IoT Controllers for Level Monitoring & Control

Integrating Level Sensors at the Edge

Measuring the level of liquids and solids is one of the most common edge data applications. It’s seen across many different industries, from oil and gas to agriculture. It’s a crucial tool for process data, inventory management, and level control. Instrumentation for level measurement is often implemented in grain silos and water tanks, along a river or lake, in industrial ponds, and beyond.

Our edge controllers are a great fit for level monitoring. Here are several advantages to relying on our modules:

• Remote accessibility: ControlByWeb IoT controllers allow you to monitor and control levels remotely, which is particularly useful to manage tanks, reservoirs, and other storage systems.
• Real-time data: Stay informed about the current status of your system and any critical changes with real-time data logging and notifications.
• Redundancy and reliability: Cellular service can be used as a failover to Ethernet or vice-versa, and ControlByWeb devices continue operating even through network outages or other failures of the central system.
• Integration: Our controllers seamlessly integrate with third-party systems, including many SCADAs and HMI displays thanks to an open REST API.
• Versatile: We have the I/O to support a wide range of sensors used in various industries, from water and wastewater management to oil and gas.
• Ease of use: A user-friendly interface and no-code logic builder make it easy to set up and manage controllers without cumbersome ladder logic or extensive technical knowledge.

Sensitive Sensors and Robust Controllers

There are many variables in level measurement. What is the solid or liquid being measured? Is it contained or flowing? Are you measuring single points, or are you continuously monitoring the level as it changes? And what are you doing with the data—is it simply being graphed, or is it being used to control pumps or other system components? Despite all the questions, there are many robust tools to tackle the task of any liquid level application.

The first consideration is the liquid level sensor. These vary in accuracy and general purpose. Some technologies, like radar and ultrasonic, offer a non-contact solution, which would be ideal for a corrosive or sensitive substance. They can be used to continuously monitor level. On the other hand, a point level switch is ideal for simply detecting when a liquid has reached a predefined level. For example, logic could be used to trigger a pump to turn on or off when that threshold is reached.

💧 Why so high?
Elevated water tanks, or water towers, are raised above ground level to create water pressure using gravity. This can be more energy efficient than systems that rely on pumps alone. The pressure at any given point in the distribution system is determined by the difference in elevation between the water in the tank and the point of use.¹

The next component is the device that bridges the gap between sensor data and the larger system. This can be an IoT gateway that captures the data and sends it to a SCADA or HMI. But it doesn’t have to be that simple. An edge controller, such as our X-412™ analog input module, can be used to bring logical control to the site of the application.

An edge controller can graph data, send notifications, and even perform basic control functions such as motor control, triggering relays, and other tasks through custom logic. This helps to offload some of the processing from the central system while adding redundancy in case of any failures in the main system.

Of course, this only touches the surface of what’s possible in level monitoring and control. If you’re unsure of the best solution for your application, it pays to consult with an expert. Our sales engineers are happy to answer any questions you have and help determine if ControlByWeb edge controllers would be the right fit. Contact us any time for a demo.

Point Level & Continuous Level
There are two types of level monitoring: point level and continuous level. Point level sensors simply measure a single preset level in the tank, while continuous level sensors measure level in a tank within a given range. Measuring single levels allows for alarm triggers at high or low points in a tank. Continuous monitoring has more robust applications and is effective in a level management system to control pumps, valves, and alarms.