Accurately Detecting Liquid Level with a Radar Sensor

Condensate on the sensor is not an issue for the latest generation of radars. The VEGAPULS 64 is unaffected by condensation or build-up on the antenna, enabling it to accurately detect the liquid level with the smallest antenna of its kind and exceptional focusing. It delivers outstanding performance every time.

Reliable Even in Messy Conditions

Highly resistant encapsulated PTFE antenna for long service life in the chemical sectors

Highly resistant encapsulated PTFE antenna for long service life in the chemical sectors

The antenna system of VEGAPULS 64 is encapsulated in PTFE or PEEK. As such, there are no cavities or crevices in which product build-up can occur. Diamond tools are utilized to very finely process the surface of the material, which also considerably reduces product adhesion.

Optimized signal processing makes VEGAPULS 64 independent of buildup.

Optimized signal processing makes VEGAPULS 64 independent of buildup.

Interference caused by build-up on the antenna system is filtered out by special software algorithms, and, the high dynamic range of the sensor means signal attenuation caused by product deposits is largely compensated. Therefore, the level can be reliably detected even when contamination occurs on the sensor.

The Benefits

  • Even with product deposits collecting during operation, high measurement certainty is ensured
  • Level measurement independent of condensation
  • After cleaning cycles, the system is quickly available for use again
  • Non-contact level measurement enables maintenance-free operation

Applications

Preparation Tank for Solvents

The various solvents and intermediate carrier materials have to be prepared first before further steps in production can commence. Normally, this process is carried out in bioreactors and in fermentation tanks. To regulate the temperature inside the mixing process, these vessels are bound with a steam heating jacket. Controlling filling and discharge and monitoring during the process all require a level measuring system.

Reliable

Approved materials in compliance with FDA and EC 1935/2004

Cost effective

Maintenance-free operation

User friendly

Simple installation

Process Data

Measuring task

Level measurement

Measuring point

Tank

Measuring range up to

1.4 m

Medium

Solvents

Process temperature

-10 … +150 °C

Process pressure

-1 … +10 bar

Special challenges

Condensation and media with low dielectric constant

Good Focusing Delivers Security

VEGAPULS 64’s cutting-edge technology and unrivaled focussing enable the radar beam to be targeted at the liquid surface with extreme accuracy. This avoids internal obstructions such as heating coils and agitators. This new generation of level sensors boasts the smallest antenna of its kind, and is entirely unaffected by either condensation or build-up.

Level in the Focus

Excellent signal focusing allows use even in confined spaces

Excellent signal focusing allows use even in confined spaces

With a transmission frequency of 80 GHz and an 80 mm antenna, the VEGAPULS 64 offers a beam angle of just 3°. The radar level sensor only receives distinct, conclusive reflections from the actual product surface, making the level measurement more precise and consistent.

A radar beam with 80 GHz only reflects from the product surface. A wider radar beam with 26 GHz also reflects from internal fixtures and agitators.

A radar beam with 80 GHz only reflects from the product surface. A wider radar beam with 26 GHz also reflects from internal fixtures and agitators.

To compare, the beam angle for a conventional radar level sensor with 26 GHz transmission frequency and an antenna of the same size is approximately 10°. The significantly wider signal beam means that agitators, fittings or build-up on the vessel wall is likely to affect the final measuring result.

The Benefits

  • Substantially simpler setup and commissioning, even with complex vessel internals
  • Improved measurement certainty over the entire measuring range through superior focusing
  • High levels of accuracy, even when a level sensor is mounted close to the tank wall

Applications

Dissolving Tank

The precursors, which are largely Naptha based, for the manufacture of color pigments are dissolved in the dissolving tank. Depending on the formulation, water and sodium hydroxide solution are added as solvents to produce the basic pigment solution. An agitator guarantees the mixing of substances is carried out uniformly as they’re added. The level measuring system is necessary to guarantee reliable values are given to the control system.

Reliable

Measurement is independent of the process conditions

Cost effective

Reliable, maintenance-free operation

User friendly

Simple installation from above through a small opening

Process Data

Measuring task

Level measurement

Measuring point

Tank

Measuring range up to

4 m

Medium

Sodium hydroxide, water, naphthols

Process temperature

+20 ... +24 °C

Process pressure

0 … 0 bar

Special challenges

Foaming, agitator

Cargo Tank in a Bitumen Tanker

Bitumen is transported at 170 °C to 190 °C approximately. An assortment of multi-layered heating tubes which are fixed on the floor and sides of the tanks, provides the heating. Efficient utilization of the tanks is ensured as well as a safe ship attitude. The levels in the bitumen tanks require precise monitoring, especially while loading and unloading.

