Level 1

Fundamental Training

RMT Training - 05 /98

Level 1 - Level

Contents

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

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

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
Tend to be larger vessels
You can

Process

Applications are more concerned with:

Control of a product level within a range
Safety (prevent overflow/ pump shutoff)
Monitor inputs of components of a process
Accuracy requirements vary widely

RMT Training - 05 /98

have a
mixture of process
and inventory
applications in a
plant

Level 1 - Level

Why measure level?

Indication vs. Control

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

RMT Training - 05 /98

Level 1 - Level

Level terminology
Level Control Loop

(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

(Outflow)

LIC

I/P

LT

RMT Training - 05 /98

Level 1 - Level

Level terminology
Parameters

Interface
Level

Density
RMT Training - 05 /98

Volume
Mass
Level 1 - Level

Level terminology
Parameters

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

1
0

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 fluid to
the density of water, thus
density of fluid
density of water

Density

= SG

Density of fluid = density of water * SG

Mass = Density / Volume

RMT Training - 05 /98

Level 1 - Level

Level terminology
Parameters
Volume

1
1

Volume only correlates directly to level when:

Tank is an upright cylinder
Density is constant
Temperature is constant
There is no change in tank wall position after filling
Volume
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
r

Volume
Vertical Cylindrical Tank
v = r2l

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

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

1
2
l

h
r

r
l

RMT Training - 05 /98

Level 1 - Level

Level terminology
Parameters

1
3

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

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

RMT Training - 05 /98

Level 1 - Level

Level terminology
Parameters

1
4

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

9
7
5
3
1

RMT Training - 05 /98

Point

Level
Volume
(inches) (gallons)

1
2
3
4
5
6
7
8
9
10

0
5
10
15
20
25
30
35
40
100

0
10
32
68
115
173
230
313
394
957

Bulging

A look-up table that

relates level to volume
for several discrete
points in a tank.
Commonly used to
eliminate Bulging Error.

Level 1 - Level

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

1
5

0
-14.7

PSIG

Steam,
Steam,vapors,
vapors,
dust
dust

Abrasive
Abrasive
fluids
fluids

RMT Training - 05 /98

Foam
Foam

Density
Changes

Corrosive
Corrosive
processes
processes

High
High
vacuum
vacuum

Temperature
Temperature
extremes
extremes

Viscous
Viscousor
or
sticky
stickyfluids
fluids

Agitation
Agitation

Level 1 - Level

Level terminology
Measurement Characteristics

1
Bottom-Up vs. Top-Down Measurement Top-down 6
Top-Down Measurement
Poses less potential for leakage
devices installed or removed
without emptying tank
e.g., dipstick, radar gauge
Bottom-Up Measurement
Typically contacts the process fluid
e.g., pressure transmitter,
weigh scale

RMT Training - 05 /98

Bottom-up
Level 1 - Level

Level terminology
Measurement Characteristics

1
7

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

1
8

Continuous vs. Point Measurement

Continuous Measurement

Point measurement

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

Has the level reached

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

RMT Training - 05 /98

Level 1 - Level

Level terminology
Measurement Characteristics
Non-Contact vs. Non-Invasive vs. Non-Intrusive
Non-Contact
implies that the
device does not
touch the fluid,
but it could be
invasive

1
9

Non-invasive
implies that the
device does not
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

2
0

Bubbler
Dipstick
Capacitance
Tuning Fork

Float

Ultrasonic

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
Contacting Noncontacting Point

Continuous Liquids Solids

2
1

Bubblers
Capacitance
Conductivity
Displacers
Floats
HTG
Hydrostatic
Laser
Magnetostrictive
Nucleonic
Optical
Phase Difference
Radar
Resistance Tape
Rotation Suppression
Servo
Tape Level
Thermal
Ultrasonic
Vibration
Weighing
RMT Training - 05 /98

Level 1 - Level

Technology selection
Classification of Level Measurement Technologies

2
2

Note: Only
continuous
devices
included

RMT Training - 05 /98

Level 1 - Level

Technology selection
Factors To Consider
Why is the level measurement needed?
What are you try to measure?
What are you trying to achieve?

2
3

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
What are the environmental conditions?

