REPORT MARCH

547 2016

Hydrocarbon process single and

multi-layer level measurement
Recommended Practice

select process
Acknowledgements
IOGP Instrumentation and Automaton Standards Subcommittee (IASSC)
Level Measurement Task Force:

BG Group PETRONAS Carigali Sdn Bhd

BP Repsol

Endress + Hauser Siemens

Emerson Statoil

Honeywell Total

Krohne Vega

Petrobras Yokogawa

Photography used with permission courtesy of michaelmjc/

iStockphoto and ThomasVogel/iStock (Front cover)
William Fawcett fotoVoyager.com (Back cover)

Disclaimer

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 REPORT MARCH
547 2016

Hydrocarbon process single and

multi-layer level measurement
Recommended Practice

Revision history

VERSION DATE AMENDMENTS

1.1 March 2016 Correction of reflector measurements (page 49) from 50mm x 50mm
to 500mm x 500mm and 500mm above the floating roof.
Minor typo corrections.

1.0 December 2015 First release


TableofContents
1. Introduction 6
1.1 Objectives 6
1.2 Scope 6
1.3 Reference documents 7
1.4 Abbreviations 8
2. General 9
2.1 Pressure vessel connection 9
2.2 Vessel bottom connection 10
2.3 Range selection 10
2.4 Material 11
2.5 Environment 11
2.6 Standpipes vs. sensor cages 11
2.7 Level sketches 12
2.8 Data 12
2.9 Emulsion 13
2.10 Calibration 14
2.11 Stilling wells 15
2.12 Centring disk 15
2.13 Control and safety 15
2.14 Heat tracing 16
2.15 Maintenance access 16
2.16 Service capabilities 17
3. Differential pressure transmitter 18
3.1 Measurement principle 18
3.2 Limitations 19
3.3 Selection 19
3.4 Design 22
3.5 Installation 26
3.6 Calibration and configuration 27
4. Displacer (buoyancy) 28
4.1 Measurement principle 28
4.2 Limitations 29
4.3 Selection 29
4.4 Design 30
4.5 Installation 30
4.6 Calibration and configuration 30
5. Ultrasonic 32


5.1 Measurement principle 32
5.2 Limitations 32
5.3 Selection 32
5.4 Design 32
5.5 Installation 33
5.6 Calibration and configuration 34
6. Capacitance 35
6.1 Measurement principle 35
6.2 Limitations 36
6.3 Selection 37
6.4 Design 37
6.5 Installation 38
6.6 Calibration and configuration 38
7. Non-contact radar 40
7.1 Measurement principle 40
7.2 Limitations 42
7.3 Selection 44
7.4 Design 45
7.5 Installation 46
7.6 Calibration and configuration 49
8. Guided wave radar 50
8.1 Measurement principle 50
8.2 Limitations 51
8.3 Selection 55
8.4 Installation 55
8.5 Calibration and configuration 62
9. Hybrid capacitance/GWR 63
9.1 Measurement principle 63
9.2 Limitations 64
9.3 Selection 64
9.4 Design 64
9.5 Installation 65
9.6 Calibration and configuration for interface level measurement 65
10. Nucleonic 66
10.1 Measurement principle 66
10.2 Limitations 68
10.3 Selection 69
10.4 Design 69


10.5 Installation 69
10.6 Calibration and configuration 71
11. Magnetic Level Indicator 73
11.1 Measurement principle 73
11.2 Limitations 73
11.3 Selection 74
11.4 Design 74
11.5 Installation 75
11.6 Calibration and configuration 77
12. Manual measurement 78
12.1 Measurement principle 78
12.2 Limitations 81
12.3 Selection 83
12.4 Calibration and configuration 83
Annexes 84
Annex A Pressure/temperature influences 84
Annex B Pressure and temperature ranges 87
Annex C Interface Measurement Selection Guidance Automatic level measurement 88
Annex D Symmetric and asymmetric capillaries 89
Table of Figures 91
Table of Tables 93

 1. Introduction
Measurementofsingleandmultilayerlevelinthehydrocarbonprocessingindustriesiscommonlyneeded,
butdoingsoaccuratelyisoftenchallenging.Thereareagreatdiversityofsituationswhichrequiresuchlevel
measurement.These can involve, for example, pure fluids, corrosives and slurries.
Theenvironmentfortheselevelsensorsvariesfromvacuumtohighpressureandfromlowtohigh
temperature.Todealwiththesevariedsituationsandenvironments,manytypesofsensors,employinga
varietyofmeasurementtechniques,havebeendeveloped.
Theseinclude,forexample,externallymounteddisplacers,differentialpressuretransmitters,guidedwave
radar,ultrasonictransducers,singleelectrodeandmultielectrodecapacitancesensors.Themethodsusedin
thehydrocarbonprocessformeasuringthesingleandmultilayerarelimitedbecauseoftherequestonhigh
reliability,varietyoffluidsandharshenvironments.

1.1 Objectives

TheobjectivesofthisIOGPRecommendedPractice(RP)areto:
provideupstreamoilandgasindustryguidanceintheprovisionoflevelmeasurementfroman
instrumentationperspective
beintheformofanIOGPformatthatispublicallyavailable
notcontradictanyexistingIEC/ISO/APIstandards,buttoprovidefurtherclarificationonthe
commonlyusedtechnologiesusedinthecontextofupstreamoilandgas
makeiteasierforProductManufacturerandAssetOwnerstodeliverlevelmeasurementdevices
proveninuseandsuitableforspecificapplications.

1.2 Scope

ThisRPcoverstheselectionandinstallationofinstrumentsusedforsingleandmultilayerlevel
measurementthatareencounteredinupstreamhydrocarbonfacilities.
Thisincludestheoverallandinterfacehydrocarbonprocesslevelmeasurementforliquids,recognizingthe
needtocaterforemulsionandfoamingissues.
Excludedfromscope:LNG(includingTankGauging),cryogenicandrefrigeratedstorage,legalmetrology(i.e.
fiscalorcustodytransfer)orsolid(pelletorsulphursilos,cokechambers,etc.)applications.

Notes
1. Thisdocumentincludestheidentificationoftheinstrumentthatcanbeusedinparticularprocess
applications(e.g.safety,controlormonitoring).
2. Thedata(e.g.temperature,DC,pressure)qualifiedinthisdocumentshouldbeconfirmedwiththeproduct
manufacturer.

1.3 Referencedocuments

APIRP551,ProcessMeasurementInstrumentation.
APIMPMSChapter3.1A,StandardPracticefortheManualGaugingofPetroleumandPetroleum
Products.
DesignandFabricationofPressureVesselsaccordingtoASMEVIII.
DesignandFabricationofPressureVesselsaccordingtoBSIPD5500.
ISO10418:2003,PetroleumandnaturalgasindustriesOffshoreproductioninstallationsAnalysis,
design,installationandtestingofbasicsurfaceprocesssafetysystems.
NFPA58.LiquefiedPetroleumGasCode.1998Edition.
ProcessIndustryPractices(PIP).PCELI001.LevelMeasurementGuidelines.

1.4 Abbreviations

BPCS BasicProcessControlSystem
DBB/SBB DoubleBlockandBleed/SingleBlockandBleed
DP DifferentialPressure
ETFE Ethylene/TetrafluoroethyleneCopolymer
FCC FederalCommunicationsCommission
FFT FastFouriertransform
FMCW FrequencyModulatedContinuousWave
FPSO Floating,Production,StorageandOffloading
GWR GuidedWaveRadar
ID InternalDiameter
LG LevelGauge
LNG LiquefiedNaturalGas
LOP LayerOfProtection
LT LevelTransmitter
LPG LiquefiedPetroleumGas
PPE PersonalProtectionEquipment
PFA Perfluoroalkoxy

PTFE Polytetrafluoroethylene

PVDF PolyvinylideneDifluoride
MLI MagneticLevelIndicator
SIS SafetyInstrumentedSystem
SS StainlessSteel

2. General

2.1 Pressure vessel connection

Levelinstrumenttappingonvesseloutletpipingarenotrecommended.APIRP551(reaffirmedin2007,
section3.2.4)providesguidancewithrespecttoadynamicflowconnection.

Levelmeasurementinstrumentsshouldbeisolatableformaintenance,dismantling/removalandcalibration
withoutaffectingproduction,exceptwhenstoppingtheproductionforsuchactivitiesisdeemedacceptable.

Levelinstrumentsmaybeinternallyorexternallymounted.Theyshouldbeprovidedwithindividualisolation
facilitiesallowingforsensorremoval,andcage/chambercleaning(seeFigure1).

Asfaraspossible,themeasurementinthesensorcage/chambershouldberepresentativeoftheactuallevel
inthevessel.Todisplayarepresentativelevel,thismightrequireadditionaltapping/connectiononthe
vessel.

IsolationvalvesID(e.g.usedforDPorRadar)shouldbethesameasthenozzleID.

Levelinstrumentflangeshouldbedesignedinaccordancewiththepiping/vesselcodeandmaterial.Flange
facingshouldbefreeofanycoating/insulationandsuitableforreceivingthepiping/vesselgaskets.

Note:Irrespectiveofthelocationofinstrumentnozzles,theweldedgedistancesrequirementfromPiping
CodesuchasASMEVIIIand/orPD5500Vesselsshouldhaveadequateaccess/distanceforconstructability
andinspection.

Figure1Pressurevesselmountingprinciple

2.2 Vessel bottom connection

Connectionstobottomvesselheadsshouldbeavoidedsinceexactpositioningisdifficult,deadlegsare
createdandoftenthevesselskirthastobepenetrated.

2.3 Range selection

Thenormaloperating/alarm/tripsettingsshouldbedefinedbyacombinationofprocess/vessel/instrument
operationallimits.

Measurementrangesusedforprocesscontrolsystem(LTforBPCSandLG)andsafetyinstrumentedsystems
(LTforSIS)shouldgenerallyhavethesamerangeandprocesstappingelevationstoallowforcontinuous
monitoringofanydiscrepancybetweenvariousmeasurements.However,ifforaccuracyorsensitivity
reasonsthiscannotbeachieved,thentheprocesscontrolsystemmeasurementrangeshouldcoverthe
safetyinstrumentedsystemsmeasurementrange.

Thedefinitionofalarmandtriplevelsshouldbereviewedbetweentheprocess,pipingandinstrumentation
specialiststoensurefeasibility.Appropriate(minimum)differentialbetweenthealarmandthetripshouldbe
considered.

Themeasuringrangeshouldbesketched/definedasinFigure2:

Figure2Measuringrange

10

2.4 Material

Allmaterialsusedforthelevelmeasurementshouldbeselectedaccordingtotheequipment(e.g.piping,
vessel,tank)andtheprocessfluids.

Unlessotherwisespecified,wetpartsofinstrumentationdevices(displacer,float,diaphragm..)shouldbe
minimumAISI316or316LSS.

Specialcareshouldbetakenforselectionofmaterial(e.g.goldplatedmembrane)incontactwithlow
molecularmassfluidorifhydrogenpermeationisexpected.

MaterialofhousingshouldbeAISI316or316LSSforoffshore.Alternatively,othermaterialssuchasA365
gradealuminum(epoxypainted)orGRPmayalsobeused.

2.5 Environment

Alldevicesusedforlevelmeasurementshouldbesuitablefortheirenvironmentalconditions.Thisappliesto
thetemperature,humidity,electromagneticcompatibility,ingressprotectionaswellasthehazardousarea.
Therelevantcertificationshouldbeprovided.

Weightandavailablespaceconstraintsparticularlytoallowremovaloftheinstrumentshouldbetakeninto
accountwhenselectingalevelmeasurementtechnology.

LevelInstrumentsshouldbeassessedfortheextremesofweatherprotectionincludingsunshadesand
protectionboxesasrequired.

2.6 Standpipes vs. sensor cages

Thetermsstandpipeandsensorcagesareoftenmixedup.Inordertoclarify,thefollowingdefinitionsare
used:

Standpipe/Bridle
Thisisanexternalextensionofthepressurevessel,towhichmultipleinstrumentscanbeconnected.
Astandpipeshouldfollowthepressurevesselcode.Usuallynoinstrumentisinstalledinsidethe
standpipeitself.Isolationvalvesmaybeusedbetweenvesselandstandpipe(asperAPIRP551
reaffirmed2007,Figure12).Eachinstrumentconnectedshouldhaveitsownisolationvalves,vents
anddraintofacilitatemaintenance.Thedistancebetweenthestandpipeandthevesselnozzle
shouldnotexceed11.5m.Longconnectionscouldpotentiallycausetemperaturegradients,
formationofhydrateandreductioninlevelcouplingbetweenthestandpipeandthevessel(referto
APIRP551reaffirmed2007,Figure12).

Sensorcage/chamber
Thisisanindividualcage/chamberinwhichthelevelsensorisinstalled,partofasinglelevel
instrument.Thesensorcage/chambercanbeattachedeitherdirectlytothepressurevesselortoa
standpipe.Thesensorcage/chambershouldhavededicatedprocessisolation,ventanddrainvalves
provided.Drainvalvesshouldbeinstalledatthebottomconnectionofthesensorcageand
provisionsshouldbemadefortheappropriatedisposalofthedrainedmaterial.Ventvalvesare

11


providedtoallowdepressurizationoftheinstrumentpriortodraining.Intoxicservices,drainsand
ventsshouldbepipedawayfromtheinstrumenttoasafeareaordisposalsystem.

Careshouldbetakentoreducethetemperaturegradientbetweenthevesselandthe
Standpipe/bridle/sensorcage/chamber.

Standpipes,bridles,sensorcagesandchamberscanbereviewedandassessedforthermalinsulationand
traceheatingrequirements.

2.7 Level sketches

Levelsketchesshouldbepreparedatanearlystageoftheengineering.Levelsketchesshouldincludedetails
relatedtonozzlesizesandheights,vesselinternalandexternalsupports,material,sensor/sourcelocation,
etc.inlinewiththeProductManufacturerrecommendation.

Levelsketchesshouldindicatealllevelrelatedinstruments(transmitters,gauges,switches)forall
applications(i.e.BPCSand/orSIS)withtappingconnectionsandnormaloperating/alarm/tripsettings.

Levelsketchesshoulddescribelevelthresholdinbothlengthand%measuredrange.

Note:Sufficientclearancetofacilitatelevelinstrumentandchamber/cagedrainingtoasafelocation/closed
drainsystemshouldbeincorporatedintothedesign.

2.8 Data

Processdatashouldbecarefullyaddressedwithalldetailedfluidfeaturesaswellasthedifferentlayerstobe
measured.

FromthedesignperspectivestheBPCSlevelmeasurementuncertaintyshouldbebetterthan+/5%ofthe
readingandtheSISlevelmeasurementuncertaintyshouldbebetterthan+/2%ofthereading.

Forfloatingfacilities(e.g.FPSO),thedesignshouldtakeintoaccountthevesselmotion(e.g.pitch,roll)which
caninfluencethemeasurementrangeandtechnologyselection.Levelsketchesshouldintegratethemargins
ofrangeandthresholdsduetothevesselmotion.

Localradiationsafetyrequirements,localradiofrequencyrequirementsandoperationalrequirements
(radiography)andhowsucheventsaremanagedtogetherwithenvironmentaldatashouldbetakeninto
account.

2.8.1 Process data

Foreachlevelinstrumenttheminimumfollowingprocessdatarange(e.g.min,max,operating,anddesign)
shouldbedefined:

processdata(e.g.density/SG,temperature,pressure,dielectric,viscosity)
specificservice(e.g.corrosive,cryogenic)
levelmeasurementrequirements(e.g.safetyorcontrolapplication,alarmsandtripvalues)

12


presenceofothernucleonicisotopesinthefluid
presenceofsalt
presenceofoilfilm/buildup
presenceofsand/water/emulsion/oil/foam
thetypeandnameofthesubstance/processfluidtobemeasured...

