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401
© 2003 by Béla Lipták
402 Level Measurement
405
© 2003 by Béla Lipták
406
Level Measurement
TABLE 3.1a
Orientation Table-Point Level Switches
Process Materials Cost
Inaccuracy-Inches[mm]
Aqueous Slurries
Aqueous Foam
Organic Foam
Over $1000
Conducting
Conducting
$300−1000
Insulating
Insulating
$100–300
Interface
Powder
Chunks
Sticky
Technology Comments/Precautions
Capacitance/RF 2000 0.125–2 E E E NA/E L/E NA/E ME IG/ME E F/E L/E Conductive coating produces false high without
[1100] [3–50] guard-type probe. Short insertions can be a
problem.
Conductivity 1800 0.125 E NA F L NA L ME IG L L NA Detects conductive process materials. Insulating
Switch [980] [3] coatings produce false lows/conductive false
highs.
Diaphragm 350 1–2 L L NA L L NA IG IG F F NA Mainly for granular solids.
[175] [50–100]
Differential 350 1–4 L L NA F F NA IG IG NA NA NA Clean liquids with constant specific gravity.
Pressure [175] [25–100]
Displacer 850 0.2–0.5 E E F F F NA IG IG NA NA NA Not recommended for sludge or slurries.
[450] [5–13] Vacuum with high viscosity can cause dynamic
instability.
Float 500 1 E E L F F NA IG/ME IG/ME NA NA NA Moving parts limit most designs to clean service.
[260] [25] Only density-adjusted floats can detect
interfaces.
Level Measurement
Waterlike Liquids Coating Liquids Foams Solids
Non-Contact Possible
Inaccuracy-%Span
Max. Temp.-°F[C]
Aqueous Slurries
Aqueous Foam
Organic Foam
$1000–2500
Over $2500
Conducting
Conducting
$300–1000
Insulating
Insulating
Interface
Powder
Chunks
Sticky
Technology Comments/Precautions
409
© 2003 by Béla Lipták
410
Level Measurement
TABLE 3.1c
Level Sensor Selection Guide
Liquid/Liquid Sticky Moist
Interface Foam Slurry Suspended Solids Powdery Solids Granular Solids Chunky Solids Solids
Liquids
Continuous Point Continuous Point Continuous Point Continuous Point Continuous Point Continuous Point Continuous Point Continuous Point Continuous
Beam Breaker — — — 2 — — — — — 1 — 1 — 3 — 1 —
Bubbler 1 — — — — 3 2 — — — — — — — — — —
Capacitance 1 1 1 1 2 1 2 — — 2 2 1 2 2 2 1 2
Conductive — 2 — 1 — 1 — — — 3 — 3 — 3 — 1 —
Differential Pressure 1 2 2 — — 2 2 — — 3 3 — — — — — —
Electromechanical
Diaphragm 1 2 — — — 2 2 — — 1 3 1 — 3 — 2 3
Displacer 2 2 2 — — 3 2 — — — — — — — — — —
Float — 2 — — — 3 — — — — — — — — — — —
Float/Tape 1 — — — — — 3 — — — — — — — — — —
Paddle Wheel — — — — — 3 — — — 2 — 1 — 3 — 2 —
Weight/Cable 1 — — — — — 1 — 1 — 1 — 1 — 1 — 1
Gauges
Glass 1 2 2 3 3 3 3 — — — — — — — — — —
Magnetic 1 — — 3 3 3 3 — — — — — — — — — —
Inductive — — — — — 2 — — — 2 2 2 2 2 2 3 3
Microwave 1 — — — — 1 1 — — 1 2 1 1 1 1 1 1
Radiation 1 — — — — 1 1 — — 1 1 1 1 1 1 1 1
Sonic Echo
Sonar — 2 2 — — — 3 1 1 — — — — — — — —
Sonic 1 3 3 — — 1 1 2 2 — 3 1 1 1 1 2 1
Ultrasonic 2 2 2 — — 1 2 1 1 — 3 2 2 1 2 2 2
Thermal — 1 — 2 — 2 — — — — — — — — — — —
Vibration — 3 — — — 2 — 1 — 1 — 1 — 1 — 1 —
This is a statement of maximum error that is usually obtained crystallization) can produce major errors in days or even
by measuring something other than level. With d/p transmit- hours. Although many instruments, properly installed, can
ters, the “other” is usually air pressure. With capacitance, it perform untouched for 20 years, any instrument can fail at
is a high-precision capacitance box. With sonic and radar any time. When instrument failure could cause more than
instruments, it is a handy wall. With displacers, it is precision irritation, backups should be mandatory. In such cases, the
weights. These results should be considered to be laboratory need for backups, such as independent level switches, cannot
inaccuracy, which relates to the least possible error. It is be overstated.
