Innovative Explosion-Proof Design with Smart Display: New Hydraulic Level Sensor Enhances Safety in Petrochemical Production

Enables Remote Precision Monitoring and Early Warning, Solving Liquid Level Measurement Challenges in High-Risk Environments

I. Industry Background and Pain Points

In industries such as petrochemicals and oil field extraction, hydraulic level monitoring is a critical aspect of ensuring production safety. Traditional level gauges often face challenges in explosive, high-temperature, and corrosive environments, including inadequate explosion-proof performance, non-intuitive data, and frequent maintenance. For example:

• The Jimsar Shale Oil Market in Xinjiang once experienced delayed warnings and increased equipment failure risks due to insufficient explosion-proof performance of level monitoring instruments;
• In scenarios such as liquid ammonia storage tanks, where media are highly toxic and explosive, level gauges require extremely high sealing and explosion-proof ratings.

II. Innovative Solution: Integration of Explosion-Proof Housing and Smart Display

To address these pain points, a company has launched a new generation of explosion-proof hydraulic level sensors with integrated displays, combining hardware upgrades and intelligent design to achieve three major breakthroughs:

1. Intrinsically Safe Explosion-Proof Design
   • The housing complies with the Ex d IIB T4 explosion-proof standard (referencing the UQK-71 series level control instrument standard), with a flameproof structure that suppresses the spread of internal arcs and sparks;
   • Utilizes glass sealing technology (as seen in the VEGAFLEX 81 application in liquid ammonia tanks) to prevent toxic media penetration and ensure long-term stability.
2. High-Brightness Display and Real-Time Data Visualization
   • Integrated LCD screen directly displays liquid level height, temperature, and pressure data, replacing the complex structure of traditional external display meters;
   • Supports local viewing + remote transmission, with data uploaded to central control systems via 4-20mA signals or wireless modules (as seen in PetroChina’s patented wireless communication design).
3. Smart Alerts and Enhanced Durability
   • Mimics the two-stage audio-visual alarm mechanism of the DML level monitoring instrument, improving warning speed by 90%;
   • The sensor employs 316L stainless steel material (similar to the AF3051 transmitter), offering corrosion resistance and impact resistance, suitable for extreme environments ranging from -40°C to 85°C.

III. Application Case: Successful Implementation in an Oil Field Scenario

In a hydraulic oil tank monitoring project at an oil field in Xinjiang, this level gauge demonstrated significant advantages:

• Safety and Efficiency: Eliminated the need for manual tank inspections, reducing exposure to hydrogen sulfide leakage risks and cutting manual inspection workload by 80%;
• Precision Control: Liquid level measurement error ≤ ±0.5%, overcoming foam interference through guided wave radar principles;
• Cost Optimization: Maintenance cycles extended to over 3 years, reducing replacement costs by 70% compared to traditional equipment.

IV. Industry Value and Future Prospects

1. Driving Intelligent Transformation: Integration of level gauges with DCS/SIS systems helps oil depots and chemical plants build digital monitoring networks;
2. Standard Leadership: Compliance with SIL2 safety and GB3836 explosion-proof national standards provides a high-reliability benchmark for the industry;
3. Scenario Expansion: Future adaptability to complex working conditions such as offshore drilling platforms and high-temperature reaction kettles in grease chemical plants (referencing VEGAFLEX 86′s application in 250°C distillation kettles).

Conclusion

The integration of explosion-proof housing and smart display marks the evolution of hydraulic level gauges from “functional tools” to “safety partners.” As Industry 4.0 advances, such innovative products will continue to provide core momentum for the safe, efficient, and low-carbon operation of high-risk industries.

We can also provide a variety of solutions for

1. Handheld meter for multi-parameter water quality

2. Floating Buoy system for multi-parameter water quality

3. Automatic cleaning brush for multi-parameter water sensor

4. Complete set of servers and software wireless module, supports RS485 GPRS /4g/WIFI/LORA/LORAWAN

For more sensors information,

please contact Honde Technology Co., LTD.

Email: info@hondetech.com

Company website: www.hondetechco.com

Tel: +86-15210548582