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Bitumen tank level sensors are further divided into types based on measurement principles and technology.
Ultrasonic Level Sensors
These sensors provide a non-contact method to measure tank levels by emitting sound waves that reflect the liquid surface back into the sensor. The time delay of the return ultrasonic wave establishes the distance measured. These sensors are known for their accuracy and dependability in most conditions, including extreme temperatures and tank vibrations. Therefore, they are mostly applied in measuring bitumen tank levels.
Float-based Level Sensors
Float sensors use a float that rises or falls with the liquid level to indicate the level of a tank. Some sophisticated calculations using magnetic fields or electrical circuits enable the float position to translate into liquid level measurement. Float sensors are easy to operate and inexpensive, making them suitable for simple applications where high precision is not critical.
Capacitive Level Sensors
Capacitive sensors function by measuring the changes in capacitance caused by different dielectrics in the presence of the liquid. Since Bitumen is a hydrocarbon-based thick and viscous liquid, capacitive sensors assess its level through a dielectric constant. These sensors were effective for their precision and integral tank design compatibility.
Radar Level Sensors
Radar sensors for tank level measurement employ electromagnetic waves that reflect the liquid surface and return to the sensor. The time interval of the returning wave establishes the liquid distance from the sensor. These sensors work effectively in high-temperature and pressure environments and are not affected by the vapor present. Therefore, they make themselves suitable for bitumen tank measurement.
Thermistor-based Sensors
Thermistors are temperature sensors whose resistance changes with temperature. They measure the temperature of bitumen and, therefore, infer tank levels by measuring its temperature gradient. This technique gives precise measurements and is highly effective in conditions of extreme temperatures. These sensors are also applied in tank heating systems, making them suitable for bitumen storage.
Road Construction
One of the most significant uses of bitumen tank level sensors is in road construction. In this process, precise monitoring of bitumen levels is vital to ensure operations continuously supply the required material. Moreover, sensors improve efficiency by preventing overflows or shortages. As a result, construction becomes timely, budgets are contained, and waste is eliminated.
Roofing Industry
In the roofing industry, bitumen is a critical component for waterproofing and insulation. Industries rely on bitumen tank level sensors to ensure adequate inventory levels. Therefore, sensors contribute to minimizing downtime, streamlining operations, and maintaining product quality through consistent material availability.
Manufacturing of Pavement Sealants
Manufacturers of pavement sealants use bitumen for sealers and coatings construction. Thus, level sensors are crucial for maintaining optimum tank levels to ensure uninterrupted production processes. In addition, the sensors help manage materials and reduce the risk of equipment damage resulting from empty tanks.
Chemical and Petrochemical Industries
Petrochemical industries store bitumen in tanks that require effective level monitoring. For this reason, bitumen tank level sensors are crucial for high safety and reliability. Thus, the sensors help keep accurate levels for process control while minimizing risks from overfilling or running out of products. Therefore, they contribute to operational efficiency and safety.
Transport Industry
In the transport industry, companies deal with the logistics of bitumen shipment and storage. Hence, level sensors play an essential role in this process. For example, they help ensure accurate measurements during loading and unloading, which optimizes the entire process. As a result, the sensors help minimize transfer times, improve resource efficiency, and effectively manage the environment.
Asphalt Production Facilities
Facilities that produce asphalt mix rely on precise bitumen level monitoring in their storage tanks. Companies use bitumen tank level sensors to maintain consistent mix ratios to produce quality asphalt. Moreover, these sensors improve inventory management, preventing both product shortages and overstock that adversely affect profitability.
Installing a bitumen tank level sensor requires care to ensure effective service properly.
Select the Installation Location
The best position for installation is near the tank top to prevent difficulty in accessing the sensor during maintenance and safely measure the liquid level. Choosing the location where measurement accuracy is required also considers the tank's common liquid movement.
Install the Sensor Mounting
This involves securing the sensor to the tank. Other sources, such as flanges or threaded fittings, are often employed. If the sensor type is contact-based, ensure that the sensor is well positioned to come in contact with the liquid. On the other hand, if it is a contactless type, ensure the corresponding area is clear of interferences.
Wiring Connections
All basic needs specifications power the sensor and transmit data. Waterproof connectors should secure all connections to prevent exposure to moisture and dust that may affect performance. Confirming the manufacturer's wiring diagram also guarantees that proper connections are employed throughout the process.
