Before: Manual monitoring. After: Automated monitoring with DR6421

Why a $50,000 Product Loss Happened Despite a Half-Full Dip Tape

Our chemical storage tank was leaking a significant amount of expensive reagent. The dip tape indicated the level was half full, but the radar measurement from DR6421 showed it was nearly empty. This discrepancy resulted in a $50,000 product loss last month. Consequently, we realized that manual dip tape readings were unreliable. In fact, the dip tape’s submersible sensor had a clogged vent, causing false readings. As a result, we lost valuable reagent and faced potential safety hazards.

Barometric Pressure vs. Radar Stability: The $50,000 Difference

Radar waves reflect off the liquid surface without any physical contact. This non-invasive feature ensures no contamination risk and works through tank roofs, eliminating the need for process penetration. During our investigation, we noticed that barometric pressure changes were affecting the dip tape readings, while the radar measurement remained stable. Specifically, the vent on the submersible sensor was clogged, leading to false readings from the dip tape. Therefore, the radar level transmitter proved immune to environmental variations, providing consistent and accurate data.

How DR6421 Solved Our Inaccurate Level Measurement Problem

We installed the DR6421 radar level transmitter, which measures through tank roofs without process penetration. This non-contact level sensor uses radar waves to detect liquid levels, ensuring no moving parts for low maintenance. Moreover, it is immune to temperature and pressure variations, making it suitable for corrosive and high-temperature liquids. The DR6421 offers 4-20mA or RS485 output options, integrating seamlessly with our existing control system. As a result, we now have reliable, real-time level data.

Why a 98% Reduction in Product Loss Changed Our Maintenance Strategy

Since the upgrade, we have seen a 98% reduction in product loss. The radar technology has proven to be reliable and cost-effective for our chemical storage needs. Additionally, the through tank radar level gauge eliminates the need for tank penetration, reducing installation costs and potential leak points. Consequently, we have minimized maintenance and improved safety. The DR6421’s non-contact operation ensures no contamination, which is critical for expensive reagents.

Key Specifications of DR6421 Level Transmitter

• Non-contact radar level transmitter
• Measures through tank roofs without process penetration
• No moving parts for low maintenance
• Immune to temperature and pressure variations
• Suitable for corrosive and high-temperature liquids
• 4-20mA or RS485 output options

How can we ensure consistent accuracy across all our tanks with minimal maintenance?

Consider implementing radar level transmitters on all critical tanks. This approach would standardize monitoring and reduce reliance on manual methods. Furthermore, regular calibration checks can maintain accuracy. For more on level measurement best practices, see [Endress+Hauser’s guide](https://www.endress.com).

Tags: #leveltransmitter #DR6421