Level Basics

Wilockx Chris

Physical Basics of Pressure Measurement

F (force)
N (Newton)
P (pressure) = --------------- = ---------------- |Pa|
A (surface)
m2
There are different pressure units:

kPa: kilo Pascal

mmHg: mm mercury

bar:

atm:

atmosphere

kg/cm2:

psi:

pound/inch2

mmH2O: mm water

inH2O: inch water

bar

Physical Basics of Pressure Measurement

Pressure Quantity
Absolute Pressure
Atmospheric Pressure
Gauge Pressure
Differential Pressure

pabs1

Symbol
pabs
pamb
pe
dp

pe1 > 0

dp
0%

pe = 0

pe2 < 0

pamb.
pabs. 2

100%

pabs = 0
(Vacum)

Physical Basics of Pressure Measurement

Pressure is equal
in all directions

Hydrostatic Paradox
P = S.g.h
S = Rho = density
|Pa| = |kg/m3|.|9,81m/s2|.|m|

Pressure Measurement Pressure U - Tube

U-Tube

Pa = S.g.h + P0
|Pa| = |kg/m3|.|9,81m/s2|.|m|

Pressure Measurement Pressure Transmitters

Boudon pressure gauge

Pressure Measurement Pressure Transmitters

p - measurement

dp - measurement

Functional Principle of P and dP Transmitters

Conversion of the Physical Factor

(i.e.: Deflection of Diaphragm) into an Electrical Factor:
Different sensors are used:
Inductive measuring principle (coil)

Capacitive measuring principle (capacitor)

Strain Gauge measuring principle (Bridge)
Piezo-resistive measuring principle (chip)

Functional principle of P and dP transmitters

inductive measuring principle:

n2 . A
L = --------l

Functional principle of P and dP transmitters

capacitive measuring principle:
diaphragm

P1

P2

E .A
C = --------d

C1

C2

Glass

Measuring
diaphragm

Functional principle of P and dP transmitters

Strain Gauge measuring principle :
R= K x

R
Strain gages array
(bonded or made
directly on the
substrate)

Metal cores

+
Measuring
diaphragm
Substrate
Bonding

Functional principle of P and dP transmitters

piezo-resistive measuring principle

DP-Sensor

Pabs-Sensor

(example 265D)

Measuring of resistance
change via crystal
lattice displacement

Functional principle of P and dP transmitters

piezo-resistive measuring principle

(e.g. 265G)

Measuring of resistance
change via crystal
lattice displacement
lower range value
span

Microprocessor based
electronics

write protect
matching
measuring
mechanism

isolating diaphragm

Pe-Sensor

Main Components
terminal
blocks

housing

push
buttons

secondary
electronics

integral
display

covers

display

covers
transducer

vents
gaskets
flanges

bolts

Functional Specifications
General
Base accuracy: ABB Model 265/266 +/- 0,04%
ABB Model 264 +/- 0,075%
Turn Down: 1/100
Ranges ABB Model 265 Pressure Transmitters:
60mbar - 400mbar - 2500mbar - 10bar - 30bar - 100bar
600bar
Ranges ABB Model 265 dP Transmitters:
10mbar - 60mbar - 400mbar 2500mbar - 20bar 100bar

Level Measurement
Different mounting positions?
open to atmosphere

P = S.g.h

________
Dead zone

Open tank liquid measurement

Level Closed Tank

If the level to be maeasured is in
a closed tank, a dp transmitter
is necessary.
N2

max. level

Dry Leg
h1

S = 0?

min. level
Wet Leg
h2

transmitter
reference line
4 mA = S . g . h2
20 mA = S . g . (h2 + h1)
S = specific gravity (medium)

Level Closed Tank

If the level to be maeasured is in
a closed tank, a dp transmitter
is necessary.

max. level

Wet Leg
h1

h4

S1

min. level
Wet Leg
h2

transmitter
reference line
4 mA = S1 . g . h2 S2 . g . h4
20 mA = S1 . g (h1 + h2) S2 . g . h4
S1 = specific gravity (medium)
S2 = specific gravity (Wet leg)

Glycol
S2

Level Closed Tank

If condensable vapours are present use the
following installation.

filling tee

0
max. level
h1

min. level

transmitter
reference line

h2

transmitter
reference line
4 mA = S1 . g . h2 S2 . g . h4
20 mA = S1 . g (h1 + h2) S2 . g . h4
S1 = specific gravity (medium)
S2 = specific gravity (Wet leg)

S1

impuls line
filled with
stable fluid
(Wet Leg)
S2

h4

Boiler-Level Measuement
Ordering data: dp transmitter with adjusted value of 300mm ... +300 mm (WC)
Actual requirement:

boiler level measurement

level to be monitored: -300 mm ... +300 mm

Distance between connection pipes: h = 1000mm

hlow (hlow) = 200mm

hhigh (hhigh) = 800mm
NN

hhigh

Density steam
Tsteam.: +200 C (Ssteam = 7.9 kg/m3)

