PROCESS AUTOMATION


EXPANDING THE REACH IN REMOTE APPLICATIONS


Emerson’s Rosemount 3408 Wireless Level Transmitter enables non-contacting radar to be deployed in applications where signal cabling is not readily available


Below: Modern non-contacting radar level transmitters provide reliable continuous measurement in solids applications where dust can affect the performance of some other technologies


Rupchanda Barman, of Emerson, explains how advances in wireless non-contacting radar are enabling operators to deploy their preferred level measurement technology in applications where wired installation would previously have been impractical or cost-prohibitive


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cross the process industries, accurate level measurement underpins safe, efficient and profitable operations. Yet tanks, silos, storage vessels and ponds can often remain


uninstrumented because installing power and signal cabling is too expensive, impractical or disruptive. As a result, operators frequently rely on manual measurements and limited process visibility, reducing efficiency, increasing operational risk and making it more difficult to optimise inventory and operations. Wireless instrumentation


addresses this challenge by extending measurement to remote and difficult-to-access facility assets. However, until recently, one important gap in the wireless portfolio remained. While wireless guided wave radar and wireless point level detection devices have been available for many years, native battery-powered wireless non-contacting radar transmitters were not. The introduction of more energy-efficient, 80 GHz frequency modulated continuous wave (FMCW) radar technology has now changed this, making it possible to combine the measurement performance associated with non-contacting radar with long-life battery operation and WirelessHART communications in a single instrument. Non-contacting radar has become the preferred


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level measurement technology for many applications because it delivers reliable measurements without contacting the process medium. This makes it particularly suited to corrosive chemicals, viscous products, hazardous materials and applications where minimising maintenance is a priority. Many of the applications where these advantages are most valuable are also among the most difficult and expensive to instrument using conventional wiring. Native wireless non-contacting radar now enables engineers to deploy their preferred measurement technology in these locations without the cost and disruption of installing power and signal cabling.


Expanding visibility Within large process facilities, there are often dozens or even hundreds of storage tanks, silos and intermediate vessels spread across extensive sites. Many lack the wiring infrastructure required to support automated level monitoring, forcing operators to rely on manual measurements. Besides consuming valuable time, manual inspection exposes personnel to hazardous areas, increases the opportunity for human error and


provides only periodic snapshots of process conditions. Collectively, these assets can represent significant operational risk if inventory levels are unknown or abnormal conditions go undetected. Across chemical manufacturing, refining, food


PROCESS & CONTROL ENGINEERING | OCTOBER 2026


production and bulk storage terminals, remote tanks often contain corrosive chemicals, solvents and hydrocarbons where non-contacting radar is the preferred measurement technology because it never comes into contact with the product. Without a sensor exposed to the process, maintenance requirements can be minimised while measurement reliability is maintained over long operating periods. Historically, however, installing power and signal cabling to remote tank farms has often made comprehensive instrumentation uneconomic. Wireless non-contacting radar removes this barrier, allowing continuous level measurements to be transmitted directly to the control system without extensive trenching or civil works. Operators gain real-time visibility of inventory, can optimise material movements and receive immediate notification of changing tank levels, while reducing the need for personnel to routinely visit potentially hazardous locations.


The same principles apply to smaller storage assets such as plastic chemical tanks, intermediate bulk containers and fibreglass vessels. These are often temporary, portable or located in isolated parts of a site, making conventional instrumentation difficult to justify. Wireless non-contacting radar is particularly well suited to these applications because the radar signal can pass through many non-metallic tank roofs, allowing accurate level measurement without penetrating the vessel or bringing the instrument into contact with potentially corrosive or hazardous contents. Installation is simplified, containment integrity is maintained and continuous inventory information becomes available without interrupting operations or introducing additional process connections.


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