If you need to monitor the diesel fuel level in generators, day tanks, or large storage tanks, specialized sensors can provide accurate tracking. But, these sensors require customization to meet your specific needs. In this post, we’ll explore key considerations when tailoring liquid level sensors for fuels, oils, and other fluids. Read on to learn what decisions you’ll need to make to get the right diesel fuel level sensor for your application.
Select the Sensing Method
The first choice is the sensing method the level sensor will use to measure fluid levels. Common options for diesel and oil tanks include:
- Float switches: Floats rise and fall with the fluid level, connecting an electrical circuit at predetermined heights. Simple and inexpensive, but usually only detect preset high or low levels.
- Ultrasonic sensors: Use sound waves to determine distance to the fluid surface. No contact with the liquid and can provide continuous measurement. Requires careful mounting.
- Capacitance probes: Use electric fields to sense liquid density changes. Can detect precise levels for automating pumps and valves. Requires still conditions.
- Weight and pressure: Measure the weight or pressure at the tank bottom. Simple but not always accurate if conditions fluctuate.
Consider the tank’s size, environment, accuracy needed, and budget when choosing a sensing method.
Determine the Required Measurement Range
Diesel and oil storage tanks come in many shapes and sizes. So you’ll need to determine the sensor measurement range based on the tank height and your desired level of monitoring. Do you need to measure the full tank height or only within a certain distance from the bottom or top? This helps tailor the calibration range so you get useful information without paying for unnecessary measurement capacity.
Pick Materials Compatible with the Fluid
Sensor materials must be chemically compatible with diesel, oils, or other fluids being measured to prevent corrosion or breakdown over time. Metal alloys, PVC, PVDF, polypropylene, and other rugged plastics are common sensor materials suitable for diesel and petroleum products. Know the fluid properties before selecting materials.
Choose Output Signals and Interface Types
Sensors use output signals and interface options to communicate data. Common outputs for diesel level management include:
- Analog signals like 4-20mA correspond to level change. Easily transmit to displays, controllers, and databases.
- Relays or digital outputs for simple high/low alarms or valve controls.
- Bus networks like Modbus connect through programmable logic controllers (PLCs). Allow digital communication with industrial control systems.
- Wireless I/O for remote level monitoring without cabling. Communicate to central systems via cellular, WiFi and other wireless methods.
Select compatible outputs and interfaces for your infrastructure and performance needs.
Determine Approvals and Certifications
For flammable fluids like diesel and oil, sensors may require hazardous location approvals like ATEX or IECEx. These certified sensors are designed to avoid igniting combustible vapors. Maritime, biogas, and other applications may also require specific sensor ratings. Clarify required compliances and environmental resistance levels upfront.
Plan Safe and Effective Mounting
Proper mounting helps sensors maintain alignment and accuracy while withstanding vibration, corrosion, and debris over time. Work with experts to determine optimal mounting locations, materials, conduit fittings, and installation methods. For large tanks, consider multiple sensors or guide wires to monitor at different heights or across different zones.
With the right considerations and partnerships, you can obtain customized sensors tailored for tracking diesel, oils, and other critical liquids for your application. Careful planning upfront ensures your level monitoring sensor and vertical float switch have the features and capabilities you really need; no more and no less. Then you can have confidence in the accuracy and longevity of your diesel fuel or fluid measurement system. Reach out to sensor specialists who can help assess your needs, walk through the available options, and get you the ideal sensor solution for the job.