Level 1 - Fundamental Training

Level

Level 1 Fundamental Training

Level 1 - Level

Contents
Topics: Why measure level? Level terminology Technology selection Technology (Pressure Transmitter, HTG & Hybrid System Other Technology (Float, Capacitance, Displacer, Servo, Nucleonic, Laser & Ultrasound) Exercise Slide No: 3-5 6 - 19 20 - 29 30 - 55 56 - 75

76 - 80

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Level

Why measure level?

5 Common Reasons Inventory
keep track of amount of material of material available for a process
3

Custody Transfer
amount of material that is bought & sold in terms of volume or weight

Effieciency
maximise storage tank capacity preventing unnecessary expense of purchasing additional vessels

Safety
prevent spillage in open vessels prevent overpressure conditions in closed vessels that may result in rupture

Consistent Supply
to maintain product quality in a process blending, pulp & paper
Level 1 - Level

Why measure level?

Inventory vs. Process Inventory
Accuracy is primary difference better than 3 mm precision needed Applications need precise measurement because of $$$$$ Transfer of ownership Exact quantity must be known Product cost You can have a Tend to be larger vessels mixture of process
4

Process

Applications are more concerned with: Control of a product level within a range Safety (prevent overflow/ pump shutoff) Monitor inputs of components of a process Accuracy requirements vary widely

and inventory applications in a plant

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Why measure level?

Indication vs. Control Indication on-site level check operator interpret measurement Indicators open loop control system help calibrate automatic control system Control closed loop system process point of measure transmitter controller control valve process
5

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Level terminology
Level Control Loop (Inflow)
I/P LIC
6

Level Loop Issues: Control At Inflow or Outflow Non-Self Regulating

LT

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Level terminology
Level Control Loop (Outflow)
7

LIC

I/P

LT

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Level terminology
Parameters
8

Interface Level

Volume Density Mass

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Level terminology
Parameters
9

Interface
Interface measurement finds the boundary between two liquids stored in the same tank each liquid has different density Liquid A to air/vapor interface Liquid A Liquid A to B interface Liquid B

Level 1 - Level

Level terminology
Parameters
10

Density
Density is a measure of the mass per volume Example: grams / cc pounds / cu ft Specific Gravity is a ratio of the density of a Density fluid to the density of water, thus density of fluid density of water = SG

Density of fluid = density of water * SG

Mass = Density / Volume

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Level terminology
Parameters
11

Volume
Volume only correlates directly to level when: Tank is an upright cylinder Density is constant Volume Temperature is constant There is no change in tank wall position after filling Volume measurements are in units such as: gallons, liters, barrels... Level measurements are in units such as: inches, feet, millimeters, centimeters, meters... Correlation of volume to level varies with geometry of tank and may be expressed in terms such as: gal/inch, liters/meter, barrels/inch...
Level 1 - Level

Level terminology
Parameters
12

Volume
Vertical Cylindrical Tank v = r2l
h

r l

Horizontal Cylindrical v = r2atan[l/(2r-l)]+h(l-r)[l(2r-l)]

Sphere Tank v = l2(3r-l)/3

r l

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Level terminology
Parameters Volume Horizontal Bullet Tank
v = r2/3 * (3r-l) + 2r2(h-2r) *atan[l/(2r-l)] + (h-r)[l(2r - l)] h r l r
13

Vertical Bullet Tank l v = r2/3(3r-l) if l r v = r2/3(3r-l) if r < l < (h - r) v = r2(h-2r) + [(l+2r-h)2]/3 * [3r-(l+2r-h)] if (h - r) l
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Level terminology
Parameters
14

Volume
Tanks with Dished Ends no standard shape use strapping tables to determine volume
10

Point 1 2 3 4 5 6 7 8 9 10

Level Volume (inches) (gallons) 0 5 10 15 20 25 30 35 40 100 0 10 32 68 115 173 230 313 394 957

Bulging

9 7 5 3 1

A look-up table that relates level to volume for several discrete points in a tank. Commonly used to eliminate Bulging Error.

