Level Measuring Instruments Selection and Appl,ication

REVISION 1 APPROVAL HISTORY

A 09- 12-2009 Draft in development DKL HVS HVS

Rev Date Description of Change Originator Reviewer Approver

Records of approval are retained in the BMSIQuality Department
I Document Number I Document Title 1 Revision I. .
I I Level Measur'

CONTENTS

1.0 PURPOSE ..........................................................................................4

2.0 SCOPE ..........................................................................................4
3.0 DEFINITIONS /Acronyms ......................................................................4
4.0 REFERENCES ..................................................................................4
4.1 Literatures .....................................................................................
4
4.2 Codes and Standards ......................................................................... 6

5.0 RESPONSIBILITY & AUTHORITY ............................................................... 6

6.0 DESCRIPTION .....................................................................................6
6.1 Principles .......................................................................................6
6.2 Application and selection criteria. installation..........................................7
6.3 Level sketches................................................................................. 9
6.4 Other considerations in level sketches...................................................II
6.5 Floating roof tanks...........................................................................13
6.5.1 Applications and selection of instruments .........................................14
6.5.2 Float operated level instruments....................................................14
6.5.3 Auto tank gauges...................................................................... -14
6.5.4 Magnetic level gauges................................................................-15
6.5.5 Level gauge board..................................................................... -17
6.6 Displacer operated level instruments .....................................................
20
A torque tube type displacer level instrument ................................................. 20
A spring operated displacer level instrument ...................................................20
6.7 Servo operated level transmitter .........................................................
-23
6.8 Radar operated level transmitters, transit time type (also called TDR-time
domain reflectometry) ............................................................................. -25
6.8.1 Non-contact type ...................................................................... -25
6.8.2 Contact type (Guided wave) Radar level sensors.................................27
6.9 Ultrasonic level transmitters, transit time type ........................................30
6.10 Capacitance type level sensors .........................................................
30
6.10.1 Calibration in field..................................................................... 32
6.11 Level measurement by D-P transmitters .............................................-32
6.1 1.1 Simple D-P transmitters ...............................................................33
6.1 1.2 D-P transmitters with flush diaphragms............................................34
6.1 1.3 D-P transmitters with remote seal diaphragms....................................35
6.1 1.4 D-P transmitters with extended diaphragm seal..................................35
6.1 1.5 Interface level measurement ht iw D-P transmitters ..............................35
6.1 1.6 Following are the key points to be remembered while specifying a D-P type
LT . 36
6.12 Hydrostatic level measurements.......................................................37
6.12.1 Submersible type...................................................................... -37
6.12.2 Applications ............................................................................ -38
6.12.3 External type ........................................................................... -38
6.1 3 Nucleonic Gauges1 Radio active sensors..............................................38
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Document Number

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I
Level Measuring Instruments Selection and
Application A
1 Petrofac EI) I A&

6.13.1 Source ...................................................................................-39

6.13.2 Radiation Safety ........................................................................ 39
6.13.3 Detectors ...............................................................................-39
6.13.4 Applications ............................................................................ -40
6.14 Level Gauge ...............................................................................- 4 0
6.15 Performance .............................................................................. -44

7.0 Work Process and Area of Attention ...................................................... 50

7.1 Work Process ................................................................................-50
7.2 Area of Attention ............................................................................52

8.0 RECORDS ........................................................................................52

9.0 APPENDICES .................................................................................... 52

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Document Number Document Title Revision
Level Measuring Instruments Selection and
SHJ-BMS-XX-GDE-X-XXXX ADDlication A

The purpose of this design guide is to outline minimum requirements that need to be
considered for the selection of level instruments, developing the specification and
associated engineering, evaluating the product i.e. supplier's offers for EPC onshore oil &
gas projects. A typical content list is presented in this document. Detailed description of
each section is not provided in this document. Document in reference list shou1.d be
referred as a detailed guide on relevant sections of the Philosophy.

2.0 SCOPE

This design guide applies to all Petrofac onshore oil & gas projects where level instruments
are used in the utility, process and off-site plants. Selection criteria, interface and
installation engineering are covered here. Special applications of level instruments
including tank gauging are also explained. This design guide is to be adopted for EPC
projects in absence of any project specific philosophy. The recommended contents of this
document may be suitably modified as per project requirement.

3.0 DEFINITIONS /ACRONYMS

LVDT Linear voltage differential transducer

LT Level Transmitter
C-C Centre to centre
DP Differential pressure
DCS Distributed Control System
ESD Emergency shutdown system
MMI Man machine interface
OD Outside diameter
ID Inside diameter
GA General Arrangement
HP High pressure port
LP Low pressure port

4.0 REFERENCES

This design guide has been constructed by referencing Petrofac's experience on various
projects as well as the application notes, procedures recommended by the leading
manufacturers and proven at various projects executed.

4.1 Literatures

Followings are some of the useful publications which may be referred.

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SHJ-BMS-XX-GDE-X-XXXX Application A

I Fisher Product Bulletin, Level lnstruments

http: / /www.documentation.emersonprocess.com/~ublic/documents/bulletins/dlO
3219x012.pdf

Magnetrol Products, Level lnstruments

http: / /www.directindustrv.com/prod /maqnetrol/displacer-level-transmitter-6020-
1 104016.html

Masoneilan, Level transmitters, Displacer type

http: / Iwww. hartcommproduct.com /inventory/pdf/masoneilan/cu3000e.pdf

I Tokyo Keiso, Technical Guidance

http: //www.tokvokeiso.co.ip/enqlish/products/download/tq/FS SERIES TG-L541E.pdf

Varec, Servo Level Gauge

http: //www.varec.com/docs/discontinued /6500/Mode1%206500%2OServo.pdf

Interface level measurement

http: //www.processonline.com.au/articles/32255-lnterface-level-detection-what-to-
consider#

I Radar Level Gauges by ABLE

http: 1/www.able.co.uk/downloads/radar%2Oleve1%20qau~e.pdf

Radiation based level gauges

h t t ~/:/www.omeqa.com/literature/transactions/volume4/T9904-14-RAD. html

Enraf, Radar Gauges

http: //pdf.directindustrv.com/pdf/enraf/enraf-radar-qauqe-7333-17363. html

Vega, Radar level sensors

http: 1/www.directindustrv.com /prod/veqa/quided-wave-radar-level-sensor-~r-9136-
34194. html

Eclipse Guided Wave Radar by Magnetrol

http: //literature.ma~netrol.com/l/tech/product/57-l00.pdf

Capacitance type level measurement

http: //www.omeqa.com/GREEN/pdf/CAP LEV MEAS. pdf

Submersible level sensors

http: / /switches-indicators-qauqes.seotechnoloqies.com.au/ taql level-sensor1

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SHJ-BMS-XX-GDE-X-XXXX Aaalication A

Hydrostatic Tank Gauging

http: //www.mht-
technoloev.co.uk/Aviation/products/cateqon//aviation hydrostatic tank ~augine/

4.2 Codes and Standards

Shell DEP32.31.00.32 - Manual lnstruments for Measurement and Control, Level

lnstruments

API RP 551 RP 551 - Process Measurement, Instrumentation, Section 3

5.0 RESPONSIBILITY & AUTHORITY

(Key responsibilities of involved parties are listed here and appropriate levels of authority
stated.]

6.0 DESCRIPTION

A brief and structured guide line is presented below focusing on the principles and
applications for level measuring devices.

Though the P&lDs or other documents provided as part of the FEED or during detail
engineering generally indicate the type of instruments s t i l l it is necessary to verify the
type even in case of an existing specification provided as part of the contract documents.

