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Level Measurement: Topic
Level Measurement: Topic
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Level measurement
Topic Page
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1.1.5 Consistent supply 6
2
if there are surges in the supply line. A storage vessel
1
between the supply and the process can act as a
buffer to ensure that outflow is kept steady despite
fluctuating inflow (Figure 1.1.2). If the process level Figure 1.2.1: Level measurements
in the storage vessel is always maintained within an
appropriate range, the supply delivery rate to the
1.2.1 Indication vs. control
storage vessel can rise and fall without affecting the
supply delivery rate from the storage vessel to the Level measurement indicators enable an on-site level
process. check. Indicators require the operator to interpret
the measurement and take the appropriate action.
Consistent supply is directly related to product Systems with level measurement indicators are
quality in for example pulp and paper industries, referred to as open-loop control systems. Indicators
where a consistent supply ensures that each sheet of are also frequently used to help calibrate automatic
paper has the same thickness as all the other sheets. control systems.
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1.2.2 Tank gauging system, continuous food and beverage and other process plants. The
level, or point level detecton majority of these tanks have a wide variety of sizes
and shapes, but most are less than 60 ft. (18 m) high.
Tank gauging systems
Many of the level applications may not be directly
A tank gauging system is used when the user has in the vessel, but rather in bypass chambers located
applications where raw materials enter a plant, are outside the vessel next to the level area of interest.
stored in intermediate tanks, or leave the plant as
finished goods, and therefore require an inventory Being inside the plant process, these applications
management or custody transfer system. These can be quite varied in terms of difficulty of the
tanks are typically 33 to 100 ft. (10-30 m) in height. measurement. Intermediate buffer or settling tanks
Some exceptions, such as additive tanks, are smaller. are some of the easier applications. Measuring inside
Accuracy requirements are high, in the order of 1-3 a chamber is another common application, while
mm. batch reactors and tanks where the product is mixed
or agitated offer other challenges.
Typical tank gauging applications:
Point level detection
• Large storage tanks that are found in terminals,
Point level detection devices, such as switches, are
pipelines, depots and other storage facilities
often used in conjunction with continuous level
• Receiver/intermediate/finished goods storage
measurements for single point high level and low
tanks in refineries
level alarms. However, they can also be used alone to
• Some large raw material and product storage
simply indicate a full or empty state. Size and space
tanks that are found in chemical, asphalt, power
constraints as well as the application conditions will
plants and airport fuel depots
determine the choice of technology.
The tank gauging system usually includes
Technology selection based on the application
temperature, pressure and water bottom
measurements in addition to level. Communications Understanding the different needs a user has makes
equipment, computer hardware and software the selection between a point/continuous level
are also included in the system solution. The measurement and a tank gauging system easier.
measurement values are used to calculate net Chapter 4 lists a number of different applications,
volumes for custody transfer (commercial and legal gives recommendations on suitable technologies,
purposes), inventory calculations, operational and and will provide key installation information and best
safety purposes. The results of the measurements are practices. Since it is not practical to cover all possible
often used for billing purposes and must be highly applications, the applications chosen for this chapter
accurate, repeatable and reliable following industry are intended to give a broad overview of some very
standards such as API MPMS 3.1B and OIML R85, or common types of applications that are found in many
national accuracy standards. The Rosemount tank industries as well as a few applications that may have
gauging system complies with these international specific challenges. It will also provide examples of
standards and is also approved in many countries where the various technologies are used. However,
for accuracy by governmental authorities, with an the final decision of the technology choice will
instrument accuracy of ± 0.5 mm. include the application conditions, the installation
constraints, and the capabilities of the technology.
Continuous level measurement
Level transmitters for continuous level measurement 1.2.3 Contacting vs. non-contacting
are commonly used in many plants. The level
In a contacting measurement, part of the
measurement is usually an independent input to
measurement system is in direct contact with the
a control system. Measurement reliability and
contents of the vessel. Examples of contacting
repeatability is more important than highly accurate
measurement techniques include guided wave radar,
readings. The accuracy requirement is typically in the
floats and dipsticks.
range of 5-10 mm.
In a non-contacting measurement, no part of the
Continuous level transmitters are found in all
measurement system directly contacts the contents
industries including chemical, oil and gas, power,
of the vessel. Non-contacting methods are preferred
refining, pulp and paper, mining, pharmaceutical,
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HE
EX
RE
IN
1.2.7 Volume
KEE
PT
GH
IT
U
I
TW RC
H E N CI
Top-down
Measurement System
Volume is the space occupied by a quantity of
material and often the level is used to calculate the
volume. Volume is typically expressed in gallons,
liters, cubic centimeters, cubic ft., or barrels. Volume
is the measurement most commonly derived from
level.