2.8.2 Level data

Foreachlevelmeasurement,thefollowingdatashouldbedefinedasaminimum:

availablenozzlediameterandflangeconnection
vesselinternalandexternalarrangementsandlayouts
vesselmaterialcompositionandwallthickness
hookup,locationinthevesselandinstallation
nucleonicsourceanddetectorscalculationnote(s)
nucleonicsourceintensity
geometry,distanceandlocationofnucleonicsourcesanddetectors
operationandmaintenancemanualsaswellasparticularinstructions(e.g.adjustmentand
calibrationinterventions)
calibrationprocedure(infactoryandinoperation)
additionalscreeningaroundfinalnucleonicsourcecontainerinstallationlocation
dippipefeatures(material,thickness,flangediameter)
proceduresforhandlingandstorage
certificatesoflicensingandregulatoryrequirements

2.9 Emulsion

Anemulsionisamixtureoftwoormoreliquidsthatarenormallyimmiscible.Emulsionsarepartofamore
generalclassoftwophasesystemsofmattercalledcolloids.Althoughthetermscolloidandemulsionare
sometimesusedinterchangeably,emulsionshouldbeusedwhenboththedispersedandthecontinuous
phaseareliquids.Asanexample,oilandwatercanform,first,anoilinwateremulsion,whereintheoilisthe
dispersedphase,andwateristhedispersionmedium.Second,theycanformawaterinoilemulsion,
whereinwateristhedispersedphaseandoilistheexternalphase.Multipleemulsionsarealsopossible,
includingawaterinoilinwateremulsionandanoilinwaterinoilemulsion.

Particularattentionshouldbepaidtoanyinterfacemeasurementinthepresenceofemulsion.Densityof
waterinoilemulsionwillchangedependingonwaterfraction.Athighwatercontent(approximately80%of
waterinoil)thedensityiscomparabletothewater.Thendensitydecreases,notnecessarylinearly,withthe
decreasingofthevolumefractionofwater.Atalowwatercontent(approximately20%ofwaterinoil),the
densitydropssharplytotheoilvalue.Thismeansthattheemulsiondensityisnotconstant.However,the
emulsiondensitycanbeseenastheaverageoftheoilandthewaterdensity.Dielectricorconductivity
valuesoftheemulsionfollowthesameprincipleofnonlineardispersion.Thisimpliesthattheemulsion
cannotbeseeneasilyasasingletwofluidsinterface.

Note:Thefoamalsoisanonuniformfluid;density,dielectricandconductivityparametersvaryina
stochasticmanner.

13

2.9.1 Sensor cage/stand pipe interface level measurement with emulsion

Anemulsionlayerattheinterfaceoftwofluidsmayormaynotbeseenbytheinstrumentdependingupon
thehookuparrangement.Whenusingasensorcage/standpipe,thefollowingcanbeconsidered:

Figure3:theinterfaceleveldeviceinthesensorcage/standpipedoesnotseetheemulsioninthe
vessel,sothemeasuredvalueonlyrepresentstheaverageinterfacelevel
Figure4:theinterfaceleveldeviceinthesensorcage/standpipeseestheemulsionlayersothe
measuredvaluerepresentsaccuratelytheinterfacelevel

Figure3Interfacelevelwithnoemulsion Figure4Interfacelevelwithemulsionrepresentativeness
representativeness

Note:theaccuracyoftheinterfacelevelmeasurementinthepresenceoftheemulsionwilldependuponthe
numberofnozzlesprovided,theselectedlevelsensortechnology,thecorrectspecificationofthetechnical
data,i.e.SGandthoroughcommissioningandcalibrationoftheinstrument.Thenumberofnozzlesthatcan
beprovidedonatankorvesselisoftenlimitedduetothespaceantthemechanicalintegrityofthevesselor
tanks.Thus,ifaccuratelevelmeasurementisrequiredinthepresenceofemulsion,adirecttopmounted
technologylevelshouldbeconsidered.

2.10 Calibration

Calibrationshouldbeperformedpriortothefactoryacceptancetestandpriortoshipment.Acalibration
certificateshouldbeprovidedthatdetailthetraceabilityofthetestequipmentused.Sitecalibrationshould
beperformedtoensurethefactorycalibrationhasnotdeterioratedduringtransportationandanysite
specificrequirementsareaccommodated.Anyshippingstops,seals,plasticfitments,temporarygrommet
sealsorguidestoensuresafeshippingshouldberemovedpriortofittingandmechanicalcompletion.

ParticularattentionshouldbepaidtocalibrationofRadar,GWR,CapacitanceandNucleonicinstruments.
Thelowerrangevalueshouldbecalibratedwithoutanyprocessfluids,butasfaraspossiblewithallvessel
utilities(e.g.energyforelectrodehydrators)present.Thisshouldtakeintoaccountanysignal
noise/disturbance.Thehigherrangevalueshouldbecalibratedwiththemaximumfluidleveltobe
measured.Specialtoolsshouldbeprovided.Anyspecialsensororprobecoatingshouldnotinfluencethe
calibration.

Arrangementforinlinecalibrationandflushingoftheinstrumentisrecommended.

OnsiteverificationshouldbecompletedforinstrumentsassignedaspartofaLOP,e.g.SISandcriticalalarms.

14

2.11 Stilling wells

Astillingwellisaperforatedpipetoallowfreemovementoffluid.Thispipeisequippedwithatopmounted
flangewhichissupportedatthebottomofthevessel.Foralongstillwell,supportshouldbeprovidedalong
itslength;howeverthesesupportsshouldnotaffectthemeasurement.

Stillingwellsprovideastablegaugereferencepoint(limitverticalmovement),andprovidearelativelyquiet
productsurfaceduringfillingandemptyingofthevessel,especiallyifswirlexists.

Stillingwellsmayactasawaveguidefortheradarenergy.Thewellhelpstoconcentratetheemittedsignal
andminimizethesignalloss.Thelossofsignalisgenerallyduetoalowproductreflectivity(causedbyalow
dielectricconstant)orsurfacephenomenalikeboilingoffandvapourmist.

Stillingwellsshouldnotbeusedwithviscousfluid,dirtyfluidorfluidfilmbuildup.Stillingwellshouldbeone
piecefromthetoptothebottom(i.e.nogaps).

Thefollowingfeaturesshouldbeconsideredforstillingwell:

AISI316SSminimumwithsmoothroughness6.3m(noweldingparts)
onepiecefromthenozzleflangewithconstantdiameter.

Stillingwellsslotwidth/holesdiametershouldgenerallybe1/10ofthestillingwelldiameterwithaminimum
of0.635cm.Spacingbetweenslots/holesshouldminimumbe15cm.

Slots/holesshouldbedeburredandtheirquantityminimized.Holesshapemaybeslottedorcircular.Holes
shouldbeonbothsidesofthestillingwell,inordertominimizetheriskofpluggingespeciallyforwaxing
service.

Stillingwelldiametershouldbeminimum20cm(asperAPIMPMS3.1A).

StillingwelldesignandconstructionshouldbeapprovedbytheProductManufacturer.

2.12 Centring disk

Centringdiskusedinstillingwellsshouldbecompatiblewiththefluidproperties(buildup,viscosity)and
mountedoutsidethemeasuringrange.Considerationshouldbetakenintoaccountwhenusingaweighted
bottommountedontherodinsteadofusingcentringdisks.Centringdisksshouldbeprovidedasperthe
ProductManufacturerrecommendation.

2.13 Control and safety

Levelmeasurementsshouldbedesignedtoensurethatthelikelihoodofcommoncause,commonmodeand
dependentfailuresbetweenmonitoring,controlorsafetyprotectionlayersareaddressed.

Thisdesignshouldconsiderthefollowing:

independencybetweenprotectionlayers

15


diversitybetweenprotectionlayers
physicalseparationbetweendifferentprotectionlayers
commoncausefailuresbetweenprotectionlayers.

Assuch,differingmeasurementprinciplesarerecommendedforcontrolandsafetyfunctions.

WithreferencetoISO10418issue2003,6.2.9.

Thetwolevelsofprotectionshallbeindependentof,andinadditionto,thecontroldevicesusedin
normalprocessoperationitissuggestedtochangetherecommendationtoarequirementfor
separatenozzles.

Thesafetyfunctionshouldprovideareliableandsufficientlyfastdetectionofprocessupsets.Sincethe
controlfunctioncanbothworkasbackupaswellascomparisonofthesafetyfunctionequalperformanceis
recommendedforcontrol(accuracyandtrippointshouldbeconsidered).

Ifshutdownmeasurementsrequireinputfromothervariables(e.g.temperatureandpressure)tocalculate
thecorrectvalue,theseinputsshouldbeseparateforcontrolandshutdownfunctions.

Itshouldnotbepossibletoinadvertentlyisolateinstrumentationforshutdownfunctionsfromtheprocess.

Levelinstrumentationusedonprocessvessels,shouldbedesignedsothatoneofthelevelinstrumentsused
forcontrolandsafety,shouldnotbeaffectedbyradioactivedisturbancefromtracers,scaleandxrays.
Levelgaugeisrecommendedfortheentiremeasuringrange.Levelgaugesareusedforlocaloperationandas
referencetolevelinstrumentation.

Ifmultipleleveldevicesarerequired(e.g.onedeviceforcontrolandseconddeviceforalarm,orpotentially
severaldevicesaspartofaSIS),theuseofdiverseleveltechnologiesshouldbeassessed.
Considerationshouldbegiventocomparisonofdifferentdevicesusedonthesameduty,withcross
comparisonandalarmsfunctionfromadeviatedpercentage,i.e.5%.

2.14 Heat tracing

Allinstrumentnozzlesshouldbelocatedsuchthattheriskofblockageandsolidificationinthenozzleis
minimized.Ifthereisriskofhydrateformationorfreezingintheinstrumentnozzlesorinstrumentimpulse
lines,applicationofheattracingshouldbeconsidered.Note,however,thattheremaybesafety
requirementsconnectedwiththeheattracing,i.e.hazardousareaequipmentrequirementsorover
temperatureprotection.

2.15 Maintenance access

Alllevelinstrumentsshouldbedesignedforlongtermstabilityandoperation.Intervalsforplanned
productionstopsarenormallytwoyearsorlonger.

Relief/drainagetubingorpipeshouldberoutedtoasafelocationaccordingtoarearequirements,i.e.toa
safelocation/closeddrainsystem.
Maintenanceoperationshouldtakeintoaccountthehazardousareacertificationtypee.g.Exia/ib,Exd

16


Levelinstrumentsdonotnormallyrequirereadabilityfromdeck.Levelgaugesorindicatorsshouldbe
readablefromdeckorpermanentplatform.
Isolationvalvesshouldbeavailableforoperation.

2.16 Service capabilities

DuringthedesignphaseitisrecommendedtoincludetheProductManufacturerintheproperdesign,
constructionandinstallationofthefacilities(e.g.levelsketch,hookup,stillingwells).

Atsite,theProductManufacturershouldhavethecapabilityofassistinginthecommissioningandstartup
activities,providingspecifictraining,performingsitecalibrationandissuingspecificdetailedmaintenance
procedureforequipmentcleaningandreplacement.

TheProductManufacturershouldprovideacomprehensivespareslisting,partnumbersandthetimetaken
toexpeditebasicconsumableitems.

TheProductManufacturershouldprovideobsolescenceplantoindicatesparepartavailabilityforeach
modelforuserstoplanforupgradingorstockingplanasappropriate.Lifecyclecost(i.e.totalcostof
ownership)maybeevaluatedforselectionofmeasurementtechnology.

Thesesparesshouldbeaddedtothemaintenancemanagementsystemsthatlogsanddetailstheinstalled
deviceonthespecificsiteandinstallation.

17

 3. Differential pressure transmitter

3.1 Measurement principle

Theprincipleofdifferentialpressurelevelmeasurementisbasedonhydrostatichead.

Hydrostaticpressuremeasurementisthemostcommonmeansforliquidandinterfacelevelmeasurements.
Formostapplications,differentialtransmittersarepreferredbecausetherangeselectionisflexibleand
widelyunderstood.Theyareusedwithopenandenclosedvessels.Differentialtransmittersareusually
connectedtothesideofavesselortankwithisolationfacilities.

3.1.1 Interface liquidliquid level calculation example

ThedifferentialpressureDP=hinterfacexgx[21]+1xgxH (Equation[1]).

Therangeis:

Athinterface=0 > DP = 1 x g x H
Athinterface=H > DP = 2 x g x H

Figure5DPmeasurement

:1Liquid1Density(kg/m3)

2:Liquid2Density(kg/m3)

hinterface:InterfaceLevelbetweentheLiquid1andLiquid(m)

g:9.81(m/s)

Interfacemeasurementrequiresitsownconnectionintotheupperandthelowerphase.

Equation[1]isapplicableifthereisonlyonevariable.Foraninterfacelevelmeasurementitshould
behinterface.

UsingthesameprincipleandEquation[1],densityofasinglefluidcanbemeasuredifbothtapping
arepermanentlyandfullyimmersed.

18
Followingtheprinciple,measurementofseveralinterfacelayerscanbeconsideredbystagingeachinterface
levelmeasurement.Foraninterfacemeasurementbetweentwoliquidsthelimitationisderivedfrom
Equation[1].

Thecombinationofdensitydifferenceandthedistancebetweentheupper/lowernozzlesshouldresultina
minimumDPrangeofaround30mbar.

3.2 Limitations

Ifbothdensityvalues2and1aresimilar,theinterfacelevelmeasurementmaynearlynotbedetectedby
thetransmitter.ThisdependsontheDPrange,accuracyanddistancebetweentheupperandlowernozzles.
Thisoccurstypicallyforaninterfacemeasurementbetweenoilandwaterthecaseofpresenceofheavyoil
(theoildensityvalueisnearlythesameasthewaterdensityvalue).

Accuracydependsontheliquiddensityvariation.Tocompensateadensitymeasurementshouldbe
provided.
Forvesselundervacuum,DPwithremotediaphragmsealisrecommended.Thetransmittershouldbe
installedbelowthebottomnozzle.
Forheavycrudeoildirty,foaming,foulingorcloggingservicestheDPwithremotediaphragmsealis
recommendedwithnozzle,flushingringandheattracing(e.g.freezingoil)asrequired.
Themountingofheavyinstrument(includingallaccessories,i.e.DBB/SBBvalves,flushingring,etc.)tothe
nozzlesshouldbeverifiedwiththenozzlelocalstressverification(staticanddynamic/fatigue).Sufficient
supportshouldbeprovidedforminimizingtheweighttransferredtothenozzles.

3.3 Selection

Differentialpressuremeasurementcouldbeconsideredformostapplicationswithliquidgasorliquidliquid
interfacelevelmeasurement.

Differentialpressuretransmitterscanbeusedinseverelyturbulent,dirty,inpresenceoffoamabovethe
liquidorfoulingservicewithdiaphragmsealsandcapillaries.

Differentialpressuretransmitterwithdiaphragmsealsandcapillariesarepreferred.Thisshouldbeprovided
withaflushingringmountedbetweentheprocessflangeandthediaphragmseal.

Capillariesshouldbespecifiedatthecorrectlength,withouttheneedforcoilingexcesscapillarythatis
surplustotherun.Capillariesshouldbeprotectedfromdamageusingabasicchannelsystem,allowing
sufficientbendradiusforthecapillaries.

Diaphragmmaterialshouldbecarefullyselectedaccordingtothetypeoffluid(e.g.goldplatedinpresenceof
hydrogen).

Theuseofwetlegswithintermediateliquidsandzeroadjustmentimpliesmorecomplexrangecalculation
andhighermaintenanceneeds.Differentialpressuretransmitterusedwithoutdiaphragmsealsand
capillariesshouldhaveblockandbleedvalvemanifoldsasaminimum.Invapourorcryogenicservices,the
drylegshouldhaveaselfpurge.

19
Aparticularattentionshouldbepaidtotheprotectionandheattracingofdry/wetlegs.Forcapillarytubing,
theselectionoftubingfluidshouldconsidertheambienttemperature(topreventfreezing).

Themountingofheavyinstrument(includingallaccessories,i.e.isolation/drainvalves,flushingring,etc.)on
thenozzlesshouldbeverifiedwiththenozzlelocalstressverification(staticanddynamic/fatigue).Sufficient
supportshouldbeprovidedforminimizingtheweighttransferredtothenozzles.

Highstaticpressurecancreateameasurementzeroandfullscaledrift.Thiscanbecompensatedasrequired,
bymeasuringandcompensatingthestaticpressure.

Forlowrange(e.g.below300mm)orsimilardensitiesbetweentwoliquids(foraninterfacemeasurement),
aparticularattentionshouldbepaidtosourcesofmeasurementerror,suchas:

temperature/densityvariationofcapillaryfluid
measurementresolutionerrordueto2or3nozzleanddiaphragm
zeroerrorduetoair/liquidpocketsinthehookup/transmitterorfoulingofthediaphragm
uncertaintiesofthetransmitterwhenmaximumpossiblecalibrationrangeofthecellismuchgreater
thanactualcalibratedrange.