Since these level instruments are mounted on Mechanical equipment which are finalized
during early phase of detail engineering the engineering activity requires very close
coordination with Process, Mechanical and Piping group.

6.1 Principles

Following are the type of level sensing principle generally in use in the projects:

(i) Sensing by float. A float moves up and down along with the level and thus
represents the level or height of a liquid.

Type of level instruments: (a) Magnetic Level gauge.

(b) Auto tank gauges (Float and tape type level indicators)
(c) Float operated Level switches

(ii) Sensing by displacer. A partially submerged displacer Loses weight in proportion to

the extent of submersion. Thus variation of Level is proportional to the change of
level.

Type of level instruments: (a) Displacer operated level transmitters.

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Application A
Petrofac
(b) Servo operated tank gauges.
(c) Displacer operated Level switches.

(iii) Sensing by pressure. The head or pressure exerted by a liquid is proportional to i t s

height or level. Differential pressure transmitters are used in this kind of
measurement.

Type of level sensors/transmitters :(a) Diaphragm sensing differential pressure

transmitters.

(iv) Sensing by change of electrical characteristics.

(a) A partially submerged resistor will have i t s resistance varying.with the level change
of a liquid i f the liquid i s electrically conductive since the portion submerged in
liquid will shorted by the conductive liquid.

(b) A partially submerged capacitor will change i t s capacitance with change of level as
the vapour space and liquid space having different dielectric values change with
liquid level.

(v) Sensing by transit time of wave. Ultrasonic transducers use sound wave and Radar
transducers use electromagnetic wave. The wave emanates from the transducer
(which contains both the source and detector)) and is reflected from the level of
liquid. Lower the liquid level the more time i s taken by the reflected wave to
reach back at the detector. This kind of measurement can be non-contact type as
well as contact (with liquid) type.

(vi) Sensing by radioactive method. Radiation i s absorbed more by liquid and less by
the vapour. This i s used for detection of level. Usually the radioactive transducers
and detectors are installed on the external surface of the equipment and not
required to be installed inside.

(vii) Sensing by weight (by load cells).

(viii) Viewing level through transparent 1 refractive medium like glass, called Level
Gauge Glass.

6.2 Application, Selection Criteria and Installation

Followings are the brief application types.

(i) Detection of level in process equipment which sees a dynamic process, for example
a two phase or three phase Separator or a flash vessel. In such applications level

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Selection and
A

needs to be detected with fast response and continuously to allow online

monitoring and control of the level i n the equipment.
Typical instruments used are:

a) Level Transmitters based on sensing liquid head measurement, DP type

b) Radar type Level Transmitters (contact and non-contact type and guided wave
type)
c) Displacer type Level Transmitters.
d) Nucleonic gauges (Sometimes used in Separators)

(ii) Measurement of level in a storage tank. In such applications Level measurement is

required to maintain inventory. Tank gauging is a more elaborate storage
application where the materials stored i n a number of tanks are controlled for
inventory by level instruments and a centralised computing system.

Typical instruments used are:

a) Auto tank gauges, for atmospheric or for tanks with Low pressure and non-toxic
fluids
b) Servo operated displacer type transmitter for pressurized tanks, bullets and for
Tank Gauging requiring high accuracy.
c) Radar type Level Transmitter
d) Ultrasonic type Level Transmitter
e) Level Transmitters based on sensing liquid head measurement, DP type

(iii) Interface level measurement is required i n equipment like Separators where

water is separated from Oil (Hydrocarbon liquid).

Typical instruments used are:

a) Radar type Level Transmitter

b) Displacer type Level Transmitter
c) Capacitance type Level Transmitter
d) DP transmitters

(iv) Sometime Level measurement or detection is required to signal the malfunction of

equipment. For example Level instruments are used in Instrument air receivers to
detect any water level. Water vapour may condense i n the air receiver i f the
instrument air dryer does not function well.

Typical instruments used are:

a) Displacer type Level Transmitters.

b) Capacitance type Level Transmitters.

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c)

6.3
Local gauge like a transparent Level gauge glass.

Level sketches.
I
Level sketches are the basis of selecting the ranges of level instruments and determining
the elevation of the nozzles to which the level instruments to be connected. These
sketches are developed by the Instrument group based on the Process equipment data
sheets and other documents issued by the Process group. The Process documents (typically
Process data sheets for equipment, P&IDs, Alarm and Trip set point values) provide
essentially the following data:

(i) Information on the process fluid and equipment.

(ii) Operating level, minimum and maximum liquid level. This includes operating high
and low levels and also very high (high-high) and very low (low-low) levels.
(iii) Interface level band.
(iv) Density of the process liquid/liquids (where interface level to be measured).
(v) Other operating conditions like pressure, temperature, physical properties like
colour, suspended solids, etc.
(vi) Type of the level instrument
(vii) Equipment internals, compartments etc.

In addition to the Process data sheets for equipment from the Process group we also get
data sheets from the Equipment group containing similar information.

Based on the above information it i s possible to select the range of the level instruments.
The range of the instrument needs to cover the maximum and minimum levels of the
process liquid. To ensure this the usual norm i s to see that the range of the instrument
selected i s large enough so that the maximum level is 90% or below the upper range
value and the minimum level is 10% or above the lower range value. Usually a level
instrument required for control or monitoring i s not required to detect High-High and Low-
Low level values as under such conditions the Process i s shut down. The level instrument
used for shutdown (trip) functions are required to measure High-High and Low-Low level
values. However, most of the project specifications require that all the instruments
whether for monitoring/control or for trip shall have the nozzles at the same locations
and shall have identical calibrated ranges. If level indicators/level gauges are also
provided they may be required to have the same nozzle elevations as those of others.
Once the ranges are fixed the elevation of the nozzles can be same as those Hi-HI and
Low-Low levels or higher to High-High level and lower than Low-Low level also.

It must be noted that the Level instruments which are inserted or installed directly inside
the equipment, they require only one nozzle (except for float operated Auto tank gauges).
Usually these nozzles are on the top or roof of the equipment.

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ADDlication A
Petrofac

Upper and lower nozzles are applicable to:

(i) DP type level transmitters for non-atmospheric equipment.

(ii) Level instruments installed in an external chamber or on stand pipes(brid1es).
(iii) Level gauge glass and Magnetic Level gauge mounted on the side walls of
equipment.
(iv) lnterface level measurement by Displacers. (interface level measurement requires
that both the upper and lower nozzles at such elevations that they completely
remain immersed in liquid (that has upper and lower parts with interface layer as
the border). lnterface level measurement sometimes may require a third nozzle in
the vapour phase of the liquid.). See the attached level sketches for details.

Only one upper nozzle i s applicable t o the following cases:

(i) Internally mounted displacer operated level instruments.

(ii) Internally mounted Radar or Ultrasonic wave operated level instruments.
(iii) Servo operated level instruments.

More than one (three) upper nozzles are required by float operated level instruments
where there will be a float suspended by a long wire. This i s the case of "Auto Tank
Gauges" where the central nozzle i s required to hang the float inside the tank and other
two nozzles are required to hang the guide wires (to guide the float) inside the tank.(See
attached appendix-vii.)

Penetrating type nucleonic level instruments require two nozzles. Usually these are
required in solid level detection and normally not encountered in upstream plants.

Limitation location of the nozzles on the equipment

Nozzles can not be installed on the tan lines of the vessels or equipment as there will be
seam or weld joints. Usually it i s necessary to leave at least 150 to 200mm gap from the
tan lines to fix the nozzles.