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Level terminology
Measurement Characteristics
...and the technologies may have to handle a number of application conditions.
0
15

-14.7

PSIG

Steam, Steam,vapors, vapors, dust dust

Density Changes

High High vacuum vacuum

Viscous Viscousor or sticky stickyfluids fluids

Abrasive Abrasive fluids fluids

Foam Foam

Corrosive Corrosive processes processes

Temperature Temperature extremes extremes

Agitation Agitation

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Level terminology
Measurement Characteristics Bottom-Up vs. Top-Down Measurement Top-down Top-Down Measurement Poses less potential for leakage devices installed or removed without emptying tank e.g., dipstick, radar gauge Bottom-Up Measurement Typically contacts the process fluid e.g., pressure transmitter, weigh scale
16

Bottom-up
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Level terminology
Measurement Characteristics
17

Inferred vs. Direct Measurement An Inferred measurement is derived from another measurement Ex: pressure transmitter HeadPressure = Level , Mass = Level Density Density Stability of variables is critical to get a good inferred measurement. If variables are not stable, compensation needs to be made. A Direct measurement looks only at the desired variable Ex: floats, dipstick
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Level terminology
Measurement Characteristics Continuous vs. Point Measurement
18

Continuous Measurement
Constant detection of product height Concerned with amount of product May be used to control addition of other components to the vessel

Point measurement
Has the level reached this point? High or low level detection Often used for alarm control May start or stop pumps May open or close valves

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Level terminology
Measurement Characteristics Non-Contact vs. Non-Invasive vs. Non-Intrusive
NonNon-Contact implies that the device does not touch the fluid, but it could be invasive NonNon-invasive implies that the device does not pass the walls of the tank nor touch the process directly
19

Intrusive NonNon-intrusive implies that the device may come in contact with the fluid, but does not protrude into the fluid or interfere with fluid movement
Level 1 - Level

Technology selection
Level Measurement Technologies
Bubbler Dipstick Capacitance Tuning Fork Float Ultrasonic Radar Sight glass Nuclear Displacer 20

Differential Pressure

Gage Glass

Ultrasonic Gap Hydrostatic Weight

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Technology selection
Classification of Level Measurement Technologies
Contacting N oncontacting Point C ontinuous Liquids Solids

21

Bubblers Capacitance Conductivity Displacers Floats HT G Hydrostatic Laser M agnetostrictive Nucleonic Optical Phase Difference Radar Resistance T ape Rotation Suppression Servo T ape Level T hermal Ultrasonic Vibration Weighing
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Technology selection
Classification of Level Measurement Technologies
Density Interface Level Bubblers Capacitance Displacers Floats HT G Hydrostatic Laser M agnetostrictive Nucleonic Phase Difference Radar Resistance T ape Servo T ape Level Ultrasonic Weighing M ass
22

Note: Only continuous devices included

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Technology selection
Factors To Consider Why is the level measurement needed? What are you try to measure? What are you trying to achieve?
Indication of fluid level Alarm set point to prevent spill over Transfer (Sale) of product Contol of Product Mix Leak Detection Interface detection
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What are the conditions within or on the vessel?

Product turbulence Obstructions Mounting constraints Angle of repose for solids Temperature and pressure limits
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Technology selection
Factors To Consider What are the environmental conditions?
Ambient Temperature Humidity Vibration Electro Magnetic Interference(EMI) Transient protection
24

What are the product characteristics?

Corrosive Viscous Dusty, Foam Variable Density Variable Dielectric constant Tendency to Coat Interfaces, gradients, suspended solids Steam or other vapors
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Technology selection
Factors To Consider Common Density/ Temperature Changes
25

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Technology selection
Factors To Consider Typical Dielectric/ Temperature Changes
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Technology selection
Factors To Consider What are the instrument requirements?
Performance requirements Location approvals Power requirements Output requirements Number, location, and size of taps Total costs
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Product Installation Maintenance

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Technology selection
Performance Consideration Temp changes Vibration Noise
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Environmental Factors

Device

Direct vs inferred Measurement capabilities Rangeability

Process Density changes Conditions temperature changes static pressure agitation aeration foam dielectric changes
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Technology selection
Working Capabilities Vary with Technologies
10000+ Capacitance 3626 Pressure w/ seals Nucleonic
29

Pressure, PSI

1000

Pressure/HTG Ultrasonic Point

Displacer

Ultrasonic 73 atm -240 -100 -40 32 195 320 400 600 Radar 800 900+

Temperature, oF
Approximate values are shown. Pressure and temperature limits are shown independently of each other. Level 1 - Level

Technologies
Pressure Transmitters Open Vessel Level Measurement In open vessel a pressure transmitter mounted near the bottom of the tank will measure the pressure corresponding to the height of the fluid above it.
30

Patm

Phigh = Phead + Patm Plow = Patm

Phead Patm
XMTR L H

Phigh - Plow = Phead What happen to Atmospheric pressure?