3.3.1 Impulse piping

Foratmosphericventedvesselthelowpressuresideisconnectedtotheatmosphere.Windeffectorinsect
shouldnotaffectthemeasurement(e.g.usingabugfilter).
Theimpulselineisusedtointerfacetheinstrumentwiththeprocessconnection.Therearetwomethods
whichcouldbeusedtoconnecttheinstrumenttheprocess:
usingawetleg
usingadryleg.

Figure6DPImpulse

Wetleg
Ifthereferencelegisfilledwithaliquid,apermanentzerooffsetwillbecreated.Thisoffsetshouldbe
compensated.
Thewettedlegliquidshouldbeselectedforavoidingtheriskofevaporationandleakage.
Atrifoliatelabelinthefieldshouldbeaffixedtothethreewaymanifoldblock,highlightingThisleveldutyis
onawetlegsystem.Equalizationofthetransmitterblockwillresultinlossofthewetleg.

20
Dryleg
Gascompatibilitywiththedrylegmaterialshouldbeconsidered.Gaschangestateorliquidpresenceinthe
drylegshouldbecarefullyaddressed.
WhereuseofDifferentialPressuredrylegsystemaredeployedonaclosedtank,theyshouldbeassessedto
ensurenoexcessfluidorcondensatecanbuildupinthelowpressure(dry)impulseleg.
Drylegsshouldincludeanisolabledrainagepotattheirlowestpoint(belowHPtap)forallowingthe
condensatestobedrained.

3.3.2 Remote diaphragm seal

Diaphragmsealcapillariesfilledwithoilrequiresadedicatedconfigurationoftherangewithazerodrift.
Incaseoftallmeasurementrange(e.g.above6m),twoseparateremotesensorsmaybeused.The
measurementprincipleisbasedonaremotesensorreplacingthecapillaries.Inthiscase,adetailed
procedureforthecalibration(includingthezeroshift)shouldbestudied.
Fordensitymeasurementtheliquidshouldalwaysabovetheuppernozzle.

Figure7DPLevelvsdensitymeasurement

3.3.3 Symmetric and asymmetric capillaries

Differentialpressuresealsystemistypicallyspecifiedwithidenticalcapillarylengthsandsealconfigurations
onboththehighandlowpressureprocessconnections.Thistypeofsystemistraditionallyspecifiedbecause
itcompensatesfortemperatureinducederrors.

Theoilvolumeinthecapillarywillexpandandcontractcausingfluctuationsintheinternalpressureofthe
capillarysystem.Thiserrorwillbecancelledoutbecausethesameexpansionandcontractionofoilvolume
willoccuronboththehighandlowsidesofthetransmitterduetosymmetricalconstruction.Thesecond
sourceoftemperatureinducedmeasurementdriftoccurswhenacapillarysealsystemisinstalledwitha
verticalseparationbetweenthetwoseals.Thedensityofthefillfluidwithinthecapillarywillfluctuatewith
thechangeintemperatureandcausetheamountofheadpressureforcethatismeasuredbythetransmitter
tovary.

21
Equallengthsofcapillarycannotcompensatethischangeindensityduetolowpressuresidegenerallybeing
mountedatahigherelevationthanthehighpressureside.Anasymmetricaldesignminimizesthefillfluid
volumeonthehighsideinordertocounteractthetemperatureinduceddensityeffectsalwayspresenton
anyverticalinstallation(seeAnnexD).

3.3.4 Electronic DP level system

Thismeasurementprincipleisbasedonindependentpressuremeasurements.RatherthanusingasingleDP
transmitterwithmechanicalimpulsepipingorcapillary,electronicDPlevelsystemusestwodirectmount
gageorabsolutesensorsthatareconnectedwithanonproprietaryelectricalwire.

ElectronicDPlevelsystemreplacesthelonglengthsofoilfilledcapillaryandimpulsepipingwithanelectrical
wirethatisimmunetotemperatureinducedeffectaswellasthelengthycapillary.Thismeansthatitwillbe
possibletogetanaccuratemeasurementoveralargerangeofambienttemperatureswithoutfillfluid
densityorvolumechangesaffectingthereading.Highandlowpressuremeasurementsarefully
synchronizedtoensurethatthedifferentialpressuremeasurementisaccurate.

IftheratiobetweentheDPpressureandthevesselstaticpressureis(DP/Static)<1/10theimpactonthe
accuracywillbenonnegligible.

TheeffectofastaticpressureonbothsideofanonelectronicDPsystemimpliesadriftthatneedstobe
compensated.ElectronicDPsystemcalculatesandcompensatesthepressureeffectdirectlywithoutspecific
calibration.

ElectronicDPLevelsystemsolvesmanyoftheproblemsthataretraditionallyseenwhenmakingaDP
measurementontallvesselsortowers.Typicalproblemsare:

Mechanicalinstallationconstraints:tworemoteseals+capillaries
AmbientTemperatureeffectonthecapillaries(fillfluiddilatation/contractionanddensityvariation)
resultsofinaccuracy:insulationorheatingtracingofcapillaries
Pluggingcondensation/evaporationofreferencecolumn
Tallmeasurementrange(e.g.above6metre).

Note:OneofthetwosensorscalculatestheDPandtransmitsitbacktothehostsystem.

3.4 Design

3.4.1 Level measurement

DPTransmittersignalvariationshouldbedirectlyproportionaltothelevelvariation.HPandLPchamber
location(i.e.vesselvsdry/wetlegsside)shouldbestudiedaccordingly.Differentialpressuretransmitters
installedaboveorbelowtheliquidlevelrangeorwithdry/wetlegsmayrequireazeroshift.

Forslurryand/orsludgeapplicationextendeddiaphragmmaybeused.Thiswouldeliminatethedeadended
cavitytypicallypresentinthenozzlesinstalledwithstandarddiaphragmsealandminimizeerrorto
measurement.Thedrawbackofthisisnoisolationvalvescouldbeinstalledduetotheextendeddiaphragm

22
insidethenozzle.Totalshutdownandisolationofthetankorvesselmayberequiredtoremovethe
diaphragmformaintenance.

3.4.2 Range

Rangesfordifferentialpressuretransmittersshouldbecalculatedusingtheminimumfollowinginformation:

exactdistancebetweenthevesselnozzles
specificgravityofliquidinvesselaccordingtothetemperatureandpressureranges
specificgravityofupperandlowerfluidfortransmittersininterfaceservice
specificgravityofliquidinthereferenceleg(ifapplicable)
Instrumentelevationinrelationtohigherandlowertappingpoints
athighoperatingpressures,zerocompensationforgasphaseweight/density.
ForexampleseePIPPCELI001revision2014,AppendixB.

3.4.3 Process connection with no diaphragm

Differentialpressuretransmitterswithnoremotecapillariessealsshouldhavetheirlocationasfollows:

keeptheimpulsetubingasshortaspossible
forliquidtappingconnection,slopetheimpulsetubingatleast1in./foot(8cm/m)upwardsfromthe
differentialpressuretransmittertowardsthevesselconnection
forgastappingconnection,slopetheimpulse tubingatleast1in./foot(8 cm/m)downwardsfrom
thedifferentialpressuretransmittertowardstheprocessconnection
avoidhighpointsinliquidlinesandlowpointsingaslines
makesurebothimpulselegsarethesametemperature
useimpulsetubinglargeenoughtoavoidfrictioneffectsandclogging
preventsedimentdepositsintheimpulsetubing
selectinstrumentmanifoldswithfrontfacingprocessconnectionstoavoidpocketsinthehookup.
Ondutiesthatarefouling,apurgetokeepthesystemclearshouldbeused.Thepurgesworkwithaconstant
pressuredeliveredusingarotameterorpneumerstatsystem,typicallywithaninertgas.

23


3.4.4 Process connection with diaphragm

Differentialpressuretransmitterswithdiaphragmsealsandcapillariesshouldbeconsideredtakinginto
accountthefollowingconsideration.

Whenflangereducerisnecessary,duetoasmallerprocessconnection(25mmor50mm)comparedtothe
75mmdiaphragm,itisrecommendedtouseflushinganddrainingconnections.

Figure8SPProcessconnectionwithdiaphragm

Incasethereisariskoffreezingliquidinthechamberoftheflangeadapter/reducerorahighviscosityheat
tracingorheatingcircuitshouldbeconsidered.Heatingmedium(steam/oil)shouldnotexceedthefluid
boilingpoint.

Processtemperatureandambienttemperatureshouldbeconsideredtoavoidthefluidboilingoraffecting
themeasurementreactiontime(incaseofhigherfluidviscosity).Inavacuumapplicationthismaycausethe
fluidtoreachtheboilingpointandconsequentlytoblowupthediaphragmanddestroyit.

Figure9DPSteamheatingfacilities

24

Diaphragmmaterialshouldbecarefullyselectedaccordingtothefluidproperties(e.g.goldplatedin
presenceofhydrogenorsubjecttohydrogenpermeation).

Flangeconnectionshouldbeselectedaccordingtothepiping/vesselcode.

Figure10DPSMorRTJdiaphragmflanges

Theinnervolumeofcapillaryfluidcanaffectthemeasurementaccuracyandresponsetime.Capillarywith
internal1mmdiameterwillminimizetheeffectoftemperaturevariationbutwillincreasetheresponsetime.
Capillarywithinternal2mmdiameterwilldecreasetheresponsetimebutwillmoreaffectedbythefluid
dilatation.

Sealfluidscompatibilitywiththelineprocessfluidsshouldbereviewedtoconfirmitissuitableandprevent
contaminationoftheprocessstream(e.g.oxygenservice).

Inthepresenceofwax,slurries,clogsflushingringsshouldbeconsidered.Flushingringsshouldbefittedwith
ventanddrainfacilities.Diaphragmsealsshouldincludeisolationfeaturestoenablemaintenance.

Connectionbyflangeadapt

Figure11DPflushing/draining

25
3.5 Installation

Capillaryfilledsealissensitivetoambienttemperaturevariation.Protectionsuchasinsulationshield,
protectivecoverorinstallationfacingtheNorthshouldbeconsidered.
Diaphragmsealsshouldhavefacilitytomaintain,remove,ventanddrain(e.g.isolationfeatures).
Theflangefittingshouldbeinstalledinaverticalorientation.Diaphragmandcapillaryshouldbeinstalledina
verticalposition.

Figure12DPcapillaryprotection

Thedifferentialpressuretransmittershouldbemountedbelowthelowestleveltobemeasured.
Thecapillarypositionshouldavoidanyrisksofvaporization.

Figure13DPCapillaryarrangement

Capillariesshouldhaveaminimumradiusofcurvatureof150mm,anyvibrationorfrictionshouldbe
avoided.
Diaphragmsealsshouldbeproperlyhandledinthefieldtoavoiddamagetodiaphragmsealandcapillary
tubingandpotentiallossofsensingfillfluid.

26
3.6 Calibration and configuration

CalibrationshouldbeperformedatProductManufacturerpremisesandverifiedpriortothecommissioning
activities.Calibrationcertificateshouldbeprovided.

Calibrationmaybeperformedinsituusingafieldpressurecalibratororusingacalibratorbench(e.g.for
diaphragmsealorspecificlowpressure).

3.6.1 Getting started, zero adjustment, scale with seals

Theoilcolumnheightshouldbetakenintoaccounttoazerooffset:
Whenthetankisempty,thesensormeasuretheLPweightoftheoilcolumn,thisvaluecausesazero
offsetinthenegative,whichcanbeadjustedatthespancalibrationorduringthecommissioningby
azeroingwithemptyvessel.
Deltascale(orspan)bycalculation,willnormallybeadjustedrelativetothedistancebetween
flangesandtothedensityoftheliquid,thenaddtothecalculatedzerovalue.Oritcanbedonewith
fullvessel.
Zerooffsetcanbethereforeevenmoreimportantthanthescaleitself(especiallywiththe
fluorinatedoil).Weshouldchooseasensorwhoseextentofadjustmentallowsthezerooffset.
Fordensityormultilayermeasurements,itwillbenecessarytomakethezerobyadjustmentwith
100%ofthelightestliquid,fullscalewillbecalculatedwith100%oftheheaviestliquid.

3.6.2 Getting started, zero adjustment, scale with impulse line dry leg on low pressure side (LP)

LPside(upperconnection),columnventedtovesselatmosphere:
When the tank is empty, the sensor measure zero on both side (HP and LP), then DP (differential
pressure)isalsozero=4mA.
When the tank is full, measurement is height multiply by density, calibration is done for 100%, In
caseitispossibletoknowanintermediatelevel,calibrationcouldbedoneforanotherpercentage.
Mostimportantthing:Thisrequiredthatliquidshouldnotarriveintotheupperconnection,orthe
drylegwillbefilledandthiswillmakeaoffsetofthezero.
Fordensityormultilayermeasurements,heightshouldbeconstant,thenusingadrylegisclearly
notpossible,measurementshouldbedoneinavesselwhichworkswithanoverflow.

27
 4. Displacer (buoyancy)

4.1 Measurement principle

TheprincipleofdisplacementlevelmeasurementisbasedonArchimedesPrinciple.Displacement
instrumentsdetermineliquidlevelbysensingthebuoyantforceexertedonadisplacerbytheliquidit
displaces.Unlikefloats,infloattypelevelinstruments,thedisplacermovesverylittlerelativetotherisingor
fallingliquid.

4.1.1 Interface liquidliquid level calculation example

TheapparentForce(Fa)=Buoyancyweight(F)Archimedesforce(Pa)SeeFigure14.

TheapparentmassisFa/g=Ma=m1xSxHSxhinterfacex[21] (Equation[2])

Therangeis:

At hinterface = 0 -> Ma = m 1 x S x H
At hinterface = H -> Ma = m 2 x S x H

Figure14DisplacementMeasurement

Liquid1Density(kg/m3)

2:Liquid2Density(kg/m3)

Hinterface:InterfaceLevelbetweentheLiquid1andLiquid2(m)

g:9.81(m/s)

S:Displacersection(m)

H:Displacerlength(m)

28
Interfacemeasurementrequiresitsownconnectionintotheupperandthelowerphase.Equation[2]is
applicableifthereisonlyonevariable.Foraninterfacelevelmeasurement,thereshouldbeaninterface.
Equation[2]canbeusedtomeasurethedensityofonefluid.Inthiscase,thedisplacerisfullyimmersedin
thefluid.

4.2 Limitations

Thelevelreadingfromthedisplacercanbeincorrectifthetemperatureand/ordensityoftheliquidinthe
vesselisdifferentfromthatoftheliquidintheexternalcage.

Unreliablemeasurementsareduetodirty,foaming,foulingserviceaswellasturbulentfluidorpresenceof
solidparticlesinthefluid(e.g.sand).

Vibration(e.g.falsealarm)andcorrosionaffectthelevelmeasurement.

Displacerscanmeasureonlytherangeofthedisplacerlength.Ifthelevelrisesabovethetopofthe
displacer,thedisplacercannotmeasurethelevel.

Displacementtransmitterscanhavehighermaintenanceneeds.Manyfaultsareduetoencrustation,
freezingofthetorquetube,displacerhangerbrokenordetached,failureofelectronicdetectorangular
motion,displacerstuck,anddisplacermasschangeduetocorrosion

Additionalfeaturesmayberequiredtoeliminateturbulentliquideffectsonthedisplacer.

Displacementtransmitterscanbemuchmoredifficulttocalibrate,particularlyifusedforinterface
measurement.

Removalofthedisplacerfromavesselmayrequirespecialrigging.

Displacersareavailableinafewstandardlengths,e.g.0.36mto0.81mlengthsbeingmostcommon.

4.3 Selection

Displacementtransmitterscanbeusedinawiderangeoftemperaturesandpressures.

Displacementtransmittersshouldbesuitableforinterfacelevelmeasurementifspecificgravitiesdiffer
significantlyandthechangeinspecificgravityduetocompositionortemperaturecannotaffectthereading.
Itisadmittedthatthedifferencebetweenspecificgravitiesisgreaterthan0.1(ifthegravitydifferenceof0.1
isused,theimpactontheaccuracyneedstobeassessed).

Displacementtypelevelinstrumentsshouldnotbeusedinseverelyturbulent,dirty,foaming,foulingservice
orincaseofpresenceofsolidparticlesinthefluid(e.g.sand).Theseconditionsleadtounreliable
measurementsfromdisplacementlevelinstruments.

Displacementtypelevelinstrumentsshouldnotbeusedforliquidliquidinterfaceswherethereispotential
emulsionforming.

29

Displacementtypelevelinstrumentsshouldnotbeusedinliquidliquidorliquidgaseousserviceswhere
eithertheupperorlowerfluidspecificgravityisnotrelativelyconstant.