Ambient Temperature
Humidity
Vibration
Electro Magnetic Interference(EMI)
Transient protection

2
4

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
Common Density/ Temperature Changes

RMT Training - 05 /98

2
5

Level 1 - Level

Technology selection
Factors To Consider
Typical Dielectric/ Temperature Changes

RMT Training - 05 /98

2
6

Level 1 - Level

Technology selection
Factors To Consider
What are the instrument requirements?

2
7

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

Environmental
Factors

Device
Direct vs inferred
Measurement capabilities
Rangeability
RMT Training - 05 /98

Temp changes
Vibration
Noise

2
8

Process Density changes

Conditions temperature changes
static pressure
agitation
aeration
foam
dielectric changes
Level 1 - Level

Technology selection
Working Capabilities Vary with Technologies
10000+

2
9
Nucleonic

Capacitance
3626

Pressure, PSI

Pressure w/ seals

Pressure/HTG

1000

Displacer

Ultrasonic Point

Ultrasonic
73
atm
-240

Radar
-100 -40

32

195

320

Temperature, F

400

600

800

900+

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

3
0

Open Vessel Level Measurement

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

P high - P low = P head

What happen to
Atmospheric pressure?
RMT Training - 05 /98

Phead

Phigh = Phead + Patm

Plow = Patm

Patm

Patm

XMTR
L

Cancelled Off
Level 1 - Level

Rosemount technologies
Pressure Transmitters
Transmitter mounted above the tap in an open vessel

3
1

What happens when the liquid level drop below the sensor ?

100%
XMTR
0%
L

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

3
Zero Suppression is often applied to compress the range of the 2

Min. Level

Actual Zero
Suppressed
XMTR
L
RMT Training - 05 /98

Range

4mA

Range

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

Actual Zero4mA
Suppressed
XMTR
L

Min. Level

H
Level 1 - Level

Rosemount technologies
Pressure Transmitters

3
Zero Elevation is often applied to cancel the effects of the head 3
caused by the seal fluid in the reference leg (low side) of a transmitter
measuring level in a pressurized vessel.

4mA
Actual Zero
Elevated

RMT Training - 05 /98

XMTR
L

Min. Level

Range

Max. Level

20mA

At min. level the low

side pressure is high
than the high side
pressure
Level 1 - Level

Rosemount technologies
Pressure Transmitters

3
4

Closed Tank Level Measurement (Dry Leg)

Dry leg: no fluid in low side impulse
piping, or leg
If the gas above the fluid does not
condense, the piping for the low
side of the transmitter will remain
empty.

Phigh
Plow

= Ptop+Phead
= Ptop

Ullage or
Vapor

Phead
XMTR
L

Phigh - Plow = Phead

RMT Training - 05 /98

Level 1 - Level

Rosemount technologies
Pressure Transmitters

3
5

Closed Tank Level Measurement (Wet Leg)

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

+P

Phigh =Phead+Ptop
Plow=Pwet leg

Ptop= Ullage

Pwet

Phead

L
H
XMTR

top

Phigh - Plow = Phead - Pwet leg

RMT Training - 05 /98

Level 1 - Level

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

RMT Training - 05 /98

3
6

Level 1 - Level

Rosemount technologies
Pressure Transmitters
Bubbler System
Consists of air supply, pressure regulator, flow meter,
transmitter & extended tube.
Can be used for very corrosive applications.
Tank vented.

TXR

3
7
Pin(flow=const)

Air is bubbled through the tube at a constant flow rate. The

pressure required to maintain flow is determined by the
vertical height of the liquid above the tube opening head
times
the specific gravity.

Pressure to maintain flow = P

Phead = H * [Link]
RMT Training - 05 /98

[Link]

Level 1 - Level

Rosemount technologies
Pressure Transmitters

3
8

Gauge Pressure Transmitter

Application of Bubbler system:

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

RMT Training - 05 /98

Valve
Air
Supply

Level 1 - Level

Rosemount technologies
Pressure Transmitters
Remote Seals

3
9

Reliable, Simple, Easy to Use, Well

Understood, Flexible Uses:

Diaphragm Seals extend limitations

due to process conditions such as:
high temperatures
corrosion
viscous materials
suspended solids
plugging
sanitary needs
RMT Training - 05 /98

Differential
Pressure
Transmitter

Level 1 - Level

Rosemount technologies
Pressure Transmitters

4
0

Typical Pressure Applications

CPI / HPI
Batch reactors
digesters
fractionators
distillation column bottoms and
reflux drums
separators
surge drums
reservoirs
intermediate storage...
Power
drum level
dearators...