achievable only in perfect applications, where the critical The best way to detect the level of all hard-to-handle
parameters are invariable. substances is by avoiding physical contact with them. This
The real-world variables that can multiply the inaccuracy can be very challenging when those substances are highly
include agitated, flung through the air space (dust), or produce weak
reflections.
• Density variation for any of the density-sensing instru-
ments
• Variations in the speed of sound resulting from the
composition in the “air space” for sonic instruments OPERATING PRINCIPLES
• Insulating coatings that change the speed of light for
TDR instruments The following provides a brief review of the various technol-
• Conductive coatings on capacitance probes ogies, grouped by sensing characteristics.
• Any kind of coating for optical instruments
• Condensation on the antennas of radar instruments
Density/Weight
The disingenuous use of lab error by manufacturers is no less Air bubblers measure the pressure required to force a
appropriate than user specifications that call for unrealistic constant flow of gas down and out the bottom of a
and unusable error limits. An example of specifiers run amok tube that is immersed in the process. This is propor-
would be “0.25% inaccuracy on a 6-ft (1800-mm) interface” tional to the length of the submerged tube times the
application, where the interface cannot be defined within 6 specific gravity of the process liquid.
in. (150 mm). Certainly, in custody transfer measurements Differential-pressure (d/p) transmitters measure differ-
of storage tanks, extreme precision is required. How realistic ential pressure between the bottom of a tank and
though, is a 0.125-in. (3-mm) measurement of the top surface some higher point, usually the top. Output is the
when water accumulation of several inches is ignored at the product of level and specific gravity, which equates
bottom of the tank? to weight only in straight-sided tanks.
When accuracy is critical, it should be quoted by the Diaphragm (continuous) transmitters are essentially
supplier, in the context of the application, just as we specify the same as d/p units used on a vented tank, except
model number, price, and delivery. Of course, this puts the that they often go into the process liquid. On short
onus on the purchaser to fully define the application spans, the atmospheric reference becomes critical to
(beyond the limits of an “ISA spec sheet”). It also requires a submerged sensor.
that the description include all chemicals (no trade names), Displacer transmitters measure buoyant force on the
including those for cleaning, purging, and so forth. It displacer body. The level signal is the length of the
should also include the functional reason for making the displacer body covered by a liquid times the specific
measurement (e.g., “control pump-out between X and Y gravity of the liquid.
feet,” “material scheduling,” “operator information,” “feed-
Load cells (See Chapter 7) weigh the entire vessel, so
forward to dryer control”) rather than descriptions such as
translation to level depends on straight sides and the
“to PLC.”
density of the process material.
Manometers traditionally use a heavier liquid than the
process one to produce a short, vertical presentation
RELIABILITY that represents the process level times its specific
gravity. A less obvious manometer effect occurs in
It is popular to confuse mean time between failures (MTBF) standpipes and sight glasses, when temperature dif-
for the electronic circuits with the expected trouble-free life ferential or changing process composition produces
of the total instrument. Because we are dealing with primary a density differential between the pipe and the tank
instruments, the effects of temperature extremes and cycling, contents. (No moving parts are employed.)
and stress due to agitation, are more significant factors in the Radiation (nuclear) transmitters use a multitude of
expected trouble-free life. The characteristics of the process geometric configurations to shoot gamma rays
materials (such as coating, foaming, density variation, and through the process to a detector. The level signal
the application, not the range of human hearing. All and fuel storage industries are competent to “hot-tap” a tank
these instruments are “sonic,” but not all are “ultra- while the level is above the new nozzle. This approach def-
sonic.” (No continuous touch is involved, and no initely requires a sensor that can be inserted through a block
moving parts are employed.) valve under pressure.