Displacementtransmitterscanbeusealsofordensitymeasurementifthedisplacerispermanentlyandfully
immersedinasinglefluid.

4.4 Design

Displacersshouldbemadeofstainlesssteelorothermaterialcompatiblewiththeprocessfluid.

Displacershouldhavetheheightaccordingtothelevelrangefortheapplication.

4.5 Installation

Thepreferredinstallationfordisplacersshouldbeacage/chamberandinstalledexternallytothevessel.
Block,drainandventvalvesshouldbeinstalledtofillandemptythechambertocarryoutmaintenance
activities.

Vesselnozzlesshouldbelocatedwithrespecttomeasuringinterfacelevel.

Instrumentconnectionsdirectlyatthebottomofthevesselshouldbeavoided.

4.6 Calibration and configuration

CalibrationshouldbeperformedatProductManufacturerpremisesandverifiedpriortothecommissioning
activities.

Calibrationmaybeperformedinsituoronabenchcalibrationwithweights.Benchcalibrationwithweights
shouldbeperformedusingtheapparentmass.

Insitucalibrationshouldbeperformedusingalevelgaugeorsightglassiffitted.Otherwise,aclearflexible
externaltubecouldbeused.

Figure15describesatypicalarrangementwhichshouldbeusedtocalibratechambermountedinstruments
insitu.

30

Figure15Displacementinsitucalibration

31

5. Ultrasonic

5.1 Measurement principle

Continuousnoncontactingultrasoniclevelmeasurementisbasedonthetimeofflightprinciple.
Anultrasoniclevelinstrumentmeasuresthetimebetweensoundenergytransmitterfromthesensor,tothe
surfaceofthemeasuredmaterialandtheechoreturningtothesensor.
Asthespeedofsoundisknownthroughthetravelmediumatameasuredtemperature,thedistancetothe
surfaceiscalculated.Levelcanbecalculatedfromthisdistancemeasurement.
EchoProcessingbuiltintotheinstrumentcanallowtheinstrumenttodeterminethemateriallevelofliquids,
solidsorslurrieseveninnarrow,obstructedoragitatedvessels.

5.2 Limitations

Ultrasonicisseldomusedinupstreamhydrocarbonprocessstreamforlevelmeasurement;itmightbeused
inatmosphericutilitiesapplications.Inapplicationswhicharesusceptibletovapourdensityvariation,
compensationreferencepinshouldbeused.
Maximummeasurementdistanceshouldbecheckedagainstthetechnology(above30mthereflectivitymay
bereducedandmightcauseameasurementerror/problem).
Ultrasonicsensorshave,asphysicallimitation,ablockingdistance(closetothesensor)wheretheycannot
measurereliably,e.g.0.25metres.
Vesselpressurelimitationshouldapproximatelybe,e.g.0.5barorless.Higherpressuremayintroduce
uncertaintyinthelevelmeasurement.
Vapour,vacuumortemperaturegradientscaninfluencethespeedofsoundandconsequentlycancause
incorrectmeasurements.
Presenceoffoamorheavyturbulenceonthesurfaceofthemeasuredmaterialcancauseunreliable
measurement.

5.3 Selection

Asultrasonicisnoncontacting,evenabrasiveoraggressivematerialscanbemeasured.
Vesselheightandheadroomshouldbeconsideredtoselectaninstrumentwithsuitableminimumand
maximumrange.

5.4 Design

Ultrasonicsensorsshouldbemadeofamaterialsuitableforthemeasuredmedium(e.g.PVDForETFE)
Solidconstructionandaselfcleaningactiononthefaceofthesensorprovideareliable,lowmaintenance
product.

32

5.5 Installation

Sensorsmaybemountedatthetopofthevessel(orcontainer)orinasensorcage.
Anyfillingstreamsshouldnotintersectthebeampathofthesensor.
Anunobstructedviewofthematerialfromthesensorisbest.Echoprocessingcanworkaroundallbutthe
mostinvasiveobstructions.
Sensorpositioninthemiddleofthetankmaycausemultiplereflections;thisisnotapreferredlocation.

Figure16UltrasonicLiquidMeasurementArrangement

Useofasubmergenceshieldonasensorwillallowanultrasonicinstrumenttooperateinpotentialflooding
conditionsreportingafullvesseltoacontrolsystemorcontinuingtooperatepumpstoremovetheflood
condition.

33


5.6 Calibration and configuration

Figure17Ultrasoniccalibration

Performinganinitialoremptycalibration:Inthisprinciple,enterthedistanceEfromthesensorfacetothe
minimumlevel(zeropoint).Itisimportanttonotethatinvesselswithparabolicroofsorbottoms,thezero
pointshouldnotbemoredistantthanthepointatwhichtheultrasonicwavereflectsfromthetankbottom.
Whenpossible,aflattargetplatethatisparalleltothesensorfaceanddirectlybelowthesensormounting
positionshouldbeaddedtothebottomofthevesselforbestemptytankperformance.
Oncetheemptydistancehasbeenset,thehighcalibrationpointor100%fullpointcanbeset.Thisisdone
eitherbysettingthedistancefromthesensorfacetothe100%fulllevelorbyenteringaspan(level)from
the0%orlowcalibrationpointtothe100%fulllevel.
Duringcommissioning,ensurethatthe100%fullorhighcalibrationpointdoesnotentertheblocking
distanceorblindzoneoftherespectivesensor.Thiswillvaryfromsensortosensor.Blockingdistancesor
blindzonescanbeextendedtoavoidfalsehighlevelreflectionscausedbyobstructions,buttheycanonlybe
reducedtoacertaindistanceduetothephysicallimitationsofthesensoritself.Theminimumlevel(distance
E/zeropoint)shouldbeconfigured.Thiszeropointshouldbeaboveanydishedboilerheadsorconical
outflowlocatedatthebottomofthetank/vessel.
Themaximumlevel(distanceF/fullspan)shouldbeconfigured.ThisdistanceFshouldtakeintoaccountboth
BDblockingdistanceandSDsafetydistances.
WhereBDrepresentsadeadzoneinwhichthewavecannotmakeanymeasurementandSDcorrespondsto
awarningoranalarmzone.

34

6. Capacitance

6.1 Measurement principle

Thecapacitivemeasuringprincipleisbasedonthemethodoftheoperationofacapacitor.
Acapacitorisformedbytwodifferentlychargedelectrodesisolatedfromeachother.Applinganalternating
currentbetweentheelectrodeswillcreateanelectricfield.Thiselectricalfielddependsonthedistance
betweentheelectrodes,thesizeofelectrodessurface,andtheisolatingmediumbetweentheelectrodes.
Ifthedistancebetweenelectrodesandsizeofsurfaceoftheelectrodesarekeptconstant,onlythemedium
wouldhaveaneffectontheelectricalcapacitance.Whenthemediumchangetheelectricalfieldchanges
alsoconsequentlythecapacitanceevolvesasfollows:
Capacitance(C)=Dielectricconstant(0)RelativeDielectricconstant(DC)ElectrodeSurfaceArea
Wherethedielectricconstant(0)istheelectricfieldconstant(0=8.81012C/(Vm).

Figure18Capacitancemeasurementprinciple

35

6.1.1 Interface

Mediawithalowdielectricconstant(DCvalue)causeverysmallchangesofthecapacitancevalueinlevel
measurementwhilemediawithahighDCvalueproducerespectivelylargecapacitancechanges.Inmany
interfaceapplications,themediumwiththelowerDCvalueisontop,e.g.hydrocarbon(DC=2)onwater
(DC=80).
Theuppermediumprovidesonlyaminimumcontributiontotheoverallcapacitancevalueonlythewater
level(theinterfacelayer)isthusindicatedaslevel.
Inordertomakeuseofthiseffect,theDCvalueofthetwomediashouldbesufficientlydifferentfromeach
other.
UsuallyamediumwithalowDCvalueisnonconductivewhileamediumwithahighDCvalueisconductive.
Thereforeinterfacemeasurementwithanonconductiveandaconductivemediumisalwayspossible.

6.2 Limitations

Conductivemedia

Nonconductivemedia

Figure19Capacitanceoperatingrange

Ifaprocesscoatsorfoulsacapacitanceprobe,acompensationoptionmayberequiredtopreventfalsehigh
levelreadings.

Continuouslevelcapacitancetransmittersrequirethattheliquidbeingmeasuredremainsataconstant
dielectricvalue.Ifthisisnotthecase,thetransmittershouldhavethecapabilitytocompensatefortheliquid
dielectricvariation.
Probesmounteddirectlyinthevesseltypicallycannotbereplacedwiththeprocessinserviceunlesstheyare
mountedinasensorcagewithisolationvalves.
Therodprobesrequiresufficientheightclearance,dependingonthelengthoftheprobe.
Itcannotmeasureliquidswhichhaveaviscosityabove2000cst.

36
6.3 Selection

Thecapacitivelevelmeasurementcanbeusedinaggressivemediawhenafullycoatedprobe(e.g.PTFE)is
used.
Capacitivemeasurementhasaveryfastresponsetimewhichmakesitidealforprocesseswithfastlevel
changesandsmallcontainers.
Themeasurementprincipleisnotaffectedbythedensityvariationofthemedia.
Forinterfacemeasurementsaconductiveandnonconductivemediaisrequired.
Atthisinterfacethedifferencebetweentheconductivityoftheconductivemediashouldbegreaterthan
100S/cmandtheconductivityofthenonconductivemediashouldbelowerthan1S/cm.
Anoilwateremulsionhasalltheconductivityrangebetween1and100S/cmdependingontheoilwater
bubblerepartition.Thismeansthatacapacitanceprobewilldetectthemediaabove100S/cm(i.e.
conductivemedia)andwillnotdetecttheemulsionlayer(between1and100S/cm)aswellasthenon
conductivemedialayer(i.e.<1S/cm).
Nonconductivebuildupontheprobeaffectsthemeasurement.

6.4 Design

Theprobesshouldbemadeofmetallic,conductiveelectrodewithfullplasticinsulationregardlessofthe
conductivityofthemedium.
Whenmounted,agoodelectricallyconductiveconnectionbetweentheprocessconnectionandthetank
shouldbeensured.Anelectricallyconductivesealingbandcanbeused.

Rodprobeswithagroundtubeshouldbeusedintheeventofseverelateralloads.
Thelengthoftheprobeshouldbedesignedinaccordancewithlevelmeasurementrange.

37


6.5 Installation

Figure20Capacitanceinstallation

Thevesselearthing(grounding)method,whichcanbecriticaltotheoperationofthedevice,shouldbe
assessed.

6.6 Calibration and configuration

Capacitanceprobesarecalibratedatthefactoryformediawithaconductivity100S/cm(e.g.forallwater
basedliquids,acids,alkalis...).

Asitecalibrationisonlynecessaryifthe0%valueorthe100%valueshouldbeadjustedtosuitspecific
measurementrequirements(e.g.tank/capacitancedistance<250mm,conductivity<100S/cmorspecific
range).

Adistinctionisgenerallymadebetweentwotypesofcalibration:

Wetcalibration:Theprobecanbecalibratedforitsfullrangei.e.lowerlevel(0%levelcalibration)
andhighlevel(100%level).Otherintermediatevaluescanalsobeperformed.
Drycalibration:Thelevelcapacitancecanbesimulatedbyenteringthelowandhighlevelvalues.
Capacitanceunitswillcalculateautomaticallythecapacitancevariationimagebasedinthefactory
calibrationforaconductivity100S/cm.

38

Figure21Capacitancecalibration

39

7. Noncontact radar

7.1 Measurement principle

Aradartransmittershouldbemountedonthetopofatank,chamber/cageorstandpipe.Thetransmitter
sendsoutmicrowavesviatheantenna,whichthentraveldowntotheproductsurface.Attheproduct
surface,theyarereflectedbacktotheantennaoftheradartransmitter.Thepropagationvelocityof
microwavesinfreespaceisthespeedoflight(300,000km/s).

Figure22Radarmeasurementprinciple

Twodifferentprinciplesareusedtomeasuretheextremelyshorttransmissiontimes:FrequencyModulated
ContinuousWave(FMCW)andpulsetechnology.TheFMCWmethodemitsmicrowavescontinuouslyovera
narrowfrequencysweep.Thefrequencyofthereturnreflectionisslightlydifferentfromthefrequency
currentlybeingtransmitted,andthefrequencydifferenceisproportionaltothedistance.Becauseof
multiplereflections,thereareseveralsignalsmixedtogether.ThereforeanFFTcalculationhastobedone
internallybytheradartransmittertodetermineallthedifferentsinglefrequencies.Thisinformationisused
tocalculateanechocurve,fromwhichthesystemcancalculatethedistance.

40

Figure23RadarFMCWprinciple

Themethodconsistsoftheemissionofmicrowaveenergypulse.Thetimethatneedstoreceiveareturn
reflectionismeasured.Thistimeistheimageofthelevel(i.e.level=velocitytime).Becauseofthehigh
propagationspeed(300,000km/s)theradartransmittercanrepeatthisseveralmilliontimesinasecond
withouthavinganyinterferencebetweentheindividualsignals.Thesesignalsareperiodical.Sothesensor
seesthesameechocurveseveralmilliontimesduringonesecond.Aspecialsamplingmethodmakesit
possibletoexpandthetimeofthisfastechocurveintoaslowertimerange.

Figure24Radarpulseprinciple

FMCWandpulsetechnologiesproducethesameresult:anechocurve.Inthepast,thelowerpower
consumptionofpulsetechnologyhasbeenanadvantageforbuildingalooppoweredradartransmitter.
Nowadays,bothtechnologiesdeliverthesameperformance.Therearenolongeranymajordifferences
betweenthesetwomeasuringprincipleswhenitcomestoaccuracy,dynamicrange,measuringrangeor
responsetime.

Radartransmittersareavailablewithdifferentoperatingfrequencies.Forthemeasurementofliquids,there
arelowfrequencies(between4.510GHz)sensorsandhighfrequency(2427GHz)sensors.

41

Figure25Radarwith6.3GHz Figure26Radarwith26GHz

Note:Thehigherradarfrequencyis,thenarrowertheradarbeanangleofthesensoris.Forexample,witha
26GHzradarandanantennaapertureof80mmthebeamangleisabout12.With79GHzradarandan
antennaapertureof80mmthebeamangleisonlyabout4.

7.1.1 License

Locallicensingrequirementsshouldbeconsidered.Radarsystemsemitradiofrequencyenergy;many
countriesrequirelicensingunderthecommunicationsregulatoryagencywhenoversomedefinedpower
level.

7.2 Limitations

Radarinstallationsrequireconsiderationofvesselgeometry,nozzlelocationandsize.Forthatreason,the
focusing(beamangle)oftheantennahastobetakenintoaccount.Thisismoreaconcernfortransmitters
withlowfrequencies(4.510GHz)thanforthosewithhigheroperatingfrequencies(2427GHz).
Internalobstructionssuchasheatingcoils,standpipes,agitators,etc.needtobeconsidered.Thisismorea
concernfortransmitterswithlowfrequencies(4.510GHz)thanforthosewithhigheroperating
frequencies(2427GHz).
InstallationandtroubleshootingmayrequireproductmanufacturerspecifictrainingandalaptopPCwith
productmanufacturersoftware.
Pureammonia,vinylchlorideormethylchloridelevelcannotbemeasuredwithradarrangeof2427GHz.
Thisisduetotherelevantgasvapourwhichdampsthe24to27GHzwaves.Forthisapplication,radarwithin
the4.510GHzcanbeused.

Heavy,thickfoamhasasubstantialdampingeffectonmicrowaves.Aparticularattentionshouldbepaidto
thefoamformationduringthedesignphase.Iftheprocessgeneratesthickfoamthatresultsinexcessive
damping,radarisnotrecommended.Consequently,itisnotpossibletorecommendanyspecificfrequency
forfoamapplication.Sensorswithincreasedsensitivityforfoamapplicationsareavailable.
Radartransmitterscanmeasureagasliquidinterfacebutnotaliquidliquidinterface.
Ifthedielectricconstant(DC)oftheproductislowerthan1.4,ithastobetakeninaccounttochoosethe
sensororthemountingwhichfitstheapplication.ThedielectricDCistheratioofelectricpermittivityofthe
producttothefreespacepermittivity.Thehigherthedielectricconstant,thestrongerthesignalreflectedby
theproduct.Thedielectricconstantoftheproducthaslessinfluenceontheaccuracy,becauseitchanges
onlytheamplitudeandnotthepositionoftheechoontheechocurve,butmoreinfluenceonthereliability
ofthemeasurement.SeeFigure27.

