Saybolt Global Inspection Manual
LIQUID LEVEL GAUGING
7.1. SAFETY CHECK BEFORE GAUGING
1. Examine gauge tapes and PETs and ensure that
grounding straps are properly attached to all gauging
and temperature measurement equipment.
2. Check to see that the clamp on the free end of the
grounding strap works properly.
3. Before climbing any tank, determine whether there is
any danger from toxic vapors, such as Hydrogen
Sulfide (H2S) or Benzene.
4. If you must go down onto a floating roof, be certain
you (1) have been trained in confined space entry and
(2) check for the presence of toxic vapors and oxygen
deficiency. If toxic vapors or oxygen deficiency is a
problem, have access to a self-contained breathing
apparatus that has been checked for proper
functioning.
5. Be certain that terminal operations personnel are
notified when you are about to climb a tank, and
request that the terminal provide an attendant while
you are working on a tank top.
6. Visually check tank stairways, ladders and condition
of the roof. Make sure that you do not climb or walk
on any stair, ladder or roof that appears unsafe or
damaged.
7. Do not carry anything onto a tank that requires the
use of both hands. One hand must always be free to
hold on to the stair rail. If a tank has a ladder, both
hands must be free.
8. Do not enter firewalls (tank pit) that are filled with
water (or mud) that is deeper than the height of your
boots.
7.2. GAUGING EQUIPMENT
7.2.1. Steel Tape and Bob Assembly
A steel tape, equipped with a reel, graduated in
meters/mm and/or ft/inches, or ft/hundredths. Tapes are
typically 10 to 30 meters (25 to 100 feet) long. They are
available in chrome finish and stainless steel and other
finishes.
Gauge tapes are designed to measure the depth of liquids
(from the liquid surface to the tank bottom) in a tank.
They have the zero point at the tip of the attached bob.
Bobs are constructed of brass or stainless steel. Bobs are
pointed on one end (to help penetrate tank bottom solids)
and have a hole to attach the tape at the other end.
NOTE: Outage (Ullage) tapes are designed to measure
the height of the space above the liquid in a tank (from the
Issued: May 1, 2002 Saybolt Inspection Support & Development Group
liquid surface to a reference point on top of the tank).
They have the zero point at the lower inside of the clip
where it attaches to the bob. Outage (ullage) bobs are
square on one end and have a hole to attach the outage
tape at the other end. Outage tapes may be used only
with outage bobs.
Saybolt Inspectors should use Saybolt-issued gauge
tapes and bobs.
7.2.2. Portable Measurement Units (PMUs)
Portable Measurement Unit (PMU) is the term used by
API to describe measurement tapes equipped with
permanent bobs that electronically sense the presence of
oil or water and temperature. PMUs are designed to fit
into vapor control valves, usually on board ships and
barges that minimize the escape of hazardous tank vapors
to the atmosphere.
Several companies manufacture the PMUs used in
Saybolt. Those companies also manufacture the vapor
control valves designed to accommodate the tapes. Since
the several brands are not identical in design, each
company also makes adapters available to permit one
brand of tape to fit the other brand of vapor control valve.
If the calibration tables have not been adjusted for the
relocated gauge point, it may be necessary to adjust the
PMU gauge reading to correct for the new reference
height.
PMUs measure the ullage (outage) of the tank contents.
They function electronically. When petroleum contacts
the sensor at the tip of the bob, a continuous beeping tone
is emitted at the hub of the tape reel. When free water
contacts the sensor at the tip of the bob, an intermittent
beeping tone is emitted at the hub of the tape reel.
Ships and barges often carry their own PMUs to be used
by vessel personnel for their own purposes. Saybolt
Inspectors should preferably use Saybolt PMUs to
take measurements. In case ship's equipment is to be
used the inspector should check this equipment (e.g.
comparison with own tape, calibration log etc.)
7.2.3. Automatic Gauging Equipment
Mechanical gauging equipment (such as Whessoe, Varec,
etc.) is affixed to the side of a shore tank. It is equipped
with a cable with a float attached to one end, and the other
end of the cable is attached to the gauge read-out box on
the side of the tank. As the oil level rises and falls, the
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float rises and falls and the cable changes the reading on
the gauge read-out box at the side of the tank.
Radar-type equipment (manufactured by Saab, Enraf and
others) is used on both ship and shore tanks. The radar
screen is mounted on top of the tank and the beam reflects
off the surface of the liquid. Gauge readings may be
displayed either at the tank top or in a remote location,
such as the control room of a ship or terminal.
Other types of automatic gauging equipment rely on
pressure or liquid-level detectors installed inside the tank.
These devices may also be read either on the top of the
tank or in a remote read-out location, such as the control
room of the ship or terminal.
7.2.4. Water-finding Paste
Water finding paste is available in both jars and tubes.
