Best Practices

in Process
Level
Measurement
Agenda
 Introduction: Technology
Trends
 Factors Impacting Level
Technology Selection
 Review Level
Technologies
– Theory of Operation
– Advantages
– Limitations
– Applying Best Practices

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Emerson Confidential
27-Jun-01, Slide 2
Diverse Technology Choices Exist for Level
Bubbler

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Emerson Confidential
27-Jun-01, Slide 3
Why You are Measuring Level?
 Maximize Storage Tank Capacity
 Prevent Spills
 Process Blending
 Custody Transfer
 Process Supply
 Indication of Fluid Level
 Leak Detection
 Interface Detection
 Liquid or Solids?

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Emerson Confidential
27-Jun-01, Slide 4
Different technologies make different measurements

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Emerson Confidential
27-Jun-01, Slide 5
Selection of the Right Technology
includes knowledge of:

Technology Installation

Application
Conditions

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Emerson Confidential
27-Jun-01, Slide 7
Application Conditions are a Key
Consideration .…

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Emerson Confidential
27-Jun-01, Slide 8
Installation Considerations Go Beyond the
Connection
Outside the tank
 Location, diameter and length of
nozzles
 Bypass connection
 Valve

Inside the tank

 Fluid flow
 Obstructions, agitators, coils
 Overall dimensions
 Bottom type

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Emerson Confidential
27-Jun-01, Slide 9
Non-Contact Radar Level Gauging
Principle

A) Microwaves transmitted towards the

surface.
B) Microwaves reflected on the surface.
C) Objects such as tank-walls, agitators
and mechanical structures reflects
disturbing echoes.
D) Reflected microwaves are received in
the gauge.
E) Radar electronics and software
process signals and data to establish
a correct level measuring.

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Emerson Confidential
27-Jun-01, Slide 10
Example
Ultrasonic Radar

Devices are set up under hot, dry conditions

20 m Same level, 10 m

Steam enters vapor space

Ultrasonic Radar
Set up at 100 C 0.0259 sec 0.03334 x 10-6
Travel over 10 m
Water vapor (100 C) 0.0247 sec 0.03343 x 10-6
Difference in travel 0.0012 sec 0.00009 x 10-6
time
Error, (based on set 0.046 m (1.8 inches) 0.0027 m (0.1 inches)
up speed of travel)
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Emerson Confidential
27-Jun-01, Slide 12
Non Contacting Radar Has Some
Limitations
• Heavy Foam:
– Poor Signal-to-Noise Ratio
– No Signal Foam

• Mounting Position Must

Be Considered
• Objects in the Radar
Beam May Interfere

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Emerson Confidential
27-Jun-01, Slide 13
 Microwave Frequencies
 Frequency determines the wavelength
 Frequency and antenna size impact Beamwidth
 Different frequencies are good for different applications

6 GHz, 4” 26 GHz, 4”
26 GHz 10 GHz
6 GHz

Beam Beam
width 37° width 9°
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Emerson Confidential
27-Jun-01, Slide 14
Low frequency is less influenced by
6 GHz (C-Band)
 Condensation

 Vapor

 Foam

 Turbulence

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Emerson Confidential
27-Jun-01, Slide 15
High frequency and its more narrow beam width
is best suited for:
26 GHz ( K-Band)
 Narrow tanks

 Tall and narrow nozzles

 Nozzles with Valves

 Vessels with disturbing obstacles

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Emerson Confidential
27-Jun-01, Slide 16
Guided Wave Radar - Principle of Operation

 TDR (Time Domain

Reflectometry)
 Microwave Pulses Guided
Down a Probe
 Dielectric Change Causes
Microwave Reflection
 Distance = Speed X Time of
travel /2

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Emerson Confidential
27-Jun-01, Slide 17
Measurement principle -Level & Interface
 FIRST PULSE
– at top level
 SECOND PULSE
– Part of pulse
continues until
reflected at lower
product surface

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Emerson Confidential
27-Jun-01, Slide 18
Time Domain Plot - Level and Interface
 Interface uses the difference in
dielectric properties
 Independent of density changes
 Dielectric of medium determines
the speed of the microwave
propagation in a product
 Accurate interface level is
dependent on the correct
dielectric value
 Dielectric difference needs to
be about 10
 Low dielectric fluid needs to be
on top.

