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Tank gauging system for inventory control and overfill prevention

A tank gauging system for inventory control and overfill prevention ensures accurate measurement of liquid levels in storage tanks while enhancing safety and operational efficiency. Here are key aspects to consider:

Types of Tank Gauging Systems

  • Servo Tank Gauges (STG) – High-precision systems like the Proservo gauge, ideal for bulk liquid storage, custody transfer, and high-accuracy applications.
  • Radar Tank Gauges (RTG) – Non-contact guided wave radar or free-space radar for real-time level measurement, suitable for crude oil, chemicals, and LNG tanks.
  • Hydrostatic Tank Gauging (HTG) – Measures liquid pressure at the tank bottom, used for mass-based inventory tracking.
  • Float & Tape Gauges – Traditional mechanical systems, reliable but less accurate than radar or servo gauges.

Key Features for Inventory Control & Overfill Prevention

  1. High Accuracy Measurement – Essential for custody transfer and precise inventory tracking.
  2. Temperature & Density Compensation – Provides corrected volume measurements to account for thermal expansion.
  3. Real-Time Monitoring – Integration with SCADA, DCS, or cloud-based systems for continuous data access.
  4. Overfill Prevention System (OPS) – High-level alarms and automatic shutdown functions to prevent spills.
  5. Redundant Alarms & Safety Compliance – Meeting standards like API 2350 for overfill protection.

Applications

  • Oil & Gas Terminals – Custody transfer and stock reconciliation.
  • Chemical Storage – Ensures safe handling of hazardous liquids.
  • LNG Tanks – Cryogenic applications with special radar systems.
  • Refineries & Petrochemical Plants – Inventory management for process optimization.
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Portable density meter for use in the lab and on-the-go

Portable density meters provide quick, accurate, and reliable density and concentration measurements for liquids and slurries, making them ideal for both laboratory analysis and field applications.

1. Key Features of Portable Density Meters

✔️ Compact & Lightweight – Easy to carry and use anywhere.
✔️ Fast & Accurate Measurements – Provides high-precision results within seconds.
✔️ Wide Measurement Range – Suitable for various liquids, including chemicals, beverages, oils, and pharmaceuticals.
✔️ Digital Display – Clear and easy-to-read LCD or touchscreen interfaces.
✔️ Battery-Powered & Rechargeable – Long-lasting lithium-ion battery options.
✔️ Multiple Measurement Units – Supports g/cm³, kg/m³, Brix, API, Baume, Plato, and more.
✔️ Robust & Durable – Resistant to chemical exposure and harsh environments.
✔️ Automatic Temperature Compensation – Ensures accuracy in varying conditions.
✔️ Data Logging & Connectivity – Stores readings and allows USB/Bluetooth transfer.

2. Applications of Portable Density Meters

  • Pharmaceuticals & Biotech – Checking API concentration in medicines.
  • Food & Beverage Industry – Measuring sugar (Brix) or alcohol in wine, beer, and juices.
  • Petroleum & Chemical Industry – Testing fuel density, API gravity, and purity.
  • Construction & Mining – Monitoring slurry and cement density.
  • Environmental Studies – Checking water quality and pollution levels.
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Simplify your infrastructure from LNG tank gauging system

An LNG tank gauging system ensures precise level measurement, density monitoring, and temperature control while streamlining operations in LNG storage and transportation. By integrating automated, highly accurate sensors, you can reduce complexity, improve safety, and enhance efficiency in your infrastructure.

Key Ways to Simplify Infrastructure with LNG Tank Gauging

✅ Automated & Accurate Level Measurement

Radar and servo tank gauges provide real-time, high-precision measurements.

Eliminates the need for manual checks, reducing errors and labor costs.

✅ Integrated Density & Temperature Monitoring

Advanced cryogenic temperature sensors and density probes ensure accurate volume calculations.

Helps in optimizing LNG storage efficiency and minimizing losses.

✅ Seamless Data Integration & Remote Monitoring

Cloud-based and SCADA-compatible systems enable real-time monitoring from a central location.

Reduces the need for on-site inspections, improving operational control.

✅ Compliance & Safety Optimization

Automated alarm systems detect leaks, overfills, and temperature fluctuations.

Ensures compliance with international LNG storage regulations (API, ISO, IEC 61508).