Calibrating the Sensor
This requires setting the sensor to understand the tank's height and corresponding level measurements. The calibration method mainly depends on the type of sensor. For example, ultrasonic sensors are calibrated by getting the ideal distance, while float and capacitive sensors require adjustment of fixed points.
Testing and Validation
After calibrating, the test tank is filled with bitumen to enable the sensor to provide level readings. These readings are then compared with the actual level for accuracy verification. If discrepancies occur, a recalibration is necessary. At this stage, a review of the system's integration with the control systems is also conducted to ensure smooth operation.
Bitumen tanks should be well monitored using sensors prone to build-ups, such as float and contact-based sensors.
These systems are required to ensure that the sensor provides accurate readings, especially after long operational periods or changes in environmental conditions.
For level sensors, ensure power and signal transfer is uninterrupted. Regularly check for signs of wear, corrosion, or loose connections that could affect performance.
There should be regular inspections conducted, especially on external conditions which might indicate cracks, corrosion, or physical damage to the sensor.
The system performance data should be analyzed to look for anomalies, such as sudden fluctuations in level readings, which might indicate a sensor issue.
The periodic testing of the sensor response to changing levels in the tank should be conducted. This ensures that sensors are in good working conditions.
Sensor Type
Contact and non-contact sensors each have their advantages and disadvantages. Go for the one that works best in the application. For example, float-based sensors work better in simpler applications, while ultrasonic sensors work in harsher environments.
Material Compatibility
Material compatibility should be considered at all times. Factors like temperature, pressure, and chemical concentration that may damage the sensor should be considered. Usual sensor materials compatible with harsh environments include stainless steel and PVDF.
Accuracy and Precision
These two factors are one of the most critical elements to consider. Check manufacturers' specifications to determine the sensor's accuracy level. Think about the required level of precision for each application. In addition, consider factors like tank size and shape that could affect performance.
Industrial Environment Conditions
Environmental factors, such as temperature variations, humidity, and dust, can impact sensor performance. So, ensure the chosen sensor is rated to work under the prevailing conditions in the industrial environment.
Integration and Compatibility
The new sensor should be able to integrate smoothly into the existing monitoring system. This is primarily for data output and communication protocols. Therefore, ensure the new sensor works with the current control systems to enhance operational continuity.
Response Time
This is particularly important in industries where Bitumen levels fluctuate rapidly due to changing demands in a production process. Therefore, selecting a sensor with a fast response time will help ensure real-time monitoring to enhance effective operational control.
Cost and Budget Constraints
Consider both upfront and long-term costs before making the purchase. This includes sensor maintenance, potential replacements, and energy consumption. In addition, weigh costs against the expected performance. Sometimes spending a little more on a higher-quality sensor saves money in the long run through improved reliability and decreased downtime.
Maintenance Requirements
Some sensors require maintenance and can be rather demanding, while others require low-maintenance operations. Always check the maintenance needs of each sensor before making a purchase. Then, consider the available resources for maintaining the monitoring system over time.
A bitumen tank level sensor is an instrument that measures the level of an ever-stored substance in a tank. Companies use it in industrial operations such as construction and chemical manufacturing. The common types of sensors are float, ultrasonic, radar, and capacitive.
This sensor works by establishing the capacitance between two conductive plates and separating them with a dielectric material. The distance then changes by measuring the level of liquid passage between the plates.
About the accuracy, the typical value range is usually ±1% to ±3%. However, this can vary depending on the sensor's quality and the measurement environment.
The performance can be affected by factors such as foam, steam, and clutter, as they can interfere with the ultrasonic waves and cause inaccurate readings.
The common techniques include using sensors that emit at higher frequencies, improving the tank surface to prevent foam, and placing the sensor near the center to avoid obstructions.
The challenges include vapor barriers, rough surfaces, and internal obstructions like agitators, all of which can reflect the radar waves and cause inaccurate measurements.
To choose, ensure effective operation, factor in the environment and application requirements. For example, guided wave radar works well in small tanks with high dielectric liquids, while free-running radar is ideal for large tanks filled with various liquids.
The contact sensors, such as float switches, require regular maintenance. This is because physical components are subjected to the challenging conditions of the stored substance or environment, leading to wear and tear.
Infrared Bitumen Tank Level Sensors work by measuring the temperature of the liquid surface and converting the temperature reading into a level measurement. These sensors function by emitting infrared radiation and measuring the amount absorbed or reflected by the liquid.
They provide accurate measurements for varying tank conditions and require minimal maintenance for contact-based sensors. Moreover, they are effective with various liquid types, including those with volatile surfaces, where other traditional measures might interfere with.
