What’s in My Bin?

20′
40′
HEADROOM? VOLUME?
80′
MASS?

Understanding Accuracy in a Bin Level Monitoring System

When it comes to monitoring inventory in bins, tanks and silos, one of the first questions often asked is “How accurate
is it?” Unfortunately, that’s a loaded question that can’t be answered easily. Here we discuss why it’s a tough question
and what you can and cannot expect from your level monitoring system.

Accuracy of a Single Point Inventory Measuring System

One consideration is the type of device you’re using to measure the material level. Bobs, guided wave radar, open air
radar, and ultrasonic level sensors are commonly used devices. What they all have in common is they all measure a
single point in the vessel. Although each device has its pros and cons (see our paper on Selecting Continuous Level
Sensors), when installed properly they all perform well to their stated or printed measure-
ment accuracy that appears in their literature.

But, what does printed measurement accuracy mean? For a single point measurement
device the printed accuracy stated on a web site or in the literature is the distance measured
from the sensor on the top of the tank to the material surface. This distance is often referred
to as headroom, because it tells you how much space you have left in your bin. So, the
printed accuracy is the accuracy of that distance in feet or meters. That one measurement is
generally highly accurate within ± 0.25% of the total distance measured. However, this is
not the accuracy of the volume or mass of material in the bin; it is simply the accuracy of
that one measurement of distance.

Volume
Volume is very different than level. Volume is the amount of three-dimensional space the
material takes up. When using the distance measured from the sensor to the material sur-
face to estimate volume, the calculation is based on the internal vessel dimensions and the distance to that one point on
the material surface. Therefore, it’s essential to have accurate vessel dimensions as mistakes in geometry will increase
the overall error in the volume calculation. Material flow, buildup, or bridging can affect volume calculations. The place-
ment of the sensor and the location of the filling and discharge points also have an impact on the overall accuracy of
volume.

Mass
Accuracy can be further impacted when attempting to use a single point measurement device to estimate mass or
weight. When converting volume to mass, the bulk density of the material – stated in pounds per cubic foot or lb./ft.3 –
can have a significant impact on accuracy. Although there are resources available that provide general information
about the bulk density of a particular material, the bulk density of the material that is actually in the bin could be quite
different than what’s posted on the Internet.1
Attributes such as particle shape, size and moisture content can profoundly impact bulk density. Compaction of mate-
rial can also cause very different bulk densities of the same material in the top or the bottom of the bin. A cubic foot of
material at the top of the bin could weigh less than that same material at the bottom of the bin, where the bulk density is
greater due to compaction by the weight of the material above it.
When using bulk density to calculate mass in a bin for a particular material, it is very important to establish an
average bulk density based upon the actual material handled at the facility, and not the stated amount given to a
material’s general name referenced on a table. One way to accomplish this is by taking a measurement before and
after a “known-weight” load is put into the bin, and adjusting the bulk density in lb./ft.3 to reflect this weight.

What to Expect
When using a single point level measuring system, there will always be an increasing level of error associated as you
progress through the conversion of distance to volume and then mass. The measured distance of most single point
technologies is quite accurate and will be around ± 0.25% of the distance measured.
However, when level is used to estimate volume, accuracy will be dependent upon the correctness and completeness
of the vessel dimensions, sensor placement, and the location and number of filling and discharge points. A vessel that
is center fill, center discharge with material that flows freely and symmetrically will give you the best results when using
a single point measuring device.
When converting volume to mass there will always be inherent inaccuracies due to variations in bulk density, regardless
of whether you are using a single point or multiple point measuring device. The accuracy of the volume calculation will
also impact the accuracy of the mass calculation.
Since there are so many variables, it is very challenging for any manufacturer of single point level measurement devices
to pinpoint how accurate the calculated value of the mass will be. With accurate vessel geometry, strategic placement
of the sensor, and a good average bulk density, the accuracy of the mass may be around 8% to 15%.

Accuracy of a Multiple-Point Inventory Measuring System

Unlike traditional devices that measure one point and determine a single distance, a 3DLevelscanner takes measurements
from multiple points within the silo. These points are used to determine the volume of material in the bin. Measurement
points are not averaged to calculate bin volume. Instead, each point is given a “weight” or relevancy rating and a complex
algorithm is used to calculate the true volume of material within the bin. This technology takes into account variations that
can occur across the topography of the material surface by measuring and mapping the high and low points.

The 3DlevelScanner provides an accurate three-dimensional profile of the top surface within a
storage vessel. This is beneficial when there are variations in the material surface due to multiple
fill and discharge points, or with materials such as powders that do not fill/discharge symmetrically.

