Real-Time TOC Analysis: Safeguarding Power Generation Equipment from Organic Water Contamination

Organic contamination in pure power plant waters poses significant operational and economic challenges, particularly in cogeneration systems where steam is utilized for both power generation and industrial heating. In such systems, the steam that condenses and returns to the boiler may become contaminated by organic compounds during industrial processes. This contamination is not always detectable through traditional conductivity measurements, as many organic compounds are non-conductive. Nonetheless, their presence can significantly compromise the efficiency and safety of power generation infrastructure.

The consequences of organic contamination are multifaceted. Organic substances can clog ion exchange resins, resulting in increased maintenance and replacement costs. More critically, they can degrade into acids under high temperatures, which lowers the pH of the water and accelerates corrosion in boilers and turbines. Organic residues may also deposit onto heat exchange surfaces, reducing thermal efficiency and causing foaming in boilers, which leads to the undesirable carryover of contaminants into the steam phase. Each of these issues can threaten the reliability and longevity of expensive equipment.

Sources of organic contamination in cogeneration plants vary widely. The most direct source is the return of condensate from production processes, where it may pick up organic matter through leaks or exposure to plant materials. Additional sources include makeup water, which is mainly derived from surface water, or reclaimed sources that vary seasonally in their organic content. Even ion exchange resins, while essential to purification, can degrade and release organic compounds. Other contributors include lubricants, leaking condensers, and certain chemical additives.

Given that traditional monitoring methods, such as conductivity or resistivity, are insufficient for detecting non-ionic organics, power plants are increasingly relying on Total Organic Carbon (TOC) measurements. TOC sensors work by oxidizing organic compounds into carbon dioxide using ultraviolet light and then measuring the conductivity of the resulting carbonic acid. This technique enables accurate detection and quantification of organic contamination, even at trace levels, allowing for real-time monitoring and rapid response.

Steam used in evaporation can pick up organics that, if returned to the boiler untreated, may damage the system. Early detection through TOC measurement enables corrective actions to be taken before significant damage occurs. Devices like METTLER TOLEDO Thornton's 450TOC and 4000TOCe analyzers provide fast, continuous monitoring and are designed to integrate into process systems with minimal disruption.

Recommended TOC Monitoring Approach:

For comprehensive organic contamination monitoring in cogeneration systems, consider implementing a dual-strategy approach using METTLER TOLEDO Thornton's proven UV oxidation technology. 

Deploy the 4000TOCe online analyzer at critical fixed monitoring points such as condensate return lines and makeup water inlets for continuous, real-time surveillance. This provides operators with immediate alerts when contamination levels exceed safe thresholds, enabling them to take rapid corrective action.

Complement this fixed monitoring with the portable 450TOC analyzer for diagnostic troubleshooting and multi-point system profiling. Utilize the portable unit to identify contamination sources, verify treatment effectiveness, and conduct regular water quality audits throughout the plant. Both analyzers deliver results in approximately 60 seconds from sample inlet to final measurement, ensuring operators can respond quickly to contamination events before significant equipment damage occurs.

This combined approach provides both the continuous protection required for critical process streams and the flexibility to investigate emerging issues throughout the water/steam cycle, offering comprehensive coverage against organic contamination risks.

Ultimately, the ability to detect and respond to organic contamination in pure water systems is essential to maintaining the performance, efficiency, and safety of cogeneration and power generation facilities. Investing in TOC monitoring safeguards equipment and helps avoid costly downtime while ensuring compliance with increasingly stringent water quality standards.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

Guided Wave Radar: The Modern Solution for Tough Tank-Level Challenges

Guided Wave Radar (GWR) level transmitters entered the process-control toolbox a little more than two decades ago and quickly earned the confidence of plant engineers because they answer an old dilemma: how to read an accurate level when vapors swirl above a boiling solvent when foam rides a fermenter, or when a mud-like slurry drags on every mechanical part it touches. GWR solves those headaches by steering short microwave pulses down a metal probe that acts as a waveguide. The pulse travels at the speed of light until it meets a change in dielectric constant at the product surface, and then it bounces back to the transmitter electronics. Because the probe confines the energy, ambient conditions—agitation, vapor, dust, even vacuum—cannot deflect the signal as they sometimes distort a conventional “through-air” radar reading. Engineers, therefore, gain repeatability better than ±3 mm without elaborate software filtering, and they keep that accuracy across the full measurement span, whether the tank stands five feet tall or 125 feet high. 

