Professional Documents
Culture Documents
LEVEL
MEASUREMENTS
Level Measurements
CONTENTS
Objectives
Page 3
Page 4
Page 8
Page 12
Page 22
Page 26
Page 38
Page 44
Page 50
Page 52
Page 53
Glossary of terms
Page 56
Level Measurements
OBJECTIVES
On completion of this module, the participant will be able to: -
Evaluate the inter conversions of different level units with the given
standard engineering units table.
Explain how to select the correct level sensor for a given application with
the given characteristics of various level sensors and their selection
criteria table.
6. Explain the zero check and use different Calibration devices and
methods to calibrate level transmitters to an accuracy of 2%.
Level Measurements
TOP I 02.4 UPK (i) Standard engineering units of level and their interconversions
INTRODUCTION
The measurement of level is defined as the determination of an existing
interface between two media.
These media are usually fluids, but may be solids or a combination of solid
and fluid. The interface can also exist between a liquid and a gas, a liquid
and its vapor or two liquids etc. The best method of measurement depends
upon the nature of the specific application, which must deal with:
1. The process to be measured.
2. The degree of accuracy required.
3. Dependability.
4. Economic considerations.
In the oil and natural gas industries, liquid level measurement is necessary
to achieve the following objectives.
1. Compute tank inventories of crude oil.
2. Protect equipment such as Compressors, turbines and pumps from
damage.
3. Protect operating and maintenance personnel against injury
resulting from liquid spillage.
4. Protect the environment from the spillage of liquids.
5. Control phase separation processes.
Discuss about the measurement of level
Discuss about the necessary of liquid level measurement
Level Measurements
Centimeter
1
100
2.54
30.48
91.44
Meter
0.01
1
0.0254
0.3048
0.9144
Inch
0.3937
39.37
1
12
36
Feet
0.0328
3.28
0.0833
1
3
Yard
0.0109
1.09
0.0278
0.3333
1
Level Measurements
SELF-REVIEW
1. Convert 40 meters of level into inches.
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REVISION
1. Write down any two main objectives of level measurement?
a). _____________________________________.
b). _____________________________________.
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TOP I 02.4 UPK (ii) The Characteristics of various level sensors and
their selection criteria
Introduction
In this session, we shall discuss the characteristics of various level sensors
and their selection criteria for a particular application within PDO
locations.
Characteristics of various level sensors and their selection criteria
Measurement of liquid level is categorized into:
1 . Direct method
2 . Inferential method (indirect)
1 . Direct method
This employs the physical principles such as fluid motion, floats, and
thermal properties. Various types of level measurement under this heading
are:
1.1 Dip stick, Dip rods, and lead lines.
1.2 Sight glass.
1.3 Float operated.
2 . Inferential method (Indirect)
This employs hydrostatic head, weight, conductivity, viscosity, buoyancy
and density. Various types of level measurement under this heading are:
VARIABLE DISPLACEMENT METHOD(BUOYANCY TYPE)
2.1 Displacer.
HYDROSTATIC HEAD TYPE
2.2 Hydrostatic gauge (DP).
ELECTRICAL METHOD
2.3 Capacitance probe gauge.
Discuss about the various types of Level measurement techniques.
Level Measurements
SENSOR TYPE
APPLICATIONS
Dip stick, Dip rods, and 1. Automobile engine
lead lines.
crank case oil level.
2. IC Engines oil level.
3. Oil tank level.
LIMITATIONS
1.Manual
measurement.
2.Does
not
give
continuous
measurement.
3. Not suitable in
pressurized tanks.
Sight Glass
1.Continuous
1. Local indication.
measurement for both 2.
Possibility
of
open and closed tanks. breakage.
2. Simple and reliable.
Float operated
1. Used for remote 1. Not used for foaming
transmission.
liquids and liquid/gas
2. Used for switches.
interface.
Displacer
1. Used for remote 1. Not suitable for wide
transmission.
density fluctuations.
2. Used for interface
level measurement.
Hydrostatic gauge
1. Used for remote 1. Zero Elevation /
transmission.
Suppression required
2. Used for interface depending
on
the
level measurement.
mounting.
Capacitance
probe 1. Used for corrosive 1.
Scaling
causes
gauge
applications.
errors.
