Cargo control and measurement instruments -Liquid

level gauges for chemical tankers

The accuracy required of chemical carrier level gauges is high

because of the nature and value of the cargo. To limit
personnel exposure to chemicals or their vapours while cargo
is being handled, or during carriage at sea, the IBC Code
specifies three methods of gauging the level of a liquid in a
tank - open, restricted or closed - according to the health
hazard of the product. Many chemical cargoes may not be
gauged by manual dipping because to do so requires an
opening to the atmosphere during operation. The use of
completely closed gauging systems is necessary, so that no
vapour is emitted.

Examples of closed systems are float gauges or radar systems.

Indirect measuring methods such as flow metering may also
be used.

Many more chemicals, although still hazardous, do not require

quite such rigorous controls, and restricted gauging accepts
that a very small amount of vapour may escape during
gauging, An example is using a sounding pipe that reaches
right into the liquid. Virtually all toxic cargoes require either
restricted gauging or closed gauging.

However, other cargoes can be gauged through openings in

the ullage space. This is called open gauging.

Float gauges

These are closed gauges, and consist of a float which rises

vertically on the liquid. It is attached by a tape to an indicating
device for local reading, with provision for a drive mechanism
for remote read-out. Particular attention is drawn to the
following:
i) floats should be secured when at sea, except briefly during
measurement of tank contents. If the float remains unsecured
at sea it will almost certainly be damaged due to sloshing of
the cargo;

ii) remote and local readings should be compared frequently to

determine discrepancies;

iii) readings may need to be corrected to allow for tape and

tank expansion or contraction, and ship trim and heel. Tables
are normally provided for this purpose;

iv) tapes should be checked regularly for free vertical

movement of the float, and if damaged, should be replaced.
Particular care is necessary with the rewind mechanisms which
are carefully balanced: if obstructed, the gauge readings will
be inaccurate;

v) when tapes are renewed, or a gauge reassembled after

maintenance, allowance should be made for the level at which
the float begins to lift. Manufacturer's instructions should be
consulted;

vi) parts should be securely assembled: special care is

necessary with tape-to-float and tape-to-reel attachments.
Figure : Types of gauging
Radar, ultrasonic or microwave gauges

These are also closed gauges, and work on the principle used
by a radar set or an echo sounder. Pulses are transmitted from
the top of the tank and the time taken for them to be reflected
back is measured, and displayed as an ullage or depth. Special
arrangements may be made to reduce interference by internal
tank structure.

Radar gauges are generally reliable, and most maintenance

can be performed from outside, with the tank in the closed
condition. Particular care is necessary to protect the delicate
transmitters and receivers, and when calibrating this type of
gauge.

Pressure gauges

Pressure gauges make use of the difference between

atmospheric pressure and the pressure in the liquid near the
tank bottom. Sometimes an additional sensor is mounted near
mid-depth in a tank to improve accuracy and reliability. In
some cases a system can adjust for cargo density by use of
sensors at known levels, and in other cases a correction factor
associated with specific gravity is necessary. A thermometer is
usually included in the sensors, but a disadvantage of pressure
gauges is that the cargo temperature may vary widely in a
tank and, because correct density is dependent on
temperature, an error in readings may develop. The delicate
nature of sensors and their susceptibility to cargo leakage
makes regular servicing essential.

Tape gauge systems

These systems use a tape to check the level of cargo in a tank.

The measuring probe may be inserted into the tank through a
small diameter pipe with a ball valve at the end, and portable
units can be attached or released from this valve by a screwed
adapter to minimise the amount of cargo released. They
sometimes have an interface detector, and a temperature
sensor built in, with appropriate indicators in the displays. A
system employing this type of connection can also be used to
take cargo samples.

It should be borne in mind that individual ship has got own

characteristics and limitations may involved handling various
chemical cargoes . The master and all personnel in all cases
must be aware of cargo/ship information that has been given
and comply with relevant safety procedures.

