Buoyancy Training

Presentation 90 min

Training Team FOXBORO Field Devices, 2018

Presented by: Oliver Niederheiser, Global Trainer

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Buoyancy Training subjects

• Level Measurement - General

• Buoyancy Principles
• Application
• Foxboro Buoyancy Technology
• Foxboro Buoyancy Portfolio
• Tools
• Summary
• Q&A

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Level measurement general
What is this measurement about?

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Level measurement general
What do we measure?

• Level measurement
– Level: It is the height from the bottom of the tank to the surface of the Distance
liquid (Tank height - Distance) in %, m, cm, mm, in, ft., …
– Distance: It is the distance from the face of the flange (or thread stop)
to the surface of the liquid in %, m, cm, mm, in, ft., … Level

• Volume or Mass measurement

– Conversion (by known density) to Volume or Mass: Provide the volume
or mass of the tank contents in m3, L, gal, ft3, kg, t, …
– Ullage conversion to Volume or Mass: Provide the empty volume or Ullage

remaining mass that can be put in the tank in m3, L, gal, ft3, kg, t, …
Volume/
Mass

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Level measurement general
What kind of measurements?

• Continuous level measurement Continuous level

measurement
– Continuous level sensors measure level within a specified range and determine
the exact amount of substance in a certain place.
This is most often used for process control or any application when absolute
precision and accuracy is of crucial importance.

• Point level detection “Switch”

– Point level sensors are devices that detect variation in levels based on the
presence or absence of media at various points in a vessel or tank.
Point level
Most often, the function of point level sensors are high level or low level alarms,
detection
spill-prevention sensors or as pump control components.

• Custody Transfer
– Custody transfer in fluid measurement is defined as a metering point (location)
where the fluid is being measured for sale from one party to another. During
custody transfer, accuracy is of great importance to both the company delivering
the material and the eventual recipient, when transferring a material. Custody
transfer is mainly used with flow measurement in oil & gas industry.
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Level measurement general
Measurable Media

• Solids
– Solids stored in a vessel do not have a flat, horizontal surface like virtually all liquids. The
shape of the surface, can vary with filling, discharging, the location of filling and discharging,
angled or multiple fill points, multiple draw points, etc. This can have a major impact on
selecting a technology to measure how much material resides in the vessel at any given time.
• Liquids
– There are many physical and application variables that affect the selection of the liquid level
measurement method. The selection criteria include: Temperature, pressure, chemistry,
density, viscosity, material properties, … . Selection of an appropriate type of sensor suiting to
the application requirement is very important.
• 2-phase liquid Interface
– Compared to standard level measurements in liquids, the detection and measurement of
liquid/liquid interfaces has its own particular challenges. Ideally, an interface would be a clear
separation between two media with different densities. Practically, a transition or emulsion
layer often exists between the two media and make the interface measurement much more
difficult.
• Gas
– Normally there is no level measurement of gases.
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 Liquid Level measurement general
(Non-)Contact Technologies (12)

Free-Space Ultrasonic Laser Detector Gamma Ray Load Cell Hydrostatic

Radar
Non-Contact

Guided Wave Buoyancy Floats Magnetostrictive Capacitance Air Bubbler

Radar
Contact

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Liquid Interface measurement general
Interface measurement Technologies (4)

Gamma Ray Guided Wave

Radar

V2 ρ2

Buoyancy Float &

Magnetostrictive

V1 ρ1

2-phase (liquid/liquid)
Interface

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Level measurement general
Technology comparison
Advantage Disadvantage Affected by
• Low priced • Dependent on media density • Density
Hydrostatic • Wide measurement range • Mounting position
Gauge / Differential Pressure • Independent of obstacles • Contact measurement

• Mounting position • Obstacles • Dielectricity

Radar • Independent of media
Free-Space Radar & • Wide measurement range
Guided Wave Radar
• Density measurement
Buoyancy • Very robust
• High Temp. / High Pressure
• Dead Zone
• Non-linearity Zone
• Dependent on media • Density
• Limited measurement range

• Top/Bottom mounting • Viscosity • Density

Floats • Overfill proof • Limited measurement range
incl. Magnetoresistive & resistive chain • Dependent on media
• Moving parts/maintenance

• Independent of media • Obstacles • Temperature

Ultrasonic • Mounting position • Limited measurement range • Noise
• Non-contact measurement • No Interface measurement
• Low priced • Foam, dust, turbulences