Jars permit re-mixing of pastes that have separated into
liquid/solid phases.
7.2.5. Product-finding Paste (Gasoline paste)
In very light products, the liquid level cannot be read
because the product evaporates while the tape is being
raised from the liquid. Product-finding paste changes
color when it contacts petroleum products. The liquid
level cut is indicated on the paste.
7.3. TANK MEASUREMENT UNCERTAINTIES
The accuracy of measuring liquid levels may be affected
by several conditions. Some of the conditions you may
encounter are listed:
7.3.1. Capacity Table Accuracy
Tanks may not have current capacity tables. Periodic
recalibration according to industry standards is
recommended.
7.3.2. Shell Expansion
Tank shells expand and contract with temperature and
with the pressure of the materials placed into the tank.
Industry standards in some locations contain the formula
for calculating shell expansion changes due to
temperature and one method is outlined in section 11.2.4
of this Manual.
7.3.3. Tank Bottom Movement
Flexing tank bottoms are a condition created when the
bottom of a tank moves up or down when liquids are
Issued: May 1, 2002 Saybolt Inspection Support & Development Group
LIQUID LEVEL GAUGING
transferred to and from the tank. Often, but not always,
flexing will be indicated by a change in the measured
gauge height. Flexing may cause mis-measurement of the
tank contents. (See Section 11 for a detailed description
of tank bottom problems.)
7.3.4. Standpipes (Stilling wells, gauge pipe)
Tanks are often fitted with standpipes. The reference
gauge point is usually located on these standpipes. There
are certain industry standards that apply to standpipes
used for gauging. Standpipes should be slotted or
perforated over the entire length to permit tank liquid
contents to flow freely inside the standpipe. Standpipes
should ideally be at least 25 cm (8”) in diameter.
7.3.5. Changes in the Gauge Height
The measured gauge height of a tank may be different
from the reference gauge height on the capacity table.
That difference may be caused by various expansion
problems of the tank, by flexing bottoms, by build-up of
solids on the tank bottom, or by debris that has fallen into
the tank at the gauge point.
7.3.6. Incrustation / Clingage
Tanks that contain products with high pour points or with
sediment may build up residues of these materials on the
walls and floor of the tank. Incrusted tanks have
decreased capacity and that, in turn, overstates the
quantity contained in the tank. Tank cleaning is the only
remedy for incrustation.
7.3.7. Leaks in the system
Measurements may be inaccurate due to leaking in the
pipeline system used by a terminal. Connecting valves
and transfer lines in a terminal may leak permitting
product to be diverted into another tank.
7.3.8. Condition of the Liquid in a Tank
When any liquid is measured, it must be still or calm,
with no motion. Ideally, it must also be free of entrained
air or foam.
7.3.9. Additional Gauge Hatches
A tank may have other openings in the roof or top where
it is possible to access tank contents for measurement.
These openings, if they can be safely reached, may be
very useful for determining flexing bottoms, innages in
cone-bottom tanks, and low levels of material. Only
official reference gauge points indicated on the capacity
table should be used for all custody transfer
measurements.
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7.3.10. Product Quantities at the Zero Gauge
Level
The capacity tables for tanks with datum plates above the
tank bottom, cone bottoms and sumps may indicate
product quantity below the zero-gauge level measured at
the reference gauge point. Inspectors should attempt to
measure at the point where the tank bottom is lowest.
These measurements can be converted to accurate
quantities only when the capacity table provides for those
measurements. If there is no capacity table for liquids
below the zero gauge point, the terminal should raise the
liquid level above the zero gauge point.
7.3.11. Floating Roof Tanks
When a tank has an floating roof, a correction for the
displacement of the roof on the product will need to be
made, except when the roof is firmly seated on its
supports. Measurements may not be taken in the roof
critical zone except when the capacity table specifically
states that this is permissible. The capacity table for most
floating roof tanks is inaccurate in the critical zone.
7.4. GAUGING THE LEVEL OF PETROLEUM
Read and record the automatic or other gauge on the side
of the tank (or in the terminal control office) before
climbing the tank. Verify that the floating roof is in the
correct (low legs) position. Report the presence of water,
snow or ice on the roof.
7.4.1. Innage Gauging
• Read the tank capacity table and record the reference
gauge height of the tank in your gauging book.
• Attach the bob to the gauge tape and apply water-
finding paste to the surface of the bob (see FREE
WATER GAUGING PROCEDURES below).
• Ground the tape to the tank before gauging.
• Gently lower the bob/tape carefully into the tank,
moving it very slowly as you near the reference
gauge height at the reference gauge point.
• When you feel the tip of the bob touch the bottom of
