June 1998

Process Industry Practices

Process Control
PIP PCCLI001
Level Measurement Criteria
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application,
and
engineering costs to both the purchaser and the manufacturer should be reduced.
While
this Practice is expected to incorporate the majority of requirements of most
users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or
engineering
situations should not be made solely on information contained in these materials.
The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having
the
same specifications are equally correct and may be substituted for those named. All
practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these practices or
guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying
or
acting on any material contained in or suggested by the Practice.
� Process Industry Practices (PIP), Construction Industry Institute, The University
of
Texas at Austin, 3208 Red River Street, Suite 300, Austin, Texas 78705. PIP
member companies may copy this practice for their internal use.
Not printed with state funds.
June 1998
Process Industry Practices Page 1 of 8
Process Industry Practices
Process Control
PIP PCCLI001
Level Measurement Criteria
Table of Contents
1. Introduction ...............................2
1.1 Purpose.............................................2
1.2 Scope................................................2
2. References.................................2
2.1 Process Industry Practices (PIP) ......2
2.2 Industry Codes and Standards .........2
2.3 Government Regulation....................3
3. Data.............................................3
4. General .......................................3
5. Differential Pressure
Instruments................................4
5.4 Remote diaphragm seals..................4
6. Displacement Instruments........5
6.1 General .............................................5
6.2 Displacer Chamber ...........................6
6.3 Displacer ...........................................6
7. Capacitance Instruments .........6
8. Non-Contact Instruments.........6
9. Nuclear Instruments .................7
10. Level Switches ..........................7
11. Level Gauges.............................7
11.1 Magnetic Gauges............................7
11.2 Reflex Glass Gauges......................7
11.3 Transparent Type Glass Gauges....8
11.4 Tubular Glass Gauges....................8
11.5 Gauge Cocks and Ball Checks.......8
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Level Measurement Criteria June 1998
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1. Introduction
1.1 Purpose
The purpose of this Practice is to provide requirements for design of level
instrumentation.
1.2 Scope
This Practice covers requirements for design of differential pressure,
displacement,
ultrasonic, capacitance, nuclear instruments, and level gauges. For weighing
systems,
see PIP PCCWE001. For tank gauging systems, see PIP PCCLI002.
2. References
Applicable requirements in the latest edition (or the edition indicated) of the
following shall
be considered an integral part of this Practice. Short titles will be used herein
when
appropriate.
2.1 Process Industry Practices (PIP)
� PIP PCCEL001 - Instrumentation Electrical Criteria
� PIP PCCGN001 - General Instrument Design Checklist
� PIP PCCGN002 - General Instrument Installation Criteria
� PIP PCCLI002 - Tank Gauging Criteria
� PIP PCCWE001 - Weigh Systems Criteria
� PIP PCELI001 - Level Measurement Guidelines
� PIP PCESS001 - Safety System Guidelines
� PIP PCILI000 - Level Installation Details
2.2 Industry Codes and Standards
# American Petroleum Institute (API)
� API RP 551
Section 3 - Level
# American Society of Mechanical Engineers (ASME)
� ASME Boiler Pressure and Vessel Code
Section I, Part PG-60 - �Requirements for Miscellaneous Pipes, Valves
and Fittings�
# ISA, The International Society for Measurement and Control (ISA)
� ISA S20 - Specification Forms for Processing Measurement and Control
Instruments, Primary Elements, and Control Valves
ISA S20.20 - Differential Pressure Instruments
ISA S20.26 - Level Instruments, �Displacer or Float�
PIP PCCLI001
June 1998 Level Measurement Criteria
Process Industry Practices Page 3 of 8
ISA S20.27 - Level Instruments, �Capacitance Type�
ISA S20.28 - Level Instruments, �Gage Glasses and Cocks�
2.3 Government Regulation
# Occupational Safety and Health Administration (OSHA)
� OSHA 29 CFR 1910.119 - Process Safety Management Standard, Appendix A
3. Data
3.1 A data set shall be provided for each sensor. The data set can be in electronic
or
hardcopy format.
3.2 Specification Forms ISA S20.20, ISA S20.26, ISA S20.27 and ISA S20.28 define
the
minimum data set.
4. General
4.1 Differential pressure transmitters are preferred for process level measurement.
4.2 Level instrument wetted materials of construction shall be compatible with the
process.
4.3 Level instruments shall be connected to vessels or standpipes and not to
process flow
lines.
4.4 Piping from the vessel to the standpipe shall not have any traps or pockets.
4.5 Piping from level gauges and external displacer type level instruments shall be
selfdraining
into the vessel.
4.6 Vent and drain valves shall be provided on level gauges or external displacer
type
level instruments.
4.7 There shall be a block valve between the vessel connection and the level
instrument
unless the instrument is designed to be mounted inside the vessel. Externally
mounted instruments are preferred over internally mounted instruments. Owner
approval is required for installations where the instrument is mounted inside the
vessel. With Owner approval, flush diaphragm instruments may be installed without
valves.