Many vessels in the form of bullets or horizontal cylinder are not allowed to have nozzles
on the sides. Nozzles are allowed only on the top and bottom.

Orientation of the nozzles

Sometimes the application will require specific nozzle orientation. To cover the process
requirement, one may have to select a displacer type level instrument or a level gauge
which need to monitor level when the level falls down to the very bottom of the
equipment. Such application will require a side-bottom type connection. If the
requirement i s to cover 100%of the vessel or equipment from top to bottom it i s necessary

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Document Title
Level Measuring Instruments Selection and
Application
Revision

A
to specify top-bottom connection. This kind of connections can be applied to displacer
instruments, float or other type of level instruments in external chambers, Level gauge
glasses, magnetic level gauges. Typical cases for displacer connections are provided in
Appendix-I.

6.4 Other considerations in level sketches

(i) Other than fixing elevation (Z-coordinate), it is important to look into X and Y
coordinates too. For example Separators will have a weir or baffle and levels are
required to be measured on both sides of the weir. The process data will be
different for the two compartments.(See typical level sketches in the Appendix.)
Thus the nozzle locations, range determination have to be considered keeping this
in mind. It is advisable to verify nozzle orientation for all such applications.

(ii) The process equipment data sheet provides several other information which is
useful to decide the location of level nozzles on the Level sketches and in more
detail on the equipment mechanical general arrangement (GA) drawings.

I Some such information could be:

I
(a) location of overflow nozzle;
(b) location of liquid inlout, gas inlout nozzles;
(c) extent of density variation; all floatsldisplacer can work within a limited band of
density that a process liquid may have;
(d) di-electric constant; required by radar type detection;
(e) presence of internals in equipment, like an agitator.

(f) presence of internals in equipment, like an agitator.

(5) Stand pipes. Stand pipes are also known as bridles. These are usually used when it
is not prudent to puncture too many nozzles on the shell of equipment. A stand
pipe is a pipe or a cylinder installed between the upper and lower nozzle of the
equipment and acts as an extension of the equipment. On the stand pipe the
several level instruments are installed. A typical diagram of a stand pipe
arrangement is shown below.

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Level Measuring Instruments Selection and
Aoolication A
1 Petrofac @

(h) Stilling wells. Stilling wells are generally indicated in the level sketches. These are
basically guide pipes or protecting pipes that houses the level sensor like displacer
or float assembly so that the instrument i s not affected or damaged by any
turbulence inside the vessel or the equipment. Stilling wells are made of pipes with
perforations over i t s surface to allow the liquid to go inside the well. Thus the
holes make the bridge between the liquid and vapour space inside the vessel and
inside the stilling well. The bottom of the stilling well i s either provided with an
end cap or with rods t o arrest the displacer or float going inside the equipment in
case there is a mechanical snaps in the suspension. Stilling wells are also used with
non-contact type radar instruments mounted inside equipment as the well acts as
guide for the wave and eliminates the interference from secondary reflections
from equipment internals. A typical sketch of stilling well i s provided in the
Appendix-ll. Stilling wells are sometimes supplied by the Level instrument supplier.
In such a case coordination i s required with the Mechanical group to ensure how
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SHJ-BMS-XX-GDE-X-XXXX Application A

the well will be installed on the equipment nozzle and that the equipment nozzle
id is adequate for the insertion of the well. It is necessary to review that the well
does not foul with equipment internal. For wells linger than a meter or for high
turbulence inside the equipment it i s necessary to support the well by members
installed within the equipment. This is taken care of by the equipment
manufacturer and all details are provided to him by drawings from the stilling well
supplier.

Stilling wells can also be provided by the equipment manufacturer and detail
drawing of the stilling well is provided by the Instrument group to the Mechanical
group.

Some project specifications and some applications may not allow stand pipe.
The level transmitters, switches used for shutdown may not be allowed on the
stand pipe and may be required to be installed on separate nozzles provided on the
equipment. This i s because i f the shutdown initiators are installed on a stand pipe,
the stand pipe is considered as an element for common mode failure. This reduces
the reliability of the shut down loop.

All such information are used t o locate the nozzles on level sketch and finally i n detail on
the GA drawings of the equipment. Refer the attached Level sketches for more
information.

(i) Additional nozzles due t o SIL study. It is possible that SIL review may demand
additional level instrument for shutdown loops. As the nonles on the equipment
are normally frozen much before the SIL study it is necessary to see whether the
Feed documents like Feed PhlDs which are used t o prepare the detailed P&lDs have
already considered the recommendation of Feed stage SIL review. Otherwise it is
necessary to review with the Process group for safety critical applications where
the P&lDs do not indicate multiple level instruments participating i n voting logic. If
necessary additional nozzles should be provided as spare for use i n future i n case it
is recommended by the SIL study at a later date.

6.5 Floating Roof Tanks

Floating roof tanks are used for the storage of highly flammable liquid like Naphtha, where
the possibility of firelexplosion i s not rare. The floating roof allows the expansion of fluid
upward as the float can move and thus reduces the intensity of explosive force on the tank
walls.

In floating roof tanks, guided wave radar type Level Transmitters are used and the guide
penetrates through the floating roof inside the tank through special seals.

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Displacer sensor is used in servo tank gauges. For floating roof application the displacer is
housed in a cage fixed t o the floating roof. Thus the displacer follows the level of
liquid/or the position of the floating roof.

6.5.1 Applications and selection of instruments

6.5.2 Float operated level instruments

(i) Floats are selected usually for benign process conditions. A few examples are
(ii) Raw water storage tank level indication
(iii) Sweet crude oil storage tank level indication
(iv) Diesel storage tank

6.5.3 Auto tank gauges

Float and tape level indicators are used to indicate levels locally as well as transmit level
signals (when provided with a transmitter). The float is guided by two guide wires. This
arrangement requires a number of mechanical interfaces with the equipment, in addition
to three nozzles on the tank top. These are cleats and brackets on the tank surface,
anchors at the tank bottom .The wire connecting the float rolls and un-rolls over a spool
located in the indicator/transmitter (called Tank side gauge).

The motion of the float is guided by two guide wires on the two sides of the float. This is
to keep the float stable during turbulence. The guide wires are anchored at the bottom or
sometimes provided with an anchor weight.

The wire moves all the way from the float over a set of pulleys to the spool through a
conduit. This means the process vapour will be present i n the conduit as well as inside the
tank side gauge. This is why the application is restricted to benign fluids and also
sometimes liquid sealing accessories are used on the tank top.

Following are the key points to be considered while specifying or evaluating a tank gauge.

(i) Wetted part materials, .e. MOC of float, wires, anchors, pulleys, conduits etc.
(ii) Density of the liquid. Density variation range.
(iii) Effects of pressure and temperature.
(iv) Liquid should be clean, non viscous, preferably non -hazardous, non-toxic.
(v) Provide all the information to the Mechanical group with respect to the
requirement and location of nozzles, guide wire anchor supports, requirement of
supporting the conduit pipe for the float wire and tank side gauge.
(vi) If the tank is to be lined or insulated/coated ensure the welding work is done with
appropriate coordination as welding on tank outside surface (for cleats etc.) and
inside surface (for anchors) might not be possible after lining or insulation/coating.

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Hence, all such arrangements are considered during the early phase of detail
engineering.
(vii) Ensure that the location of the nozzles for the guide wires and the float are as per
the dimensions provided by the instrument supplier. Similarly ensure that the
bottom anchor fixing supports provided on the tank bottom are aligned with the
guide wire nozzle location.
(viii) Tank side gauge can display level by a pointer moving over a graduated dial and /
or by mechanical counter. These gauges are also available with transmitters for
remote monitoring.
(ix) Usual nozzle sizes are 1.5" or 2" for this application.