2. Contain no moving 2. Temperature change
parts and easy to clean. affects
change
in
dielectric property.
TABLE No.2 LEVEL SENSORS SELECTION CRITERIA
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SELF REVIEW
1. What are the two types of liquid level measurement?
a) ___________________________________.
b) ___________________________________.
3. Write any one type of liquid level measurement under Indirect method.
a) ____________________________________.
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REVISION
1. Name at least two devices used for direct measurement of liquid level
a) __________________________________
b) __________________________________
2. Name any one type of device used for inferential measurement of level.
a) __________________________________
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Dip rods may take the form of a solid round rod or a flat bar with
graduations over a length of 2.5 meters approximately. The rod is made
from non-spark metal and is inserted through a vertical guide tube until it
touches the bottom of the tank. Certain hydrocarbon liquids may contain
water, which accumulate at the bottom of the tank. The depth of water may
Discuss about the principle of operation of Dipstick and Dip rod
Level Measurements
be measured by coating the end of the rod with a water detecting chalk,
which changes from white to blue, or a water detecting paste which
changes from green to red, if water is present. The lead line or otherwise
called manual gauging tape has replaced the dip rod as a method of
measuring liquid levels in large storage tanks. This is widely used in PDO
locations to measure storage tank levels. Obviously, dip rods over 10
meters long are too heavy to carry up to the top of large tanks and are also
too difficult to operate due to the amount of oil left sticking to the surface
during withdrawal.
The lead line consists of steel or glass fiber tape wound on a reel and a
brass weight, shaped like a plumb bob, is clipped on the free end. The bob
weight keeps the tape tight and suspended vertically inside the tank. The
tape and the bob are calibrated in meters and millimeters.
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SELF REVIEW
1. The bottom of the tank is the ______________ for correct insertion of
the dip stick.
2. Name at least one reason why lead line is preferred over dip rod.
Level Measurements
Level Measurements
In tank A " the displacer is suspended by a spring balance that shows the
weight of the displacer in air, 3 Kg. This represents a 0 % water level in the
tank. As we increase the level in the tank to 50 %, water rises vertically and
more length of the displacer is now immersed in the water (tank " B "). You
will notice three things:
1. The weight of the displacer is reduced to 2 Kg, as indicated by the
spring balance.
2. The relative position of the displacer in the water is raised due to
the buoyancy force exerted by the water.
3. The relationship between the reductions in weight of the displacer
and the height of liquid is linear.
This is further clarified by the situation in tank C ". As the liquid level is
increased to 100 %, the weight of the displacer further decreases to 1Kg.
The rise in level and the reduction in weight of the displacer are
directly proportional.
In industrial applications, the spring balance is not a convenient method of
indication of the level and will be replaced by a torsion spring called
Torque tube. Almost all manufacturers of displacement type level
measuring instruments use this unique mechanism to convert the vertical
movement of the displacer to a rotary movement in the instrument for
indication or transmission. The torque tube has two main functions
1. Transmits the motion from the displacer to the control
mechanism.
2. Provides a positive seal against the process fluid and its pressure.
Discuss about the principle of operation of Displace type level
measurement.
Level Measurements
Level Measurements
In operation, when the displacer is freely hanging in air and the full weight
of the displacer is acting on the torque arm, this will produce a torque on
the length of the torque tube which is fixed at one end. The torque tube will
twist and when it twists the torque tube rod will also twist. Here the torque
tube is acting as a spring.
As the displacer loses its weight due to a rise in level, the twist on the
torque tube will be reduced and the torque tube rod will rotate accordingly.
This rotation is proportional to the weight of the displacer, which is also
proportional to the rise in level.
The successful application of the torque tube will depend upon the material
of construction. It should be designed to provide the necessary load
carrying ability with low operating stress. The following needs to be
considered when selecting the torque tube material.
1. Capability of the material to resist corrosion.
2. Elastic properties of the material over a wide range of
temperatures.
