22.11.2022

The Advantages of Level Switches
Level switches are an economical method for monitoring, controlling, and regulating the levels of bulk materials and fluids or liquids. Every manufacturing process necessitates control of raw materials to avoid waste and ensure efficiency. This has become more important in today’s competitive markets, where slight inconsistencies and errors can have multiple effects on production and product development.


The minute and small appearance of level switches may cause them to be categorized and defined as inconsequential. In reality, the minor investment in level switches can lead to the effective use of raw materials.


Level Switch Advantages:

1.Preventing Waste

The control of the storage of bulk and liquid materials assists in avoiding waste from spillage and overflows. A properly programmed level switch can activate a valve or pump to control overflow and avoid losses. With continuous level measurement level switches, the correct amount of raw materials is constantly maintained. Point level detector level switches can sound an alarm when a container is too full or the level is too low.


2.Money Savings

In modern business, every attempt to save money helps in increasing profits. The inventory and raw materials of a company are its greatest assets and have to be protected, monitored, and controlled to avoid losses. Though there have been substantial developments in the computerization of inventory control, every financial officer knows that there will be losses when the official count is taken.


The commonality of inventory loss necessitates constant monitoring of assets. In the case of bulk materials and fluids, such monitoring can be difficult due to the nature of the products. Level switch manufacturers are well aware of the difficulties associated with controlling the loss of bulk materials and have designed a wide selection of level switches capable of providing detailed data regarding the volume and quantities of on hand raw materials.


3.Automatic Advantages

Unlike floats, yardsticks, and other methods of product level monitoring, level switches are capable of automatically providing accurate data on time to a computer without the need to activate or initiate another device. In cases where the level switch is not connected to a controller, the data can be read from a digital or analog display with little effort.


For many years, the monitoring of silos, storage tanks, vats, and large containers required a routinely scheduled and constant surveillance of products by personnel. In most cases, the readings were inaccurate and not completed. All the footwork and labor required by the old fashion data collection systems has been eliminated by the automatic reporting level switches.


4.Reliability Advantage

The design and engineering of modern level switches remove any concern for poor performance or inaccurate data. The casings and materials used to produce level switches ensure that they will provide precise accurate readings for a long time. Since level switches have few moving parts, they do not require repairs or maintenance to accumulate data. Minor calibrations and adjustments may be necessary to guarantee the accuracy of a level switch but its failure is highly unlikely.


5.Switch Installation

Regardless of the type of level switch, whether it is continuous level measurement or point level detection, installation is easy. They can be installed and operating in an hour or two, depending on the type of switch. The ease of installation makes it possible to move and reposition them when there are changes in storage arrangements.


6.Compact Benefit

Unlike massive data collection methods, level switches are compact and can be handheld. Their compact design makes it possible to fit them into any size container regardless of its shape, dimensions, or location. Their compact configuration makes it possible to position a switch accurately such that it can collect data without obstructions.


7.Switch Sensitivity

The main reason for investing in level switches is their accurate sensitivity and ability to provide exceptional precision data. As every manager and supervisor knows, it is impossible to make correct decisions without up to date and accurate information. When materials are being sent from a container to production, they must be in the exact quantities that the process requires. It is for these reasons that level switches are an essential part of inventory control and production operations.


8.Level Switch Versatility

Regardless of the type of material being monitored, there is a level switch to manage and monitor it. This includes viscous slurries, tar, petroleum, grain, flour, and molten metals. The wide range of level switches is capable of meeting the challenge and performing beyond expectations. This aspect of level switches has made them such an essential part of production and processing.


Advantages and disadvantages of liquid level gauge
At the scene of the liquid level level of the industry, we can see all kinds of different measurement principle, structure and appearance of different liquid level measuring instrument, including magnetic liquid level meter, float level gauge, radar level gauge, turning into type level gauge, ultrasonic level meter, are more common type of liquid level meter, each kind of level gauge has the adaptive measurement conditions, in meet the working conditions of instrument measurement, can maximize the efficacy of liquid level measurement, and also be helpful for the service life of the instrument.


However, for so many instrument varieties, how to make the correct selection, so that every novice instrument users have a headache.The following is a brief analysis of the commonly used liquid level instruments in various places, hoping to help you.


1.Input level gauge


The advantages of the input level gauge are high measuring accuracy.Convenient equipment;Signals can be transmitted to remote control;Different materials can be selected to resist the corrosion of various media;Suitable for explosion-proof applications;The price is moderate.


Defects are shown as follows: measurement signal demand conversion;Unable to measure the temperature of high temperature media beyond 125℃;The density of the measuring medium must be uniform and common.


