Project Background
A chemical manufacturing plant operates multiple vertical storage tanks used for storing liquid raw materials and intermediate products. During daily operation, the tanks are subject to continuous filling and discharge, while some media generate foam or have changing dielectric properties due to temperature and composition variations. In addition, certain tanks contain layered media, requiring reliable detection of liquid–liquid interfaces for inventory control and process safety.
Previously, the site used float-type and ultrasonic level sensors. However, due to agitators inside the tanks, surface turbulence, foam formation, and vapor interference, the level signals were often unstable. Frequent recalibration and maintenance were required, and interface levels could not be measured reliably, affecting production scheduling and automated control accuracy.
Measurement Challenges
- Unstable level readings caused by agitation, foam, and vapor
- Difficulty measuring liquid–liquid interface levels
- Multiple media types including high-viscosity liquids and solid residues
- Requirement for continuous, reliable level signals for PLC-based control systems
- Limited maintenance access in hazardous chemical environments
Solution
To address these challenges, the plant selected the KLD701 Guided Wave Radar Level Meter for tank level monitoring. The KLD701 uses guided wave radar technology, transmitting low-energy microwave pulses along a probe installed in the tank. Reflected signals from the product surface and interface layers are processed to provide stable and accurate level measurements.
Unlike ultrasonic or float sensors, guided wave radar measurement is largely unaffected by foam, vapor, agitation, or changes in dielectric constant, making it particularly suitable for chemical storage tanks with complex process conditions. The KLD701 supports continuous measurement of liquids, solids, and interface layers within a single device.
System Configuration & Integration
| Component | Function |
|---|---|
| KLD701 Guided Wave Radar Level Meter | Continuous level and interface measurement |
| Probe & Process Connection | Installed through standard tank nozzle |
| 4–20 mA / RS485 Output | Real-time signal transmission |
| PLC / SCADA System | Monitoring, alarm, and process control |
The level signals were integrated directly into the plant’s PLC and SCADA system, enabling real-time monitoring, alarm triggering, and automated process control.
Application Results
After installation, the KLD701 guided wave radar level meter delivered stable and repeatable level measurements under all operating conditions. Foam and agitation no longer affected the measurement accuracy, and interface levels could be detected reliably for the first time.
The plant reported reduced maintenance frequency, improved inventory accuracy, and enhanced process safety. By integrating real-time level data into the control system, operators were able to optimize filling and discharge operations and improve overall production efficiency.
Conclusion
This application demonstrates that the KLD701 Guided Wave Radar Level Meter is a reliable solution for chemical storage tank level monitoring in complex industrial environments. It provides accurate, continuous measurement of liquids, solids, and interface layers, supporting safe operation and automated control in modern process industries.
For more technical details, wiring diagrams, or model selection guidance, please click here to learn more or contact our technical team.
