Level Instrumentation State of Technology

SPECIAL REPORT
STATE OF TECHNOLOGY REPORT:
LEVEL INSTRUMENTATION
Simple in concept, measuring the height or quantity
and switchesfloat/displacer, differential pressure (DP),
of solids and liquids in tanks and vessels is amazingly
capacitance/admittance/conductance, vibration, magneto-
complex in practice because there is a virtually infinite
striction, radar, laser, nuclear, weightare well established.
number of combinations of materials and operating

conditions under which they must be measured. Solving
Our following and most recent coverage focuses on
the resulting problems with agglomeration, separation,
expanding applications and solving problems with using
corrosion, foam, vapor and adhesion, as well as high and
conventional technologies in existing applications. Read
low pressures and temperatures, etc., has resulted in
on to see how to deal with (or eliminate) DP impulse line
markets for many niche as well as broad applications for
problems, control oil/water interfaces, improve boiler
a wide variety of instrumentation.
drum level control, and more. Should this report not

satisfy your level of interest, you can find more articles
Every few years, advances in manufacturing and signal
on level instrumentation and control in the Control 2015
processing bring a new technology, such as laser, into the
State of Technology Report: Level & Flow.
practical realm of industrial applications, but for the most

part, todays fundamental technologies of level instruments
The Editors
Point and multi-point solutions
Widest selection of wetted materials
Liquids, slurries, foams
Global agency approvals for Ex installations
No moving parts
SIL 2 compliance
Single and dual alarm models
Nuclear safety qualified
Multi-function: level and temperature
3-year warranty
www.controlglobal.com
TABLE OF CONTENTS
Digital signals support low-maintenance approach

to differential pressure measurement
Level technologies get faster and more precise
Controlling levels of parallel separators
15
Advanced control for boiler drum level?
19
Remote tank gauging
23
Experts weigh in on distillation plant measurement problems
25
ADVERTISER INDEX
Fluid Components International
Endress+Hauser4
Kobold7
Krohne22
Vega

14
State of Technology Report: Level Instrumentation
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Digital signals
support low-maintenance
approach to differential
pressure measurement
Digital precision and stability allow accurate DP level and flow readings
using two pressure transmitters
By John Rezabek
differential pressure (DP) application had capillariessmall-bore armored tubing connecting the remote seal to the transmitterin excess of 50 feet. When the
weather turned cold, there was enough of a viscosity change in the fill fluid to
cause a time lag in the longer leg, making an otherwise quiescent measurement extremely
noisy. If this had been real DP instability, it could have meant death and destruction for
the millions of dollars of precious metal catalyst in the reactor, so it caused more than a
little trepidationuntil we figured out the correlation with cold weather.
Twenty years ago, a lot of end users became enamored with remote seals as an alternative to
wet-leg DP level and DP flow applications. Using DP for level has its appeal: one gains some
commonality or uniformity of spare parts with flow and pressure applications, calibration standards and procedures are similar, and service is uncomplicated compared with external-cage
methods. But wet legs are a challenge when the fluid filling the impulse lines (the tubing connecting the DP transmitter to the level taps) is prone to freezing, polymerization or plugging of
other kinds. And since the DP measurement is in effect weighing the head of the liquid above
each tap, undetected changes in density or specific gravity will cause an offset or error in the
level measurement, as will gradual vaporization of fill fluid in the wet leg.
Remote-seal DP transmitters for level address a number of the pitfalls of conventional wet-leg
applications. Only the vessel nozzle and the isolation valve to which the seal connects are
vulnerable to freezing and plugging, and they
We thought we might have to heat trace
benefit from the conducted heat of the pro-
the capillaries. Fortunately, we had digitally
cess itself. The fluid in the wet legs is purged
integrated (fieldbus) transmitters.
free of any vapor pockets, 100% filled with a

synthetic oil, and sealed with high-integrity
Today, the reactor DP and a dozen other DP
welds. This isolation also makes them ap-
and level measurements have been convert-
pealing for high-pressure, corrosive or toxic
ed from DP transmitters to DP by differ-
applications where we prefer that the instru-
ence using two static pressure transmitters.
ment tech isnt exposed to the hazards. But
It works because the transmitters commu-
since such systems are sealed, they impede
nicate digitally, and carry a tighter spec and
everyday DP transmitter calibration and spare
warranty for accuracy and stability right out
parts procedures. Frequently a dedicated
of the box. It costs moreyoure buying two
spare is needed for each application. Even
transmitters instead of onebut the method
though these properties caused the price to
has become the standard whenever preci-
be double a normal DP level transmitter, we
sion and reliability is critical. If youre mea-
specified quite a few of them.
suring several DPs across a tower or reactor,

you only need N+1 transmitters (for example,
When the measurement is differential pres-
three to measure two DPs), so the cost dif-
sure, whether direct (DP) or indirect (level),
ference is less.
why not just use two pressure transmitters