2.Float level gauge


Floating ball level gauge is a method to measure liquid level based on buoyancy principle.Usually by means of a float and scale, the observer can visually read the height of the liquid level.


Strengths: fast, intuitive reading;Low prices;Simple equipment.


Defects: low accuracy;The equipment is greatly constrained by the shape and layout of containers.Not suitable for corrosive and dangerous media;Unable to complete teleport and conditioning.


3.Magnetic flip gauge


Magnetic flip plate liquid level gauge is based on the magnetic float installed in the inside of the container and the magnetic flip plate outside of the flapper to complete signal transformation and liquid level display.


Strengths: fast, intuitive reading;Lower prices;Complete remote transmission and conditioning.


Defects: low accuracy;Equipment clutter;Range constraint;The equipment volume is relatively large.


4.Capacitive level gauge


Capacitive level gauge is used to measure the concave and convex liquid surface by changing the capacitance value between the two electrode plates.


Advantages: small size, simple remote transmission and conditioning;Suitable for corrosive and high pressure media.


Defects: the dielectric constant of the medium and the liquid surface must be accurately measured with stable brilliance.The measuring scale is limited by the length of metal bar.High demand for container materials;The measured medium has conductivity.


5.Radar level gauge


The radar level gauge is the information that is reflected from the liquid surface by the microwave (electromagnetic wave with very short wavelength) declared by the exploration itself.


Advantages: can measure liquid level in pressure vessel, can ignore the influence of high temperature, high pressure, scale and condensate;High precision;No direct touch with medium;Corrosion resistance;Can be used in vacuum environment;Simple equipment.


Defects: noble price;Affected by the container layout and material characteristics;Simply disturbed by electromagnetic waves.


6.Ultrasonic level gauge


Ultrasonic level gauge is the signal conversion of liquid/object level azimuth after ultrasonic wave reflected by the liquid surface declared by the exploration itself.


Advantages: no direct touch with medium;Corrosion resistance;High precision;Simple equipment.


Defects: price comparison noble;The ultrasonic wave is influenced by the gas composition.It is greatly affected by the container layout characteristics.Not suitable for medium with bubbles or suspended matter;Simply disturbed by electromagnetic waves.


7.Bubble method


The bubble method is to inflate into the medium through the bottom of the air source stabilizer.Only when the air pressure in the air supply system is balanced with the hydrostatic pressure at the bottom of the container will the gas enter the container from the trachea to form bubbles.The static pressure at the measuring point can be converted by measuring the pressure in the air supply system, and then the liquid level value can be obtained.


Advantages: corrosion resistance;High temperature media can be measured.


Defects: high maintenance cost;Low accuracy.


Radar Level transmitter- Working, Advantages
A radar level transmitter measures the distance between the transmitter installation point and the surface of a process material located at a distance. It measures the distance by measuring the time of flight of a traveling wave.Radar level transmitters are the most widely used level transmitters in many critical applications. Radar level transmitters accurately measure the levels in the tank. Basically, the radar level transmitter works on a very basic principle of time of flight.


Time of flight Principle

Time of flight is the time taken by any wave or particle to travel through a given medium, after being reflected from the object. The total time taken by these waves or particles is termed as the time of flight.


-Working of Radar Level Transmitter

A trans receiver sends and receives waves. It calculates the time taken by the waves to go towards the target, reflect from it and come back.


The speed of the waves is equal to the speed of light( 3 X 108 m/s). The transmitter algorithm calculates the time. Thus, by using the above-mentioned formula, the radar level transmitter calculates the distance between the trans receiver and target.


The radar type level transmitter has a trans receiver that sends the electromagnetic wave signal and receives the signal after reflecting from the object. Thus, the transmitter measures the time of flight.


The basic working of the radar transmitter is sending the microwaves (which can be of different frequencies for different applications) to the vessel or the tank and knowing the time it takes to travel to and fro from the level filled in the vessel or the tank. Using the formula, distance= speed X time, the radar transmitter calculates the distance from the transmitter to the top of the material filled in the tank.


The important factor in selecting the frequency of the microwave is dependent on the dielectric constant of the filled material and vapors and also the medium present above the fill level.


The measuring accuracy of the radar level transmitter depends on the dielectric of the object. The object that has high dielectric absorbs the microwave more, and the measurement accuracy is less because of the less received signal at the transmitter. In this case, the microwave frequency must be higher.


-Advantages of Radar type level transmitter

1.Radar type level transmitters are suitable for measuring levels of liquids, solids, slurries, or interfaces.

2.Since there is no moving part, maintenance is very less.

3.No effects on measurement by liquid turbulence, change in density, temperature change, and pressure change.

