Escolar Documentos
Profissional Documentos
Cultura Documentos
Fundamental Training
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
Level 1 - Level
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
Level 1 - Level
Inventory
Process
have a
mixture of process
and inventory
applications in a
plant
Level 1 - Level
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
Level 1 - Level
Level terminology
Level Control Loop
(Inflow)
I/P
LIC
LT
Level 1 - Level
Level terminology
Level Control Loop
(Outflow)
LIC
I/P
LT
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
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
Level 1 - Level
Level terminology
Parameters
Volume
1
1
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
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
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
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
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
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
Bottom-up
Level 1 - Level
Level terminology
Measurement Characteristics
1
7
Level 1 - Level
Level terminology
Measurement Characteristics
1
8
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
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
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
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
Product turbulence
Obstructions
Mounting constraints
Angle of repose for solids
Temperature and pressure limits
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
Corrosive
Viscous
Dusty, Foam
Variable Density
Variable Dielectric constant
Tendency to Coat
Interfaces, gradients, suspended solids
Steam or other vapors
Level 1 - Level
Technology selection
Factors To Consider
Common Density/ Temperature Changes
2
5
Level 1 - Level
Technology selection
Factors To Consider
Typical Dielectric/ Temperature Changes
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
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
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
Phead
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%
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
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
XMTR
L
Min. Level
Range
Max. Level
20mA
Rosemount technologies
Pressure Transmitters
3
4
Phigh
Plow
= Ptop+Phead
= Ptop
Ullage or
Vapor
Phead
XMTR
L
Level 1 - Level
Rosemount technologies
Pressure Transmitters
3
5
+P
Phigh =Phead+Ptop
Plow=Pwet leg
Ptop= Ullage
Pwet
Phead
L
H
XMTR
top
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
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)
Phead = H * S.Gf
RMT Training - 05 /98
S.Gf
Level 1 - Level
Rosemount technologies
Pressure Transmitters
3
8
Valve
Air
Supply
Level 1 - Level
Rosemount technologies
Pressure Transmitters
Remote Seals
3
9
Differential
Pressure
Transmitter
Level 1 - Level
Rosemount technologies
Pressure Transmitters
4
0
Level 1 - Level
Rosemount technologies
Hydrostatic Tank Gauging (HTG)
It is basically a method for
measuring mass.
4
1
Rosemount technologies
Hydrostatic Tank Gauging (HTG)
4
2
Measurement Options:
PT
Mass
Density = (PB - PM ) / H
H
PM
HBT
TT
PB
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)
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)
Level 1 - Level
Rosemount technologies
Hybrid Inventory System
Top Pressure
Radar
Gauge
Transmitter
D
Middle Pressure
Transmitter
H
L
Temperature
Sensor
Bottom Pressure
Transmitter
Measurement Options:
4
6
Level 1 - Level
Rosemount technologies
Hybrid Inventory Systems
4
7
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------------
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 !
Level 1 - Level
Rosemount technologies
Radar Gauge
Radar Techniques
5
0
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
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
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
Level 1 - Level
Other technologies
Float Mechanism
Internal Still pipe
to guide the float
Indicator
5
6
Float
Tank
Isolating Valve
Float
Drain
Valves
Indicator
Level 1 - Level
Other technologies
Capacitance Probe
5
7
where
K = dielectric constant of material
Eo = permitivity of vacuum
A = Area of plates (probe)
C = capacitance (pF)
d = distance between plates
d
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
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
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
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
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
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
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
6
5
Storage Drum
Cable
Balance
Detector
Servo
Motor
Displacer
Level 1 - Level
Other technologies
Nucleonic Gauging
6
6
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
Level 1 - Level
Other technologies
Nucleonic Gauging
6
8
Advantages:
Limitations:
Unaffected by:
High temperatures
High Pressures
Corrosive Materials
Abrasive Materials
Viscous Materials
Agitation
Clogging/Plugging
Level 1 - Level
Other technologies
Nucleonic Gauging
Typical Applications
Chemical
Distillation Tower
Batch Reactor
Storage Tanks
Resin Bed level
Hydrocracker reactor
Pulp & Paper
Digester Level
Wood Chip Bins
Bleach Tower
Consistency
Effluent Waste
Slurries
Liquor concentrates
Refining
Fractionator Tower
Surge Tanks
Coke Drum Interface
Desalter
Food and Beverage
Hopper Level
Blending Vats
Mining
Crusher Level
Storage silos
Slurries
Utilities
SO2 / Lime scrubber
Fly ash Slurries
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
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
temperature
dust
vapor composition
stratification of the vapor
Sound Waves
Level 1 - Level
Other technologies
Ultrasonic Gauging
Application Considerations
7
3
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
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
Differential Pressure
Servo Level Gauge
Capacitive Probe
Nucleonic Gauging
Ultrasonic Gauging
Radar Gauging [
Bubbler System [
[
[
[
[
[
]
]
]
]
]
]
]
Level 1 - Level
Exercise
3. For HTG, why is a 2nd Pressure Transmitter added to tank in the middle ?
7
7
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
Level 1 - Level
Exercise
7
9
7.
10
Level 1 - Level
Exercise
8.
Pmeasured = 150 inH2O
s.g.
8
0
Pin(flow=const)
= 1.5
Level 1 - Level