--------------Calibrate for Level

Module 12407

Instrument Trainee Task Module 12407

CALIBRATE FOR LEVELObjectives:

Upon completion of this module, the trainee will be able to: 1. Discuss and describe elements used in level measurement. 2. Discuss and describe instruments to be calibrated. 3. Select and set up test equipment based on available data s eets. 4. Discuss and prepare required documentation o! test per!ormance. ". #er!orm test procedure !or calibration o! level.

#rerequisites
Success!ul completion o! t e !ollo$in% &as' Modules is required be!ore be%innin% stud( o! t is tas' module: )**+, &as' Modules 12401 t orou% 1240-.

,equired Student Materials

1. Student Modules 2. ,equired Sa!et( +quipment

.nstrument &rainee &as' Module 12407

*ourse Map .n!ormation

& is course map s o$s all o! t e Wheels o f Learning tas' modules in t e !ourt level o! t e .nstrument curricula. & e su%%ested trainin% order be%ins at t e bottom and proceeds up. S'ill levels increase as a trainee advances on t e course map. & e trainin% order ma( be adjusted b( t e local &rainin% #ro%ram Sponsor.

/+0+/ 4 *OM#/+&+

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&23/+ O4 *O)&+)&S
Section Topic Page 1.0.0 .ntroduction 5555555555555555555555555555.. " 2.0.0 &(pes o! /evel Measurin% Devices 55555555555555555 2.1.0 4loat /evel Devices 5555555555555555555555555 2.1.1 6au%e 6lasses 7Si% t 6lass8 55555555555555555555 9 2.1.2 *apacitance #robe /evel Devices 55555555555555555510 2.1.3 Displacer /evel Devices 55555555555555555555555 13 2.1.4 *onductivit( #robe /evel Devices 55555555555555555.. 12.1." Di!!erential #ressure /evel Devices 55555555555555555 12.1.- :ltrasonic /evel Detectors 555555555555555555555. 20 3.0.0 .nstruments to be *alibrated 55555555555555555555 23 4.0.0 Selection o! &est +quipment 55555555555555555555. 24 ".0.0 *alibration;&est #rocedures 55555555555555555555.. 24 ".1.0 *alibration * ec' o! a /evel &ransmitter 55555555555555 24 -.0.0 &est #er!ormance Documentation 55555555555555555. 2"

.nstrument &rainee &as' Module 12407

&rade &erms .ntroduced .n & is Module

Accounting grade measurements: /evel measurements o! tan' or vessel inventories t at are required to be ver( accurate !or t e accountabilit( o! t ese substances. Arc imedes! Princip"e: 2 bod( $ oll( or partl( immersed in a !luid is buo(ed up $it a !orce equal to t e $ei% t o! t e !luid displaced b( t e bod(. Ba"" #"oat: A t(pe o! level device t at consists o! a ollo$ metal sp ere desi%ned to !loat on t e sur!ace o! t e contents o! a tan' or vessel. Capacitance: & e propert( o! a circuit element t at permits it to store a c ar%e Conducti$it%: 2 measure o! t e abilit( o! a substance or material to conduct an electrical c ar%e. &%drostatic &ead Pressure: pressure produced in a tan' due to t e $ei% t o! t e liquid above t e measurement point. Immisci'"e: incapable o! mi<in% or blendin%. (agnetic 'ond "e$e" de$ice: 2n inner ma%net located in a ollo$ tube $ ic is attracted to an outer ma%netic !loat $ ic rises and !alls $it tan' level. & e inner ma%net is connected to a pointer $ ic indicates level rise or !all. Pie)o-E"ectric Cr%sta": cr(stals= $ ic stress= produce a volta%e. $ en subjected to mec anical

Sonar: So7und8 )a7vi%ation8 ,7an%in%8= a s(stem usin% transmitted and re!lected acoustic $aves to locate submer%ed objects. Stu##ing Bo*: mac ined cavit( desi%ned to prevent lea'a%e alon% moveable s a!ts. old pac'in% in order to

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1.0.0 .)&,OD:*&.O)>
& e stora%e and processin% o! substances in process s(stems involves t e use o! vessels suc as tan's= pools= pits= basins= sumps= etc. & e substances can be liquids= bul' solids= or a combination o! t e t$o called ?slurries.? & ere must be some met od emplo(ed !or determinin% t e amount o! t e substance stored or processed $it in t ese vessels. One suc met od is to measure t e level or ei% t o! t e substance $it in t e vessel. & e main objectives o! measurin% t e level o! substances in vessels are: a8 to prevent over!ill= b8 to prevent total runout= and c8 to provide inventor( monitorin%. /iquid level measurin% devices eit er measure t e ei% t o! t e liquid in a vessel= or t e( measure t e (drostatic ead pressure created b( t e ei% t o! t e liquid. 3ul' solid and slurr( level measurin% devices eit er measure t e ei% t o! t e substance= or t e( measure t e $ei% t o! t e substance in a vessel o! 'no$n volume. /evel measurin% devices are classi!ied as eit er direct@met od t(pes or in!erred@met od t(pes. 2n e<ample o! a direct met od is t e dip stic' o! a car en%ine $ ic is used to measure t e ei% t o! oil in t e oil pan. 2n e<ample o! an in!erred met od t(pe is t e use o! a pressure %au%e connected to t e bottom o! a $ater tan' to measure t e hydrostatic head pressure !rom t e ei% t o! t e $ater. & is module discusses several t(pes o! level measurin% devices includin% operation= calibration= and adjustments.

2.0.0 &A#+S O4 /+0+/ M+2S:,.)6 D+0.*+S>

/evel measurement applications can be broadl( %rouped b( service as !ollo$s: atmosp eric vessels= pressuriBed vessels= and accountin% %rade. Accounting grade measurements are made in bot atmosp eric and pressuriBed vessels. & e need !or accurac( in accountin% %rade installations is especiall( important i! t e level measurement is used as t e basis !or custod( trans!er o! aBardous materials. & is section $ill describe several di!!erent t(pes o! level indication devices and o!!er some insi% t into t e accurac( available !rom eac t(pe.

