Author Archives: webtechs

 

There are several ways to measure water height or water level, from straightforward manual methods to more sophisticated electronic and digital sensors. The accuracy needed, the kind of container or body of water being measured, and the particular application all play a role in the measuring method selection. Here are a few typical techniques for measuring water depth:

1. Dipstick or Measuring Stick: This is a simple and effective technique. A graded stick or rod is lowered into the water, and the marks on the stick are used to determine the water level.

2. **Float and Tape System**: This technique involves placing a float on the water’s surface and connecting its location to a tape or wire that has measurement markings. The float moves in response to variations in water level, and the tape is then read to determine the appropriate height.

3. **Float and Scale**: A float is attached to a vertical scale with markings, much as the float and tape system. The placement of the float along the scale indicates the water level.

4. “Hydrostatic Pressure Sensors”: These sensors work on the premise that the pressure in a liquid at a given depth is inversely proportional to the height of the liquid. An underwater pressure sensor is placed at a given depth, and the pressure reading is used to calculate the water level.

5. Ultrasonic water level sensors: These devices create sound waves that reflect off the water’s surface and then bounce back to the sensor. The distance to the water’s surface is calculated using the time it takes for the waves to return; this distance is then used to calculate the water level.

6. Radar water level sensors: Radar sensors employ radio waves rather than sound waves to determine the distance to the water’s surface. They operate on a similar basis to ultrasonic sensors.

7. “Capacitance Probes”: Capacitance-based sensors assess the variation in capacitance between the sensor and the water’s surface. The capacitance varies with the change in water level and enables the measuring of water height.

8. **Pressure Transducers**: Pressure transducers, commonly referred to as pressure sensors, can be positioned at the bottom of a water container or immersed. A reading of the water level is created from the pressure the water column is exerting.

9. “Tilt Level Sensors”: These sensors work on the theory of tilting or inclining according to the level of the water. The tilt sensor’s position changes in response to variations in water level, and this variation is utilized to calculate the water height.

10. **IoT-Enabled Water Level Sensors**: A few contemporary water level sensors have IoT features that enable remote monitoring and real-time data transmission for effective management and control.

Each of these approaches has benefits and is appropriate for particular purposes. It’s crucial to take environmental circumstances into account as well as aspects like accuracy, reliability, cost, and cost-effectiveness when choosing a water level measurement technology.

Displacement and velocity are the two most popular methods for measuring flow, and each one uses a different set of technologies. The oscillating piston and nutating disc meters are examples of typical displacement designs. Turbine meters and single- and multi-jet meters are examples of velocity-based designs.

Additionally, there are non-mechanical designs including electromagnetic and ultrasonic meters as well as meters made for specific purposes. In a normal water distribution system, the majority of meters are only intended to measure cold potable water. Design materials for specialty hot water meters can tolerate higher temperatures. Reclaimed water meters have unique lavender register covers to indicate that the water should not be consumed.

There are other electromechanical meters, such as automatic meter reading meters and prepaid water meters. The latter combines a mechanical water meter with an electronic measurement component and an LCD. The signal output for mechanical water meters often comes from a reed switch, hall, or photoelectric coding register. Data are sent to the LCD or sent to an information management system after processing by the microcontroller unit (MCU) in the electronic module.

A public water provider, whether a city, rural water association, or private water corporation, often owns, reads, and maintains water meters. In some instances, a utility may bill the owner of a mobile home park, apartment building, or commercial structure based on the reading of one meter, with the costs being divided among the tenants according to some sort of key (size of the apartment, the number of occupants, or by separately monitoring the water consumption of each unit, a practice known as submetering).

WATER DISPLACEMENT METER

Positive displacement, or “PD” meters, are the usual name for displacement meters. Nutating disk meters and oscillating piston meters are two popular varieties. In either case, the movable measuring element is physically displaced by the water in direct proportion to the water flow through the meter. The piston or disk moves the register’s driving magnet.

