Enhancing Safety and Efficiency in Industrial Applications with Hazardous Area Approved Liquid Level Switches

Introduction

In various industries, the measurement and control of liquid levels are critical for ensuring safety, optimizing processes, and maintaining operational efficiency.   Adhering to strict safety regulations is essential in hazardous environments where flammable substances are present, such as oil refineries, chemical plants, water treatment and pharmaceutical facilities. 

In this blog, we will explore the significance of hazardous area-approved liquid level switches, the advantages they offer in enhancing safety and efficiency, and how PST's Liquid Level ATEX sensors are uniquely positioned to fulfill these critical needs. 

Understanding the Role of Liquid Level Switches in Hazardous Areas 

Precise monitoring and control of liquid levels become paramount in hazardous environments where explosive or flammable substances are prevalent. Liquid level switches play a pivotal role in this scenario, including:

Safety Control 

The primary role of liquid level switches in hazardous areas is to maintain levels of liquids. Flammable liquids can cause serious accidents if their levels are not properly monitored and controlled. Liquid level switches can automatically trigger safety measures when liquid levels exceed or drop below safe limits. For example, if a tank is nearing capacity, a switch can trigger an alarm or shut off the inflow to prevent overflow. If a level drops too low, it could indicate a leak, and the switch can trigger an alarm or shut down the system to prevent further leakage.

Process Control  

Liquid level switches help maintain operational efficiency by ensuring that the process variables stay within their desired range. In many industrial processes, the level of certain substances must be maintained within a specific range for the process to operate optimally. Liquid level switches help maintain these levels, triggering a response when levels deviate from the set range. 

Early Warning and Preventive Maintenance 

Liquid Level sensors can provide early warning indications of abnormal conditions, such as sudden changes in liquid levels or system malfunctions. This allows operators to take immediate corrective actions, preventing accidents, equipment failures, and production disruptions. The sensors also facilitate proactive maintenance by identifying potential issues before they escalate. Overfilling or underfilling tanks and vessels can damage them, causing costly repairs or replacements. Liquid level switches help protect these assets by maintaining levels within safe operating ranges. 

Regulatory Compliance 

In many jurisdictions, maintaining specific levels of hazardous substances and taking appropriate action if those levels are exceeded is not just good practice—it's the law. Liquid level switches help facilities stay compliant with these regulations, providing documentation that levels were maintained within the required limits. 

Hazardous Area Certification

Liquid level switches used in hazardous areas must be certified for safe operation in those environments. ATEX is a certification standard defined by the European Union to regulate equipment and protective sensors intended for use in potentially explosive atmospheres. It ensures that equipment used in such environments meets specific safety requirements and reduces the risk of ignition sources that could trigger an explosion. The ATEX directive classifies hazardous areas into zones, namely Zone 0, Zone 1, and Zone 2, depending on the probability and duration of the presence of explosive atmospheres.

PST Intrinsically Safe Liquid Level Switches are certified for use in Zone 0 environments: 

Group II Category 1 G Ex ia T4 Ga Ta -30 °C to +80 °C 

IECEx: Ex ia IIC T4 Ga Ta -30 °C to +80 °C 

Standards Used: IEC 60079-0:2017, IEC 60079-11:2011 

PST Intrinsically Safe Liquid Level Switches

Oil and Gas Industry:

 In oil refineries, petrochemical plants, and offshore platforms, liquid level sensors are used for measuring and controlling the levels of flammable substances, such as crude oil, gasoline, and liquefied natural gas (LNG). Accurate level monitoring helps prevent overfilling, leakage, and spillage, reducing the risk of fires and explosions.

Chemical Processing:

 In chemical manufacturing facilities, liquid level sensors ensure the safe handling and storage of volatile substances. They continuously monitor liquid levels in storage tanks, reactors, and pipelines, preventing potential hazards associated with improper liquid levels. 

Pharmaceutical and Biotechnology:

 liquid level sensors play a crucial role in pharmaceutical and biotechnology industries, where precise control of liquid levels is essential for the production of drugs and vaccines. These sensors help maintain the integrity of critical processes and prevent contamination risks. 

Food and Beverage Industry:

In environments where potentially explosive substances, such as alcohol or flammable gases, are present during food and beverage production, liquid level sensors ensure the safe handling and storage of liquids, such as ethanol, spirits, and other volatile ingredients. 

Water treatment:

In waste water treatment and processing plants hazardous area liquid level switches are used to control liquid levels in areas where combustible gases may occur in sufficient levels to produce an explosion or fire.

PST Liquid Level ATEX Solution 

PST Liquid Level ATEX sensors are indispensable in industries where explosive atmospheres pose significant safety risks. By providing accurate and real-time liquid level measurements, these sensors contribute to maintaining safe operations, preventing accidents, and ensuring compliance with regulatory standards. With their intrinsically safe design and advanced sensing technology, these sensors enhance safety and efficiency in hazardous environments, enabling industries to operate while prioritizing employee well-being and environmental protection confidently. PST also supplies ATEX-rated intrinsically safe barriers and cables.