8/30/2018 Ultrasonic Level Transmitter Principle, Limitations, Calibration and configuration Instrumentation Tools

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Ultrasonic Level Transmitter Principle, Limitations,

Calibration and con guration
 S Bharadwaj Reddy  Leave a comment

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Measurement principle Ca

Continuous non‐contacting ultrasonic level measurement is based on the time of ight principle.

An ultrasonic level instrument measures the time between sound energy transmitter from the sensor, to the surface of the
measured material and the echo returning to the sensor.

Categor
As the speed of sound is known through the travel medium at a measured temperature, the distance to the surface is calculated.
Level can be calculated from this distance measurement.
Select Ca

Echo Processing built in to the instrument can allow the instrument to determine the material level of liquids, solids or slurries
even in narrow, obstructed or agitated vessels.

Limitations

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8/30/2018 Ultrasonic Level Transmitter Principle, Limitations, Calibration and configuration Instrumentation Tools

Ultrasonic is seldom used in upstream hydrocarbon process stream for level measurement; it might be used in atmospheric SPONSOR

utilities applications. In applications which are susceptible to vapour density variation, compensation reference pin should be
used.
Ca

Maximum measurement distance should be checked against the technology (above 30 m the re ectivity may be reduced and
might cause a measurement error/problem).
C

Ultrasonic sensors have, as physical limitation, a blocking distance (close to the sensor) where they cannot measure reliably, e.g.
0.25 metres.

Vessel pressure limitation should approximately be, e.g. 0.5 bar or less. Higher pressure may introduce uncertainty in the level
measurement.

Vapour, vacuum or temperature gradients can in uence the speed of sound and consequently can cause incorrect
measurements.

Presence of foam or heavy turbulence on the surface of the measured material can cause unreliable measurement.

Selection
As ultrasonic is non‐contacting, even abrasive or aggressive materials can be measured. Vessel height and head room should be
considered to select an instrument with suitable minimum and maximum range. Like our

Design
Ultrasonic sensors should be made of a material suitable for the measured medium (e.g. PVDF or ETFE) Solid construction and a
self‐cleaning action on the face of the sensor provide a reliable, low maintenance product.
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8/30/2018 Ultrasonic Level Transmitter Principle, Limitations, Calibration and configuration Instrumentation Tools

Figure – Ultrasonic Liquid Measurement Arrangement. Inst Too

Use of a submergence shield on a sensor will allow an ultrasonic instrument to operate in potential ooding conditions reporting a
full vessel to a control system or continuing to operate pumps to remove the ood condition.

Calibration and con guration

Inst Too

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Figure – Ultrasonic Level Transmitter calibration

BD : Blocking Distance
SD : Safety Distance
E : Empty Calibration ( Zero Point )
F : Full Calibration ( Span )
D : Nozzle Diameter
L : Level

Performing an initial or ‘empty calibration’: In this principle, ‘enter’ the distance E from the sensor face to the minimum level (zero
point). It is important to note that in vessels with parabolic roofs or bottoms, the zero point should not be more distant than the
point at which the ultrasonic wave re ects from the tank bottom.

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8/30/2018 Ultrasonic Level Transmitter Principle, Limitations, Calibration and configuration Instrumentation Tools

When possible, a at target plate that is parallel to the sensor face and directly below the sensor mounting position should be
added to the bottom of the vessel for best empty tank performance.

Once the empty distance has been set, the high calibration point or 100% full point can be set. This is done either by setting the
distance from the sensor face to the 100% full level or by entering a span (level) from the 0% or low calibration point to the 100%
full level.

During commissioning, ensure that the 100% full or high calibration point does not enter the ‘blocking distance’ or ‘blind zone’ of
the respective sensor. This will vary from sensor to sensor. Blocking distances or blind zones can be extended to avoid false high
level re ections caused by obstructions, but they can only be reduced to a certain distance due to the physical limitations of the
sensor itself. The minimum level (distance E/zero point) should be con gured. This zero point should be above any dished boiler
heads or conical out ow located at the bottom of the tank/vessel.

The maximum level (distance F/full span) should be con gured. This distance F should take into account both BD ‘blocking
distance’ and SD ‘safety distances’.

Where BD represents a dead zone in which the wave cannot make any measurement and SD corresponds to a warning or an
alarm zone.

Also Read : Ultrasonic Level Sensors Questions & Answers.

Source : International Association of Oil & Gas Producers

Acknowledgements :  IOGP Instrumentation and Automaton Standards Subcommittee (IASSC), BG Group, BP, Endress + Hauser,
Emerson, Honeywell, Krohne, Petrobras, PETRONAS Carigali Sdn Bhd, Repsol, Siemens, Statoil, Total, Vega, Yokogawa.

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