At the low-to-moderate flow rates typical of household and small business users, PD meters are typically fairly precise and typically range in size from 5/8″ to 2″. Displacement meters often are not practicable in big commercial applications needing high flow rates or little pressure loss since they depend on all water flowing through the meter to “push” the measurement element. The measuring element of PD meters is typically shielded from rocks and other objects that could halt or break it by an integrated strainer. PD meters typically have plastic, bronze, brass, or moldable plastic bodies with stainless steel and plastic measurement chambers inside.

WATER VELOCITY METER

A velocity-type meter calculates the flow rate through a known internal capacity meter. The utilization can then be calculated by converting the flow’s speed into its volume. Water flow velocity can be measured by a variety of meters, including single-jet and multi-jet jet meters, turbine meters, propeller meters, and mag meters. The majority of velocity-based meters contain an adjustment vane to allow for the meter’s accuracy calibration.

SEVERAL-JET METER

Multi-jet meters are frequently used in sizes between 5/8″ and 2″ for home and small commercial users since they are particularly precise in tiny sizes. The water jets produced by multi-jet meters are directed against an impeller whose rotational speed is governed by the water flow velocity through a series of ports around an interior chamber. Multi-jets are exceedingly precise at low flow rates, but as they lack the straight-through flow channel required for high flow rates used in big pipe diameters, there are no large size meters. The internal strainer feature of multi-jet meters often prevents the jet ports from becoming clogged. Typically, multi-jet meters feature bronze alloy bodies or outside casings, with contemporary thermoplastics and stainless steel used to make the inside measuring components.

CONVERGENCE METER

At low flow rates, turbine meters are less precise than displacement and jet meters, but the measuring element does not completely obstruct or substantially impede the flow stream. In comparison to displacement-type meters, the flow direction through the meter is often straight, allowing for larger flow rates and less pressure loss. For large business users, fire protection, and master meters for the water distribution system, they are the preferred type of meter. In order to protect the measuring element from gravel or other particles that can enter the water distribution system, strainers must often be positioned in front of the meter. Turbine meters are typically offered for pipe sizes ranging from 1-12″ to 12″ or higher. Bronze, cast iron, or ductile iron are frequently used as materials for turbine meter bodies. Plastic or non-corrosive metal alloys can be used as internal turbine elements. Although the flow profile and fluid conditions have a significant impact, they are correct under normal working conditions.

Specialized turbine meters called “fire meters” can handle the high flow rates needed for fire protection. They frequently have Factory Mutual (FM) or Underwriters Laboratories (UL) approval for use in fire protection.

In order to measure the amount of water flowing out of a fire hydrant, special portable turbine meters called fire hydrant meters are mounted to the hydrant. The meters typically have a 3′′ capacity and are manufactured of aluminum to keep weight to a minimum. They are frequently required by utilities for monitoring water consumption on building sites, for filling swimming pools, or in other locations without permanent meters.

COMBINATION METER
When high flow rates are required yet occasionally smaller flow rates also need to be precisely recorded, a compound meter is utilized. A check valve controls the flow between the two measuring parts of compound meters. Water is typically routed mostly or entirely to the high flow element at high flow rates. A turbine meter is often used as the high flow component. A check valve closes to direct water to a smaller element that can monitor the lower flow rates precisely when flow rates fall to the point where the high flow element can no longer record them reliably. A multi-jet or PD meter is often the low flow component. The utility keeps track of the overall amount of water consumed by summing the values recorded by the high and low elements.

Electrical flow meter
Although technically a velocity-type water meter, magnetic flow meters, sometimes known as “mag meters,” calculate the water flow velocity using electromagnetic qualities as opposed to the mechanical methods employed by jet and turbine meters. The electromagnets in mag meters must be powered by AC or DC electricity from a power line or battery in order to function, and they use the physics principle of Faraday’s law of induction for measurement. Mag meters often have the advantage of being able to measure flow in any direction since they lack a mechanical measuring device. Instead, they employ electronics to measure and totalize the flow. Since there is no mechanical measuring element that can be clogged or damaged by debris flowing through the meter, mag meters can also be effective for measuring raw (untreated/unfiltered) water and waste-water. Since there is no measuring element in the stream of flow that could be harmed, mag meters do not require strainers. The majority of mag meters are built with either grounding rings or grounding electrodes to direct stray electricity away from the electrodes used to measure the flow inside the flow tube since stray electrical energy flowing through the flow tube might result in false results.