• Non-contact measurement • High priced • Temperature

Load cell • High Temp. / High Pressure • High calibration costs • Density
• Independent of obstacles • Limited mounting possibility • Vibrations
• High commissioning costs

• Low priced • Dependent on media • Dielectricity

Capacitance • Top/Bottom mounting • Limited measurement range • Conductivity
• Adhesion • Temperature

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Level measurement general
Temperature comparison

500
450
400
350
300
250 T max (°C)
200
150
100
50
0
1 2 3 4 5 6

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Level measurement general
Pressure comparison

500
450
400
350
300
250 p max (bar)
200
150
100
50
0
1 2 3 4 5 6

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Level measurement general
Pressure / temperature rating

Pressure (bar)
Example, I’m looking for: 40 bar (580 psi) at 100°C (212 °F)

Competitor devices provides:

• Process pressure from 0 to 41,4 bar (full vacuum to 600 psi)
• Process temperatures from -73 to +204 °C (-100 to +400 °F)

That do not necessarily to mean:

41,4 bar (600 psi at 400 °F) at 204 °C !
or even 40 bar (580 psi) at 100°C (212 °F)

Temperature (°C)
In this case:
At needed temperature: 35,5 bar (515 psi) @ 100°C (212 °F)
At needed pressure: 55 °C (104 °F) @ 40 bar (580 psi)
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Buoyancy
Principle

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Buoyancy Principle
History

History:

A crown had been made for King Hiero II, who had supplied the pure gold to
be used and Archimedes was asked to determine whether some silver had
been substituted.
Archimedes had to solve the problem without damaging the crown, so he
could not melt it down into a regularly shaped body in order to calculate its
density.
While taking a bath, he noticed that the level of the water in the tub rose as
he got in and realized that this effect could be used to determine the volume
of the crown.
So the submerged crown would displace an amount of water equal to its
own volume. By dividing the mass of the crown by the volume of water
displaced, the density of the crown could be obtained.
This density would be lower than that of gold if cheaper and less dense
metals had been added.
Archimedes then took to the streets naked, so excited by his discovery that
he had forgotten to dress, crying "Eureka!" (Greek meaning "I have found
it!"). The test was conducted successfully, proving that silver had indeed
been mixed in.

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Buoyancy Principle
Buoyancy Principle

“Any object, wholly or partially immersed in a fluid, is buoyed up by a force

equal to the weight of the fluid displaced by the object.”

Higher density (more mass per volume) =

More Buoyancy force

Smaller object (less displaced volume) =

Lower Buoyancy force

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Buoyancy Principle
Buoyancy Principle

“Any object, wholly or partially immersed in a fluid,

is buoyed up by a force equal to the weight of the fluid
displaced by the object.”
- Archimedes of Syracuse -
(287 B.C. - 212 B.C.)

Highest force on the sensor: Lowest force on the sensor:

0% Level 100% Level Mass = Volume * Density

Force = Mass * Gravity

20N 0N 20N 20N 4N 16N 20N 9N 11N 20N 14N 6N 20N 18N 2N

Force = Volume * Density * Gravity

1,8 l

2,0 kg

Weight force of the displacer / Buoyancy force / total force

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Buoyancy Principle
Level measurement

• Buoyancy measurements systems detect the level of liquids

• The liquid can be measured directly inside a vessel or in a side cage
• Buoyancy level sensors measure level within a specified range
• No measurement of level and interface at the same time!

244LD 244LVP 244LD 244LVP

Level measurement direct in a vessel Level measurement in a side cage

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Buoyancy Principle
Interface measurement

• Buoyancy measurements systems detect the Interface of liquids

• The liquids can be measured directly inside a vessel or in a side cage
• Buoyancy level sensors measure Interface within a specified range
• Displacer need to submersed completely and the density difference >300 (>50) kg/m³

244LD 244LVP 244LD 244LVP

Interface measurement direct in a vessel Interface measurement in a side cage

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Buoyancy Principle
Interface vs. Emulsion Layer

An interface is a surface, forming a clear boundary

among two different phases,
such as two immiscible liquids.

