In the chemical industry, precise level measurement is crucial for production safety and quality control. A chemical factory faced challenges with the level monitoring of its hydrochloric acid storage tank. Hydrochloric acid is highly corrosive and volatile, and the storage tank is often located outdoors, subjected to significant temperature fluctuations between day and night and complex climatic conditions. The previous solution of using a traditional single-flange level gauge in combination with guided wave radar level meters encountered multiple difficulties. The single-flange level gauge, due to contact with highly corrosive media, suffered frequent damage to its seals and diaphragms, leading to a sharp increase in measurement errors, a significant reduction in equipment lifespan, and high maintenance costs, causing great distress to the factory.

Based on the working conditions of the hydrochloric acid storage tank, the double flange level gauge stands out. Its core principle is based on differential pressure measurement. Two flanges are installed at the top and bottom of the storage tank respectively, and the static pressure difference generated by the liquid level height is measured and converted to obtain the liquid level height, cleverly avoiding the direct scouring and erosion of the measuring components by the medium. According to the characteristics of hydrochloric acid, the Hastelloy C - 276 material is selected. In line with the 5 - meter - high storage tank and the accuracy requirement (±0.5% FS), a model with a range of 0 - 6 meters and an accuracy of 0.25% is determined. During installation, strict attention is paid to keeping it horizontal, avoiding interference areas, and the capillary tubes are laid in a standardized manner. During debugging, zero calibration is carried out first, followed by step - by - step verification and fine - tuning.

After being put into operation, the double flange level gauge has shown excellent performance. During a one-year operation cycle, the failure rate of the equipment was reduced by 80% compared with the old scheme, and the maintenance frequency dropped sharply from 2 - 3 times per month to once per quarter, greatly saving manpower and material resources. The liquid level measurement accuracy was stably maintained at ±0.3% FS, providing reliable data support for the production automation control system, enabling precise control of the hydrochloric acid filling volume. Thanks to the accurate material proportioning, the product output rate was increased by 10%. Moreover, with accurate liquid level warnings, three potential leakage and spillage safety hazards caused by abnormal liquid levels were successfully avoided, strengthening the safety line for chemical production and becoming an indispensable and crucial part for the efficient and stable operation of the chemical plant.