Level 1 1

Fundamental Training

RMT Training - 05 /98 Level 1 - Level

 Contents 2

Topics: Slide No:

• Why measure level? 3-5
• Level terminology 6 - 19
• Technology selection 20 - 29
• Rosemount Technology (Pressure 30 - 55
Transmitter, HTG & Hybrid System
• Other Technology (Float, Capacitance, 56 - 75
Displacer, Servo, Nucleonic, Laser &
Ultrasound)
• Exercise 76 - 80

RMT Training - 05 /98 Level 1 - Level

 Why measure level?
5 Common Reasons 3

Inventory
• keep track of amount of material of material available for a process
Custody Transfer
• amount of material that is bought & sold in terms of volume or weight
Effieciency
• maximise storage tank capacity
• preventing unnecessary expense of purchasing additional vessels
Safety
• prevent spillage in open vessels
• prevent overpressure conditions in closed vessels that may result in
rupture
Consistent Supply
• to maintain product quality in a process
» blending, pulp & paper
RMT Training - 05 /98 Level 1 - Level
 Why measure level?
Inventory vs. Process 4

Inventory
• Accuracy is primary difference
» better than 3 mm precision needed
• Applications need precise measurement because of $$$$$
» Transfer of ownership
» Exact quantity must be known
» Product cost You can have a
» Tend to be larger vessels mixture of process
Process and inventory
• Applications are more concerned with:
applications in a
plant
» Control of a product level within a range
» Safety (prevent overflow/ pump shutoff)
» Monitor inputs of components of a process
» Accuracy requirements vary widely

RMT Training - 05 /98 Level 1 - Level

 Why measure level?
Indication vs. Control 5

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

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Level Control Loop 6

(Inflow)

I/P LIC

• Level Loop Issues:

– Control At Inflow or Outflow
– Non-Self Regulating

LT

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Level Control Loop 7

(Outflow)

LIC I/P

LT

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Parameters 8

Interface

Level

Volume
Density Mass

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Parameters 9

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

Liquid B

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Parameters 10

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

density of fluid = SG
density of water
Density of fluid = density of water * SG
Mass = Density / Volume
RMT Training - 05 /98 Level 1 - Level
 Level terminology
Parameters 11

Volume
• Volume only correlates directly to level when:
» Tank is an upright cylinder
» Density is constant
» Temperature is constant Volume
» There is no change in tank wall position after filling
• Volume measurements are in units such as:
» gallons, liters, barrels...
• Level measurements are in units such as:
» inches, feet, millimeters, centimeters, meters...
• Correlation of volume to level varies with geometry of
tank and may be expressed in terms such as:
» gal/inch, liters/meter, barrels/inch...
RMT Training - 05 /98 Level 1 - Level
 Level terminology
Parameters 12

r
Volume
• Vertical Cylindrical Tank h
l
» v = πr2l

• Horizontal Cylindrical r
» v = πr2atan[l½/(2r-l)½]+h(l-r)[l(2r-l)]½ l

r
• Sphere Tank
l
» v = πl2(3r-l)/3

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Parameters 13

Volume
• Horizontal Bullet Tank
» v = πr2/3 * (3r-l) + 2r2(h-2r) *atan[l½/(2r-l)½] + (h-r)[l(2r - l)]½
h

r
l
r

h
• Vertical Bullet Tank
l
» v = πr2/3(3r-l) if l ≤ r
» v = πr2/3(3r-l) if r < l < (h - r)
» v = πr2(h-2r) + [π(l+2r-h)2]/3 * [3r-(l+2r-h)] if (h - r) ≤ l

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Parameters 14

Volume
• Tanks with Dished Ends
» no standard shape
– use strapping tables to determine volume
Point Level Volume Bulging
10
(inches) (gallons)

1 0 0 A look-up table that

2 5 10 relates level to volume
3 10 32 for several discrete
9
4 15 68
7 points in a tank.
5 20 115
5 6 25 173
3 7 30 230 Commonly used to
1 8 35 313 eliminate Bulging Error.
9 40 394
10 100 957
RMT Training - 05 /98 Level 1 - Level
 Level terminology
Measurement Characteristics 15