and take the difference? The problem is, the
If youre using a legacy platform, you can get
difference we aim to measure is often a min-
the approximate performance by using any
ute fraction of the systems static pressure. In
of the much-lauded electronic remote seals
the case of our reactor, the static pressure is
offered by Emerson Process Management, or
nearly 5,000 psi, and the DP of interest had a
similar products from Endress+Hauser and
full scale of around 100 psi. If you happen to
Vega. Similar to our method, the difference
find a transmitter with an upper range value
is computed digitally in the transmitter, but
(URV) of 5,000 psig, the full scale of the DP
sent to the system as 4-20 mA. You wont
measurement is 2% of span. A change of 1 or
find a Profibus or Foundation fieldbus ver-
2 pounds was meaningful, which translates to
sion of these products, because the precision
0.02% of span. As Profibus expert and author
required is already there.
James Powell pointed out in a November 2015

posting on the Profinews website, the un-
John Rezabek is a process control
certainty of 4-20 mA analog is degraded even
specialist for ISP Corp., Lima, Ohio.
further when the configured span is a fraction
Email him at jrezabek@ashland.com.
of the transmitters capability.
LEVEL
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Level technologies get

faster and more precise
Level instrumentation, peripheral technologies, networking and software
are being coordinated in efforts to obtain faster, more accurate readings
By Jim Montague
evel measurement might be the wrong word. Changeable, dynamic or chaotic

measurement might reflect reality better. This is because the contents of most
tanks, silos and other process vessels are often anything but level. Theyre typi-
cally pouring in, mixing with other substances, reacting chemically or draining out.
Of course, most process materials have enough time to settle before theyre measured, but
users churning out increasingly complex products faster are pushing existing level devices
to their limits. As a result, engineers, integrators and suppliers are helping users implement
more sophisticated level technologies, combining existing level devices in new ways and
also adding peripheral components and software that can help.
GUIDED BY RADAR
Two of the todays most popular and frequently compared level solutions are through-air/
non-contact radar and guided-wave radar (GWR). The first sends electromagnetic microwave
pulses through the atmosphere, while GWR directs its pulses along a probe or, increasingly,
flexible cable. As usual, the trick is to have the right level technology to fit the application.
For instance, Red Arrow Products Co. produces natural smoke condensates and food flavorings at its plant in Manitowoc, Wisconsin, and it stores wood oil in a 1.5-meter collection tank,
which must maintain a constant level as part of its evaporation process. The company had been
measuring the oils level with a capacitance

sensor, but coating problems in the tank
were causing unreliable measurements and
hampering operations. Normally, capacitance
devices work well with high-temperature,
viscous and sticky substances. The wood oil
tank was especially difficult because it operates with a vacuum, and its measurement
device has to cope with vapor, mist and a tarlike buildup on its probe that could degrade
signals. Consequently, Red Arrows wood
oil tank was migrated to a Rosemount 5300
GWR transmitter with one rigid probe and
Signal Quality Metrics (SQM) software from
Emerson Process Management.
In the past, occasional unplanned shutdowns due to probe failures or coating
issues would upset our process, reducing
STORING SAND
Figure 1: Sibelco UKs quarry uses flush-mounted, non-contacting Sitrans LR560 through-air
radar level measurement transmitters from
Siemens to avoid abrasive damage. They operate at a higher frequency of 78 GHz and use a
narrower 4 beam angle to make sure their level
measurements are accurate.
product throughput and increasing energy use, says Barry Schardt, Red Arrows
over extended, continuous runs.
equipment manager and electrical engineer.

Since we installed Emersons GWR trans-
Were seeing more acceptance of radar
mitters a few years ago, we havent had
technologies as they mature, and GWR is
premature shutdowns during a production
growing faster than other level technolo-
run due to level probe failure.
gies, says Christoffer Widahl, senior product

manager for new level programs at Emerson.
GWR isnt affected by pressure and vaporspace changes, and SQM provides diag-
FLY THROUGH THE AIR
nostic information that relates directly to
As capable as GWR is in many applications,
the coating on the probe and to changing
there are others where through-air/non-con-
surface conditions. These values can be
tact radar is indispensable for getting pulses
assigned as process variables and tracked
through and securing accurate signals.
over time. This means Red Arrows staff can

use their SQM data to maintain ideal operat-
For example, Sibelco UK ships 750,000 to
ing conditions and improve product quality
800,000 tons of red and white silica sand
FOAM FIGHTER
Figure 2: The coagulation tank at

