Effect of Tank Design on Accuracy of Level Measurement

In many industrial applications and processes, including as manufacturing, chemical processing, oil and gas, water treatment, and others, level measuring is a crucial component. In order to monitor processes, manage inventories, and ensure secure and effective operations, level readings must be accurate. 

The tank’s design has a big impact on the accuracy and reliability of level measurements. Let’s examine each of the key elements in greater detail:

Tank Shape and Geometry

• Tanks come in different shapes and geometries, such as cylindrical, spherical, rectangular, or irregular.
• Cylindrical tanks are commonly used due to their simple design, providing consistent and predictable level measurements.
• Irregular shapes or complex geometries may introduce measurement errors due to uneven distribution of contents, leading to variations in measurements.

Tank Size and Height

• The size and height of the tank can affect the accuracy of level measurement.
• Due to the relative greater influence of sensor tolerances, readings of smaller tanks may have higher percentage errors.
• Taller tanks can introduce hydrostatic pressure variations, impacting measurement accuracy and requiring compensation for pressure effects.

Construction Material

• The tank’s material can affect the accuracy of level measuring.
• Non-metallic or non-conductive materials, for example, can have an impact on the performance of level measurement technologies such as capacitance or conductive sensors.
• Due to electromagnetic phenomenon, metal tanks may cause signal interference for several non-contact level measuring devices.

Tank Wall Thickness

• The thickness of the tank walls can impact level measurement accuracy.
• Thick walls can reduce signal penetration for certain technologies, leading to less precise measurements.
• For ultrasonic or radar-based measurements, thick walls may also introduce reflections and echoes that affect the accuracy of readings.

Effects of Sloshing and Waves

• The presence of sloshing and waves in the tank can result in measurement errors.
• These effects can be most noticeable in tanks containing free surface liquids, such as gasoline tanks on moving vehicles or ships.
• In such instances, specific strategies or technologies may be necessary to adjust for sloshing effects.

Pressure and temperature

• To achieve accurate level measurements, tank design should take temperature and pressure variations into account.
• Temperature changes might cause the liquid to expand or contract, affecting the observed level.
• Thermal influences might cause the tank to expand or contract. This can have a big influence on level-based measurements instead of volume measurements since an extended tank might have more fuel in it at a certain midpoint than it would have at the same midpoint without expansion.
• High-pressure conditions can have an impact on the performance of some measurement devices, requiring pressure corrections.

Properties of Liquids

• The physical qualities of the liquid being measured can have an impact on the accuracy of the level measurement.
• Certain level measurement devices may be hampered by liquids with high viscosity or low dielectric constants.
• Proper measuring equipment selection can account for these qualities and provide reliable measurements.
• The expansion of the shell caused on by the substance contained

Fumes and Vapors

• Tanks containing volatile liquids can emit vapors and fumes that can interfere with certain level measurement systems, such as ultrasonic or optical sensors.
• To ensure measurement accuracy, proper ventilation or the use of vapor-resistant sensors may be required.

Calibration and Sensor Positioning

• Accurate level measurements require proper calibration and sensor positioning.
• Calibration ensures that the readings correlate to the liquid’s real level.
• To avoid incorrect readings, sensor placement should take into account the tank’s internal features as well as potential obstacles.

Agitators and Baffles

• Tanks containing baffles and agitators might have an impact on level measuring accuracy.
• Wave reflections caused by baffles can result in misleading level measurements during measuring.
• Agitators can cause disturbances on the liquid surface, altering its stability and introducing measuring inaccuracies.

Maintenance and Human Error

• Human error during tank installation or maintenance can result in inaccurate level measurement.
• To maintain sustained accuracy, regular maintenance and calibration checks are required.
• Human errors can be reduced by properly training workers involved in tank operations and level measurement.

Environmental Aspects

• External environmental conditions can have an impact on the accuracy of level measurement.
• Sensor performance can be impacted by vibrations, electromagnetic interference, and temperature variations.
• Sensor shielding or isolation may be required in settings with severe electromagnetic interference.

Technology for Level Measurement

• The level measurement system selected should be compatible with the tank design and intended application.
• Ultrasonic, radar, capacitance, and hydrostatic technologies all have variable degrees of the suitability for various tank designs.
• Each approach has advantages and disadvantages, and the best option is determined by criteria such as tank size, contents, and environmental conditions.

Control System Integration

• The accuracy of level measurement should be in line with the overall control system requirements.
• Disagreements in level readings may result in inefficiencies in process control or inventory management.
• Monitoring and communication between level sensors and control systems in real time can help to optimize operations.

Concerns Regarding Safety

• To avoid spilling or overfilling, tank design should prioritize safety, which can affect level measuring accuracy.
• Even in critical circumstances, proper safety procedures can assure reliable and precise measurements.
• In the event of incorrect level readings, safety shut-off mechanisms can prevent catastrophic events.