A major gas processing plant faced operational inefficiencies due to the need for manual level measurement in their sewage water drain collection pit. The plant required personnel to manually check the pit level and then, depending on the present level in the pit, call a collecting vehicle to drain the sump, leading to delays, inefficiencies, and safety concerns. To enhance automation and remote monitoring, the customer sought a continuous, non-contact radar solution to eliminate human error and improve response time.
CHALLENGES
The plant’s existing manual level measurement procedure presented multiple operational and safety challenges:
- Time-Consuming & Inefficient: Manual level checks delayed response time.
- Human Dependency: Staff had to physically monitor the sump, increasing workload.
- Safety Risks: Direct human involvement in a sewage water environment posed safety hazards.
- Need for Remote Monitoring: The customer wanted an automated solution to monitor the sump level in real-time.
APPLICATION DETAILS
The plant initially requested a Guided Wave Radar (GWR) solution. However, due to the nature of this often debris filled sewage application, a Non-Contact Radar (NCR) technology was recommended.
No previous competitive equipment was considered for replacement.
SOLUTION
Following a thorough assessment, we recommended:
- Non-Contact Radar (NCR) Technology: The 80 GHz Model R80 is suitable for sewage applications, as they:
- Eliminate physical sensor contact with sewage, reducing maintenance.
- Ensure accurate level readings without interference from sludge or debris.
- Provide remote monitoring capabilities, reducing human intervention.
- Full Automation: Enabling real-time level monitoring and automatic scheduling of sump drainage.
RESULTS & BENEFITS
The implementation resulted in significant operational improvements:
- Eliminated manual monitoring, freeing up personnel for more critical tasks.
- Improved safety by reducing human exposure to sewage water.
- Increased efficiency through realtime monitoring and automated drainage scheduling.
- Significant time savings, minimizing delays in sump draining.
Business Impact
- Reduced manual labor costs associated with monitoring.
- Lowered operational risks, ensuring a safer work environment.
- Enhanced uptime and reliability by eliminating measurement inconsistencies.
CONCLUSION
Automating sewage sump level monitoring significantly improved safety and efficiency. Successful implementation of the Model R80 opened the door for potential expansion of similar automation in other areas of the plant. Looking to automate and optimize level measurement in industrial wastewater applications?
Contact us today to explore how our Non Contact Radar solutions can improve your operations. With this success, the plant is now evaluating additional automation opportunities to further reduce manual monitoring