Each instrument has a specific function for keeping the contents inside the tank:

1 High-level overfill prevention switch is installed to indicate when the liquid in the tank reaches a dangerously high condition. It’s often called a high-high level switch, as it is mounted above the high-level switch used to indicate the tank’s normal stop-fill point.

If the high-level switch fails, the high-high level switch is there to prevent the tank from overfilling. High-high level switches typically include a way to function test the switch to ensure its integrity. Because high-high level switches are mounted above the normal maximum fill point, they can be in service for years without ever “seeing” liquid in the tank. Because of this, the ability to test the switch on a periodic basis to verify its function is critical.

In far too many tanks, a high-high switch is the only protection against spills. This is unacceptable. Additional spill and overfill detection methods are needed.

2 Temperature sensor measures tank liquid temperature because the volume of most chemicals expands or contracts with temperature change. Without compensation, these volume changes look like level changes when, in fact, the actual tank contents have not changed. Again, temperature measurement accuracy is very important, in this case to provide proper compensation. Temperature sensors with multiple measurement points and accuracy of 0.1 degree C are required for this application.

3 External level switch mounted inside the retention dike indicates if a liquid is accumulating. The level switch needs to be able to detect any liquid present. Even rainwater accumulating after a storm should be detected as it must be removed to maintain the appropriate volume of the dike. Essentially, any accumulation of liquid within the dike, water or a chemical, requires a response. As such, switches that reliably indicate liquid presence, such as tuning forks, are best suited for this application.

4 Tank-side monitor performs corrected-volume calculations using the temperature probe output and the radar transmitter signal to determine the height of the material in the tank. It also provides intrinsically safe loop-power to the level gauge and the temperature transmitter, reads data from all connected devices and displays the values of each instrument.

5 Radar level transmitter continuously monitors level in the tank. To detect leaks, spillage or overfills, it is extremely important that the level gauge be very accurate. A high degree of accuracy is needed to allow indication of level decreases when the tank liquid is not actively being transferred or pumped out. If the level starts to decrease during inactivity, a leak in the tank is indicated and an alarm should sound. Given the application, accuracy needs to be measured in fractions of millimeters. Dechuang Electric design and manufacture the DCRD1000C series guided radar level gauge with accuracy up to 1 millimeters, which can monitor and measure the level of liquid, corrosive liquid and liquid with surface fluctuation.

6 PC-based monitoring software is a typical PC-based HMI software package that displays tank output in a tank farm, as well as volume calculations. Such software packages are available from several suppliers. These software packages typically have Web-server capability built-in, so an operator or engineer can quickly and easily access tank information from any PC or handheld device via a browser.

The software also monitors tank level and can react to any level change. The software should have a feature that allows an inactive tank to be “Locked Down.” If the level in a locked down tank drops, it would indicate a leak, and the software would produce an alarm.