the tank (or the datum plate), read the observed
gauge height at the reference gauge point marked on
the tank gauge hatch. (Be careful not to lower the
tape so far into the liquid that the bob may tilt.) If the
observed gauge height and the reference gauge height
are the same, slowly reel in the tape until you can see
and note the liquid cut on the tape.
Issued: May 1, 2002 Saybolt Inspection Support & Development Group
LIQUID LEVEL GAUGING
Note: If the observed gauge height and the
reference gauge height are not the same,
raise the bob slightly and carefully allow it
to drop onto the bottom of the tank to
penetrate any sediment on the tank bottom.
Recheck the observed gauge height. If the
observed and reference gauge heights are
still not the same, record the difference and
proceed with the gauging process.
• Lower the tape and bob carefully into the liquid at
least once again and read the liquid cut each time.
(Three consecutive readings are required unless the
first two measurements are within a 3 mm (1/8”)
span.)
• The two readings that are identical (within the same
3mm (1/8" span)) are reported.
Note: It may be possible to gauge at more
than one location. Additional innage gauges
should be measured, recorded and averaged
to obtain the reported innage gauge for that
tank.
7.4.2. Ullage (Outage) Gauging
• Note: Ullage gauges are reliable only when the
measured reference height is the same both
before and after cargo transfer.
• Read the tank capacity table and record the reference
gauge height of the tank in your gauging book.
• Attach the bob to the gauge tape and apply water-
finding paste to the surface of the bob
Note: An ullage tape and bob may also be used
to measure ullage gauge.
• Ground the tape to the tank before gauging.
• Lower the bob/tape carefully into the tank, moving
very slowly as the bob nears the surface of the liquid.
• After the bob has stopped swinging, continue to
lower the tape slowly until a small portion of the bob
or tape is immersed in the liquid and an even round
figure (or inch) graduation on the gauge tape is at the
reference gauge point.
• Withdraw the tape and bob from the tank and read
the liquid cut on the tape or bob.
• (Three consecutive readings are required unless the
first two measurements are within a 3 mm (1/8”)
span.)
• The two readings that are identical (within the same
3mm (1/8" span)) are reported.
• Determine the ullage (outage) gauge using one of the
following procedures:
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If you are using innage equipment to measure an
ullage, the reading on the innage bob is subtracted
from the reading at the reference gauge point to obtain
the ullage gauge.
Example 1:
Innage Tape reading at reference point: 03' 04"
Innage Bob reading at liquid cut: -00' 02"
Difference (ullage): 03' 02"
Innage Tape reading at reference point: 123 mm
Innage Bob reading at liquid cut: 12 mm
Difference (ullage): 111 mm
If you are using an outage tape and bob to measure
an ullage, the reading of the cut on the outage bob is
added to the reading at the reference gauge point to
obtain the outage gauge.
Example 2:
Outage Tape reading at reference point: 03' 04"
Outage Bob reading at liquid cut: 00' 02"
Sum: 03' 06"
7.5. SPECIAL PROCEDURES FOR GAUGING
BITUMEN (including ASPHALT)
Refer to chapter 19, Bitumen.
7.6. FREE WATER GAUGING PROCEDURE
Free water beneath the oil in a tank may be measured by
the innage or outage method. The innage method is
preferred.
NOTE: Free water that is on top of high-density
material in a tank cannot be accurately gauged. If
water paste is used to measure under these conditions,
report procedure used.
NOTE: When determining free water levels using a
PMU (interface detector) always confirm this level with
water finding paste since interface detectors may give a
false reading due to suspended water in the product.
Immediately after a vessel has loaded, free water
measurements may not be accurate since some or all of
the free water may remain in suspension in the oil for
some period of time.
7.6.1. Procedure
• Until you know which brand of paste gives the
best reading in a particular type of oil, select
the one that gives the highest clear water cut.
(Extremely sensitive pastes, such as SarGel,
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LIQUID LEVEL GAUGING
are not recommended for use in petroleum)
• If water paste is supplied in jars, mix the paste before
using if it has developed a liquid phase.
• Apply the paste to the bob in an even layer that is just
thick enough to hide the surface of the bob. Do not
cover the graduations or numbers.
• Lower the bob carefully into the oil until it just rests
on the tank bottom (or datum plate).
• Allow the bob to remain in place for at least 10
seconds (significantly longer periods may be required
for heavy or high-viscosity oils).
• Coating the paste with light lubricating oil before
immersion should help speed readability in heavy oil.
• If heavy dark oil prevents reading the water cut when
the bob is withdrawn, pour or lightly spray a mild
solvent on the bob, well above the anticipated water
cut, and allow the solvent to rinse the dark oil from
the paste.
• Some water pastes do not adhere well to the bob in