Other info pages

Draegar Chemical detector tubes use and reading correction

guideline
These instruments, often referred to as Draeger tubes,
normally function by drawing a sample of the atmosphere to
be tested through a proprietary chemical reagent in a glass
tube. The detecting reagent becomes progressively discoloured
if a contaminant vapour is present in the sample. The length of
the discoloration stain gives a measure of the concentration of
the chemical vapour which can be read from the graduated
scale printed on the tube. Detector tubes give an accurate
indication of chemical vapour concentration, whatever the
oxygen content of the mixture

Requirements of various grade chemical cargo heating

: The voyage orders will contain heating information, if heating
is required. As a rule the final heating instructions are given by
the Shipper in writing to the Master / Chief Officer in the port
of loading. If those written instructions are not given, the
master should request them and issue a Letter of Protest if
they are not received at departure. In the latter case the
management office should be immediately informed.

Recommended temperature monitoring equipments onboard

:Temperature sensors are fitted so that the temperature of the
cargo can be monitored, especially where required by the IBC
Code. It is important to know the cargo temperature in order
to be able to calculate the weight of cargo on board, and
because tanks or their coatings often have a maximum
temperature limit. Many cargoes are temperature sensitive,
and can be damaged by overheating or if permitted to solidify.
Sensors may also be fitted to monitor the temperatures of the
structure around the cargo system.

Cargo instruments
:In order to maintain a proper control of the tank atmosphere
and to check the effectiveness of gas freeing, especially prior
to tank entry, several different gas measuring instruments
need to be available for use. Which one to use will depend
upon the type of atmosphere being measured.

Liquid level gauges

:The accuracy required of chemical carrier level gauges is high
because of the nature and value of the cargo. To limit
personnel exposure to chemicals or their vapours while cargo
is being handled, or during carriage at sea, the IBC Code
specifies three methods of gauging the level of a liquid in a
tank - open, restricted or closed

Overflow control
:Certain cargoes require the designated tank to be fitted with a
separate high level alarm to give warning before the tank
becomes full. The alarm may be activated by either a float
operating a switch device, a capacitive pressure transmitter, or
an ultrasonic or radioactive source. The activation point is
usually pre-set at 95% of tank capacity.

Oxygen analysers
:Oxygen analysers are normally used to determine the oxygen
level in the atmosphere of an enclosed space: for instance, to
check that a cargo tank can be considered fully inerted, or
whether a compartment is safe for entry.

Vapour detection
:Ships carrying toxic or flammable products (or both) should
be equipped with at least two instruments that are designed
and calibrated for testing the gases of the products carried. If
the instruments are not capable of testing for both toxic
concentrations and flammable concentrations, then separate
sets of instruments should be provided.

Alarm circuit
:An important feature of many modern measurement and
control instruments is the ability to signal a particular
situation. This can be a main operational alarm that gives an
indication of a pre-set situation such as liquid level in a tank,
or a malfunction alarm indicating a failure within a sensor's
own operating mechanism. The designs and purposes of alarm
and shutdown circuits vary widely, and their operating system
may be pneumatic, hydraulic, electrical or electronic. Safe
operation of plant and systems depends on the correct
operation of these circuits and a knowledgeable reaction to
them.

Gas freeing
:Gas freeing onboard chemical tankers is required for entry
into cargo tanks, for hot works or washing for clean ballast
tanks. Gas Freeing is one of the most hazardous operations
routinely undertaken onboard a Chemical Tanker and the
additional risk created by cargo gases expelled from the tanks,
which may be toxic, flammable and corrosive, cannot be over-
emphasised.

Cargo tank damage during pigging operations

:Blowing and pigging of pipelines at terminals poses inherent
risks for the terminal and a chemical tanker. Frequent
damages to tanks have occurred. If there are doubts about the
shore operation or signs of problems ashore the OOW must
immediately request clarification.