+300 mm

hlow

Density water
Tuper.: +200 C (Sup= 865 kg/m3)
Tref.: +30 C (Sref= 996 kg/m3)

- 300 mm

Boiler-Level Measuement
DP Transmitter with an adjusted value of: -300 ... +300 mm (WC)

hl

hh

+300 mm

- 300 mm

P1 (-300mm)

= (-h* Sref * g + hl * Super. * g + [h-hl] * Ssteam * g) * 102 =

= (-1 * 996 * 9.81 + 0.2 * 865 * 9.81 + 0.8 * 7.9 * 9.81) * 102 = -80.1 mbar

P2 (+300mm)

= (-h* Sref * g + hh * Super. * g + [h-hh] * Ssteam * g) * 102 =

= (-1 * 996 * 9.81 + 0.8 * 865 * 9.81 + 0.2 * 7.9 * 9.81) * 102 = -29.7 mbar

Adjusted value: -80.1 ... -29.7 mbar

Remote Seals
Protect Transmitters from
High temperature
Corrosive components

Media with high viscosities

Media with tendency to

polymerization

Useful for
Prevention of deposits in the
process Connection

Adaptation to various process

connections

Level Open Tank

e.g.: a seal transmitter
flange mounted on the
high pressure side of the
transmitter is
recommended in case of
dirty liquid fluid or process
temperature > 107 C

transmitter
reference line

P=S.g.h

Level Closed Tank

N2

max. level

h1

e.g.: a seal transmitter

flange mounted on the
high pressure side of the
transmitter is
recommended in case of
dirty liquid fluid or process
temperature > 107 C

min. level

h2

min. level may not

be below this line

transmitter
reference line

Level Closed Tank

low side seal
reference line
Sg

filled
capillary

max. level

h1

h4

Sc
min. level

h2

S
h3

high side seal

reference line

4 mA = S . g . h2 + Sg . G .(h4-h2) Sc . g . h4
20 mA = S . g . (h1 + h2) Sc . g . h4
S
Sg
Sc

= specific gravity (medium)

= specific gravity (gas above fluid)
= specific gravity (filling oil capillary tube)

transmitter
reference line

Level Transmitter 265D

Compact Version

Remote Seals Design

..... with Flush or Extended Diaphragm in Flange design
DN 25

Pressure Rating PN 10...PN 250

DN 50 / DN 80 Pressure Rating PN 16...PN 100

DN 1

Pressure Rating 150 psi...1500 psi

DN 2 / DN 3

Pressure Rating 150 psi...600 psi

Remote Seals
.... via Capillary Tube to Transmitter

Remote Seals Design

.... with Flush or Extended Diaphragm in Sandwich Design

DN 50 / DN 80

Pressure Rating up to PN 400

DN 2 / DN 3

Pressure Rating up to 2500 psi

Remote Seals Design

Corrosion Resistant Materials
Stainless Steel

Hastelloy C
Monel 400
Tantal
FEP coated
Gold plated
Ect

Capillary tube stainless steel, with

PVC protective cover as an option

Remote Seals Design

Filling liquids depending on the
application
Silicon Oil

as Standard

Carbon Fluoride

for Oxygen Service

White Oil

for Food and Beverage

High Temperature Oil

up to 400 C

Vacuum proof design with special liquid for use down to an

absolute pressure of 5 mbar abs.
ABB is a recognized leader in the all welded technology where Remote
Seals System can be welded at every junction.

Application Limits

Filling Liquid

Id
20C (68F)

Silicone Oil

Pressure rating in mbar abs.

100C (212F) 150C (302F) 200C (392F) 250C (482F) 400C (752F)

IC

> 500

> 500

> 500

> 750

> 1000

---

> 1000

> 1000

> 1000

---

---

---

IH

> 500

> 500

> 500

> 750

> 1000

> 1000

White Oil

WB

> 500

> 1000

> 1000

> 1000

> 1000

---

Vacuumproof
Design

IC-V

>5

> 25

> 38

> 50

---

---

Carbon
Fluoride
High-temperature
Oil

Application Limits

Seals Design Performance

Accuracy is primarily affected by
Fill volume change due to temperature
Capillary length
Diaphragm stiffness

Low fill volume and low stiffness of diaphragm is

required for high accuracy

Questionaire

Questionaire for P-/DP-Transm. with remote seals

Level Measurement

dP

air supply
regulator

Bubble measurement

Liquid Level (example oil on water)

S2
S3
range of
interface level

h
interface level
S1
LT

S1 = H2O
S2 = oil
4 mA =
20 mA =

S2 . 9,81 . h
S1 . 9,81 . h

(only oil)
(only H2O)

(simplified illustration; without the influence of capillary tube S3)

Interface level measurement

Density

S1 = low specific gravity

S2 = higher specific gravity
S3 = specific gravity of filling oil in capillary tube

