Plant operators need to continuously measure bulk material levels/weight to make sure their processes are running safely, efficiently and without any bottlenecks. Measuring these levels allows operators to automate vessel filling/emptying logistics or verify that a process is using the right amount of material.
How do you measure bulk material levels/weights in silos and hoppers?
There are a variety of bulk material level/weight monitoring sensors in the market. These sensors include distance measuring devices like laser, ultrasonic, and radar; or weight measuring devices like load cells and strain gauges. Our engineers prefer to implement strain gauge based solutions because they are very accurate and do not require structural modification.
For these solutions, our engineers identify the silo/hopper load paths and our technicians install strain gauges at these locations. By calibrating the strain gauge sensors to load and summing the load data for all load paths, we can accurately measure the total weight of the bulk material.
A typical silo monitoring system consists of weatherproofed strain gauges for each silo leg and a National Instruments (NI) CompactRIO embedded controller for inputs, calibration, and outputs housed in a stainless steel enclosure.
video link: https://youtu.be/TwVtDYLkFKs.