Advantages of Guided Wave Radar (GWR)

Using Advanced Radar Technology Helps Improve Separation Process

Performance
14/10/2019 | Author / Editor: Denny Nelson* / Dr. Jörg Kempf

The separation of two immiscible

liquids contained in the same tank or
vessel is a fundamental aspect of
many production processes.
Optimising the performance of these
applications can have a significant
effect on final product quality. To
achieve this, plant managers need to
implement devices that can accurately
and reliably measure the interface
level between the two liquids.

Examples of immiscible liquids requiring

Guided wave radar (GWR) is a well- separation include oil over water, oil over
established and field-proven technology in
acid, low dielectric organic solvents over
interface level measurement applications
water, and low dielectric organic solvents
such as oilfield production tanks.(Source:
©THATREE - stock.adobe.com) over acid. Low dielectric organic solvents
include toluene, benzene, cyclohexane,
hexane, turpentine and xylene. In most
applications the liquids will separate naturally due to their differing densities, with the
lower density liquid settling on top of the higher density liquid. For example, when oil
and water occupy the same vessel, the oil floats on top of the water, and the interface
would be the upper level of the water and the lower level of the oil.

In some interface level measurement applications, it is necessary to know the

thickness of the upper liquid layer. This includes instances where only the upper liquid
needs to be poured off and an accurate indication of when to stop pouring is required.
It is also essential when controlling the flow of both liquids out of the vessel and into
independent channels, as this process must be achieved with as little cross-
contamination of products as possible. For example, in the oil production process, it
can prove extremely costly if oil is channelled to the water tank, or if water is sent
further along the process.

The most straightforward way to measure an interface level is through a sight glass on
the side of a vessel, but this basic method has some obvious disadvantages. By
requiring operator inspection, it is both labour-intensive and time-consuming. Also,
sight glasses require regular maintenance, and in applications that are prone to
condensation, an operator may be unable to see the interface well enough to make an
accurate measurement. Alternative methods of measurement include floats and
displacers, capacitance transmitters, differential pressure transmitters, and
magnetostrictive sensors. However, these technologies can also have limitations in
terms of their accuracy and reliability under certain process conditions, and can have
complex maintenance and calibration requirements.
Guided wave radar (GWR) is a well-established and field-proven technology in
interface level measurement applications such as oilfield production tanks; free water
knock-out vessels; water and skim tanks; accumulators; desalters; scrubbers; and
storage and buffer tanks containing oil, condensate, water, or solvents.

GWR transmitters deliver a top-down, direct measurement of the distance to the

product surface and the interface, and provide many advantages compared to other
technologies. Changes in pressure, temperature and most vapour space conditions
have no impact on the measurement accuracy of GWR devices. Also, no
compensation is required when there are changes in the dielectric constant,
conductivity or density of the liquid. GWR provides accurate and reliable
measurements in vessels with tight geometry, in chambers, and in tanks of all sizes.
GWR transmitters have no moving parts and therefore require minimal maintenance,
and their advanced diagnostics ensure that operators are quickly alerted to any
degradation in performance. Easy system integration and the introduction of wireless-
enabled devices that remove the need for data or power cabling are further significant
advantages of GWR transmitters.

How an Interface Level Is Measured

GWR technology is based on the time domain reflectometry principle. A low-energy
pulse of microwaves, travelling at the speed of light, is guided along a probe that is
submerged in the process media. When a pulse reaches the surface of the material it is
measuring, a significant proportion of the microwave energy is reflected up the probe to
the transmitter. The time difference between the generated and reflected pulse is
converted into a distance from which the level is calculated. As a proportion of the
pulse will continue down the probe through low dielectric fluids, a second echo can be
detected from an interface between two liquids at a point below the initial liquid level.

Influence of the Dielectric Constant

The speed of travel of the pulse — and therefore the accuracy of the interface level
measurement — is dependent on the dielectric constant of the two products. Top-down
GWR transmitters are suitable for use in interface level measurement applications only
if the first liquid detected by the device has a lower dielectric constant than the second
one, and if there is a difference between the two dielectric constants of at least six.

In typical applications, the upper liquid would have a low dielectric constant of less than
three, while the lower liquid would have a high dielectric constant greater than 20. For
example, the dielectric constants of oil and gasoline range from 1.8 to four, while water
and water-based acids have high dielectric constants of more than 20. Therefore, in an
oil and water interface level measurement application, because water has a
significantly higher dielectric constant than oil, the interface of the two fluids can be
easily detected by a top-down GWR transmitter.
If the upper product has a higher dielectric constant than the liquid below, this prevents
a top-down interface measurement using GWR. However, in this circumstance the
mounting position of the transmitter can be inverted, so that the device is mounted on
the bottom of the vessel to measure the distance to the interface.

What to Do in Case of Emulsion Layers

The accuracy of interface level measurement can be influenced by the presence or
absence of a distinct interface between the two liquids. Occasionally the two liquids do
not separate precisely, and instead an emulsion layer (i.e., a mixture of the two
products) forms between them. Typically, the thicker the emulsion layer, the more
challenging it becomes to accurately measure the interface level. Depending on their
composition, some emulsions may break down into two distinct layers if given time to
settle. In these applications, installation of the GWR transmitter in a calm, still area of
the vessel where the layers have a chance of breaking down may enable the interface
measurement. The use of a stilling well can help to achieve better product separation
and therefore more accurate interface level measurements.

