Simple level monitoring for stormwater and containment basins

The wastewater treatment plant in Steinen operates four stormwater basins and one containment basin used for the safe retention of contaminated or critical wastewater. These facilities are essential for protecting the sewer system and the environment during heavy rainfall events. To improve measurement reliability, increase transparency and modernize the existing installation, the wastewater treatment plant in Steinen replaced its previous system with FlexView FMA90 control units and Micropilot FMR20B 80 GHz radar level sensors.

The implemented solution provides the wastewater treatment plant in Steinen with stable level measurements across the entire basin height, even during highly dynamic rainfall events and at very low fill levels. Thanks to focused 80 GHz radar technology, interfering reflections from basin structures are reliably suppressed.

At the same time, level visualization, remote access to data and diagnostic functions via the FlexView FMA90 control unit simplify the intuitive interpretation of measurement values and significantly reduce the need for on-site inspections. This enhances both operational safety and efficiency. The solution enabled the modernization of existing measurement points without major modifications to the control cabinet layout or extended plant downtime.

The measurement points in the stormwater and containment basins of the wastewater treatment plant in Steinen are difficult to access, as they are located in shafts or potentially hazardous areas. This makes on-site inspection and maintenance time‑consuming. At the same time, the existing control unit offered only limited transparency and remote access to measurement data, as the installation in the control room was still largely based on established analog technology. Operators were therefore faced with the task of modernizing these installations and enabling a seamless combination of analog and digital systems.

A simple start to smarter control was achieved at the wastewater treatment plant in Steinen by implementing a non‑contact radar level measurement setup. The existing measurement setup was modernized using FlexView FMA90 control unit with Micropilot FMR20B 80 GHz radar level sensor. The retrofit allowed a one‑to‑one replacement using the existing cable, eliminating the need for rewiring or process downtime. Upgrading both the control unit and the level sensors improves measurement reliability while ensuring a future-proof and operationally reliable solution.

The non‑contact radar sensor Micropilot FMR20B uses 80 GHz radar technology to measure level independently of foam and condensate. With its narrow beam angle of up to 4°, the radar signal is precisely focused on the water surface. This reliably suppresses interfering reflections from concrete edges and basin structures, ensuring stable measurements across the entire basin height, even at low fill levels. Measurement reliability was further improved by implementing a simple mapping under wet conditions. Micropilot FMR20B ensures safe operation in outdoor and potentially hazardous areas.

FlexView FMA90 enhances the level sensors and brings every insight into clear view by visualizing level values and trend views directly at the device or via remote access. At the wastewater treatment plant in Steinen, the panel housing was integrated directly into the existing analog panel with 1-inch mosaic cut‑outs, enabling a straightforward retrofit without major changes to the control cabinet layout. Operators can access all relevant data using the integrated web server and Wi‑Fi connectivity from the control room, via smartphone, tablet or desktop computer, significantly reducing the need for on‑site inspections at hard‑to‑reach measurement points. By upgrading both the sensors and the control unit, the solution not only improves measurement performance but also enables modern visualization, remote access and diagnostic capabilities. The possibility to upgrade the complete system step‑by‑step without changing the existing infrastructure was a key factor in the selection process.