Level indicator float

Types of level indicator float

Level indicator floats work through different operating principles, and each type has its advantages depending on the characteristics of the measuring medium and the requirements of the application. Some of the most common types are:

• Continuous measurement types

  These provide an uninterrupted output of liquid levels within a reservoir or tank. They are primarily used where precise measurement is necessary. Operational examples include radar and magnetic level indicators.

• Point measurement types

  Only detect levels at specific points are adequate for on/off control applications or point level detection. Common point measurement types include float switches and capacitive level sensors.

• Mechanical and non-mechanical classes

  Another categorization of level indicators is based on their operating technology – mechanical floats linked to the gauge glass via levers or chains, providing a visual reading, whereas non-mechanical indicators like radar, ultrasonic, or pressure transducers work without direct contact with the fluid, offering diverse industrial-fitting needs and safety requirements.

Industrial Application

• Chemical industry

  In chemical processing plants, these indicator floats are essential for measuring and controlling the level of various chemicals in reactors, storage tanks, and vessels. They help ensure safety by preventing overflows or dry runs in critical equipment. Depending on the float materials and design, these level indicators withstand corrosive substances, making them ideal for use in such harsh environments.

• Oil and gas industry

  Used in refineries, oil rigs, and storage facilities to measure liquid levels in tanks, separators, and pipelines. The float level gauge are crucial for monitoring product levels, maintaining safety standards, and optimizing operational efficiency. They give reliable readings in extreme conditions like high pressures and temperatures.

• Food and beverage industry

  Float indicators measure and control liquid levels in brewing, fermentation, and storage tanks, ensuring consistent product quality. In dairy, these floats handle varying liquid densities and temperatures. They are critical in delivering precise and dependable measurements for effective production processes.

• Pharmaceutical industry

  Used in the drug manufacturing process to maintain levels in mixing, storage, and filtration vessels. They need to fulfil strict cleanliness and accuracy standards. The right level measurement solution – whether contact or non-contact – guarantees precise formulation, reduces waste, and assures regulatory compliance.

• Water and wastewater treatment

  Indicator floats monitor levels in tanks, clarifiers, and digesters, automating pump control and ensuring efficient treatment processes. They are vital in managing water levels and quality in municipal and industrial treatment facilities. Float types measure sludge, scum, and liquid levels, enabling proper flow management and treatment sequence adherence.

Product Specifications and Features

Technical specifications

• Requirements: Specify the accuracy and range of level measurement required in the float level gauge.
• Medium characteristics: Identify the measured liquid or material and its properties, density, dielectric constant, and temperature.
• Tank information: Include tank size, shape, and material, as well as any obstructions inside that might affect the measurement.
• Operating conditions: Identify the pressure, temperature, and environmental conditions where the float indicator will operate.
• Installation requirements and connectivity: Determine how the float level gauge will be configured into the existing industrial systems.

Key Features

• Contact floats: Designed for direct contact with the measured liquid, providing reliable and accurate level readings. They are simple, cost-effective, and have few moving parts, making them ideal for various industrial applications like water treatment and chemical storage.
• Guided wave radar: This GWR type uses a probe and works well for most liquids and some pastes and solids. It works under extreme conditions and doesn’t need a clear surface.
• Magnetic floats: A magnetic float level switch uses a float that tracks magnetic fields to measure levels. It’s simple and needs little upkeep. It’s good for gases, liquids, and some steams, and works well in diverse conditions, including oily and dirty fluids.
• Ultra sonic level sensor: Uses sound waves to check levels and does this without touching the liquid or solid measured. It’s simple to set up, low on power, and fits many spaces. It works best on clean liquids and dry materials and is suited for food, water, and mining tasks.

Installation

• Preparation: Different types of level indicator floats should be chosen based on the nature of liquids or slurries to achieve a smooth installation process, after which the site should be prepped by clearing the area above the tank or vessel where the float will be installed, ensuring easy access and eliminating safety hazards.
• Positioning: Locate the point where the float will be installed. This is usually on the top of the tank or at the side.
• Mounting: Each float, whether a mechanical one with a pulley or a radar type, should be properly fixed on top of the tank. This provides a clear space for the float to work without touching the liquid inside.
• Wiring: Level floats usually have wires to connect to gauges or controls. This part needs careful handling to prevent loose ends.
• Calibration: Calibrating each type of float is essential for accurate measurements after installation. This is done by emptying and filling the tank while adjusting the float settings.

Quality and Maintenance

Quality

Some of the common float type level indicators include:

• Stainless steel floats: Used where the liquid is caustic, heat, or pressure high, they keep the float tough and rust-free for years.
• Hollow glass floats: These are light and help check if tanks and pipes are full or need a refill. They are easy to see on liquids.
• Magnetic floats: Embedded with a magnet, they follow the field from a float outside the tank to show how full it is inside, working without touching the liquid.

Maintenance

• Regular inspection: Check for any wear, corrosion, or damage to the float and stem, which should be done at the same time the floats within the system undergo cleaning.
• Testing: Manually check the float level gauge in the tank by raising and lowering the float to see if it tracks properly.
• Calibration: Adjust settings or replace worn parts to keep the gauge accurate, which should be done as part of the annual servicing task.
• Lubrication: Some level floats have moving parts that require lubrication to reduce friction and extend the lifetime of the device.
• Replace worn parts: Any mechanical parts that have gone through wear should be replaced immediately.

How to Choose level indicator float

When buying, consider these factors:

• Application and environment

  Indicator floats hold and work with liquids that are easy to identify. In food and chemicals, get smooth floats that touch the stuff. For water storage, choose simple switches and cylinders. Radar and ultrasonic types work in rough spots.

• Level of accuracy

  For accurate readings, use radar or magnetic types. Floating switches, though less exact, are good for basic tasks.

• Cost

  Switches and cylinders with simple mechanical floats are cheap at first. Magnetic, radar, and ultrasonic ones cost more upfront but save in power use and fewer breakdowns.

• Requirement for maintenance

  Indicate floats with no moving parts, like radar, need less care. Switches and mechanical floats need more regular checks.

• Material

  The float's makeup matters. Plastics work on food. Stainless steel suits chemicals. Every type provides safety.

Q&A

Q1. Why is a level float used?

A1: These level gauges let one know how much liquid or solid is inside something, like a tank or barrel. They give a clear, simple look at the levels, unlike other tools that are harder to read. They are easy to set up and cost less than some high-tech choices. Unlike some sensors, they work well with all kinds of materials. Even in tough places, like extreme heat or pressure, they can keep going strong.

Q2. What are the benefits of a level float?

A2: Level floats are inexpensive and reliable, making them easy to use regularly. Unlike other options, they don't need power to work. They are well-made to take shocks. In factories and storage, these simple tools help keep things running smoothly without complex electronics.

Q3. What are the limitations of a level float?

A3: They can get stuck and give false low readings. If dirty or full of foam, they miss the mark by a wide margin. Some types need power or get in the liquid, which might not suit all tasks.

Q4. How long do level floats last?

A4: Most last about 15 years if cared for. Clean them often, and avoid extreme heat or pressure to keep them working. With minimal wear and tear, they can keep going long past their expected years of service.