Cancelled Off
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Technologies
Pressure Transmitters Transmitter mounted above the tap in an open vessel What happens when the liquid level drop below the sensor ?
100% XMTR 0% L H g 0% h
31

The sensor will not be able to sense any pressure change !!

The 0% has to be at least at the same level as the transmitter sensor or below the tapping point..
Level 1 - Level

Technologies
Pressure Transmitters
Zero Suppression is often applied to compress the range of the transmitter OR to cancel the effects of the liquid head in the pipe connecting the transmitter to a tank when the transmitter is mounted below the vessel connection. At min. level the High side
32

pressure is high than the low side pressure

20mA

20mA 4mA Actual Zero Suppressed XMTR L H

Max. Level
Range

Max. Level
Range

Min. Level

Actual Zero4mA Suppressed XMTR L H

Min. Level

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Technologies
Pressure Transmitters
33

Zero Elevation is often applied to cancel the effects of the head caused by the seal fluid in the reference leg (low side) of a transmitter measuring level in a pressurized vessel.

20mA

Max. Level
Range

4mA Actual Zero Elevated

XMTR

Min. Level

L H

At min. level the low side pressure is high than the high side pressure
Level 1 - Level

Technologies
Pressure Transmitters Closed Tank Level Measurement (Dry Leg)
Dry leg: no fluid in low side impulse piping, or leg If the gas above the fluid does not condense, the piping for the low side of the transmitter will remain empty.
34

Ullage or Vapor

Phead
XMTR L H

Phigh = Ptop+Phead Plow = Ptop Phigh - Plow = Phead

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Technologies
Pressure Transmitters Closed Tank Level Measurement (Wet Leg)
Wet leg pressure is additive to pressure on low side of the transmitter. If the gas above the liquid condenses, the piping for the low side of transmitter will slowly fill with liquid. To eliminate this potential error, the pipe is filled with a convenient reference liquid.
35

Ptop= Ullage

Pwet

Phead

Phigh =Phead+Ptop Plow=Pwet leg

top

Phigh - Plow = Phead - Pwet leg

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+P

L H XMTR

Technologies
Pressure Transmitters Limitations Bottom-mount technology: potential leakage Often requires 2 taps Variable density creates errors Temperatures beyond 600 F High vacuum applications are tricky Highly corrosive processes limit life Abrasive processes can damage diaphragms Liquids Only
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Technologies
Pressure Transmitters Bubbler System
Consists of air supply, pressure regulator, flow meter, transmitter & extended tube. Can be used for very corrosive applications. Tank vented. TXR
Pin(flow=const)
37

Pressure to maintain flow = Phead

Air is bubbled through the tube at a constant flow rate. The pressure required to maintain flow is determined by the vertical height of the liquid above the tube opening times the specific gravity.

H S.Gf

Phead = H * S.Gf

Level 1 - Level

Technologies
Pressure Transmitters
Gauge Pressure Transmitter
38

Application of Bubbler system: Allows dp to be a top down measurement No process contact with transmitter Open or low pressure Control of Air supply is important for accuracy

Valve Air Supply

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Technologies
Pressure Transmitters Remote Seals Reliable, Simple, Easy to Use, Well Understood, Flexible Uses: Diaphragm Seals extend limitations due to process conditions such as: high temperatures corrosion viscous materials suspended solids plugging sanitary needs
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Differential Pressure Transmitter