Thinner Top Layer Measurement

Although GWR transmitters are a proven and widely-applied solution in interface level
measurement applications, the top liquid layer must be of a certain minimum thickness
to enable the device to distinguish between the signals reflected from the two different
liquids. This minimum thickness has typically varied between 50 and 200 millimetres,
depending on the transmitter model and probe style being used. However, Rosemount
GWR transmitters from Emerson provide functionality that enables the minimum
detectable thickness of the upper liquid layer to be reduced to 25 mm.

Such a significant enhancement has been enabled by Emerson’s Peak in Peak

interface algorithm. This allows the transmitter to detect signal peaks that are closer
together without having to decrease its signal bandwidth, which would reduce its high
sensitivity and its ability to overcome liquid disturbances.

Being able to detect a thinner top liquid layer helps to prevent unwanted product
ingress and optimises the performance of the separation process, helping end users
maximise operational efficiency and profitability. The ability to detect a thinner layer is
especially beneficial in cases where there should be no second product in the vessel,
and where the presence of a hydrocarbon on top of methanol, for example, is an
indication that there is something seriously wrong with the process.

Measurement to the Top of the Tank

Accurate level and interface measurement right to the top of a tank is challenging for
GWR transmitters, even when they are used with a large diameter coaxial probe.
These probes provide the strongest return signal, have no upper dead band, and their
accuracy is not affected by obstacles on the tank wall. However, high amplitude noise
created as microwaves pass through the process seal between transmitter and probe
has traditionally affected measurement accuracy at the top of the tank. By improving
the design of its process seal, Emerson has eliminated this noise, thereby facilitating
accurate and repeatable measurement to the top of the vessel and enabling users to
optimise tank capacity and increase throughput and profitability.

Double Bounces? How to Increase Reliability

Another challenge to the measurement reliability of GWR technology in separator tanks
is the so-called double bounce. This is when a radar signal bounces back and forth
between the product surface and the tank roof (or another object within the tank) before
being detected by the transmitter. Normally these signals have a low amplitude and are
ignored by the transmitter, but sometimes the amplitude may be strong enough for the
transmitter to interpret the double bounce as a surface echo. To increase measurement
reliability, the latest GWR transmitters feature a factory-configured threshold setting
that determines the minimum signal amplitude limits of key parameters such as surface
echo, interface echo, reference peak and end-of-probe peak. For upstream oil and gas
applications, an echo below the threshold is considered as oil, and an echo above the
threshold is considered as water. This prevents double signal bounces from being
mistaken as an interface level measurement, and enables more predictable behaviour,
making the device a true plug-and-play option.

Proof-testing in Safety Applications

Regular proof-testing is an essential requirement for safety instrumented systems in
separator tanks, to ensure the integrity of devices in safety-critical applications such as
overfill prevention and dry pump protection. Traditionally, proof-testing has been
performed with multiple technicians in the field and one in the control room, verifying
the safety system reaction. This requires a considerable amount of time and effort, can
pose safety risks to workers, can result in the process being taken offline, and can be
prone to errors. However, technological advances in modern GWR devices enable
proof-testing to be performed remotely, making the process much quicker, safer and
more efficient.

The latest GWR transmitters can be remotely proof-tested with 94 % test coverage
using verification reflector functionality. The verification reflector function uses an
adjustable reference reflector fitted to a flexible single lead probe, at a desired height to
generate a unique echo signature. The device constantly tracks the reflector echo to
determine if the level is above or below the alarm limit. A test function built into the
device software verifies that the GWR has been correctly configured and is correctly
tracking the reflector echo. It also confirms that the alarm loop is working, with a high-
level alarm being displayed in the control room. This test function can be accessed
remotely using software packages, as well as locally using a hand-held device.
 Testing can be performed in minutes from the control room during operation, thereby
reducing downtime, minimising risk and maximising safety. Compared with traditional
diagnostics, which only monitor the transmitter electronics, verification reflector
functionality can also be used to diagnose problems affecting the upper parts of the
probe inside the tank, such as product build-up, corrosion and other process-related
conditions.

*The author is Marketing Engineer, Emerson Automation Solutions, Göteborg/Sverige.

Copyright ©2019- Vogel Communications Group

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Guided wave radar (GWR) is a well-established and field-proven technology in interface level
measurement applications such as oilfield production tanks. (©THATREE - stock.adobe.com)
A typical guided wave radar level and interface measurement application (Emerson Automation Solutions)
Reducing the minimum detectable thickness of the upper liquid layer improves insight into the separation
process. (Emerson Automation Solutions)
Emerson’s Rosemount 5300 guided wave radar level transmitter, with a large coaxial probe, enables the
minimum detectable thickness of the upper liquid layer to be reduced to 25 mm, and measurement
accuracy to be maintained to the top of the tank. (Emerson Automation Solutions)
(Emerson)