In the demanding environment of coal-fired power plants, ensuring clean and efficient filtration systems is essential to guarantee smooth operation, reduce energy consumption, and comply with environmental standards. Until now, monitoring these filters has been a manual and time-consuming task. However, integrating Industrial Internet of Things (IIoT) technology is driving a significant shift in filter monitoring. With real-time monitoring and intelligent alerts, IIoT not only enhances plant operations—it redefines them.
Manual monitoring in a challenging environment is difficult
Coal-fired power plants require a wide range of filters to regulate air quality and protect critical equipment. In one real-world example, a plant uses twelve different filter types, including filters for exhaust air in coal transfer hoppers, coal collection bins, truck loading areas, ash separation systems, ash-quality monitoring equipment, and homogenizers. Each of these filters is monitored using differential pressure gauges that indicate when a filter is clogged and needs to be cleaned or replaced.
Previously, plant personnel had to check each gauge manually. Given the size of the facility, this process was not only labor-intensive but also inefficient. The effort required for manual readings was substantial, and the risk of human error was ever-present. Dirty filters that were not replaced in time led to increased energy consumption, while routine maintenance often resulted in the replacement of filters that were still fully functional. These inefficiencies contributed to higher operating costs and increased the risk of unplanned downtime.
IIoT-enabled filter monitoring with WIKA differential pressure sensor
To address these challenges, the power plant implemented a smart monitoring system using WIKA’s A2G-500 differential pressure sensor. The sensor continuously measures the differential pressure across each filter and transmits the data wirelessly via the LoRaWAN® protocol. With a measuring range of 0 to 2,500 Pa (0 to 25 mbar) and a transmission rate of once per hour, the system ensures accurate and timely data acquisition.
WIKA also supported the strategic placement of the LoRaWAN® gateway to ensure reliable signal coverage throughout the entire plant. The gateway forwards the captured data to a central dashboard—also provided by WIKA—where operators can monitor the differential pressure readings of all filters in real time directly from the control room.
Benefits: smart alerts and centralized control
One of the key advantages of this system is automated alerting. When the pressure across a filter exceeds a predefined threshold, the dashboard immediately notifies the operator. This enables timely, targeted maintenance, eliminates manual routine checks, and ensures that filters are serviced only when necessary.
The introduction of IIoT technology has delivered significant benefits for the power plant. Operational efficiency has improved through early detection of filter issues and optimization of filter performance. Maintenance can now be carried out more precisely—reducing downtime and avoiding unnecessary interventions. The system has also generated substantial cost savings by lowering maintenance and energy costs. Most importantly, it has increased safety by preventing operational disruptions and reducing the risk of incidents caused by clogged filters.
Conclusion: a strategic step toward smarter power generation
By using IIoT for filter monitoring, coal-fired power plants can move from reactive to proactive maintenance strategies. WIKA’s A2G-500 with LoRaWAN® not only simplifies operations, but also supports a more sustainable and cost-effective approach to power generation. In an industry where reliability, efficiency, and environmental responsibility are top priorities, smart monitoring is more than just a technological upgrade—it is a strategic step toward the future.
Text taken over from original and translated – WIKA