Vibration (point). Using a fork or a single vibrating For new tanks, regardless of the level transmitter selected,
rod, these devices are now available for solids or a wise precaution is to add a spare 8-in. (200-mm)* and a
liquids. They operate on a modification of the vibra- spare 2-in. (50-mm) nozzle to the top of the tank. If there is
tion character, switching a relay when submerged a problem in the measurement, or whenever the process is
in the process material. Coating and packing mate- modified, this will allow the installation of nearly any level
rials can be a problem. They tend to be delicate transmitter. The smaller nozzle allows for the addition of an
because of the sensitivity required. overfill switch. The nozzle length should be as short as pos-
sible (4 to 6 in. or 100 to 150 mm) as compatible with
Optical required bolting space.
Lasers. Lasers constitute the best way to measure coal
in silos. They are not susceptible to spurious reflec-
tions as are radar and sonic devices. They require a APPLICATIONS
clear optical path and reflectance rather than trans-
mittance from the process material. (No continuous Level measurement applications can be broadly grouped in
touch is involved, and no moving parts are employed.) terms of service as atmospheric vessels and pressurized ves-
Optical (photocell) switches. Generally, these are sels. With the exception of liquefied gases, accounting-grade
quite limited by coating and temperature. An opti- measurements are made in atmospheric vessels. These are a
cal switch has the virtue of isolation from the pro- quantum leap in precision from the process control or mate-
cess material but requires that the isolating medium rial scheduling class of measurement.
be optically and process compatible. (No continu-
ous touch is involved, and no moving parts are Atmospheric Vessels
employed.)
Level (sight) gauges. A sight gauge is a simple mech- Liquid level detection in atmospheric vessels rarely presents
anism with complex limitations. Liquids that coat a serious problem. The most common problems are caused
obscure the actual level. The level indication most by high temperature or heavy agitation. Instrumentation gen-
trusted by operators (“seeing is believing”). A tem- erally can be selected and installed so that it is removable
perature differential between the tank and glass, a for inspection or repair without draining the vessel. With few
classic boiler glass problem, causes incorrect indi- exceptions, a level indicator located at eye level, combined
cation. (No moving parts are employed.) with the available digital communication technologies, elim-
inates the necessity for the operator or instrument technician
to climb the vessel. Most of the transmitters (with the excep-
tion of d/p types) are available as top-mounted designs, elim-
TANK ACCESS inating the possibility of a spill if the instrument or nozzle
corrodes or ruptures. Most vented-to-atmosphere vessels can
Existing tanks often present a challenge to placing the mea- be manually gauged. It is always comforting to know that
suring instrument in the correct location to perform properly. such a simple procedure as manual gauging is available to
Glass-lined and coded pressure vessels provide no possibility calibrate or verify an instrument output. Various float types
of adding or enlarging any penetrations. If an external stand- can be used in low-volume storage tanks, underground tanks,
pipe proves to be troublesome as a result of plugging or transport tankers, and other applications outside of the pro-
thermal differential, the level instrument needs direct access cessing area.
to the tank. The simplest possibility is to place a spare nozzle Solids level measurement also is generally done in atmo-
of sufficient diameter and short length on top of the tank. spheric tanks, but, in this case, the specifier has fewer avail-
Failing that, there is always a chance of “teeing” into the vent able level detecting devices and less installation flexibility.