Some of the familiar equipment where this i s used are:

(i) Crude oil storage tank;

(ii) Potable water storage tank;
(iii) Fuel storage tank.

Performance: These gauges can measure liquid level within an accuracy of +/-5mm. These
gauges work well with clean liquids in storage tanks with low pressure or connected to
atmosphere.

6.5.4 Magnetic level gauges

The float moves up and down with the level i n a sealed chamber and the float is provided
with a permanent magnet. A series of wafers/rollers of magnetic material are arranged
vertically. Each wafer has two different colours on i t s two surfaces. As the float moves up
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or down the waferslrollers roll over changing the colour. Thus the indicator below the
level and above the level will show two different colours which identify the liquid level.
These magnetic level gauges are preferred to Reflex or Transparent type level gauge
glasses as these are sturdier than level gauge glasses and offer a very good isolation
between the process fluid and the indicator.

Instead of providing indication over a vertical scale gauges are also available where the
movement of the float i s converted into level indication by a pointer moving on a circular
scale. This dial type instrument will display the indication at the tan top. Here two
magnets are used. One i s fixed to the float which moves inside a guide tube. The guide
tube has a suspended magnet. As the float moves up or down the suspended magnet is
either pulled toward it or pushed away from it. The suspended magnet i s connected to a
drum mechanism which rolls and operates the indicator pointer and the other.

Following are the key points to be considered while specifying or evaluating a tank gauge:

(i) Wetted part materials, i.e. MOC of float, float tube, seals. Non magnetic metals,
alloys like stainless steel material is used so as to avoid any interference with the
magnetic circuit of the sensing mechanism.
(ii) As SS is a common material for this instrument, it is likely that SS flange of the
instrument may be coupled to the CS flange of the equipmentlvalve. In all such
cases ensure that the flange ratings of the SS flange covers the maximum pressure
/temperature ranges as CS flanges are having higher design limits than SS flanges.
Similarly review i f any insulating gaskets are required between flanges of dissimilar
materials.
(iii) Density of the liquid. Density variation range.
(iv) Pressure and temperature.
(v) Top mounting or side mounting.
(vi) Any requirement of graduated scale to read liquid level in engineering units.
(vii) The performance may be influenced by presence of strong external magnetic field.
(viii) These gauges are suitable for high temperature and pressure.
(ix) Though these gauges are usually used for indication, when fitted with magnetic
coupled switches they function as a good level switch also.
(x) lnstead of bi-coloured wafer or roller indication these gauges are also provided
with magnetically coupled cursor moving over a vertical scale.
(xi) lnstead of level gauge glass, magnetic level gauges should be considered for sour
service application, high pressure services or other services with hazardous liquids.
(xii) In case of Magnetic type Level gauges the cc distance can be up-to 3000mm.

If it is acceptable to the client one can go up to 6000mm. Additional support will be

required for the typically for Level gauges more than 2500 mm.

However same can be followed as per suppliers recommendations.

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- Application A

6.5.5 Level gauge board

These are float operated simple mechanical indicator and similar to auto tank gauges. A
guided float moves inside the tank along with the liquid level. The float suspension is
connected to a cursor that moves along a vertical scale fixed vertically on the tank
surface.

A few examples of application area are Tank farm where storage tanks are provided with
these kinds of gauges for a gross view of the tank level from a distance. It is used for Low
pressure tanks with non sour or non hazardous Liquids.

Float operated level switch

)It&%ma@aetic
l3clasing fitle
Svviteh tu%chanian

A m W Sleeve

There are various kinds of float operated level switch available. Essentially they are of
following type:

Side mounted
Top mounted
Guided float

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Side mounted type

In side mounted type, a float is inserted in the process equipment through a nozzle on the
upper or lower side of the equipment. The float is connected to an arm. The float hangs
down as long as the liquid level is below. As the liquid level rises to reach the float, the
float starts moving up following the liquid level and this produces a movement of the float
arm also. The arm is pivoted inside an external chamber and its movement inside the
chamber operates a magnetic sleeve which follows the arm's motion and it is magnetically
coupled to a magnetic switch. The magnet actuates the lever of a contact switch to
produce contact change over. Thus the liquid level is detected when the level reaches the
elevation of the side nozzle. Usually the switching takes place when the arm coincides
with the axis of the nozzle.

Top mounted

In side mounted type the float along with the arm undergoes an angular motion over an
arc. In vertical or top mounting type, the motion is also in vertical direction.

Top mounted types are available with guided floats where the float moves with the liquid
level along a guide rod. Inside the guide rod assembly, at the required switching elevation,
magnetically coupled switches are located and wired to a terminal box located on the top,
outside the process equipment. This type is called rigid stem type and can have multiple
switching points in a single instrument.

In another variety of rigid stem type multiple floats are arranged on a single vertical stem.
The floats are arranged at different switching elevations. The motion of each float is
restricted and it can move only slightly up or down from its position on the stem. Each
float operates a magnetically coupled switch arranged i n the stem assembly to provide the
level detection.

Switching differential

Level switch set points are specified either for rising Level or for falling level. This is
because switching does not happen at the same level when the liquid level rises and when
it falls. This difference in switching points is known as switching differential.

Switching differential is sometimes desirable and is used to reset an alarm or trip

conditions. Suppose a level switch trips a pump on a low level and one does not wish to
reset the trip condition unless the level builds up sufficiently above the trip level (say by
60mm). Thus a level switch with switching differential of 60mm or higher is suitable for
this purpose.

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Applications:

Water services (Potable water, DM water)

Lube oil tank
Seal pot
Fuel oil day tank
Refrigeration liquid level
Hydraulic oil reservoir level

Following are the key points to be considered while specifying or evaluating a float
operated level switch.

Avoid specifying float switch in severe services like viscous liquid or slurries, liquid with
suspended solids. Normally float gets stuck in these services.

Avoid specifying float switch in equipment having turbulence. Use external chamber i f
unavoidable.

Ensure that for side mounted type the nozzle elevation is as per switching requirement in
process data and float position at exact switching requirement matches with the level
instrument supplier's data.

Review the switching differential

Ensure that the float can be inserted through the nozzle and that nozzle i d i s adequate.
Consider the thermal insulationlheat tracing of the external chamber i f the same i s
applied to the main equipment.

Review the float selection with respect to density of the process fluid, the variation in
density values and the resulting inaccuracies.

Consider stilling well for top mounted level switches mounted inside the process
equipment.

The MOC of wetted parts like float, stem, stilling well, external chamber, seals etc. shall
be as per the vessel trimlpiping specifications.

Review the correct contact rating of the switch, the form of the contact, cable entry and
hazardous area protection.
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6.6 Displacer operated level instruments

A torque tube type displacer level instrument

A spring operated displacer level instrument

LVDT

MOVIng LVDT

Encl-alng fu-

*nge aprl n-

Displacers are used widely for level transmitters and switches. They work well i n harsh
process conditions (high pressure, temperature) and where the range of level is small
(typically between 25 mm to 100mm). In these applications some time displacers excel
differential type level transmitters. Some typical examples of small range level
measurement are:

(i) detection of Desalter filling level

(ii) detection of water in Instrument air receiver
(iii) detection of level in knock out drums

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Displacer type Level transmitter essentially contains the following parts:

(i) displacer
(ii) torque tube / spring
(iii) secondary sensor, transmitter
(iv) displacer housing or chamber, stilling well

As the level rises or falls the displacer buoyancy force on the displacer changes. This i s
sensed by the spring or the torque tube.

