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Ready to ShipCeramic capacitive liquid level sensors come in various configurations and types. The differences in their structure mostly relate to the characteristic of the application where they will be employed to achieve optimal liquid measurement. Below is a list of the most common types for different applications based on their functionalities and designs:
Submersible ceramic capacitive sensors: These sensors are designed to measure liquid levels while being submerged in the liquid itself. They are often used in deep reservoirs and have a robust construction to withstand the pressures and temperatures of the liquid environments. Submersible sensors provide accurate real-time measurements at any depth in the liquid column.
Ceramic pressure transducer level sensors: These sensors convert liquid level measurements into pressure readings. They are based on the measurement of changes in pressure caused by the liquid column above it. This type of sensor has been mostly used in deep tank applications where other level measurement methods may prove less effective. They provide precise measurements in large and challenging environments.
Radial ceramic sensor: Unlike cylindrical sensors that measure capacitance axially, radial ceramic sensors are designed with an architecture that measures capacitance. This is from a radial perspective across the dielectric surface. Their difference in orientation provides a unique sensitivity. It focuses on more shallow liquid levels and can potentially differentiate better in thin film applications.
Bubbler system ceramic sensors: These interractive ceramic sensors use air bubbles to measure liquid levels. Air is forced through a submerged ceramic tube, and the pressure and flow of the bubbles are analyzed to determine the liquid's level. It is widely used in liquid pits and basins, where effective cleansing is crucial for maintaining measurement precision. A characteristic advantage of this method is that it is unaffected by changes in liquid density or viscosity.
Optical ceramic sensors: These sensors use light to measure liquid levels. It typically involves a light beam. The light beam reflects off the liquid surface. Changes in this reflection caused by the liquid surface rising or falling are used to compute the liquid's level. These sensors are mostly used for transparent or semi-transparent liquids. This is due to their advantage in measuring without coming in contact with the liquid. Which is the case with some capacitive sensors.
Ceramic capacitive liquid level sensors have proven vital in several industrial applications due to their strong resistance to corrosion, high accuracy, and dependability in hostile and varying environments. Below are some of the most common utilization case scenarios:
Chemical industry
In the chemical industry, liquids frequently come in contact with highly corrosive substances. That's why having reliable and durable equipment is so important in this industry. The fine finish on ceramic materials increases the sensor's endurance to chemical attack. This makes it well-suited for measuring levels in acid, bases, and other corrosive liquids. Accurate and precise level measurement prevents overfilling and reduces hazardous spills within the environment. This makes the sensors also applicable in one of the most crucial processes and more volatile environments.
Oil and gas
In the oil and gas sector, sensors are often exposed to variable temperatures, pressures, and corrosive fluids. The characteristic durability of ceramic capacitive sensors makes them suitable for tracking liquid levels in storage tanks, pipelines, and other crucial processes. Their ability to operate reliably in extreme conditions helps enhance operational safety and efficiency. This is achieved by minimizing downtime due to equipment failure.
Water and wastewater management
Built-in water treatment plants, reservoirs, and well systems, ceramic capacitive sensors measure water and wastewater levels. They feature high resistance to the formation of biological films and sedimentation. This helps maintain their accuracy within dirty and variable conditions. Reliable level detection is key to optimizing pumping systems and preventing overflow. It improves the overall work process in the water and wastewater management industry and enhances ecological safety.
Food and beverage processing
The food and beverage industry require non-toxic and hygienic measurement devices because the majority of their output consists of liquids for human consumption. Ceramic capacitive sensors are ideal in this case because they provide food-grade surfaces that comply with safety and hygiene standards. They are employed in measuring liquid foodstuffs such as juices, milk, and beer, as well as in cleaning-in-place systems. Their accuracy and reliability help maintain product quality and consistency in this highly regulated industry.
Pharmaceutical industry
Like the food and beverage industry, the pharmaceutical industry employs ceramic capacitive sensors to manufacture most of its output liquid medications. Because of their non-reactive surfaces and high level of precision, these sensors are applicable in level measurements of active pharmaceutical ingredients and other liquids. It helps ensure the safety, efficacy, and quality of drugs by providing dependable measurements during critical pharmaceutical processes.
Measuring range
Ceramic capacitive sensors typically have a measuring range that varies between a few millimeters to several meters. This range is usually determined by the application that requires it. Most standard industrial sensors have measuring ranges of about 0 to 10 m.
Output signal
The output signals also depend on the user preference. Usually, it can be either 4-20 mA, 0-5 V, and 0-10 V. All these output signals are then modulated proportionally to the liquid level measured. This makes the output signal suitable for most industrial operations.
Capacitance exciter frequency
The operational frequency for capacitance excitation in ceramic capacitive liquid level sensors is often between 1 kHz and 100 kHz. Selection of this frequency range is dependent on factors like the type of liquid and the application involved. Lower frequencies are more ideal for dielectric mediums that are high in capacitance. While higher frequencies is where low capacitance dielectrics are encountered.
Temperature working conditions
The working temperature of a ceramic capacitive liquid level sensor is contingent on its application or environment. However, most of them can withstand temperature variations of between -40°C to 125°C. Some ruggedized types can even go up to 200°C.
Sealing and protection
To improve the sensor's performance in hostile environments, typical sensor housings are sealed to at least an IP67 or IP68 standard. This means that the sensors have a total protection benchmark against dust ingress as well as temporary immersion or continuous in water.
