Customized Level Control Solution Tailored for Large Storage Tank Applications
In industrial production processes, liquid level management for large-capacity storage tanks requires not only accurate level monitoring but also long-term stability under complex operating conditions, corrosive environments, and continuous operation.
A customer required a reliable liquid level monitoring and control solution for a 15-ton liquid storage tank. The system needed to achieve four independent level control points, including real-time level display, alarm functions, and automatic control.
After a detailed evaluation of the customer’s tank structure, installation requirements, liquid characteristics, and operating environment, the ELECALL technical team selected the EFLT-2 RS485 Digital Float Level Transmitter with 4–20mA Output as the optimal solution.
Unlike conventional level switches that only provide point-level detection, the EFLT-2 enables continuous liquid level measurement and transmits accurate level data through industrial standard signals, allowing seamless integration with PLCs and control systems for intelligent level management.
Precisely Matched with the Customer’s 15-Ton Storage Tank Structure
Based on the customer’s actual tank parameters:
- Total tank height: 3.5 m
- Effective vertical height: 2.95 m
- Tank diameter: 2.53 m
- Tank opening diameter: 65 cm
ELECALL customized the EFLT-2 according to the customer’s specific installation conditions.
Since the tank height was relatively large, a standard-length level transmitter could not fully cover the required measuring range. Therefore, ELECALL provided a customized design including:
- Customized probe rod length: 2.65 m
- Probe rod diameter: Φ14 mm
- Installation method: Flange-mounted insertion installation
- Connection flange: DN50 flange
The customized EFLT-2 effectively covers the entire liquid level range inside the tank while ensuring secure installation through flange mounting, making future maintenance more convenient.
This customized approach ensures that the level transmitter perfectly matches the customer’s tank structure and avoids common issues such as insufficient measuring range, installation limitations, or unstable operation caused by improper product selection.
316 Stainless Steel Construction Ensures Long-Term Reliability in Harsh Environments
Considering that the equipment would operate continuously in an industrial environment with potential exposure to corrosive liquids, humidity, and demanding operating conditions, ELECALL enhanced the liquid-contact components of this project by adopting a SUS316 stainless steel structure combined with PTFE (polytetrafluoroethylene) anti-corrosion coating.
Compared with conventional materials, 316 stainless steel provides excellent durability and corrosion resistance, including:
- Excellent resistance to chemical corrosion
- Strong oxidation resistance
- Good high-temperature performance
- Long-term stability in continuous liquid contact environments
In addition, the PTFE protective coating creates an additional corrosion-resistant barrier on the surface of the liquid-contact components, further improving resistance against acids, alkalis, chemicals, and other aggressive media.
The PTFE coating provides additional advantages:
- Superior chemical resistance for harsh liquid environments
- Excellent non-stick properties, reducing liquid residue and impurity adhesion
- Improved wear resistance for long-term operation
- Enhanced protection of metal components against corrosion and degradation
Even under harsh industrial conditions involving corrosive media, high humidity, or continuous operation, the SUS316 stainless steel structure combined with PTFE anti-corrosion protection maintains stable performance, effectively reducing corrosion-related failures and extending the service life of the level transmitter.
For large storage tank applications, the reliability of liquid-contact materials directly determines equipment lifespan, maintenance requirements, and overall operating costs. By adopting a 316 stainless steel + PTFE composite protection design, ELECALL provides customers with a safer, more durable, and long-lasting level measurement solution, ensuring reliable operation even in challenging industrial environments.
From Level Measurement to Automatic Control — Meeting Comprehensive Application Requirements
The customer required more than simple level alarm detection. The project needed to achieve:
- Real-time liquid level display
- Multi-point level control
- 高レベルおよび低レベル警報
- Automatic control linkage
- Remote data monitoring
The EFLT-2 adopts a reliable float-type level measurement principle. As the liquid level changes, the float moves accordingly, and the displacement is converted into an accurate level signal.
The transmitter supports multiple output options:
- 4～20mAアナログ出力
- RS485 digital communication
- 1–5V output
- 2–10V output
These output options allow easy connection with PLCs, DCS systems, and other industrial control platforms for intelligent tank management.
