August 30, 2017

Importance of level measurement system in bulk material handling industry

Level Measurement SystemIn a plant, to assure the safety and profitability of processes, it is essential that plant is equipped with reliable and precise level measurement system.

Basically, level measurement is simply about determining the position of a surface inside a tank, reactor or another vessel.

Level measurement is the determination of the linear vertical distance between a reference point that is the base of a holding container and the surface of the material in the holding container.

Accurate control of the level of material in a tank, reactor, or other vessel is important in many process applications especially, in bulk material handling industry.

One of the main purposes of the level measurement system is to measure inventory. In order to achieve good control, accurate measurement is a must. ( In our previous blog we have referred to the problems encountered when the continuous level of col is not maintained in the bunker causing disruption in electricity generation.)

All the level measurement system involves interaction between a sensing device, element, or system and a product inside the holding container.

Why measuring level is so crucial?


The main reason for measuring level is to keep track of inventory in terms of volume or weight. There is an increase in the demand in the industry for control of inventory. Level measurement is one key component in a tank gauging system for reliable and accurate inventory control.

The other measures for inventory control are temperature, pressure and water level. Having efficient control on your inventory is of high importance. Not only for operators using the content in a storage vessel but for the whole company, including company executives, accounting, loss and leakage control managers and others. This is a result of increased focus on safety, cost of ownership and the value of products stored.

Process efficiency

Accurate level measurement increases efficiency. Suppose if a tank farm needs to keep a certain amount of material on hand at all times and the storage tanks are not filled to full capacity, the facility will incur the unnecessary expense of purchasing and maintaining additional storage vessels. Efficient use of storage space prevents the extra cost of needlessly acquiring more storage vessels.


The level is also measured for safety reasons. If a vessel is filled above its capacity, it may cause safety hazards by spills (overflowing) in open vessels. Supposedly if the material in the container is caustic, reactive, hot, flammable, or hazardous materials, spills or overpressure may cause catastrophic results. Monitoring levels in tanks to make sure they are not leaking is also important for the same types of hazardous materials. Preventing overfills and leak detection is also important for meeting environmental regulations.

Consistent supply

Many processes require a steady supply of inputs and outputs. A consistent supply may be difficult to maintain if the supply is delivered at varying rates or if there are surges in the supply line. A storage vessel between the supply and the process can act as a buffer to ensure that outflow is kept steady despite fluctuating inflow. If the process level in the storage vessel is always maintained within an appropriate range, the supply delivery rate to the storage vessel can rise and fall without affecting the supply delivery rate from the storage vessel to the process. Consistent supply is directly related to product quality in coal, pulp, and paper industries.

AAG Engineering Technologies offers bunker level measurement system that records the bunker level continuously and convert the level difference in mass (Tons/Kgs) by means of press-fit type special and unique strain gauge sensor and compression type gauge. These sensors are filled on to the support structure of bunker and can operate without any concern of failure and maintenance.

If you wish to maintain a constant level of inventory in your plant contact AAG Engineering at

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