Aston Martins paint shop uses a
VegaPuls WL61 through-air radar
sensor and its signal-focusing, 80mm antenna to penetrate foam,
secure millimeter level readings,
maintain optimum water levels in
the tank and prevent overflows.
per year from its 12-15-meter-deep quarry
nance, says Adam Daniels, Sibelcos opera-
in Arclid, Cheshire, U.K. The white sand is
tions unit manager. Were pleased with the
used for making glass, and the red sand is
time savings weve gained from using these
used for playing-field drainage, animal bed-
transmitters.
ding and other purposes. Once the sand is

conveyed, cleaned, conditioned, graded and
Herman Coello, level market manager at
sorted, its stored in 20- and 49-meter silos.
Siemens, adds, Ten or 12 years ago, you

had to be an expert to set up a radar level
These silos previously used GWR, but the
transmitter, but today theyre super simple
abrasive sand was hard on the contact de-
and can be set up in a couple of minutes. To
vices, and forced technicians to adjust them
avoid overspills and fines, radar solutions can
often to get accurate level readings. As a
also be combined with secondary technolo-
result, Sibelco recently switched to Sitrans
gies such as mechanical floats, electronic
LR560 through-air radar level measure-
capacitance devices or point-level switch for
ment transmitters from Siemens. Operating
vessesls needing alerts and alarms.
at a higher frequency of 78 GHz and using

a narrower 4 beam angle, LR560 ensures
Similarly, Aston Martin Lagonda Ltd. in
that level measurements are consistently
Gaydon, Warwick, U.K., adds up to nine
accurate. And, because the transmitters are
coats of paint to its auto bodies during a
flush-mounted and non-contacting, Sibel-
50-hour process.
cos technicians dont need to worry about

the abrasive sand affecting the instruments.
As a result, its paint shop must be carefully

controlled. This includes its water recycling
The LR560 needs very little, if any, mainte-
application and 3.5 x 5 x 8-meter coagula-
10
The readings we now get are to the millimeter, which is extremely

accurate, and allows us to have a greater level of control,
especially as this measurement also governs the water make-up
valve, which operates to re-level the tank as water evaporates
due to the process, stated Aston Martins engineers.
tion tank with 140,000-liter/minute effluent
that they caused false readings and needed
flow, where entrained solids are removed
frequent cleaning.
(Figure 2). At the inlet, two transfer pumps

force the incoming stream downwards,
Consequently, a couple of years ago, Aston
aerating the water to accelerate and im-
Martins engineers changed out its contact
prove the separation process. The coagu-
devices and implemented a contactless Veg-
lated solids settle at the bottom of the tank,
aPuls WL61 radar level sensor. Its designed
and the clean, aerated water at the surface
for water/wastewater applications, features
flows over a weir to be further treated and
an IP68 housing with an encapsulated an-
reused. The solids at the bottom are period-
tenna thats ideal for harsh, effluent-plant en-
ically pumped away for drying and disposal.
vironments, and is suited for them because

the liquid density and substances contained
Because effluent treatment problems can
in the liquid have no bearing on measure-
quickly halt painting and production, As-
ment accuracy. Most importantly, VegaPuls
ton Martins engineers report its crucial
WL61 can cope with all reasonable levels of
to maintain optimum level and prevent
foam due to its signal sensitivity and 80-mm
overflow in the tank. However, this can
antenna that focuses its signal.
be difficult because the waters surface

is turbulent, it foams readily and heavily,
The readings we now get are to the mil-
and buildup on any contact device quickly
limeter, which is extremely accurate, and
causes problems. In fact, after installing a
allows us to have a greater level of control,
GWR and trying point level switches, they
especially as this measurement also governs
found the heavy, unpredictable buildup and
the water make-up valve, which operates to
contamination on the probes was so severe
re-level the tank as water evaporates due to
11
the process, stated Aston Martins engi-
x 22-meter silos that can hold up to 10,000
neers. All of the control strategy for the co-
tons, but grizzly bars across an aperture at
agulation tank water system was rewritten
the bottom of the silos must always be cov-
after installation due to the radar level sen-
ered by enough material to avoid damage
sors greater level of accuracy, and so far
or blockages caused by rocks and gravel
weve enjoyed a 100% efficiency rate. The
entering the silos.
safety surrounding the tank has also been

increased because we dont have to enter
As a result, AGA recently adopted Rose-
the guarded area around the tank to clean
mount 5708 3D acoustic solids scanners in
off buildup. Being non-contact is ideal in
its gold ore silos to provide reliable content
this application, so if the pit is cleared out,
volume measurements. The resulting 3D
we dont risk any sensor damage either.
graphical output of the mapped surface allows AGAs site operations team to monitor if
Jeff Brand, product manager at Vega Ameri-
theres sufficient gold ore for production and
cas Inc., reports that its improving perfor-
make sure its spread out enough to cover
mance of both through-air and GWR with
and protect the grizzly bars. They also enable
more powerful, less costly microprocessors.
the team to see from a safe location if bridg-
Better chips allow level measurement devic-
ing or buildup is happening inside the silo.
es to send and receive more pulses quicker,

says Brand. Those rates have doubled over
The 3D solids scanner provides us with
the past five years, so we have much better
accurate measurements in our large silo,
resolution and signal processing, and were
which allows us to protect our equipment,
able to resolve levels faster and more accu-
says Ernst Smith, C&I manager at AGA.
rately. The typical accuracy for our throughair products is 1 mm where it used to be 8
Similarly, ABB K-Tek recently released its
mm, and this means better inventory control
VM3D volumetric measurement, 3D laser
and decision making for users.
scanner that can form 3D maps of stockpiled

solids in vessels. Uses can use VM3D to laser-
Beyond radar, some developers and users
trace profiles of chemical, fertilizers, coal,
are implementing sonic scanners and laser-
potash and other materials to more accurate-
based devices to map material surfaces in
ly determine their inventories, says Charles
vessels and help calculate their volumes and
Richard, ABB K-Teks global products man-
contents. For instance, Anglo Gold Ashantis
ager for radar and magnetostrictive products.
(AGA) Moab Khotsong mine contributes