✅ Reduced Maintenance & Long-Term Cost Savings

Non-contact radar gauges minimize wear and tear.

Self-calibrating systems reduce downtime and maintenance costs.

Recommended Gauging Solutions

  • Radar-based tank gauges – High accuracy, low maintenance.</li
  • Servo gauges – Precise level and density measurement.
  • Multi-point temperature sensors – Critical for LNG stratification monitoring.
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Smart Flash Infrared Servo Tank Gauge

The Smart Flash Infrared Servo Tank Gauge (STG) is an advanced tank gauging system that utilizes infrared sensing technology along with servo-based measurement to provide highly accurate and reliable liquid level, interface, and density measurements in storage tanks. It is widely used in the oil and gas, petrochemical, and chemical industries for inventory management, custody transfer, and process control.

Key Features of Smart Flash Infrared Servo Tank Gauge


High-Precision Measurement

Measures liquid level with an accuracy of ±0.4 mm, making it suitable for custody transfer applications.

Capable of detecting interface levels (e.g., oil-water separation) and liquid density profiling.

Infrared Sensor Technology

Uses infrared-based detection for non-contact signal transmission, improving accuracy and reducing signal interference.

Enhances data reliability even in challenging tank conditions, such as high vapor presence.

Real-Time Monitoring & Data Logging

Provides continuous real-time level measurement for process control and inventory tracking.

Compatible with SCADA, DCS, and tank management systems via standard communication protocols (HART, Modbus, Foundation Fieldbus).

Enhanced Safety & Compliance

Designed for use in hazardous environments with certifications such as ATEX, IECEx, and API compliance.

Supports overfill prevention systems (OPS) and leak detection.

Multi-Tank Compatibility

Works with floating-roof, fixed-roof, and pressurized tanks storing crude oil, refined fuels, LNG, LPG, and chemicals.

Remote Diagnostics & Calibration

Features remote monitoring and self-diagnostic functions, reducing maintenance costs.

Can be calibrated without opening the tank, minimizing downtime.

Applications in the Oil & Gas Industry

  • Crude Oil & Fuel Storage Terminals – Ensures precise inventory control and regulatory compliance.
  • Refineries & Petrochemical Plants – Optimizes process automation and blending operations.
  • LNG & LPG Cryogenic Tanks – Measures level and density with high accuracy at low temperatures.
  • Pipeline & Distribution Facilities – Enhances custody transfer accuracy and loss control.
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Servo tank gauge used in the oil and gas industry

Servo tank gauges are high-precision instruments used in the oil and gas industry for measuring liquid levels, interface levels, and density in storage tanks. They are essential for accurate inventory management, ensuring operational efficiency, and maintaining safety in refineries, terminals, and petrochemical plants.

Key Features of Servo Tank Gauges in the Oil & Gas Industry:

  1. High Accuracy Measurement – STGs offer precise level measurement with an accuracy of up to ±0.4 mm, making them ideal for custody transfer and inventory control.
  2. Multi-Parameter Monitoring – In addition to liquid level, STGs can measure interface levels (e.g., oil and water separation), density, and temperature.
  3. Continuous Real-Time Monitoring – Provides real-time data for process control, reducing risks of overfills and ensuring compliance with safety regulations.
  4. Integration with Inventory Management Systems – Compatible with digital communication protocols (Modbus, HART, Foundation Fieldbus) for seamless integration with SCADA and DCS systems.
  5. Suitable for Various Tank Types – Used in floating-roof tanks, fixed-roof tanks, and pressurized tanks storing crude oil, refined fuels, chemicals, and LPG/LNG.
  6. Reliable Operation in Harsh Conditions – Designed to withstand extreme temperatures, high-pressure environments, and hazardous areas with ATEX and IECEx certifications.
  7. Automatic Density Profiling – Helps in detecting stratification and changes in product composition inside the tank.