USING ULTRASONIC METER
In order to measure the water’s velocity, ultrasonic water meters use one or more ultrasonic transducers to send ultrasonic sound waves through the fluid. When the velocity of the water is measured, it is possible to determine the volume of water passing through the meter with a high degree of accuracy since the cross-sectional area of the meter body is a set and known value. Most ultrasonic water meters measure the water temperature as part of the volume computation since water density varies with temperature.

In water metering, there are 2 main ultrasonic measurement techniques used:

Doppler effect meters that use the Doppler Effect to calculate how fast water is moving through the device.
Transit Time meters are used to determine how long it takes an ultrasonic signal to travel between two or more fixed sites within the meter.
The design of ultrasonic meters can either be “clamp-on” or “flow-through.” Designs known as “flow-through” are those in which the water flows straight through the meter; they are frequently used in residential or commercial settings. For bigger diameters when the sensors are placed to the outside of pipelines, etc., clamp-on types are typically employed.

Residential meters can measure down to 0.01 gallons or 0.001 cubic feet, making ultrasonic water meters (if built in) often quite accurate. Additionally, because they don’t have any internal mechanical components that could break down, they offer broad flow measurement ranges, need no maintenance, and last a very long time. Ultrasonic meters have been utilized in commercial applications for many years, despite being relatively new to the American water utility sector, and are gaining popularity because of their benefits over conventional mechanical designs.

ADVANCED WATER METER
Depending on the type of payment, meters might be postpaid or prepaid. Electromagnetic and ultrasonic meters, as well as the majority of mechanical water meters, are prepaid models. Prepaid water meters allow users to prepay for a specific volume of water at a vending machine. On a piece of media, like an IC or RF type card, the amount of water credited is recorded. The primary distinction is whether the card requires interaction with the prepaid water meter’s processing section. In some places, the interface for entering the water credit on a prepaid water meter is a keypad.

 

The Internet of Things (IoT) is a concept that you’ve probably heard of if you follow technological advancement in the industrial sector. The IoT is fundamentally altering the game, and now is the time to participate.

But where do you even begin? Tank level monitoring is one example.

Tank level monitoring (TLM) is an excellent first step towards becoming familiar with the IoT, whether you’re tracking frac tank levels for a well stimulation project or monitoring a straightforward water tank. The objective of tank level monitoring, as with any IoT project, is to gather accurate and trustworthy data so that you can take action and produce results. People won’t trust your tank monitoring system if your data is inaccurate, lacking, or late, and you won’t receive the desired business outcomes.

Tank level sensors are the “bedrock” of any solution for remote tank monitoring. Your sensors are the first stop on the data route for tank level monitoring since they produce the information that eventually supports decision-making. Nothing else matters if your tank level sensors don’t get reliable data. The greatest analytics and most attractive dashboards cannot compensate for subpar tank sensors.

It’s true what they say: “Garbage in, garbage out.”

We wanted to discuss how to select the best tank level sensor for your project because of how crucial tank level sensors are to your whole tank monitoring system. You may purchase accurate and trustworthy tank sensors that generate excellent field data without spending a fortune with a little help.

Five Typical Tank Level Sensor Types
Tank level sensors come in five different categories:

water-pressure sensors
ultrasound detectors
Infrared sensors
Float detectors
Sensitive capacitors

Your application will determine which tank level sensor is ideal, so we’ll outline the main benefits and drawbacks of each sensor to assist you in making an informed decision for your tank level monitoring project.

