At Processplus, we specialise in delivering practical engineering solutions tailored to our clients' operational needs, with safety, compliance, and usability at the heart of everything we do.

In one of our recent projects, a water industry client approached us with a clear but technically complex requirement: they needed local level displays installed next to their sludge thickener tanks, so that tanker drivers could easily identify which tanks required emptying.

Project Overview

Client Need:
The site’s operations team needed to streamline tanker collections by installing visible level displays adjacent to the tanks. This would save time and reduce the margin for error in identifying which tanks were ready for emptying.

Project Challenges:

• The sludge thickener tanks are 10 metres tall, with ATEX (Ex-rated) zones starting halfway up.
• Installation would require working at height and full compliance with hazardous area restrictions.
• The displays had to be durable, readable, and easy to maintain, while fitting seamlessly into the existing infrastructure.

Our Solution

The Processplus team developed a complete solution that balanced technical accuracy, safety, and long-term usability.

• Instrumentation: We selected Siemens radar level transmitters and LT500 controllers to provide real-time measurement of the sludge level, percentage full, and volume in each tank.
• Safe Working Practices: Our engineers implemented rigorous working-at-height safety protocols and ensured ATEX compliance through careful material selection and robust installation procedures.
• Accessible Design: We identified and utilised an accessible cable run to simplify installation and maintenance.
• A custom glazed enclosure was installed to house the level transmitters, offering protection from the elements while allowing site personnel to view and interpret readings with ease.

Project Outcome

The project was delivered safely and efficiently over several days, with no incidents reported. The system is now fully operational and already proving its value.

Client feedback was overwhelmingly positive:

"I think it's an excellent piece of work, really tidy finish and the guys were great on site.
I was showing the tanker driver today when he was in taking a load and he was delighted with it as well."

Why It Matters

This project is a great example of how smart instrumentation and careful project planning can directly improve operational efficiency and safety on site. By making critical data more accessible at ground level, we’ve helped our client reduce delays, eliminate guesswork, and streamline their sludge management process.

Looking for a bespoke engineering or instrumentation solution?
Contact the Processplus team today to discuss your project needs. We’re here to help - safely, smartly, and with precision.