Tank level gauge for liquid

Types of Tank Level Gauges For Liquid

Various kinds of tank level gauges for liquids are accessible for distinct liquids and situations. Tank level gauges' resistance is one of the significant differences because of the liquid's characteristics and the environment in which it is stored. These include the following:

Mechanical Gauges

Mechanical gauges determine liquid heights using float devices, chains, and pulleys. Some systems, for example, use a float that moves up and down a vertical rod, with the rod being marked glass tube that displays the level. Mechanical gauges are advantageous since they are easy to install and require very little energy. However, they may not measure levels as accurately in large tanks or with viscous fluids.

Electronic Gauges

With the help of sensors and liquid level detectors, these instruments accurately measure tank levels and present readings on an LCD or LED. Common types include ultrasonic and pressure gauges. Electronic gauges are excellent for complex systems due to improved accuracy. They need regular sensor maintenance and can be difficult to repair due to their smaller parts.

Bull's Eye Gauges

Bull's eye gauges utilize liquid-filled sight glasses to show levels. Since these are so simple, they are inexpensive and straightforward. Chemical reaction is a sight glass that has two metallic elastic rings and two small glass windows between them. One ring expands and moves when the liquid level rises, pushing the other through a little opening so it can be observed. Unfortunately, accurate measurement becomes problematic if the liquid's temperature or pressure changes significantly.

Magnetic Gauges

Using floats with magnets that move along a magnetic track, tanks using liquids with extreme temperatures or pressures are preferred to use magnetic gauges. A float that rises with the liquid activates an outside visual indicator while the magnetic track stays put. The gauge is very accurate and does not require energy. However, due to its complicated design, magnetic gauges can be very costly.

Visual Gauges

These are transparent tubes fixed with high and low water natural rubber ball plugs. The rubber ball plugs seal off the outlets from the tube when the water level drops below the gauge or rises above it. A removable union is provided in the middle section of the gauge to allow for servicing without removing the entire gauge. The gauge can then be replaced without the need to remove the plugs.

Tank Level Gauge Industry Applications

Liquid tank level gauges are important because many industries depend on accurately measuring the fluid levels in their tanks. Listed below are several industry applications of liquid tank level gauges:

Chemical Industry

Liquid chemical tank gauges help control and monitor chemicals in manufacturing. Accurate level measurement is crucial since chemicals fluctuate and need precise levels for ideal processing. Pressure gauges help measure the level of chemicals under pressure. It helps ensure that operations are smooth and reduces the chance of explosion or other dangerous occurrences.

Oil and Gas

Oil and gas industries handle several liquids with varying densities from high-pressure tanks to atmospheric storage tanks. Therefore, liquid nivel gage systems help these industries monitor their fluids and prevent spillage, which is expensive and causes environmental damage. These gauges assist with leak detection, which can be crucial to safety and environmental concerns. Furthermore, remotely monitoring these levels helps control operations safely from a distance and cutting costs.

Water Treatment

Water treatment plants use tank level gauges to monitor the intake and output of water, hence ensuring that supply meets demand. They help measure how much treated and untreated water is in storage. Furthermore, these gauges help in additive monitoring. For example, accurate level measurement in water treatment helps ensure that chemicals used for treating water, like chlorine, are in the right amount.

Food and Beverage

The food and beverage industry uses liquid level gauges to monitor ingredients in tanks and ensure the production process is hygienic. They also monitor and control sanitization levels of tanks and vessels that hold food liquids and beverages. Accurate measurement is crucial in this industry for health and safety and for maintaining consistency in high-value products like champagne and whiskey. Since regulation compliance is a must, most food storage tanks use liquid level gauges.

Marine and Shipping

Tank gauges on ships and boats measure fuel, water, cargo, and ballast. As balanced ships, ships must have accurate liquid level measurement. In marine and shipping industries, portable and durable gauges are highly preferred due to the ship's and tanker's movements. Furthermore, the gauges help evaluate cargo stability and ensure fuel and water supplies for the journey are adequate.