Pulp & Paper

Headbox
Stock Tanks
Chemical Storage tanks
Evaporators
Low concentration liquor
tanks...
Food and Beverage
Fermentors
storage tanks
aging tanks
brew kettles...
And many more!

RMT Training - 05 /98

Level 1 - Level

Rosemount technologies
Hydrostatic Tank Gauging (HTG)
It is basically a method for
measuring mass.

4
1

Top transmitter PT only used on nonatmospheric 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.
RTD measures tank contents
temperature for reference correlations.

RMT Training - 05 /98

A local processor handles all the

real-time calculations for
transmitter algorithms and
equations for MASS, DENSITY,
LEVEL and VOLUME.
Level 1 - Level

Rosemount technologies
Hydrostatic Tank Gauging (HTG)

4
2

A system approach to tank inventory

Effective Level

Measurement Options:
PT

Mass

= (PB - PT) x Area

Density = (PB - PM ) / H
H

PM

HBT

TT

Volume = Mass / Density

PB

Level = (PB - PT) /Density + HBT

RMT Training - 05 /98

Level 1 - Level

Rosemount technologies
Hydrostatic Tank Gauging (HTG)
RS-485 MODBUS
Communications
Network
(can take up
to 31 AIMs)

Top Pressure
Transmitter

SCADA
Package

4
3

Middle Pressure
Transmitter
Temperature
Sensor
Bottom Pressure
Transmitter

HART
Communicator

Smart Application
Module (SAM)
(1 unit per tank)
[Handles tank calculaton]

Application Interface
Module (AIM)
(obtain data from SAM
& convert to std
MODBUS outputs)
(can take up to
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)
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

4
4

Level 1 - Level

Rosemount technologies
Hybrid Inventory System
RS-485 MODBUS
Communications
Network
(can take up
to 31 AIMs)

Top Pressure

Radar
Gauge
Transmitter

SCADA
Package

4
5

Middle Pressure
Transmitter
Temperature
Sensor
Bottom Pressure
Transmitter

HART
Communicator

Smart Application
Module (SAM)
(1 unit per tank)
[Handles tank calculaton]

Application Interface
Module (AIM)
(obtain data from SAM
& convert to std
MODBUS outputs)
(can take up to
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
Top Pressure

Radar
Gauge
Transmitter
D

Middle Pressure
Transmitter

H
L

Temperature
Sensor
Bottom Pressure
Transmitter

RMT Training - 05 /98

Measurement Options:

4
6

LEVEL is calculated by Radar Gauge

L=H-D
VOLUME is computed by Radar Gauge
Through Strapping Table
relationship level to volume
DENSITY is computed by the system
S.G = Head Pressure / Level
Head pressure measured by
bottom pressure transmitter
MASS is computed by the system
Mass = Density X Volume
CORRECTING for Density & Volume back
to standard values is computed

Level 1 - Level

Rosemount technologies
Hybrid Inventory Systems

4
7

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 375F (190C) 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

4
8

Frequency
Electromagnetic Wavelength, Meters
Cycles/second

Spectrum

10 22

gamma rays

10 20

10 -11
x-rays

10 18
10 16
10 14

ultra violet
visible light

10 12
10

10

10 8
10 6

10 -13

10 -9
10 -7
10 -5

Radar is an
Electromagnetic Wave
Radio Detection And Ranging
Radar,
3-30 GHz

10 -3
--------super high freq--------------ultra high freq-------------------TV broadcasting-----------------FM Radio-------------

10

-1

10

Microwave oven,
2 - 10 GHz

10 3

Cellular, pager,

10 4

10 5

300-3000 MHz

10 2

10 7

-------low frequency------------

RMT Training - 05 /98

Level 1 - Level

Rosemount technologies
Radar Gauge

4
9

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
Radar Techniques

5
0

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
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

5
1

Level 1 - Level

Rosemount technologies
Radar Gauge
Radar Application Considerations
Sensors can be completely removed from process by
use of a window made out of a nonmetallic material,
such as Teflon, Ryton, Ceramic
Sensors can be removed from the process without
opening the vessel