2.1.0 4loat /evel Devices

& is t(pe device depends on t e abilit( o! a material to !loat on t e sur!ace o! t e substance to be measured. & ere are several variations o! !loat@t(pe level instruments includin% ball !loat= c ain !loat= and ma%netic bond !loat. 3all !loat mec anisms provide a direct met od o! liquid level measurement. 2 ollo$ metal ball or sp ere is one o! t e most practical desi%ns !or t e !loat member. Co$ever= t ere are no restrictions as to siBe= s ape or material t at ma( be used. & e ball !loat mec anism

.nstrument &rainee &as' Module 12407

consists o! a ball !loat attac ed to a rod= as s o$n in Figure 1. & e rod is attac ed to a rotatin% s a!t $ ic indicates level on a scale. & e ball !loat s ould be $ei% ted so t at it $ill sin' to its lar%est section= $ ic is t e center i! it is a sp ere. & is $ill provide ma<imum sensitivit( and t e %reatest !orce in bot directions to overcome !riction.

4i%ure 1. 3all 4loat Mec anism

& t & t

e travel o! t e ball is usuall( limited b( desi%n to be $it in D30E !rom e oriBontal plane= $ ic results in optimum response and per!ormance. ere!ore= t e actual level ran%e t at can be measured is determined b( e len%t o! t e connectin% arm.

& e stuffing box provides a $ater@ti% t seal around t e s a!t to prevent lea'a%e o! liquid out o! t e vessel. * ain !loat %au%es ave !loats up to 12? in diameter and are used $ ere t e small level limitations imposed b( ball !loat %au%es must be e<ceeded. & e amount o! level measured is limited onl( b( t e siBe o! t e vessel. & e !loat is connected to a rotatin% member b( a c ain= as s o$n in Figure 2. A c ain sproc'et turns t e rotatin% member. :suall( a $ei% t is attac ed on t e opposite end o! t e c ain to provide a means o! 'eepin% t e c ain taut durin% c an%es in level.

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4i%ure 2. 3asic * ain 4loat 6au%e

& e ma%netic bond met od $as developed to overcome t e problems associated $it ca%es and stu!!in% bo<es. *onstruction usuall( includes a ma%netic !loat $ ic rises and !alls $it c an%es in liquid level= as s o$n in Figure 3.

4i%ure 3. Ma%netic 3ond /evel Detector

& e !loat is %uided b( a non@ma%netic tube= $ ic ouses an inner ma%net. & is in turn is attac ed to an indicator. 2s t e !loat rises and !alls= t e outer ma%net attracts t e inner ma%net= causin% t e inner ma%net to !ollo$ t e liquid level in t e vessel.

2.1.1 6au%e 6lasses 7Si% t 6lass8

2 simple met od o! measurin% vessel liquid level is b( attac in% a

.nstrument &rainee &as' Module 12407

transparent tube to t e vessel= as s o$n in Figure 4.

4i%ure 4. &ransparent &ube 2ttac ed to 0essel

& e vessel s o$n in Figure 4(a) is !or applications $ ere t e liquid is at ambient temperature and pressure conditions. & e vessel s o$n in Figure 4(b) is !or applications $ ere t e liquid is at an elevated pressure or at a partial vacuum. )otice t at t e vessels and t e attac ed transparent tubes e!!ectivel( !orm ?:@&ube Manometers?. & e liquid see's its o$n level. & e transparent tube is called a ?%au%e %lass=? or ?si% t %lass=? because t e level o! t e liquid in t e tube is %au%ed to a calibrated scale b( line o! si% t. Some %au%e %lasses are made o! tubular %lass or plastic= and are used !or service up to 4"0 psi% and 400E4. 4or service at i% er pressures and temperatures= anot er t(pe o! %au%e %lass is used in $ ic t e bod( is made o! metal= $it a eav( %lass or quartB section providin% a visual openin% !or observin% t e liquid level. 6lass is muc stron%er under compression !orces t an it is under tension !orces= t ere!ore= t e %lass section is usuall( !lat in s ape to provide additional. stren%t and sa!et(. Figure 5 s o$s a t(pical transparent %au%e %lass.

*alibrate !or /evel 1 Module 12407

4i%ure " &ransparent 6au%e 6lass

6au%e %lasses are available in standard siBes $it t e visual %lass section var(in% in len%t !rom 10 inc es up to 20 inc es. Several o! t ese standard len%t %au%e %lasses can be attac ed to !orm a lon%er sin%le unit !or use on taller vessels. & e ma<imum len%t is limited b( t e total $ei% t o! t e unit= and b( t e structural support provided. 6enerall(= eac %au%e %lass unit is provided $it top and bottom isolation valves to isolate t e %au%e %lass !rom t e vessel in case o! a lea'. +OTE: 2 si% t %lass t at contains a transparent liquid ma( appear to be empt(= $ en it is actuall( !ull.

Figure 6 s o$s anot er t(pe o! %au%e %lass= called a ?re!le<? %au%e %lass. .t emplo(s a desi%n t at aids in distin%uis in% t e liquid level in t e %au%e %lass.