Unlike ultrasonic sensors, GWR ignores temperature gradients, condensation, and pressure swings. The probe physically shields the pulse from turbulence, so the device delivers stable output while a feed pump hammers the vessel or a mixer whips the surface. Operators can push the process to 400 °C and 4,000 psi if metallurgy allows, yet the electronic head remains at a comfortable ambient temperature because the probe alone penetrates the hot zone. High-pressure gaskets, steam jackets, or low-temperature insulation never disturb the reading; the microwave reflects when it sees the interface.  

GWR also thrives in low-dielectric applications that challenge float switches and capacitance probes. Light hydrocarbons often register below εr = 2, too weak for older technologies, but a guided pulse still returns with a readable amplitude. When an emulsion blankets the boundary between oil and water, the transmitter resolves the first echo and continues down the probe until it meets the second interface. Hence, operators track both layers simultaneously and confidently automate their draw-off valves.  

Maintenance crews appreciate the simplicity. A GWR instrument contains no moving parts, so it never sticks or drifts as a displacer can. Calibration involves entering the probe length and telling the device where the vessel zero lies—usually the bottom nozzle. After that initial setup, the transmitter self-monitors. Modern models supply Power-over-Ethernet so technicians can pull diagnostic waveforms, check echo curves, or update firmware from any browser without opening the enclosure.  

Engineers sometimes ask where a GWR truly shines because the technology tolerates such a wide envelope of process conditions. Separators in the upstream oil and gas sector illustrate the ideal fit. A wellhead separator must measure the height of crude-produced water and the frothy hydrocarbon vapor that hovers above them. Pressure fluctuates with every surge from the formation; temperatures shift as the heater treater cycles; paraffin and scale can coat anything that intrudes into the vessel. A guided wave radar slips through a small coupling, rides inside a stainless or Hastelloy probe, and delivers a clean echo from each fluid layer. The refinery no longer relies on floating skimmers or rinser sprays to keep sight glasses clear; instead, control logic receives real-time level data even while the brine level rises, the oil contracts with temperature, or the gas cap foams. Well-test operators, therefore, send the proper fractions to storage, reinjection, or sales without pausing to recalibrate. The result: tighter material balance, less flaring, and fewer unscheduled call-outs.

Closer to home, chemical formulators, power-plant boiler operators, and food processors borrow the same advantages. They install GWR on sulfuric-acid day tanks, black-liquor dissolvers, milk-powder silos, or de-min water drums, confident that CIP detergents, vacuum swings, or blanket nitrogen will never trip the reading. The probe adapts to slender stilling wells, bridle pipes, and long-stroke retractable assemblies, so designers rarely reposition nozzles when they retrofit older equipment.

Alliance Technical Sales of Clarendon Hills, Illinois, supplies a standout example: the Hawk Measurement Centurion Guided Radar Level Transmitter. This model adds Power-over-Ethernet, built-in display, SIL-2 safety approval, and a 38-meter measuring range, so it covers everything from small skid tanks to towering asphalt silos. Plants across Indiana, Illinois, and Wisconsin rely on Alliance’s application expertise and local inventory to shorten lead times and keep projects on schedule. Contact their team to see how the Hawk Centurion can deliver rock-solid level measurement in your toughest vessel.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

Shattering Traditional Limits: How the InPro X1™ Revolutionizes Dairy pH Measurement

The Mettler-Toledo InPro X1™ pH sensor sets a new standard for in-line pH measurement in the food and beverage industry by combining unbreakable X-Chip™ technology with a robust, user-friendly design. Operators eliminate the worry of glass contamination because the InPro X1 does not contain a fragile glass bulb. This feature proves especially critical in dairy processing, where product purity and safety remain top priorities, and even the smallest glass fragment can cause expensive rework or scrapped products.