4 mA =

(S1 . h S3 . h) . 9.81

20 mA =

(h * SG2 h * SG3) * 9.81

Density measurement

output
(volume)

Level measuement in a spheric tank

v = 1/3 pi * h2 (3r h)

input (level = h)

Input [%]
(Level = h)

Ouput [%]
(Volume)

0.00
3.75
7.75
11.75
16.75
22.00
28.00
35.25
45.75
55.00
65.00
72.25
78.50
83.75
88.25
92.50
96.25
100.00

0.00
0.41
1.71
3.82
7.48
12.39
19.13
28.52
43.64
57.48
71.82
81.17
88.12
92.94
96.18
98.40
99.59
100.00

Level measuement - warning

Pressure (vacuum)
Temperature
Medium
Foam
Agitator
Flow inlet

Intelligent Transmitters

Conventional
1965

HART
1987

4 ... 20 mA

A
E

4 ... 20 mA + superimposed,
digital communication

A
E+#

FSK-Modem

Fieldbus
1985/95/97/99

A
#

Intelligent Transmitters

Functionality

Fieldbus
More values
Multi variabel
High resolution
Diagnostic data
Quality signal
Status
Decentral Functions
Distributed Control
Bi-directional
Asset Optimization
Graphics

HART
Traditional
Value
Device
Parameter

Value

Time
4-20mA

SMART

Fieldbus

Intelligent Transmitters
Value (measuring)
Status
Scaling
Filter time
Alarm / warn limits
Alarm summary
TAG

Cyclic
services
(Analog value)

Acyclic
services
(Hart)

Device diagnostic

Spontaneous
services

Manufacture
specific
parameter

Acyclic
services

Intelligent Transmitters
Analog Technology

Bus Technology

-400 mbar

4 mA

Floating Point 32 bit

0 mbar

20 mA

Sensor range limits

200 mbar

Basic range value

400 mbar

Communication mode: Point-to-Point

2600T

e.g. power
supply
FSK modem

US > 10.5 ... 45 V DC (HART)

R > 250 Ohms

Communication mode: FSK Bus

2600T

TZN 128
e.g. power
supply
FSK modem

TZN 128

FSK modem

SmartVision

SmartVision

SmartVision

Communication Requirements
Connecting cable
Communication between transmitter and PC/laptop requires

shielded and twisted pair lines.

The minimum wire diameter should be:
- 0.51 mm for lines up to 1500 m

- 0.81 mm for lines longer than 1500 m

The maximum line length is limited to:
- 3000 m for twin-core cable
- 1500 m for multicore cable

Electrical Safety - Explosion Protection

The areas where this can occur are classified depending upon the
probability that gas/vapour, in dangerous combination with air, is
present.
In Europe and some part of the world, except the American continent,
the classification is as follows, according to IEC Publication 79-10:
ZONE 0: an area in which an explosive gas-air mixture is present
continuously or for long periods.
ZONE 1: an area in which an explosive gas-air mixture is likely to occur
in normal operation.
ZONE 2: an area in which an explosive gas-air mixture is not likely to
occur in normal operation, and if it occurs, it will exist only for a short
time.

Electrical Safety - Explosion Protection

In North America, the classification refers to only two divisions, which
may be briefly defined as follows, according to NEC article 500:
Division 1: hazard may be present in normal operation.

Division 2: hazard may be present only in abnormal

operation.
Therefore the following rough equivalence apply:
CONTINUOUS
HAZARD
(> 100 h / y)
EUROPE (IEC)

North America *

INTERMITTENT
HAZARD
(1 - 100 h / y)

ZONE 0

ZONE 1

DIVISION 1

ABNORMAL
CONDITIONS
(0.01 - 1 h / y)
ZONE 2

DIVISION 1

*Note: The Zone classification like IEC is now possible also for North America
according to article 505 of the NEC/Edition 1996, ANSI/NFPA70

Electrical Safety - Explosion Protection

The various gases/vapours are grouped considering their "likeness" in terms of
ignition energy.
Each group has a "representative gas". Representative gases and relevant minimum
ignition energy (microjouls) are shown here below:
Representative Gas

IEC / CENELEC
(EUROPE)

NORTH AMERICA

Minimum Ignition
Energy [micro joules]

Acetylene

II C

Class I Group A

20 J

Hydrogen

II C

Class I Group B

20 J

Ethylene

II B

Class I Group C

60 J

Propane

II A

Class I Group D

180 J

Note: according to IEC classification II means surface industries

(as an alternative to mining atmosphere)

Electrical Safety - Explosion Protection

The temperature classification relates to the maximum attainable temperature
of the transmitter, or part of it (normally assuming a 40 C ambient), to the
ignition temperature of a gas / vapour.
Max. Temp.
[ C]

North America

Max. Temp.
[ C]

IEC/CENELEC
(EUROPE)

200

T3

450

T1

180

T3A

300

T2

200

T3

135

T4

100

T5

85

T6

165
160

135

T3B
T3C

T4