4.Non-contact type radar level transmitters are most suitable for highly corrosive fluids as well.

5.Limitations of Radar type level transmitter

If there is a change in the material’s dielectric constant, then readings will vary.In using contact type radar, if any material sticks on the probe, then it will form echoes and we will get the wrong reading. We need to pull the probe out and clean and again reinstall.

In non-contact type radar also, if any material sticks on the antenna, then we need to clean it.For interference measurement, the minimum difference in dielectric constant should be 5. Else we won’t be able to measure interface echo properly.


-Applications of Radar Level Transmitters:

Mining Industry

Captive Power Plant

Paper and pulp industry

Aeronautics industry

Cement Plants

Steel Plants


Maintenance of flow meter
A flow meter (or a flow sensor) is an instrument that is used to indicate the amount of liquid, gas, or vapor moving through a pipe or conduit by measuring linear, non-linear, mass, or volumetric flow rates. Since flow control is often essential, measuring the flow of liquids and gasses is a critical need for many industrial applications – and there are many different types of flow meters that can be utilized depending on the nature of the application.


In the process of use, the maintenance of flowmeter is very necessary. Here are some information about flowmeter maintenance:


A number of factors influence maintenance requirements and the life expectancy of flow meters. The major factor, of course, is matching the right instrument to the particular application. Poorly selected devices invariably will cause problems at an early date. Flow meters with no moving parts usually will require less attention than units with moving parts. But all flow meters eventually require some maintenance.


Primary elements in differential pressure flowmeters require extensive piping, valves, and fittings when they are connected to their secondary elements, so maintenance may be a recurring effort in such installations. Impulse lines can plug or corrode and must be cleaned or replaced. And improper location of the secondary element can result in measurement errors. Relocating the element can be expensive.


Flowmeters with moving parts require periodic internal inspection, especially if the liquid being metered is dirty or viscous. Installing filters ahead of such units will help minimize fouling and wear. Obstruction-less instruments, such as ultrasonic or electromagnetic meters, may develop problems with their secondary element's electronic components. Pressure sensors associated with secondary elements should be periodically removed and inspected.


Applications where coatings may occur are also potential problems for obstruction-less instruments such as magnetic or ultrasonic units. If the coating is insulating, the operation of magnetic flowmeters will ultimately be impaired if the electrodes are insulated from the liquid. This condition will be prevented by periodic cleaning. With ultrasonic flowmeters, refraction angles may change, and the sonic energy absorbed by the coating will cause the meter to become inoperative.


The Pros and Cons of Gas Detector
When choosing gas detectors, many factors come into play. The type of facility in which they will be placed, the gases they are designed to detect, environmental conditions, and more all play a role in determining the accuracy and reliability of the detectors. Due to the numerous factors involved, it is important to think carefully about the pros and cons associated with the gas detection system you are considering. To help with this, here is some additional information to help with your decision.


Portable vs. Fixed Detectors

For many facilities, one of the first questions they have is whether they should use fixed gas detectors or portable gas detectors. In most situations, the answer is both. While fixed detectors are important in that they can often scan large areas for gas leaks, they sometimes may not be as effective in monitoring confined spaces. Since these areas are often smaller and in isolated areas, technicians and engineers in these areas require portable detection equipment that can be clipped to clothing or placed nearby while they perform equipment installations, testing, and repairs.


Alarm Systems Comparisons

In many cases when selecting gas detection systems, companies fail to take into consideration the types of alarm systems that will be most effective in their facilities. As an example, if a facility is known for having high levels of noise, it is best to select detectors that have flashing lights or strobes that can alert workers in noisy areas. Along with this, if a facility has lower noise levels but instead has employees spread out over large distances, sirens can be the most effective method used to alert workers to a dangerous gas leak.


Wireless Technology

If a company has its buildings using wireless networks, it is always best to select gas leak detectors that possess this same technology. By doing so, they will be easily integrated into existing networks and systems, enabling them to produce results that are accurate and reliable. As many companies are now choosing to upgrade their detection systems to take advantage of wireless technology, one of the biggest advantages is having the capability to link the detectors with mobile devices such as smartphones. In doing so, engineers, technicians, management, and safety personnel can always have immediate access to real-time data, enabling them to make decisions regarding evacuations or other procedures much faster.


Multiple Gas Detection

Since many facilities will have numerous types of gases at their sites, it is crucial to select detection systems that include multi gas detectors. Though these detectors often cost more, they are long-lasting, can be used in virtually any type of facility and work environment, and allow for monitoring of multiple types of gases, both toxic and explosive. Along with this, they can use advanced technology, such as infrared sensing, to quickly locate various gases and transmit data to on-site personnel and off-site monitoring centers.

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