Mounting of the sensor
Mount the sensor in a vertical orientation above the liquid surface within the tank or vessel concerned. Ensure that the mounting area is clean and free of debris to avoid damage to the sensor.
Powering operation
The sensors usually require a specific voltage input to operate. This detail is found in the manufacturer's data sheet for the sensor concerned. The data sheet has all the safety and efficiency information you need for proper operation and avoidance of risks.
Signal output connection
The output signal of a ceramic capacitive sensor needs to be connected to a receiving device where that information is processed. It could be a PLC, DCS, or a local indicator. Remember that the output can differ from sensor to sensor. These outputs can be mA or V. Hence, it is very important to the connected devices the output type.
Testing of the system
Once a sensor is properly installed and the connections have been made, it is now time to test the system. Allow the sensor to receive signals and see if the output value makes sense. There should be a variation in output proportional to liquid level changes within the measurement range. If the sensor is equipped with a zero point or span adjustment, tweak them further until accurate readings are obtained.
Routine cleaning
Ceramic sensors have smooth non-porous surfaces. This helps them resist dirt accumulation and offers easy cleaning. Frequent inspections and washings are essential to remove all the deposits on the sensor surfaces. This ensures reliable readings all the time.
Inspect for damges
A visual inspection should be done on the sensors for obvious indications of breakdowns. Typical damages include things like cracks, chipping, or physical deformations. Users should especially pay attention to the sensor head and the area surrounding the housing. These are usually susceptible to physical harm. Upon noticing any damage, immediate replacement or repair should be done to avoid incidents and inconveniences.
Signal calibration
Ceramic capacitive liquid level sensors may need occasional re-calibration from time to time to maintain their accuracy and reliability. Calibration frequency heavily depends on the user's working conditions and requirements. Calibration techniques usually include span and zero adjustments and a check against standard references.
Check electrical connections
Frequent electrical disconnections and connections may occur when operating level sensors. During such times, it is important to ensure that all electrical connections are solid to prevent wrong signal outputs and sensor failures in the middle of important operations. Loose connections not only result in erroneous readings but may also damage the internal components of the sensor concerned. Check occasionally to avoid that and ensure professionals do all reconnections.
Ceramic capacitive liquid level sensors are highly durable and possess qualities that optimally favor their use in practically all industrial applications. These particular needs are usually influenced by the conditions they have to endure during operation and their inner build structure. Here are some essential quality parameters concerning its durability and made-of- materials:
Ceramic material quality
It is the reason for their high temperature and chemical resistance. The ceramic used in these sensors can typically withstand temperatures up to around 200°C. This makes them ideal for use in extreme operating environments. Moreover, ceramic is a highly superior material against corrosive chemicals' susceptibility. It makes capacitive sensors more ideal for chemical, oil and gas, and more industries that face these environments daily.
Robust design
Ceramic capacitive sensors have rugged designs to withstand mechanical stresses, vibrations, and pressure. All these imperatives mean increased operational reliability. They can therefore be utilized in industrial processes with constant movement and fluctuations in pressure without losing precision. In fact, they are designed for durability.
IP67 rating
Usually, these sensors come with an Ingress Protection IP rating of at least 67. This means total protection against solid particle ingress and temporary immersion in liquids. This durable build allows sensors to work reliably in outdoor industrial settings where dust, water, and extreme weather are a concern.
Resistance to mechanical fatigue
The capacitive sensing method used in ceramic capacitive sensors ensures high durability over time, with almost no mechanical wear and tear. This feature is particularly relevant in high-frequency applications that require continuous monitoring of liquid levels. No mechanical fatigue ensures long life and less frequent sensor replacements. Thus, resulting in lower maintenance costs in the long run.
Stable performance
A ceramic capacitive level sensor's degree of measurement does not change with environmental conditions. Such things as liquid dielectric constants, temperature coefficients of expansion, and pressure interferences. Its high accuracy and low drift also come with great stability in various environmental conditions. This makes the sensor adapt to transient changes without reflecting on its measurements.
A1. A ceramic capacitive liquid level sensor operates by measuring the change in capacitance between its plates that are caused by the level of liquid it comes into contact with during its operation. The capacitance is the liquid's dielectric constant. It varies as the level of liquid changes. One of its key advantages is the fine quality of the ceramic material. It provides excellent resistance to high temperatures and all types of corrosive chemicals.
A2. They are highly accurate, especially in viscous non-conductive liquids. They have a good operational lifespan of about a decade. Because of their non-contact measurement capability, they are good in hazardous environments. They are quite versatile; applicable to various media, including liquids, solids, and powders. They are also cost-effective and require no external calibration due to their stable accuracy level.
A3. Their performance is greatly affected by changes in the dielectric constant of the measured medium. This makes them unreliable in heterogeneous mixtures or media with fluctuating permittivities. Their sensitivity to changes in the environment can cause erratic behavior in conditions such as foam or condensation. Close proximity to one another may result in crosstalk. Finally, they require proper installation and calibration to perform at their best when measuring levels.
A4. Yes, a capacitive sensor can measure ammonia. It offers great compatibility with this highly corrosive chemical. An ammonia liquid level sensor is typically made of a ceramic element coupled with a stainless steel probe. Stainless steel offers great intrinsic protection against corrosion to the probe. Meanwhile, ceramic provides a smooth and noncorrosive surface against ammonia on the probe that will not degrade its surface even with long exposure. It also ensures high accuracy amidst the liquid's varying dielectric constant.