X-Chip technology relies on a fully solid composite pH-sensing element that replaces traditional glass with layers bonded through advanced diffusion processes. This composite material forms a stable gel layer, which responds to hydrogen ion activity just like conventional glass electrodes but without the mechanical weakness of a thin glass bulb. As a result, operators no longer need costly retractable housings or protective hardware to guard against accidental breakage. The InPro X1 has undergone rigorous testing and demonstrates remarkable resistance to impact and thermal shock, making it an ideal candidate for the stringent cycles of cleaning-in-place (CIP) and sterilization-in-place (SIP) that dairy production demands.

The sensor’s pre-pressurized liquid electrolyte maintains stable measurement conditions during high-temperature processes, reducing drift and extending intervals between calibrations. Conventional glass pH probes often exhibit increasing drift as temperatures rise, mainly because an internal buffer changes over time. The InPro X1’s solid-state design eliminates that buffer and ensures consistent measurement, even in repeated CIP or SIP procedures that subject sensors to drastic temperature fluctuations. Dairy operations benefit from greater accuracy during critical steps like fermentation and pasteurization, where slight pH variations can significantly impact product consistency and flavor.

The InPro X1’s innovative form also simplifies installation and servicing. Its 12 mm diameter matches standard sensor housings, so operators can swap it in quickly without modifying existing hardware. The sensor works seamlessly with Mettler-Toledo’s Intelligent Sensor Management (ISM™) platform, which allows convenient, off-line calibrations and advanced diagnostics. Plant managers gain real-time insight into sensor status and can schedule proactive maintenance based on actual operating data rather than following arbitrary timetables.

Dairy processors rely on precise pH monitoring to ensure product safety and quality, and the InPro X1 rises to that challenge by combining high accuracy with unmatched durability. Glass-bulb sensors present contamination risks and demand frequent recalibrations, but X-Chip technology lifts these limitations. Instead of worrying about fragile probes, operators focus on improving efficiency and consistency, confident that the InPro X1’s measurement signal remains stable throughout demanding processes. By enabling safer operations and delivering accurate results under challenging dairy conditions, the InPro X1 pH sensor ushers in a new era of reliable in-line pH measurement for the food and beverage industry.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

Top-Tier Process Control: Alliance Technical Sales Delivers Reliable Analytics and Instrumentation

Alliance Technical Sales, based in Clarendon Hills, IL, partners with industrial and municipal facilities throughout the Midwest to deliver outstanding process control solutions. Their product specialties include process analyzers, process instrumentation, and electric process heating. Alliance Technical Sales helps clients optimize their operations and maintain consistent quality by combining technical expertise with top-tier brands like Mettler-Toledo, Jogler, Micronics, and BriskHeat.

Alliance Technical Sales proudly offer its robust process analytics solutions for facilities that monitor chemical composition, environmental parameters, or other critical factors in real-time. These include:

• pH/ORP Sensors: Reliable inline probes ensure precise control of acidity or alkalinity across applications such as water treatment, chemical processing, and food and beverage production.
• Dissolved Oxygen Sensors: Advanced optical measurement technology reduces maintenance requirements and delivers fast, accurate readings for various process conditions.
• Conductivity and Resistivity Sensors: Continuously measuring the ionic content in liquids helps identify contamination, verify purity, and maintain compliance with strict process specifications.
• Turbidity and Suspended Solids Analyzers: Inline solutions provide real-time insights into particle concentration, helping operators preserve product quality and meet regulatory standards.
• Gas Analyzers: Certain production lines must track oxygen, carbon dioxide, and other gases, and Mettler-Toledo's analyzers deliver dependable results to protect personnel and products.

Alliance Technical Sales works closely with customers to match Mettler-Toledo's process analytics devices to specific applications. This personalized approach ensures that each instrument addresses site-specific challenges and compliance requirements. These high-performance systems also include built-in diagnostic tools that alert operators to sensor drift, fouling, or other issues before they impact production.