3. The nature of the fluid being handled.
Type 316 stainless steel (316 SS) is commonly used for temperatures up to
250 C. Above 250 C INCONEL (alloy) is found to be satisfactory. There
are other materials like Monel, Hastelloy C etc., which are suitable up to
250 C. These materials have good corrosion resistance properties.
This particular instrument is designed by Fisher Controls Company and
their torque tube design is unique. Here the transmission mechanism is
pneumatic but electronic versions which produce 4 to 20 mA signal are also
available. Necessary explosion proof instrument enclosures are needed to
use the electronic versions in the oil field. The other popular design which
P.D.O. installations use is manufactured by MASONEILAN Company.
Discuss the principle of operation of Displacer type level transmitter.
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If we calculate the pressure at the base of the vessel, this is the pressure the
pressure gauge will be measuring in this particular installation.
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We
know that:
Discuss
about the principle of Hydrostatic head
P=h x x g
Where h = 2 m
= 1000 Kg / m3
g = 9.81 m / s2
Therefore P = 2 x 1000 x 9.81 = 19620 N / m2
= 19.620 kPa
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Level Measurements
The vapor of the liquid when connected to the LP impulse line and taken to
the ambient temperature will condense to liquid and remain as liquid inside
the LP impulse line. In this situation the LP side is fully or partially filled
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Level Measurements
The D/P cell is located below the datum level (zero level). When the liquid
level is at the zero percentage (lower range value), we expect the D/P cell
to produce an output either 4 mA or 20 kPa, depending upon the type of
transmission. But in this case when the level is actually at 0%, the HP side
measures the hydrostatic head produced by the liquid height "X". This
will make the transmitter send a signal, which is more than 4 mA or 20
kPa. The information given by the transmitter is not true from the
measurement point of view but this error is a definite (fixed) error because
the liquid trapped inside the HP leg remains there all the time. Since the
signal given out by the transmitter is more than zero, this needs to be
corrected for. This type of correction is termed as ZERO SUPPRESSION.
This means that to bring the increased transmitter output back to zero,
(4mA or 20 kPa), to represent the 0% of the measurement (level).
The example on the next page explains the point further.
Level Measurements
Level Measurements
Discuss
Solution
1 about the Zero suppression.
Range of measurement = 0 m to 2 m (0% to 100% level).
Head created by 0% level = 0 kPa (LRV).
Head created by 100% level = 2 x9.81x 0.92x1000 Pa.
= 18050.4 Pa.
= 18.0504 kPa (URV).
Therefore range of measurement = 0 to 18.0504 kPa (Ans).
Span of measurement = URV - LRV.
= 18.0504 - 0 = 18.0504 kPa (Ans).
Solution 2
When the level is at datum, the transmitter measures a hydrostatic head
created by the column of liquid inside the HP impulse line. This line has a
vertical distance of 1 meter (C).
Therefore the pressure due to this height = 1x9.81x0.92x 1000
= 9025.2 Pa
= 9.0252 kPa (Ans)
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Level Measurements
Note the changes in this drawing. Now let us assume that the level is at the
datum point, and the outside wet leg is completely filled with the same
liquid as in the tank.
The hydrostatic head seen by the HP side = C x x g = 9.0252 kPa.
The hydrostatic head seen by the LP side = B x x g = 54.1512 kPa.
Looking at the above pressures we can see that the LP side has more
pressure than the HP side when the level is at the datum point. This will
drive the transmitter zero below 4 mA. Also even if the level rises in the
tank the transmitter cannot produce any positive output because the LP side
will always have more pressure than the HP side.
To compensate for this type of error ZERO ELEVATION IS REQUIRED
in the transmitter. This means to apply bias as in the case of dry leg
installation. Let us now see how this can be done by looking at the
pressures involved.
The net pressure seen by the LP side of the transmitter, when the level is at
the datum point is:
{(B x x g) - (C x x g)}
= (B-C) x ( x g)
= 5x 0.92 x 1000 x 9.81
= 45.126 kPa
The pressure due to height "C" in Hp side is also there in LP side. These
two pressures cancel each other. The remaining height of liquid in the LP
Level Measurements
side is creating the 45.126 kPa. This is the pressure, which is measured by
the LP side, and drives the transmitter zero below 4 mA.
Zero elevation kits can be fitted to the transmitter to cancel the effect of
such pressures, and make the transmitter read 4 mA when the level is at
0%.
SELF REVIEW
1. Write the formula inter-relating pressure, height of the liquid column,
density and acceleration due to gravity.