42

 Figure27Radarwith26GHz

Withmodernhighqualityradar,itisnowadayspossibletomeasureeventheproductswiththelowest
dielectricconstantlikeLNG/LPGinliquids.Forolderorlesssensitiveradartransmitters,itmightberequired
toinstallastillingwelltomeasureLNG/LPG.Someproductmanufacturershavemodelsavailablewitha
specialelectronic.ThisspecialelectronicincreasesthesensitivitytoallowtheLNG/LPGmeasurement
withoutastillingwell.Ingeneral,forproductslowerthanDC<1.4,theproductmanufacturers
recommendationshouldberequired.
Dielectric
Product
constantDC

Vacuum 1

LNG 1.4

Oil 24

Water 80
Table1Exampleofproductdielectricconstant

Note:Duetothelowdielectricconstantofsomematerial,itspossibletomeasurethroughplastic,glassor
ceramic.

Figure28Radarmeasuringthelevelthroughtheplasticvessel

43
7.3 Selection

Verystrongturbulencesontheproductsurfacesareabletoreflectthemicrowavesindifferentdirections.
Thiswilldecreasetheechoamplitudeaswell.Inverystrongturbulences,likeareactorwithastrongagitator
thishastobeconsideredforthemountingpositionofradar.Theradartransmittershouldbepositioned
behindabaffle.Thisallowsaveryeasyandrepeatablemeasurement.
WhetherRadarisusedonturbulencesurfaceastillingwellorsensorcageshouldbeconsidered.Sensorcage
orstillingwellshouldminimumhavesameIDasradarhorndiameter.

Vapourcondensationanddepositscanaffecttheradarmeasurementperformance.Inthiscase,necessary
heattracingandaroundpieceofPTFEmaybeinstalledinthemountingflangetopreventtheaccumulating
ontheradargaugecone.Auseofapurgemayalsobeconsidered.

TheuseofaPTFEshieldontheradarconepreventscorrosion.

Radarmounteddirectlyonvesselwhichcannotbeshutdownedshouldbeprovidedwithisolationvalves
(fullboretype).

Radartransmittersareavailablewithawiderangeofantennadesignsandsizesfordifferentapplications.
Radartransmittersareavailablewithdifferentmaterials,sealsandhousingstofittheprocessconditionsand
environment.
Lowfrequency(410GHz)ispreferredwhenmeasuringinvapourandfoam.
Highfrequency(above25GHz)ispreferredinmostotherapplicationsduetogreatermountingflexibility.(A
smallbeamangleiseasiertoinstall.)
HighFrequencyMicrowavesaresuitableformostapplication,havelessinstallationconsiderations,have
narrowbeamangleavoidsdisturbancesmoreeasilyandprovidelongermeasuringrangeduetomore
focusedenergy.
LowFrequencyMicrowavesprovidelongerwavelengthswhichpenetratefoam,heavyvapourand
condensationmoreeasily.Widebeamanglecaninsomecasespassdisturbancesmoreeasily(whenthe
disturbingechoislocateddirectlyundertheradar).

44


7.4 Design

Differentantennasizesandtypesareavailabletofitwiththehookuprequirements.

Hornantenna Parabolicantenna Encapsulatedhornantenna

Suitableformost Longrangeapplication(e.g.more Condensation

application than50m)
Aggressive/corrosivefluid
Figure29Radarantennashape

Therearedifferentantennasizesanddesignsavailable.Biggerdiameterhornantennaisthepreferred
solutionasthisprovidesamorefocusedbeam.However,theantennaalsoneedsmorespaceandtherefore
theprocessconnectionisgettingbigger.
Theencapsulatedhornantennaisespeciallymadeforaggressiveorcorrosiveapplications.Theonlymaterial
whichisincontactwiththemediumisPTFEorPFA(therearenosealsormetalpartsincontactwiththe
medium).

45

7.5 Installation

Radartransmitterscanbedirectlymountedonthetopofthevessel,withoutanyvalveorstandpipe.This
installationprinciplecanbeusediftheprocesscanbeshutdownedwhentheradarneedsmaintenance.
Whenradarsareinstalledinanozzle,actualvesselsortankdrawingsshouldbecheckedbeforeselectingthe
antennasize(e.g.NozzleIDsmaybesmallerthanexpected.Thistypicallyoccursinhighratingflangeor
specificfeaturessuchasLongWeldNeckflanges).

Figure30RadarDirecttopvesselInstallation

Thesensorshouldbemountedperpendiculartothesurface.Themountingsocketontopofavesselshould
beasshortaspossible.Inthecaseofinstrumentswithhornantennas,thelengthofthesocketshouldbeless
thanthelengthofthehornantenna.

Figure31Radaralignment

46

 Figure32Radarsocketornozzleradarinstallation

Ifanaccesstotheantennaisrequired(e.g.maintenance/operation)afullboreballvalveshouldbeused.
Note:Electronicofnoncontactmeasurementaregenerallyremovablewithoutaprocessshutdown.

Thisreducestheinfluenceonthemicrowaveandallowsareliableandaccuratemeasurement.Fullbore
valveisasolutionifthereisneedtoremovetheconeantennaformaintenance(cleaning).Radarelectronic
canbechangedwithoutopeningthetank.

Figure33Radarfullportballvalve

Wheninstallinganoncontactingradarsensoronastillingwellorchamber/cagetube,theIDshould
minimumbethehorndiameter.
Note:Ifthestillingwellorchamber/cageIDisnotconstant,specialparametercanbeconfigured.

47
 Figure34Radarinstallationusingstillingwell

Figure35Radarinstallationusingchamber/cagetube

Forapplicationsininsulatedvessels,itisrecommendedtoinsulatealsothenozzle,ballvalve,flangeandpart
oftheinstrument.Thispreventscondensationandbuildupontheantennaandnozzleandincreasesthe
reliabilityandsecurityforthemeasurement.

48
7.5.1 Floating roof tanks

Insomefloatingroofapplications,itmaybebeneficial,oreventheonlyway,tousetheradartomeasureto
thefloatingroofinsteadoftheliquid.Thesensorshouldbemountedperpendiculartothesurface.Inthis
application,theradartrackstheroofinsteadoftheliquid.Anoffsetshouldbeenteredintheradartoallow
fortheroofthickness.

Theradarwilltracktheleveldowntowheretheroofleglands.Whenthelegshavelanded,theradarwill
showthepositionoftheroofevenifthelevelissignificantlylower.

Theradarlevelaccuracyislimitedtohowwelltheroofisfollowingtheliquid.Therearesealfrictionsthat
influencehowfreelytheroofismovingupanddown.Insomecases,theroofcanstickduringfillingand
emptyingandthatcouldresultinmeasurementerrors.Ifalotofsnoworwateriscollectedontheroof,the
radargaugecouldstarttomeasuretothesnow/waterinsteadoftheroof.

IftheradarisinstalledinanexternalfloatingrooftanktheradarneedstohaveaFederalCommunications
Commission(FFC)license.TheradargaugehasanFCCpart15licensewhichisvalidforaregulartank
installation.Intheexternalfloatingroofcase,theradargaugeisinopenairandaFFCpart90;alicense
needstobeprovided.Theapplicationisstraightforwardandcanbemadeonline.Thisparagraphispertinent
fortheinstallationslocatedontheUnitedStatesofAmericaterritoryorwheretheUSAregulationsare
mandatoryandwhereFCCregulationapplies.

Theradarneedsahorizontalreflectorinstalledontheroofiftheroofisnotflat.Thisisnormallythecasefor
externalfloatingrooftankswherethepontoonhasaslightangle.Thereflectorneedstobeaminimum
500mm500mmand 500 mm above the floating roof.Thereflectorshouldbeinstalledinanareaonthe
floatingroofwithasfewmetalobstructionsaspossibleandhorizontallymounted.

7.6 Calibration and configuration

NoncontactRadarsareinitiallycalibratedinfactorywithaninitialdielectricvalue(e.g.1.6).

Drycalibration:ZeroandFullscalevaluesareadjustedmanually.Thesescalevaluesrepresentsthe
minimumandmaximumleveltobemeasured.Thesesettingscanbemadeinsituornot.
Wetcalibration:wetcalibrationisnecessarytotakeintoaccountallthefalseechoesduetothe
internalvesselshape.Theelectronicrecordthesefalseechoes.Thesefalseechoesarefilteredand
arenolongertakenintoaccountduringthelevelmeasurement.Thiswetcalibrationshouldbe
performedwiththeactuallowlevelsothatallpotentialinterferingreflectionsaredetected.

49


8. Guided wave radar

8.1 Measurement principle

Guidedwaveradar(GWR)technologyisbasedontheTimeDomainReflectometry(TDR)principle.Low
powernanosecondpulsesareguidedalongaprobesubmergedintheprocessmedia.Whenapulsereaches
thesurfaceofthematerialitismeasuring,partoftheenergyisreflectedbacktothetransmitter,andthe
timedifferencebetweenthegeneratedandreflectedpulseisconvertedintoadistancefromwhichthetotal
levelorinterfaceleveliscalculated.
Thespeedoftravelofthepulseisimpactedbythedielectricofthemedium.Thischangeintraveltimeis
predictableandallowscompensationforthemeasurementtobeaccomplished.
Thereflectivityoftheproductisakeyparameterformeasurementperformance.Ahighdielectricconstant
(DC)ofthemediagivesbetterreflectionandalongermeasuringrange.

Figure36GWRTypicalinterfacelevelreflection

Whenaninterfaceleveloftwoimmisciblelayersshouldbemeasured,thefirstfluidshouldhavethelower
dielectric.Thereflectionfromthisfirstlowdielectricfluidisweak.Thispermitstotherestofthesignalto
detecttheinterfacebetweenthesetwofluids.Lessthan5%ofthesignalisreflectedbacktothetransmitter
forafluidwithadielectricof2(e.g.oil).Interfacemeasurementaccuracydependsontheupperproduct
dielectricandadistinctinterface(lowemulsionlayeroffewmm)betweenthetwofluids.

50

8.2 Limitations

Whileguidedwaveradarworksinmanyconditions,someprecautionsneedtobetakenwithrespectto
probechoice.Severalprobestylesareavailableandtheapplication,length,andmountingrestrictions
influencetheirchoice.Unlessacoaxstyleprobeisused,probesshouldnotbeindirectcontactwitha
metallicobject,asthatwillimpactthesignal.
Iftheapplicationtendstobestickyorcoat,thenonlysingleleadprobesshouldbeused.Singleleadprobes
arepreferredwhenthereisariskofcontamination(becausecoatingcanresultintheproductbridgingacross
thetwoleadsfortwinversionsorbetweentheinnerleadandouterpipeforthecoaxialprobes,andmay
causeerroneouslevelreadings).Forviscousorstickyapplications,PTFEprobesarerecommendedto
facilitateproductflow.Periodiccleaningmayalsoberequired.Maximumerrorduetocoatingis110%
dependingonprobetype,dielectricconstant,coatingthicknessandcoatingheightaboveproductsurface.
Thepresenceofoilfilmonthesingleprobewillnothaveanyeffect.
SomeadvancedGWRsonthemarkethaveadvanceddiagnostics,withtheabilitytodetectbuilduponthe
probe.Thisgivesindicationofhowgoodthesurfacesignaliscomparetothenoise,andwhentocleanthe
probe(predictivemaintenance).
GWRcanbeusedoncryogenicapplication(e.g.196C)withrecommendationofcoaxialprobe.Proper
insulationmayberequiredtoreduceiceformationontheupperpart(e.g.insulatethenozzle).
GWRmeasurementinfoamyapplicationsdependsonthefoamproperties:lightandairyordenseandheavy,
highorlowdielectrics,etc.Ifthefoamisconductiveanddense,thetransmittermaymeasurethesurfaceof
thefoam.Ifthefoamislessconductive,themicrowavesmaypenetratethefoamandmeasuretheliquid
surface.Thistypeofapplicationsshouldbeconsideredonacasebycasebasis.Dependingonfoam
properties,GWRmaydetectthefoam/liquidinterfaceorthetopofthefoamorthetopoftheliquid.
GWRarenotsuitableforwatersandinterface.Sincethesandisembeddedinwater,whichisahigh
dielectricmedia(DC=80),thetransmittercanonlyseethewater.Thesameistrueforallmediathatare
dissolvedinwater.
Differentparameters(factors)affecttheechoandthereforethemaximummeasuringrangediffers
dependingonapplicationaccordingto:
disturbingobjectsclosetotheprobe
mediawithhigherdielectricconstantgivesbetterreflectionandallowsalongermeasuringrange
surfacefoamandparticlesinthetankatmospheremayaffectmeasuringperformance
heavycoatingorcontaminationontheprobeshouldbeavoidedsinceitcanreducemeasuringrange
andmightcauseerroneouslevelreadings.

51

Figure37GWRinterfacelevelmeasurement

Wheninterfacewillbemeasured,thecriteriaaccordingtoFigure38shouldbefulfilled:

Figure38GWRInterfacemeasurementdielectriccriteria

52

 Figure39GWRMaximumdielectricconstantvstechnology

Themaximumallowableupperproductthickness/measuringrangeisprimarilydeterminedbythedielectric
constantsofthetwoliquids.Anexampleofthemaximumupperproductthicknessfortheflexiblesingle
probeispresentedinFigure40.However,characteristicscanvarybetweenthedifferentapplications.

Figure40GWRMaximumupperproductthickness

8.2.1 Emulsion/rag layer

Emulsions/foamaboveafewcentimetresdisrupttheinterfacemeasurement.Theresultsvarywiththefluid
mix. Inmanycases,theinterfaceismeasuredatthetopoftheemulsionlayer.Emulsionlayersabovefew
centimetrescannotbemeasurewiththeGWRprinciple.Thisisduetotheemulsiondielectricstochastic
repartitionandtheemulsionbubblecomposition.Iftheemulsionlayerisgreaterthanfewcentimetresonly
thetopoftheupperlayercanbedetected.

Sometimesemulsioncanbeformedofamixtureoffinesolidscombinedwithemulsifiedoilandwater,
sometimesincludingmultiplecomponents.Stableliquidemulsionandsolidparticlestriggerrapidemulsion
layergrowth.Themoreparticlesarepresent,thelargersuchanemulsionis.Althoughapplicationswith
emulsionsaredifficultforGWRmeasurement,theusageofastillingwellcanhelptoachievebetterproduct
separationandthereforemoreaccuratemeasurements.

53


Figure41GWRinterfacemeasurementinvesselwithemulsion

54

8.3 Selection

GWRprovidesaccurateandreliableinterfacemeasurementsandcanbeusedinawidevarietyof
applications.Itisatopdown,directmeasurementasitmeasuresthedistancetotheproductsurface.
GWRshouldbeconsideredforcleanliquidliquidinterfaceand/orcleanliquidgasinterface.

GWRinterfacemeasurementwithemulsion,foam,fluidbuilduporcrystallizationisnotpossible(deposit
causesfalsereading).

GWRlevelinstrumentaccuracyisafunctionoftheliquiddielectricconstant.Careshouldbetakento
determinethedielectricconstantsofthefluidsbeingmeasuredovertheirfullrangeofpossiblecompositions
andoperatingconditions.

Thevesselinternalse.g.supportsandreinforcementshouldnotbeatthevicinityofthelevelmeasurement
deviceorintheradarpath.

GWRrequiresarelativelyflatfluidsurface.IfsurfaceisturbulentthenaStillingWellshouldbeconsidered.

Forlongprobes,thelowerprobeendshouldbefittedwithanadditionalstainlesssteelcylinderwithfixing
eyetoensureanadequatefixingtothebottomofthevessel.

GWRinstalledinasensorcageorstandpipeshouldneverbeincontactwiththecage/standpipeinternals.
Centringdiskmaybeused.Thecentringdiskshouldprovideisolationbetweentheprobeandthe
cage/standpipeinternals.

GWRsensorcage/standpipemeasuringrangeshouldbecarefullystudied.Forasidesidesensorcage/stand
pipethemaximummeasuringrangeshouldbebetweenthemiddle(axe)oftheupperandthelowertapping
connection.