Tank Level Gauge Product Specifications And More

Technical Specifications of Tank Level Gauges

• Float material: The floats of liquid fuel level gauge are made of numerous materials, such as stainless steel, polypropylene, and nylon. The float material is based on the liquid's density and the service environment.
• Mounting type: Tank level gauges can be mounted externally, on top of the tank, or inside the tank. Internal floats give more accurate measurements than top-mounted ones.
• Measurement range: Most tank level gauges operate in the range of three to twenty feet. Larger tanks will need higher range gauges than smaller tanks.
• Power source: Most tank level gauges use DC power from batteries or solar panels. AC powered gauges are available for stationary applications.

How To Install Tank Level Gauges

• Preparation: Clean the area around the mounting point of the tank before starting the installation. Ensure the gauge is suitable for the liquid and environment of the tank.
• Mount the gauge: Follow the manufacturer's instruction on how to mount the gauge. For external gauges, mounting them on top of the tank is easier. For internal floats, the gauge has to go through the opening of the tank.
• Wiring: Connect the electronic level gauge to the power source and any monitoring system it needs. Ensure all connections are secure and insulated to come into contact with the hazardous liquid in the tank.
• Testing: After installing, check the gauge by manually moving the float or checking the tank's liquid level. Ensure that it shows accurately. Also, ensure that while the gauge seems accurate, it is also wired to the remote monitoring system.

Maintaining Tank Level Gauges

• Regular Inspection: Check the tank level gauges often for visible damage like cracks or corrosion. Also, inspect the readings to account for inaccuracies.
• Calibration: Too inaccurate gauged calibrate them. Depending on the type, install a calibration kit provided by the manufacturer or follow the manual's instructions.
• Cleaning: Solid accumulation and dirt affect the gauge reading. Clean the gauge often to remove any stains and deposits.
• Functional tests: Conduct periodic function tests to check the gauge responds to level changes.
• Replace worn parts: Inspect the level gauge frequently for signs of wear, like the float breaking or the sensor failing. When worn, replace them as soon as possible.
• Professional servicing: When in doubt about the gauge's condition, consult a professional for help. Servicing the gauge wrongly will affect the level of accuracy it produces.

Tank Level Gauge Quality And Safety Considerations

Important Considerations For Quality (Said And Unsaid)

• Accuracy: The most important task of any gauge is to be accurate. Liquid level monitors should provide correct readings to prevent overflow or dry run of pumps attached to the tank.
• Durability: Tank level gauges should be robust, especially those in industrial environments. Corrosion-resistant materials like stainless steel and IP67-rated enclosures must be used. This helps protect the gauge from dust and water while ensuring it lasts long.
• Temperature and pressure rating: The level gauge must meet the tank's operational temperature and pressure ratings. This will help ensure that the gauge functions properly and remains intact even under extreme conditions.
• Resolution: Resolution refers to the smallest change in liquid level that can be detected by the gauge. High-resolution gauges provide more accurate measurements, hence more pertinent in industries where precision is key.
• Compatibility: Make the gauge from the appropriate material to avoid corrosion and damage. Chemical exposure, tank material, and gauge construction should be considered.

Safety Measures To Consider

• Proper installation: Follow the manufacturer's instructions when installing a tank level gauge. Wrong installation may cause inaccurate readings, damage to the gauge, and even accidents.
• Explosion-proof design: Many liquids have the potential to cause explosions. Such liquids need level gauges with explosion-proof designs to reduce risks in hazardous areas.
• Regular maintenance and inspection: Gauges that are not maintained frequently become faulty, leaving them compromised. Ensure that all kinds of tank level gauges are inspected and maintained regularly to keep them in safe working conditions.
• Wear Personal Safety Equipment: Always wear protective clothing, including gloves and goggles, when dealing with any liquid in the tank. The liquid can be dangerous, and hands and eyes are the targets of any splashes.
• Lock-Out/Tag-Out procedures: Before opening, servicing, or working near a tank, employ Lock-Out/Tag-Out methods. This signifies and secures that all energy sources are turned off and that all intentional equipment deactivation measures are used.