With the 3DLevelScanner as with single point measurement sensor, the volume accuracy
is still dependent upon the accuracy of the vessel dimensions and sensor placement. When
converting the volume to mass there will still be inherent inaccuracies due to bulk density
variables. But, the improved accuracy of the volume calculation will improve the accuracy of
mass calculation.

In the case of a 3DLevelScanner, “more is better” with multiple measurement points contribut-
ing to a higher degree of accuracy. Given correct vessel geometry and proper sensor place-
ment, you can expect volume accuracy of 3% to 5%. When combined with a good average
bulk density, the accuracy of the mass may be around 5-10%.
1
By performing a keyword search for “bulk density table,” “bulk density chart,” or “bulk density guide,” you will come up with a variety of reference charts
for bulk density of a variety of materials.

800.278.4241 • 402.434.9102 • www.binmaster.com • info@binmaster.com

© 2014 BinMaster. ®All Rights Reserved.
How Continuous Level Sensors Work
4″ to 8″ Upper Dead Zone

SmartBob 2 and TS1

Measuring range is from the tip of the “Bob”
when fully retracted to where the Bob contacts
Measuring material at the bottom of the vessel. The Smart-
Range
(up to 180′) Bob measures the level of headroom from a single
point on the material surface directly below the
sensor’s mounting location.

14″ to 36″ Upper Dead Zone

Guided Wave Radar
Measuring range is from 14” to 36” below the
threads on the process connection (upper dead
Measuring zone), to 4” above the top of the counterbalance
Range weight (lower dead zone). It measures the level
(up to 78′)
of headroom at a single point where the cable is
located in the vessel.

Lower Dead Zone

14″ to 36″ Upper Dead Zone Open Air Radar

Measuring range is from 14” to 36” below the
threads on the process connection (upper dead
zone). Open Air Radar measures the level of
headroom at a single point on the material surface
Measuring
Range directly below where the unit is aimed. For liquids it
(up to 230′) is generally pointed straight down (vertical), and for
bulk solids it is aimed at the discharge to prevent
the signal from bouncing off an angled hopper bot-
tom causing false reflections.

Dead zones: Radar, Ultrasonic, and 3DLevelScanners have a default blanking distance, or dead zone, typically from the end of the process connection to allow the units to stop
transmitting after the transmit pulse is applied and before the receiver circuit is turned on to listen for the return echo. For example, if using a 3DLevelScanner 19” below the
threaded process connection would be considered a full tank. Dead zones can be increased if a lower full point is desired. Most manufacturers have the blanking distance
pre-set in the controller, based on the unit selected. The SmartBob’s dead zone is from the tip of the sensor probe hanging from the cable when the unit is fully retracted.
 19″ Upper Dead Zone
3DLevelScanner
Models S, M, MV, ML & MVL
Measuring range is from 19” below the threads
on the process connection (upper dead zone).
The 3DLevelscanner takes measurements from
Measuring
Range multiple points within the silo. These points are
(up to 200′) used to determine the volume of material in the
bin. Measurement points are not simply averaged
to calculate bin volume. Instead, an advanced
algorithm assigns each point a “weight” to deter-
mine the true volume of material in the bin.

19″ Upper Dead Zone

RL Acoustic Level Device
Measuring range is from 19” below the threads
on the process connection (upper dead zone).
The RL measures the level of headroom from a
Measuring single point on the material surface directly be-
Range
(up to 200′) low where RL acoustic level device is mounted.

SmartSonic
4″ to 14″ Upper Dead Zone
Ultrasonic Transmitters
Measuring range is from 4” to 14” below the
threads on the process connection (upper dead
Measuring
zone). Ultrasonic measures the level of headroom
Range from a single point on the material surface directly
(Up to 60′
liquids only)
below where the unit is aimed. For liquids it is
generally pointed straight down (vertical), and for
bulk solids it is aimed at the discharge to prevent
the signal from bouncing off an angled hopper
bottom causing false reflections.

