Tank, Silo & Valve Monitoring

IIoT & Predictive Monitoring · MI-PM-03

LoRaWAN level sensors on two tanks, a valve-position sensor, an outdoor gateway and a dashboard with low-level alarms and valve state — replacing dipping rounds and manual checks.

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• ₹62,200pilot BOM · hardware only
• 3 – 4 daysto a live pilot
• Intermediateintegration level
• 3validated providers

Why dipping rounds miss the stock-out

The problem

Coolant, chemical, diesel and raw-material tanks are dipped by hand once a shift. Silos run out on a Sunday, valves are left in the wrong position after maintenance, and the person who knows the yard is the only one who knows the levels.

• Manual dipping is infrequent, unsafe at height and easy to skip
• Stock-outs and overflows are discovered too late
• Valve positions after maintenance are checked on rounds, if at all
• No level history for consumption planning or reorder

The solution

Ultrasonic or radar LoRaWAN level sensors mount on the tank roof and report level every few minutes; a LoRaWAN valve-position sensor reports open/closed. A solar-capable outdoor gateway covers the yard. The dashboard shows level percentage, consumption trend and valve state, with low-level and overflow alarms.

• Level in percent and litres, every few minutes, without opening the tank
• Low-level, high-level and rate-of-change alarms
• Valve open/closed state with a timestamp
• Consumption trend for reorder planning

Validated service providers

Validated by TwoElectrons and ranked by validation score: verified credentials, completed jobs on the platform and client ratings.

1. Sample Provider D — Chennai · Condition monitoring & PdM · ★ 4.9 · 17 jobs
2. Sample Provider E — Pune · PLC / Modbus integration, OEE · ★ 4.7 · 12 jobs
3. Sample Provider F — Ahmedabad · Process instrumentation · ★ 4.6 · 9 jobs

Provider listings are samples pending live registrations.

Pilot BOM and cost

Reference hardware to run the pilot. Unit costs are indicative Indian market prices for the component class.

POC BOM cost only — hardware for a pilot. Installation, integration and provider services are quoted separately. Request for Quote

How wireless tank and valve monitoring works

1. Mount. Fit two level sensors on tank roofs and one valve sensor on the key valve.
2. Cover. Place the outdoor gateway (solar if needed) to cover the yard.
3. Calibrate. Enter tank geometry so the dashboard shows litres, not just distance.
4. Alarm. Set low-level and valve alarms with the utilities team.

Pilot architecture

2× Level sensors + valve sensor (ultrasonic / radar · LoRaWAN) → LoRaWAN outdoor gateway (solar option) → Cloud LNS + platform (litres · trend · alarms) → Utilities dashboard (levels · valve state)

Two tanks and one valve in the pilot; a single outdoor gateway typically covers the whole tank farm.

Business case: rounds, stock-outs, losses

Ranges are typical figures reported for this class of solution; your pilot establishes the numbers for your plant.

• Zero dipping rounds (and no working at height for readings)
• Days of advance notice on stock-outs (from consumption trend)
• Minutes to a valve-state alarm (after maintenance leaves it wrong)
• 3 – 4 days to a live pilot (two tanks, one valve)

Who this is for: Utilities and maintenance heads, Stores and procurement, Chemicals, paints and process plants, Foundries and diesel-fed operations, Food and beverage, Any site with a tank farm or silos.

Illustrative case study

Illustrative scenario · not a client reference

A textile processing unit with a chemical tank farm in Surat (illustrative)

Set-up. Radar sensors on the caustic and peroxide tanks, valve sensor on the caustic transfer valve, solar gateway on the tank-farm mast, alarms to the utilities supervisor.

What happened. The dashboard showed caustic consumption doubling on night shift for three days — a transfer valve had been left partly open after maintenance. Closing it stopped a slow loss; the plant then added sensors to all nine tanks and uses the consumption trend for weekly reorders.

• Pilot budget: ₹62,200 hardware
• Loss found: valve left open
• Reorder planning: from live trend

FAQ

Ultrasonic or radar?

Ultrasonic suits clean liquids and open tanks; radar handles foam, vapour, dust and pressurised or agitated tanks. The provider chooses per tank.

Are the sensors safe in chemical or hazardous areas?

Standard sensors suit most utility tanks; ATEX/IECEx-rated variants are available for hazardous zones and are quoted separately.

Can the valve sensor control the valve?

In the pilot it reports position only; actuated valves can be commanded in a scale-up phase.

What does the ₹62,200 cover?

Two level sensors, a valve sensor and an outdoor gateway on a free-tier dashboard. Installation, hazardous-area variants and provider services are quoted after a Request for Quote.