16.4% of the gold ore used by AGAs South
MULTITASKING MEASUREMENT
African operations. The ore is stored in 10
Though level methods havent changed
12
much at their roots in recent years, they
vice, says Richard. The GWR measures
have been combining technologies for bet-
liquid and produces a 4-20 mA signal; the
ter measurement, joining with microproces-
magnetostrictive device detects the bullet
sors and software that make sensors and
float inside and has a 4-20 mA output; and
level transmitters smarter and more capa-
the float and magnetic gauge have a local
ble, and using networking and data man-
indicator. Having two independent and re-
agement tools that help users make better
dundant transmitters and a local indicator is
decisions based on their analyses.
getting popular because theyre safer.
Gene Henry, senior product manager for
Henry agrees that more powerful, less
level at Endress+Hauser, reports that E+H
costly microprocessors, software and algo-
launched its Levelflex FMP55 multiparame-
rithms are enhancing level measurement
ter device a couple of years ago to combine
capabilities and coordination. The real in-
guided radar and capacitance in one com-
novations in level today are on the software
ponent. This cooperation is useful in level
side because we can use more of the data
applications with an emulsion layer, and its
were getting from the same instrumenta-
even more helpful when there isnt a clear
tion, says Henry. So if weve got foam, and
separation between these layers.
were monitoring the signal strength of freeair radar coming through it, we can now
With a rag layer like this, the overall radar
evaluate that signal with software, quantify
signal can get lost sometimes, and when
how much foam is developing based on
this happens, our FMP55 can automatically
how much the output signal strength is di-
switch to capacitance, explains Henry.
minished, and decide when and how much
Basically, the FMP55 provides two out-
defoamer to add. Previously, defoamer was
puts. One is the overall guided radar, while
added periodically, which meant too much
the other can interface with capacitance or
was used at too much cost.
guided radar. Many products are separated

by density, but now users no longer need to
Jim Montague is executive editor of
have two devices.
Control magazine, and has served as

executive editor of Control Design
Richard adds that ABB K-Teks Magwave
and Industrial Networking magazines.
solution combines magnetostrictive, GWR
Hes worked for Putman Media for more than 10 years,
and local float components in one device
and has covered the process control and automation
with one set of process connections, and
technologies and industries for almost 20 years. He
can add magnetically actuated switches
holds a B.A. in English from Carleton College and lives
to the float. This is a dual-chamber de-
in Skokie, Illinois.
13
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Simply world-class!
www.vega.com/radar
Controlling levels of parallel

separators
By Bla Liptk
We have a horizontal separator that works under level control (with gas-blanketing on top) and feeds a set of parallel-operating pumps. The level control valve
(LCV) is at the pump discharge header, and gets the control signal from the level
transmitter (LT) on the separator.

To handle increased influent flow rate to the existing separator, a new separator roughly
half the design capacity of the existing one will be added to work in parallel. Two new
pumps will be added to handle the additional effluent from the new vessel.
The separators are for separating oil from water. The exact size of the new separator is unknown for now as it is yet to be sized. Operations people want the new separator to have the
same diameter and to operate at the same normal liquid level (NLL) as the existing separator,
so the liquid level in both vessels could be controlled with one level control valve at the pump
discharge. The operators wish is not the designers of course, as the separator dimensions and
NLL are dictated by residence time considerations, and fixing it because of level control considerations is perhaps not a step in the right direction.
Id be obliged if you could review the three sketches A,B and C (Figure 1) and comment on
how to best control the levels in the two vessels.
Farooq Ghilazi / farooq.ghilzai@gmail.com
15
Solution A
LT
Option A will work if the inlet flow

distribution is guaranteed by hy-
draulic design, and is the easiest to imple-
LT
ment. Another option is described below,
B
C
D
which will also work, but is not necessarily
superior.
Solution B
LT
The key to good separator control is keep-
A
B
ing residence time (volume/flow) above the
LT
required minimum for good separation. In
C
D
addition, good blanketing gas, water inter-
face level control and oil level control are
Solution C
LT
required. For the purposes of this discussion, the gas pressure and the interface
controls are assumed to be properly de-
LT
signed.
Existing process
Modification
B
C
D
E
When controlling two separators in parallel, distribution must also be controlled.