800.278.4241 • 402.434.9102 • Fax: 402.434.9133 • info@binmaster.com • www.binmaster.com

© 2014 BinMaster. ®All Rights Reserved.
 BinMaster Level
Measurement Systems

Selecting Continuous Level Sensors

PROS CONS
SmartBob • Not affected by dust or other adverse process • On-demand system, does not provide an instanta-
Weight & conditions
• Not affected by material buildup on sensor
neous response to change in the material level
• Seasonal maintainence may be required to clean
Cable Level • Can be used in extremely light, signal-absorbing out mechanical cavity in very dusty conditions, if
materials air-purge is not used
• Measures bins up to 180 feet (SmartBob-TS1 • Not recommended in high pressure bins
up to 60 feet)
• Not affected by material characteristics such as
low dielectric constant or angle of repose
• Remote sensor requires no calibration
• High temperature models available up to 1000°F
• Low purchase cost ($900 to $1,600)
• Very simple setup and installation
• Consistent, repeatable, and accurate
measurements
• Minimal contact with stored material
• Leading-edge eBob networkable PC
software available
• A variety of digital and analog outputs available
• Cable replacing, wireless interfaces available
• Hazardous location approvals available

GWR-1000 PROS CONS

• Sensing probe is in constant contact with material
Guided Wave • Continuous level measurement in powders, granules,
bulk solids, and liquids • Minimum dielectric constant of material must be
Radar Level • Performs in vessels prone to dust, humidity, above 2.2
temperature, pressure and bulk density changes • Maximum range is limited to 78 feet, and may be
• Suitable for vessels of most any shape or limited for heavier materials due to tensile load
diameter, including narrow tanks • Material like large rock may damage probe and be
• Can be used on high pressure vessels (232 psi max.) difficult to sense
• High temperature range up to 392°F
• Accuracy of ± 0.2 inches (5 mm)
• Microwave energy is focused and travels along a
wave guide, concentrating the radar beam within
a small diameter

800.278.4241 • 402.434.9102 • Fax: 402.434.9133 • info@binmaster.com • www.binmaster.com

© 2014 BinMaster. ®All Rights Reserved.
 SmartWave PROS CONS
Open Air • Continuous level measurement • Low dielectric products are difficult to measure. Not
Radar Level • Non-intrusive, non-contact design enough radar energy can be reflected from the product
surface. Requires a minimum dielectric constant of 2.0.
• Ranges up to 100 feet
• High temperature applications up to 350°F • Susceptible to condensation and product buildup on
the antenna. This causes signal attenuation that will
• In liquid applications, radar is not adversely
adversely affect the performance. The higher the
affected by steam or foam
frequency, the more signal attenuation. The higher
• Measurement is virtually unaffected by changes frequency units have smaller antennas, thus the same
in process temperature, pressure, density or gas/ level of coating or condensation on a smaller antenna
vapor composition within the vessel naturally has a greater affect on the performance.
• Cone-bottom vessels can sometimes be problematic
when nearing empty. The cone acts as an excellent
reflector, throwing energy around the vessel some-
times confusing the transmitter.
• High purchase cost ($2,500)

SmartSonic PROS CONS

Level • Continuous level measurement • Performance affected by dusty conditions, pres-
• Non-intrusive, non-contact design sure fluctuations, turbulence in vessel, and large
• Ranges up to 90 feet (liquids) particulate size
• High temperature applications up to 260°F • Not recommended if steam will be present in vessel
• Sanitary models are available with • Will measure the surface of the foam, if present
tri-clover fittings • Maximum pressure of 29 psi
• Low purchase cost ($675 to $1,200)
• Self-cleaning transducer face
• Automatic compensation for temperature changes
• Analog and digital communication options
• PC software used to diagnose and calibrate sensor
is free with purchase of SmartSonic unit
• Very easy to install and calibrate
• Available in multiple voltages

PROS CONS
3DLevelScanner • Continuous level measurement • The 3DLevelScanner is an acoustic device and
Level • Non-intrusive, non-contact design elevated background noise can have an affect on
its performance.
• Measures uneven powder or solid material surfaces
• Detects cone up, cone down and sidewall buildup • Setup requires care in mounting the sensor in the
proper location, and mapping the vessel
• Provides minimum, maximum and average distances
• Time required to process multiple pulse echoes limits
• Performs in extreme levels of dust the sample rate
• Calculates highly accurate bin volume due to • Not recommended for liquid applications
mapping the surface of the material with
• Corrugation on small vessels can cause false echoes
multiple measuring points.
• Not recommended for materials with a bulk density
• Measuring range up to 200 feet
under 11 lb./cu. ft. due to absorbing the acoustic
• Self-cleaning with minimal maintenance pulse
• High temperature applications up to 365°F
• Automatic compensation for temperature changes
• Analog and digital communication options
• Leading-edge 3D MultiVision networkable PC
software available for multiple vessel monitoring
• Can generate a 3D image of material surface
• Cable-replacing, wireless interfaces available
• Approved for hazardous locations
• Not affected by material characteristics or low
dielectric constants