...and the technologies may have to handle a number of

application conditions.
0

-14.7
PSIG

Density High
High Viscous
Viscousoror
Steam,
Steam,vapors,
vapors,
Changes vacuum
vacuum sticky
stickyfluids
fluids
dust
dust

Abrasive
Abrasive Corrosive
Corrosive Temperature
Temperature
fluids
fluids Foam
Foam processes
processes extremes
extremes Agitation
Agitation

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Measurement Characteristics 16

Bottom-Up vs. Top-Down Measurement Top-down

Top-Down Measurement
• Poses less potential for leakage
• devices installed or removed
without emptying tank
e.g., dipstick, radar gauge

Bottom-Up Measurement
• Typically contacts the process
fluid
e.g., pressure transmitter, Bottom-up
weigh scale

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Measurement Characteristics 17

Inferred vs. Direct Measurement

• An Inferred measurement is derived from another
measurement
Ex: pressure transmitter
HeadPressure = Level , Mass = Level
Density Density
Stability of variables is critical to get a good inferred
measurement.
If variables are not stable, compensation needs to be
made.

• A Direct measurement looks only at the desired variable

Ex: floats, dipstick

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Measurement Characteristics 18

Continuous vs. Point Measurement

Continuous Measurement Point measurement

• Constant detection of • Has the level reached
product height this point?
• Concerned with amount • High or low level
of product detection
• May be used to control • Often used for alarm
addition of other control
components to the vessel • May start or stop
pumps
• May open or close
valves

RMT Training - 05 /98 Level 1 - Level

 Level terminology
Measurement Characteristics 19

Non-Contact vs. Non-Invasive vs. Non-Intrusive

Non-Contact
implies that the
device does not Non-invasive
touch the fluid, implies that the
but it could be device does not
invasive pass the walls of
the tank nor touch
the process
directly
Intrusive

Non-intrusive implies
that the device may
come in contact with the
fluid, but does not
protrude into the fluid or
interfere with fluid
movement
RMT Training - 05 /98 Level 1 - Level
 Technology selection
Level Measurement Technologies 20

Bubbler
Dipstick
Capacitance
Float Ultrasonic
Tuning Fork Radar

Sight glass

Nuclear

Displacer

Gage Glass
Differential
Pressure
Ultrasonic Gap
Hydrostatic

Weight

RMT Training - 05 /98 Level 1 - Level

 Technology selection
Classification of Level Measurement Technologies 21

Contacting Noncontacting Point Continuous Liquids Solids

Bubblers
Capacitance
Conductivity
Displacers
Floats
HT G
Hydrostatic
Laser
M agnetostrictive
Nucleonic
Optical
Phase Difference
Radar
Resistance T ape
Rotation Suppression
Servo
T ape Level
T hermal
Ultrasonic
Vibration
Weighing

RMT Training - 05 /98 Level 1 - Level

 Technology selection
Classification of Level Measurement Technologies 22

Density Interface Level M ass

Bubblers
Capacitance
Displacers
Floats
HT G
Hydrostatic
Laser
M agnetostrictive
Nucleonic
Phase Difference
Note: Only
Radar continuous
Resistance T ape devices
included
Servo
T ape Level
Ultrasonic
Weighing
RMT Training - 05 /98 Level 1 - Level
 Technology selection
Factors To Consider 23

• Why is the level measurement needed?

What are you try to measure?
What are you trying to achieve?
– Indication of fluid level
– Alarm set point to prevent spill over
– Transfer (Sale) of product
– Contol of Product Mix
– Leak Detection
– Interface detection
• What are the conditions within or on the vessel?
Product turbulence
Obstructions
Mounting constraints
Angle of repose for solids
Temperature and pressure limits

RMT Training - 05 /98 Level 1 - Level

 Technology selection
Factors To Consider 24

• What are the environmental conditions?

Ambient Temperature
Humidity
Vibration
Electro Magnetic Interference(EMI)
Transient protection
• What are the product characteristics?
Corrosive
Viscous
Dusty, Foam
Variable Density
Variable Dielectric constant
Tendency to Coat
Interfaces, gradients, suspended solids
Steam or other vapors
RMT Training - 05 /98 Level 1 - Level
 Technology selection
Factors To Consider 25

Common Density/ Temperature Changes

RMT Training - 05 /98 Level 1 - Level

 Technology selection
Factors To Consider 26

Typical Dielectric/ Temperature Changes

RMT Training - 05 /98 Level 1 - Level

 Technology selection
Factors To Consider 27

• What are the instrument requirements?

