and MA diaphragm pressure switches has been successfully implemented. The solution also covers pressure monitoring for the enterprise's sintering project, effectively addressing key pain points such as high static pressure, low-range differential pressure measurement and furnace explosion-proof safety monitoring.

Project Challenges

The project covers two major processes: gas power generation and sintering, with harsh site conditions and multiple measurement difficulties:

• High static pressure DP measurement: The maximum working pressure of some measuring points reaches 40 MPa. The DP transmitter must withstand high static pressure and avoid performance degradation;

• High-precision low-range measurement: Flow points need to measure tiny differential pressure at the level of hundreds of Pa, requiring low-range configuration for accurate acquisition;

• Mandatory explosion-proof safety: The FSSS furnace safety supervision system operates in flammable and explosive gas environments. Reliable instrument action is essential for furnace safety with almost zero fault tolerance.

Customized WIKA Product Solution

Based on site operating conditions, WIKA provides a complete set of instruments balancing accuracy, explosion protection and long-term stability:

UTP-18 Pressure Transmitter & UTD-10 DP Transmitter

• The UTD-10 DP transmitter withstands high static pressure and supports low-range configuration to precisely capture micro differential pressure of hundreds of Pa;

• The UTP-18 pressure transmitter features a measuring range from 0.01 MPa to 70 MPa for gauge and absolute pressure monitoring;

• Both instruments hold NEPSI, ATEX and IECEx explosion-proof certifications, with long-term stability of 0.1%FS over 10 years.

MA Diaphragm Pressure Switch

• Built with Ex d flameproof enclosure and IP66 protection rating for FSSS furnace safety monitoring;

• Switching repeatability is less than 1%, delivering stable trigger signals in hazardous gas zones;

• Robust diaphragm design adapts to gas media and requires minimal maintenance.

Project Benefits

WIKA UTP/UTD instruments have finished installation and commissioning for the sintering project, with all performance indicators meeting design expectations:

• Stable micro DP measurement under high static pressure; flow deviation stays within process tolerance, providing credible data for process control;

• Full explosion-proof certifications for hazardous area application; FSSS pressure monitoring works without false triggering or failure;

• Excellent long-term stability reduces on-site calibration and equipment replacement frequency, cutting annual operation & maintenance cost.

As a professional B2B industrial instrument platform, Intellprime offers global customers working-condition assessment, product selection, datasheet support and project quotation for full-range WIKA instruments. Leveraging WIKA's comprehensive product portfolio and rich field experience, we deliver customized measurement solutions for gas power generation, sintering and other steel processes to support safe and efficient plant operation.