4i%ure -. ,e!le< 6au%e 6lass

.n t is t(pe o! %au%e %lass= one side o! t e %lass section is !ormed in t e s ape o! prisms. & is means t e %lass is molded on one side $it F00 an%les t at run len%t $ise. & e prisms re!lect t e li% t ra(s t at stri'e t e %lass. & e li% t ra(s stri'e t e outer side o! t e %lass at a F00 an%le= t en travel t rou% t e %lass and stri'e t e inner side o! t e %lass at a 4"0 an%le. & e presence or absence o! liquid in t e c amber determines i! t e li% t ra(s are re!racted into t e c amber= or are re!lected bac' to t e outer sur!ace o! t e %lass. 2ssumin% t at t e liquid is at an intermediate level in t e c amber= and assumin% t at t e liquid is $ater= t e li% t ra(s ?see? an air@%lass inter!ace in one portion o! t e c amber= and t e( see a $ater@%lass inter!ace in t e ot er portion o! t e c amber. .n t e portion o! t e c amber t at contains air= t e li% t ra(s are re!lected bac' to t e outer sur!ace o! t e %lass= so t e %lass appears silver(@$ ite. ,e!lection occurs because t e critical an%le !or a li% t ra( to pass !rom %lass to air is 42E. .n t e portion o! t e c amber t at contains $ater= t e li% t ra(s are re!racted into t e c amber b( t e prisms. & e %lass appears blac' because it is possible to see

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t rou% t e $ater to t e $alls o! t e c amber $ ic are painted blac'. ,e!lection o! t e li% t ra(s bac' to t e outer sur!ace o! t e %lass does not occur because t e critical an%le !or a li% t ra( to pass !rom %lass to $ater is -2E.

2.1.2 *apacitance #robe /evel Devices

2 capacitor consists o! t$o conductors isolated b( an insulator. & e conductors are called ?plates? and t e insulator is re!erred to as t e ?dielectric.? & e c aracteristic nature o! a capacitor is its abilit( to accept and store an electric c ar%e. G en a capacitor is connected to a batter(= as s o$n in Figure 7, t e ne%ative electrons on plate H2 are attracted to t e positive electrodes o! t e batter( and t e ne%ative electrons on plate H 1 are repelled b( t e ne%ative electrode o! t e batter(. & e electrons !lo$ until t e batter( potential is establis ed across t e capacitor. & e lar%er t e capacitor= t e more current $ill !lo$ to c ar%e t e unit. 2 per!ect capacitor is one in $ ic no current !lo$s !rom one plate to t e ot er. & e ma%nitude o! !lo$ is directl( proportional to t e siBe o! t e capacitor.

4i%ure 7. & e *apacitance /oop and t e *apacitance o! *(lindrical +lements

2 c an%e in t e c aracteristics o! t e material bet$een t e plates $ill cause a c an%e in dielectric constant= $ ic is o!ten lar%er= more de!inite= or more easil( measured t an c an%es in ot er properties. & is ma'es t e dielectric measurement suitable !or detection not onl( o! level= but also composition= moisture content= or c emical structure o! a substance. 3ecause t e dielectric constant o! %ases is nearl( unit(= %as composition cannot be measured b( capacitance tec niques. 2s can be assumed= c an%es in process material c an%e t e dielectric constant. G ile t ese c an%es are elp!ul in measurin% various c aracteristics o! t e material= t e( also in!luence t e accurac( o! level measurement Hnd= t ere!ore= must be evaluated care!ull(. 0ariations in process level cause c an%es in capacitance. *apacitance is measured b( a brid%e circuit e<cited b( a i% !requenc( oscillator 70."@ 1." me%a erB8. 2s s o$n in Figure 8, t e probe is insulated !rom t e vessel and !orms one plate o! t e capacitorI t e vessel !orms t e ot er. 7#rocess pressures and temperatures determine t e t(pe o! seal used at

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t e insulator= and corrosion conditions determine t e t(pe o! probe material.8 & e process material bet$een t e plates is t e dielectric. 2s level rises= vapors $it lo$ dielectric constant 71.08 are displaced b( t e i% er dielectric process materials. *apacitance c an%es are detected $it an instrument calibrated in units o! level.

4i%ure 9. 3are *apacitance #robe

4or measurement o! non@conductive materials= t e bare metal probe s o$n in Figure 8c can be used. * l is t e ?dead capacitance? o! t e s(stem $ ic is una!!ected b( level c an%es. *2 is t e capacitance in t e vapor p ase= and *3 is !or t e process material. , is t e e!!ective resistance bet$een t e probe Jand vessel= $ ic varies $it t e level in t e vessel. .! its value cannot be appro<imated as in!inite 7*e K *l L *2 L *38= t e measurement cannot be made $it a bare probe. & e capacitance o! t e s(stem s ould be a!!ected b( c an%es in level onl(. 4or measurin% t e level o! conductive materials= insulated 7normall( &e!lon coated8 probes are used. 2s s o$n in Figure F= t is measurement is lar%el( una!!ected b( t e e!!ective resistance and t ere!ore t is probe desi%n is applicable to bot conductive and non@conductive processes.

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4i%ure F. *oated capacitance probe

.! t e process material ad eres to t e probe= a level reduction in t e vessel $ill leave a la(er o! !luid on t e probe. G en t is la(er is conductive= t e $et portion o! t e probe $ill be coupled to %round and t e instrument $ill not read t e ne$ level but $ill re%ister t e level to $ ic t e probe is coated. Ot er t an t e c an%es in process material dielectric constant= t is represents one o! t e most serious limitations o! capacitance installations. .t s ould be noted t at i! t e probe coatin% is non@conductive= t e inter!erence $it measurement accurac% is muc less pronounced. One ot er problem !requentl( encountered $it capacitance probe installations is %roundin% t rou% t e ead assembl(. Moisture can enter t rou% capillar( lea'a%e or a cable entrance= causin% a %round. Sensitivit( and dri!t in t e measurement s ould be considered care!ull(. Some devices are sensitive to 0." pico!arads 7p!8 and $ill dri!t " p! o$in% to a temperature c an%e o! 100E4 7"-E*8. & e best qualit( units available are sensitive to 0.1 p! and ave a dri!t o! 0.2 p! per 100E4 7"-E*8.