Comment: If a block valve is not provided, the instrument can only be maintained
if the vessel can be taken out of service.
4.8 Float or probe chambers and standpipes shall conform to the most stringent
piping
specifications of the piping connected to the vessel.
4.9 The designer shall inform the vessel design group of any instruments that may
require evaluation for weight stress and additional support.
4.10 Instrumentation shall be approved for the electrical area classification.
Probes
internal to a vessel shall be approved for the electrical area classification
inside the
tank (normally Div.1).
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Level Measurement Criteria June 1998
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4.11 Differences in specific gravity between the vessel contents and the external
level
piping or sealing fluids shall be taken into consideration for calibration of the
level
instrument.
4.12 Standpipes shall not be used for services with process temperatures below
minus
40# F. For these services, level instruments shall be individually connected
directly
to the vessel.
4.13 Level bubblers shall be located so there is sufficient overhead clearance for
their
removal.
4.14 Selection of field mounted level instruments for highly toxic services (listed
in
OSHA 1910.119 Appendix A) shall be subject to Owner�s approval.
4.15 Field mounted level instruments and gauge glasses shall be readily accessible
from
grade, platforms, fixed walkways, or fixed ladders. Isolation Valves (root valves)
shall be accessible. Use of a portable ladder or man-basket may be acceptable. See
PIP PCCGN002 Section 4.3 for general accessibility requirements.
4.16 Dedicated, independent process connections shall be used for level
measurements
that are part of safety instrumented systems or where required to enhance
reliability.
See PIP PCESS001 for additional information.
4.17 Heating and insulation of liquid pockets may be required for winterization.
See
PIP PCCGN002 for general winterization requirements.
4.18 Dimensional level calculations shall be provided to Owner. See PIP PCELI001
for
sample level sketches.
5. Differential Pressure Instruments
5.1 Span calculations shall be based on the anticipated operating specific gravity
of the
process.
Exception: If the intent is to prevent the overflow of the tank, the minimum
anticipated specific gravity should be used. See PCELI001 for a discussion of
when normal specific gravity verses minimum or maximum specific gravity
should be used.
5.2 Transmitters are preferred to be mounted at or below the centerline of the high
pressure nozzle (lower nozzle on vessel).
Comment: For alternate mounting see PIP PCELI001.
5.3 The diaphragm seal fluid, seal leg fluid, or purge fluid shall be compatible
with the
process and ambient temperature extremes.
5.4 Remote diaphragm seals
5.4.1 Transmitters with remote diaphragm seals shall be mounted at or below the
high pressure nozzle (lower vessel nozzle).
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Process Industry Practices Page 5 of 8
5.4.2 Provisions shall be made for relieving pressure between the block valve and
the diaphragm seal.
Comment: Clean out or purge connections may be required on the process
side of diaphragm seals in applications where plugging is likely.
5.4.3 Capillary tubing seal legs shall be mechanically protected and adequately
supported to prevent sagging.
5.4.4 Remote diaphragm seals used in vacuum service applications shall be
specifically designed for vacuum service by the manufacturer.
5.4.4.1 Welded capillary connections shall be specified for vacuum
applications.
5.4.4.2 Fill fluid shall be rated for the maximum temperature and
maximum vacuum conditions.
5.4.5 Diaphragm seal capillary tubing lengths shall be designed to take into
account routing requirements. Capillary tubing shall be manufacturer�s
standard lengths.
Comment: Capillary lengths that are too long are as undesirable as
capillary lengths that are too short. They cannot be modified in the field.
Comment: Long capillary lines shall be protected from exposure to
sunlight which can cause errors in measurement even in compensated
systems.
Comment: Capillary lines shall be routed away and/or insulated if they
pass by steam or high temperature heat transfer media jackets on a vessel
or other high temperature sources.
5.4.6 Capillary length of both seal legs shall be identical on a remote seal
differential pressure transmitter.
5.4.7 Remote diaphragm seals without block valves shall not be installed until the
flush and pressure test of the vessel is complete.
6. Displacement Instruments
6.1 General
6.1.1 Displacement type level instruments shall not be used:
a. For extremely viscous materials
b. For services which require purging to prevent:
1. Plugging and/or sticking
2. Excessive condensation or vaporization of fluids in the
chamber due to vessel-chamber temperature differences
c. Without Owner approval if level measurement range exceeds 48
inches
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Level Measurement Criteria June 1998
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d. For services which have agitated fluids
6.1.2 Displacement transmitters and switches in services with temperatures below
0# F or above 400# F shall have air fins or some other means of isolating the
transmitter from the process temperature in accordance with the
recommendations of the transmitter/switch manufacturer.
6.1.3 Displacement transmitters shall not be used in liquids that coat or build up
deposits on the displacer and rod.