Sensors for Hydrostatic Tank Level
A tried-and-true method for obtaining affordable, precise tank level data is using hydrostatic tank level sensors. These sensors are used to gauge the fluid column’s hydrostatic pressure. Typically, hydrostatics are mounted to discharge piping at the bottom of tanks, submerged in the liquid at the tank bottom.

Hydrostatic tank level sensors can be installed in various types of tanks without the need to create a new sensor because they are affordable, accurate, power-efficient, and have variable ranges.

Unfortunately, because hydrostatic sensors are frequently entirely submerged in liquid, they can experience greater failure rates. This can be quite difficult, especially with corrosive or caustic solutions. The cable gland, where fluids can enter and short circuit the delicate electronics that power the sensor, is one of the most frequent locations for failure in hydrostatic sensors.

Tank level ultrasonic sensors
Ultrasonic tank level sensors, as their name suggests, assess liquid levels using sound waves. They are installed on top of your tanks, use ultrasonic waves to “bounce” off the liquids’ surfaces, and gauge level by timing how long it takes to hear the “echo.”

The fact that ultrasonic sensors are non-contact, meaning they don’t make direct contact with the liquid in the tank, is one of its key advantages. They can operate well in tanks with mixers or other moving mechanical parts in the liquid, and you don’t have to worry as much about their compatibility with those fluids. However, the mixers must be turned off for accurate level readings because sloshing and turbulence interfere with ultrasonic sensors.

Additionally, the cost of these sensors is reasonable, ranging from $300 to $400 per sensor. If you want greater performance or hazardous area certifications, though, budget closer to $1,000.

The fact that ultrasonic sensors use a lot of electricity is one of their key drawbacks. They can need 10-100 times as much power as hydrostatic sensors, hence they are often not appropriate for battery-powered installations.

Additionally, compared to other sensors, ultrasonic sensors typically require more upkeep. They must be installed correctly, a dead band or “blanking zone” must be maintained between the sensor and the fluid, and the detecting element must occasionally be cleaned (certain fluids can produce a film that degrades performance).

Last but not least, noise interference is a major threat to ultrasonic sensors. The ultrasonic waves that travel to and from your sensors can encounter problems if there is foam or vapor present.

Tank level sensors using radar
In that they gauge tank levels by the amount of time it takes radio waves to travel between the sensors and fluid surfaces, radar sensors are comparable to ultrasonic sensors in this regard. Like ultrasonic sensors, radar sensors are non-contact, which appeals to operators. However, compared to their sound-based predecessors, radar sensors are more accurate and better equipped to withstand interference because of more precise electronics.

 

Radar sensors are often substantially more expensive when compared to the other two gadgets we’ve discussed so far. A competent radar tank level sensor should cost more than $2,000 in total. Radar still requires a substantial blanking zone between the bottom of the sensor and the top of the tank despite the more precise electronics. It can be challenging to obtain precise measurements as tanks fill due to the fact that light waves move so much more quickly than sound.

One advantage of radar sensors is their ability to measure fluid interfaces, such as the presence of oil in water. Even a small amount of emulsion between the interface can be taken into account by more sophisticated electronics while maintaining reliable measurements.

Sensors for Float Tank Level
Float sensors extend a probe into the liquids near the bottom of your tank, and they have continuous detecting elements along the probe that are activated by floats. Float tank sensors may be made to be extremely accurate using this approach. They can even monitor fluid interfaces by utilizing numerous floats for various liquid densities because they don’t suffer from noise or interference issues.

Float sensors, on the other hand, can be very pricey. The price of a float sensor is almost immediately inversely correlated with tank height. You might pay $1,000–$2,000 for shorter tanks (less than 5 feet tall). On the other hand, larger tanks exceeding 25 feet may cost up to $3,000 or more.

“Sticking” is one problem that float tank sensors may have. Although some manufacturers’ recent technological innovations have addressed this issue in some circumstances, it can still arise in certain circumstances. For instance, floats may adhere to the probes in liquids that result in sticky or waxy substances, leading to inaccurate static level measurements. Investing in oleophobic probes that don’t stick or performing routine cleaning can assist guarantee float sensors are accurate.