The motion of the displacer spring i s transmitted to an armature which i s linked to the
spring -displacer assembly. The displacement of the armature i s sensed by LVDT sensor
which provides an output proportional to the liquid Level.

Instead of spring Torque tube i s also used to sense the change of level. The displacer i s
suspended from an arm that is attached to a torque tube or torque rod. A knife-edge
bearing supports the movable end of the torque tube. This type of bearing provides an
almost frictionless pivot point. As the buoyant force changes on the displacer the torsion
force on the torque tube changes and the torque tube undergoes a rotation by an angle till
it reaches to equilibrium. The torque tube is attached to a set of magnets. The rotation of
the magnet changes the magnetic field around a Hall Effect transducer which produces an
analogue signal proportional to the level.

Refer Appendix-Ill for a detail view of the torque tube type displacer transmitter
internals.

Following are the key points t o be considered while specifying or evaluating a

displacer type level transmitter (or switch):

Wetted part materials, i.e. MOC of displacer, spring, displacer housing, torque tube, any
other wetted parts.

a) Density of the liquid. Density variation range.

b) Pressure and temperature.
c) Top mounting, inside the equipment or side mounting into an external camber.
d) As explained above in the section of 'Level Sketches', the displacer instrument may
be required to have side-side or top-side or top bottom etc. connections. This has
to be reviewed with respect to the process data and equipment drawing to see
what i s applicable to cover the entire process range.
e) Flange-Flange distance for side mounted installation. There could be cases Like
side-side, side-top, side-bottom, top-bottom connections. Most of the applications
require side-side or internal displacer mounted on the equipment top. However,
sometimes the type of equipment or the level detection range requires the other
type of installation.

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f) Length of the displacer. The length must be sufficient so that the displacer remains
submerged over the entire variation of level from minimum to maximum value.
g) Standard displacer lengths are available with standard C-C distance. Refer the
Appendix-l for the standard lengths. Nonstandard lengths are also available as per
the requirement, however it is better to select the standard displacers i f possible
as it may make the manufacturing process easier.
h) Usually a displacer used for switching signal is selected for a length that the
switching is triggered when the displacer is half submerged. This allows the
provision of set point changes i n future and good reliability.
i) Requirement of stilling well displacer chamber in internally mounted displacer
Level Transmitters. Stilling well shall be correctly designed with respect to
material, size, installation and supports.
j) Specify displacer in externally mounted chamber i f

the liquid inside the equipment is turbulent or boiling;

the displacer instrument is expected to have frequent maintenance;

k) Rotatable or fixed headlorientation of the transmitter assembly.

1) MMI for calibration checking and adjustments.
m) Weight of the displacer assembly and its load on the nozzleslnonle; equipment
nozzle ID for internal type displacer.
n) Thermal insulation /heat tracing of the externalldisplacer chamber, connection of
chamber vent and drain point. This is required i f the equipment on which the
displacer is installed is having the thermal insulation 1 heat tracing. This is to
conserve the thermal energy. This may be also required to eliminate any
appearance of wax or solidification.
o) Displacer, springltorque tube, displacer chamber are required to undergo rigorous
NDEs and other testing as per the vessel trimlpiping specification requirement. The
fabrication of the displacer chamber involves welding. This shall be as per project
welding specifications and testing. Sometimes for application in sour service the
displacer chamber internal is cladded with the high specification material required
by vessel trimlpiping specification to economize the cost.
p) Review the displacer head orientation, accessibility, free space for removal from
nozzle and re-insertion. Ensure that while fixing the external displacer location on
the equipment the rooms for accommodating the chamber drain and vent
connections and extension of the connections to header (if any) are available.

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6.7 Servo operated level transmitter

These are also displacer operated level sensors but unlike other displacer instruments,
displacer is a smaller body that always remain partially submerged in the liquid.

The displacer is suspended by a wire wound on a grooved drum. The drum winds and
unwinds the wire by a stepper servo motor. With the Liquid level changing the buoyant
force on the displacer changes and so the tension in the wire. With rising level the tension
decreases and it increases with falling Level. The drum i s magnetically coupled to the shaft
of the servo motor by gears. As the displacer moves due to the change of buoyant force
the change in tension of the wire i s detected and the signal is sent to the servo motor. The
motor winds or unwinds so that the displacer submersion in the liquid i s brought back to
the earlier value. Thus the displacer always follows the liquid level. The stepper motor i s
controlled by a microprocessor and the number of steps provides the rotation of the drum
and change of liquid level. Due to the digital signal conversions the resolution of this
Level Transmitter can be as high as O.lmm and it can measure level with an accuracy of
+/- 1mm or better.

The servomotor is magnetically coupled to the displacer and is thus completely isolated
from the displacer/process medium.

The displacer weight is balanced by a spring mechanism and the change of suspension wire
tension i s detected by the deflection of a 'balance plate' which is connected to the
spring. The deflection of the plate i s detected through a magnetic circuit and i s converted
into electronic signal to the servo amplifier.

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The servo motor drives a mechanical counter for display of Level as well as an encoder.
Transmitter output i s available in analogue as well as in digital signals.

The instrument can also be used to detect the density of a liquid because the change of
buoyancy i s directly proportional to the density i f the level remains constant.

Some of the typical application area of the Servo gauges is as below:

(i) LNG /LPG storage

(ii) Liquefied Ammonia storage
(iii) Tank-farm applications where the inventories of valuable products stored i n tanks
are monitored and reconciled with the transfer of liquids into the tanks and
transfer of liquids from the tanks. These gauges are used because of the high
accuracy, ability to perform under high pressure (tanks are sometimes pressurized
to keep the product in liquefied form).

Following are the key points to be considered while specifying or evaluating a Servo type
level gauge.

(i) Wetted part materials, MOC of displacer, wire, drum, stilling wellldisplacer guide,
calibration chamber, isolation valve. Cage and seal material for floating roof
indication.
(ii) The guidelstilling well also acts as a conduit to discharge static electricity form
the liquid.
(iii) Gas tightness of drum housing material and seal / o-ring material.
(iv) Density of the liquid. Density variation range.
(v) Pressure and temperature.
(vi) Size of equipment nozzle for mounting.
(vii) Temperature variation of the liquid.
(viii) Temperature is usually measure i n storage tanks by multi point temperature
elements. This is to ensure the measurement of average temperature and thereby
an accurate density value of the liquid.
(ix) Earthing lugs/ connection and earthing strap/conductor.
(x) Calibration chamber. This is required to do off line but i n situ calibration of the
displacer. The calibration camber is an external chamber between the flange of
the servo gauge and equipment nozzle. It has an internal calibration reference. For
example this reference could be in the form of a calibration plate that can be
inserted in the calibration camber. The displacer is made to lower from the top to
the calibration plate. The servo gauge is set to display a reference value based on
the relative position of the calibration plate and tank bottom. The calibration
reference could be also a stopper inside the upper part of the calibration chamber.
The displacer is moved from the tank bottom t o the stopper and this fixed the
calibration.

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(xi) DBB isolation valve. This is a full bore isolation ball valve with block-bleed-block
arrangement, provided to remove the displace from the tank. Isolation is required
as the tank is pressurized and may contain Hydrocarbon or other chemicals, sour
liquid.

