Level Sensing in Large Hot Wax Tank

Suggestion: weigh the tank; mount it on 3 weigh-cells.

TDR Radar level transmitter.

Maybe some self-limiting type of heat tracing around the existing sensor, if the configuration permits.

PWSLACK suggestion is THE best. You could use 3 or 4 load cells depending on structure. The only remark to be done is that this approach is good ONLY if wax specific weight is constant if your customer wants to know the level. If he used the level to determine the content then the solution offers the lowest uncertainty.

A local wax manufacturer uses top mounted Guided Wave Radar for process tanks with jacketed steam heat.

I sometimes think that some people tent to choose overly complex solutions for simple issues.

Think guillotine - think catch to hold the blade up, think handle and rope to release catch, to allow the blade to drop, and another rope and pulley to lift the blade backup.

I am assuming that the wax tank is to store hot wax for making candles, or patterns or for some other one way process...

What is wrong with basic technology like a float?

There is also two issues:

1. The known amount of wax being extracted from the tank, and

2. The level at which the tank needs to be refilled...

The easiest way to monitor this is the have a periodic check - based upon the regular consumption or extraction of wax from the tank - like a daily plant check at the start of each shift...

One can use a simple window or windows into the tank to see the max and minimum levels of the contents (like a dip stick) which goes well with the daily inspections.

And one can also have a basic float switch to automatically activate the refilling of the tank by dropping in blocks of wax from a conveyor or chute...

You can use one that is used in Glass Furnace. It is up/ down moving probe attached to 360' potentiometer, voltage value is recorded/ registered only when probe just touches wax (capacitance sensor). I worked on such level sensors and are very reliable.

If you are pleased with the performance of the ultrasonic system, I would find a way to either make it condensation proof or eliminate the root cause of the condensation problem(the condensate). If you switch to another measuring system (that may not work as well) you may find a similar failure mechanism.

KTEK makes a laser gage that would work great in this application. www.ktekcorp.com and look into the LM80 or SS140 if you need explosion proof environment.