The selection of the best point level or
liquid level sensor to monitor the inventory of valuable liquid, powder and solid chemicals is a challenging task. However, by means of customization options, it is possible to design the sensor that matches the specifications of the inventory measurement.
With the availability of different kinds of sensors and a number of options, the decision-making and product-specification processes become extremely difficult. The utility of a level measurement sensor in a specific application can be optimized with a customized level sensor.
The following devices have more options to manufacture a device based on users’ specifications:
Ultrasonic level sensors
Magnetostrictive sensors
Pressure transducers
Tilt switches
Diaphragm switches
Vibrating rods
Capacitance probes
Rotaries
These sensors show promise in providing precise and repeatable level detection. However, each sensor will achieve its optimal performance level when designed for a particular application. Customized point level indicators will provide the best solution depending on whether the vessels have corrosive materials, sanitary regulations, high temperatures, thick walls or any one of the many specifications.
Rotaries
Rotary level indicators are designed for high, mid and low-level detection applications in tanks, bins or other vessels carrying bulk solids and powder. They are linked to an alarm panel or combined to a PLC. As the contents of the tank achieve a specific limit, the indicators are programmed to transmit audible or visual alerts. These alarms prevent overfilling or depletion of tank which could be an expensive and unwanted outcome of incapable level monitoring system.
It is possible to customize inventory management to each vessel using galvanized or stainless steel extension options. Vertical rotaries are suitable for applications where the rotary is operated as a high-level alarm. Most of the operators avoid filling the vessels completely and leave a certain amount of headroom. It is possible to overcome this situation by using a customized shaft length that is adjusted according to the desired amount of headroom. An alert will be sent by a rotary shaft customized for high-level detection as the material achieves the desired limit so as to prevent bin overfill.
In order to address the issues related to lump material level measurement, another extension option is manufactured. Flexible shaft rotaries are suitable for high level detection in heavy materials or other lump solids. In all these cases, heavy materials tend to damage a rigid extension. A flexible cable in place of a fixed solid shaft extension is linked to the rotary and mounted on top of the vessel. With its extra movement capabilities, the rotary can detect high levels under a complex condition without bending a rigid rotary extension shaft.
Horizontal rotary extensions can be used to provide a clear structure of the shaft and paddle in case the vessel carrying the material to be measured has thick bin walls, including a concrete silo that allows the rotary to perform its task. Horizontal extensions allow the side-mounted rotaries to carry out high, mid or low-level detection in a vessel. This design enables the rotary to be attached via the side of a bin wall, thereby minimizing the damage risk during operation.
Adjustable top mounted rotaries can be used to place varying material levels in a bin or silo as they allow convenient changes without replacing the device or entering the bin. They are mounted on top of the bin, and include an adjustable coupling capable of moving up and down the shaft length. With this movement, the rotary can accommodate material levels that are subjected to changes.
A mini-rotary is the best choice for level measurement in smaller bins or hoppers with confined space. The small size of the mini- rotary designed to control material levels in compact spaces enables it to operate in an environment where other devices may not fit easily. The small, mini-rotaries have a rugged design and can deal with a number of light to heavy materials. The motor is mounted on the top or side of a bin, and can rotate when there is no material. With the increase in the material level, the operator is alerted by the sound from an alarm.
Fail-safe rotary level indicators are provided with a sophisticated technology where a system alerts the power loss, and motor/electronics failure in addition to monitoring vessel levels. This type of rotary is one of the best choices for applications that demand continuous operation, thanks to its progressive fail-safe capabilities. This is also preferred when operators need to constantly keep a track on the unit’s status. These rotaries ideal for a wide range of bulk solids, and can either be mounted on the top or side of the vessels.
In the presence of corrosive materials, a stainless steel process connection can be used along with a rotary so as to ensure a prolonged service life of the device and more precise measurement. Rotaries with the connection are designed such that all the materials that make contact with the bin are stainless steel. This ensures that stainless steel process connections are ideal for food and pharmaceutical applications with sanitary needs. It is also ideal for rugged applications, such as those that involve caustic or corrosive materials.
A heat tube can be included to distance electronics that are far away from the heat source when external temperatures outside the bin become higher. Heat tubes are attached to the top or side mounted rotaries in environments with elevated temperatures. Using these tubes, the rotary can be extended beyond insulation on the outside of a vessel.
Rotary customization options include:
Heat tubes
Stainless steel process connections
Fail-safe rotaries
Mini rotaries
Adjustable top mount rotaries
Horizontal rotary extensions
Flexible shaft rotaries
Vertical rotaries
The rotary device can be further customized by choosing one of the many paddle options, besides a myriad of rotary extensions and custom fittings. This also ensures high performance of the device. An appropriate selection of paddle will enhance the rotary’s function irrespective of the measurement of the levels of light or heavy material.
In order to achieve the suitable fit for each vessel, the diameter of the options for single blade, double blade, three-vane and bayonet style paddles is varied. Collapsible rotary paddles are available to avoid the entry of personnel into the bins. The paddles are made up of stainless steel or nylon, and are attached to the top and side mounted rotary level indicators.
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