6.2 Displacer Chamber
6.2.1 Displacer chambers shall have a Maximum Allowable Working Pressure
(MAWP) equal to or greater than that of the vessel.
Comment: Typically the displacer chamber is isolated and vented or the
level instrument is removed during a field hydrotest. The displacer will
often collapse if exposed to a hydrostatic test.
6.3 Displacer
6.3.1 All wetted parts (displacer element, hanger rod, torque tube or springs, and
assembly components) shall be compatible with the process.
6.3.2 For measuring liquid-liquid interface the displacer shall be completely
submerged.
6.3.3 For measuring liquid-liquid interface with standard displacers, the
difference
in specific gravity of the two liquids shall be greater than 0.1. The
manufacturer shall be consulted for interface measurement.
6.3.4 The displacer shall be freely suspended in the liquid (i.e., it shall not
contact
the bottom/sides or any buildup on the vessel or chamber).
7. Capacitance Instruments
7.1 Capacitance level transmitters shall not be used if the liquid conductivity may
change from non-conductive (less than 10 micro mho/cm) to conductive (greater than
10 micro mho/cm).
7.2 A special probe with a separate electrode for signal return shall be used on
nonmetallic
or lined vessels.
7.3 The probe shall be externally grounded to the vessel if PTFE tape or other pipe
thread coatings are used.
8. Non-Contact Instruments
8.1 Non-contact instrument types include ultrasonic, sonic, microwave, and radar
technology. Use of non-contact instruments requires Owner approval.
8.2 When non-contact instruments are used for solids service, they shall be
designed for
that service.
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June 1998 Level Measurement Criteria
Process Industry Practices Page 7 of 8
8.3 The manufacturer shall concur with the application and the installation.
9. Nuclear Instruments
9.1 Nuclear source type level instruments shall only be used with Owner�s approval.
9.2 Nuclear instruments shall be installed and maintained in accordance with
instructions of the instrument manufacturer and applicable local, state, and
federal
regulations.
9.3 At the time of purchase, the vendor shall state in writing that they will
dispose of the
source after the instrument is removed from service.
9.4 Owner�s policy for installation, handling, and control of nuclear sources shall
be
followed.
10. Level Switches
10.1 Level switches can be of Capacitance, RFI, Ultrasonic (contact), Nuclear, Ball
Floats, Displacers, Thermal, Vibration, or Electromechanical types.
10.2 Level switches that contain mercury shall not be used.
10.3 Provisions shall be made for testing and maintenance of level switches.
10.4 Owner approval is required to use in safety instrumented systems.
11. Level Gauges
11.1 Magnetic Gauges
11.1.1 Magnetic gauges shall not be used in dirty or plugging service.
Exception: If the provision for flushing the gauge with a suitable liquid
can be made, magnetic gauges may still be acceptable.
11.1.2 The float shall be designed for the range of process fluid specific gravity
per
the data set.
11.1.3 The float material of construction shall be compatible with the process.
11.1.4 The float shall be suitable for the maximum operating pressure of the
vessel.
11.2 Reflex Glass Gauges
11.2.1 Reflex gauges shall have a minimum pressure/temperature rating of 1000
psig at 600# F.
11.2.2 Tempered borosilicate, Pyrex# glass, or equal glass shall be used in
applications at or below 600# F.
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Level Measurement Criteria June 1998
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11.3 Transparent Type C
11.3.1 Boiler steam drums shall have transparent gauges designed for steam drum
service in accordance with the ASME Boiler and Pressure Vessel Code
(Section I, Part PG-60) and other applicable codes.
11.3.2 Transparent armored gauges shall have a minimum pressure/temperature
rating of 600 psig at 600# F.
11.3.3 Gauges shall have plastic frost shields for applications in which the
process
liquid has a temperature below 32# F.
11.3.4 Mica shields are required on steam boiler glass level gauges (600 psig or
greater) and caustic services.
11.3.5 If illuminators are provided, they shall be suitable for the electrical area
classification.
11.3.6 Tempered borosilicate, Pyrex# glass, or equal glass shall be used in
applications at or below 600# F.
11.4 Tubular Glass Gauges
11.4.1 Tubular glass gauges shall not be used unless Owner approved.
11.4.2 Tubular glass gauges shall not be used in process applications.
11.5 Gauge Cocks and Ball Checks
11.5.1 Gauge cocks and ball checks shall be used only with Owner approval.
Appropriate boxes checked in PIP PCCGN001 Section 3.4.5.5 constitutes
Owner approval of use of gauge cocks and ball checks.
11.5.2 Gauge cocks and ball checks shall be installed per Owner criteria.
11.5.3 Gauge cocks and ball checks, when used, shall be purchased as assemblies as
part of the level gauge.
11.5.4 Gauge cocks with ball checks shall not be used in vacuum applications.