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It is very important in numerous
industrial procedures to regulate the quantity and temperature of the liquid
accurately. Of these, two important components that help such control are
provided by liquid level controller and immersion heaters. Understanding their
roles and different classification and uses will make a big difference in the
business operations, especially in the safety aspect.
What Is
a Liquid Level Controller?
A liquid level controller is an automated
system that helps the control of the amount of liquid in a vessel or a tank. Its
main usage is to keep a steady liquid level to avoid problem such as over flow,
damage to equipment or other adverse working conditions caused by low level. As
safety gadgets, low-level conditions are applied in electrical immersion
heaters used in processes to guarantee that the heaters are submerged into the
liquid to reduce overheating that might lead to fire outbreak.
Types
of Liquid Level Controllers
Process Technology offers various controllers
customized to different applications:
• LP Series
Liquid Level Control: Specifically
intended for fast and accurate control of most aqueous and waste treatment
processes in tanks, LP series also functions as leak detection and to safeguard
tanks against damage due to build up of low-level conditions that are fire
hazards. It comes in two models: LC2 which consists of dual probe units for
single point control and LC3 which consists of multi-probe units for two point
control, increase the accuracy and versatility in controlling liquid level.
• LC Series Control: These series afford automated commanding so that
liquid portions in aqueous processes and waste treatment tank could be
maintained stable. The equipment is used to detect leakage and also prevent
tanks and associated equipment from suffering from low level conditions. Furthermore,
it can control a valve to add liquid in a tank and as a result, it is suitable
for uses in different industries where there is need for refill of liquids.
What Is
an Immersion Heater?
Immersion heater is an electric
heating element that is submerged in the liquids in order to heat it. This type
of heater is famous to be used in industrial tanks, they are highly effective
for heating water, oils, solvents as well as corrosive solutions. They are
produced in different types of materials and designs to further compatibility
for the intended uses.
Types
of Immersion Heaters
Process Technology offers a range of
immersible heaters, including:
- Metal Heaters: Made up of stainless steel or titanium,
these heaters are for use where the medium remains in the liquid state
such as water or low corrosion environments.
- Fluoropolymer (PTFE) Heaters: Using PTFE sleeved elements, these
heaters register very high chemical compatibility and are suitable for use
in aggressive acids and just about any chemistry. For example the 3HX
Series PTFE immersion heater is produced for applications such as
anodizing, precious metal deposition, electrochemical deposition, water
treatment, and electropolishing.
- Screwplug and Flange Heaters: Mounted directly into tanks or vessels,
it is widely used in the industries for heating liquids with industrial
procedures.
The
Importance of Combining Liquid Level Controllers with Immersion Heaters
Integrating controllers with immersible
heaters is vital for several reasons:
- • Safety: Low liquid
level controllers do not allow heaters to work at low levels to
minimize overheating and dangers of burning. For example, the Protector 1
overtemperature control system provides thermal protection against
overheat conditions, as a heat-sensitive fuse is installed. Located within
a thermowell in contact with the heater sheath, the fuse is designed to
interrupt the power supply to the heater in the event of low liquid
conditions which could be destructive.
- Efficiency: Flashing control when implemented means
that the liquid levels of immersion heaters shall always be at their best
hence leading to constant heating and efficiency as well as saving on
energy.
- Equipment Longevity: Element burnout and decrease of
equipment lifespan are the negative consequences of heaters’ exposure to
air, which is eliminated with the help of proper controller.
Applications
in Industry
The combination of liquid level
controllers and immersion heaters is prevalent in various industries:
- Chemical Processing: Flame protection as well as averting
over-temperature conditions and exceeding the required boiling point of
the components.
- Water Treatment: It cools down dangerous water
temperatures for hot water uses while at the same time avoiding
overfilling of tanks or running heaters dry.
- Surface Finishing: Closely monitoring such things as
temperature of plating baths to give consistent production of quality
finishes, and checking a plating bath for proper solution level.
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Selecting
the Right Equipment
When choosing liquid level controllers
and immersion heaters, consider the following factors:
·
Chemical
Compatibility: These heaters
should be made of materials that will not react with the liquids you are using
in your process, so as to avoid cases of corrosion. For instance, PTFE heaters
display high resistance to rather corrosive agents, known as aggressive acids.
- Temperature Requirements: Choose heaters which will be capable of
reaching, let alone sustaining, temperatures required in your process.
- Tank Dimensions: Selection of heaters and controllers
should also be in correct sizes to make appropriate contact with the tank
and to heat uniformly.
- Control Precision: It is possible to use single point as
well as multi point controllers depending on how accurate the process
needs to be.
Installation
and Maintenance Tips
- • Proper Installation: Due to poor installation, heaters and
controllers can be a dangerous thing to handle, thus, the importance of
following the manufacturer’s instructions by installing heaters and
controllers accurately and ensure they have all safety devices. For
instance, electric immersion heaters need a thermal overtemperature device
as well as the need for an immersible heater to need liquid level control
to minimize fire risks.
- Regular Maintenance Maintenance
is to check periodically the equipment in use to see if it has developed
any signs of wear or corrosion or if some parts are accumulating dust and
dirt and then clean it as need be.
- Safety Checks: Check safety options such as
overtemperature protectors and liquid level sensors to see that they’re
working properly.
Conclusion
Understanding liquid level controller as well as immersion
heaters are critical controller machines in an industrial process as regard
safety, efficiency, and reliability. Thus, through proper selection of the
equipment, providers of services to your specific application, extending beyond
acquisition of appropriate equipment, UK based firms can extend this
recommendation through installation of the right types and kind of equipment
and by frequently servicing or maintaining the equipment to increase
performance.
Process Technology provides Industries with products like LP Series liquid
level controllers and immersible heater that guarantee reliability and
durability that is ideal for industries for example Chemical processing &
water treatment & Surface finishing industry. In addition to being critical
for enabling exact regulation these components also lends towards energy
economy and longevity of the equipment.
Read More: Is
Process Technology Your Go-To Brand for Inline Water Heaters Electric?