layered applications. It may be necessary to wipe the
bob dry and re-apply the paste under those
conditions.
• Always record the highest continuous clear cut as the
official water level measurement.
• The height of any spotting should be noted on the
report.
7.7. GAUGING WITH PORTABLE
MEASUREMENT UNITS (PMUs)
The following procedure is necessary for using PMUs and
vapor control valves:
• Examine the vapor control valves as soon as you
board the vessel to be certain that the PMU is
equipped to fit the valve. It may be necessary to fit
an adapter to the PMU.
• Examine the vessel’s tank capacity tables and verify
whether tables have been modified for the new
reference gauge location.
• Apply a thin but opaque coating of water finding
paste on the bob of the PMU above the sensor.
• Fit the PMU into the vapor control valve and secure
the locking collar on the PMU.
• Slowly open the vapor control valve, protecting
yourself from by-pass spray of petroleum if the valve
is not gas-tight.
• Unwind the tape from the PMU until the sounding
device on the reel emits a continuous beeping tone.
• Raise and lower the tape & bob just above and below
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 Saybolt Global Inspection Manual
the liquid surface until you are satisfied that the
sensor is exactly at the surface of the petroleum.
• Read and record the ullage of the petroleum at the
readout area specified by the PMUs manufacturer.
• Continue to lower the tape & bob into the liquid until
the beeping tone becomes intermittent.
• Raise and lower the tape & bob just above and below
the free water interface until you are satisfied that the
sensor is exactly at the interface of the oil and water.
• Read and record the ullage of the free water at the
readout area specified by the PMUs manufacturer.
(See note above regarding interface detection with
PMUs)
• Continue to lower the tape & bob until you can feel
the bob just rest on the tank bottom.
• Allow the bob to remain in that position for as long
as necessary to obtain a confirming water
measurement.
• Reel in the tape & bob, reeling slowly as you
approach the vapor control valve, until the bob is
securely inside the upper housing of the valve but
also well above the valve itself.
NOTE: If you close the vapor control valve
while the bob is below the valve, you will
either seriously damage the bob or cut the
tape. Take great care when using PMUs to
avoid the need for expensive repairs.
• When the bob is secured inside the upper valve
housing, slowly close the valve.
• Unlock the locking collar on the PMU and withdraw
the PMU assembly.
7.8. GAUGING SOLIDS OR SLUDGE ON TANK
BOTTOMS
The presence of solids or semi-solid material on a tank
bottom is common in crude oil tanks and in tanks that
contain high pour point material. These dense materials
may consist of sediment, sand, soil, or solidified
hydrocarbons.
The presence of solids or sludge is usually detected by
• The presence of sludge or heavy material on the gauge
bob when it is withdrawn from the tank;
• The “feel” of the innage bob as it tries to penetrate
the material under the oil layer;
• The reference gauge height being greater than the
measured gauge height.
NOTE: Both of the above means of detection
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LIQUID LEVEL GAUGING
may result from other factors such as foreign
objects dropped into the tank (e.g., a broken
sample bottle or wiping rags) or flexing of
the tank bottom.
There is no reasonable way to determine whether solids or
sludge are spread evenly across the bottom of a tank.
Therefore only inferential steps can be taken to obtain the
best possible measurement:
• Use the ullage method for cargo measurements;
• The terminal should not drain the tank to a point below
the measured solids level;
• The terminal should consider maintaining a layer of
free water on the tank bottom.
7.9. ROLLING GAUGES ON BOARD MARINE
VESSELS
Vessels subject to movement in the water from rolling
seas will usually have a problem with cargo in the tanks
being in motion. Under those conditions, Inspectors may
not be able to get two matching gauges out of three.
When cargo is in motion on ships or barges, take five (5)
ullage gauges as quickly as possible and record all five
gauges. Average the five gauges to obtain the mean
ullage to be used for liquid being measured in the tank.
7.10. MEASURING ICE BOTTOMS IN SHORE
TANKS
In very cold climates, free water on the bottom of shore
tanks may become ice, particularly when a tank is not
very active. Some special considerations are needed
when measuring custody transfers of cargoes involving
these tanks.
For cargo loadings, the ice does not usually present a
problem because its level will remain the same before and
after loading a vessel.
For cargo discharges, there may be a problem with
quantifying free water discharged from the vessel. The
following procedure should be followed.
1. When gauging shore tank(s), apply water-finding
paste to the innage bob before measuring the
reference gauge height, being certain that the paste
extends all the way to the tip of the bob. Then
measure the gauge height allowing the tip of the bob
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 Saybolt Global Inspection Manual