Popular Applications in the Oil & Gas Sector:

  • Crude Oil Storage Terminals – Ensures precise measurement for custody transfer and regulatory compliance.
  • Refineries & Petrochemical Plants – Used for process control and product blending.
  • LNG & LPG Storage – Monitors cryogenic liquids with high accuracy.
  • Pipeline & Distribution Facilities – Helps in tracking inventory and preventing losses.
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Automatic Calibration of Portable Density Meter

Automatic calibration in portable density meters ensures accurate and reliable measurements in various applications such as chemicals, food & beverage, pharmaceuticals, and petroleum industries. Here’s how it works and why it’s essential:

1. How Automatic Calibration Works:

  • Built-in Reference Standard: Some portable density meters come with an internal reference oscillator or pre-programmed standard values for calibration.
  • Preloaded Calibration Liquids: The device uses known-density calibration liquids (e.g., distilled water, air, or certified standard solutions).
  • Temperature Compensation: Automatic temperature control and correction eliminate errors caused by thermal expansion or contraction.
  • One-Touch Calibration: Users can initiate calibration with a single button, minimizing manual errors and ensuring repeatability.

2. Calibration Methods:

  • Air & Water Calibration: Standard method using air (0.000 g/cm³) and distilled water (0.9982 g/cm³ at 20°C).
  • Certified Reference Liquids: Used for high-precision applications, ensuring accuracy within industry standards.
  • Two-Point Calibration: Enhances accuracy by calibrating at two density reference points.

3. Benefits of Automatic Calibration:

✅ Eliminates manual errors

✅ Ensures consistent accuracy over time

✅ Saves time with quick, automated adjustments

✅ Extends device lifespan by preventing incorrect readings

4. Applications of Automatic Calibration in Portable Density Meters:

  • Beverage Industry – Quality control of juices, wines, and spirits.
  • Petroleum & Lubricants – Fuel density testing.
  • Chemical & Pharmaceutical – Ensuring formulation consistency.
  • Environmental Monitoring – Water quality assessment.
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The LNG tank gauging system is based on the principle of displacement measurement

LNG tank gauging systems commonly utilize displacement measurement principles to ensure accurate monitoring of the liquid level and inventory in storage tanks. This method is particularly effective in the challenging environment of LNG storage, where extreme cold temperatures and dynamic conditions are present.

Principle of Displacement Measurement in LNG Tank Gauging

Displacement measurement involves detecting the position or movement of a probe, float, or mechanical element that responds to changes in the liquid level. This method is widely used in systems like servo gauges for precise LNG level monitoring.

How Servo Tank Gauges Work (Common Displacement Method)


    1. Suspended Displacer:

A small displacer (float) is suspended inside the tank using a measuring wire connected to a servo motor.


    1. Equilibrium Mechanism:

The servo motor continuously adjusts to keep the displacer at the interface between the liquid and vapor phases.


    1. Force Detection:

The LNG tank gauging system measures the force required to maintain this balance, which directly correlates to the liquid level.


    1. Density Measurement:

Advanced servo gauges can also determine liquid density by analyzing the buoyancy force acting on the displacer.

Key Advantages of Displacement-Based Gauging in LNG Tanks

✅ High Accuracy — Servo gauges offer precision within ±1mm, ideal for managing valuable LNG inventory.

✅ Density Profiling — Helps detect stratification in LNG, improving safety and efficiency.

✅ Reliable in Cryogenic Conditions — Displacement methods are well-suited for LNG’s extremely low temperatures.

✅ Continuous Monitoring — Provides real-time data for accurate inventory control.

Displacement-based LNG tank gauging systems are highly trusted in industries where precision and safety are paramount, especially in large-scale LNG storage facilities.

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Servo tank gauge is accurately positioned in the liquid medium

A Servo Tank Gauge (STG) is a highly precise instrument used for continuous level measurement in storage tanks containing liquids such as crude oil, chemicals, LNG, and refined petroleum products. The accurate positioning of the gauge in the liquid medium is critical for ensuring high-precision inventory control, custody transfer, and safety monitoring.

How Servo Tank Gauges Ensure Accurate Positioning

Servo Motor Control System

The gauge uses a servo-driven displacer suspended in the liquid.

The servo system continuously adjusts the displacer’s position to maintain equilibrium.

Displacer-Based Measurement

The displacer is partially or fully submerged, and the buoyant force changes based on liquid level.

The system precisely detects these changes to determine the exact level.

Automatic Density Compensation

By measuring the displacer’s buoyancy, the STG can calculate liquid density in real time.

This ensures accurate compensation for varying product densities.

High-Resolution Feedback Mechanism

Equipped with high-resolution encoders, the gauge detects even the smallest changes in level.

Measurement accuracy is typically ±0.4 mm or better, depending on the model.