Performance requirements
Location approvals
Power requirements
Output requirements
Number, location, and size of taps
Total costs
– Product
– Installation
– Maintenance

RMT Training - 05 /98 Level 1 - Level

 Technology selection
Performance Consideration 28

Temp changes
Vibration
Noise
Environmental
Factors

Process Density changes

Device Conditions temperature changes
static pressure
agitation
Direct vs inferred
aeration
Measurement capabilities
foam
Rangeability
dielectric changes

RMT Training - 05 /98 Level 1 - Level

 Technology selection
Working Capabilities Vary with Technologies 29

10000+ Nucleonic
Capacitance

3626
Pressure w/ seals
Pressure, PSI

Pressure/HTG
1000 Displacer
Ultrasonic Point

Ultrasonic
73
atm Radar

-240 -100 -40 32 195 320 400 600 800 900+

Temperature, oF
Approximate values are shown. Pressure and temperature limits are shown independently of each other.
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Pressure Transmitters 30

Open Vessel Level Measurement

In open vessel a pressure transmitter
mounted near the bottom of the tank Patm
will measure the pressure
corresponding to the height of the
fluid above it.

Phigh = Phead + Patm Phead

Plow = Patm
Patm
XMTR

Phigh - Plow = Phead L H

What happen to
Atmospheric pressure? Cancelled Off
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Pressure Transmitters 31

Transmitter mounted above the tap in an open vessel

What happens when the liquid level drop below the

sensor ?
100%

XMTR
0% h
L H g
0%
The sensor will not be able to sense any pressure change !!

The 0% has to be at least at the same level as the transmitter

sensor or below the tapping point..

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 32

“Zero Suppression” is often applied to compress the range of the

transmitter OR to cancel the effects of the liquid head in the pipe
connecting the transmitter to a tank when the transmitter is mounted
below the vessel connection. At min. level the High side
pressure is high than the
low side pressure
20mA Max. Level 20mA Max. Level

Range

Range
4mA Min. Level

Actual Zero
Suppressed Actual Zero4mA Min. Level
Suppressed
XMTR XMTR

L H L H

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 33

“Zero Elevation” is often applied to cancel the effects of the head

caused by the seal fluid in the reference leg (low side) of a transmitter
measuring level in a pressurized vessel.

20mA Max. Level

Range
XMTR Min. Level
4mA
Actual Zero
Elevated L H At min. level the low
side pressure is high
than the high side
pressure

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 34

Closed Tank Level Measurement (Dry Leg)

Dry leg: no fluid in low side impulse Ullage or

piping, or leg Vapor
If the gas above the fluid does not
condense, the piping for the low
side of the transmitter will remain
Phead
empty.

Phigh = Ptop+Phead XMTR

Plow = Ptop
L H
Phigh - Plow = Phead

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 35

Closed Tank Level Measurement (Wet Leg)

Wet leg pressure is additive to
pressure on low side of the transmitter.
If the gas above the liquid condenses, Ptop= Ullage
the piping for the low side of
transmitter will slowly fill with liquid. To
eliminate this potential error, the pipe
is filled with a convenient reference Pwet
liquid. Phead

Phigh =Phead+Ptop L H
XMTR
Plow=Pwet leg+Ptop
Phigh - Plow = Phead - Pwet leg
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Pressure Transmitters 36

Limitations
• Bottom-mount technology: potential leakage
• Often requires 2 taps
• Variable density creates errors
• Temperatures beyond 600 F
• High vacuum applications are tricky
• Highly corrosive processes limit life
• Abrasive processes can damage diaphragms
• Liquids Only

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 37

Bubbler System
TXR
Consists of air supply, pressure regulator,
flow meter, transmitter & extended tube. Pin(flow=const)
Can be used for very corrosive
applications.
Tank vented.