6.8 Radar operated level transmitters, transit time type (also called TDR-time
domain reflectometry)

6.8.1 Non-contact type

-the instrument consists of a transmitter, an antenna, a receiver with signal processor, and
an operator interface. The transmitter is a solid state oscillator that emits
electromagnetic or microwave and is mounted on the top of the equipment, i n the vapour
space. It is made to emit waves of a particular frequency band and intensity. -the signal
is radiated by an antenna. The frequency can be anywhere between 3 to 30GHZ. 10 GHZ is
a typical value.

-the source situated on the equipment top send the waves through the vapour space
toward the liquid. As the vapour has relatively low dielectric constant than liquid, so when
the wave falls on the liquid surface a large part of it is reflected back. The detector
detects the reflected wave reflected back from the liquid surface. The electronics
calculates the time taken by the incident wave to travel up to the liquid surface and then
t o reach the detector after reflection. This time is called transit time and from this it is
possible to measure how far is the liquid level from the source or the level of liquid in the
equipment.

Radar type detector has the advantage that it can see through the process, i.e. its
function is not impeded by the fumes or foams inside the process equipment.

Radar type transmitters are also used for detecting interface level. This is done by using
the selective behaviour of the electromagnetic wave with respect to dielectric constant
value of a substance. When an electromagnetic radiation falls on the surface of a liquid,
the higher the dielectric constant of the liquid more the wave is reflected back from the
liquid surface. Conversely, lower the dielectric constant of the liquid more the radiation is
absorbed by the liquid and less is reflected back. Thus the electromagnetic wave is
absorbed more as the dielectric constant of the liquid is lesser and is reflected more as
the dielectric constant is higher. Thus, as the wave falls on the surface of the upper liquid
a part of the wave is reflected and detected by the antenna. The rest of the energy passes
through the emulsion layer which is an overlap region between the top and bottom liquid
and then the radiation reaches the surface of the bottom liquid. The reflection now occurs
from the surface of the bottom/second liquid and amount of radiation reflected is
different from that reflected from the surface of the first liquid. The second reflection
also is detected by the antenna. The Radar detector recognises these two reflections as
from two different surfaces because of the difference i n dielectric constant values and

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consequent difference in radiation energy amount reflected from the two surfaces. The
interface level is determined from the time detected for the two reflections.
There are various type of non-contact radar antennas are available for different
applications.

Followings are the various type of antennas used to meet different applications.

(i) Horn or cone type. These are commonly used and have suitable application
software that improves i t s performance. They are also used with stilling well i n
floating roof applications (for Naphtha, Crude oil etc.). for equipment with large
heights antenna cross sections are large as it needs to emit more energy and
collect back also more reflected energy. Usually a nozzle of 2" to 4"
accommodates various sizes.

(ii) Rod type. 'These are simple and preferred because they easily suit equipment
nozzle size. Generally the waves emitted by rod antenna are less focused than
those by others and so its application is limited.

(iii) Parabolic type. These are bulky and emit well focused waves and thus are used in
fiscal applications like i n Tank Gauging. Usually they require a nozzle size of 6 inch
or higher.

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(iv) Windowed and flush mount type. (This type has application in Food,
pharmaceutical industries where pad type flanges are used.)

Each type of antenna emits energy in a specific way and is thus required to be selected
after studying the application. More high is the frequency, more focused i s the beam.

There could be secondary reflections form the internals of the equipment, like reflection
from baffle plates or agitator blades. It is possible to programme the instrument so that
the secondary reflections are ignored.

A few examples of applications for Horn and Rod type antenna are as below:

Sour water tank level

Crude oil storage tank
Sump pits
Pump seal liquid
Solids (Sulphur) in bunker

6.8.2 Contact type (Guided wave) Radar level sensors

In this kind of sensors, the microwave is guided along a rod or cable down to the liquid or
solid surface whose level is to be measured. Since the wave is completely guided to the
target the measurement is unaffected by secondary reflections.

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Guided waves radars are available in the following versions:

(i) Rod type (guide)

This i s recommended for use with water based solutions of higher dielectric constant
values (Typically more than 10).

(ii) Coaxial type

This i s usually used in clean, non viscous liquids. For viscous liquids or where vapour
condensation may happen in the upper part of the probes making a liquid bridge between
the two co-axial members, the annular gap between the two probes are made larger. It i s
suitable for low dielectric constant values (typically >1.4) and i s available for the
measurement of both upper fluid and interface level.

(iii) Twin probe

Similar to co-axial probe and can be used for liquids with high viscosity or solids with build
ups. Typical value for dielectric i s >2.
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(iv) Cable type single or twin probes

Usually used for measurement of solids, powders, granules. It is also used where the depth
of the liquid i n the tank limits the use the Rod or Co-axial type probes.

These kinds of probes are particularly useful for difficult measurements like those listed
below:

i) Liquids that have low dielectric values (e.g., propane, butane);

ii) Low specific gravity liquids;
iii) Turbulent liquids;
iv) Viscous liquids, slurries
v) Internal physical obstructions (e.g., baffles);
vi) Heavy foam layers; and,
vii) Problematic solids.

Guided wave radar antenna is very widely used in external chamber in the upstream Oil
and Gas applications. The external chamber provides a means for isolating the instrument
from the process, perform calibration or maintenance work without shutting down the
process itself.

The chambers must be specified for the correct MOC and testing requirements (in line
with the vessel trim Ipiping specifications). The chambers are provided with vent and
drain ports provided with isolation valves1 plugs. For sour service applications the drain
and vents are extended to piping headers for safe disposal.

Followings are some of the typical examples of Co-axial probe applications in external
chambers:

(i) Separator levels(lnterface level)

(ii) Stabilizer pre-flash drum (Interface level)
(iii) Crude oil storage tank (Interface level)
(iv) Desalter (Interface level)
(v) Slop tank ((Interface level)
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As already stated above the applications of Co-axial probe must be reviewed with respect
to the bridging of the coaxial probes by viscous liquid, wax, suspended solids. Such
bridging will result into faulty detection. As the suspended solids, wax is very common in
sump pits containing oil water one should specify Coaxial probe with larger annular gap to
avoid bridging.

Another case of bridging reported in Co-axial probe i s due t o condensation of hydrocarbon

vapour at the upper region of the probe (which is i n vapour space). This problem also has
been eliminated by increasing the annular gap.

Following are the key points to be remembered while specifying or evaluating a contact
type Radar level instrument:

i) Wetted part materials, MOC of antenna, guide, transmitter housing.

ii) Dielectric constant(s) of the process mediumlmedia.
iii) Equipment internals, agitators.
iv) Type of liquids, viscous, condensing, foaming etc.
v) Pressure and temperature.
vi) Size of equipment nozzle for mounting.
vii) Range of level, number of interfaces, emulsion layer depth.

6.9 Ultrasonic level transmitters, transit time type

This is similar to radar type but uses ultrasonic wave pulse, typical frequency is 30 KHz.
These are suitable for use is simple services as ultrasonic waves are sensitive to vapour,
fumes, foams etc. These instruments exhibit a blocking distance, typically 0.5M. if the
distance between the antenna and the Liquid surface is less than the blocking distance,
the instrument will no longer sense the variation in level.

This is cheaper than the radar type and can be used in simple applications like
measurements of levels i n atmospheric tanks.

6.10 Capacitance type level sensors

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This sensor essentially consists of two capacitance electrodeslplates and the process
vapour and the process liquidlsolid form the dielectric between the two plates. As the
liquidlsolid level varies, the impedance value between the two plates varies providing a
signal of voltage change proportional to level change. Usually an AC voltage of low radio
frequency (typically 5-1OMHz) is used.

