09,18,2026 11 views
To determine whether the ultrasonic level gauge needs to be replaced, it is necessary to consider the equipmentFault frequency, degree of performance degradation, maintenance costandSafety complianceBased on comprehensive evaluation, the following are specific criteria and scenarios for judgment:
1、 CoreperformanceInvalid, unable to be restored through repair
The measurement accuracy continues to exceed the tolerance and cannot be calibrated
After multiple calibrations (such as empty cans) /After full tank calibration and temperature compensation calibration, the measurement error still exceeds the nominal range of the equipment (such as ± 0.5% FS), and the deviation remains stable (such as always being larger/smaller than the fixed value).
Example: Range A 10 meter liquid level gauge with an actual error exceeding ± 5 centimeters for a long time, affecting production measurement (such as batching and storage statistics), and excluding external factors such as installation, medium, and environment (such as ineffective after reinstallation), indicates that the core components of the sensor (piezoelectric crystal, signal processing circuit) have aged and failed.
Signal lost /Frequent disconnection, ineffective maintenance
Irregular appearance Signal loss and fault alarm occur frequently even after replacing probes, cables, and wiring terminals, and the host self-test displays hardware abnormalities (such as circuit fault codes detected by manufacturer specific software).
Example: Under normal operating conditions (no severe interference, no medium adhesion), the disconnection exceeds Three times, each time the device needs to be restarted to restore, which seriously affects automation control (such as pump valve linkage losing control).
2、 The frequency of malfunctions is too high, and the maintenance cost is close to that of a new machine
Key components are repeatedly damaged, and the cost performance of repairs is low
Multiple replacements of core components (such as probes, motherboards, power modules) within a short period of time (such as within six months), and the cumulative cost of each repair reaching the price of a new machine More than 50%.
Example: Probe corroded /Replace it twice within six months of aging, with a cost of 1000 yuan each time, while the price of a new machine is 3000 yuan. Continuing maintenance is no longer economical.
The maintenance cycle is too long, which affects the continuity of production
After equipment failure, due to the discontinuation of accessories (such as old models without spare parts) or maintenance cycles exceeding 3 days, resulting in production interruption (such as inability to monitor tank level, forced manual inspection or shutdown waiting), with indirect losses far greater than the cost of new equipment.
3、 Equipment aging leads to safety or compliance issues
Failure of protective performance and potential safety hazards
shell /Aging of sealing components (such as corrosion of explosion-proof surfaces and hardening of sealing rings in explosion-proof equipment) can lead to a decrease in protection level (such as downgrading from IP67 to IP54), which may cause safety accidents (such as short circuit leakage and explosion-proof failure) in humid, dusty, corrosive or explosion-proof environments.
Example: The explosion-proof liquid level gauge used in the chemical explosion-proof area cannot reach the explosion-proof surface after damage Ex d Ⅱ CT4 level, violating safety regulations, must be replaced.
Not meeting current standards or production requirements
The device's functionality cannot meet the new process requirements (such as the original range) 5 meters, the current storage tank has been expanded to 8 meters, and the use beyond the range has caused measurement failure; Or due to industry standard updates (such as increased measurement accuracy requirements), old equipment may not meet the standards.
Example: Upgrading of the food industry After GMP certification, it is required that the liquid level gauge has a sanitary probe (such as 316L+PTFE material), but the old equipment is made of ordinary ABS material, which cannot meet the sanitary requirements.
4、 After long-term use, the equipment naturally ages to its designed lifespan
The design lifespan of ultrasonic level gauges is usually 5-8 years (depending on the usage environment: it may be shortened to 3 years in harsh environments, and extended to 10 years in clean and normal temperature environments). If the device has exceeded its design life, even if it can temporarily work, it may suddenly collapse due to component aging (such as capacitor degradation, circuit oxidation). It is recommended to replace it in advance to avoid risks.
Summary: Typical Scenarios for Priority Replacement
Measurement accuracy is out of control and cannot be calibrated;
Failure frequency>monthly Once, the maintenance cost is high;
There are safety hazards (such as explosion-proof failure, insufficient protection level);
Exceeding the design lifespan and without spare parts support;
Unable to meet current production needs /Compliance requirements.
If it is only an occasional fault (such as loose wiring, probe contamination) and can operate stably after repair, there is no need to replace it. The service life can be extended by strengthening maintenance (such as regular cleaning and calibration).