Integration with Tank Gauging Systems

Servo gauges integrate with inventory management software for real-time monitoring.

Compatible with temperature and pressure sensors to correct for environmental factors.

Advantages of Accurately Positioned Servo Tank Gauges

✅ Highly Accurate Liquid Level Measurement – Essential for custody transfer and stock reconciliation.

✅ Real-Time Density and Interface Measurement – Useful for multiphase liquids (e.g., oil-water interface detection).

✅ Minimal Maintenance & Long-Term Stability – Reliable operation with automated self-checking.

✅ Safe for Hazardous Environments – Explosion-proof and ATEX-certified options available.

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Audible and visible alarms of grounding and overfill protection system

An audible and visible alarm system is a crucial component in a grounding and overfill protection system for storage tanks, especially in industries like petroleum, chemicals, and hazardous materials storage. These systems are designed to ensure that tanks remain grounded to prevent the buildup of static electricity (which could lead to fires or explosions) and to avoid overfilling, which could lead to spillage, environmental damage, or safety hazards.

Here’s an overview of the audible and visible alarm systems used in conjunction with grounding and overfill protection systems:

1. Grounding Protection Alarms

Grounding protection systems are used to ensure that tanks, especially large storage tanks, are grounded properly to avoid the accumulation of static electricity, which can cause sparking and ignition in flammable environments.

Audible Alarm for Grounding Protection:

  • Purpose: Alerts operators when there is a failure or interruption in the grounding system.
  • Type of Signal: Typically a continuous or intermittent sound, such as a siren or buzzer, that increases in volume to capture attention.
  • Triggering Event: The alarm is activated when the grounding system is either disconnected or unable to perform as intended. This could occur due to cable breakage, corrosion, or disconnection.
  • Safety Implications: Immediate response is needed to either correct the grounding issue or stop operations to prevent static discharge hazards.

Visible Alarm for Grounding Protection:

  • Purpose: Provides a clear visual indication of a grounding issue, so that operators can identify problems quickly even if they are not in close proximity to the tank.
  • Type of Signal: A flashing light (often red) or a series of indicator lights (e.g., green for “safe,” yellow for “warning,” and red for “alarm”).
  • Triggering Event: The light or visual signal is activated when the grounding system is compromised or fails.
  • Location: These lights are often placed on the tank or on the control panel, and are clearly visible from a distance.
  • Safety Implications: Helps personnel identify grounding issues from a distance, allowing them to take corrective actions before static electricity poses a significant risk.

2. Overfill Protection Alarms

Overfill protection systems are designed to prevent tank overfills, which can lead to spills, fire hazards, and environmental contamination. These systems often include sensors that detect the level of the liquid in the tank, and alarms that alert operators when the tank reaches a certain level.

Audible Alarm for Overfill Protection:

  • Purpose: Warns operators when a tank is nearing its capacity, alerting them to take action before an overfill occurs.
  • Type of Signal: Commonly a loud, continuous alarm such as a siren, bell, or horn that immediately draws attention to the overfill situation.
  • Triggering Event: The alarm is activated when a high-level sensor detects that the tank is reaching its maximum safe capacity (typically 90% or 95% of the tank’s total volume).
  • Safety Implications: The alarm gives operators time to stop the filling process or to adjust the flow to prevent an overfill, which could lead to leaks, spills, or even catastrophic tank failure.

Visible Alarm for Overfill Protection:

  • Purpose: Provides a visual alert that a tank is approaching or has exceeded its fill level.
  • Type of Signal: Visual indicators include flashing lights, such as red or amber lights, and digital displays that show the tank’s liquid level or the alarm status.
  • Triggering Event: Similar to the audible alarm, the visible signal is activated when the tank reaches a predetermined high-level point.
  • Location: The visible alarm may be mounted on the tank itself, at the filling station, or on the central control panel, so operators can observe the status of all tanks from a central location.
  • Safety Implications: The visible indicator allows operators to quickly see which tanks are near overfill status, particularly in large facilities where multiple tanks are being filled simultaneously.

3. Integration of Audible and Visible Alarms

For both grounding and overfill protection systems, combining audible and visible alarms ensures that the alert is both heard and seen, which is essential in large, noisy environments (like oil refineries, chemical plants, or storage terminals) where communication or sound alone might be missed.