Various kinds of probes are available for example:

i Rod type probes

ii) Co-axial probes
iii) Cable probes

Followings are some of the selection criteria for the probes.

For clean non coating conductive liquids i n metallic tanks, insulating rod type probe is
used.

Clean, non-coating non-conductive liquids (such as many hydrocarbons) in nonmetallic

tanks require concentric or co-axial probes.

Clean, non-coating non-conductive liquids (such as many hydrocarbons) in metallic tanks

require special consideration. A bare (un-insulated) rod probe can be used, but one must
insure that the probe does not come in contact with any conductive liquid that may
contaminate the non-conductive liquid (such as water i n oil). If this occurs, the output will
be driven t o full scale, regardless of the actual level in the tank. Note that an insulated
probe can also be used. The probe's metal fitting must be grounded to the metal tank
wall, and the distance from the tank wall to the probe must be constant along the entire
length of the probe, to provide a linear change in analogue output per change in fluid
height.

Usually in oil and gas industries these probes are used in simple measurements and also for
switching purpose. The transmitter outputs are not always linear and require field
calibration. But point detection or switching can be done very reliably with these switches
i f the die-electric of the liquidlvapour or liquidlliquid are adequately different.

These switches are also useful for solid levels.

Typical applications are:

(i) Detection of water levels in air receiver tanks

(ii) Detection of levels in seal pots
(iii) Detection of refrigerant level
(iv) Detection of interface Level
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6.10.1 Calibration in fie1.d

"Capacitive level transmitters must always be calibrated for zero and span in the field.
The concentric probe can be tested in a bucket or small tank of the liquid t o be measured;
all other probes must be calibrated after final installation by changing the material level
and adjusting the zero and span pots."

6.11 Level measurement by DP transmitters

This is one of the most widely used measurement types. The measurement is done by a DP
transmitter, whose HP-port is connected to the lower nozzle of the equipment t o sense
the liquid head (+ vapour pressure on the liquid surface) and LP-port is connected to the
upper nozzle located in the vapour space to sense the vapour pressure. Thus the resultant
i s the difference of pressure between the lower and upper nozzle which is the liquid head
and is proportional t o the liquid level (provided the density of liquid remains constant).

However as the impulse tube contains non-flowing fluid, the temperature of the fluid
inside the impulse tubes assumes the same temperature as that of the ambient. This may
give rise to condensation of vapour into liquid in the impulse tube sensing the vapour
space pressure. This can happen when the ambient temperature falls, say during winter
season or during the night. The vapour again evaporates with the rise of ambient
temperature. This creates a variable condensate head inside the impulse tube causing
error in transmitter output. Whether a vapour will condensate or not depends on the
minimum ambient temperature and the boiling point of the liquid at the operating process
pressure regime. This needs t o be reviewed with the process group and to do away this
following measure are taken:

(i) sense the vapour pressure through remote seal with filled capillary connection (see
below);
(ii) heat trace the vapour space impulse line so that the vapour can never condense;
this is the case of dry leg;
(iii) i f the vapour is supposed to condense naturally i n the impulse tube even under
highest ambient temperature(i.e. if the boiling point of the process liquid under
the process operating pressure is higher than the highest ambient temperature)
then use a condensate pot at the top of the vapour space to allow the impulse tube
always filled with constant liquid head; this is the case of wet leg;

In accurate measurements, temperature or density of the liquid is separately measured

and corrections done t o obtain the correct level value. Temperature is measured for cases
where the density variation is possible only due to temperature.

The above measurement principle is not affected by the variation of vapour pressure of
the liquid.

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Zero suppression and elevation

As stated above, in case a transmitter is used with a wet leg, the pressure on the LP port
will be always higher than that on the HP port except when the level in the equipment is
loo%, i.e. level rises to the elevation of HP port. This means, when the level is 0%or the
liquid elevation inside is at the HP port the transmitter is experiencing a negative
differential pressure equal to the liquid head in the vapour space impulse line. So, the
zero of the transmitter is suppressed and it is necessary to elevate the zero by an amount
equal to the liquid head in the impulse tube connected to vapour space.

Similarly i f a transmitter is located below the elevation of the lower n o n l e of the

equipment which is connected to the HP port, the transmitter HP port will see a liquid
head even when the liquid level is below the tower n o n l e elevation. So the zerb of the
transmitter is elevated and it is necessary t o suppress the zero.

The zero elevation or suppression can be done electronically by the Transmitter

calibrator. In pneumatic transmitters it can be done by the adjustment of the
suppression/elevation spring inside the transmitter housing.

It is necessary to calculate these values based on actual location of the transmitter with
respect to nozzles and condition of vapour space leg, i.e. whether it is a dry or a wet leg.
Further the zero suppression /elevation requirement also is dependent on the density o f
the filled liquid i n remote seal transmitters (see Section 6.11.3). In the normal
transmitters it is usually possible to suppress or elevate the zero by an amount equal to
the calibrated range. But it may not be so in a transmitter with remote seal(s). It is
necessary to verify whether the zero elevation/suppression is possible with the supplier
for the selected remote seal transmitter. The remote seal level transmitter shall be
finalized only after fixing the location of the transmitters with respect t o tapping point
locations.

Some examples of zero elevation suppression calculation and calibration ranges are given
i n the Appendix-IV.

Followings are the usual DP transmitter type used application wise.

6.1 1.1 Simple DP transmitters

Used for clean liquids i n atmospheric tanks.

Used for clean liquids in closed tanklequipment with condensing vapour.

Three or five valve manifolds are used with these transmitters to allow i n situ verification
of transmitter zero.

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6.1 1.2 DP transmitters with flush diaphragms

Used for clean as well as difficult services, suitable for viscous as well as corrosive liquid.
Usually the diaphragm size i s 3" so that pressure (force x area) i s adequate on the
diaphragm to produce high measurement resolution.

Flush diaphragms are sometimes used with drip rings (refer appendix-V) which provides a
means to flush or clean the diaphragm assembly to eliminate choking, as well as a means
to do in-situ calibration and verification.

For pressurized vessel and non-atmospheric tanks the vapour space connection i s
accomplished by:

(i) connecting the vapour space to the transmitter LP port by impulse tubing; this i s
used i f the physical properties of the vapour allows the impulse tube to either
remain dry (always filled with vapour) or remain wet (always filled with liquid
formed by condensing vapour);

(ii) connecting the vapour space to the transmitter LP port by a remote seal which
consists of a diaphragm assembly fixed to a flange connected to a liquid filled
capillary that i s connected to the LP port of the DP transmitter; with this
arrangement (elimination of impulse tube for sensing vapour pressure) there i s no
issue with respect to irregular condensation or vaporization inside impulse tubing.

DP transmitters with flush and remote seal diaphragms are used in many process
equipment level measurements such as:

i) Separators;
ii) Knock out drums;
iii) Columns;

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6.1 1.3 DP transmitters with remote seal diaphragms

These transmitters are having remote seals at both the HP and LP sides. Why remote seal
i s used on LP side has been explained above.

Remote seals are required on the HP side (on the lower nozzle) i f there i s a problem with
access or space with respect to lower n o n l e of the equipment. For example a pressurized
bullet (containing a pressurized liquefies gas) may be inside a dyke and for such cases
usually it i s preferred to install the transmitter outside the dyke. This i s easily done with
remote seals at both the ends.

6.1 1.4 DP transmitters with extended diaphragm seal

Extended type diaphragm seals are used instead of flush type for the applications involving
slurries, highly viscous liquids. As the liquid is stagnant in the nozzle region and can form
deposits on a flush mounted type diaphragm seal, extended diaphragms as shown above
are used so that the diaphragm sensor is outside the stagnation zone.