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Technologies
Pressure Transmitters Typical Pressure Applications
CPI / HPI Batch reactors digesters fractionators distillation column bottoms and reflux drums separators surge drums reservoirs intermediate storage... Power drum level dearators... Pulp & Paper Headbox Stock Tanks Chemical Storage tanks Evaporators Low concentration liquor tanks... Food and Beverage Fermentors storage tanks aging tanks brew kettles...
And many more!
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Technologies
Radar Gauge
Frequency Electromagnetic Wavelength, Meters Cycles/second 41

Spectrum

10 22 gamma rays 10 20 10 18 10 16 10 14 10 12 10 10 10 8 10 6 10 4 10
2

10 -13 10 -11

Radar is an Electromagnetic Wave

Radio Detection And Ranging

x-rays ultra violet visible light

10 -9 10 -7 10 -5 10 -3

Radar, 3-30 GHz Microwave oven,

--------super high freq--------------ultra high freq-------------------TV broadcasting-----------------FM Radio-------------------low frequency-----------10 -1

2 - 10 GHz
10 1 10 3 10 10
5

Cellular, pager, 300-3000 MHz

Level 1 - Level

Technologies
Radar Gauge Radar Techniques Pulse Measures range ( distance ) Transmits a pulse and measure time until echo is received Accuracy depends on ability to measure time
Radar signals travel at the speed of light. Must measure in picoseconds ( x10-12 ) ! Cost-effective electronics do not exist to do this accurately !
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Technologies
Radar Gauge Radar Techniques FMCW: Frequency Modulated Continuous Wave Does NOT calculate time-of-flight Evaluates the phase difference between the transmitted and return signal Plotting these phase differences against the transmitted signal yields a result proportional to distance
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Technologies
Radar Gauge Advantages of Radar Gauge Non Contact, Non Intrusive Tolerates Wide Range of Process Conditions Corrosive Processes High Temperatures Changes in Vapor Space Variable Density Variable Dielectric Viscous or Sticky Products Low Maintenance No Special Licenses Required Can measure long distances Liquids, pastes, solids
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Technologies
Radar Gauge Radar Application Considerations Sensors can be completely removed from process by use of a window made out of a nonmetallic material, such as Teflon, Ryton, Ceramic Sensors can be removed from the process without opening the vessel Radar Limitations Cost May not work with processes with low dielectric constant May not work in applications with large amounts of turbulence Process connections tend to be large (>4 flanges)
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Technologies
Radar Gauge Possible Applications
Pulp & Paper High Density Storage Color tanks Bleach tanks Hydropulpers Retention tanks Black liquor tanks Pharmaceutical Batch reactor Chemical storage Power Slurries Chemical Polymers Latex High temp LPG tanks Butane sphere Batch reactors Two-phase sludge Cyclohexane Minerals Steel Scale Holding Tanks
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And More!
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Technologies
Radar Gauge Radar vs. Ultrasonic Gauge Similarities:
Both technologies Top down, non contact Easy to install Good for abrasive materials, slurries Not affected by changing fluid properties: density, conductivity, dielectric
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Differences:
Radar Full vacuum to several hundred psi Wide temperature limits Can handle steam, fog, vapors Can handle some foams and agitation Can be used with windows Ultrasonic Very slight vacuum to about 100 psi Narrow temp band (<200 F) Is greatly affected by changes in vapor space Signal is lost in foam and agitation
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Technologies
Radar Gauge Radar vs. Ultrasonic Gauge
Gas Dry Air Temp (oC) 0 100 100 RADAR million m/s 299.91 299.94 299.10 299.85 299.87 299.93 297.64 ULTRASOUND m/s 331.8 386 404.8 250.0 279.0 415.0 223.0
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Water vapor

Carbon Dioxide 0 50 Ammonia Acetone 0 0

Source: Instrument Engineers Handbook, Liptak

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Technologies
Float Mechanism
Internal Still pipe to guide the float Float Isolating Valve Tank External Still pipe to guide the float Indicator
49

Float

Drain Valves

Indicator

Float-operated gauge level-indicator, indicates liquid level in cone or flat roof unpressurised tanks. Recommended for use on tanks storing water, fuel, oil, chemicals or other liquid products where operations do not require extreme accuracy.
Level 1 - Level