In Figure 2, I assumed that the distribution is 2:1 and is taken care of by hydraulic
design. If it is not the case, a flow ratio
SECOND SEPARATOR IS SMALLER
Figure 1: To handle increased influent, a new

separator roughly half the capacity of the existing one will be added in parallel, with two additional pumps. Whats the best way to control the
levels in the separators?
control loop must be added. This addition

naturally not only increases the first and
maintenance costs, but also, because it
suction manifold. In that case, when both
increases turbulance, increases the resi-
separators are in operation, the level mea-
dence time required and therefore lowers
surement is obtained by averaging the
separation capacity.
two transmitter signals. When operating

only one separator, this averaging func-
As to oil-level control, one should equal-
tion is bypassed.
ize the oil levels in the two separators by

desiging a balancing pipe that is hydrauli-
As to the pump capacity controls, I would
cally capable of balancing the levels, and
not waste energy by valve throtting on the
can also be used as the pump stations
discharge side of the pumps. Instead, my
16
Flow = 100%
67%
LT
33%
Ave
Water
LC
LT
Water
Large-diameter
balancing pipe
PAY ATTENTION
TO HYDRAULICS
Figure 2: When controlling

two separators in parallel,
distribution must also be controlled. Here, that is done by
hydraulic design; otherwise a
flow ratio control loop must
be added. Equalize the oil levels with a balancing pipe, and
use a variable-speed pump to
avoid wasting energy.
preference is to have at least one variable-
Maybe it would work if the inlet flows were
speed pump in the station, so that pump-
controlled according to the size difference.
ing capacity can be modulated without
If you tell operations that they have to add
energy waste.
two flow control loops to save one level

loop you would get the correct result, which
For a good book on hydraulic design for
is separate level control loops. Also, throt-
residence time determination, refer to
tling inlet flow could further mix oil and
Chemical Engineering Research and De-
water, increasing the separation/residence
sign.
time, which increases the tank size for a
Bla Liptk / liptakbela@aol.com
given flow.
Maybe it would work if one of the new

It seems to me that the residence
pumps had variable-speed control, which is
time in one separator cant be mod-
set by a separate level controller in the new
eled after the time in another. It might work
tank. Youd need logic to start the other
if both separators are identical and cleaned
pump if the variable pump got to 80% of full
frequently. It also might work if an operator
speed or so. That saves the cost of a new
periodically, physically checks the interface
valve and its installation and maintenance.
levels in both separators. I dont know what

hed do to fix an imbalancepossibly stop
Disclaimer: Ive designed and started up con-
a pump for the low tank. Operations wont
trols for many things, but not separators.
like that.
Bill Hawkins, HLQ Ltd. / bill@iaxs.net
17
LIC
Separator 1
HS
<>
CONTROLS LEVELS
AT THE PUMP
LT
Figure 3: The level indicating controller (LIC)

controls the valve so the
highest level is pumped
down, and the High-Low
selector allows automatic
or manual selection of the
separators. If the level is
too low, stop the pumping.
LIC
Separator 2
LT
Figure 3 shows a simplified sketch
being depends on the hydraulic balance on
of how you may be able to connect
the inlet piping and the outlet piping. You
the two separators to a common inlet and
can end up with one tank on high level or
outlet header. The level indicating control-
one running empty.
ler (LIC) will control the valve in such a

way that the highest level is pumped down,
Another possible solution would be to
and with the High-Low selector, you can
re-arrange the piping, so you have a larger,
automatically or manually select any of the
common suction header to the pumps. This
separators. This way, if the level is too low,
will mean that it can act as a sort of bal-
you can stop pumping.
ance line, and then you would run the control on high-level override, with the valve
This, to say the least, is a simplified sketch.
controlled by whichever level is the high-
For detailed loop design, more data needs
est. Im not sure this will work; its a ques-
to be analyzed.
tion for the process engineers to confirm.
Alex (Alejandro) Varga / vargaalex@yahoo.com
But the real solution is not in the controls;
it has to be a workable hydraulic design.

Youre correct to be concerned about
Simon Lucchini, Chief Controls Specialist /
how the tanks are tied together. One
Simon.Lucchini@Fluor.com
way I can see to possibly make it work would

be to have a separate, large enough bal-
This series is moderated by
ance line between the tanks, but that would
Bla Liptk, automation and safety
require modifying the existing tank.
consultant and editor of the Instrument and Automation Engineers
Otherwise, what the individual levels end up
Handbook (IAEH).
18
Advanced control
for boiler drum level?
By Bla Liptk
I read some papers regarding boiler drum level control and almost all mention
that, for better performance, we should go for fuzzy logic controllers or modelbased controllers instead of traditional PID controllers. However, in those papers,
the results are obtained by simulating through Matlab. So I want to know, is it possible to
implement such controls?
Swastik Bhandari / swastikbhandari@gmail.com
There is nothing fuzzy about boiling water. You should use a three-element feedwater
control system on large boilers to arrest disturbances and to rapidly react to load changes.
As shown in Figure 1, in a three-element feedwater system, the water flow loop is closed.
This way, pressure disturbances that would affect the feedwater flow are handled immediately by the fast response of the flow loop. In addition to the three primary control variables
(three elements)drum level, steam flow, and feedwater flowdrum vapor-space pressure
can also be utilized to compensate for density changes. The pressure is passed through a
calculator (DY in Figure 1) that calculates a multiplier to apply to the raw level signal. The
multiplier is based on the density change vs. pressure for saturated steam.
In making gain adjustments on a three-element feedwater system, the first step is to determine the relative gains between level and flow loops. By observing a change in boiler load,
19
THREE-ELEMENT BOILER DRUM

