Radar Level Sensors Eliminate Downtime in Production Tanks
Non-contact radar technology ensures reliable measurement in agitated, vapor-rich tanks with internal obstructions
A manufacturer faced persistent issues with unreliable level readings in storage tanks containing volatile paint and solvent mixtures. These tanks are critical to production, and inconsistent sensor performance led to operational disruptions and increased maintenance. The facility needed a reliable, maintenance-free solution capable of withstanding the challenging tank conditions.
Challenge
The plant’s existing ultrasonic level sensors frequently produced false readings due to dense solvent vapours and surface turbulence. Internal tank structures further complicated measurements by generating false echoes, reducing data reliability. These challenges limited process visibility and increased the risk of unplanned downtime in a high-throughput environment.
Solution
ABM collaborated with the plant’s control team to evaluate the tank specifications and process conditions. To address the issues, ABM recommended its non-contact radar level sensors (model ABM300-017R6C4-SSATE-EXP). Unlike ultrasonic, radar technology is unaffected by vapors, temperature fluctuations, or pressure changes. The selected radar model features a build-up resistant Teflon rod antenna with self-cleaning abilities. To eliminate interference from internal structures, the sensors were installed inside metal stilling well pipes.
Results
The upgrade to ABM’s radar technology resulted in significant improvements in accuracy and reliability in the vapour-heavy, agitated tanks. The optimized installation eliminated false echoes and shielded the signal from obstructions. As a result, the facility now enjoys maintenance-free operation and enhanced production uptime.
“The radar sensors gave us the precision and reliability we were missing. We’ve had zero issues since the upgrade.” – Controls Engineer
Conclusion
The facility successfully resolved persistent measurement issues caused by vapour, agitation, and tank obstructions by transitioning to radar level sensors with metal stilling well installations. ABM’s application-focused approach ensured the right technology and configuration were selected, resulting in a stable, maintenance-free solution that has restored process visibility and trust in level readings.
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Explosion Proof Radar Level Sensor R-EXP
Radar Sensors
