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Ready to ShipThere are several types of industrial level sensor transmitters based on properties like the characteristics of the materials measured.
Capacitive level transmitters work by determining the change of capacitance that occurs as the level of liquid substances changes. This means that liquid and solid materials have different dielectric constants. The probe acts by forming a capacitor with the tank and the material used as the dielectric medium. When the level of the material in the tank rises, the dielectric constant also changes, thus changing the capacitance, which is measured to give the level of the material.
The bubbler level transmitter determines the level of liquid by measuring the pressure of the gas at the surface of the liquid. This is done by submerging a pipe in which gas is passed, and the end of the pipe is in the liquid. As the liquid level rises, the pressure exerted by the liquid column on the gas is proportional to the level. This makes it very suitable for use in vessels with agitation.
Guided wave level transmitters use a conductor wave gauge. The waves travel through the probe that is partially submerged in the measured liquid. The probe transmits electromagnetic waves into the liquid. When the wave reaches the surface of the liquid, part of the wave will reflect back, and part will transmit through the liquid. The time it takes for the reflected wave will give the level of the liquid.
A vibration fork level transmitter works by measuring the change in resonance frequency caused by material accumulation on the tuning fork. Fork sensors vibrate at a known frequency. When the sensor is installed in a tank, the newly vibrated fork will be affected by the liquid's density and stopped by the solid. The fork will vibrate at the same frequency, and the change in vibration will be measured. It works for both liquids and solids and is good where space is limited.
Hydrostatic level transmitters determine level by measuring the pressure exerted by the column of liquid above the sensor. The pressure is proportional to the liquid level and can be calculated using the equation: level = (pressure)/(ρ* g). Ranged often from 1m to 100m and can be used to measure the level of open and closed tanks. Suitable for stable conditions and gives high accuracy.
Liquid level sensors are widely applied in industrial, commercial, and residential scenarios where liquid levels need to be measured and controlled to maintain safety and operational efficiency. Some of the applicable industries are elaborated below.
Level transmitters in water treatment plants are important in the control and monitoring of water levels in reservoirs, tanks, and treatment basins. This levels management helps in pumping operations, chemical dosing, and preventing overflow or dry states that can cause damage. In wastewater facilities, level transmitters help in the monitoring of the influent and effluent levels, thus enabling better filtration and treatment.
The food and drinks industry uses level sensors and transmitters to monitor the level of liquids like milk, juices, and beer in storage tanks, mixing vessels, and bottling lines. This helps in the control during processing, prevention of overflow during storage, and maintaining product consistency. The liquid sensors also help ensure that critical liquids are at required levels for safety and compliance with health regulations.
In the oil and gas industry, level sensors are used to monitor tank levels in storage, pressure vessels, separators, and pipelines. Level sensor gauges help in the prevention of overflow, the balance between production and storage, and the detection of potential hazards. In solid oil mining, it also helps monitor solid oil levels in storage silos and transport containers. This is important for safety and environmental reasons.
The pharmaceutical industry uses level sensors to monitor liquids and solids during drug processing. They are used for chemical and raw material storage tanks as well as mixing vessels to monitor the amount of active ingredients and excipients. This not only helps maintain compliance with health and safety standards but also helps in quality control and waste minimization.
In power plants, level transmitters are used to monitor water levels in steam generation systems, cooling ponds, and other reservoirs. This aids the maintenance of equilibrium during electrical generation and the prevention of machinery damage. In reservoirs, hydro level sensors help in the measurement of water levels to compute energy generation capability.
Level indicator transmitter specifications can vary depending on the type of sensor and intended application. Buyers should consider such key features before investing in level sensor transmitters.
Safety and quality considerations for liquid level sensors and transmitters are related to accuracy, reliability, and material compatibility based on the environment. Below are some key considerations.
The level sensors and transmitters should also be made from materials that can withstand harsh chemical, heat, or corrosion. Commonly used materials include 316 stainless steel, titanium, and PTFE. Such materials should be used based on the environment and the type of liquid measured. Sensitive instruments should be housed in protective casings to prevent damage from external factors like dust or moisture.
In industries such as oil and gas, mining, and chemical processing where flammable liquids or gases are present, level sensors should be explosion-proof or intrinsically safe. In such areas, non-contact type sensors like radar or ultrasonic are preferred to minimize ignition risks.
Most industrial sensors have IP/ NEMA ratings that protect them from dust, water, and other environmental hazards. Ultrasonic, radar, and capacitive sensors work well in tanks with vapors, fumes, or dust. However, guided wave and pressure sensor transmitters are prone to fouling or contamination.
Critical operations have redundant sensors in place to avoid failure or inaccuracies that cause downtime or hazards. These backup systems help maintain accurate level measurements when one sensor fails or experiences unexpected. Routine maintenance helps ensure proper functioning. Also, keep an eye on wear and damage and regularly clean and calibrate to maintain accuracy.
Strong electrical fields or noise from nearby equipment may interfere with liquid level sensor signals. This causes inaccurate readings. To avoid this, shield the sensors using protective conduit or cable. Also, use remote-mounted versions to minimize the effect.
A1: While both tools measure liquid levels, a level sensor simply detects the level and gives an alarm, while a level transmitter converts that level into a signal to send out.
A2: Level sensors are extensively used in the water, chemical, and food industries. They help in monitoring and controlling liquid levels in tanks, treatment plants, and processing equipment.
A3: A level sensor detects fluid levels, while a level gauge visually indicates the fluid level in a tank or vessel. Both perform the same task, but the level sensor provides an output and signal, whereas the gauge only shows the reading.
A4: Level transmitters work by converting level measurements into electrical signals. They use techniques such as pressure measurement, buoyancy, and capacitance to give the readings.
A5: Level sensors can fail due to physical damage, excessive temperatures, power supply issues, signal interference, poor wiring, and harsh environmental exposure.
