Flow, level & control
Radar level sensors ensure chemical tanker truck safety
A trucking company focused on supporting California oil wells transports various acids, solvents, and chemical blends required for drilling. These chemicals make oil wells more productive, and they make drilling easier and safer. Some of the chemicals can be dangerous so the company uses VEGA level measurement instrumentation to ensure the safety of employees and clients.
O
il wells are often found in remote locations, so it is crucial for the organisations
supporting them to make the most of each supply run. For this trucking company, that means filling their two- and three-compartment tanker trucks to the highest possible safe level. Chemical transportation companies
in California must comply with the rules and regulations from multiple different agencies, including the California Air Resource Board and the Department of Transportation (DOT). Often, this means opening truck hatches and making sight checks are non-permissible, so another level measurement method is required – one that does not exceed certain DOT height restrictions.
FindinG ThE riGhT TEChnoloGy To meet all the necessary requirements, the trucking company had been using small ultrasonic devices to measure the level in each compartment on their trucks. Unfortunately, these sensors proved to be unreliable and inaccurate for a multitude of reasons. The ultrasonic devices struggled
to receive a signal from the acid products, and this problem was especially prevalent during filling
when the product surface is agitated and foam forms. Near zone issues, which are common with ultrasonic measurement sensors, prevented the transportation company from getting accurate measurements to the top of the tank, and the rounded bottom of the tanks caused the sensor signal to scatter, resulting in unreliable and inaccurate measurements. Frustrated with poor results, the chemical transportation company told the level and pressure measurement experts at VEGA they wanted an alternative cost-effective level measurement sensor that could overcome the challenges they had been facing. The company’s local VEGA representative suggested a VEGAPULS C 21 radar level sensor paired with a VEGADIS 82 display unit. Installing both instruments on the
truck was simple and their small sizes did not add much to the profile of the truck. The low power consumption of the radar and display units enabled the instrumentation to be powered by the truck battery without the need for any additional power sources like a generator or extra battery. Additionally, both instruments have a quick startup time, which minimizes power consumption and provides accurate measurement data as soon as users need it. Setup was completed wirelessly with
a secure Bluetooth connection and a smartphone with the free VEGA Tools app. The guided step-by-step setup process includes inputting the size of the truck tanker and the type of liquid being measured, among other data points. Once complete, the chemical trucking company was receiving accurate level measurements within ±2 mm on a variety of products, including xylene, hydrochloric acid, and ammonia water at 10 per cent.
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improVEd SAFETy pAyS For iTSElF
Ultrasonic and radar level measurement technologies both use the time-of-flight principle to make a non-contact measurement, but that is where the similarities end. The radar level sensor provided more reliable, more accurate level measurements from the bottom of the tanker vessels all the way to the top. The improved measurements
ensured safer operations, minimising overfill risks while maximising each shipment. The new radar sensor maintained an accurate measurement during filling and emptying when foam is most likely to form. And once a tanker vessel was completely drained, the radar sensor output an empty measurement instead of an error. All these factors enabled the chemical transportation company to accurately bill customers for the chemicals used. The new radar sensor and display
unit offered a better measurement solution that simultaneously improved personnel safety and operational procedures. The easy setup with secure Bluetooth connectivity was simply a bonus. Looking ahead, the chemical transportation company is now looking to outfit all their trucks with a VEGAPULS C series radar and VEGADIS display unit to optimise their entire fleet.
VEGA Controls
www.vega.com/uk
June 2021 Instrumentation Monthly
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