Customize magnetic flap level gauges with special widths!

Project Background 

In December 2025, our company received a special request from a large domestic chemical enterprise. The newly-built chemical raw material storage tank of this enterprise has a diameter of 12 meters and a height of 18 meters, which is a rare large-scale storage tank in the industry. The traditional magnetic flap level gauge could not meet its requirement for an extremely wide viewing range. The customer needed to be able to clearly observe the liquid level changes throughout the entire height range on one side of the tank. 

Customer challenge 

1. Visual range requirement: It is necessary to display the full range of liquid level from 0 to 18 meters at one time, while the maximum height of the standard magnetic level gauge is only 4 meters.
2. Installation limitation: The storage tank has been basically constructed and the structure cannot be changed to install multiple segmented level gauges.
3. Accuracy requirement: The measurement error should be controlled within ±5mm to ensure the accuracy of raw material ratio.
4. Environmental adaptability: The medium is corrosive chemical raw materials, and the working temperature ranges from -20℃ to 80℃.
5. Safety standard: It needs to meet explosion-proof requirements (Ex d IIC T6). 

Customized solution 

Technical solution design 

After 15 days of research and design by our technical team, we have proposed an innovative solution: 

Modular segmented design

- The 18-meter liquid level gauge is divided into 4 independent modules: 0-4.5m, 4.5-9m, 9-13.5m, 13.5-18m
- Each module is independently sealed and can be maintained separately
- Special connection technology is adopted between the modules to ensure overall accuracy 

2. Ultra-wide Panel Design- The total width of the panel reaches 600mm, which is 2.5 times wider than that of traditional products
- The liquid level can still be clearly identified from a distance of 50 meters 

3. Application of Special Materials
- Main material: SUS316L stainless steel with PTFE coating
- Flip plate material: Special engineering plastic with fluorescent material added
- Sealing material: Perfluoroether rubber, corrosion resistance increased by 300% 

Production and manufacturing breakthrough 

1. Special production line renovation
- Customized 18-meter long linear guide rail assembly platform
- Developed a verticality calibration system with an accuracy of 0.01mm/m
- Established segmented pressure testing equipment 

2. Quality Control Innovation
- Set calibration points every 0.5 meters, with a total of 36 calibration positions
- Conduct over 100 full-stroke simulation tests
- Perform extreme temperature tests before obtaining explosion-proof certification 

Project implementation 

Timeline
- Days 1-15: Requirement analysis and scheme design
- Days 16-45: Prototype manufacturing and testing
- Days 46-50: Customer on-site verification
- Days 51-70: Batch production (2 units in total)
- Days 71-75: On-site installation and commissioning
- Days 76-80: Operational training and delivery 

Installation Innovation

To address the installation challenges of ultra-long level gauges, we have developed:
- Three-point suspended installation brackets to reduce the impact of thermal expansion and contraction
- Laser alignment system to ensure the straightness of the four modules
- Design of a high-altitude safety operation platform 

Results and Value 

Technical indicators achieved
| Parameter | Customer Requirements | Actual Achievement | |------|---------|---------|
| Measurement Range | 0 - 18m | 0 - 18m |
| Visual Distance | > 40m | 55m clear visibility |
| Measurement Error | ±5mm | ±3mm |
| Temperature Range | -20 to 80℃ | -30 to 120℃ |
| Explosion-proof Grade | Ex d IIC T6 | Ex d IIC T6 | 

Customer value creation 

1. Safety Benefits
- Avoids the risk of misinterpretation that may arise from segmented measurements
- Explosion-proof design has passed the highest-level certification
- Reduces the number of manual tank inspections by 80%, thereby lowering the risk of high-altitude operations by 80% 

2. Operational Efficiency
- The control room enables direct observation of the on-site liquid level, reducing the inspection time.
- The improvement in accuracy leads to a 2.3% increase in raw material utilization.
- Annual potential loss savings amount to approximately 1.8 million yuan. 

3. Maintenance Costs
- The modular design reduces maintenance time by 60%
- A single module failure does not affect the overall usage
- The estimated annual maintenance cost is expected to decrease by 45% 

Customer feedback 

"This is the first time we have achieved full-range intuitive display on such a large storage tank. This customized liquid level gauge not only solved our monitoring problems, but its ultra-wide viewing design has also become the highlight of our factory. It has been visited and inspected by customers from the same industry on multiple occasions. Since the product has been in operation for 8 months, its stability has exceeded our expectations." 

-- Mr. Zhang, the Project Director of the Client 

Project Insights 

1. Customized value: Special needs are not obstacles but opportunities for innovation.
2. The significance of collaborative R&D: The success of this project is attributed to the deep collaboration with the customer's technical team.
3. Transformation of technical accumulation: Our company's long-term accumulation in magnetic flap technology has been fully applied in this extraordinary product.

Conclusion

The successful customization of this ultra-wide magnetic flap level gauge not only solved a specific technical problem, but also opened up a new way of thinking for liquid level monitoring in large storage tanks. This case has applied for 3 patents and has become a benchmark project for our company in the field of special level gauges. We believe that true technological innovation comes from a deep understanding of customer needs and an uncompromising pursuit of technology. 

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This case demonstrates the entire process from requirement analysis to product delivery, highlighting the professional value of customized industrial instruments. Our company will continue to strive to provide precise and reliable liquid level measurement solutions for various industries.