Other technologies
Capacitance Probe
50

A capacitance instrument measures amount of capacitance between two plates of a capacitor. The capacitance of a capacitor increases if a dielectric is placed between the plates Circuit applies high frequency signal to probe C = KEoAd where
K = dielectric constant of material Eo = permitivity of vacuum A = Area of plates (probe) C = capacitance (pF) d = distance between plates
d

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Other technologies
Capacitance Probe How Capacitance varies with process fluid? Level is proportional to dielectric change
Nonconductive Fluid Process fluid is the dielectric barrier Tank Wall forms second plate The variation of dielectric is the measurement Conductive Fluid Process fluid is the second plate Insulation on probe is dielectric The variation of the plate size is the measurement
Nonconductive Coating

51

Level is proportional to plate area change

Level 1 - Level

Other technologies
Capacitance Probe Limitation Change in Dielectric creates error Coating on probe by product creates errors With non metallic tanks or tanks without vertical walls, addition of reference probe is required Calibration can be difficult especially since one cannot bench calibrate Changing vapor space can affect output
52

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Other technologies
Capacitance Probe Potential Applications Pulp & Paper Sewage level Liquor tanks Bulk solids Chemical Interface: fatty acid/water, oil/water Carbon black Separators Food & Beverage Storage silos Oil & Gas Water bottom Water cut
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Other technologies
Displacers Based on Buoyance Force The displacer is buoyed up by a force proportional to the weight of the liquid it displaces Vertical movement of the displacer is converted to angular movement by mechanical linkages
0 0 54

pounds

pounds

Angular movement is then converted to electrical or pneumatic output.

Buoyant force increases as level rise

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Other technologies
Displacers Good for short span measurement
55

Liquid Level Measurement

Interface Measurement

Density Measurement

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Other technologies
Displacers Benefits: Simple, Reliable. Good for Interface measurements. Good for Density measurements. Unaffected by Agitation. Tolerates High Temperatures and pressures. Point or Continuous . Limitations: Does not tolerate viscous, dirty, or sticky fluids Variable density causes errors in level measurement Typically used for smaller spans (cost effective) Must be installed carefully Intrusive & Contact
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Other technologies
Displacers Typical Applications: Oil and Water interface Oil and Gas Separators Stripper Reflux Drum Level Dehydration Units Effluent Separators Absorption Towers Condensate Discharge Accumulators Density and Interface Measurements
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Level 1 - Level

Other technologies
Servo Gauging
Uses a combination of a displacer and a spring balance The servo motor strives to obtain an equilibrium between the displacer and the balance. Any change in level will cause a change in equilibrium. Advantages: Very precise (1 mm accuracy) Can measure level, interface relatively low cost Limitations: Intrusive Mechanical linkages
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Storage Drum

Cable

Balance Detector

Servo Motor

Displacer

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Other technologies
Nucleonic Gauging Single Point System
Gamma rays are emitted from the source. The presence or absence of the gamma rays is measured by the detector.
Gamma
59

Nucleonic level switches use Source radioisotope sources sized to provide measurable radiation at the detector when no product material is present between source and detector.

Detector

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Other technologies
Nucleonic Gauging Continuous System
Nucleonic level transmitters use the same radioisotope sources, but respond to the total absorption of gamma rays as they pass from the source to detector. The amount of radiation reaching the detector is inversely proportional to the amount of material in the vessel.
Detector
60

Source

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Other technologies
Nucleonic Gauging Advantages: Unaffected by:
High temperatures High Pressures Corrosive Materials Abrasive Materials Viscous Materials Agitation Clogging/Plugging
61

Limitations: Large density changes can create errors Layer of coating on vessel walls create errors Licensing Required Leak Checks required Cost

Point and Continuous Liquids and Solids Interface (based on H2 density)

Level 1 - Level

Other technologies
Nucleonic Gauging Typical Applications
Chemical Distillation Tower Batch Reactor Storage Tanks Resin Bed level Hydrocracker reactor Pulp & Paper Digester Level Wood Chip Bins Bleach Tower Consistency Effluent Waste Slurries Liquor concentrates Refining Fractionator Tower Surge Tanks Coke Drum Interface Desalter Food and Beverage Hopper Level Blending Vats Mining Crusher Level Storage silos Slurries Utilities SO2 / Lime scrubber Fly ash Slurries
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Other technologies
Laser
Function: Uses infrared light to send a focused beam towards surface. Time of travel and reflection is measured. Narrow, focused beam: good for applications with space restrictions. Non contacting: uses a window Accuracy: +/- 1 cm Works best in cloudy, shiny liquids or solids May pass through surfaces of clear, still fluids Cannot tolerate dust, fog, steam or vapors High cost Alignment is critical
glass window laser device
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Other technologies
Ultrasonic Gauging
64

A sound pulse(9 to 160 kHz) is transmitted and reflects off the surface back to the transceiver. The true reflected echo pulse is extracted and the time interval between transmission and reception is evaluated electronically.