Akeyadvantageofradaristhatchangesinpressure,temperature,andmostvapourspaceconditionshave
noimpactontheaccuracyofitslevelmeasurements.Moreover,nocompensationisnecessaryforchanges
indielectric,conductivity,ordensityofthefluid.
Changingdensityisoneofthemajorissueiswhenmeasuringlevelorinterfaceusingoldertechnologies,
suchasdisplacers;theyaremorelikelytohappenduetochangesinprocessorambientconditions,andthus
havemoreinfluenceonthereliabilityandaccuracyofdensitybasedtechnologies.
Inaddition,radardeviceshavenomovingparts,somaintenanceisminimal.GWRiseasytoinstalland
enablessimplereplacementofoldertechnologies,evenwhilethereisliquidinthetank.

8.4 Installation

8.4.1 Direct measurements on the top of the tank (flanges connection)

Belowarerecommendationsforthenozzleconfigurationanddimensionsforflangedinstallationsontopof
thetank/vessel.

55

Avoid nozzles with

reducer (unless
using coaxial probe)

Table2GWRnozzlediameter

Chamberswithadiameterlessthan7.62cmcancauseproblemswithbuildupandmightmakeitdifficultto
avoidcontactbetweenchamberwallandprobe.
Chambersprovideafixedviewofthelevelinavessel.Thus,whentheleveldropsbeloworrisesabovethe
chamber,itwillnotbeseeninthechamber.Theeffectivemeasurementrangeofachamberisthearea
betweenthetaps.

Figure42GWRpossibleerrorchambersmeasurement

8.4.2 Chamber installation and sizing

Thelocationofthechambershouldbeasclosetoareaofmeasurementaspossible.Ifthechamberisfurther
away,thefluidinsideitislesslikethefluidinthevessel.Moredistancegivesmoretimeforthefluidtocool
(orheatupincryogenicapplications).Coolerfluidwillbemoreviscousanddense.Moreviscousfluidwillnot
respondasquicklyandinextremecases,cancompletelyplugthechamber.Largerconnectionsbetweenthe
vesselandthechamberwillenhanceflowthroughofthefluidandallowfreshfluidtomovethroughthe
chambermoreeasilyandmorecloselyresemblethematerialinthevessel.
Ifthedensityinthechamberislowerthanthedensityofthefluidinthevessel,itmayactuallyappearto
shrinkandcausethelevelmeasurementtobelowerinthevesselthanitactuallyis,especiallyiffluid
movementisstagnant.

56

 Figure43GWRchamberinstallationandsizing

8.4.3 Match product level in tank and chamber

Belowareexamplesofcasesthatmightoccurinfieldconditions.

Figure44GWRCase1Differenceinproductspecificgravity(SG)

57


Figure45GWRCase2Lackofcirculationinchamber

58

8.4.4 Level and interface applications

Measurementoflevelandinterfaceinachambershouldbeavoidedasthelackoffluidflowwillnotprovide
representativemeasurements.However,chambersareoftenusedforinterfacemeasurementsbetweenoil
andwater.Incaseswhereitistheonlywaytogetameasurement,multipleconnectionstochamberwillhelp
toenhancefluidflow.Theadditionalcrossoverconnectionsshouldbelocatednearthemorecritical
measurementareas.Intheseapplications,thereshouldbegoodflowthroughofboththetopandbottom
fluidfortheinterfacemeasurementtobetracked.Careshouldbetakentoavoidhavingalayeroffluid
trappedinthechamber.
Interfacemeasurementsshouldassessthedielectricconstantofbothlayerstoproperlyconfigurethedevice
fortheintendedlevelapplication.Specificconfigurationparametersmightrequireadjustmentoncethe
devicehasbeencommissioned.

Figure46GWRchamberwithmultipleconnections

8.4.5 Fully submerged interface applications

Asubmergedinterfaceapplicationisonewheretheupperportionoftheprobeisinoilorasimilarfluidand
theinterfacebetweentheupperfluidandlowerfluidisthedesiredmeasurement.Oftenthismeasurement
isdonewiththeGWRmountedinachamber/cage.Thisiscalledafloodedchamber.
Asingleleadprobeshouldalwaysbeusedforthisapplicationasthisprovidesthemostdistinctreference
pulse.Ideally,thereshouldbenoairgappresentatthetopoftheprobe.However,airisoftentrappedinthe
chamber.
Ifthereisanairpocket,thenitcreatesanoffsetinthemeasurementreadingduetothedifferenceinthe
speedoftravelofthemicrowavesintheairspacecomparedtotheupperfluid.Forexample,ifthedeviceis
configuredwithoilastheupperfluidwithdielectricconstantof2,theoffseterrorwillbe30%ofthesizeof
theairpocket(thatis,a15.7in.(40cm)airpocketcreatesa4.7in.(12cm)offseterrortothereading).
Thereareseveraloptionsavailabletoovercometheerrorintroducedduetotheairpocket:
Ifprocesssafetyallowsit,aventcanbeincludedinthetopofthechamberthatallowstheairtobe
removed.Thisventcanbepipedbacktoprocess.AflushingringcanbeinstalledbetweentheGWR
flangeandthechamberflangetoaccommodatethis.

59
 Figure47GWRfullysubmergeairpocket

Iftheairpocketissmallandiswithintheupperblindzoneofthedevice,UpperNullZonecanbe
configuredtoblockanypotentialincorrectreadingofthesurface.

Figure48GWRfullysubmergeairpocketecho

60
8.4.6 Interface measurements in vessels

Themostcommoninterfaceapplicationinvesselsimpliesmeasurementsofbothupperproductleveland
interfacelevel.

Figure49GWRinterfacemeasurementinvessel

Thoughnotverycommon,fullysubmergedvesselinterfaceapplicationscanbepossibletoo.Agoodexample
ofsuchapplicationaredesaltersandinvertedinterfacemeasurements.

8.4.7 Inverted interface measurements

ThepreviousexamplescoversituationswhentheupperproducthasalowerDCthanthelowerone.
However,sometimesthereareapplicationswhereproductdispositionisinverted:thehighdielectricproduct
liesontopofthelowdielectricone,whichmakestopdownmeasurementimpossibleforGWR.Inthiscase,
theGWRmountingpositionisinvertedsothatitisinstalledatthebottomofthetank.Forapplications
wheretheremaybesomesolidsorslushydepositsatthebottomofthevessel,itisadvisabletoputa
flushingconnectioninthemountingnozzletoallowoccasionalcleaning.

Figure50GWRinterfacemeasurementinvesselwithlowerDCupper

61

Configurationroutineisthesameasforstandardinterfacemeasurementsusinginterfacewithsubmerged
probemode.

Dielectricconstantshavetobesetaccordingtoproductseparation.Upperproductmeanstheonethatis
closertothetankbottom.

WheninstallingGWRonthetankbottom,thereisnolimitofprobetypestobeused.Flexibleprobesneedto
beattachedtothetankroof.Thiscanbedonebyfollowingthesameguidelines,providedforstandard
installations.

8.5 Calibration and configuration

TheactualuppermediaDCvalueisknown.TheconfigurationneedstoincludetheactualDCvalue(atfactory
oratsite).
IftheactualupperDCisnotknowninarangeof20%aroundtheactualmeasure,theaccuracywillbe
impacted.

Abovethis20%value,itisrecommendedtoperformasite/fieldcalibrationtoimprovethemeasurement
accuracy.

62

 9. Hybrid capacitance/GWR

9.1 Measurement principle

Themeasurementisbasedonahybridtechnology:capacitanceandGWR.Therespectivemeasuring
principlesaredescribedinsection6[Capacitance]andsection8[Guidedwaveradar].Thesystemisbasedon
theGWRtechnology,whereasforinterfaceapplicationsthismethodiscombinedwithacapacitive
measurement.Thetwotechnologieswerechosenbecauseoftheperformanceofcapacitancetechnology
withemulsionlayersandtheGWRsperformanceforpreciseoveralllevel.
ThereferencepointRofthemeasurementislocatedattheprocessconnection.

TheMeasuringRange

RodProbe4m/13ft

RopeProbe10m/33ft

Coaxialprobe6m/20ft

Figure51Hybridcapacitance/GWRmeasurementprinciple
63
9.1.1 Interface with emulsion layer

Ifaclearinterfacelayerexists,thehybridsystemmeasurestheoveralllevelandtheinterfaceviatheguided
radarmode.Inthebackground,thecapacitiveanalysisalwaysoperatessimultaneouslyandcalculatesthe
capacityvalueusingthemeasureddistancesandtheknowncapacitiveconditionsofthecoaxialprobeand
derivestheDCvalueoftheoillayerfromit.ThismeasuredDCvalueisused,inturn,forthetimeofflight
correctionintheinterfacemeasurementthroughtheoillayerwhichmakesitpossibletomeasureinterfaces.
Intraditionalguidedradarprobes,theemulsionlayercausesalossofsignaloftheinterfacesurfacebut
keeptheupperlayerlevel(e.g.oil).Thehybridcapacitance/GWRautomaticallyswitchestothecapacitive
modeandprovidethelowerlevel(water).
Inpresenceofemulsion,thehybridcapacitance/GWRmeasurestheupperlayerlevelandthelower
conductivelayerbelowtheemulsion.Theoverallemulsionlayercannotbeknown.

9.2 Limitations

GWRandcapacitancelimitationsalsoapplytothehybridcapacitance/GWRtechnology.Inpresenceof
emulsion,onlythecapacitancetechnologymeasuresthepresenceofwater.
TheDCoftheuppermediumshouldbeknownandconstant.
TheDCoftheuppermediummaynotbegreaterthan10.
TheDCdifferencebetweentheuppermediumandlowermediumshouldbe>10.
Thedistancebetweentheupperlayerandtheinterfaceshouldminimumbe60mm.
Conductivityoftheuppermedium:<1S/cm
Conductivityofthelowermedium:>100S/cm
Cannotmeasureamediawhichleadtofoulingorheavybuildupontheprobe.

9.3 Selection

Forinterfacemeasurement,ideallycoaxprobesorrodprobesinachamber/cage/stillingwellareused.
Coaxprobesaresuitedtoliquidswithviscositiesofuptoapproximately500cst.Coaxprobescanmeasure
mostliquefiedgases,asofadielectricconstantof1.4.Installationconditions,suchasnozzles,vesselinternal
fittingsetc.havenoeffectonthemeasurementwhenacoaxprobeisused.Acoaxprobeoffersmaximum
EMCsafetywhenusedinplasticvessels.
Ropeprobesmaybeusedinachamber/stillingwell,ifthereissufficientheadroomtoinstallarodprobe.
Thiscanexcludetheropeorendofprobeweighttouchesthewallofthetube(diameterlargeenough,
preciselyverticaltube).

9.4 Design

Thehybridcapacitance/GWRshouldhavetherightprobefortheappropriatelevelrangefortheapplication.

64


9.5 Installation

Rod/ropeprobescanbemountedinastillingwellorchamber/cage.Inthiscase,thedistanceoftherod/rope
probeandinternaldiameterofthechamber/cage/stillingwellshouldbebetween40mmand100mm.The
distancefromtheendofrod/rodeprobetothebottomofthevesselshouldminimumbe10mm.
Coaxprobecanalsobeusedandbemountedatanarbitrarydistancefromthewallofthevessel.
Withinthemeasuringrange,therod/rope/coaxprobeshouldnotgetintocontactwiththechamber
/cage/stillingwellwall.Ifrequired,centredisksshouldbeused.Centredisksshouldnotbelocatedinthe
measuringrange.
Forlongrope/coaxprobeanadditionalweightoraspringshouldbeconsidered.
Forundergroundvesselsrod/rope/coaxprobeshouldbedesignedwithlargenozzlediametersinorderto
avoidreflectionsatthenozzlewall.
Fornonmetallicvesselscoaxprobeisrecommended.
Forvesselswithheatinsulation,theelectronichousingshouldbelocatedoutsidethevesselinsulation.Thisis
topreventtheelectronicsfromheatingupasaresultofheatradiationorconvection.
Theinsulationshouldnotexceedthepointslabeledmaxinthefigurebelow.

Figure52Hybridcapacitance/GWRinstallationwithheatinsulation

9.6 Calibration and configuration for interface level measurement

Calibrationisperformedinthefactorywithcompleteassembly.Insitucalibrations(lowandhighrange)are
onlyusedforrecordingthelinearityprotocol.Incasethecalibrationvaluesaredifferentfromthefactory
onestheyshouldbesetasacustomizedparameterization.
TheactualuppermediaDCvalueshouldbeknown.
Wetcalibration:Theprobecanbecalibratedforitsfullrange,i.e.lowerinterfacelevel(0%level
calibration)andhighinterfacelevel(100%level).Otherintermediatevaluescanalsobeperformed.
Lowinterfacelevelsimulationaimstosuppressthefalseecho(forGWRmeasurement)andprovide
0%levelvalueforthecapacitancepart.
HighinterfacelevelsimulationaimstoprovidethemaximumrangevalueforbothGWR
measurementandcapacitancepart.
Drycalibration:Thelevelcapacitancecanbesimulatedbyenteringthelowandhighlevelvalues.
Capacitanceunitswillcalculateautomaticallythecapacitancevariationimagebasedinthefactory
calibrationfor100S/cm.

65

10. Nucleonic

10.1 Measurement principle

Thenucleonicmeasuringprincipleisbasedontheattenuationofgammaradiationasitpenetratesmaterials.
Theradioactiveisotope(gammasource)isinstalledinacontainer,alsoreferredtoasshielding,whichemits
theradiationonlyinonedirection.
Thesourcecontainerandthetransmitterdetectingtheradiationareusuallymountedonoppositesidesofa
vesselorpipe.
Theemittedradiation(e.g.gammarays)passesthroughthevesselwallsandthemediumcontainedinthe
vessel.
Theactualmeasuringeffectresultsfromtheabsorptionoftheradiationbythemedium.
Theintelligenttransmittercalculatesthelevel,densityortheconcentrationofthemediumfromthe
radiationreceived.
Thehigherthelevelorthedensityofthemediuminthevesselthelowertheintensityoftheradiation
received.
Inconventionallevelanddensitymeasurements137Cesiumand60Cobaltarecommonlyused.241
Americiumor244Curiummaybeusedforheavyelementmeasurementinamediumconsistingoflighter
elements.

10.1.1 Continuous level measurement/full absorption

Inthismeasurementprinciple,theradiationisfullyabsorbed.Theradiationdifferencebetweenthesource
andthedetectorvariesgiventheimageofthelevel.Theradiationactivityiscalculatedfromthepulserate
received.
Typicallythepulserate(radiationlevel)at100%leveliszero,meaningthegammaraysarecompletely
absorbedbythemedium(fullabsorption).Forexample,at50%ofthefullrangelevel,onlytheupperpartof
thedetectorreceivestheradiation.Consequentlythepulserateincreases.

66

Figure53Continuouslevelmeasurement/fullabsorptionprinciple

10.1.2 Interface measurement

Innucleonicinterfacemeasurement,thesourcemaybeinsertedinanencloseddiptubewithacable
extensionwhichexcludesanycontactofthesourcewiththemedium.
Dependingonthemeasuringrangeandtheapplication,oneorseveraldetectorsaremountedontheoutside
ofthevessel.
Theintelligenttransmittermeasurestheaveragedensityofthemediumbetweenthesourceandthe
detectorfromtheradiationreceived.
Adirectrelationshiptotheinterfacelayercanthenbederivedfromthisdensityvalue.

Figure54NucleonicInterfaceMeasurementPrinciple

67

10.1.3 Density profile

Themostexactinformationontheoil/wateremulsionlayerisachievedbyamultidetectorsolution,theso
calledprofiling.
Severaltransmittersarearrangedonthevesselonavesselwallorinsidethevessel.
Eachdetectormeasuresanabsorptionimageofthedensity.
Themeasuringrangeissubdividedintozonesandanapplicabledensityvalueiscalculatedforeachzone.
Thedensityimageisanalyzedviaanalgorithmandvisuallyprovidedonamonitor.