2.1.3 Displacer /evel Devices

Archimedes' Principle states t at a bod( $ oll( or partiall( immersed in a !luid is buo(ed up b( a !orce equal to t e $ei% t o! t e !luid displaced. 3( detection o! t e apparent $ei% t o! an immersed displacer= a level instrument can be devised. .! t e cross@ sectional area o! t e displacer and t e densit( o! t e liquid are constant= t en a unit c an%e in level $ill result in a reproducible unit c an%e in displacer $ei% t. & e simplest level device o! t is t(pe involves a displacer t at is eavier t an t e process liquid and is suspended !rom a sprin% scale. G en t e liquid level is belo$ t e displacer= t e scale s o$s t e !ull $ei% t o! t e displacer. 2s t e level rises= t e apparent $ei% t o! t e displacer decreases= t ereb( (ieldin% a linear and proportional relations ip

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bet$een sprin% tension and level. & e sprin% scale can be calibrated 0 to 100 percent= or in ot er level units. & is simple device is limited to applications in open tan's. .n actual industrial measurement= t e basic problem is to seal t e process !rom t e sprin% scale or ot er !orce@detectin% mec anism. & is seal as to be !riction@less and use!ul over a $ide ran%e o! pressures= temperatures= and corrosion conditions. & e variations in t e desi%n o! t is seal distin%uis t e t(pes o! displacement detectors. & e( are t e ma%neticall(@coupled s$itc = t e torque tube= t e diap ra%m and !orce bar= t e sprin%@balanced= t e !le<ible disc= and t e !le<ible s a!t desi%n. +ac o! t ese units operates on 2rc imedesM #rinciple= but are di!!erent as !ar as t eir seals are concerned. 2ll o! t em can detect liquid@vapor inter!ace= liquid@liquid inter!ace and= i! level is constant= t e( can be used to detect densit( c an%es. & e !le<ible disc unit is available as a pneumatic transmitter= and t e !le<ible s a!t unit is available as a i% @%ain pneumatic controller. & e ot er desi%ns are available $it local pneumatic controllers and pneumatic or electronic transmitters. & e torque tube s o$n in Figure 1 uses a torsion sprin% to support t e displacer. 3( usin% a ollo$ torsion tube it is !easible to bot support t e displacer= $ ic is al$a(s eavier t an t e process !luid= and to provide a !rictionless pressure seal. & is ma'es it possible to trans!er t e c an%es in t e apparent $ei% t o! t e displacer t rou% t e $all o! t e pressure vessel into a suitable measurin% device. Figure 1 %ives a sc ematic presentation o! t e displacer and torque tube. & e displacers are c(lindrical and can be !urnis ed in a $ide selection o! plastic and allo( materials. 2lt ou% an( len%t displacer up to 10 !t. 73m8 can be obtained= t e most common len%t s used are 14= 32= 49= and -0 in. 70.3= 0.9= 1.2= and 1."m8. & e volume o! t e standard displacer is 100 cu. in. 71=-39 cc8 and consequentl(= t e diameter is reduced as t e len%t increases.

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4i%ure 10. &orque &ube Displacer /evel Detector

& e torque arm connects t e displacer to t e torque tube and absorbs lateral !orces. 4riction is minimiBed b( use o! a 'ni!e@ed%e bearin% support. +OTE: *are s ould be ta'en not to dama%e t e 'ni!e ed%e= as t is ma( prevent proper calibration.

2 limit stop prevents accidental over@stressin% o! t e torque tube b( limitin% t e do$n$ard motion o! t e torque arm. & e an%ular displacement o! t e torque tube and torque arm are t e same at t e 'ni!e ed%e end o! t e tube. 2t t e !lan%e end= t e tube does not rotate at all because it is solidl( eld= but t e torque rod is !ree to rotate t e same amount as it did at t e 'ni!e ed%e. & e an%ular displacement= $ ic amounts to about " or - de%rees= is linearl( proportional to apparent $ei% t o! t e displacer and t us level. Git t e di!!icult pressure sealin% problem solved= it is a simple matter to convert t e an%ular displacement to a usable electronic or pneumatic analo% si%nal. & e standard torque tube material is .nconel but it is also available in stainless steel= Castello(= Monel= nic'el= or Durimet. Figure 11 illustrates t e !le<ible disc desi%n. 2s risin% liquid level reduces t e apparent $ei% t o! t e displacer= t e !loat arm moves t e bello$s and noBBle seat to$ard t e noBBle. & is increases t e noBBle bac'@pressure= $ ic causes t e air pilot to increase its output pressure until t e

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!eedbac' air to t e bello$s rebalances t e s(stem. Since t e apparent $ei% t o! t e displacer= t e !orce o! t e Bero adjustment sprin%= and t e !orce %enerated b( t e !eedbac' bello$s must al$a(s be in equilibrium= t e unit is classi!ied as !orce balance. & e output si%nal is directl( related to t e level in t e vessel. Span adjustments are made b( c an%in% t e total len%t o! t e !loat

4i%ure 11 4le<ible Disc Sealed Displacement &ransmitter

& e !loat arm is supported b( t e !le<ible disc. O$in% to t e !orce balance principle o! operation= all members maintain t eir predetermined position $it essentiall( no movement= protectin% t e !le<ible disc !rom bendin% !ati%ue. & e $ei% t o! t e displacer and !loat arm is carried b( t e !le<ible disc= and t e static pressure in t e vessel acts upon t e t rust pivots. /imit stops 'eep t e !loat arm motion $it in t e elastic limits o! t e disc $ en t e vessel is empt(. & is desi%n as t e same limitations as t e ot er displacer units but as a narro$er ran%e o! application because t e !le<ible disc seal limits use up to 100 psi% 70.7 M#a8 operatin% pressure. 2t i% er pressures= t e unit !irst becomes inaccurate= and t en unsa!e. & e !le<ible disc is normall( made o! stainless steel but it is also available in Monel or nic'el. & e displacer can be made o! a $ide variet( o! materials. 4rom a per!ormance and application standpoint= t is unit is in!erior to some ot er desi%ns.