Advantages:

Sound Waves

Non Contact No element contamination Can be used for liquids and solids Tolerates Many Process Conditions: Varying Density Corrosive Processes Viscous Product Varying Dielectric Sludge Buildup

The higher the level the faster echo reflected

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Other technologies
Ultrasonic Gauging Application Considerations Conditions of the vapor space impact speed of signal travel and thus, the measurement Changes could be due to:
temperature dust vapor composition stratification of the vapor
65

Sound Waves

Some units have temperature compensation Gas blankets can be used to provide uniform vapor space condition
Level 1 - Level

Other technologies
Ultrasonic Gauging Application Considerations Process surface conditions can affect signal return . Surface must have ability to reflect signal. Heavy agitation and foam may cause signal to be absorbed Vortex in fluid can misdirect signal In open, outdoor installations, wind can blow signal off coarse Stilling wells can be used to isolate the surface and contain signal.
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Other technologies
Ultrasonic Gauging Limitations not suitable for vacuum service Cannot tolerate high temperatures (>200 F) Foam interferes with signal Agitation may distort signal Internal obstacles can create false echoes Nearby equipment could generate frequencies that will cause errors Vapor pressure limited to 50 psi
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Level 1 - Level

Other technologies
Ultrasonic Gauging Typical Applications
Chemical Distillation chamber Corrosives Slurries Latex PVC Waxes Food and Beverage Dearating vessel alcohol fermenter baking batter chocolate dairy products grain storage Cryogenic systems (point level) Waste water Clarifier Settling tanks Reservoirs Flood control Sludge levels Pulp & Paper Black liquor w/ solids Pharmaceutical Emulsions Lotions Marine Fuel or ballast water indication Bilge alarm
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Exercise
1. Which has the best accuracy on 6 meter High Water tank? A. Hollow or glass fill float with mechanical gauge (1 inch) B. Servo Gauge (1 mm) C. Pressure Transmitter 0.1% of F.S [ ]

69

2. An inground reservoir is 5 meters deep. Which of the following method(s) will be suitable to measure and transmit the level without having to dig a hole to reach the bottom of the reservoir or the scour main. (Answer Yes [Y] or No [N]) A. B. C. D. E. F. G. Differential Pressure Servo Level Gauge Capacitive Probe Nucleonic Gauging Ultrasonic Gauging Radar Gauging Bubbler System [ [ [ [ [ [ [ ] ] ] ] ] ] ]
Level 1 - Level

Exercise
3. For HTG, why is a 2nd Pressure Transmitter added to tank in the middle ?

70

4. Which one of the following tank gauging system is based on Mass? (A) Radar (B) Nucleonic (C) Servo Balance (D) HTG [ ]

5. Which of the following statement about Radar Gauge is NOT True ? (A) Top-down mounting (B) Can handle agitated & sticky process fluid (C) Can be used on a tank with non-metallic internal surface. (D) Can handle process with deep vacuum [ ]

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Exercise
6.

71

Assuming SG is = 1.1 What is the volume?____________ft3 What is the density of this fluid?___________#/ft3

10

What is the mass?__________pounds What is the pressure level reading? ________in H2O

water = 62.4 # / ft3

Level 1 - Level

Exercise
7. Now, suppose the SG changes to 1.05 and the level does not change What is the volume?____________ft3 What is the density of this fluid?___________#/ft3

72

10
What is the mass?__________pounds What is the pressure level reading? _______in H2O

water = 62.4 # / ft3

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Exercise
8. Pmeasured = 150 inH2O s.g. = 1.5 What is the fluid level in the tank?

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Pin(flow=const)

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