5
2

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

5
3

Possible Applications
Pulp & Paper
High Density Storage
Color tanks
Bleach tanks
Hydropulpers
Retention tanks
Black liquor tanks
Pharmaceutical
Batch reactor
Chemical storage
Power
Slurries

Chemical
Polymers
Latex
High temp
LPG tanks
Butane sphere
Batch reactors
Two-phase sludge
Cyclohexane
Minerals
Steel Scale Holding Tanks

And More!
RMT Training - 05 /98

Level 1 - Level

Rosemount technologies
Radar Gauge
Radar vs. Ultrasonic Gauge
Similarities:

5
4

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
Full vacuum to several hundred psi
Wide temperature limits
Can handle steam, fog, vapors
Can handle some foams and agitation
Can be used with windows

RMT Training - 05 /98

Ultrasonic
Very slight vacuum to about 100
psi
Narrow temp band (<200 F)
Is greatly affected by changes in
vapor space
Signal is lost in foam and
agitation
Level 1 - Level

Rosemount technologies
Radar Gauge

5
5

Radar vs. Ultrasonic Gauge

Gas

Temp (oC)
0
100

RADAR
million m/s
299.91
299.94

ULTRASOUND
m/s
331.8
386

Dry Air
Water vapor

100

299.10

404.8

Carbon Dioxide 0
50

299.85
299.87

250.0
279.0

Ammonia

299.93

415.0

Acetone

297.64

223.0

Source: Instrument Engineers Handbook, Liptak

RMT Training - 05 /98

Level 1 - Level

Other technologies
Float Mechanism
Internal Still pipe
to guide the float

External Still pipe

to guide the float

Indicator

5
6

Float
Tank

Isolating Valve

Float

Drain
Valves

Indicator

Float-operated gauge level-indicator, indicates liquid level in cone or flat

roof unpressurised tanks.
Recommended for use on tanks storing water, fuel, oil, chemicals or other
liquid products where operations do not require extreme accuracy.
RMT Training - 05 /98

Level 1 - Level

Other technologies
Capacitance Probe

5
7

A capacitance instrument measures amount of

capacitance between two plates of a capacitor.
The capacitance of a capacitor increases if a dielectric is
placed between the plates
Circuit applies high frequency signal to probe
C = KEoAd

where
K = dielectric constant of material
Eo = permitivity of vacuum
A = Area of plates (probe)
C = capacitance (pF)
d = distance between plates
d

RMT Training - 05 /98

Level 1 - Level

Other technologies
Capacitance Probe
How Capacitance
varies with process
fluid?

Nonconductive
Coating

Level is
proportional
to dielectric
change

5
8

Level is
proportional
to plate area
change

Nonconductive Fluid

Conductive Fluid

Process fluid is the dielectric

barrier
Tank Wall forms second plate
The variation of dielectric is the
measurement

Process fluid is the second plate

Insulation on probe is dielectric
The variation of the plate size is
the measurement

RMT Training - 05 /98

Level 1 - Level

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

RMT Training - 05 /98

5
9

Level 1 - Level

Other technologies
Capacitance Probe

6
0

Potential Applications
Pulp & Paper
Sewage level
Liquor tanks
Bulk solids
Chemical
Interface: fatty acid/water,
oil/water
Carbon black
Separators
Food & Beverage
Storage silos

RMT Training - 05 /98

Oil & Gas

Water bottom
Water cut

Level 1 - Level

Other technologies
Displacers
Based on Buoyance Force
The displacer is buoyed up by a
force proportional to the weight of
the liquid it displaces

6
1
0

pounds

pounds

Vertical movement of the

displacer is converted to angular
movement by mechanical
linkages

Angular movement is then

converted to electrical or
pneumatic output.
RMT Training - 05 /98

Buoyant force
increases as level rise
Level 1 - Level

Other technologies
Displacers
Good for short span measurement

Liquid Level
Measurement
RMT Training - 05 /98

Interface
Measurement

6
2

Density
Measurement
Level 1 - Level

Other technologies
Displacers
Benefits:
Simple, Reliable.
Good for Interface measurements.
Good for Density measurements.
Unaffected by Agitation.
Tolerates High Temperatures and pressures.
Point or Continuous .