LEVEL CONTROL
Figure 1: The fast response of the

flow loop handles pressure disturbances that would affect feedwater
flow, while drum vapor-space pressure control compensates for density
changes.
one can note the particular boiler swell
It is also desirable to precondition the level
characteristics of the particular unit. Maxi-
controller, so the control system will work
mum system stability is obtained when the
during start-up or at other times when the
negative effect of swell equals the posi-
feedwater is controlled manually. This can
tive effect of flow. For example, if a 20% of
be achieved by external feedback from a
maximum steam flow change produces a
flow-difference measurement, from which
20% change in the steam flow transmitter
feedback is applied to the level controller.
output, and this flow change also produces
Otherwise, an increase in steam or blow-
a 3-inch swell, which is 10% of the 30-inch
down flow will immediately increase the
range transmitter output, then the gain of
feedwater flow, without waiting for the level
the level loop should be double the gain of
to change. If this feedforward configura-
the flow loop.
tion is used, the controller mode settings

are less critical and shrink, swell or inverse-
Feedforward can further improve the system
response effects are further reduced.
by maintaining the steam-water balance,
thereby reducing the influence of shrinkswell and inverse-response. This loop keeps
the feedwater and steam flows equal as long
as the level is constant and on setpoint. Flow
Using model predictive control (MPC)

for boiler drum level control is not
advised. Im not an expert on boiler control,
measurement errors and the withdrawal of
but there are many books devoted to this
perhaps 2.5% of the water as blowdown
topic, and you should be able to get some
(which is not converted to steam) will pre-
additional help by searching for advanced
vent the two flow signals from being iden-
boiler control on the Internet. MPC is
tical. Therefore, the level controller must
complex and is usually used when there are
readjust the setpoint of the flow-difference
many interacting control loops, often with
controller to strike a steady-state balance.
significant dead times involved. Although
20
a modern DCS can implement small MPC
They were aiming at the fastest recovery
loops, off-line identification is often re-
and minimum area under the curve of the
quired to build the dynamic model.
drum level signal. The tuning parameters

were used to compare with those in the real
Drum level is only one control loop of a typi-
plant under supervision by the Control Parish
cal boiler. Feed-forward control is often used
Engineers in the marshalling area. The results
for boilers where there is a wide range of
were, of course, different because in the real
varying demand and where the feedwater
plant there were other major parameters
is returned at varying temperatures, as from
to be considered and closely monitored by
steam condensate. Feed-forward control
Operations. These included (but were not
is designed to remove the effects of load
limited to) the drum skin temperature and
variables as they make their way to the boiler
its rate of change (to be strictly followed
to remove these loads from the feedback
according to design based on size of the unit
control loops around the boiler. Most pro-
and pressure ratingsthis being 1.56 C/min-
cess control textbooks use boiler controls to
ute at all times, particularly at start up, when
illustrate the use of feed-forward control. For
only single element was used).
more on three-element boiler feedwater control, read this informative article, Cascade,
In the 1990s, in another power plant in
Feed Forward and Boiler Level Control.
Canada, I remember using principal compo-
Dick Caro / RCaro@CMC.us
nent analysis in conjunction with other vari-
ous tools to identify the key parameters (no

Back in the 1980s, in my C&I Training
greater than six out of hundreds in boiler
room in a power plant in Hong Kong,
controls) for steam pressure (and flow). Yes,
I had a control simulator that simulated
I agree with you that PID, model-based, fuzzy
shrink-and-swell effects using hardwired
logic, etc., are just tools for computation.
B&W Series 4 control modules, the same
Finding the right primary parameters for con-
equipment being used in the plant (4 x 350
trol and experience are necessary in pursuing
MW power plant) at the time. The trainees
the answer to this minimum-phase control
used the fastest recorder available at the
problem for boilers of specific sizes. Im not
time to trace the effect of drum level-based,
sure if Matlab has all its problems solved.
three-element control as the load (Boiler
Gerald Liu / gerald.liu@shaw.ca
Master) changes, and produced hard copies of the recorded signals (drum level, feed
flow, steam flow and steam pressure) and
the various tuning parameters of the PID
controllers as the load changed.
When I read papers on advanced

controls, one of the first things I check
is if it was actually implemented in the real

world or simply simulated on a computer.
21
Many control advances work extraordinarily well in lab simulations, but seem to wilt
and stumble when faced with the messiness
of actual plant operations. As to your question, I can say that after 30 years of plant
experience in a variety of industries including
chemical, pulp and paper, mining and others, I have yet to see a boiler level running on
fuzzy logic. That is not say it doesnt exist,
but it certainly isnt commonplace.
Three-element control isnt new or sexy, but it
works reliably and robustly in a huge number
of boilers. It is relatively easy to implement
and easy to tune, and operators understand
it. No doubt there are special applications
(very small boiler drums, very high pressures,
wildly gyrating steam and heat loads, etc.)
that may warrant something more involved
Solid Performance
than a standard three-element control, but in

the vast majority of applications, it works very
well and is infinitely easier to set up.
If a boiler is exposed to outside disturbances
(such as wild swings in steam load on the
header), you will find that insulating the boiler
using back-pressure controllers and/or automatic vents on the header will work far better
than expending a great deal of effort on
implementing complicated level controls that
probably wont handle the upset anyway.
P. Hunter Vegas / phvegas50@gmail.com
OPTIWAVE 6300 Reliable, Efficient Radar Level