6.11.5 Interface level measurement with DP transmitters

In this application, the LP side of the DP transmitter sees only the upper liquid. If the
transmitter is a t the same elevation as that of the lower nonle, it can be shown that the
differential pressure acting on the transmitter is h (p,. p2).

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However this is not a very accurate method as the difference (pl- pz) is usually very small
and the resulting differential pressure on the transmitter is also small for accurate results.

6.1 1.6 Following are the key points to be remembered while specifying a DP type Level
Transmitter.

i) Ensure that the liquid level range or liquid head variation is adequate for the DP
pressure sensing capsule to sense accurately.
ii) If there is a variation in the density of the liquid due to temperature or due to
change of liquid physical property, better to use Radar type Level Transmitter. If
there is a variation in density due to temperature, usually a look-up table or a
curve with density versus temperature is used i n the DCS to correct for the
variation of density.
iii) Select the filled liquid in the isolating diaphragm chamber appropriately
considering the boiling point of the liquid, vis-a-vis the maximum operating
temperature of the liquid. The seal liquid remains pressurized by the process
pressure. But i f the process pressure dips very low toward vacuum, the filled fluid
may boil inside the chamber (due to the lowering of boiling point by the fall of
pressure) and damage the diaphragm as well as the transmitter internals.
iv) If dry or wet impulse tubing is used ensure that the tube remains dry or wet with
respect to the ambient temperature variation. Heating1 thermal insulation may be
required on the impulse tubing.
v) For DP transmitter with impulse tubing, the HP port should be preferably at the
same elevation of the lower nozzle provided for level measurement on the
equipment or below the lower nozzle.
vi) For DP transmitter with two remote seals the transmitter should always be
installed above the lower nozzle (to keep the diaphragm seal liquid under
pressure). Elevation below lower nozzle requires approval from the supplier.
Obtain the recommendation from the transmitter supplier.
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vii) Diaphragm or remote seal transmitters work best with 3" diaphragm assemblies.
However 2" assemblies are also available. Before selecting 2" assembly ensure that
the required accuracy, resolution and response time are fulfilled.
viii) If a very fast trip action i s required ensure that diaphragm seal or capillary does
not make the transmitter response slow.
ix) Avoid long capillary lengths as it introduces errors (due to the effect of ambient
temperature variation and consequent change of pressure of the filling liquid on
the diaphragm). It also introduces delay in the response time.
x) Specify capillary with armour as capillaries are susceptible to damage. Plan a safe
layinglrouting of the capillary tubes.
xi) The remote seal on the vapour space side will introduce the effect of capillary
head on the LP port of the transmitter. It i s necessary to determine the realistic
capillary lengthlhead and inform supplier to implement zero elevation. .
xii) Ensure the errors introduced due to capillary are within acceptable limits.
xiii ) Determine the requirement of valve manifolds, capillary armourlinsulation, range
required, static pressure (vapour pressure) while selecting the transmitter.
xiv) Select the material of construction in line with project specification, corrosion
Isour service requirement. This will include all wetted parts of the transmitter,
flanges, o-rings, capillaries, drip ring, valve manifold transmitter housing.
Usually transmitters are required to be specified with local display which can be in
% level or in the units of length.

6.12 Hydrostatic level measurements

6.1 2.1 Submersible type

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This kind of sensor consists of a pressure sensing capsule located i n a rugged housing which
i s installed as submerged in the liquid by a suspension cable which also contains the loop
wires for the instrument power supply and signals. The diaphragms sensor used can be of
ceramic or of other material. Ceramic is suitable for many corrosive application. The
pressure on the diaphragm is transmitted to the signal converter which may be a strain
gauges or a piezeo electric transducer. The suspension cable is made of corrosion resistant
materials like Polyurethane, Polypropylene etc.

6.1 2.2 Applications

i) Level switch for automatic start, stop and shutdown of submersible pumps.

ii) Level transmitters 1 switches for underground tanks, drain vessels.

Limitation of this application is the high temperature of the liquid which may not be
tolerable by the sensor electronics or the suspension cable.

6.1 2.3 External type

The level as well as density (so mass) is measured accurately be 3 pressure transmitters.
Two transmitters are used to sense the liquid (+ vapour head). Another transmitter is used
i n the vapour space to measure the vapour pressure. The difference of outputs of the
transmitters in the liquid and vapour space provides the level measurement. The two
transmitters used in the liquid space are located at separate elevations. Since these two
transmitters see the same liquid head, any variation in the difference of outputs of these
two transmitters provides the variation in density. Thus with the help of three
transmitters it is possible to measure the mass in the equipment provided the equipment
has a regular geometrical cross section to calculate the volume from the level.

6.1 3 Nucleonic Gauges/ Radio active sensors

The sensor essentially consists of a radio active source and a detector. The radiation
passes through the medium whose level needs to be measured. The amount of radiation
absorbed by the sensor depends upon the length of the path the radiation has to pass to
reach the detector after travelling through the medium. The strength of the radiation i s
measured i n the detector and thus the amount of radiation absorbed by the medium is
calculated. From this the level of the medium is derived.

These instruments are immune to the process conditions and properties of the fluids and
can very accurately measure levels in very difficult services.

Followings are some of the details and features of the instrument.

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6.13.1 Source

Radiation source Cesium 137, Cobalt 60 i s commonly used. Cesium is popular because it
has greater half life period than that of cobalt.

6.13.2 Radiation Safety

"The Nuclear Regulatory Commission (NRC) limits radiation intensity to a maximum of 5

milliroentgens per hour (mrlhr) at a distance of 12 in from the nuclear gage. If it i s more,
the area requires Radiation Area posting. The distance of 12 in is critical, because
radiation intensity decreases by the inverse square of distance. Nuclear level gages are
sized to provide radiation intensity at the detector that exceeds the minimum required,
but is under the 5 mrlhr maximum. For ion chamber detectors, the minimum i s 1 mrlhr.
For Geiger-Mueller switches, it is 0.5 m r l hr. And for scintillation detectors, it i s 0.1-0.2
mrlhr. Because the nuclear gage is basically measuring the vapour space above the liquid,
as the level rises in the tank, the intensity at the detector drops. When the tank i s full,
radiation intensity is practically zero. "

The engineers1 technicians are provided with safety training to maintain these devices.
The transport, storage and disposal of the source are governed by rules and regulations to
maintain safety.

6.13.3 Detectors

Ion chambers and Scintillation count detectors are used to detect radiation (gamma ray)
that passes out of the process medium.

In Ion chamber an electrode i s kept pressurized gas chamber. The electrode is biased with
a small voltage. As the radiation enters the chamber it ionizes the gas and the ions are
collected at the electrodes. This produces an electrical current signal proportional to the
strength of radiation or level of the medium.

In Scintillation counter, the radiation (Gamma rays) hits a Scintillator material which
emits photons when the radiation falls on it. The photons are amplified to electrical
current signal by photo multiplier device. These detectors are preferred over Ion
chambers as these are more sensitive and can be used with a low energy radioactive
source.

For point detection of levels, Geiger Muller counters are used. These counters are also Ion
chambers.

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6.1 3.4 Applications

(i) Separator levels. A single device can measure accurately the liquid, emulsion and
interface levels i n a separator. It is mounted externally and does not need any
process shutdown for maintenance or trouble shooting.
(ii) Level of solids i n bunkers, chutes.

6.14 Level Gauge

There are essentially three types of gauge glasses.

a) Transparent gauge glass - These are used for viewing colourless liquids.

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