Level of Interface

An emulsion is a mixture of two liquids

which are normally immiscible.
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Buoyancy Principle
Density measurement

• Buoyancy measurements systems detect the density of liquids

• The liquid can be measured directly inside a vessel or in a side cage
• Buoyancy level sensors measure density within a specified range
• Displacer need to submersed completely and the density range need to be know

244LD 244LVP 244LD 244LVP

Density measurement direct in a vessel Density measurement in a side cage

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Buoyancy Principle
Density measurement

The density of a substance is its mass per unit volume

The symbol for density is ρ (rho)
mathematically, density is defined as:
mass divided by volume (kg/m³)

m = 2,5 kg Density of liquids (kg/m³):

𝒎 Fuel 750
ρ =
𝑽 Diesel 830
V= 0.001 m³

ρ = Density Water (fresh) 1000

m = Displacer mass
V = Displacer Volume Water (salt) 1030
Sulfuric Acid 1834
Mercury 13595

Density Displacer = 2500 kg/m³ Air 1.2

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Buoyancy Principle
Density measurement

Dead Sea ρ=1240 kg/m³

ρDisplacer > ρMedia ρDisplacer = ρMedia ρDisplacer < ρMedia
=> sinking => neutral buoyancy => floating
ρDisplacer > ρMedia ρDisplacer ≤ ρMedia
The density of the displacer
MUST be greater
than the density of the fluid !

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Buoyancy
Example: Separator Application

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Buoyancy application
Oil/Water Separator

The Oil/Water Separator is a gravity separation

device designed to separate oil, water and solids
based on their specific gravity.

Based on that design criterion, most of the

suspended solids will settle to the bottom of the
separator as a sediment layer, the oil will rise to
top of the separator, and the wastewater will be
the middle layer between the oil on top and the solids on the bottom.

Typically, the oil layer is skimmed off and re-processed, the bottom sediment layer is removed
and the water layer is sent to further treatment.

Typical customers for liquid-liquid-separation are chemical and Oil & Gas companies,
if the throughput is too big for a batch system.

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Buoyancy
Foxboro Technology

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Foxboro Buoyancy Technology
Top mounted 244LVP

Top mounted

Sensor

Displacer

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Foxboro Buoyancy Technology
Sandwich mounted 244LD and 167LP

Sandwich mounted
Main components 244LD:

150 Displacer with suspension chain

133 Transmission lever

134 Torque tube

121 Sensor

Torque Tube

Sensor

Displacer
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Foxboro Buoyancy Technology
Force measuring sensor

= 0,065 mm

Wheatstone Bridge

Force
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Foxboro Buoyancy Technology
Level measurement

Level:

Mass Displacer – Mass Displacer immersed

Volume Displacer * ρ Media

1.998 kg 1.872 kg 1.613 kg

1.998 - 1.872 21.64%

0.000677 * 860

1.998 - 1.613 66.13%

0.000677 * 860
Displacer Volume : 677cm³ = 0.000677m³
ρ Media : 860 kg/m³
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Foxboro Buoyancy Technology
Interface measurement

Buoyancy = V *ρ* g

Buoyancy = (V1*ρ1 + V2*ρ2) * g

V2 ρ2 Level =

Mass Displacer – Mass Displacer immersed

Volume Displacer * ρ Media
V1 ρ1

Interface measurement only

Interface =
when displacer is 100%
submerged ! Mass Displacer – Mass Displacer immersed
(Volume1 * ρ1 + Volume2 * ρ2)

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Foxboro Buoyancy Technology
Density measurement

Level = ρ Media =
Mass Displacer – Mass Displacer immersed Mass Displacer – Mass Displacer immersed
Volume Displacer * ρ Media Volume Displacer * Level

ρ Media = 1.998 - 1.358 0.640 945.35 kg/m³

0.000677 * 1 0.000677

1.998 kg 1.613 kg 1.358 kg Density measurement only when displacer is 100%

submerged !

Displacer Volume : 677cm³ = 0.000677m³

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Foxboro Buoyancy Technology
Unique Autorange Mode

In case of process changes: No recalibration, no manual adjustments, …

Just change the displacer or media data and everything else is done automatically.

