【2026 Level Gauges】Process connection methods from standard to specialized for radar level gauges
Thread Content
As a vital tool for measuring liquid and material levels in industrial production, radar level gauges have a process connection method that directly determines the stability of installation and the accuracy of measurements; it also affects whether they can adapt to the complex operating conditions in different industries.
I. Main connection methods (covering 80% of application scenarios) The main connection methods are divided into 3 categories, each with specific applicable scenarios; they can be quickly matched based on the pressure, temperature, and type of container in use. 1. Flange connection: The preferred choice for high-pressure sealing, with the greatest versatility. Flange connection is the most common and standard method of connection for radar level gauges; it involves mating the gauge’s flange with the container’s flange, and using gaskets and bolts to achieve a tight seal.
Core parameters: The nominal diameter is commonly DN50, DN80, DN100； Common pressure ratings include PN16, PN40, Class150, Class300 ； Sealing surfaces come in types such as RF (raised surface) and FF (fully flat surface); the materials used are usually 304/316L stainless steel or carbon steel, while for corrosive media, a PTFE-lined version can be used. Advantages: Excellent sealing performance to effectively prevent leaks, capable of withstanding high temperatures and pressures (up to over 4.0 MPa) ； It features a secure installation, vibration resistance, a long service life, and is suitable for most industrial applications. Disadvantages: It has a large volume and weight; special tools are required for installation and removal, and its cost is slightly higher than that of threaded connections.
Applicable scenarios: medium and high-pressure vessels, large storage tanks, pressure vessels in industries such as chemicals, petroleum, power, and metallurgy, as well as in corrosive and high-temperature environments.
2. Threaded connection: Compact and economical, suitable for tight spaces. The threaded connection is a “cost-effective” type of connection; it has a simple structure. The external threads of the instrument (usually of the G or NPT type) are simply screwed into the internal threaded interface of the container, eliminating the need for flanges and bolts. This makes installation and removal very convenient.
Core parameters: The common specifications are G1/2", G3/4", G1", NPT3/4", and NPT1". Among these, the G type refers to European thread standards, while NPT refers to American tapered thread standards; the appropriate one can be chosen based on the actual connection requirements. Advantages: small size, light weight, low cost ； It can be installed and removed quickly without the need for special tools, making it ideal for installation in tight spaces. Shortcomings: Lower pressure resistance, generally not exceeding 1.6 MPa ； The sealing effect relies on tape or sealant, and it is prone to aging and leakage when exposed to high temperatures over time.
Applicable scenarios: low-pressure, normal-temperature conditions; small storage tanks, pipelines, intermittent equipment, as well as equipment renovation projects (no additional drilling is required, as existing threaded connections can be used directly).
3. Hygienic clamp connection: A sterile and easy-to-clean connection designed specifically for the food and pharmaceutical industries. Also known as Tri-Clamp, this connection method is used in industries such as food, beverages, and pharmaceuticals; it relies on quick-release clamps, flat connectors, and food-grade gaskets to ensure there are no areas where dirt can accumulate, thus meeting the industry’s sterile requirements.
Core parameters: Complies with the Tri-Clamp (ISO2852) standard; common pipe diameters range from DN25 to DN100； The material must be 316L stainless steel (with a surface roughness of Ra≤0.8μm). Gaskets should be made of food-grade materials such as EPDM, FKM, and PTFE, and must comply with GMP, FDA, and EHEDG standards. Advantages: no dead corners, easy to clean, prevents residue; supports CIP (online cleaning) and SIP (online sterilization) ； It features quick assembly and disassembly, facilitating daily maintenance and sterilization, and fully meets the requirements for aseptic production. Disadvantages: Its pressure resistance is moderate, generally not exceeding 1.0 MPa, and its cost is higher than that of flange or threaded connections.
Applicable scenarios: industries with extremely high hygiene requirements, such as food, beverages, pharmaceuticals, bioengineering, and high-purity chemicals.
4. Bracket connection: Designed for special scenarios, suitable for containers without openings or those that are open. This connection type is not a direct one; instead, it involves using metal brackets to suspend the radar level gauge above or outside the container opening, eliminating the need for a direct connection to the opening. This approach meets the installation requirements in special situations such as those with no pre-existing interfaces or open containers.