Sensors for capacitive tank levels
Capacitive sensors will be the final category we discuss. These sensors consist of two electrodes, which are conductive probes that protrude into your tank. These probes track variations in capacitance when the fluid level in the tank rises and falls to determine the amount of fluid present.

The adaptability of capacitive tank level sensors is one of its main selling points. They can be applied to a variety of media, including solids and powders that aren’t liquids. They are also comparatively affordable. Capacitive sensors fall somewhere between radar/float sensors and hydrostatic sensors in terms of cost compared to the other sensors we’ve covered.

 

It’s crucial to be aware of the sensitivity and susceptibility of capacitive sensors before making a purchase. Capacitive level sensor readings can be impacted by temperature, humidity, and fluid type. Capacitive sensors provide another degree of operational complexity by requiring operators to calibrate equipment while tanks are both empty and full.

Keeping the Big Picture in Mind
All of this was just thrown at you. But let’s not lose sight of the main goal: you want better tank level information so that you can make business decisions more quickly. Choosing the right sensors for your tanks is crucial to achieving this objective.

To assist you in choosing the optimum tank level sensor for your application, we have created this summary matrix. For your project, use it to find the best tank level sensor.

Why Choose Water Line Controls

All of our water level controls and water level control systems are assembled right here in the U.S.A. where we monitor every step of the process.

If you follow technological advancement in the workplace, you’ve probably heard about the Internet of Things (IoT). The IoT is fundamentally altering the game, and now is the time to participate.

But where do you even begin? Tank level monitoring is one example.

Tank level monitoring (TLM) is an excellent first step towards becoming familiar with the IoT, whether you’re tracking frac tank levels for a well stimulation project or monitoring a straightforward water tank. The objective of tank level monitoring, as with any IoT project, is to gather accurate and trustworthy data so that you can take action and produce results. People won’t trust your tank monitoring system if your data is inaccurate, lacking, or late, and you won’t receive the desired business outcomes.

Tank level sensors are the “bedrock” of any solution for remote tank monitoring. Your sensors are the first stop on the data route for tank level monitoring since they produce the information that eventually supports decision-making. Nothing else matters if your tank level sensors don’t get reliable data. The greatest analytics and most attractive dashboards cannot compensate for subpar tank sensors.

Garbage in, garbage out, as the saying goes.

We wanted to discuss how to select the best tank level sensor for your project because of how crucial tank level sensors are to your whole tank monitoring system. You may purchase accurate and trustworthy tank sensors that generate excellent field data without spending a fortune with a little help.

Five Typical Tank Level Sensor Types

Tank level sensors come in five different categories:

Water-pressure sensors
Ultrasound detectors
Infrared sensors
Float detectors
Sensitive capacitors

Your application will determine which tank level sensor is ideal, so we’ll outline the main benefits and drawbacks of each sensor to assist you in making an informed decision for your tank level monitoring project.

Sensors for Hydrostatic Tank Level

A tried-and-true method for obtaining affordable, precise tank level data is using hydrostatic tank level sensors. These sensors are used to gauge the fluid column’s hydrostatic pressure. Typically, hydrostatics are mounted to discharge piping at the bottom of tanks, submerged in the liquid at the tank bottom.

Hydrostatic tank level sensors can be installed in various types of tanks without the need to create a new sensor because they are affordable, accurate, power-efficient, and have variable ranges.

Unfortunately, because hydrostatic sensors are frequently entirely submerged in liquid, they can experience greater failure rates. This can be quite difficult, especially with corrosive or caustic solutions. The cable gland, where fluids can enter and short circuit the delicate electronics that power the sensor, is one of the most frequent locations for failure in hydrostatic sensors.

Tank level ultrasonic sensors

Ultrasonic tank level sensors, as their name suggests, assess liquid levels using sound waves. They are installed on top of your tanks, use ultrasonic waves to “bounce” off the liquids’ surfaces, and gauge level by timing how long it takes to hear the “echo.”