1.2.5 Direct vs. indirect measurement In other cases, the volume may be calculated in a
Distributed Control System (DCS) or a programmable
Direct measurement indicates that the level is
logic controller (PLC) or determined from a look-up
measured directly. For example, when you use a
table that relates level to volume.
dipstick to check the oil level in your car, you are
making a direct measurement. A direct measurement
The relationships between level and volume for
is independent of any other process parameters.
several common tank shapes are shown overleaf:
Indirect measurement, also known as inferred
measurement, indicates that a variable other than
level is first measured and then used to determine
a level measurement. For example, pressure
transmitters use mass and the fluid’s specific gravity
to calculate level.
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Where: r
v = tank volume
r = tank radius
H = tank height (or length)
L = product level L
r
H
L r
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10 1 0 0
2 5 10
3 10 32
4 15 68
9
5 20 115
8
7 6 25 173
6
5 7 30 230
4
8 35 313
3 Figure 1.2.10: Bulging error
2
9 40 394
1
10 100 957
In certain applications (e.g. petroleum storage and
transfer), bulging errors may cause suppliers to over-
Figure 1.2.9: Strapping table or under-charge customers.
Mass=Density x Volume
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Are there any mounting constraints on the vessel? To get good representation of the level in the tank,
the size of the connections need to be large enough
Existing taps should be used if at all possible. Some
to provide good flow-through in order to keep fluid
installations are more difficult if the vessel is glass
fresh. Distance between tank and chamber should
lined or double walled. Smaller tanks have less
be minimized for the same reason. Insulation/heat
available mounting area. Tanks that are underground,
tracing may be required to keep fluid temperature as
close together, close to the ceiling, or wrapped with
close as possible to what is in the vessel.
heating coils may have limited accessibility. Floating
roofs may limit the mounting of some top-down
devices. 1.3.4 What are the environmental and
external conditions?
Technology Pressure* Temperature What effect will environmental conditions have on
Nuclear No limit No limit the instrument’s performance?
Capacitance Full vacuum* to -200 to 900 °F Indoor installations are likely to have a fairly stable
5000 psig and up surrounding environment with minimal temperature
(345 bar) (-129 to 482 °C) changes and constant humidity. Outdoor installations
are more likely to have temperature and humidity
Pressure Full vacuum to -157 to 770 °F
extremes. Vibration, electromagnetic interference,
with seals 4000 psig (-105 to 410 °C)**
and transients (power surges caused by lightning)
(276 bar)
are other external issues that must be considered.
Pressure Full vacuum to -40 to 380 °F Transient protectors (or surge protectors) and
4000 psig (-40 to 193 °C) good grounding practices can help protect against
(276 bar) transients.
Ultrasonic -3.6 to 44 psig -22 to 158 °F
non-contact (-0.25 to 3 bar) (-30 to 70 °C) 1.3.5 What are the product characteristics?
Non- Full vacuum to -76 to 752 °F All processes cannot be measured by the same type
contacting 1450 psig (100 (-60 to 400 °C) of device. Corrosive processes may require special
radar bar) construction materials on the level sensor. If special
materials are required, consider whether these
Guided Full vacuum to -320 to 752 °F materials are readily available or if it would be better
wave radar 5000 psig (345 (-196 to 400 °C) to select a device that does not have to contact the
bar) process.
Vibrating Full vacuum to -94 to 500 °F Process characteristics can affect different devices in
fork 1450 psig (-1 to (-70 to 260 °C) different ways:
100 bar)
• A viscous product may plug the ports on some
Displacer Full vacuum to -40 to 900 °F devices
4000 psig (276 (-40 to 482 °C) • Dust, surface foam, and vapors may interfere with
bar) some transmitted signals
Float switch Full vacuum to -72 to 752 °F • If the process density changes, the level indication
2900 psig (200 (-60 to 400 °C) for pressure devices could be affected unless
bar) compensated for
• If the dielectric constant (electrochemical
*Full vacuum = -14.7 psig; atmospheric = 0 psig property of a fluid related to the fluid’s ability
**The upper temperature for seals is limited in vacuum to transmit electrical charges from one body to
applications. another) changes, capacitance measurements will
be affected
Table 1.3.1: Pressure and temperature limits
• Process coating tendencies could affect the
Should the instrument be mounted in a chamber? sensitivity of devices requiring contact
• Solids tend to pile up in a vessel and are not likely
Chambers provide accessibility to the instruments to have a flat surface. Consider at what point on
for calibration or troubleshooting while the process is the angle of repose (maximum slope without
running. They can be positioned to cover the area of product sliding) the level should be measured and
interest instead of the entire range. whether or not this point is consistent
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1.3.6 What are the accuracy requirements What are the outputs required?
for the application?