Reliable

Consistent measurement solution for adhesive media

Cost effective

Precise measurement of the tank contents, irrespective of medium and degree of contamination

User friendly

Maintenance-free and reliable operation

Process Data

Measuring task

Level measurement and point level detection

Measuring point

Tank

Measuring range up to

15 m

Medium

Bitumen

Process temperature

+170 … +190 °C

Process pressure

0 … 0 bar

Special challenges

High temperatures, chemically aggressive medium, condensation, highly viscous, heavy build-up, heating pipes at the base of the tank, ship approvals

Small Fittings Extend the Area of Application

Smaller is better concerning contactless level measurement of liquids in small containers. VEGAPULS 64 boasts the smallest antenna of its kind, with its superior focusing capabilities and insensitivity to condensation or build-up. All this makes for a truly exceptional radar sensor.

How Does It Work?

Smallest antenna in the world, process fittings down to ¾

Smallest antenna in the world, process fittings down to ¾" thread

VEGAPULS 64 works at a transmission frequency of 80 GHz. This corresponds to a factor of 3 when compared to the technologies used until this time.

With its compact design and process fittings down to ¾

With its compact design and process fittings down to ¾" thread, VEGAPULS 64 can be used very effectively on small tanks and containers.

The antenna system and process fitting can have respectively smaller dimensions as a result. That makes radar level measurement technology more attractive for a greater variety of applications. Vessels with small process fittings can be equipped with radar sensors without carrying out expensive modifications beforehand.

The Benefits

  • Easy retrofitting of existing vessels, without expensive changes
  • Threaded, flange and hygienic fittings for vastly different areas of industry

Applications

Level Measurement in the Batch Filler Vessel

The small batch filler vessels of approximately 1 m in height and 60 cm in diameter alongside the production facility supply the filler heads of the tank. Products can differ from conserves and peanut butter to chocolate spread, all possessing a wide range of viscosity and temperatures. Additionally, the product density will change from batch to batch. To achieve the optimal filling of jars, a level system is required.

Reliable

Measurements are taken independent of density and viscosity

Cost effective

Accurate level measurement optimizes use of jars and medium

User friendly

Simple setup

Process Data

Measuring task

Level measurement

Measuring point

Vessel

Measuring range up to

1 m

Medium

Conserves and spreads

Process temperature

+10 ... +70 °C

Process pressure

0 … 0 bar

Special challenges

Differing product density, condensate, small vessel

Mixing Vessel

Mixing vessels are used for the transfer of a wide range of pharmaceutical goods, as well as for preparation and storage. These vessels are used for the production of antibiotics, blood plasma products, as well as injection and infusion solutions.

After preparation, substances are transferred to a filling station. The liquid level in the mixing vessel must be consistently and continuously monitored to ensure an overall reliable process.

Reliable

Certified hygienic design (3A/EHEDG) and approved materials according to EC 1935/2004 and FDA

Cost effective

Continuous operation with absolute hygiene

User friendly

Standardized adjustment, process data storable and transferable

Process Data

Measuring task

Level measurement

Measuring point

Vessel

Measuring range up to

1.2 m

Medium

Antibiotics, injection and infusion solutions, blood plasma products

Process temperature

+50 ... +150 °C

Process pressure

-1 … +6 bar

Special challenges

Varying product density, regular cleaning cycles, small vessels.

This information has been sourced, reviewed and adapted from materials provided by VEGA Grieshaber KG.

For more information on this source, please visit VEGA Grieshaber KG.

Citations

Please use one of the following formats to cite this article in your essay, paper or report:

  • APA

    VEGA Grieshaber KG. (2018, November 23). Accurately Detecting Liquid Level with a Radar Sensor. AZoSensors. Retrieved on June 18, 2019 from https://www.azosensors.com/article.aspx?ArticleID=1475.

  • MLA

    VEGA Grieshaber KG. "Accurately Detecting Liquid Level with a Radar Sensor". AZoSensors. 18 June 2019. <https://www.azosensors.com/article.aspx?ArticleID=1475>.

  • Chicago

    VEGA Grieshaber KG. "Accurately Detecting Liquid Level with a Radar Sensor". AZoSensors. https://www.azosensors.com/article.aspx?ArticleID=1475. (accessed June 18, 2019).

  • Harvard

    VEGA Grieshaber KG. 2018. Accurately Detecting Liquid Level with a Radar Sensor. AZoSensors, viewed 18 June 2019, https://www.azosensors.com/article.aspx?ArticleID=1475.

Tell Us What You Think

Do you have a review, update or anything you would like to add to this article?

Leave your feedback
Submit