Reflex level gauge

Introduction

A reflex level gauge is a direct liquid level indicator applied visually to observe the level of liquids within tanks or vessels. It works on the light reflection and refraction principle to differentiate between the liquid and vapor phases within the chamber.

The gauge is a glass plate that has specially grooved surfaces attached to one side of a metal chamber. On illuminating the glass, the liquid component will be dark because the light will be absorbed, whereas the vapor component or empty component will be bright or silvery because the light will be reflected. This simple contrast can make it simple to visually ascertain the fluid level with no outside source of power.

The reflex level gauges are found extensively in boilers, chemical plants, refineries, and water treatment systems because of their durability, dependability, and high-pressure and high-temperature capability. They are particularly applicable where there is a need to continuously monitor the level and where there is no necessity to observe fluid properties using transparency.

IBR Reflex level gauge of Fidicon

The Fidicon IBR Reflex Level Gauge is a high-performance liquid level indicator that has been specifically designed to fulfill the demanding needs of the Indian Boiler Regulations (IBR) combined with the reliable performance demands of worldwide industrial applications. This gauge is carefully designed, having a specially grooved reflex glass that offers high-contrast, clear visualization of both liquid and vapor phases without resorting to external illumination. It is strong enough to bear pressure and temperature, and thus it is used in boilers, pressure vessels, and chemical process systems. Fidicon guarantees compliance with international safety and quality standards to ensure that every unit is reliable and can be used across different industries to monitor the levels accurately and in a way that is maintenance-friendly and regulation-compliant to the operating conditions of different industries globally.

Principle of working of reflex level gauge

A reflex level gauge is based on the principle of light reflection and refraction by which the liquid phase and the vapor (or gas) phase of a tank or vessel are clearly distinguished. It employs a special reflex glass having prismatic grooves on the side next to the medium.

When light is introduced in the glass:

The light is reflected in the grooves in the vapor or gas space, and this portion of the glass will appear bright or silvery to the observer.

In the liquid-filled region, the liquid attenuates the light and minimises internal reflection. This makes that part of the glass look dark or black.

This combination of bright (gas) and dark (liquid) zones makes it simple and direct to read the level of the fluid, even at a distance, without the use of auxiliary lighting or complicated devices.

Reflex gauges work particularly well in high-pressure, high-temperature systems and are popular in boilers, chemical tanks, and process lines in industry.

Installation of Reflex Level Gauge

Our reflex level gauge will be installed in the most optimal manner at Fidicon so as to provide the best performance, safety, and compatibility with the international standards in the industry. The gauge is to be mounted vertically on the vessel or tank side, where it fits the range to be measured.

Start by making sure that the isolation valves, drain valve, and vent valve are correctly fitted and that the flanges that connect the valves are clean and aligned. Apply appropriate gaskets and tighten the bolts with equal torque to avoid leakage. The gauge should be installed at a height where the indicator should be able to span the entire range of the required liquid level.

After the mechanical installation is made, examine the alignment, and make sure the prismatic face of the glass is clear and visible. When applied in high-pressure systems or boilers, be sure to check that it meets local codes and certifications such as IBR or ASME, depending on the area.

Once installed, carry out a leak test followed by a functional level test before placing the gauge in continuous operation. To be safe, Fidicon advises one to use original accessories and mounting hardware that come with the unit to guarantee reliability in a variety of operating conditions within the global market.

Benefits of Reflex Level Gauge

The reflex level gauge provided by Fidicon provides a set of convenient benefits and can be considered an optimal option to use in order to monitor the liquid level reliably in any industry globally. The gauge is designed to be durable and precise enough to offer a sharp, high-contrast image that clearly indicates the liquid and vapor phases without the need for external lighting or complicated instrumentation. It is highly durable, and its compact mechanical design makes it low maintenance, and it can withstand high pressure and high temperatures, which makes it perfect in boilers, pressure vessels, and chemical processing systems. This design of Fidicon, by use of reflex glass and precision-cut grooves, eliminates the need for extra accessories such as transmitters or illumination panels, thus lowering the cost of the system. The small size, simple installation, and international standards, such as IBR certification, of this gauge make it a popular option in the world industry, which requires cost-effective, reliable, and regulation-ready level measurement.

Reflex level gauge safety precautions

Safety is one of the main considerations during the design, production, and use of our Reflex Level Gauges at Fidicon, particularly when being used in high-pressure industrial settings in the global market. During installation, operation, and maintenance, the following precautions should be taken to ensure safe and reliable operation.

Ratings:

Pressure and Temperature Make sure that the gauge is not used beyond its pressure and temperature range, since going beyond these limits may lead to glass breakage or leakage.

Proper Installation:

Position the gauge vertically and mount it with the right flange connections or couplings. Gaskets and fasteners should be approved and checked to ensure that the gauge body or glass is not stressed.

Protective Shielding:

When the glass is present in high-risk areas or places that have personnel, always use transparent safety shields or guards around the glass to protect against accidental breakage.

Isolation Valves:

Install isolation valves and drain valves on the gauge to enable the safe shutdown and servicing without subjecting operators to hot or pressurized fluids.

Regular Inspection and Cleaning:

Carry out routine checks to detect evidence of leakage, corrosion, or glass wear. Use proper tools and solvents to clean the glass and keep it clear with no residues.

Blow-off Devices Used:

In high-temperature or boiler use, provide blow-off connections so that the gauge can be cleaned safely without breaking out the system.

Personnel Only Trained:

Only qualified personnel should be allowed to make the installation and maintenance since they have been trained on how to deal with pressurized systems and the safety regulations of the area and abroad.

Ahead of use, leak testing:

Hydrostatic testing or pressure testing should be undertaken before commissioning to check that all the joints and seals are tight and that the gauge is not leaking.