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Foxboro Buoyancy Technology
244LD/LVP Verification

How we do a traceable verification

for our buoyancy device?
• Locally
At max. level
• Cheap
min. force ~ 5 N
5N ~ 0,5 kg • Fast

We know that:
Force = Mass * Gravity

At min. level
max. force ~ 25 N
25 N ~ 2,5 kg
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Foxboro Buoyancy Technology
Filter & Smart Smoothing

Time averaging filter

To smoothen the current output, filter with adjustable time interval
can be switched on/off.
When there is a jump at the input (100 %), the output level is at 63 % after the time
interval (e.g.: 8 s) has been reached.
The time interval can be set from 0 to 32 sec.
If the time interval is set to 0 sec, the current output follows the input.

Smart Smoothing
In factory the Smart Smoothing Band is set to 2 % of sensor range.
The Integration Time of the average value is set to 10 sec.

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Foxboro Buoyancy Technology
Smart Smoothing vs. damping

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 State-of-the-art Technology: Foxboro Eckardt LevelStar
The only buoyancy measurement without moving parts
Moving Parts could fail !

Foxboro Eckardt:
NO Moving Parts Gap <0.03mm = <0.001 inch
Wheatstone Bridge

Measuring
- cell
Displacer
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Buoyancy
Portfolio

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Foxboro Buoyancy Portfolio
LevelStar comparison

• Measuring range up to 10 (50) m

bar / psi
• HART 7 & Foundation Fieldbus
500 / 7250
• ATEX, IECEx, FM, EAC Certified

!!! LevelStar USP !!! • SIL2 (up to 5 yr. proof-test interval)

400 / 5800
• Long durability
350 / 5080
• Requires virtually no maintenance
300 / 4350 244LD
250 / 3600
• Rugged and extremely reliable
• Handles difficult process media
200 / 2900 167LP
150 / 2175

100 / 1450
244LVP
40 / 580

100 / 150 / 200 / 300 / 350 / 400 / 500 / °C / °F

212 302 392 572 662 752 932

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Foxboro Buoyancy Portfolio
Transmitter Comparison

Product 244LD LevelStar 244LVP LevelStar 167LP

High Temperature / High Enhanced Pneumatic
Pressure
Version Sandwich Direct Sandwich
Size DN (70) / 80 / 100 DN (50) / 80 / 100 DN (70) / 80 / 100
ANSI 3” / 4” ANSI 3” / 4” ANSI 3” / 4”
Pressure Full vacuum up to Full vacuum up to Full vacuum up to
500 bar / Cl 2500 PN 150 / Cl 900 250 bar
Temperature -196 to 500 °C -50 to 150 °C -196 to 500 °C

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Foxboro Buoyancy Portfolio
244LD LevelStar temperature curve

244LD Levelstar evaluation of process heat travel

Max. Process temperature 500°C
Transfer from waver body to electronic module in amplifier
35°C 600°C
34°C

Temperature at waverbody
Temperature at electronic

33°C
32°C 506 500°C
31°C 31
30°C
29°C 400°C
28°C
27°C 300°C
26°C
25°C
24°C 200°C
23°C
22°C
21°C 100°C
20°C
19°C
18°C °C
0 1 2 3 4 5 6 7 8 9 10
Duration [h]
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Foxboro Buoyancy Portfolio
Foxboro 244LD LevelStar

• Right or left hand mounted

• Heating Jacket
• SS and HT/HP version

Available materials:
• Wafer Body: 316L , 321, Duplex, Hastelloy C, Inconel 625, Inconel 825

• Torque Tube: 316L , Hastelloy C, Inconel 600, Monel K500

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Foxboro Buoyancy Portfolio
Transmitter Selections 244LVP LevelStar

• Top mounted
• Available materials:
• Flange: 316Ti

• Sensor 316L

• SS housing version

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Foxboro Buoyancy Portfolio
Transmitter Selections 167LP

• Right or left hand mounted

• Available materials:
• Wafer Body: Carbon Steel, 316L, Hastelloy C

• Torque Tube: 316L , Hastelloy C, Inconel 600, Monel

• Signal range:
• 0,2 - 1,0 bar or

• 3 - 15 psi

• 20 - 100 kPa

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Foxboro Buoyancy Portfolio
Overview Accessories

244LVP
% 0 01
204BCF
204FK

100 %

244LD

204FK
204DE
204DC
DC Displacer Chamber
DE Displacer Element
BCF Blind Cover Flange
FK Flange Kit 204BCF

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Foxboro Buoyancy Portfolio
204DC Displacer Chamber

• Mounting type:
• Side - Side

• Side - Bottom

• Side - Top (not for LVP)

• Top - Bottom (not for LVP)

• Available materials: Carbon Steel, 316L, 316Ti, Duplex,

Hastelloy C, Inconel 625, Inconel 825
• Heating Jacket available
• Optional drain valve and flushing connector

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Foxboro Buoyancy Portfolio
Displacer Element 204DE

• Displacer for
• liquid level (and density) or

• Interface level

• Available materials:
• 316L, 321, PTFE, Hastelloy C, Inconel 625, Monel 400, Titan

• Displacer length = maximum measurement range

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Foxboro Buoyancy Portfolio
Divided displacer 204DE

Displacers with a length of more than 3 m (1 m with PTFE) are divided.