Figure55Nucleonicdensityprofileprinciple

10.2 Limitations

Inmanycountries,theuseofnucleonicsystemsrequiresthepossessionofalicenseduetothepotential
hazardtopersonnel.Inordertobeinaccordancewithlocal,state,andfederalregulationsextensivepaper
workmightberequired.Theinstallationisregulatedatthelocal,state,andonthefederallevel.Sometimesa
periodicwipetestinghastobeconducted.
Governmentregulationsmayrequiretheappointmentofaradiationsafetyofficerresponsibleforenforcing
regulationsattheownerssite,includingperiodicinspectionsandtestsofallnucleargauges.
Dependingoninstrumentdesignsomeapplicationsmayrequireextremelylargesources,whichcanincrease
deliverytimes,licensingrequirements,andmayrequirespecialmountingconsideration.
SensitivitytoXray(NDT(nondestructivetesting)methods)cancauseafalsetriptoarunningunit.
Nucleardevicescanbedifficulttocalibrateaccurately.Itmayberequiredtoemptyandfillthevesseltozero
andspanthedevicetoobtainthedesiredcalibrationaccuracy.Thehardpartisnormallyrelatedtohow
practical/easyitistogettherequiredprocessconditionsforcalibration.
Duetothefactthatthesourcecontainersuseleadtoshieldtheradiation,thecontainerscanbeveryheavy
andacranemightberequiredforinstallation.
Theuseofnucleonicmeasurementprinciplesforfastcontrollooporsafetyapplicationshouldbeevaluated
basedonrequiredresponsetime(astheprofileisreconstructedfromdensityprofileusingseveral
sources/detectorsandcalculationunits).

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Dependingondistanceandpositionofsourcetosensor,smalllevelsoffoamcanhavesignificanteffecton
themeasurements.Thisisduetothedensitydifferencebetweenfoamendgasvapours.
Interfacemeasurement/densityprofilemaybeusediftheemulsionlayerthicknessorthedensityprofile
needstobemeasured.HoweverIfspecificvalueswaterandoilofanemulsionhavebeenusedduringthe
calibrationstage,thentheoperatedvaluesofwaterandoilshouldbethesameotherwiseitwillnotbe
possibletocharacterizetheotherlayers.Forexamplethatiftheoildensityvariesfrom900kg/m3
(calibrationvalue)to800kg/m3andif800kg/m3havebeendeclaredasemulsionthenthenewoildensity
willbeseenasanemulsion.

10.3 Selection

Nucleoniclevelmeasurementisusedinsituationswhereotherinstrumentscannotbeplacedinavesselor
reactorduetoverycorrosiveorextremelyadhesiveproducts,inreactorsorfurnacesatveryhighpressures
and/ortemperatures.

10.4 Design

Anucleonicsystemneedstobeengineeredaccordingtotheapplicationrequirements.Thesourceactivity
requirediscalculatedbasedonthevesseldesign(wallthickness,wallmaterial,etc.)aswellastheinstallation
possibilities.
Additionalaspectstobeconsideredare:measuringrange,thedensityoftheprocessmedium,expected
thicknessanddensityofbuildupformation(ifany),obstaclesinvesselandtheambienttemperatureatthe
detector.
Intermsofaninterfacemeasurementordensityprofilesystemengineeringisrequiredtodeterminethe
correctpositionofthenuclearsource.Ifthesourceneedstobeplacedinsideadiptube,anappropriate
nozzleneedstobeavailable.Thediptubecanbecurvedifrequiredtoallowthesourcetobeinsertedtothe
correctpointevenifnosuitablespareprocessconnectionisavailable.
Forinterfaceorprofilerapplications,ifthemeasurementrangeexceeds1.5mmorethanonesourceis
required.
Propershieldingneedstobeconsidered,dependingontheexpecteddoserates(emptyvessel).
Particularattentionshouldbepaidtothetemperatureofthedetectors.Typicallydetectorscanoperatein
standardprocessconditions.Therefore,forsomeapplications,acoolingsystemmayberequired.Ifitisthe
casethecoolingsystemsshouldbeincludedinthedesignandsubmittedtotheproductmanufacturerfor
approval.Thiscoolingsystemshouldminimumcompriseheaderfromthecoolingskid,suitabletappingpoint
withisolationvalvesbetweenheaderanddetectors,awatercoolingskid(centrifugalpump,aircooler,
expansionbottle,temperatureandpressuregaugesasrequired,temperature,pressureandflow
transmittersasrequired).

10.5 Installation

Thislevelmeasurementmayhavethesource(s)andthedetector(s)internallyorexternallymounted(see
Figures56to59).

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Thismountingarrangementshouldbestudiedtakingintoaccountfluids,processconnections,vessel
material,thesourceanddetectordistanceandanglesbetweenthesourceandthedetector.Thisstudy
shouldhighlightthemountingarrangementproandcons.

Equipmentmountedexternallyorinternallymightrequireadditionalsupportingstructures.

Theapplicablesketchshouldbedevelopedbasedonthevesselshapeandmaterial,thefluidfeatures
(includingbuildup),theoperationandmaintenancerequirements(e.g.onsitecalibration).Thesizesand
distancesstatedinthehereundershouldbestudied.

Figure56Nucleonicinternalsourceanddetectorprincipleintwoseparateddippipesexample

Figure57Nucleonicinternalsourceanddetectorprincipleinonedippipeexample

70

Figure58Nucleonicinternalsource/detectorandexternaldetector/sourceexample

Figure59Nucleonicexternalsourceanddetectorexample

10.6 Calibration and configuration

Anuclearsystemalwaysneedstobecalibratedinthefield.Forinterfaceorprofileapplications,itis
recommendedtousetwodifferentmediaforthecalibration.

Aoneortwopointcalibrationmethodcanbeusedtosetupaninterface/profilingapplication.

Aonepointcalibration(e.g.withwater)ismoreconvenientifavesselcanonlybefilledwithonedefined
homogeneousmedia.However,theinterfacemeasurementaccuracywilldependonthedifferencebetween
thelowerandupperfluiddensity.

Onepointcalibration

71

Figure60Nucleoniconepointcalibration

Twopointscalibration

Figure61Nucleonictwopointscalibration

Calibrationprocess

performbackgroundcalibration(vesselabsorption)
switchOFFtheradiation.Performwater(othermediaarepossibleifthedensityisknown)calibration
(1.Point):Ensurethatthevesselisfilledwithwateronly.Thewaterlevelshouldbeatleastatthe
heightoftheupperdetector.SwitchONtheradiation.
switchOFFtheradiation.Performoil(othermediaarepossibleifthedensityisknown)calibration(2.
Point):Ensurethatthevesselisfilledwithoil.Theoillevelshouldbeatleastattheheightofthe
upperdetector.SwitchONtheradiation.

72

11. Magnetic Level Indicator

11.1 Measurement principle

TheMagneticLevelIndicator(MLI)isasimple,ruggedinstrumentdesignedtoindicatelevelorinterface.It
indicateslevelusingafloatmagneticallycoupledtoanindexoracolumnofrotatingflaps.Itisidealfor
aggressivemediastoredinvesselswhenthePTFEliningoptionisused.
Thefloatisequippedwitharingsystemofpermanentmagnetsfortransmissionofliquidleveltothe
indicator.Theindicatorislinkedmagneticallytothemagnetsysteminthefloat.
Forthepurposeofdesign,theminimumlevelinthemeasuringtubeisgivenbythelowerlateralflange
connectionaxisi.e.liquidlevelzeroisthecentrelineofthelowerconnectingflange.
MagneticlevelIndicators(MLI)arepreferredLevelIndicator(comparedwithglassorreflexindicators)
becauseofsaferperformanceagainstexternalexplosionsandhighpressureapplication.
Thereisadifferencebetweenthetrueliquidlevelandtheindicatorpositionbecause:
thefloatisimmersedtoacertaindepthdependingontheproductdensityandfloattype
thefloatmagnetsarepositionedbelowthefloatcentrelineinorderforthefloattohavegood
stability.
Thescaleisdeliveredcorrectlysetupformeasuringtheproductspecifiedintheorder.Theredreference
markatthetopofthemeasuringtube(item1inthediagrambelow)showswherethetopofthescale
shouldbeclampedfortheindicatortogiveanaccuratereadingofliquidlevel.Nofurtheradjustmentis
necessarywhenthegaugeiscommissioned.
Notes:
1.Ifthereisalargechangeinproductdensity,aproductotherthantheonespecifiedintheorderis
measuredoradifferentfloatisinstalled,thescaleontheMLImayrequireadjustingtogiveanaccurate
reading.
2.MagnetostrictiveLevelTransmittermaybeconsideredforgivingthecapabilitytotransmitalevel
measurementsignalremotely.

11.2 Limitations

IftheuserwishestousetheMLItomeasureanotherproduct,thenthefollowingpointsshouldbenoted:
thedepthofimmersionofthefloatincreasesasproductdensitydecreases.Thisdepthisalso
dependentonthefloatmodelandmaterialused(AISI316L,AISI316Tiortitanium)
thetopofthefloatshouldbenomorethan35mmabovetheproductsurfacetoensurereliable
floatabilityandaccuratemeasurement
ensurethatthefloatandchamberaredesignedaccordingtothedesignpressureandtemperature.

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Thechambershouldberegularlydraineddowntopreventthebuildupofdebrisandcleaned.Floatsshould
beinspectedtoensuretheyarenotdamaged,corrodedorpitted.Therotatingflapsshouldbelubricatedand
checked,asoftentheycanstickcausinganincorrectandmisleadinglevel.

11.3 Selection

MLIshouldbesuitableforinterfacelevelmeasurementifspecificgravitiesdiffersignificantlyandthechange
inspecificgravityduetocompositionortemperaturecannotaffectthereading.Itisallowedthatthe
differencebetweenspecificgravitiesisgreaterthan0.1.

MLIinstrumentsshouldnotbeusedinseverelyturbulent,dirty,foaming,foulingserviceorincaseof
presenceofsolidparticlesinthefluid(e.g.sand).Theseconditionsleadtounreliablemeasurementsfrom
displacementlevelinstruments.

MLIshouldnotbeusedforliquidliquidinterfaceswhenthetwofluidsformanimportantemulsion(abovea
fewcentimetres)ordonothaveacleaninterface.

MLIshouldnotbeusedinliquidliquidorliquidgaseousserviceswhereeithertheupperorlowerfluid
specificgravityisnotrelativelyconstant.

11.4 Design

MLIshouldbemadeofstainlesssteelorothermaterialcompatiblewiththeprocessfluid.

MLIshouldhavetheheightaccordingtothelevelrangefortheapplication.Therangeofmeasurementisthe
CClength.

Floatsareselectedinaccordancewiththeliquiddensity.

74

11.5 Installation

Theinstallationshouldbereviewedandanyrequirementsfortraceheatingorinsulationincorporatedinto
thedesignandinstallationofthemeasuringtube.

Operatingproceduresshouldpreventrapidpressurizationofthefloatchamber.Damageandfailureofthe
floatcanoccurifthechamberispressurizedquickly.Thefloatcanberammedtooneendofthechamber.

Floatstopsshouldbeprovidedatbothendsofthechamber.(ThisrequirementfromATEXapplications,
typicallyfabricatedusingahighqualityspringfittedwithacarbonorPTFEbuffer,dependingondesign
processconditions.)

11.5.1 Mechanical installation requirements

Theeffectivepressureoftheinstallation(themaximumpermittedbythepressurelimitingvalve)should
neverbegreaterthanthemaximumpermittedpressurePsoftheinstrumentnameplate.

Theapplicationshouldbecompatiblewiththefluidandconformtoageingcharacteristicsofthefluidused
andthemeasurementenvironment.

Theexternalpressure(Pext)shouldbeequaltoatmosphericpressure(Patmos).

1Tank

2Liquidproduct

3MLI

Figure62MLIMechanicalinstallationrequirement

11.5.2 Mounting on the vessel

Thechamber/cagelevelindicatorshouldbeinstalledverticallyonthevessel.
Wheninstallingthechamber/cagelevelindicatorwithorwithouttheelectricalleveltransducersystem,
makesurethatanymagneticfieldsgeneratedbyotherequipmentwillnotaffectmeasurements.

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Selectedboltsandgasketsshouldcorrespondtothepressureratingoftheconnectingflangeandthe
operatingpressure.Theprocessconnections(flanges)shouldfitproperly,i.e.theyshouldbecentred,parallel
andboltedinaprofessionalway,inordertoavoidunnecessarymechanicalstressontheinstallation

Thevesselshouldbefreeofcontaminants.Itisrecommendedtoinstallisolationandvent/drainelements,
e.g.cocks,valves,etc.betweenthevesselandchamber/cagelevelindicatortoallowthechamber/cagelevel
indicatortobecleanedindependentlyofthevessel.Thedrainpluginthebottomflangeshouldalsobe
replacedbyadrainagecockwithdischargeline.

76

11.6 Calibration and configuration

Calibrationshouldbeperformedatproductmanufacturerpremisesandverifiedpriortothecommissioning
activities.

Correctingthescalepositiontoaccuratelyreadtrueliquidlevel(Processconditionschanges)

Thescale*canbecorrectedusingthefollowingprocedure:

Step Action

1 Findthefloatimmersiondepthc

2 Subtractthedimensiona,floatbasetomagnetcentreline(givenonthefloatdimensioned,fromctogetthe
dimensionb,scalecorrectionfactor.

Item Description

b= ca(differencebetweenliquidlevelandindicator
positionduetoproductdensity)

c= floatimmersiondepth(afunctionofproductdensity)

a= distancefromcentrelineofmagnetsystemtothe
floatbase

1= Float

2= Followermagnetofindicator(orlimitswitch)

3= Positionofmagnetsmountedinthefloat

3 Loosenthetwoclampcollarsholdingthemeasuringscaleontothemeasuringtubeusingascrewdriveror8mm
wrench.

4 Bringthezeropointonthescaleintolinewiththecentrelineofthebottomlateralprocessconnection.

4a Undotopcollar

1 Measuringscale

2 Measuringtube

3 Topmeasuringscalecollar

77

12. Manual measurement

Althoughthescopeofthedocumentisaboutfixedinstalledmeasuringinstruments,manualmeasurements
shouldbeatleastdiscussedbriefly.Manualmeasurementsarestillquiteoftenusedastheyareperceivedas
lowcost(atleastinitial),donotrequirecablingorpowerandareoftenusedforduringcommissioning,or
verificationofinstalledinstrumentation.

12.1 Measurement principle

Therearethreemainsmanualmeasurementprinciplesused:

tape,rulerordipstick
sightglass
portableelectronic.

Bothofthesemanualmethodsmakeuseofagraduatedmeasurementtape,rulerordipstick,toreadthe
leveland/orinterface.

12.1.1 Tape, ruler and dipstick

Thismeasurementistypicallyusedonlargetanks.

Figure63Typicalgaugetapes,bobsandawatergaugebar(Source: Figure64Photooftypicaldiptapeasuseonbulkstorage
APIMPMSCh.3.1A) tanks

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Arulerordipstickistypicallyusedforrelativesmalltanks.Apracticallimitis2to3metresheightmax.In
someareas/countriesalsosocalledsliptubegaugesareusedforonLPGrailtankers.

NFPA58describessliptubegaugeasaAvariableliquidlevelgaugeinwhicharelativelysmallpositiveshutoffvalve
islocatedattheoutsideendofastraighttube,normallyinstalledvertically,thatcommunicateswiththecontainer
interior.Asliptubeisbasicallyadipstick.

Figure65Exampleofdipstickasusedforundergroundstorage Figure66Exampleofdipopeningofforegroundstation(petrol
tanks station)

Onclearliquidsandverylightproductswhicheasilyevaporate,includingwater,oftenacoloringpasteis
used.Thepastechangescolorwhenindirectcontactwiththeliquid.
Forwaterdetectionwhichisoftencalledwaterfindingruletodetectalevelisrecommended.Water
findingrulesaretypicallymadeofbrasswithalternatingtransparentplasticsections,whichallowsseeing
wherethepastehasdiscoloredwhenmeasuringwaterinopaqueoils

12.1.2 Sight glass

Forclosedtanks,andproductswhicharetoxic,easilyevaporateorareflammable,oftenasightglassisused.
Thesightglassistypicallyinstalledaspartofachamber/cage.Itcaneitherbeatransparentpieceofpiping
orametalenclosurewithtypicallyahardenedflatglassviewpane.
Thetankconnectionsoftenhaveblockvalves,whichallowmaintenanceonthesightglassandsightglass
body.Somesightglassdesignsalsoincorporatedrainvalveswhichallowscleaning(flush)thesystem.

79

Figure67Sightglassonfueltank Figure68Examplesofvariousformsandshapesofsightglasses

Reflexgaugesareaspecialformofsightglassgauges,anduseopticalrefractionandreflectionforan
improvedvisibilityofinterfacesinandbetweenvapour/gasandliquidzones.

Figure69Exampleofsightglass Figure70SightglassinstalledonLPGhorizontal Figure71Highpressuresightglasswith
constructionforpressurized bullettank graduatedscale
application

Issomespecificareasandequipment(steamgenerators,boilers,powergeneration),theuseofsightglass
typelevelgaugesmayalsobemandatorytofulfillthedesigncode(e.g.ASMEI).