The most common output is a continuous analog
How is the instrument accuracy specified? 4–20 mA signal, although digital signals are also
widely used. Also wireless signals are gaining
A device that works well on a small tank may not
popularity. In some instances, an alarm or control
provide the accuracy required for a larger tank. For
relay may be needed.
example, a device with an accuracy of 0.1% of span
gives an accuracy of ±0.06 in. (1.5 mm) on a 5 ft. (1.5
To maintain the required resolution and accuracy
m) tank level. The same device provides an accuracy
in a tank gauging system, a digital communication
of ±0.6 in. (15 mm) on a 50 ft. (15 m) tank level.
is required from the instrument to the distributed
control system.
Other devices, such as top-down radar devices,
generally specify accuracy to within a certain value
What power is available?
(± 0.1 in or 3 mm) or as a percentage of distance
measured. The impact of other performance Most devices will run on 12–24 V dc (direct current),
parameters (e.g. temperature effect) should also be although there are some devices that run on 110 or
evaluated. 220 V. A few devices may operate on low power or
wireless with battery power.
Is there a need for high accuracy?
The primary goal in some applications may simply 1.3.8 What is the total cost of the device?
be the ability to make a reliable measurement. In
The list price of the level measurement device
other applications, repeatability may be far more
is important, but the cost of installation and
important than accuracy, i.e. the ability to provide
maintenance should be given an equivalent amount
the same measurement when repeatedly measuring
of consideration. In general, the lower-cost devices
a steady level.
(usually mechanical) tend to require higher levels
of maintenance. The more sophisticated electronic
For tank gauging applications (custody transfer and
instruments are often higher priced, but the
inventory application) there is huge value in using
maintenance cost is much lower. The initial costs of
gauges with a highly accurate, stable and repeatable
some of the electronic technologies are dropping as
level measurement. Without them, the economical
technical capabilities and market demand increase.
impact on the financial transactions may be very
large and the user may not be able to follow the
Another cost consideration is the life of the
international and national legal custody transfer
measurement device. An inexpensive device that
requirements.
needs to be replaced frequently can be very costly
compared to a more expensive device that is more
1.3.7 What are the instrument requirements? durable, reliable, or better suited to the application.
In general, high-performance devices tend to cost
What approvals are needed?
more.
Hazardous approvals need to comply with local
requirements. A standard of “explosion proof” may
1.3.9 What is the operator comfort?
be sufficient for many devices, but some plants or
applications may require intrinsic safety or other Lastly, consider the ease of using the device.
approvals. In other instances, sanitary requirements
may need to be met. Will the method selected be understood by the
people who have to use it everyday?
For inventory and custody transfer applications,
Will the device be easy to install, calibrate, and
several different local meteorological approvals are
maintain?
applicable and sometimes are also required in their
respective country. The main international standard While performance and engineering issues are
for custody transfer is the OIML R85. critical, the everyday use of a level measurement
device can be a key factor in its ultimate selection
and long-term use.
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Initial cost
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1.5 Dielectric constants and radar to vacuum with a dielectric of 1. When other
level measurement materials are measured, they are compared to the
vacuum. In reference to this, various materials tested
“What is its dielectric value?” This is a question that under the same conditions have the following values
often comes up when radar or capacitance is being at 68 °F (20 °C).
considered as the technology. Non-contacting radar,
guided wave radar and capacitance level transmitters • Air: 1.00058
are all impacted to some degree by the dielectric • Benzene: 2.3
value of the material to be measured. So what is • Acetic acid: 6.2
dielectric, what affects it, and how does it impact the • Ammonia: 15.5
level device? • Ethanol: 25
• Glycerol: 56
• Water: 81
1.5.1 What are dielectric constants?
To help understand dielectric constant, it helps to The conductivity of a solution is dependent upon its
consider it in relation to “dielectric”. By definition, chemical composition, ionization capabilities, and
“Dielectric” is: “A substance with a very low electrical concentration. While there is not a simple conversion
conductivity, i.e., an insulator. Such substances have formula from conductivity to dielectric however,
electrical conductivity of less than 1,000,000 mho/ it is generally safe to assume that if the material is
cm. Those with a somewhat higher conductivity not conductive then the dielectric value will be low
(10-6 to 10-3 mho/cm) are called semiconductors. whereas conductive materials have higher dielectric
Among the more common solid dielectrics are values. A key exception to this generalization is water.
glass, rubber and similar elastics, and wood
and other cellulosic materials. Liquid dielectrics Water-based fluids, alcohols, most inorganic acids,
include hydrocarbon oils, askarel and silicone and caustic based materials will have a high dielectric
oils.” (Reference: Hawley's Condensed Chemical constant. Since water is a polar molecule, its dielectric
Dictionary; 12th Edition. Richard Lewis). constant is quite high. Most hydrocarbons are non-
polar and thus their dielectric constants tend to be low.