Alarm Synchronization:

  • In many modern systems, both the audible and visible alarms are synchronized, triggering simultaneously for maximum effectiveness.
  • Some systems may also have different alarms for different levels of urgency, such as:
    • Warning Level: A lower-pitched tone or amber flashing light when the system is approaching a critical condition (e.g., nearing the fill limit or a minor grounding issue).
    • Critical Level: A higher-pitched or continuous alarm with a red flashing light for immediate action, such as an overfill situation or grounding failure.

Centralized Control System:

  • The alarms are often connected to a centralized control panel, where operators can monitor multiple tanks at once. This control system provides clear indicators of which tank has triggered an alarm and allows for quick intervention.
  • Advanced systems may have remote monitoring capabilities, allowing operators to receive notifications on mobile devices or computers if an alarm goes off, even if they are not physically present at the site.

4. Maintenance and Testing of Alarms

Regular testing and maintenance of both audible and visible alarms are crucial to ensure they are functioning correctly. Some systems may have built-in self-diagnostics that alert operators to any issues with the alarm or grounding/overfill protection systems.

  • Routine Testing: Periodic tests should be conducted to check the sound levels of audible alarms and the clarity and intensity of visible alarms.
  • Maintenance: Ensuring that the alarm equipment, such as sirens, flashing lights, and sensors, is in good working condition and not subject to environmental degradation (like corrosion or wear).
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LNG tank gauging system consists of the primary and secondary level gauges

The LNG tank gauging system typically consists of both primary and secondary level gauges, which work together to provide accurate and reliable measurements of the liquid level in LNG (Liquefied Natural Gas) storage tanks. These systems are critical for ensuring safety, inventory management, and compliance with industry standards, particularly in facilities where precise monitoring of cryogenic liquid levels is necessary.

Here’s how the primary and secondary level gauges function in an LNG tank gauging system:

Primary Level Gauge (PLG)

The primary level gauge is the main device used to measure the level of LNG within the storage tank. It typically uses technologies such as guided wave radar or differential pressure transducers for accurate level detection.

Guided Wave Radar (GWR):

  • Principle: Sends radar waves along a probe that is immersed in the LNG. The wave is reflected back from the surface of the LNG, and the time taken for this reflection is used to calculate the liquid level.
  • Advantages: Provides continuous level measurement with high accuracy. It’s particularly well-suited for cryogenic temperatures in LNG tanks.
  • Common Applications: Used in high-precision systems where level measurements need to be accurate for inventory management, custody transfer, and safety purposes.

Differential Pressure (DP) Transmitters:

  • Principle: Measures the difference in pressure between the top and bottom of the tank. The level of the LNG can be inferred from the pressure difference.
  • Advantages: Reliable and well-established method for measuring liquid levels in large tanks, including cryogenic storage tanks.
  • Common Applications: Often used for level measurement in bulk liquid storage tanks, including LNG, due to its proven accuracy and long-term reliability.

Secondary Level Gauge (SLG)

The secondary level gauge is an auxiliary system used to verify the readings provided by the primary gauge. It serves as a backup to ensure the accuracy and reliability of the primary measurement.

Common Technologies Used in Secondary Level Gauging:

Float-and-Tape Systems:

  • Principle: A float is placed on the surface of the LNG, and the movement of the float is measured by a tape or other mechanical device.
  • Advantages: Provides a redundant level measurement to cross-check the readings of the primary gauge. While it is less common in modern systems, it is still used in some LNG applications.

Capacitance Probes:

  • Principle: Measures changes in capacitance between electrodes to detect the liquid level.
  • Advantages: Suitable for verifying the accuracy of the primary gauge in some systems, especially in more straightforward storage tank setups.

Ultrasonic or Radar-Based Secondary Measurement:

  • Principle: Similar to the primary level gauge, but used for additional verification.
  • Advantages: These sensors can be installed at different points or angles in the tank, allowing for further redundancy and reliability in the gauging system.

Conclusion:

The combination of primary and secondary level gauges in an LNG tank gauging system ensures high levels of accuracy, safety, and reliability. Both systems work together to monitor the LNG levels in the tank, detect any discrepancies, and ensure regulatory compliance. The primary gauge provides continuous, real-time measurements, while the secondary gauge acts as a backup to verify the readings and safeguard against failures.