6
3

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
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

6
4

Level 1 - Level

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

RMT Training - 05 /98

6
5

Storage Drum

Cable

Balance
Detector

Servo
Motor

Displacer

Level 1 - Level

Other technologies
Nucleonic Gauging

6
6

Single Point System

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

Nucleonic level switches use

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

RMT Training - 05 /98

Detector

Level 1 - Level

Other technologies
Nucleonic Gauging

6
7

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

Other technologies
Nucleonic Gauging

6
8

Advantages:

Limitations:

Unaffected by:

Large density changes can create

errors
Layer of coating on vessel walls
create errors
Licensing Required
Leak Checks required
Cost

High temperatures
High Pressures
Corrosive Materials
Abrasive Materials
Viscous Materials
Agitation
Clogging/Plugging

Point and Continuous

Liquids and Solids
Interface (based on H2 density)

RMT Training - 05 /98

Level 1 - Level

Other technologies
Nucleonic Gauging
Typical Applications
Chemical
Distillation Tower
Batch Reactor
Storage Tanks
Resin Bed level
Hydrocracker reactor
Pulp & Paper
Digester Level
Wood Chip Bins
Bleach Tower
Consistency
Effluent Waste
Slurries
Liquor concentrates

RMT Training - 05 /98

Refining
Fractionator Tower
Surge Tanks
Coke Drum Interface
Desalter
Food and Beverage
Hopper Level
Blending Vats
Mining
Crusher Level
Storage silos
Slurries
Utilities
SO2 / Lime scrubber
Fly ash Slurries

6
9

Level 1 - Level

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

RMT Training - 05 /98

glass window

laser
device

7
0

Level 1 - Level

Other technologies
Ultrasonic Gauging

7
A sound pulse(9 to 160 kHz) is transmitted and reflects off the surface
1
back to the transceiver. The true reflected echo pulse is extracted and
the time interval between transmission and reception is evaluated
electronically.

Advantages:

Sound Waves

Non Contact
No element contamination
Can be used for liquids and solids
Tolerates Many Process
Conditions:
Varying Density
Corrosive Processes
Viscous Product
Varying Dielectric
Sludge Buildup
RMT Training - 05 /98

The higher
the level the
faster echo
reflected
Level 1 - Level

Other technologies
Ultrasonic Gauging
Application Considerations

7
2

Conditions of the vapor space impact speed

of signal travel and thus, the measurement
Changes could be due to:

temperature
dust
vapor composition
stratification of the vapor

Sound Waves

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
Application Considerations

7
3

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
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

7
4

Level 1 - Level

Other technologies
Ultrasonic Gauging
Typical Applications
Chemical
Distillation chamber
Corrosives
Slurries
Latex PVC
Waxes
Food and Beverage
Dearating vessel
alcohol fermenter
baking batter
chocolate
dairy products
grain storage
Cryogenic systems (point level)
RMT Training - 05 /98

Waste water
Clarifier
Settling tanks
Reservoirs
Flood control
Sludge levels
Pulp & Paper
Black liquor w/ solids
Pharmaceutical
Emulsions
Lotions
Marine
Fuel or ballast water indication
Bilge alarm

7
5

Level 1 - Level

Exercise
1. Which has the best accuracy on 6 meter High Water tank?
A. Hollow or glass fill float with mechanical gauge (1 inch)
B. Servo Gauge (1 mm)
C. Pressure Transmitter 0.1% of F.S
[
]

7
6

2. An inground reservoir is 5 meters deep. Which of the following method(s) will be

suitable to measure and transmit the level without having to dig a hole to reach the
bottom of the reservoir or the scour main. (Answer Yes [Y] or No [N])
A.
B.
C.
D.
E.
F.
G.

Differential Pressure
Servo Level Gauge
Capacitive Probe
Nucleonic Gauging
Ultrasonic Gauging
Radar Gauging [
Bubbler System [

RMT Training - 05 /98

[
[
[
[
[
]
]

]
]
]
]
]

Level 1 - Level

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

7
7

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

7
8

6.

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

10

What is the mass?__________pounds

What is the pressure level reading? ________in H2O

water = 62.4 # / ft3

RMT Training - 05 /98

Level 1 - Level

Exercise

7
9

7.

Now, suppose the SG changes to 1.05 and the

level does not change
What is the volume?____________ft3
What is the density of this fluid?___________#/ft3

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
8.
Pmeasured = 150 inH2O
s.g.

8
0
Pin(flow=const)

= 1.5

What is the fluid level in the tank?

RMT Training - 05 /98

Level 1 - Level