Sensor Wire Break Monitoring in Multi-tank Systems

• When operating water storage tanks, continuous measurement is critical, but that can be interrupted by issues like a wire break.
• A universal transmitter can detect wire breakage and alert operators without disrupting level measurement capabilities.
• This set up, using a PR 4116, creates a reliable level measurement system that even calculates the total supply amongst multiple tanks.

In industries where multiple tanks store substances or solids, accurate level measurement is crucial for operational efficiency and safety.  Equally important is the ability to monitor and respond to a sensor wire break. This ensures consistent data integrity and system reliability. Operators can easily create a system configuration that achieves these objectives.

Level Measurement and Wire Break Case Study

In a case study, a system comprises three collection tanks, each featuring a PR electronics 4116 device for level measurement. The end user views only the total fill level of these containers. Doing this requires a seamless integration and summation of individual measurements. This configuration not only provides accurate data but also includes a failure identification mechanism for sensor wire break incidents only visible to the supplier.

Level Measurement

Each PR 4116 universal transmitter continuously measures the fill level in its tank, thus accurately determining the content volume. These measurements transmit to a PR 4184 signal transmitter, which combines the data from all three tanks to calculate the total fill level by summarizing and measuring the individual currents. This single measurement then transmits to the end user, providing a comprehensive overview of the total volume of the medium.

Wire Break Detection and Management

The system’s wire break detection and management capabilities makes it quite robust. When a 4116 transmitter detects a wire break, via a fault current of 0 mA, it triggers Relay 2. In turn, this relay sends an error message to the supplier’s control center, discreetly alerting maintenance personnel without alarming the end users. In case of a wire break error, the end users are thus presented with the minimum available medium volume. The PR 4116 is even suitable for use in systems up to Performance Level “d” according to ISO-13849.

Technical Configuration

The precision of the system lies in its technical configuration. PR 4116 universal transmitters are meticulously set to handle specific current ranges, thus ensuring that it measure the correct minimum values during sensor failures. This configuration guarantees that the end users always receive reliable data, without an effect from potential sensor issues.

Benefits of Safe Monitoring

This level measurement and sensor wire break monitoring system is versatile and also suitable for any sector that manages multiple storage tanks. It is especially valuable in industries that prioritize accuracy, reliability, and non-disruptive operations. The system’s ability to silently manage sensor issues while providing consistent data to the end users enhances operational trust and efficiency. 

This setup for measuring levels in systems with multiple tanks, which includes sensor wire break monitoring, demonstrates technical excellence. By ensuring accurate data collection and discreet handling of sensor issues, the system supports continuous operations. Additionally, it maintains the end users’ trust in data reliability, thus ensuring steady operational performance.