Level Measurements
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D
Where: C = Capacitance
K = Dielectric constant
A = Area of the plates
D = Distance between the plates
In most of the applications, the area of the plates and the distance between
the plates are fixed values. The dielectric varies with the level in the tank
and this variation is used to produce a signal, which is proportional to the
level. Industrial application of the capacitance type of level measurement is
confined to ON-OFF control purposes (point measurement, switching).
Best measurement results are obtained when the difference between the
dielectric constants of the two media is relatively high. This is because the
change in capacitance with the variation in level is a direct function of the
dielectric constant, and is greater when the height of the measured medium
with a high K (liquid) replaces a medium with a low K (gas).
Discuss the principle of measurement of capacitance type liquid level
measurement.
It should
be noted that the dielectric constant of liquid varies with
temperature. An increase in media temperature results in a decrease in
dielectric constant. Since level variations are inferred from variations in
dielectric, the changes in temperature will affect the accuracy of
measurement. Therefore suitable temperature compensation is required
when significant variations in media temperature are anticipated.
Two typical situations of capacitance measurement are:
1) Non conducting liquids.
2) Conducting liquids.
Non conducting liquids.
When measuring the level of a non-conducting liquid, a bare metal probe
can be used. The total (effective) capacitance of the system is given by the
equation:
C e = C1 + C 2 + C 3
Level Measurements
C e = C1 +
C C
C2C4
+ 3 5
+
C 2 C 4 C 3 + C5
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Level Measurements
R3
R1
Detector
Voltage Source
a.c.
G
C
2
R
2
Ce
Rx
The bridge is said to be balanced when the ratio of the impedances is equal.
It can be mathematically shown that the effective capacitance is equal to:
Ce =
R1 C 2
R3
Level Measurements
SELF REVIEW
1. What is the function of capacitor?
Level Measurements
2. Write the relationship between the capacitance, plate area, the distance
between them and dielectric constant.
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Level Measurements
When both fluids are liquids, the displacer is always IMMERSED in liquid. Let
us consider a vessel containing two immiscible liquids such as NGL and
WATER. The specific gravity of NGL is 0.75 and of water is 1.0. A
displacer is placed in this vessel to measure the interface between water
and NGL. With the displacer completely immersed in NGL the weight of
the displacer is 1.4 lb. (600 gm.).
The weight of the displacer in air is 3.0 lb. (1.4 Kg). When the water level
in the vessel is increased to half of the length of the displacer, the displacer
weight is reduced to 1.2 lb. (540 gm).
This decrease in weight of the displacer is due to change in buoyancy.
When the water level is increased further the displacer weight is further
reduced to 1.0 lb. (450 gm). This further reduction in weight is again due to
greater portion of the displacer is immersed in heavier liquid, which is
water.
Discuss about the principle of Displacer type interface measurement.
Level Measurements
From this example it can be seen that the weight of the displacer is a
function of the position of interface. When the displacer weight varies,
the rotary motion of the TORQUE TUBE also varies proportionally and
hence the output.
2 . DIFFERENTIAL PRESSURE METHOD
As discussed earlier, differential pressure method can be used for level
measurements. By this method we infer the level position by measuring the
hydrostatic head governed by the relationship:
P = hg
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Level Measurements
SELF REVIEW
1. Mention the two common methods used to measure interface level.
Level Measurements
Mercury pellet
Com
NC
NO
pivot
spring support
magnetic sleeve
magnet
spring
float rod
liquid level
Level Measurements
open contacts are being used. This is because of getting a closed contact
under normal conditions to safeguard the tank or vessel in the event of
loose connections in the circuit, which is otherwise called as fail-safe
condition.
SELF REVIEW
1. What is the most commonly used type of level switch used in PDO
locations?
3.
applications
________
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Level Measurements
= 0.911
(c) CALCULATION
Weight of the displacer + Hanger in air (W) = 1600 gms.
Loss of weight in 100% Oil (W1)
= (V x 1) =457.322 gms.
Weight of the displacer in 100% Oil
= W W1 =1142.678 gms.
Weight of the displacer in 50% Oil
= W W1 =1371.339 gms.