Pressure to maintain flow = Phead

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

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 38

Gauge Pressure Transmitter

Application of Bubbler system:

Valve
• Allows dp to be a top Air
Supply
down measurement
• No process contact with
transmitter
• Open or low pressure
• Control of Air supply is
important for accuracy

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 39

Remote Seals
Reliable, Simple, Easy to Use, Well
Understood, Flexible Uses:

Diaphragm Seals extend limitations

due to process conditions such as:

high temperatures
corrosion
viscous materials Differential
suspended solids Pressure
Transmitter
plugging
sanitary needs

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Pressure Transmitters 40

Typical Pressure Applications

•CPI / HPI •Pulp & Paper
Batch reactors Headbox
digesters Stock Tanks
fractionators Chemical Storage tanks
distillation column Evaporators
bottoms and reflux drums Low concentration
separators liquor tanks...
surge drums •Food and Beverage
reservoirs Fermentors
intermediate storage... storage tanks
•Power aging tanks
drum level brew kettles...
dearators... And many more!

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Hydrostatic Tank Gauging (HTG) 41

It is basically a method for

measuring mass.
Top transmitter PT only used on non-
atmospheric tanks to compensate for
ullage pressure differences.

Middle transmitter PM located at a

specific distance “H” above PB to
calculate liquid density (PB-PM)

Bottom transmitter PB located at

the base of the tank measures
static head. A local processor handles all the
real-time calculations for
RTD measures tank contents transmitter algorithms and
temperature for reference correlations. equations for MASS, DENSITY,
LEVEL and VOLUME.

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Hydrostatic Tank Gauging (HTG) 42

A system approach to tank inventory

Effective Level
Measurement Options:
Mass = (PB - PT) x Area
PT

Density = (PB - PM ) / H
H PM

TT
Volume = Mass / Density
HBT

PB

Level = (PB - PT) /Density + HBT

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Hydrostatic Tank Gauging (HTG) 43
SCADA
Top Pressure RS-485 MODBUS Package
Transmitter Communications
(can take up Network
to 31 AIMs)

Middle Pressure
Transmitter
HART
Communicator
Temperature Application Interface
Sensor Module (AIM)

Bottom Pressure
Smart Application (obtain data from SAM
Transmitter
Module (SAM) & convert to std
MODBUS outputs)
(1 unit per tank) (can take up to
[Handles tank calculaton] 14 SAMs)

All Smart transmitters are in multi-drop mode - Digital signals only

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Hydrostatic Tank Gauging (HTG) 44

Advantages of HTG
Multi-Parameter Measurements
⌫MASS: Inventory and Billing
⌫DENSITY: Quality Control
⌫VOLUME: Inventory & Billing
⌫LEVEL: Tank Capacity
Continuous Density Measurement
Improved Accuracy
High Reliability
Low Maintenance
Diagnostic
Easy Installation
Non-Intrusive
No Moving Parts
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Hybrid Inventory System 45
SCADA

Radar Gauge
Top Pressure RS-485 MODBUS Package
Transmitter Communications
(can take up Network
to 31 AIMs)

Middle Pressure
Transmitter
HART
Communicator
Temperature Application Interface
Sensor Module (AIM)

Bottom Pressure
Smart Application (obtain data from SAM
Transmitter
Module (SAM) & convert to std
MODBUS outputs)
(1 unit per tank) (can take up to
[Handles tank calculaton] 14 SAMs)
When the Middle transmitter is removed & the Top Pressure
Transmitter is replaced by a Radar Gauge, then the whole system
will be known as Hybrid Inventory System
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Hybrid Inventory System 46

Radar Gauge
Top Pressure
Transmitter
Measurement Options:
• LEVEL is calculated by Radar Gauge
D L=H-D
• VOLUME is computed by Radar Gauge
Middle Pressure Through Strapping Table
Transmitter
H – relationship ⇒ level to volume
• DENSITY is computed by the system
Temperature
L Sensor S.G = Head Pressure / Level
Bottom Pressure – Head pressure measured by
Transmitter bottom pressure transmitter
• MASS is computed by the system
Mass = Density X Volume
• CORRECTING for Density & Volume
back to standard values is computed