The fact that ultrasonic sensors are non-contact, meaning they don’t make direct contact with the liquid in the tank, is one of its key advantages. Fluid compatibility is less of a concern, and they can function effectively in tanks where the liquid contains mixers or other moving mechanical components (note that the mixers must be off for accurate level readings, as sloshing and turbulence interfere with ultrasonic sensors).

Additionally, the cost of these sensors is reasonable, ranging from $300 to $400 per sensor. If you want greater performance or hazardous area certifications, though, budget closer to $1,000.

The fact that ultrasonic sensors use a lot of electricity is one of their key drawbacks. They can need 10-100 times as much power as hydrostatic sensors, hence they are often not appropriate for battery-powered installations.

Additionally, compared to other sensors, ultrasonic sensors typically require more upkeep. They require precise installation, maintenance of a dead band or “blanking zone” between the sensor and the fluid, and periodic cleaning of the detecting device (some fluids can create a film that affects performance)

Last but not least, noise interference is a major threat to ultrasonic sensors. The ultrasonic waves that travel to and from your sensors can encounter problems if there is foam or vapor present.

Tank level sensors using radar

In that they gauge tank levels by the amount of time it takes radio waves to travel between the sensors and fluid surfaces, radar sensors are comparable to ultrasonic sensors in this regard. Like ultrasonic sensors, radar sensors are non-contact, which appeals to operators. However, compared to their sound-based predecessors, radar sensors are more accurate and better equipped to withstand interference because of more precise electronics.

 

Radar sensors are often substantially more expensive when compared to the other two gadgets we’ve discussed so far. A competent radar tank level sensor should cost more than $2,000 in total. Radar still requires a substantial blanking zone between the bottom of the sensor and the top of the tank despite the more precise electronics. It can be challenging to obtain precise measurements as tanks fill due to the fact that light waves move so much more quickly than sound.

One advantage of radar sensors is their ability to measure fluid interfaces, such as the presence of oil in water. Even a small amount of emulsion between the interface can be taken into account by more sophisticated electronics while maintaining reliable measurements.

Sensors for Float Tank Level

Float sensors extend a probe into the liquids near the bottom of your tank, and they have continuous detecting elements along the probe that are activated by floats. Float tank sensors may be made to be extremely accurate using this approach. They can even monitor fluid interfaces by utilizing numerous floats for various liquid densities because they don’t suffer from noise or interference issues.

Float sensors, on the other hand, can be very pricey. The price of a float sensor is almost immediately inversely correlated with tank height. You might pay $1,000–$2,000 for shorter tanks (less than 5 feet tall). On the other hand, larger tanks exceeding 25 feet may cost up to $3,000 or more.

“Sticking” is one problem that float tank sensors may have. Although some manufacturers’ recent technological innovations have addressed this issue in some circumstances, it can still arise in certain circumstances. For instance, floats may adhere to the probes in liquids that result in sticky or waxy substances, leading to inaccurate static level measurements. Investing in oleophobic probes that don’t stick or performing routine cleaning can assist guarantee float sensors are accurate.

Sensors for capacitive tank levels
Capacitive sensors will be the final category we discuss. These sensors consist of two electrodes, which are conductive probes that protrude into your tank. These probes track variations in capacitance when the fluid level in the tank rises and falls to determine the amount of fluid present.

The adaptability of capacitive tank level sensors is one of its main selling points. They can be applied to a variety of media, including solids and powders that aren’t liquids. They are also comparatively affordable. Capacitive sensors fall somewhere between radar/float sensors and hydrostatic sensors in terms of cost compared to the other sensors we’ve covered.

It’s crucial to be aware of the sensitivity and susceptibility of capacitive sensors before making a purchase. Capacitive level sensor readings can be impacted by temperature, humidity, and fluid type. Capacitive sensors provide another degree of operational complexity by requiring operators to calibrate equipment while tanks are both empty and full.