2
(d) CALIBRATION
INST. READING
WEIGHT
TRANSMITTER
Level Measurements
(%)
(GRAMS)
OUTPUT (mA)
0
1600
4
50
1371.339
12
100
1142.673
20
MMPS T-2412
TAG No. : 24-LEA-259LL
SERVICE: INTERFACE (OIL / WATER)
(a) DISPLACER DETAILS
Length of the displacer (L)
Diameter of the displacer (D)
Volume of the displacer (V)
= 35.6 cms
= 9.8 cms.
= DL = 22 x 9.8 x 9.8 x 35.6
4
7x4
Level Measurements
INST. READING
(%)
0
50
100
SELF REVIEW
WEIGHT
(GRAMS)
1552.71
1426.45
1300.19
TRANSMITTER
OUTPUT (mA)
4
12
20
2. Calculate the Volume (V) of the displacer if the Length (L) and Diameter
(D) of the displacer are 11.8 cms and 5.7 cms respectively.
3. Calculate the loss of weight in 100% oil (W1) using the following details
a) Volume of the displacer (V)
b). Specific Gravity of Oil (1)
4. Calculate the loss of weight in 100% Water (W2) using the following
details
a). Volume of the displacer (V)
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= 1.005
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Level Measurements
Unit
Element
UPK (i)
: I 02
: I 02.4
: Standard engineering units of level and their interconversions.
UPK (ii) : The characteristics of various level sensors and their selection
criteria.
Learning Objective:
The participant will be able to evaluate the inter-conversions of different
level units with the given standard engineering units table and explain how
to select the correct level sensor for a given application with the given
characteristics of various level sensors and their selection criteria table.
Total Session Time:
1 period
Time
Activity
Resources
10 min
Introduction
TRANSPARENCIES
VIDEO CASSETTE
REF. NO:TVAR 1186.88
20 min
Explain
the
standard TRANSPARENCIES
engineering units of level and
their inter-conversions.
Explain the characteristics of TRANSPARENCIES
various level sensors and their
selection criteria.
20 min
Level Measurements
15 min
Self review
15 min
Revision
Learning Session Plan
Unit
Element
UPK (iii)
: I 02
: I 02.4
: Construction and working principle of direct method of level
measuring devices.
Learning Objective:
The participant will be able to explain the construction and working
principle of direct method of level measuring devices
Total Session Time:
3 periods
Time
Activity
Resources
10 min
Introduction
TRANSPARENCIES
60 min
70 min
70 min
Level Measurements
15 min
Self review
15 min
Revision
Learning Session Plan
Unit
: I 02
Element : I 02.4
UPK (iv) : Construction and working principle of displacer type level
measuring devices.
Learning Objective:
The participant will able to explain the construction and working principle
of displacer type level measuring devices.
Total Session Time:
1 period
Time
Activity
Resources
10 min
Introduction
TRANSPARENCIES
40 min
15 min
Self review
Level Measurements
15 min
Revision
Unit
Element
UPK (v)
: I 02
: I 02.4
: Construction and working principle of hydrostatic type level
measuring devices.
Learning Objective:
The participant will be able to explain the construction and working
principle of hydrostatic type level measuring devices.
Total Session Time:
4 periods
Time
Activity
Resources
10 min
Introduction
OHP
TRANSPARENCIES
280 min
Level Measurements
15 min
Self review
15 min
Revision
Unit
Element
UPK (vi)
: I 02
: I 02.4
: Construction and working principle of capacitance type level
measuring devices.
Learning Objective:
The participant will be able to explain the construction and working
principle of capacitance type level measuring devices.
Total Session Time:
2 periods
Time
Activity
Resources
10 min
Introduction
OHP
TRANSPARENCIES
120 min
Level Measurements
15 min
Self review
15 min
Revision
Unit
Element
UPK (vii)
: I 02
: I 02.4
: Construction and working principle of interface level
measuring devices.
Learning Objective:
The participant will be able to explain the construction and working
principle of interface level measuring devices.
Total Session Time:
2 periods
Time
Activity
Resources
10 min
Introduction
OHP
TRANSPARENCIES
120 min
Level Measurements
15 min
Self review
15 min
Revision
Unit
: I 02
Element
: I 02.4
UPK (viii) : Construction and working principle of level switching
devices.