Process Instrumentation and Electric Process Heating

In addition to Mettler-Toledo analyzers, Alliance Technical Sales supplies process instrumentation, and electric process heating solutions. Their selection spans sensors, transmitters, controllers, and other devices that govern critical variables such as flow, level, temperature, and pressure. Operators rely on these measurements to maintain operational efficiency, reduce downtime, and enforce product consistency.

On the heating side, Alliance Technical Sales collaborates with customers to specify electric heating solutions that tackle challenging environmental and process conditions. Their portfolio includes heat tracing and container heating for freeze protection and viscosity maintenance,  and more specialized products that keep materials at the right temperature without excessive energy use.

Territory and Service

Alliance Technical Sales covers Illinois, Indiana, Iowa, and Wisconsin. They emphasize local, hands-on support to address immediate concerns and offer on-site consultation. Their experienced engineers are ready to assist with product selection, system design, and ongoing troubleshooting.

Clients rely on Alliance Technical Sales for more than just the products themselves. Their commitment to customer success includes streamlined project management, training, and responsive customer service. This dedication, combined with top-quality brands such as Mettler-Toledo, BriskHeat, and Micronics, places Alliance Technical Sales at the forefront of the Midwest's process analytics, instrumentation, and electric heating solutions.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

In the Heart of Winter: Safeguarding Ancillary Equipment From Icy Threats

Industrial facilities often focus on preventing frozen pipes and valves during winter, but many overlook the equally critical task of protecting ancillary equipment. Control panels, pumps, instrumentation, and hoses face the same subfreezing dangers as piping networks. When ice forms on these components, it jeopardizes the efficiency and longevity of the entire operation, leading to costly downtime and safety hazards. With temperatures dipping well below freezing in the middle of winter, facility managers must take proactive measures to safeguard all equipment—not just the apparent pipes and valves.

BriskHeat, headquartered in Columbus, Ohio, offers a range of solutions designed for comprehensive freeze protection and precise temperature maintenance. Their heating tapes, cables, silicone rubber heating blankets, drum and tote heaters, and other flexible heating products give plant operators control over sensitive equipment. Unlike traditional methods that only heat primary piping systems, BriskHeat’s products wrap around or attach directly to ancillary components. This direct-contact approach prevents cold air infiltration and condensation buildup on pumps, sensors, control boxes, and more.

Many industrial processes require freeze protection and accurate temperature regulation to preserve product quality and ensure safe operating conditions. At low temperatures, some liquids become more viscous or even solidify, interrupting process flow and compromising end-product integrity. Heating cables and silicone blankets from BriskHeat apply uniform warmth that keeps substances at optimal temperatures. Technicians avoid clogs and maintain consistent flow rates without risking overheating sensitive materials.

Industrial safety also depends on reliable temperature control. Excessive chilling in certain chemicals increases the risk of leaks or pressure-related incidents. Sensitive electronic components may fail under extreme cold, potentially halting critical operations. By enclosing or wrapping these items with BriskHeat’s flexible heating solutions, facility managers reduce the risk of malfunctions and maintain a safer environment for personnel.

BriskHeat’s decades of experience in electric surface heating applications underscore the importance of proactive planning. Waiting for a pipe to burst or an instrument to malfunction mid-winter often results in expensive repairs and production delays. Instead, engineers can use heating tapes or blankets, combined with insulation and temperature controllers, to create consistent heat zones for every piece of equipment that handles liquids, gases, or temperature-sensitive materials.

Winter conditions grow harsher daily, and industrial facilities must do more than protect primary piping systems. Pumps, control boxes, instrumentation, hoses, and containers are vital in efficient operations. The entire process feels the impact when even one of these components freezes. BriskHeat’s products offer an effective way to keep every part of a facility running smoothly and safely, whether the goal involves freeze protection, steady temperature maintenance, or both. Operators cannot afford to neglect these critical solutions when the stakes involve safety, product integrity, and overall process efficiency.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com