pipe or pressure relief line. If there is a manway on top of Devices that are suitable for point level detection of solids
the tank, the cover can be removed and a nozzle welded on include the capacitance/RF, diaphragm, rotating paddle, radi-
in the shop. There are ways to sneak a continuous sensor into ation, vibration, microwave, and optical types. Some level
a tank from a side nozzle, but this usually entails a bit of switches must be located at the actuation level; this can lead
plumbing ingenuity and customarily reduces the maximum to accessibility problems. Except for the radiation-type
height that can be measured. Obviously, a d/p transmitter can device, it also means that a new connection must be provided
be mounted on a tank bottom nozzle, but it could also accept
an RF probe mounted upside down. Most switch technologies
have provision for vertical or horizontal entry. The refining * Or 4-in. (100-mm) in horizontal cylinders.
if the actuation point is raised or lowered. Paddle, vibration, have recently discovered that much related maintenance and
and RF sensors can be extended at least 10 ft (3 m) from the rebuilding can be avoided by using electronic sensing. The
top, and RF allows the switching point to be adjusted elec- existing rugged “cages” can be retrofitted with lower-
trically. Solids that behave unpredictably can cause serious maintenance instruments. Strength is important in the petro-
measurement problems. If the solid is not free flowing, sens- leum industry, because a break at the instrument connection
ing should be limited to an area beyond the expected wall could cause a hydrocarbon spill above the autoignition tem-
buildup. If it can bridge or rat-hole, particular care must be perature. The low-side (vapor-phase) connection of these cages
taken in the location and installation of the level switch. does not require a chemical seal. This reduces maintenance
Continuous level measurement of solids can be made by requirements and eliminates possible inaccuracies that a d/p
yo-yo (automatic plumb-bob), laser, nuclear, RF, TDR, radar, transmitter might produce. Most refinery processes are com-
and sonic instruments. The yo-yo was formerly most popular, patible with carbon or alloy steel materials, which are readily
but its problems with its moving parts in dusty bins have available in all sensor designs.
spurred the use of stationary devices. These designs are gen- In other chemical processing industries, first consider-
erally top mounted, but all can be equipped with ground-level ation usually goes to the d/p transmitter when a level signal
or remote readouts. Density variation and angle of repose are is required. It is reliable and accurate (provided that specific
inherent in the granular solids. Both can cause inaccuracy of gravity is constant), and many modifications are available for
the level measurement, which is a substantial multiple of the unique services. The major problem with the d/p transmitter,
instrument’s laboratory error specification. As with the when used for level measurement on pressurized vessels, is
switches, good performance requires that the solids be free in handling the low-pressure tap. If the low side of the d/p
flowing. These measurements will all be suitable for material cell can be connected directly to the vapor space of the vessel,
scheduling functions. If an inventory grade measurement is the problem is eliminated, but this is rarely the case. Nor-
required (definitely a weight measurement), load cells are mally, the low-pressure leg must be filled with a seal oil or
used. Load cells are covered in Chapter 7. with the process material. If a seal oil is used, the oil must
be compatible with the process. If the leg is filled with the
process material, the process fill must not boil away at high
Pressurized Vessels ambient temperatures. In either case, ambient temperature
variations will change the density of the fill, which can cause
Point level detection of liquids in a pressurized vessel can be
inaccuracies in the level reading. The liquid seal also requires
made using one of ten types of level sensors. For clean
frequent inspection. Low-pressure-side repeaters and chem-
services in industrial processing plants, preference has tradi-
tionally been given to the externally mounted displacer ical seals are also available, but although they eliminate the
switch. This unit is rugged and reliable, it has above-average seal problem, they introduce inaccuracies of their own and
resistance to vibration, and its actuation point can be easily increase the purchase cost. Despite this, d/p cells are suc-
changed over a limited range. There are a number of cases cessfully used in a wide range of applications and can be
in which microwave, sonic, capacitance, and float switches considered whenever the span to be measured is greater than
are considered if they are installed so that they can be 60 in. (1.5 m). Other devices, such as capacitance/RF, nuclear,
removed for repair without venting the vessel to the atmo- sonic, radar, and TDR technologies, are in use for level mea-
sphere. Conductivity switches are used in water services to surement in pressurized vessels, especially where level indi-
700°F (370°C) and 3000 PSIG (21 MPa). Optical and thermal cation must be independent of density.
