Project Background
A chemical company in Shaanxi Province operates several Liquefied Petroleum Gas (LPG) storage tanks used to store LPG for supplying the company’s production line and surrounding markets. To improve the accuracy of level measurements, reduce manual inspection work, and ensure the safe operation of the LPG tanks, Kacise provided an external ultrasonic level meter to help the client achieve non-contact, real-time level monitoring.
Solution
External Ultrasonic Level Meter:
Due to the special nature of LPG tanks (low temperature and high-pressure environment), an external ultrasonic level meter was selected. This device can be installed on the outside of the tank without direct contact with the liquid. The level meter uses ultrasonic technology to calculate the liquid level height by measuring the reflection time of sound waves, thus avoiding the impact of the low-temperature environment on the device’s performance.
The level meter is equipped with a low-temperature compensation function, enabling it to work in extremely low temperatures ranging from -40°C to -20°C, making it suitable for the working conditions of LPG tanks.
Installation and Commissioning:
The device was installed directly on the outside of the LPG tank using adhesive, eliminating the need to damage the tank’s structure. The installation process was simple, avoiding the safety risks associated with drilling holes in the tank, as required by traditional level meters.
Level Monitoring System Design:
The system is equipped with a level alarm, which automatically alerts when the tank level exceeds the preset range, prompting operators to adjust the tank operation in a timely manner.
Operators can view real-time level data of each LPG tank through a remote monitoring platform, perform trend analysis, and take preventive measures when the liquid level approaches the safety threshold.
The system supports data storage and report generation, facilitating the retrieval and analysis of historical level data, and helping to develop more scientific inventory and scheduling strategies.
System Maintenance and Training:
Regular training on equipment use and troubleshooting was provided to operators to ensure they could handle system faults and abnormal level situations promptly.
Results
High-Precision Level Monitoring:
The external ultrasonic level meter successfully provided high-precision level measurements for the LPG tanks, with measurement errors within ±2 mm, significantly improving the accuracy of level monitoring.
For tanks with rapid level changes, the equipment responded in real-time, ensuring high reliability and timeliness of the level data.
Enhanced Safety:
As the external ultrasonic level meter uses non-contact measurement, it avoids issues such as corrosion from the liquid or water accumulation on the device, reducing safety risks caused by level meter failures.
The level alarm function can automatically alert operators when the level exceeds the set range, preventing tank overflow or low liquid levels, which could lead to pressure imbalance, significantly improving the safety of the tanks.
Remote Monitoring and Automation:
The remote monitoring system enables operators to monitor tank levels at any time, avoiding the inconvenience and errors associated with traditional manual inspections.
The automated level monitoring system makes inventory management more precise, reduces labor costs for level monitoring, and allows dynamic allocation of storage resources based on level changes.
Increased Work Efficiency and Reduced Maintenance Costs:
The external design avoids the complicated construction process of drilling holes in the tanks, saving both installation time and cost.
After implementation, the failure rate of the equipment decreased by about 30%, and the maintenance cycle became more predictable and scientifically managed.
Conclusion
The application of the external ultrasonic level meter in LPG tanks successfully overcame the limitations of traditional level measurement methods in harsh environments such as low temperatures and high pressures. By using non-contact measurement technology, the system provided high-precision, low-maintenance, remote monitoring, and high safety level monitoring, significantly enhancing the operational safety and management efficiency of LPG tanks. This case not only provided the company with a reliable level monitoring solution but also offers an effective reference for liquid storage tank level monitoring in similar industries.