Measurement of Solids
Powder, granulates and bulk solids are
no problem for the OPTIWAVE 6300 C. Its
narrow FMCW radar beam produces highly
accurate and reliable measurement - even
in dusty environments up to 260 feet.
The innovative drop antenna is impervious to
dust buildup - thus minimizing maintenance.
- Technology driven by KROHNE.
This series is moderated by Bla Liptk, automation

and safety consultant and editor of the Instrument and
Automation Engineers Handbook (IAEH).
Email: info@krohne.com
Tel: 1-800-FLOWING
us.krohne.com
Remote tank gauging

By Bla Liptk
Remote level monitoring? Figure 1 shows our hydrostatic tank gauging (HTG)
system. Do you have a device or combination of devices that can replace the
hydrostatic interface unit (HIU) and application interface module (AIM)? They are
now unsupportable.
Im open to a new communication protocol/fieldbus and possibly changing the field instru-
ments for compatibility, but my constraints are: no laying of new instrument/power/homerun cables; field is Class I, Div. 2 hazardous location; no shutdown or tank depressurization;
and no new instrument impulse lines. Distance from field to control room is about 500 meters. Note that field instruments dont have individual cables, but are daisy-chained on one
twisted pair to the HIU.
The transmitters have isolation valves, and can be replaced without shutting down the
process. The RTDs are insert type. There are five tanks in total with four storing products at
sub-zero temperatures. The instrumentation on each tank is fully redundant, i.e. two sets of
transmitters per tank on two networks.
My thought is that there should be a HART (or some other bus) device out there that can poll the
transmitters in turn, perform the level computation, and communicate output to the host systems.
The device can even be placed in the control room. I just havent found any of them yet.
23
OBSOLETE INTERFACE MODULES PRESENT COMMUNICATION CONUNDRUM
Figure 1: Are there HART or other bus device(s) that can replace the functions of the shaded area?
I have checked Honeywells HTG system
wireless transmitters, because the system
based on FDI 877, but it requires separate
will automatically report which transmitter is
AC power supply, and hasnt been con-
the one that needs maintenance or battery
firmed to be capable of powering three
replacement. Smart, wireless transmitters can
HART transmitters in daisy chain (versus
also be useful if you want historical trend, in
individual wires from each instrument). Ive
and out flow, vaporization loss or other, more
also considered battery-powered wireless
sophisticated displays or calculations.
HART transmitters communicating to a
gateway, but that solution has its cons.
Moore Industries makes a HART-to-
Olusegun Komolafe / segunkom@gmail.com
Modbus converter (HCS) that might
In your present installation, I consider
handle this application. Here is a link.
the fully redundant transmitter ap-
proach outdated. The cost of three trans-
Without chasing all of the details, I dont
mitters is usually less than the cables plus
know for certain that it will work, but either
increased maintenance of the redundant. I
this product (or a similar one) might be a
prefer three because in a redundant sys-
good place to start
tem, all you know is that one is wrong, but
Hunter Vegas / phvegas50@gmail.com
you dont know which one. Since you have

shutoff valves on the pressure transmitters,
installing three of them is no problem.
Once you have a voting system, you can use
24
Experts weigh
in on distillation plant
measurement problems
Bla Liptk and his crew tell how to resolve difficulties with measuring
column differential pressure and flows of flare and natural gas
By Bla Liptk
Installation differential pressure transmitters on tall towers (inlet and outlet) for
vapor service has been a big problem for me. I have mounted a differential pressure
(DP) transmitter above the outlet line of the tower with its low-pressure side con-
nected by a sloping tube to the outlet pipe, and high-pressure side connected to the tower inlet
pipe with a 14-meter-long tube. We have two pressure gauges on the inlet and outlet pipes
showing 3 PSID while the DP cell reads 600 mbar (9 PSID). What is the problem, condensation?
What is the remedy, increasing slope or insulation? A similar case has not been resolved, and I
had to use two pressure transmitters (PT) to get software differential value. When I touch the
low tapping, its temperature is colder than the other leg. Butene is the measured vapor.
Rahim Romel / rahim1356@gmail.com
The left side of Figure 1 shows my understanding of what you have now and on the
right I am showing what I would do to fix your problem. In general, I do not like to use
conventional DP cells to measure the pressure difference between points that are at different
elevations, because the lead lines can introduce errors due to condensation, or due to errors
caused by differences in temperature or density on the two sides of the cell. These problems
can be reduced by using capillaries or pressure repeaters, but why bother? The best solution
in my experience is to use two good pressure transmitters and measure the difference between their outputs, as shown on the right of Figure 1.
25
Flowmeter engineering is intertwined

PT
with deep understanding of pro-
cess, process behavior, operational ranges,
PT
2
P1
2
process thermodynamics, and flow system

engineering as to what is the objective, for
P1-P2 = 200 mb
example, custody transfer, process control
PT= 600 mb
or flow indication as the questions indicate.