LIQUID LEVEL GAUGING

to sit on the tank or ice bottom for at least 15

seconds.
2. Record the difference between the table gauge height
and the measured reference gauge height.
3. Examine the water finding paste for color change. If
only the paste at the tip has changed color, the
difference between the measured reference gauge
height and the capacity table gauge height should be
assumed to be the ice ullage. If the water paste has
changed color higher up on the bob, the water cut
will represent the combined free water/ice ullage in
the tank.
4. After the vessel has finished unloading, repeat steps
1, 2 and 3 above.
5. The difference between the free water/ice (or ice
only) ullage before discharge vs. the free water/ice
(or ice only) ullage after discharge is the quantity of
free water discharged from the vessel.
Free Water + Ice Before Discharge
- Free Water + Ice After Discharge
= Free Water Discharged from the Vessel
Inspectors may also use the field notebook to record raw
data but the data must be transferred to an authorized
form or computer program to ensure that all required data
has been recorded and to leave a copy of raw data with
approved parties.
Minimum raw data information required is as follows:
• Terminal, Tank No., Product, Vessel Name
• Automatic gauge reading
• Measured Gauge Height and Reference Gauge
Height
• Ullage or Innage product gauge
• Free water innage gauge
• Temperatures at each level measured
• Shore line capacity and condition as stated by the
terminal
• Date, time, Inspector’s name, Witness’s name (if
any)

6. Free water coming from the ship may become ice by

the time measurements are taken, or it may remain
water, or it may be a combination of ice and water. If
ullage measurements are used for the free water or ice
layer, distinguishing between ice and water is not
necessary.

During inventories, if ice bottoms are measured, the level

of ice may be found to be somewhat greater than the level
of liquid water on the terminal's inventory records. If the
increase is minimal, it is the result of the tendency of
water to expand after freezing, and is not a gain in the
quantity of water.

Note: Some shore tanks have special center gauge

hatches for measuring water bottoms. These hatches
should be used for ice/water measurements following the
above procedure however care must be taken to reference
the capacity table that applies to the center gauge hatch.

7.11. REPORTING LIQUID LEVEL GAUGES

To avoid errors, each liquid level gauge shall be written

down immediately after the liquid level has been
measured. Saybolt Inspectors should use the appropriate
field form to make initial entries of all raw measurement
data.
Issued: May 1, 2002 Saybolt Inspection Support & Development Group Chapter 7, Page 6 of 6