2.1.4 *onductivit( #robe /evel Devices

Figure 12 illustrates t e principle o! operation o! t e conductivit( level probe. & e electrode is s o$n above t e liquid level on t e le!t side o! t e

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s'etc . & e circuit= t ere!ore= is open and no current is !lo$in% t rou% t e rela( coil to ener%iBe t e rela( and close t e load contact. G en t e liquid level rises= as s o$n on t e ri% t side o! t e s'etc = a conductive pat bet$een t e electrode and t e %rounded tan' is establis ed= closin% t e circuit t rou% t e rela( coil. +ner%iBation o! t e rela( closes t e load contact= operatin% pumps= solenoid valves= or ot er processin% equipment. .n t is s(stem= t e liquid in t e tan' acts as a s$itc in t e rela( circuit. & e sin%le probe installation described is normall( used !or i% or lo$ level detection. 2lt ou% electro@mec anical rela(s are s o$n in t e !i%ure= solid state rela(s are commonl( used. 2lso= i! t e tan' is !abricated o! !iber%lass or ot er insulatin% material= t e s$itc in% circuit can be made bet$een t e sensin% probe and a re!erence probe.

4i%ure 12 Sin%le #oint *onductivit( S$itc

2.1." Di!!erential #ressure /evel Devices

/iquid level can be measured b( a di!!erential pressure 7d;p8 instrument. 4or vessels operated at atmosp eric pressure= t e i% side o! t e instrument is connected to t e bottom o! t e vessel and t e lo$ side is vented to atmosp ere. 4or pressuriBed vessels= t e i% side is connected to t e vapor space in t e vessel. & is installation $ill %ive an accurate measurement o! t e liquid level provided t at t e densit( o! t e process does not c an%e. & eoreticall(= di!!erential pressure can be detected b( sensin% t$o pressures separatel( and ta'in% t e di!!erence to obtain liquid level. .n practice= it is desirable to use a sin%le pressure di!!erence sensor so t at t e static pressure levels are intrinsicall( balanced. & e importance o! t is consideration can be visualiBedI !or e<ample= on a 0 to 100 in. 70 to 2." m8 $ater column measurement $ ere t e e<pected accurac( $ill be D 1;2 in. 7D 12.7 mm8 $ater column. .t $ould be impossible to approac t is accurac( i! t e measurement $ere made at a static pressure level o! 1=000 psi% 7-.F M#a8 usin% t$o independent sensors. & e cate%ories o! devices considered are: dr( !orce balance desi%ns= dr( motion balance desi%ns= and manometers. 6enerall(= dr( !orce balance desi%ns are used $ en a pneumatic or an electronic transmission si%nal is required. & e pneumatic transmitters are considered !irstI t e options discussed are also available on electronic transmitters.

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Figure 13 s o$s a sc ematic illustration o! t e pneumatic transmitter. 2 pair o! diap ra%ms is $elded to t e opposite sides o! t e cell and t e space bet$een t em is liquid@!illed. & is !ill is used !or dampenin% out process noise= a common problem $ en t e d;p cell is used on !lo$ applications= but not normall( a consideration !or level installations. & e di!!erential pressure to be detected is applied to t e t$o M sides o! t is diap ra%m capsule. & e resultin% !orce is t en brou% t out o! t e d;p cell via t e !orce bar. G en a c an%e o! di!!erential occurs= t e !orce bar c an%es its position relative to t e noBBle= causin% a c an%e in t e pneumatic output si%nal. & e c an%e in air pressure is sensed b( t e !eedbac' bello$s and a ne$ state o! equilibrium 7!orce balance8 is establis ed b( t e bar !orce bein% opposed b( an equal !orce developed in t e !eedbac' bello$s. 2s a result= t e output si%nal is maintained proportional to di!!erential pressure sensed b( t e cell.

4i%ure 13. 4orce 3alance d;p *ell Sc ematics

Several important desi%n !eatures o! t e d;p cell merit attention. 2s s o$n in Figure 14, t e unit as Bero= span= and elevation;suppressor adjustment. .! t e unit is piped so t at t e i% and lo$ sides can be equaliBed= t e Bero settin% o! t e instrument can be c ec'ed b( readin% t e output %au%e. & e span adjustment is lar%e= %enerall( in t e ran%e o! 10 to 1. & e elevation; suppressor adjustment can be used to ?Bero out? a constant ead on eit er t e lo$ side or t e i% side. & e pressure ratin% o! t e unit is determined b( t e ratin% o! t e enclosure and can be as i% as 10=000 psi% 7-F M#a8.

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4i%ure 14. 4orce 3alance Di!!erential #ressure *ell 2djustments

+<posure o! one side or t e ot er to t is pressure $ill not dama%e t e instrument or necessitate recalibration because overpressure causes t e diap ra%ms to bottom out on t e capsule supports be!ore t e elastic limit o! t e diap ra%ms is reac ed. & e displacement volume o! t e unit is smallI t us= var(in% static pressures $ill not cause t e level in t e seal le% to drop. 2lso= because o! limited motion= t ere is ver( little !riction or $ear in t e unit. 4inall(= on some desi%ns t e lo$ side and i% side volumes are t e same= so t at liquid e<pansion or contraction due to temperature c an%e as t e same e!!ect on bot sides o! t e diap ra%m. & is is important i! t e unit is !urnis ed $it liquid@!illed c emical seals. 2 $ide ran%e o! materials are available !or process@$etted parts. 2 common diap ra%m material is Castello(. & e bod( can be !urnis ed in carbon steel= stainless steel= i% allo(s= and plastics suc as &e!lon= alt ou% plastic desi%ns $ill ave a considerabl( lo$er pressure ratin%. /iquid manometers are t e simplest di!!erential pressure detectors and are economical= reliable= and accurate. G ere local visual indication is su!!icient and t e static pressures are compatible $it t e transparent tube desi%n= t e %lass tube manometers can be considered. 4loat versions o! t e liquid manometers can be installed on i% @pressure services or $ ere remote readout is desired. 4i%ure 1" illustrates t e most elementar( :@tube manometer. & e di!!erence in level bet$een t e t$o columns o! liquid is an indication o! t e pressure di!!erential. & ere are no movin% parts= no !riction or inertia involved in t e measurement= and t ere!ore accurac( is limited onl( b( scale visibilit(. 2s s o$n in 4i%ure 1-= a more easil( read scale can be attac ed to t e $ell manometer. & e liquid sur!ace area on t e i% pressure side is 1=000 or more times %reater t an t e area on t e lo$ pressure side. & ere!ore= c an%es in di!!erential pressure cause variations onl( in t e lo$ side column ei% t and leave t e i% side level practicall( una!!ected. * an%es in $ell liquid level are compensated !or b( slidin% t e scale Bero to matc t is level.