Tank Level Gauge Shipping And Storgae

Shipping Considerations

• Packaging: The tank level gauge must be packaged properly for transportation to avoid damage during the journey. Use sturdy packaging materials, such as bubble wrap and foam, to cover the gauge. This also includes a waterproof outer layer, like plastic film or waterproof boxes, to protect the gauge from the water and other environmental hazards.
• Weight and Size Considerations: Tank level gauges are relatively small and light, making their movement anywhere easy. However, based on the type and what the gauge is made of, it can get a little bulky. Small and compact electronic gauges are easier to transport, but larger bull eyes or magnetic gauges take larger spaces.
• Method of transportation: Due to their weight and size, liquid level detection can be transported using any method, including by road, rail, air, or sea. Nevertheless, air transport is best suited for delicate or time-sensitive shipments.
• Customs and regulations: This applies to liquid level gauges, especially to buyers in a foreign country. Buyers need to know the import taxes and money spent before they arrive. They should also be aware of the policy regarding the import of industrial instruments.

Storage Considerations

• Climate-Controlled Storage: Electronic gauges with sensitive parts like sensors and circuits can be affected by extreme heat or cold. Store these gauged in a climate-controlled environment with regulated temperature and humidity.
• Dry Environment: While tank level gauges are made to resist various elements, moisture can lead to corrosion or electrical damage, particularly in electronic models. Store the gauged in a dry area away from water and other hazardous liquids.
• Organized Storage: Store the liquid level indicator in an orderly fashion to facilitate the finding of specific gauged when needed. Use shelving or containers to prevent the gauges from becoming harmful or mixed up.
• Protection From Impact: Tank level gauges are delicate equipment and can be damaged if subjected to any impact or rough handling. Protect the gauged during storage by using protective covers or padding.
• Regular Inspection: Inspect the tank level gauges often to get a glimpse of any damage, wear, or corrosion, especially if they are stored in a hazardous environment.

Frequently Asked Questions (FQAs)

Q1. What are tank level gauges?

A1. Tank level gauges measure the liquid level in a tank. They find application in various industries ranging from food and petrochemical to water treatment plants.

Q2. What is the function of a tank level gauge?

A2. Tank level gauges help monitor the liquid level in a tank. They help prevent overflow, keep the stored liquid at safe levels, and determine when the liquid supplies are a need.

Q3. How do tank level gauges function?

A3. As the liquid level in the tank changes, the float moves up or down. The movement is then converted into an electronic signal that is processed to display the level of liquid in the tank.

Q4. Are tank level gauges accurate?

A4. Tank level gauges are accurate as long as they are maintained and calibrated. The gauge could wear, become dirty, or go faulty; without inspection, the gauge will produce inaccurate results.

Q5. How are tank level gauges maintained?

A5. The first step to maintaining a tank level gauge is to inspect it, followed by cleaning, calibration, and replacement of worn-out parts. Also, consult a professional for help when in doubt or when damage is visible.

Q6. Are there tank level gauges with explosion-proof designs?

A6. Yes, some tank level gauges are equipped with an explosion-proof design. These types of gauges use intrinsic safety barriers to reduce the chances of explosions, especially in hazardous environments.

Q7. Do tank level gauges needs to be stored in a regulated environment?

A7. Yes, a regulated environment is ideal for storing a tank level gauge. While the electronic gauges should be stored in a climate-controlled environment regulated with humidity and air, the mechanical and visual ones can be stored in any dry area.

Q8. What are the common materials used to make liquid tank level gauges?

A8. Tank level gauges are made of various materials depending on the fluid inside the tank. These materials include stainless steel, polypropylene, and other corrosion-resistant materials.