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Hybrid Inventory Systems 47

Advantages of Hybrid System

Highly accurate Multi-Parameter Measurements
⌫MASS: Inventory and Billing
⌫DENSITY: Quality Control
⌫VOLUME: Inventory & Billing
⌫LEVEL: Tank Capacity
Radar can be installed without removing the tank
from service
Radar unit can be used with or without a stilling well
Process conditions up to 375°F (190°C) and 150 psi
(10 bar)
Optional average temperature measurement
Good for density-stratified products
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Radar Gauge 48

Frequency Electromagnetic Wavelength, Meters

Cycles/second
Spectrum
10 22
10 -13
Radar is an
gamma rays
Electromagnetic Wave
10 20 10 -11

18 x-rays Radio Detection And Ranging

10 10 -9

10 16 ultra violet 10 -7
Radar,
visible light
10 14 10 -5
3-30 GHz
10 12 10 -3

10
--------super high freq--------- Microwave oven,
10 10 -1
------ultra high freq----------
2 - 10 GHz
10 8
----------TV broadcasting---------- 10 1
--------FM Radio-------------
10 6 10 3 Cellular, pager,
-------low frequency------------
10 4 10 5 300-3000 MHz
10 2 10 7

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Radar Gauge 49

Radar Techniques
• Pulse
» Measures range ( distance )
» Transmits a pulse and measure time until
echo is received
» Accuracy depends on ability to measure time
– Radar signals travel at the speed of light.
– Must measure in picoseconds ( x10-12 ) !
– Cost-effective electronics do not exist to do this
accurately !

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Radar Gauge 50

Radar Techniques
• FMCW: Frequency Modulated Continuous Wave
» Does NOT calculate time-of-flight
» Evaluates the phase difference between the
transmitted and return signal
» Plotting these phase differences against the
transmitted signal yields a result proportional to
distance

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Radar Gauge 51

Advantages of Radar Gauge

• Non Contact, Non Intrusive
• Tolerates Wide Range of Process Conditions
» Corrosive Processes
» High Temperatures
» Changes in Vapor Space
» Variable Density
» Variable Dielectric
» Viscous or Sticky Products
• Low Maintenance
• No Special Licenses Required
• Can measure long distances
• Liquids, pastes, solids
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Radar Gauge 52

Radar Application Considerations

• Sensors can be completely removed from process by
use of a window made out of a nonmetallic material,
such as Teflon, Ryton, Ceramic
• Sensors can be removed from the process without
opening the vessel
Radar Limitations
• Cost
• May not work with processes with low dielectric constant
• May not work in applications with large amounts of
turbulence
• Process connections tend to be large (>4” flanges)

RMT Training - 05 /98 Level 1 - Level

 Rosemount technologies
Radar Gauge 53

Possible Applications
•Pulp & Paper •Chemical
»High Density Storage »Polymers
»Color tanks »Latex
»Bleach tanks »High temp
»Hydropulpers »LPG tanks
»Retention tanks »Butane sphere
»Black liquor tanks »Batch reactors
•Pharmaceutical »Two-phase sludge
»Batch reactor »Cyclohexane
»Chemical storage •Minerals
•Power »Steel Scale Holding Tanks
»Slurries
And More!
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Radar Gauge 54

Radar vs. Ultrasonic Gauge

Similarities:
Both technologies
Top down, non contact
Easy to install
Good for abrasive materials, slurries
Not affected by changing fluid properties: density, conductivity, dielectric

Differences:
Radar Ultrasonic
Full vacuum to several hundred psi Very slight vacuum to about 100
Wide temperature limits psi
Narrow temp band (<200 F)
Can handle steam, fog, vapors
Is greatly affected by changes in
Can handle some foams and vapor space
agitation Signal is lost in foam and
Can be used with windows agitation
RMT Training - 05 /98 Level 1 - Level
 Rosemount technologies
Radar Gauge 55

Radar vs. Ultrasonic Gauge

Gas Temp (oC) RADAR ULTRASOUND

million m/s m/s
Dry Air 0 299.91 331.8
100 299.94 386

Water vapor 100 299.10 404.8

Carbon Dioxide 0 299.85 250.0

50 299.87 279.0

Ammonia 0 299.93 415.0

Acetone 0 297.64 223.0

Source: Instrument Engineer’s Handbook, Liptak

RMT Training - 05 /98 Level 1 - Level
 Other technologies
Float Mechanism 56

Indicator
Internal Still pipe External Still pipe
to guide the float to guide the float