The term ‘dielectric constant’ is widely assumed
to be another term for relative permittivity or the Water has some unique characteristics in regard to
amount of energy that can be stored in a material conductivity and dielectric properties. For example,
or can accept an electromagnetic field compared the conductivity of water will vary depending upon
to vacuum. The dielectric constant of a material is its level of purity. Deionized and distilled water are
dimensionless because it is a ratio of the permittivity very pure due to the removal common minerals such
of the material under discussion to the permittivity as calcium, magnesium and iron. While distilled or
of vacuum. The dielectric constant of a conductor deionized water has a conductivity that is very low
(copper, say) is infinite because it cannot accept a (<2 µmho), the dielectric constants are still high
field. The dielectric constant of air is 1.0006 because (> 40). Drinking water from most cities will have a
it can accept an electromagnetic field almost as well conductivity of 100 to 300, but the DC is 70 to 80.
as can a vacuum.
1.5.2 What impacts dielectric constants?
Materials that are good insulators have a low relative
permittivity, or dielectric constant. Materials that are Many variables can impact the dielectric constant
conductive have higher dielectric constants. of a material. Test methodology for determining
Though still in wide use, dielectric constant is not the value as well as the physical properties of
a preferred term as it is not absolute, and because the compound can influence the results. Other
permittivity is not constant - it changes with significant factors can include temperature, the test
frequency, pressure and temperature, relative frequency. The impact of each component can vary
humidity and other variables. (Reference: A Guide with the compound tested.
to characterization of dielectric materials at RF
and microwave frequencies - The Institute of The electrical polarity characteristics of a molecule
Measurement and Control, London 2003). affect the dielectric constant. Asymmetrical
In level measurement terms, the dielectric constant compounds, especially those with polar ionization
(DC) is used to indicate the reflectivity of a material. characteristics such as water, have a strong positive
Standard measurements of dielectric are referenced charge on one end. This results in higher dielectric
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constants. More symmetrical compounds, such as As the temperature increases, the dielectric
most oils and other hydrocarbons, have little polarity constant decreases because the molecules spread
and thus low dielectric constant. out more and minimize the ability of the material
to transmit electrical potential energy. However,
Phase changes can result in significant changes in the typical changes in dielectric constants observed
dielectric. For example, ice has a dielectric constant in Hydrocarbons range from 0.0013 to 0.05% per
of 3.2 at 10 °F (-12 °C) and freshly fallen snow (which degree Celsius. The following chart illustrates the
contains a lot more air) has a dielectric constant of percentage of change in relation to the DC change:
about 1.3 at -4 °F (-20 °C). The crystalline structure
changes the polarity and thus the dielectric constant
drops.
Temperature can also cause a dielectric change. Table 1.5.2: This illustrates the increase of the dielectric of steam
Temperature affects the dielectric constant of a as the pressure and temperature is increased.
material because the density of the material can cause
more or less molecules to be within a known volume.
Media DC at a frequency of DC at a frequency of
DC 710 2.98 100 Hz 2.60 10 GHz
Pentachlorobiphenyl 5.58 10 kHz 2.68 10 GHz
Methanol 31 1000 kHz 8.9 10 GHz
Jet fuel JP-1 2.12 10 kHz 2.09 3 GHz
Table 1.5.1: Dielectric constants (DC) for different media at different frequencies
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For general radar level applications, the dielectric of Hawley’s Condensed Chemicals Dictionary, 12th
the material will impact the strength of the returned edition 1995
signal. Any changes in dielectric will have no impact
on the accuracy of the measurement. In determining
the impact of the dielectric though, an exact number
is not crucial. Instead, a relative characterization of
the dielectric into low, medium, or high values is one
part of the information needed to determine the
appropriateness of radar. Other information includes
the vessel height, nozzle size, antenna size or probe,
and surface conditions to determine the appropriate
radar choice.
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1.6 Pressure based level subtracted from total pressure to determine liquid
measurements pressure, particularly in level applications.
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