Service of reflex level gauge recommended.

A reflex level gauge should also be serviced regularly to make it work accurately and safely at all times. It allows clear visibility of the liquid level and avoids the failure of equipment in critical process applications.

The most important service suggestions are as follows:

Routine Inspection:

Occasionally check the gauge to see if it is wearing out, corroding, or leaking. Check the glass for discoloration or cloudiness, as this can interfere with vision.

Cleaning of the Glass Surface:

Wipe the reflex glass with a soft cloth and non-abrasive cleaner regularly. Do not use coarse chemicals or scrapers, which may destroy the prismatic grooves.

Seal Integrity Check:

Check the gaskets and seals to see whether they are hardened, cracked, or have leaks. Change them in case of degradation symptoms to guarantee pressure maintenance.

Tighten Fasteners:

Make sure that all bolts, nuts, and mounting hardware are tight. Apply the right torque as indicated by the manufacturer to prevent overtightening.

Functional Testing:

Occasionally, take the gauge out of service and make test level changes (where possible) to ensure that the float movement and the visual indication are functioning properly.

Replacement of Worn Parts:

Use original manufacturer parts to replace any parts that are damaged, including reflex glass, valves, or the gauge body, to ensure safety and reliability.

These service jobs should be done at specific intervals to assist in ensuring that the reflex level gauge keeps providing accurate level indications as well as operating safely under different process conditions.

Reflex level gauge components

The reflex level gauge consists of a number of important parts that interact to give a clear graphical representation of the level of liquids contained in a vessel or tank. The principal elements are listed below:

Reflex Gauge Glass:

The most important component is a component of special grooved borosilicate glass.

The grooves are used to reflect light in the vapor space and absorb light in the liquid space to provide a vivid contrast between the two.

Chamber Gauge Body:

A strong metal frame containing the glass and attaching to the tank.

Typically stainless steel or carbon steel is used to resist pressure and temperature.

Cover Plate or Glass Holder:

It keeps the reflex glass firmly against the chamber.

Sealed using gaskets and evenly bolted down to avoid spilling.

Gaskets:

Seal the glass and the gauge body to avoid leakage of fluid or gas.

They are constructed of heat-, pressure-, and chemically resistant materials.

Protective Mica Shield (Optional):

A sheet of glass, usually transparent, overlapping the reflex glass to guard against corrosion or high-pressure steam, particularly in boilers.

End Valves (Isolation Valves):

At the top and bottom of the gauge to isolate the gauge and process fluid.

May have automatic shut-off, drain valves, and vent valves.

The kind of mounting brackets or flanges:

To hold the gauge to the tank or vessel.

They are made in such a way that they maintain alignment and structural stability.

Vent and Drain Connections:

Permit safe drainage of the liquid and relief of entrapped air or vapors during maintenance or inspection.

Gauge glass cleaning of Reflex level gauge

A reflex level gauge has a gauge glass which should be properly cleaned to provide clear visibility and accurate level indication. The glass may be covered over time by scale deposits, sediment or chemical residues, which may compromise performance.

The following are the suggested cleaning steps:

Isolation of Gauge:

Close the top and bottom isolation valves of the gauge before cleaning. Cool the gauge and depressurize it in case it was in use.

Gauge Chamber drain:

Unscrew the drain valve to drain whatever fluid is still in the chamber. Ensure that you collect and dispose  the fluid safely, by observing the appropriate environmental and safety precautions.

Take Apart:

In case of a severe buildup, it might be necessary to unscrew the front cover plate and remove the reflex glass outside to clean it up. During disassembly apply the correct tools and adhere to manufacturer torque and safety guidelines.

Apply Non Abrasive Cleaners:

Rinse the glass surface using a soft cloth or sponge and mild cleaning solution that is not abrasive. Do not use sharp tools, wire brushes, or other harsh chemicals that might scratch or otherwise damage the prismatic grooves of the reflex glass.

Care and Clean:

Clean then rinse in clean water and leave the glass to dry thoroughly before reassembling. Ensure that the parts are not residue-ridden.

Reassemble and Test:

Reinstall the glass and cover plate, ensuring proper alignment and gasket seating. Tighten bolts uniformly. Reopen the isolation valves slowly and check for leaks and proper level visibility.

Recommend disposal. Reflex level gauge

It is important to dispose of a reflex level gauge properly in order to achieve environmental safety and adherence to the rules of industrial waste. Disposal procedure ought to be as per the norms, particularly in the event that the gauge has been exposed to harmful or corrosive fluids.

The following are the main disposal recommendations:

Isolation and Depressurization of the Gauge:

The gauge should be safely removed and isolated in the process line, completely depressurized, and emptied of all residual liquids before being discarded.

Decontamination:

In case the gauge was used with toxic, flammable, or corrosive media, it is necessary to clean it with the help of suitable neutralizing agents. Handle chemical residues in a safe manner.

Breaking of the Parts:

Remove the gauge in a disassembling manner. Important parts like the reflex glass, gaskets, chamber body, and valves must be dissociated to be handled separately and classified as materials.

Recycling and Segregation of Materials:

Metal components (such as the gauge body and flanges) may often be recycled as scrap metal.

Uncontaminated glass components may be disposed of with industrial glass waste.

Depending on the material, gaskets and seals can require treatment as industrial or chemical waste.

Hazardous Waste Handling (where appropriate):

In case the gauge has been in contact with dangerous materials, then it should be discarded in a certified hazardous waste disposal facility. They have to be labeled and documented properly.

E-waste Consideration:

In case the Reflex Level Gauge has electrical or remote sensing parts, discard them as e-waste according to local e-waste laws.

Documentation and Compliance:

Have proper records on the disposal process to meet audit and regulatory requirements, particularly in those industries where safety or environmental regulations are high.