The 4–20mA output provides excellent transmission distance and strong interference resistance, making it ideal for industrial environments. The RS485 communication interface enables centralized monitoring and data management for future system upgrades.
High-Accuracy Measurement Meets the Requirements of a 2.95m Tank
For a storage tank with an effective liquid height of nearly 3 meters, measurement accuracy is critical for stable operation.
The EFLT-2 provides:
- Standard accuracy: ±2 cm
- Optional accuracy: ±1 cm
This allows precise detection of liquid level changes and fully meets the customer’s requirement for four independent level control points.
By configuring different level positions, the system can achieve:
- Low-level refill reminders
- Intermediate level monitoring
- High-level alarms
- Full-level protection
This helps prevent pump dry running caused by insufficient liquid levels while reducing overflow risks caused by excessive filling.
Industrial-Grade Design for Long-Term Continuous Operation
To meet the customer’s requirements for reliable long-term operation, the EFLT-2 features a rugged industrial design.
Precision Integrated Welding Structure
The product adopts advanced integrated welding technology:
- Reduces connection points
- Improves overall sealing performance
- Prevents liquid leakage effectively
This ensures reliable operation even in long-term submerged working conditions.
Durable Housing Design
The transmitter features an aluminum alloy spray-coated junction box with high-temperature treatment and multiple polishing processes:
- Excellent wear resistance
- Anti-aging performance
- 耐腐食性
- Stable appearance over long-term use
The sealed electrical interface and ABS engineering plastic protection housing effectively protect internal electronic components from moisture, dust, and external environmental impact.
Project Solution Highlights
For this 15-ton liquid storage tank project, ELECALL EFLT-2 was not simply a standard level measurement product. Instead, ELECALL developed a customized liquid level monitoring and control solution based on the customer’s actual tank dimensions, installation requirements, and operating conditions.
Through customized structural design, corrosion-resistant materials, and flexible signal configurations, the EFLT-2 achieved excellent compatibility with the customer’s application, providing reliable level measurement, stable signal transmission, and long-term operation performance.
Key Advantages of This Customized Solution:
Customized 2.65m probe rod designed for the 2.95m tank height, ensuring complete liquid level coverage
DN50 flange installation matched the customer’s 65cm tank opening, providing secure and stable mounting
Four level control points enabled real-time monitoring, alarm functions, and automatic control
SUS316 stainless steel liquid-contact components combined with PTFE anti-corrosion coating provided excellent corrosion resistance for harsh environments
4–20mA and RS485 output options enabled seamless integration with PLC, DCS, and industrial control systems
±2cm high measurement accuracy ensured precise liquid level management for large storage tanks
Customer Requirements & ELECALL Customized Solutions
| Customer Requirements | ELECALL Customized Solution |
|---|---|
| Nearly 3-meter liquid level measurement range | Customized 2.65m probe rod to achieve accurate level detection coverage |
| Long-term operation in large storage tanks | SUS316 stainless steel liquid-contact structure with PTFE anti-corrosion protection for enhanced durability |
| Secure and stable installation required | DN50 flange connection for reliable mounting and convenient maintenance |
| Accurate liquid level feedback required | Continuous level measurement based on float technology |
| Need for automatic control integration | Supports 4–20mA analog output and RS485 digital communication |
| Need for on-site level monitoring | Real-time digital LCD display for clear and convenient viewing |
ELECALL EFLT-2: A Reliable Liquid Level Control Solution for Industrial Storage Tanks
Through customized structural design, upgraded material selection, and flexible signal configuration, ELECALL EFLT-2 Digital Float Level Transmitter successfully solved key challenges in large storage tank applications, including installation compatibility, signal stability, and long-term durability.
From analyzing tank dimensions to customizing product specifications and optimizing field installation, ELECALL focuses on actual customer operating conditions to provide accurate, reliable, and durable liquid level control solutions for industrial applications.
Contact ELECALL for Your Customized Level Control Solution
Every industrial project has unique application requirements. With professional customization capabilities, advanced manufacturing technology, and extensive experience in liquid level measurement, ELECALL provides accurate, stable, and reliable level control solutions tailored to different operating conditions.
Whether your project requires customized probe lengths, special material selection, flange connections, or specific output signal configurations, the ELECALL technical team can design the most suitable solution based on your actual application needs.
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