Learning Objective:
The participant will be able to explain the construction and working
principle of level switching devices.
Total Session Time:
1 period
Time
Activity
Resources
10 min
Introduction
OHP
TRANSPARENCIES
40 min
Level Measurements
15 min
Self review
15 min
Revision
Unit
Element
UPK (ix)
: I 02
: I 02.4
: Applications of level measuring/switching devices in PDO
locations.
UPK (x)
: Calibration methods.
Learning Objective:
The participant will be able to explain the zero check and use different
Calibration devices and methods to calibrate level transmitters to an
accuracy of 2% and explain the applications of level measuring/switching
devices in PDO locations.
Total Session Time:
1 period
Time
Activity
Resources
10 min
Introduction
TRANSPARENCIES
Level Measurements
20 min
20 min
Explain
the
calibration TRANSPARENCIES
methods for level measuring
devices.
15 min
Self review
15 min
Revision
= 39.37 inches
= 30.48 centimeters.
25 feet
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11. Dip stick is used to measure the liquid level under direct measurement.
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12. Write any one type of liquid level measurement under indirect method.
a) Displacer.
14. Name at least two devices used for direct measurement of liquid level.
a) Dip stick
b) Sight glass
15. Name any one type of device used for inferential measurement of level.
a) Hydrostatic gauge(DP)
Level Measurements
18. The bottom of the tank is the reference point for correct insertion of the
dip stick.
19. Name atleast one reason why lead line is preferred over dip rod.
Dip rods are too heavy to carry up to the top of large tanks.
Level Measurements
21. Name any two types of sight glasses used in oil industry.
a) Window type sight glass.
b) Tubular type sight glass.
22. Write the formula inter-relating pressure, height of the liquid column,
density and acceleration due to gravity.
P= h * * g
Where P = Pressure
h = height of the liquid from a given datum
= density of the liquid
g = acceleration due to gravity
Level Measurements
23. A pressure gauge is mounted in a tank 30 feet below the datum line of
the tank. The specific gravity of the process liquid is 0.80.What is the
pressure on the gauge in psi? (1 psi = 6.895 kPa ; 1 ft = 0.3048 m)
P=h**g
= (30 * 0.3048) * 800 * 9.81 N/m2
= 71762.112 N/m2
= 71762.112
psi
1000 * 6.895
= 10.4078 psi
24. The zero suppression is used to bring the increased transmitter output
back to zero due to the definite error caused when the D/P level is located
below the datum level. True/False?
True.
25. Convert 5 kPa into inches of water column using the formula.
P=h**g
5 * 1000 =h * 1000 * 9.81
h = 5000 = 0.5096 meters
9810
= 0.5096 * 39.37 inches
= 20.06 inches
26. What is the function of capacitor?
A capacitor is an electrical component that consists of two conductors
separated by a dielectric or insulator.
Level Measurements
27. Write the relationship between the capacitance, plate area, the distance
between them and dielectric constant
C = K xA
D
Where: C = Capacitance
K = Dielectric constant
A = Area of the plates
D = Distance between the plates
29. Mention the two common methods used to measure interface level.
a) Buoyancy type.
Level Measurements
Level Measurements
32. What is the most commonly used type of level switch used in PDO
locations?
MAGNETROL
33. For high and high-high level switch applications normally closed
contact is being used.
34. For low and low-low level switch applications normally open contact
is being used.
Level Measurements
35. Write the formula used in calculating the volume of the displacer.
Volume of the displacer = (D2 L) / 4
36. Calculate the Volume (V) of the displacer if the Length (L) and
Diameter (D) of the displacer are 11.8 cms and 5.7 cms respectively.
Volume of the displacer = (D2 L) / 4 = (3.14 x 5.7 x5.7 x 11.8) / 4
= 300.95 cubic cms.
37. Calculate the loss of weight in 100% oil (W1) using the following
details
a) Volume of the displacer (V)
b). Specific Gravity of Oil (1)
Loss of weight in 100 % oil (W1) = (V x 1)
38. Calculate the loss of weight in 100% Water (W2) using the following
details
a). Volume of the displacer (V)
= 1.005
= (444 x 1.005)
= 446.22 gms.
Level Measurements