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4i%ure 1". :@&ube Manometer

4i%ure 1-. Gell Manometer

& e liquid !ill !or manometers must be inert and must be compatible $it = immiscible $it = and eavier t an t e process. 6lass tube manometers are available $it ran%es up to 120 in. 730" cm8 $ ic is su!!icient !or most level applications i! t e !illin% !luid is mercur(. Desi%ns !or pressures up to 1=000 psi% 7-.F M#a8 can be obtained= but t eir use is discoura%ed because o! t e potential !or dan%er i! t e tube is dama%ed. .n industrial installations= t e use o! %lass tube manometers is limited to locations $ ere tube brea'a%e $ill not endan%er t e operator eit er due to t e e<plodin% %lass particles or because o! t e nature o! t e process material released. 4or installations $ ere remote readouts are required= or $ ere t e process material is aBardous or at a i% pressure= !loat manometers can be used. 2s s o$n in Figure 17, variations in pressure di!!erential cause t e level o! !illin% liquid to c an%e= movin% t e !loat. 4loat motion is brou% t out o! t e c amber b( a lever rotatin% in a pressure seal bearin%. 7Ot er desi%ns are available usin% torque tube or ma%netic !ollo$ers.8 /ever rotation can be used to drive local indicators= or transmittin%

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devices !or remote readout.

4i%ure 17. 4loat Manometer

& ese instruments can be e<posed to static pressures up to -=000 psi% 741 M#a8 and detect pressure di!!erentials !rom 20 to 1=000 inc es o! $ater column 7" to 2"0 '#a8. /o$er di!!erentials are not practical because o! inaccuracies= and i% er ones $ould require un$ield( re!erence c ambers. Stainless steel :@tube manometers avin% ma%netic !loats in bot le%s ave been used !or i% precision at static pressures to 10=000 psi% 7-F M#a8. & e !loat positions in t is desi%n are detected b( electric coils $ ic provide a ver( precise measurement o! di!!erential pressure.

2.1.- :ltrasonic /evel Detectors

:ltrasonic level devices can be used !or bot continuous and point measurement. & e point detectors= !or measurement o! %as;liquid= liquid;liquid= liquid;!oam= or solid;%as inter!aces can be %rouped b( desi%n into dampened sensor and on@o!! transmitter cate%ories= and b( met od o! pac'a%in% as sin%le element or t$o@element units. & e continuous level detector desi%ns can be cate%oriBed as under@liquid sensors and above@ liquid sensors. Most desi%ns use a 20 'CB or i% er oscillator circuit as t e ultrasonic si%nal %enerator. Some desi%ns incorporate !ilters or discriminator( circuitr( in electronics to prevent !alse readin%s t at mi% t be caused b( random noise. +ac o! t ese basic desi%n variations $ill be discussed separatel(. & e devices in t is cate%or( operate on similar principles to t at o! t e vibratin% reed s$itc . 2s lon% as t e sensor !ace is in t e vapor space o! t e tan'= it vibrates at its resonance !requenc( but is dampened out $ en t e process material contacts it. Some desi%ns incorporate a piezoelectric crystal in t e vibratin% tip. Figure 18 s o$s some o! t e elements and t eir installation. 4our units are s o$n in t e !i%ure. ?2? notes t e top entr( installation $ ere t e vibratin% !ace is in t e vapor space 7and t ere!ore undampened8. & is desi%n can be repositioned manuall( or automaticall( !or !le<ible adjustment o! control point. .nstallation ?3? is a unique desi%n in t at it does not penetrate t e tan'

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$all and t us is not in contact $it t e process !luid. G en t e liquid rises to t e opposite side o! t e $all= t e transducer is dampened and a s$itc action is indicated. Desi%ns ?*? and ?D? s o$ t e side@mounted s$itc elements= one dampened= t e ot er in undampened condition. & ese units are normall( limited to liquid service because t e dampenin% e!!ect o! solids is not su!!icient in most cases. Desi%n ?3? can be used on an( liquid= $ ile t e ot ers are limited to clean= non@coatin% !luids.

4i%ure 19. Dampened :ltrasonic Sensors

On@o!! transmitter@t(pe level s$itc es contain transmitter and receiver elements. & e transmitter %enerates pulses in t e ultrasonic ran%e and t e receiver detects t ese pulses i! t e( are transmitted t rou% t e media in $ ic t e probe is located. & e transmitter and receiver can be mounted on t e same probe or t e( can be located on t e opposite sides o! t e tan'. Figure 1! illustrates some o! t e variations o! t is desi%n. .nstallation ?2? s o$s a desi%n $ ere t e transmitter and receiver are pac'a%ed separatel(. & is desi%n transmits in airI t e s$itc $ill actuate $ en t e ultrasonic sound beam is interrupted b( t e risin% process material. ,e!lectors are installed to narro$ t e sonic beam an%le $ en t e distance bet$een source and receiver is more t an ten !eet 73 m8. .nstallation ?3? is a sin%le probe desi%n in $ ic t e pulses %enerated b( t e transmitter $ill be sensed b( t e detector onl( i! t e( are submer%ed in a non@compressible liquid. & e pulses are not transmitted in t e vapor space. Desi%n ?*=? $ ic is similar to ?3=? transmits onl( in liquid. G en !luid is present in t e %ap o! t e sin%le probe= t e ultrasonic sound beam is received b( t e detector in t e top and si%nals t e presence o! liquids. #robe ?D? is a multi@point variation o! ?*? allo$in% t e measurement o!