Float
Float

Tank

Isolating Valve
Drain
Valves

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

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Capacitance Probe 57

• A capacitance instrument measures amount of

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

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Capacitance Probe 58

How Capacitance Nonconductive

Coating
varies with process
d fluid?
Level is Level is
proportional proportional
to dielectric to plate area
change change
Nonconductive Fluid Conductive Fluid
• Process fluid is the dielectric • Process fluid is the second plate
barrier
• Insulation on probe is dielectric
• Tank Wall forms second plate
• The variation of the plate size is
• The variation of dielectric is the the measurement
measurement

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Capacitance Probe 59

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

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Capacitance Probe 60

Potential Applications
•Pulp & Paper •Oil & Gas
Sewage level Water bottom
Liquor tanks Water cut
Bulk solids
•Chemical
Interface: fatty
acid/water, oil/water
Carbon black
Separators
•Food & Beverage
Storage silos
RMT Training - 05 /98 Level 1 - Level
 Other technologies
Displacers 61

Based on Buoyance Force 0 0

The displacer is buoyed up by a

force proportional to the weight of pounds pounds

the liquid it displaces

Vertical movement of the
displacer is converted to angular
movement by mechanical
linkages

Angular movement is then

converted to electrical or
pneumatic output. Buoyant force
increases as level rise
RMT Training - 05 /98 Level 1 - Level
 Other technologies
Displacers 62

Good for short span measurement

Liquid Level Interface Density

Measurement Measurement Measurement

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Displacers 63

Benefits:
• Simple, Reliable.
• Good for Interface measurements.
• Good for Density measurements.
• Unaffected by Agitation.
• Tolerates High Temperatures and pressures.
• Point or Continuous .
Limitations:
– Does not tolerate viscous, dirty, or sticky fluids
– Variable density causes errors in level measurement
– Typically used for smaller spans (cost effective)
– Must be installed carefully
– Intrusive & Contact
RMT Training - 05 /98 Level 1 - Level
 Other technologies
Displacers 64

• Typical Applications:
Oil and Water interface
Oil and Gas Separators
Stripper Reflux Drum Level
Dehydration Units
Effluent Separators
Absorption Towers
Condensate Discharge Accumulators
Density and Interface Measurements

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Servo Gauging 65

Uses a combination of a displacer and a

spring balance
The servo motor strives to obtain an
equilibrium between the displacer and
Storage Drum
the balance. Any change in level will
cause a change in equilibrium.
Advantages: Balance Servo
– Very precise (1 mm accuracy) Cable Detector Motor
– Can measure level, interface
– relatively low cost
Limitations:
– Intrusive
– Mechanical linkages
Displacer

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Nucleonic Gauging 66

Single Point System

Gamma rays are emitted from the
source. The presence or absence of the
gamma rays is measured by the
detector.

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

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Nucleonic Gauging 67

Continuous System
Nucleonic level transmitters use the
same radioisotope sources, but
respond to the total absorption of
gamma rays as they pass from the
source to detector. Source

The amount of radiation reaching

the detector is inversely
proportional to the amount of
material in the vessel.

Detector

RMT Training - 05 /98 Level 1 - Level

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Nucleonic Gauging 68

Advantages: Limitations:
– Unaffected by: – Large density changes
• High temperatures can create errors
• High Pressures
– Layer of coating on vessel
• Corrosive Materials
walls create errors
• Abrasive Materials
– Licensing Required
• Viscous Materials
• Agitation – Leak Checks required
• Clogging/Plugging – Cost
– Point and Continuous
– Liquids and Solids
– Interface (based on H2
density)

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Nucleonic Gauging 69

Typical Applications •Refining

•Chemical Fractionator Tower
Distillation Tower Surge Tanks
Batch Reactor Coke Drum Interface
Storage Tanks Desalter
Resin Bed level •Food and Beverage
Hydrocracker reactor Hopper Level
•Pulp & Paper Blending Vats
Digester Level •Mining
Wood Chip Bins Crusher Level
Bleach Tower Storage silos
Consistency Slurries
Effluent Waste •Utilities
Slurries SO2 / Lime scrubber
Liquor concentrates Fly ash Slurries
RMT Training - 05 /98 Level 1 - Level
 Other technologies
Laser 70