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Emerson Confidential
27-Jun-01, Slide 19
Three Measurement Variations Are Possible

Level Only
Level and Interface

Interface w/Immersed Probe

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Emerson Confidential
27-Jun-01, Slide 20
Guided Wave Radar has Many of the Same Advantages
as Non-contacting, but Has Others As Well
Non-contacting  Easy swap (small openings)
 Top-down  Solids, powders, granules
 Handles changing density, dielectrics,  Interface
conductivity, temperature, pressure,
pH and viscosity
 Handles a variety of tanks from difficult
geometry to storage vessels
 Virtually unaffected by dust, vapor and
turbulence
 Direct measurement
Can be isolated from process by using
barriers such as Teflon windows or
valves
No moving parts

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Emerson Confidential
27-Jun-01, Slide 21
GWR can offer significant stability over technologies
affected by density, turbulence or other factors

For a 20 inch span, a

density change of 20% can
yield a 4” error. A 0.2
change in SG is common
in many oil separators

Output Signal Plots

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Emerson Confidential
27-Jun-01, Slide 22
Guided Wave Radar has Some
Limitations
 Contacting technology
 Agitators, blades, baffles may
interfere with probe installation
 Foam is unpredictable
 Caution is needed for highly
viscous fluids and heavy
coating
 For interface
measurements,the upper fluid
dielectric needs to be stable

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Emerson Confidential
27-Jun-01, Slide 23
Probe Choices can Impact Success of
Measurement
 Sticky, coating,
crystallizing
products
 Installation
 Fluid movement or
turbulence
 Pull forces in solids
applications

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27-Jun-01, Slide 24
Signal strength and form vary with
probe style

Coaxial

Twin Leads

Single Leads

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Emerson Confidential
27-Jun-01, Slide 25
Heavy coating can lead to bridging

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27-Jun-01, Slide 28
Single lead probes can handle coating

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Emerson Confidential
27-Jun-01, Slide 30
Application: Pump Sump Pit at Refinery
Application:
 Sump pit, separate oil and
water
 Consistent and reliable
measurement needed to
avoid level upsets and
subsequent overflow.
Solution;
 3302 and a 2.35 m long rigid
twin lead probe
 Reliable measurement of
both oil and water layer
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Emerson Confidential
27-Jun-01, Slide 31
 Application Example: Turpentine Storage
 A mixture of water and
turpentine is pumped into
storage tank and separates
 Turpentine is removed from
vessel by pumping water into er = 2.2
the tank to push out turpentine
 Probe is completely immersed;
distance to the water interface
level is measured
 Previous method: visual

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Emerson Confidential
27-Jun-01, Slide 32
Application Example: 3300 and 3051:Interface of High
Dielectric Foam and Liquid

 Black Liquor and Soap mixture

often has up to 10 ft of foam;
overspills were common
 DP measured liquid only; Foam
was measured manually
 Foam has higher dielectric and
is too sticky for a good interface
measurement with GWR
 Radar measures top of foam
 Foam height – liquid height =
interface of foam and liquid

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Emerson Confidential
27-Jun-01, Slide 33
 DP Level Theory of Operation: Simple
and Well Understood
 Level in a tank is proportional to
the head pressure exerted by the
process fluid
 Changes in working pressure of
tank accommodated by referencing
low pressure side of DP to head
space of tank
 ‘Remote Seals’ often used on level
measurements to handle severe
operating conditions or special
process connection needs

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Emerson Confidential
27-Jun-01, Slide 34
Pressure Has Many Advantages as a
Level device
 Reliable, Simple, Well Understood
 Flexible Uses:
– Level, density, interface, mass
 Unaffected by Agitation or Foam
 Unaffected by internal tank equipment
 No moving parts
 Diaphragm Seals extend limitations due to
process conditions such as:
– High Temperatures
– Corrosive processes
– Dirty or Viscous mediums
– Sanitary Connections

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Emerson Confidential
27-Jun-01, Slide 35
 Pressure Has Some Limitations
 Often requires 2 taps
 Variable density creates errors
 Temperatures beyond 660 F/ 350 C
 High vacuum applications are tricky
 Highly corrosive processes limit life
 Abrasive processes can damage diaphragms
 Liquids Only

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Emerson Confidential
27-Jun-01, Slide 36
Questions?

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Emerson Confidential
27-Jun-01, Slide 37