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bot i% and lo$ levels b( t e same probe. Desi%n ?+? is mounted at about 10 de%rees !rom t e oriBontal= and it can be used !or detection o! liquid; liquid inter!aces. & e ultrasonic sound beam %enerated b( t e receiver cr(stal is in onl( one liquid. .! an inter!ace is present in t e probe cavit(= t e inter!ace $ill re!lect t e si%nal= preventin% it !rom reac in% t e receiver.

4i%ure 1F. &ransmittin% :ltrasonic #oint Sensors

& e principle o! operation o! continuous level detectors is ver( similar to t at o! t e $ell'no$n ec ometers used to measure t e dept o! $ells. .n t at desi%n= a blan' s ell is !iredI t e time needed !or t e ec o to return is converted to an indication o! t e dept . & e continuous ultrasonic level detector ( !"A#$ measures t e time required !or an ultrasonic pulse to travel to t e process sur!ace and bac'. & e source is an oscillator@t(pe ultrasonic spea'er= and t e receiver= in most cases= is a metal disc $ ic is bot electricall( and mec anicall( resonant. & e transducer can be mounted eit er under or above t e liquid level. Figure 2 illustrates some o! t e desi%n !eatures and possible installations. .nstallation ?2? s o$s a t$o@element continuous detector= $ ere t e transmittin% and receivin% transducers are pac'a%ed separatel(. & is device transmits in air. & e time required to receive t e ultrasonic re!lection !rom t e sur!ace is t e measure o! t e vapor dept o! t e space= $ ic is an indirect indication o! level. 2not er version o! an ?in@air=? continuous level s(stem is illustrated in ?3.? & e transducer and receiver are pac'a%ed as a sin%le unit. & e transducer %enerates s ort bursts o! ultrasonic ener%(= and $ ile t e acoustic ener%( is bein% produced= t e receiver is blan'ed o!!. G en t e ultrasonic $aves are on t eir $a(= t e receiver %ate is opened to detect t e ec o. Mountin% t e transducers in t e vapor space as t e advanta%e t at t e instrument does not contact t e process materials= but it as t e disadvanta%e t at some ener%( is lost

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in travelin% t rou% t e vapor space.

4i%ure 20 *ontinuous :ltrasonic /evel Detectors

On liquid level applications= t e aimin% an%le must be $it in D2 de%rees !rom t e vertical. G en measurin% level o! solids= t e an%le o! repose s ould be tested. :nit ?3? in Figure 20 is s o$n equipped $it a calibration bar. .n t is desi%n= t e electronics pac'a%e as a level detector and a calibration detector. Since t e len%t o! t e bar is 'no$n= t e unit is bein% calibrated continuousl(. :nits so equipped can be ver( accurate= provided t at t e densit( o! t e material in t e vapor space is uni!orm. .n installation ?*=? t e time !or t e ultrasonic ec o is a true indication o! level. & e transducer can also be mounted on t e outside o! t e tan' 7?D?8= $it t e added advanta%e t at t e sensin% element does not penetrate t e tan'. Desi%ns ?*? and ?D? are applicable to continuous detection o! clean liquid levels= $ ile desi%ns ?2? and ?3? also can be used to measure t e level o! solids. 3( usin% several sensors in t e same bin= a visual pro!ile can be obtained= s o$in% t e an%le o! repose and indicatin% i! t e bin is bein% !illed or disc ar%ed.

3.0.0 .)S&,:M+)&S &O 3+ *2/.3,2&+D>

.n t e previous sections= $e ave e<plained t e operation o! several level sensin% devices. & ou% t ere are numerous di!!erent t(pes o! t ese devices= t e( all !all into !our cate%ories based on t e !unction t e( $ill per!orm. & e( $ill be used as indicators= controllers= s$itc es= or transmitters. .ndicators= suc as si% t %lasses= provide local or remote indication o! level in a tan'. 2ccurate level indication is necessar( !or man( process controls= especiall( i! aBardous materials are involved. S$itc es ma( provide a means component in a process s(stem. pump on or o!!. 4or e<ample= at s$itc $ill close= completin% t e o! automaticall( controllin% a particular O!ten= level s$itc es are used to c(cle a some predetermined level in a tan'= t e circuit to t e pump motor controller. & e

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pump starts and commences pumpin% do$n t e tan' contents. 2t some lo$er level in t e tan' t e s$itc opens= interruptin% po$er to t e pump= causin% it to s ut do$n. .n t is application= a level s$itc assists in maintainin% a $or'in% level in t e tan' and prevents an over!lo$ condition. *ontrollers ta'e inputs !rom various sensin% processes t ese inputs= and sends si%nals to maintain t e desired s(stem parameters $it in a o! operation o! a controller is muc t e same as in a computer. devices in t e s(stem= various components to speci!ic band. & e t eor( a central processin% unit

&ransmitters are merel( translators. & e( convert a level si%nal to a usable si%nal t at can be used to drive a motor or ot er electrical;electronic component.

4.0.0 S+/+*&.O) O4 &+S& +N:.#M+)&>

& e calibration o! level sensin% devices requires detailed preparation to ensure success!ul results. One o! t e most important steps in t is process is t e selection o! t e correct test equipment !or t e device to be tested. & is selection $ill be based on t e t(pe o! instrument= t(pe o! test si%nal= and ran%e o! test parameters. & e $ritten test document s ould provide= alon% $it a procedure= data s eets $ ic $ill identi!( values o! minimum or ma<imum pressure= volta%e= ampera%e= etc. Git t is in!ormation= a trainee can select t e ?ri% t tool !or t e job.? & e !ollo$in% are e<amples o! t e uses o! t e various t(pes o! test equipment:

+lectronic simulators used to calibrate electro@mec anical level transmitters. #neumatic po$er supplies and simulators provide variable test pressure !or calibration o! pressure@t(pe level devices. Standin% pipe level ri%s are used as a re!erence !or comparin% t e level instrument bein% tested a%ainst a 'no$n level. 0olt@o mmeters provide a means o! accuratel( measurin% resistance and volta%e values. Obtainin% t ese values and comparin% t em to in!ormation !rom data s eets ma( be one o! t e calibration procedural steps.