dispersion switches have no moving parts, are inexpensive,
and are used on clean services. Accounting Grade (Tank Gauging)
Continuous liquid level detection in pressurized vessels
is subdivided into clean and hard-to-handle processes. For Accounting-grade measurements are made in both atmo-
clean services requiring local indication only, the traditional spheric and pressurized vessels. The need for accuracy in
choice is the armored sight gauge. Even when a transmitted accounting-grade installations can be demonstrated as fol-
signal is required, many users specify that transmitters be lows. A typical 750,000-barrel American Petroleum Institute
backed up with a sight gauge for use in calibration and to (API) storage tank has a diameter of 345 ft (105 m), and it
3
allow that the process can run manually if the transmitter is takes some 8000 gallons (30 m ) to raise the level 1 in. (25 mm).
out of service. Nevertheless, the need for a sight gauge should A level measurement error of 1 in. (25 mm) would therefore
3
be carefully evaluated, as it can be a weak point (personnel indicate that 8000 gallons (30 m ) have been gained or lost.
hazard) in high-pressure processes and can become plugged In the case of hydrocarbon storage tanks, the accumulation
in sludge and slurry services. In hazardous services, magnetic- of water at the bottom must be factored into the measurement,
float level gauges can be used. or errors equivalent to several inches of product could result.
Preferences for clean service transmitters vary from This is no small matter, particularly if the level measurement
industry to industry. Petroleum refiners have traditionally is used as a basis for custody transfer of the product. Sub-
preferred the externally mounted displacer transmitter but stantial effort has been put into the development of storage
FIG. 3.1f
Steel support-mounted strain gauges (see Chapter 7) can be calibrated by measuring the output when the tank is empty, and again when
it is full. (Courtesy of Kistler-Morse.)
Capillary dielectric constant in the foam that is greater than 1.1 (vac-
uum and gases are 1.0). In the case of heavier foams, vibrat-
ing or tuning fork switches and beta radiation gauges have
been used; in some cases, optical or thermal switches have
also been successful.
Boiling will change the hydrostatic weight of the liquid
column in the tank due to variable vapor fraction. As the rate
of boiling rises, the relative volume of bubbles will also
increase, and therefore the density will drop. Density rises
Filled Elements as the rate of boiling is reduced. Density also varies with
level as bubbles expand on the way up. Therefore, the mea-
To surement of hydrostatic head alone can determine neither the
Controller
level nor the mass of liquid in the tank. This problem is
common when measuring the water in nuclear, boiling-water
reactors (BWRs) or in the feedwater drums of boilers. High-
temperature capacitance/RF transmitters can do the feedwa-
ter job, but the fluorocarbon insulation is not applicable to
nuclear reactors. A standpipe with a series of 10 to 20 hori-
zontal conductance sensors is very common in these appli-
cations. If only level indication is required, then the refraction-
type level gauge is sufficient, given that it shows only the
interface between water and steam. These “external” strate-
gies require the temperature to be equal with the tank to be
Differential- useful.
Pressure Some agitators prevent the use of probe-type devices,
Transmitter
because they leave no room for them, and they also challenge
FIG. 3.1h the use of sonic and radar transmitters unless programmed
Chemical seals with temperature compensation and extended dia- to ignore the agitator blades and sense the rough surface.
phragm protect a d/p transmitter from plugging and chemical attack. Glass-lined reactors are a classic enemy of probes, as they
usually have heavy agitation, and the lining prevents support
or anchoring. A probe, broken due to fatigue, can cause very
a controlled and constant thickness of foam. In these types expensive damage in these vessels. Radar transmitters with
of processes, one must detect both the liquid–foam interface “tank mapping” software are quite suitable as long as the
and the foam level. The detection of the liquid level below dielectric constant is greater than 2 (most common). Agitation
the foam is the easier of the two level-measurement tasks, usually does not affect the performance of the displacer and
because the density of the foam tends to be negligible relative d/p-cell-type level sensors, which are external to the tank.
