The practical application of 80G Hz radar level gauge in lubricating oil industry

The practical application of 80G Hz radar level gauge in lubricating oil industry

As a high-frequency microwave measuring equipment, 80GHz radar level meter is widely used in the material measurement scenarios of lubricating oil industry due to its advantages such as high precision and strong anti-interference. The following explains the technical characteristics, practical application scenarios, advantages and matters needing attention:

I. Technical characteristics of 80GHz radar level gauge:

Working principle: Based on FMCW (Frequency Modulated Continuous Wave) technology, it emits 80GHz high-frequency microwaves. By measuring the time or frequency difference between the microwave's emission and its return to the receiver after encountering the material surface, the liquid level height of the material is calculated. The high-frequency signal has a shorter wavelength (approximately 3.75mm), concentrated energy, strong penetration, and is less affected by dust, steam, and medium characteristics.

High precision: The measurement accuracy can reach ±1mm, which is suitable for accurate measurement in lubricating oil production. Anti-interference: It is not affected by temperature (-40℃~150℃), pressure (-0.1MPa~4MPa), medium viscosity (up to 100,000cSt) and volatile gas.

, Easy to install: support top installation, antenna size is small (such as the diameter of the horn is less than 100mm), suitable for narrow space.

, Safety explosion-proof: in line with ATEX, IECEx and other explosion-proof certification,

Raw material storage tank level monitoring: Application scenario: Real-time level measurement of basic oil and additive (such as viscosity index improvers, anti-wear agents) storage tanks. Technical value: Basic oil has high viscosity and is prone to adhesion, making traditional level gauges (like magnetic flip boards) susceptible to interference from adhered materials. 80GHz radar, with its high-frequency signals that penetrate the surface of the medium, is not affected by adhered materials. Additive storage tanks are typically small-volume containers, and the millimeter-level accuracy of high-frequency radar enables precise control of trace amounts of raw materials.

Level Control of Blending Vessel: Application Scenario: During the blending process of lubricating oil, this system monitors and controls the dynamic level of the raw material in the reactor. Technical Value: The temperature during the blending process can reach 80 to 120℃. Steam or volatile gases can interfere with ultrasonic level meters, but the 80GHz radar is unaffected by aerosols, ensuring stable level data. It supports integration with DCS systems, providing real-time feedback on level data. When used with a metering pump, it ensures precise addition ratios (with an error of no more than 0.5%).

Finished tank area inventory management: Application scenario: Batch inventory measurement and inventory counting for finished oil tanks, such as gear oil and hydraulic oil. Technical value: High-frequency radar can penetrate the oil and gas layers inside the tanks, unaffected by volatile gases, with a measurement error of ±3mm or less, meeting trade settlement-level measurement requirements. It supports multi-tank network monitoring, transmitting data via 4G/5G or optical fiber, enabling unmanned tank area management (such as remote alarms and automatic refilling).

Waste hazardous material processing: Application scenario: Monitoring the liquid level in waste lubricating oil recovery tanks (where the oil contains impurities and foam). Technical value: The narrow beam angle of the 80GHz radar (<=3℃) can avoid obstacles such as agitators and pipes inside the tank, focusing on the material surface to reduce false echoes. Non-contact measurement prevents direct contact between the sensor and corrosive waste oil, extending the equipment's lifespan (maintenance cycle of at least 12 months).

	80GHz, radar level meter
	±1~3mm	± 1~5mm (affected by aerosol)	±3~5mm	±5~10mm
anti-hazard classification	Ex d IIC T6 Gb	Some models support explosion-proof	Support explosion-proof

Installation Points: Avoid Interference Sources: Keep at least 300mm away from the tank's agitator and heating coils to prevent microwave reflection interference. Antenna Selection: Given the characteristics of lubricating oil, PTFE or stainless steel horn antennas (with a temperature resistance of 150℃ and corrosion resistance) are recommended. Explosion-proof Certification: The tank area is classified as a Zone 2 hazardous location, requiring the use of equipment with Ex nA or Ex d explosion-proof ratings.

Calibration and maintenance: Regular calibration: manually compare and calibrate the tank side magnetic flip board level gauge every quarter (no adjustment is required when the error is less than 5mm). Anti-material hanging treatment: For high viscosity lubricating oil storage tanks, the antenna surface can be regularly blown with compressed air (blow pressure is less than 0.2MPa).

Data integration- **Communication protocol**: Supports Modbus RTU/ASCII, HART 7.0, and can be connected to the factory SCADA system to realize liquid level data visualization (such as trend curve, alarm threshold setting).

5. Typical Case: A lubricating oil factory installed a DN80 flange-type 80GHz radar level gauge. This radar features a 3℃ narrow beam angle and high-frequency signals, providing strong penetration capabilities. Even in a lubricating oil tank with numerous heating coils, the 3℃ beam angle radar can penetrate the coils to detect the signal at the bottom of the tank.