".0.0 *2/.3,2&.O);*C+*O #,O*+D:,+S>

& is section $ill outline a basic procedure !or t e calibration o! a level transmitter. .t is important to note t at a !ield calibration procedure $ill be more detailed and s ould be !ollo$ed verbatim.

".1.0 *alibration * ec' o! a /evel &ransmitter

& e !ollo$in% is a %eneral procedure !or calibratin% an electronic level transmitter.

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Step ,: .solate t e level transmitter !rom t e process. Step -: 0ent t e level transmitter to atmosp ere. Step .: *onnect t e di%ital multimeter to t e current output o! t e level transmitter. Step /: ,ecord t e !ollo$in% on a c ec'list: @ @ +OTE: &ransmitter output current in ma ,emote indication 3e certain t at (ou 'no$ t e correct tolerance codes.

Step 0: .! t e transmitter output current value is %reater t an 1;2 t e speci!ied tolerance= adjust Bero to calibrate t e transmitter $it in 112 t e speci!ied tolerance. Step 1: ,ecord t e !inal transmitter output current readin%s and !inal remote indication on a c ec'list. Step 2: .! t e transmitter cannot be calibrated to $it in 1;2 t e speci!ied tolerance= or t e remote indication is %reater t an 1;2 t e speci!ied tolerance= post t e appropriate equipment condition ta%. Step 3: #lace t e level transmitter bac' into service.

-.0.0 &+S& #+,4O,M2)*+ DO*:M+)&2&.O)>

One o! t e most important tools !or an( test or calibration evolution is t e $ritten procedure !rom $ ic instructions !or per!ormance $ill be obtained. & is document= i! properl( $ritten= $ill be t e recipe !or timel( and accurate calibration o! t e various components in t e s(stem. & e !ollo$in% is a brie! list o! in!ormation t at s ould be part o! t is procedure:

*omponent operational sc ematic s o$in% test connections and leads. &est equipment list. #ersonnel and equipment sa!et( precautions. *omponent speci!ications= i.e.= ma<imum and minimum suppl( pressures= volta%es= current= an( operatin% temperature limits= !lo$ rates= etc. *omponent operatin% instructions. Data s eets !or annotatin% various parameters. 2cceptance criteria. Detailed steps !or correct per!ormance o! t e procedure.

2 !inal report s ould also be prepared to document success!ul completion o! t e procedure $it an( data associated $it it.

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Summar(
*alibration;adjustment o! various level instruments in a process s(stem is essential to t e e!!icient and sa!e operation o! t e s(stem. +ac o! t e components discussed in t is module require di!!erent t(pes o! test equipment and procedures !or proper adjustment. 2 t orou% understandin% o! o$ eac test is per!ormed and t e test equipment to be used $ill prove invaluable to a trainee in t e !ield.

,e!erences
"ns#ru$en# %ngineer&s 'an(boo), * ilton 3oo' *ompan(= #enns(lvania= 1F92.

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*asic "ns#ru$en#a#ion + "n(us#rial ,easure$en#, Mc6ra$@Cill= )e$ Aor'= 1F--.

S+/4 *C+*O ,+0.+G ; #,2*&.*+ N:+S&.O)S

1. G at is t e advanta%e o! a c ain !loat %au%e over a ball !loatP a. * ain !loat %au%es ave a muc lar%er ran%e o! level measurement. b. * ain !loat %au%es are less e<pensive. c. * ain !loat %au%es ave better resolution. d. * ain !loat %au%es ave !e$er movin% parts and are t ere!ore easier to maintain. 2 si% t %lass level measurin% device operates based on t e principle o!: a. 2 di!!erential pressure diap ra%m b. 2 bello$s c. 2 pressure capsule d. 2 :@tube manometer G at is t e purpose o! t e brid%e circuit in a capacitance probe level detectorP a. .ncreases t e dielectric bet$een t e capacitor plates. b. Decreases t e dielectric bet$een t e capacitor plates. c. Measures t e c an%e in capacitance due to increase or decrease in level. d. Measures t e current !lo$ bet$een t e terminals o! t e capacitance probe po$er suppl(. G a. b. c. d. at is a limitation o! a displacer level deviceP *an onl( be used in a pressuriBed tan'. Cas ver( limited measurin% ran%e. *an onl( be used in an open tan'. *annot detect a liquid@vapor inter!ace.

2.

3.

4.

".

G ere is t e i% side o! a di!!erential pressure instrument connected in a pressuriBed vessel applicationP a. & e bottom o! t e vessel. b. & e re!erence le%. c. & e side o! t e vessel just belo$ t e minimum liquid level. d. & e vapor space in t e vessel. G at does a continuous ultrasonic level detector measureP a. & e time it ta'es !or an ultrasonic pulse to travel to t e process sur!ace and bac' to t e detector. b. b & e amplitude o! t e ultrasonic return !rom t e process sur!ace. c. & e time it ta'es !or an ultrasonic pulse to travel to t e tan' bottom. d. & e time bet$een ultrasonic pulses.

-.

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#+,4O,M2)*+ ; /23O,2&O,A +Q+,*.S+

1. *alibrate a level transmitter. Step Step Step Step 1: 2: 3: 4: Grite a test procedure to calibrate t e device. Select t e proper test equipment. Set up test equipment and per!orm calibration. Document test results.

S+/4 *C+*O ,+0.+G ; #,2*&.*+ 2)SG+,S

1. 2. 3. 4. ". -. a d c c d a

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