• Function: Uses infrared light to send a laser

focused beam towards surface. Time of glass window device
travel and reflection is measured.
• Narrow, focused beam: good for
applications with space restrictions.
• Non contacting: uses a window
• Accuracy: +/- 1 cm
• Works best in cloudy, shiny liquids or
solids
• May pass through surfaces of clear, still
fluids
• Cannot tolerate dust, fog, steam or vapors
• High cost
• Alignment is critical

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Ultrasonic Gauging 71

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

• Advantages: Sound Waves

Non Contact
No element contamination
Can be used for liquids and solids
Tolerates Many Process
Conditions:
Varying Density
Corrosive Processes The higher
Viscous Product the level the
Varying Dielectric faster echo
Sludge Buildup reflected

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Ultrasonic Gauging 72

Application Considerations
• Conditions of the vapor space impact
speed of signal travel and thus, the
measurement
• Changes could be due to: Sound Waves
– temperature
– dust
– vapor composition
– stratification of the vapor
• Some units have temperature
compensation
• Gas blankets can be used to provide
uniform vapor space condition

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Ultrasonic Gauging 73

Application Considerations

• Process surface conditions can

affect signal return . Surface must
have ability to reflect signal.
• Heavy agitation and foam may
cause signal to be absorbed
• Vortex in fluid can misdirect signal
• In open, outdoor installations, wind
can blow signal off coarse
• Stilling wells can be used to isolate
the surface and contain signal.

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Ultrasonic Gauging 74

Limitations
– not suitable for vacuum service
– Cannot tolerate high temperatures (>200 F)
– Foam interferes with signal
– Agitation may distort signal
– Internal obstacles can create false echoes
– Nearby equipment could generate frequencies that
will cause errors
– Vapor pressure limited to 50 psi

RMT Training - 05 /98 Level 1 - Level

 Other technologies
Ultrasonic Gauging 75

Typical Applications •Waste water

•Chemical Clarifier
Distillation chamber Settling tanks
Corrosives Reservoirs
Slurries Flood control
Latex PVC Sludge levels
Waxes •Pulp & Paper
•Food and Beverage Black liquor w/ solids
Dearating vessel •Pharmaceutical
alcohol fermenter Emulsions
baking batter Lotions
chocolate •Marine
dairy products Fuel or ballast water
grain storage indication
•Cryogenic systems (point level) Bilge alarm
RMT Training - 05 /98 Level 1 - Level
Exercise 76

1. Which has the best accuracy on 6 meter High Water tank?

A. Hollow or glass fill float with mechanical gauge (1 inch)
B. “Servo” Gauge (1 mm)
C. Pressure Transmitter ±0.1% of F.S [ ]

2. An inground reservoir is 5 meters deep. Which of the following

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

RMT Training - 05 /98 Level 1 - Level

Exercise 77

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

middle ?

4. Which one of the following tank gauging system is based on Mass?

(A) Radar
(B) Nucleonic
(C) Servo Balance
(D) HTG [ ]

5. Which of the following statement about Radar Gauge is NOT True ?

(A) Top-down mounting
(B) Can handle agitated & sticky process fluid
(C) Can be used on a tank with non-metallic internal surface.
(D) Can handle process with deep vacuum [ ]

RMT Training - 05 /98 Level 1 - Level

Exercise 78

6.

Assuming SG is = 1.1
5’
What is the volume?____________ft3

What is the density of this fluid?___________#/ft3

10’ What is the mass?__________pounds

What is the pressure level reading? ________in H2O

water = 62.4 # / ft3

RMT Training - 05 /98 Level 1 - Level

 Exercise 79

7.
Now, suppose the SG changes to 1.05 and the
5’ level does not change

What is the volume?____________ft3

What is the density of this fluid?___________#/ft3

10’
What is the mass?__________pounds

What is the pressure level reading? _______in H2O

water = 62.4 # / ft3

RMT Training - 05 /98 Level 1 - Level

Exercise 80

8.
Pmeasured = 150 inH2O Pin(flow=const)
s.g. = 1.5

What is the fluid level in the tank?

RMT Training - 05 /98 Level 1 - Level