to the liquid. A d/p transmitter installation (Figure 3.1h) will They can measure level in the special case, where the specific
measure the hydrostatic weight of the foam, disregarding gravity is constant. Of the two, the d/p cell is preferred,
most of its height. Different industries tend to use different because it is looking at the liquid inside the tank and not in
sensors for measuring the foam–liquid interface. In Kraft an external chamber, where its temperature and therefore its
processing, for example, radiation detectors are used to detect density can be different. Of course, the primary reason for
that interface in the digester vessel. RF (capacitance) and heavy agitation is to keep unlike components mixed, which
TDR transmitters and conductance and RF switches make implies variable specific gravity.
excellent foam level measurements as long as the foam is
conductive (in fact, only very specialized RF switches can
differentiate between conductive foam and liquid). Interface Measurement
The continuous measurement of insulating foam level is
more difficult and, for that reason, some people will circum- When detecting the interface between two liquids, we can
vent its measurement by detecting some other process param- base the measurement on the difference of densities (0.8:1.1
eter that is related to foaming. These indirect variables can is a typical ratio), electrical conductivity (1:1000 is common),
be the vapor flow rate generated by the stripper, the heat input thermal conductivity, opacity, or sonic transmittance of the
into the stripper, or just historical data on previous batches two fluids. Figure 3.1i illustrates the difference in typical
of similar size and composition. If direct foam level mea- separator response between the conductivity sensors and the
surement is desired, it is easier to provide a point sensor than density sensors. One should base the measurement on what-
a continuous detector. Horizontal RF switches generally ever process property gives the largest stem change between
operate successfully if density is sufficient to produce a the upper and the lower fluid. If, instead of a clean interface,
Conductivity
µS/cm
1 600 1200 1800 2400 3000
7 (Oil)
Level
(FT.) 6
5
Visual
Electrical Interface Emulsion
4
= Conductivity
3
= Specific Gravity
2 (Water)
Bottom of Tank 0
FIG. 3.1i
Graph of density (bubblers, d/p, displacer, nuclear) and conductivity (capacitance, conductance, TDR) versus level in a typical heavy crude/
water separator.
10° angle from the horizontal. At one end of the gap is the
ultrasonic source, and at the other is the receiver. The instru-
ment depends on the acoustic impedance mismatch between
Transmitter the upper and lower phases. When the interface is in the gap,
Crystal it will attenuate the energy of the sonic pulse before it is
received at the detector. This switch is used in detecting the
interface between water and oil or other hydrocarbons. Of
course, this is no way to control the interface, because, once
outside, it could be above or below the gap. It is suitable as
Receiver a backup to an interface control system.
Crystal
D/P transmitters can continuously detect the interface
FIG. 3.1j between two liquids, but, if their density differential is small,
Sonic interface level switch. (Courtesy of Thermo MeasureTech.) it produces only a small pressure differential. Changes in
density typically produce 5 to 10 times the error on an inter-
face calibration that they do on a single-liquid calibration. A
there is a rag layer (an emulsion of the two fluids) between major limitation is that the range of interface movement must
the two fluids, the interface instrument cannot change that cause a change that is as great as the minimum d/p span. If
fact (it cannot eliminate the rag layer). If the separator and the difference in conductivity is at least 100:1, such as in
its control system are properly designed, the emulsion can case of the dehydrating of crude oil, continuous capacitance
be kept out of both separated products. or TDR probes make excellent interface transmitters. Inter-
Interface-level switches are usually of the optical (Figure face between two insulating liquids (a rare situation) can be
3.1e), capacitance, displacer, conductivity, thermal, micro- accomplished with TDR but is unreliable using capacitance.
wave, or radiation designs. The unique sonic switch described Sonic transducers lowered into the brine layer of oil or liquefied
in Figure 3.1j utilizes a gap-type probe that is installed at a gas storage caverns (Figure 3.1k) can measure the interface
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