The (metal) displacer elements are screwed together and secured with the
wire clip 151 to avoid bending or damage during insertion into the vessel.
The elements of (metal) displacers with Ø < 13 mm or PTFE are not
screwed together; they are secured with hook and eyelet 152 .
Lengths < 350 mm or > 3000 mm,
and density ranges <100 kg/m³ or >2000 kg/m³ on request.

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Foxboro Buoyancy Portfolio
Damping element for displacer 204DE

In operating conditions with strong external vibrations - e.g. nearby

compressor stations - the damping element should be used.
It is hooked onto the suspension chain of the displacer in place of 7 chain
links (105 mm).
This spring is specially matched to the resonance frequency of the
displacer and is made of

- Stainless Steel 1.4310 (operating temperature up to 250°C / 482°F)

- Hastelloy C (operating temperature up to 350°C / 662°F).

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Foxboro Buoyancy Portfolio
204BCF Blind Cover Flange & 204FK Flange Kit

• 204BCF:
• Available materials: Carbon Steel, 316L, 316Ti, Duplex, Hastelloy C,
Inconel 625, Inconel 825
204FK
• Vent plug available

• 204FK:
• Available materials: Carbon Steel, 316L, 316Ti, Duplex, Hastelloy C,
Inconel 625, Inconel 825

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Buoyancy
Tools

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Buoyancy Tools
Level Competitive Translator

Level Translator for:

• Magnetrol E3 Europe-Version
• Magnetrol E3 US-Version
• Mobrey MLT100
• Fisher 249

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Buoyancy Tools
Displacer Element Sizing – It is no rocket-science!

4 × 𝐹𝐴
𝐷(𝑚𝑚) = 1000
𝜋 × 𝑔 × 𝜌1 − 𝜌2 × 𝐿

D = Outside diameter of displacer in mm

FA = Buoyancy force of displacer in N
• Min 3 N
• Middle 7 N
• Max 15 N
g = Acceleration due to gravity (9.807 m/s²)
ρ1 = Density of heavier liquid in kg/m³
ρ2 = Density of gas or lighter liquid in kg/m³
L = Measuring span in m

Example:
Measuring span L= 1,50 m
ρ1 = 1000 kg/m³
ρ2 = negligible (ρair = 1,2922 kg/m3)
Calculated: D(7N) = 24,6 mm
Confidential Property of Schneider Electric │ Field Devices │Training Page 52
Buoyancy Tools
LevelStar FDT / DTM

• Parameterization

• Online Diagnostics

• Report

• Advanced

• Calibration

• Factory Tool

Confidential Property of Schneider Electric │ Field Devices │Training Page 53

Confidential Property of Schneider Electric │ Field Devices │Training
Confidential Property of Schneider Electric │ Field Devices │Training
Buoyancy Summary
• Multiple measurements • Measuring range up to 10 (50) m
• Level • Long durability
• Interface • Requires virtually no maintenance
• Density • No moving parts
• High Temperature up to 500°C • Rugged and extremely reliable
• High Pressure up to 500 bar • Handles difficult process media
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Devices │Training
Questions?

Confidential Property of Schneider Electric │ Field Devices │Training Page 57

Who do you call?
Foxboro Assistance Center

Center of Excellence
Where to go for help?

Schneider Electric
Field Devices
Technical Assistance Center (TAC)
at Foxboro, MA, USA

By phone: +1 508-549-2424 (UTC -5h) Foxboro TAC

By fax: +1 508-549-4999

By email: fielddevices-support@schneider-electric.com

MENA support center

EMEA support center

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 Thank you

For questions or recommendations

please contact

oliver.niederheiser
@schneider-electric.com

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Field 59
Devices │Training
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