Sightglassmayalsobeusefulwheredirectvisionofthefluidisrelevant.

12.1.3 Portable electronic gauging

Portableelectronicgaugingcanmeasurethelevelofullageandtheoilwaterinterface.Portableelectronic
gaugingissuitableforopenandclosedapplications.Closedgaugingoperationswillgenerallyrequirethe
portableelectronicgaugingtobeusedinconjunctionwithacompatiblevapourlockvalve.

80

Figure72Portableelectronicgaugingsystemwithvapourlockvalve

Representativemeasurementsofthetemperatureofthetankcontentsmayalsobemeasuredwiththe
portableelectronicgauging.Thistemperaturemeasurementpermitstoconverttheobservedvolumetoa
standardvolumemeasurement.

12.2 Limitations

12.2.1 Tape, ruler and dipstick

Tape,rulerordipstickcanonlybeusedwhenthetankisnotpressurizedandthetankcontentsare
consideredtobesafe(i.e.nottoxic,dangerousanddonotposeanenvironmentalissue).

Figure73Necessarysafetyprecautions(PPE)ontoxicproducts

81

12.2.2 Sight glass

Sightglassescannotbeusedfortankscontainingsedimentorsolids,astheconnectionmightbecome
blocked.
Useofsightglassescanbeconsideredforinterfacemeasurementalso,providedtheinterfacelayerisclearly
visible.
Sightglassinstallationisalsopossibleonpressurizedtanksbutsometimesperceivedasasafetyrisk.
Ontankswhichalsocontainsolids,thereadingofthesightglasscanbeunreliableasresultofblockage.For
theseapplicationsstrictproceduresforperiodicflushingthesightglassandconnectionsshouldbe
considered.
Sightglasssystemshavethelimitationofwherethelevelcanbebetweenglassesandinthebrassareaand
henceitisdifficulttounderstandwherethelevelis.
Sightglassesrequireregularmaintenanceandcleaning.Thepresenceofsomehydrocarbonliquidscancause
stainingandthiscanmakeitdifficulttoascertainwherethetruelevelactuallyisplaced.

12.2.3 Portable electronic gauging

Safetyandenvironmentalregulationsmayrestricttankgaugingoperationswhichcanresultinthereleaseof
hydrocarbonsorothervolatileorganiccompoundsintotheatmosphere.Inthesecircumstances,itwillnot
normallybefeasibletousetraditionalopengaugingproceduresviaanopengaugehatchorgaugingaccess
point.

Figure74Portableelectronicgaugingsystemwithvapourlockvalve

82

12.3 Selection

Foralltoxic,pressurizedanddangerousproducts,closedsolutionsarepreferred.
Ifmanualmethodsaretobeused,thesafeuseshouldbecoveredbyproceduresandformaltraining.

12.4 Calibration and configuration

Forapplicationswheretheaccuracyisofimportance,thegraduatedscaleontape,dipstickorsightglasscan
becalibrated.
Itisimportanttorealizethatitisalwayscriticaltousethecorrectdatumpointontheparticulartank.This
datumpointcanbeadipplateonthebottomoraclearmarkedmechanicalprovisiononorinthetank
nozzle.
Sightglassescanbeadjustedbyshiftingthegraduatedscale.
Theportableelectronicgaugingsensoriscalibratedonceatthefactoryanddoesnotrequiresubsequent
calibration.

83

Annexes

Annex A Pressure/temperature influences

A.1 Wave radar

Highpressures/temperaturesreducethepropagationvelocityofthemeasuringsignalsinthegas/vapour
abovetheliquidinterfacetobemeasured.Theresultofthehighpressure/temperatureisasystematic
measuringerror.Table3givesseveralmeasuringerrorsfordifferentgases/vapours.

Table3Exampleofmeasuringerroronwaveradarwithhighpressure/temperature

Theseerrorsmaybecompensatedwithtwomainmethods:

compensationwithexternalpressureandtemperaturesensors
compensationwithareferencesignal.
Compensationwithexternalpressureandtemperaturesensorisachievedbycalculationwithexternal
pressureandtemperaturesensors.

Compensationwithareferencesignalmeansthattheactualwavevelocityismeasuredbycalculatinga
referencereflectionbetweentwoknownpointsaknowndistance(Lref)andrelevanttransittime.

Lref=ActualVelocityTransittimeofthisLref.

HavingthisActualVelocityinthemedia,thedistancecanbecalculatedfromtheactualreflectiontime
measurement.TheLrefshouldbeupperthehighermaximuminterfacelevelwithamargin(e.g.150mmin
Figure75).

84

Figure75Exampleofhighpressure/temperaturecompensationwithreferencesignalmountingarrangement

A.2 Nucleonic

Theattenuationofgammaraysdependsonthedistancebetweensourceanddetectoraswellasthedensity
alongthebeampath.Pressureandtemperaturevariationaffectthegas/vapourdensity.Duetothischange
ofgas/vapourdensity,thegammasourcecountrateisimpactedandthereforethelevel.The
pressure/temperaturevariationisnotlinearconsequentlyactualpressureandtemperatureshouldbe
measuredandcompensated.

Tocompensatetheinfluenceofthevapourdensitytheattenuationfactorshouldbecalculatedregardingthe
vapourdensity.

85

Figure76Exampleofvapourdensitycompensation

86

Annex B Pressure and temperature ranges

Table4givestypicalpressureandtemperatureranges.Processactualdatashouldbecheckedagainstthe
ProductManufacturerparticulartechnology.

Typicalrange

Temperature(C)

Pressure(barg)
Technology Min Max Min Max
DP(impulselines) VesselLimits 0.975 450
DP(diaphragmseals) 75 600 0.975 400
DP(ElectronicDP) 75 600 0.975 400
Displacer(buoyancy) 60 450 1 200
Ultrasonic 40 90 0.25 3
Capacitance 200 400 1 150
NonContactRadar 200 450 1 160
GuidewaveRadar 200 400 1 400
HybridCapacitance/GWR 50 200 1 40
Nucleonic VesselLimits VesselLimits
MagneticLevelIndicator 200 500 0 400
ManualMeasurement 0 350 1 100

Table4Typicalpressure/temperatureranges

87

Annex C Interface Measurement Selection Guidance Automatic level

measurement

Table5givessomeguidancerelatedtotheoilwaterinterfacelevelmeasurementforasingletechnology.
However,itisimportanttounderstandtheneedofthemeasurement.Forsomeapplicationseveral
technologiesmaybeusedtofixaneedwhichcannotbesolvedbyonetechnologyonly.Table5highlights
someusecasesbutdoesnotsupersedethescopeandlimitationgiveninthisrecommendedpractice.

DP Displacer Radar GWR Capacitance Hybrid Nucleonic

Capacitance/GWR
OilgasInterface Suitable Suitable Suitable Suitable NotSuitable Suitable Suitable

CleanOilwater Suitable Suitable Not Suitable Suitable Suitable Suitable
interface Suitable

Oilwater Not Not Not Not Partially PartiallySuitable Suitable
interfacewithan Suitable Suitable Suitable Suitable Suitable (Detectbelowthe
important Note1 Note1 (Detectbelow emulsion
emulsionlayer theemulsion around80%of
around80% waterandabove
ofwater) theoil)
Liquidliquid Suitable Suitable Not Not Suitable Suitable Suitable
interfacewitha (lossof (lossof Suitable Suitable
littleemulsion accuracy) accuracy)
layer(fewcm)
Soliddeposit, Not Not Not Not NotSuitable NotSuitable Suitable
water,emulsion, Suitable Suitable Suitable Suitable
oilandfoam

Note1:Theemulsionlayercannotbemeasured.Theaveragedensitybetweentheupperandlowerdensity
fluidmayrepresentstheemulsiondensity

Remark:Allmeasurementmaybechallengedinthepresenceofdirtyfluids(e.g.buildup).Productoften
providesbuildupcompensationfunctions.

Table5InterfaceMeasurementSelectionGuidance

88

Annex D Symmetric and asymmetric capillaries

Symmetriccapillary

1.SealEffect:IftheambienttemperatureincreasesthecapillaryvolumeVwilltendtoexertforcesontheDP
seal(bothsides).

Ifbothcapillaryhavethesamefeatures(volume,sealthickness,fillfluidandlength)arethesame,allthe
resultingforcesontheDPsealwillbeequaltozero(blackDPsealpositionfigurebelow).

2.HydrostaticPressure:ThehydrostaticpressurefigurebelowisP=gD(whereandgareconstants).
Fortheincreaseinambienttemperature,thedensitywilldecrease.

ThismeansthehydrostaticpressurePwilldecreasealso.Thiswillcreateanupperforce(againstthegravity
force).

Theresulting(final)DPsealpositionisshowninredfigurebelow.

Figure77Symmetriccapillary

AsymmetricCapillary

Hypothesis:ThevolumeV1<<toV(V1isnegligible)

1.SealEffect:IftheambienttemperatureincreasesthecapillaryvolumeVwilltendtoexertforcesonone
sideoftheDPseal(blueDPsealpositionFigure78).

2.HydrostaticPressure:ThehydrostaticpressureinFigure78isP=gD(whereandgareconstants).
Fortheincreaseinambienttemperature,thedensitywilldecrease.

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ThismeansthatthehydrostaticpressurePwilldecreasealso.Thiswillcreateanupperforce(againstthe
gravityforce).Thiswilltendtocompensatethesealeffectforce.

Theresulting(final)DPsealpositionisshowninblueinFigure78.

Figure78Asymmetriccapillary

Thisasymmetricresultingforceisinferiortothesymmetricresultingforce.

Limitation

Tallvesselsandtowershaveposedasignificantmeasurementchallenge.Inparticular,longverticaltapto
tapdistancesrequireextendedlengthsofcapillarytofacilitatetheinstallation.Asthetaptotapdistance
grows,theresultingheadpressureswithinthecapillarybecometoogreattotuneout.Timeresponsecan
besuboptimalontallvesselsandtowersasthedistancethepressuresignalpropagatesthroughis
substantiallygreater.Overall,asthelengthofcapillaryattachedtothetransmitterlowsideincreases,an
accuratemeasurementbecomesincreasinglymoredifficulttoachieve.

90

Table of Figures
Figure1Pressurevesselmountingprinciple........................................................................................................9
Figure2Measuringrange...................................................................................................................................10
Figure3Interfacelevelwithnoemulsionrepresentativeness..........................................................................14
Figure4Interfacelevelwithemulsionrepresentativeness...............................................................................14
Figure5DPmeasurement..................................................................................................................................18
Figure6DPImpulse............................................................................................................................................20
Figure7DPLevelvsdensitymeasurement........................................................................................................21
Figure8SPProcessconnectionwithdiaphragm...............................................................................................24
Figure9DPSteamheatingfacilities...................................................................................................................24
Figure10DPSMorRTJdiaphragmflanges........................................................................................................25
Figure11DPflushing/draining...........................................................................................................................25
Figure12DPcapillaryprotection.......................................................................................................................26
Figure13DPCapillaryarrangement...................................................................................................................26
Figure14DisplacementMeasurement..............................................................................................................28
Figure15Displacementinsitucalibration.........................................................................................................31
Figure16UltrasonicLiquidMeasurementArrangement...................................................................................33
Figure17Ultrasoniccalibration.........................................................................................................................34
Figure18Capacitancemeasurementprinciple..................................................................................................35
Figure19Capacitanceoperatingrange..............................................................................................................36
Figure20Capacitanceinstallation......................................................................................................................38
Figure21Capacitancecalibration......................................................................................................................39
Figure22Radarmeasurementprinciple............................................................................................................40
Figure23RadarFMCWprinciple........................................................................................................................41
Figure24Radarpulseprinciple..........................................................................................................................41
Figure25Radarwith6.3GHz.............................................................................................................................42
Figure26Radarwith26GHz..............................................................................................................................42
Figure27Radarwith26GHz..............................................................................................................................43
Figure28Radarmeasuringthelevelthroughtheplasticvessel........................................................................43
Figure29Radarantennashape..........................................................................................................................45
Figure30RadarDirecttopvesselInstallation....................................................................................................46
Figure31Radaralignment.................................................................................................................................46
Figure32Radarsocketornozzleradarinstallation...........................................................................................47
Figure33Radarfullportballvalve.....................................................................................................................47
Figure34Radarinstallationusingstillingwell...................................................................................................48
Figure35Radarinstallationusingchamber/cagetube......................................................................................48
Figure36GWRTypicalinterfacelevelreflection...............................................................................................50
Figure37GWRinterfacelevelmeasurement....................................................................................................52
Figure38GWRInterfacemeasurementdielectriccriteria................................................................................52
Figure39GWRMaximumdielectricconstantvstechnology.............................................................................53
Figure40GWRMaximumupperproductthickness..........................................................................................53
Figure41GWRinterfacemeasurementinvesselwithemulsion......................................................................54
Figure42GWRpossibleerrorchambersmeasurement....................................................................................56

91


Figure43GWRchamberinstallationandsizing.................................................................................................57
Figure44GWRCase1Differenceinproductspecificgravity(SG)..................................................................57
Figure45GWRCase2Lackofcirculationinchamber....................................................................................58
Figure46GWRchamberwithmultipleconnections..........................................................................................59
Figure47GWRfullysubmergeairpocket..........................................................................................................60
Figure48GWRfullysubmergeairpocketecho.................................................................................................60
Figure49GWRinterfacemeasurementinvessel..............................................................................................61
Figure50GWRinterfacemeasurementinvesselwithlowerDCupper............................................................61
Figure51Hybridcapacitance/GWRmeasurementprinciple.............................................................................63
Figure52Hybridcapacitance/GWRinstallationwithheatinsulation...............................................................65
Figure53Continuouslevelmeasurement/fullabsorptionprinciple.................................................................67
Figure54NucleonicInterfaceMeasurementPrinciple......................................................................................67
Figure55Nucleonicdensityprofileprinciple.....................................................................................................68
Figure56Nucleonicinternalsourceanddetectorprincipleintwoseparateddippipesexample...................70
Figure57Nucleonicinternalsourceanddetectorprincipleinonedippipeexample......................................70
Figure58Nucleonicinternalsource/detectorandexternaldetector/sourceexample....................................71
Figure59Nucleonicexternalsourceanddetectorexample..............................................................................71
Figure60Nucleoniconepointcalibration.........................................................................................................72
Figure61Nucleonictwopointscalibration........................................................................................................72
Figure62MLIMechanicalinstallationrequirement..........................................................................................75
Figure63Typicalgaugetapes,bobsandawatergaugebar(Source:APIMPMSCh.3.1A)..............................78
Figure64Photooftypicaldiptapeasuseonbulkstoragetanks......................................................................78
Figure65Exampleofdipstickasusedforundergroundstoragetanks............................................................79
Figure66Exampleofdipopeningofforegroundstation(petrolstation).........................................................79
Figure67Sightglassonfueltank.......................................................................................................................80
Figure68Examplesofvariousformsandshapesofsightglasses.....................................................................80
Figure69Exampleofsightglassconstructionforpressurizedapplication.......................................................80
Figure70SightglassinstalledonLPGhorizontalbullettank.............................................................................80
Figure71Highpressuresightglasswithgraduatedscale..................................................................................80
Figure72Portableelectronicgaugingsystemwithvapourlockvalve..............................................................81
Figure73Necessarysafetyprecautions(PPE)ontoxicproducts......................................................................81
Figure74Portableelectronicgaugingsystemwithvapourlockvalve..............................................................82
Figure75Exampleofhighpressure/temperaturecompensationwithreferencesignalmountingarrangement
............................................................................................................................................................................85
Figure76Exampleofvapourdensitycompensation.........................................................................................86
Figure77Symmetriccapillary............................................................................................................................89
Figure78Asymmetriccapillary..........................................................................................................................90

92

Table of Tables
Table1Exampleofproductdielectricconstant.................................................................................................43
Table2GWRnozzlediameter............................................................................................................................56
Table3Exampleofmeasuringerroronwaveradarwithhighpressure/temperature.....................................84
Table4Typicalpressure/temperatureranges...................................................................................................87
Table5InterfaceMeasurementSelectionGuidance.........................................................................................88

93

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Measurement of single and multi-

layer level in the hydrocarbon
processing industries is commonly
needed, but doing so accurately is
often challenging. There are a great
diversity of situations which require
such level measurement, ranging
from pure fluid to viscous, muggy
and corrosive fluids.
This Recommended Practice covers
the selection and installation of
instruments used for single and
multi-layer level measurement
that are encountered in upstream
hydrocarbon facilities.