Instrumentation engineering is applied sci-
P1
1
PT
1
ence, requiring more knowledge than just

transmitters and orifice plates.
You have
Your transmitter leg on the high side is very
Replace with
Figure 1: Tower pressure drop measurement
long compared to the low side, and because of this the effect of the fluid thermal
so that this low side will be self draining back
expansion/contraction in the impulse line
into the top outlet pipe. With this configu-
has a potential of giving you this error. As
ration, the high pressure side of the dp cell
you know, the coefficient of thermal expan-
will have a very lead line connecting it to the
sion varies by the cube of the expansion
pressure tap at the bottom of the column
coefficient. Insulation of the impulse tubes
inlet pipe. Depending on the thermal insula-
may helpmy suggestion would be to use
tion used on the lead lines and on the tem-
capillary-filled tubes of equal length on both
peratures of the process streams at the in and
the low and high side. Make sure the capil-
outlets of the column, there might be conden-
lary lengths of both legs are the same, and
sation in these tubes, which might introduce
are exposed to the same ambient condi-
some errors. Yet, this configuration is still bet-
tion. One leg should not be in shade and the
ter than locating the dp cell down at the level
other in sun, because we want to negate the
of the inlet pipe, because then the lead line to
thermal effects. The capillary should elimi-
the low side will not be self draining, but can
nate the effect of phase changes etc., so it
fill and if it does, that side will become the
would give a more accurate measurement.
high pressure side. In any case you may need
Romel S. Bhullar, senior technical director,
to recalibrate the transmitter.
Fluor Corp. / romel.bhullar@fluor.com
Alex (Alejandro) Varga / project & construction

management, Devco / vargaalex@yahoo.com
Since the low pressure side of the dp

cell is connected to the pressure tap
at the top of the column, it is recommended
that the cell itself be located above that point
26

Level Instrumentation State of Technology

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Level Instrumentation State of Technology

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SPECIAL REPORT

STATE OF TECHNOLOGY REPORT:

and switchesfloat/displacer, differential pressure (DP),

of solids and liquids in tanks and vessels is amazingly

capacitance/admittance/conductance, vibration, magneto-

complex in practice because there is a virtually infinite

striction, radar, laser, nuclear, weightare well established.

number of combinations of materials and operating

Our following and most recent coverage focuses on

the resulting problems with agglomeration, separation,

expanding applications and solving problems with using

corrosion, foam, vapor and adhesion, as well as high and

conventional technologies in existing applications. Read

low pressures and temperatures, etc., has resulted in

on to see how to deal with (or eliminate) DP impulse line

markets for many niche as well as broad applications for

problems, control oil/water interfaces, improve boiler

a wide variety of instrumentation.

drum level control, and more. Should this report not

Every few years, advances in manufacturing and signal

on level instrumentation and control in the Control 2015

processing bring a new technology, such as laser, into the

State of Technology Report: Level & Flow.

practical realm of industrial applications, but for the most

Point and multi-point solutions

Widest selection of wetted materials

Liquids, slurries, foams

Global agency approvals for Ex installations

Single and dual alarm models

Nuclear safety qualified

Multi-function: level and temperature

Digital signals support low-maintenance approach 

Level technologies get faster and more precise

Controlling levels of parallel separators

Advanced control for boiler drum level?

Remote tank gauging

Experts weigh in on distillation plant measurement problems

Fluid Components International

A new dimension of radar

State of Technology Report: Level Instrumentation

vulnerable to freezing and plugging, and they

We thought we might have to heat trace

benefit from the conducted heat of the pro-

the capillaries. Fortunately, we had digitally

cess itself. The fluid in the wet legs is purged

integrated (fieldbus) transmitters.

free of any vapor pockets, 100% filled with a

Today, the reactor DP and a dozen other DP

welds. This isolation also makes them ap-

and level measurements have been convert-

pealing for high-pressure, corrosive or toxic

ed from DP transmitters to DP by differ-

applications where we prefer that the instru-

ence using two static pressure transmitters.

ment tech isnt exposed to the hazards. But

It works because the transmitters commu-

since such systems are sealed, they impede

nicate digitally, and carry a tighter spec and

everyday DP transmitter calibration and spare

warranty for accuracy and stability right out

parts procedures. Frequently a dedicated

of the box. It costs moreyoure buying two

spare is needed for each application. Even

transmitters instead of onebut the method

Digital signals support low-maintenance approach

Level technologies get faster and more precise

Controlling levels of parallel separators

Advanced control for boiler drum level?

Remote tank gauging

Experts weigh in on distillation plant measurement problems

Fluid Components International