Multi-Sensor Monitoring of a Catch Basin at DOW
Germany’s First Multi-Sensor Monitoring Ensuring Structural Integrity & and Leak-Tightness
Texplor proudly introduces Germany’s first advanced multi-sensor structural health monitoring (SHM) system at DOW’s Stade facility. By combining real-time leak detection with high-precision movement and settlement monitoring, this solution provides a comprehensive structural assessment, ensuring safety, maintenance optimization, and extended infrastructure lifespan.
Project Highlights
- Catch Basin Size: 4,000 m² with 4 large and multiple small tanks
- Technology: MSS® Leak Monitoring & TEXtant® GNSS Movement Monitoring
- Key Benefit: Optimized maintenance and enhanced environmental safety
- Client: Dow
Why Catch Basin Monitoring Matters
The monitored catch basin, a secondary containment system surrounding a tank farm, is the last protective barrier between the tank system and the environment. It plays a critical role in environmental protection and risk mitigation.
However, cracks have formed in the basin floor, likely caused by heavy tank loads and external environmental factors, including groundwater fluctuations and tidal forces from the nearby Elbe River.
To identify the cause of these cracks and monitor ongoing risks, Texplor installed a time-synchronized multi-sensor system that continuously tracks the structural behavior of both the tanks and the basin.
With our latest innovative Multi-Sensor Monitoring system, we can accurately detect and assess the tightness of storage tanks, monitor the integrity of the entire containment basin, and track even millimeter-scale movements. This ensures early detection of potential risks, enhancing safety and reliability in storage operations.”
Ernst Geutebrueck, PhD.
CEO, Texplor Group
Advanced Leak Monitoring
Texplor’s MSS® Leakage Monitoring System enables real-time integrity assurance of the catch basin at DOW’s Stade site. Designed for early leak detection and instant alerts, it replaces traditional 5-year inspection cycles with continuous structural health monitoring—enhancing safety, reducing risk, and protecting the environment.
Texplor’s MSS® Leak Monitoring System was seamlessly retrofitted into the existing infrastructure with minimal disruption. The system consists of:
- 16 leakage sensors
- Conductive cord net in the basin floor
- Automated leak detection & instant alarm
- TEX-Sky Monitoring Cloud with SHM 4.0
This explosion-proof system, designed for chemical environments, uses a low millivolt current emitted by the conductive net embedded in the basin floor. If a leak occurs, the current reaches the outer sensors, triggering an automatic alarm via the central monitoring computer.
The system’s time-synchronized data is uploaded to the TEX-Sky Monitoring Cloud, where it is correlated with structural movement data from the GNSS monitoring—delivering a unified overview of catch basin integrity.
Installation takes just a few days and is suitable for both new builds and existing infrastructure. With minimal sensor requirements, the system remains cost-efficient while ensuring reliable monitoring. Texplor’s FGM®/EFT® mobile detection system can then pinpoint the exact leak location for targeted repair and reduced downtime.
With this system, DOW has 24/7 control over the integrity of its critical secondary containment. In an emergency, the basin must hold the tank contents—it must be leak-proof.”
Bastian Merten, MSc.
CTO, Texplor Group
Movement & Settlement Monitoring
Uneven settlement can lead to serious structural instability. Texplor’s TEXtant® GNSS Monitoring System detects even the smallest shifts with millimeter accuracy. Currently, one of the four large tanks is equipped with four GNSS antennas to measure movement and tilt in all directions. These precise measurements answer critical structural questions:
- Is the tank sinking evenly, or is one side settling faster?
- Do groundwater levels or tidal fluctuations impact the structure?
- Is a tank tilting over time—and if so, by how much?
A key focus is the Z-value, which represents vertical displacement—crucial in identifying settlement-related risks.
Smart Infrastructure for Smarter Decisions
Texplor’s monitoring system is designed for rapid deployment and adaptability. Whether installed on new builds or retrofitted, it significantly reduces the need for manual inspections, enabling data-driven maintenance planning.
- Quick installation without disrupting operations
- Real-time data access via the TEX-Sky Monitoring Cloud
- TÜV-approved reporting for compliance and risk management
- Compatible with existing infrastructure
- Scalable system with options for additional sensors
Future-Proof & Modular Expansion
Texplor’s system is fully scalable. Additional multi-sensors, including corrosion and additional client sensors can be integrated into the central computer and TEX-Sky Monitoring Cloud. The more sensors integrated, the more complete the monitoring insights, helping prevent long-term degradation.
- Quick installation without disrupting operations
- Real-time data access via the TEX-Sky Monitoring Cloud
- TÜV-approved reporting for compliance and risk management
- Compatible with existing infrastructure
- Scalable system with options for additional sensors
Partner with Texplor
With 30+ years of global expertise, Texplor delivers scalable, reliable, and future-ready monitoring solutions. Partner with us to enhance safety, reduce costs, and ensure infrastructure longevity.
+49 (0)160 66 03 381