HOW TO RANGE DISPLACER LEVEL/ INTERFACE LEVEL TRANSMITTERS ACCURATELY FOR REALTIME INDUSTRIAL PROCESSES: MASONEILAN DRESSER 12300

Contents
Contents..................................................................................................................... 1

1.0 AN INTRODUCTION TO LEVEL/ INTERFACE MEASUREMENT...................................2 2.0 INSTRUMENT RANGING VS CALIBRATION...............................................................3 3.0 ARCHIMEDES PRINCIPLE AND DISPLACERS ..........................................................5 4.0 RANGING DISPLACER LEVEL TRANSMITTERS: MASONEILAN DRESSER 12300........8 5.0 RANGING INTERFACE LEVEL TRANSMITTERS: MASONEILAN DRESSER 12300......10 6.0 SPECIAL CASES...................................................................................................11 7.0 A LAST WORD.....................................................................................................12

1.0 AN INTRODUCTION TO LEVEL/ INTERFACE MEASUREMENT

Industrial Instrumentation sees to measurements of industrial process parameters/variables. Amongst various parameters or variables to be measured, level/level interface is one of the most common. Let us consider 2 domestic cases 2

1. Water level in a bucket could be determined. 2. If the same bucket contained water and oil, the level of water could still be determined. Case 1 would require level measurement. Case 2 would require the interface level between water and oil. The oil would float on the water with an interface between water and oil. These two types of measurements define level (1) and interface (2) measurement and are readily available in process industries. An example of industrial interface measurement is found in separators for oil and gas production where interface measurement indicates the water level in the separator vessel. Figure 1. Shows the contents of a typical 3 phase separator

Fig. 1: Horizontal Oil and Gas Separator

2.0 INSTRUMENT RANGING VS CALIBRATION

Instruments used in measuring level/ interface, like any other instrument, must be adapted to a specific process and checked periodically for reliability. Ranging is adapting your level instrument to your application. The instrument will measure between its preset lower range value (LRV) and upper range value (URV).For example, 3

LRV = 0m URV = 10m Since different applications require different LRV and URV, ranging of instruments is left to the user. Measuring the level of kerosene in a tank 2m height is different application from measuring level of palm oil in tank of 5ft height. Ranging is to define the limits to which your instrument will measure. Usually, instruments have their own range as specified by their manufacturer. An instrument may be capable of measuring up to a maximum of 2 ft level but it can be ranged for to measure 1ft level maximum. Calibration, on the other hand, is to make sure that the input/output from your instrument transmitter is as correct as possible. Instrument calibration should be performed periodically by instrument technicians to ensure the accuracy and precision of instruments. A sensor may become fatigued after years of use, thus, degrading in accuracy. A pressure sensor may read 10.7 bars from an actual pressure of 11 bars. In essence, this sensor requires calibration if this deviation of 0.3 bars is still within the tolerance stated in the sensor datasheet. If 0.3 bar pressure is beyond the tolerance, then its high time to replace the sensor.

The same philosophy applies to transmitter outputs. Consider measuring maximum 2ft liquid level, the transmitter output is 4mA when the tank is empty and 20 mA when tank is 2ft full of liquid. In reality, however, there is always a deviation between the ideal and the actual output. It could be 4.1mA instead of 4mA at your low range value (LRV). The deviation should not exceed the stated value on the instrument manufacturer data sheet after calibration. For more reading on instrument calibration, visit www.isa.org to order your copy of Calibration: A technicians guide from International society for Automation. The point to note here is the difference between instrument ranging and calibration. Ranging defines the application while calibration checks the transmitter output accuracy. In analog instrument transmitters, calibration and ranging are done at the same time. This is not so for digital instrument transmitters. I have been confused over these concepts in my beginning years as an instrument technician. As such, I believe it is worth mentioning here. Whenever, you are required to install an instrument, please simply range it for your application. Most of the time, these instruments are already factory calibrated so you need not bother yourself. From my experience, ranging could be quite tricky for level/ interface applications. Level depends on what you have defined. A vessel may have a 4

height of 1.5 m but its measured level of interest may be between 0.8 and 1.5 m. Just 0.7m!!!! Sometimes, the instrument is mounted through an extended nozzle from the tank or vessel as shown below

NOZZLE LEVEL INSTRUMENT CAGE RANGE

FIG. 2: Nozzle and Cage Level Assembly Two nozzles extend from the tank, Upper and lower. The range is, as shown, between the top of the lower nozzle to the bottom of the upper nozzle. The nozzle and cage assembly is a form of the U tube. The top nozzle ensures that the pressure on both the cage and the tank are equal thereby leading to equal levels in tank and cage. I have seen a lot of instrument technicians get confused over what the true level range is a couple of times. The truth is if you dont know your range, who will? It will certainly be the beginning of your troubles and frustration. Before reading, please ensure that you understand what your expected level range is before attempting work on level/ interface level instruments.

3.0 ARCHIMEDES PRINCIPLE AND DISPLACERS

Archimedes Principle states that A body that is partially or wholly immersed in a fluid experiences a loss in weight which is equal to the weight of the fluid displaced. Using Archimedes principle, we can measure level/ interface. To do this, a body of constant weight and shape is allowed to be immersed in the liquid whose level is to be measured. The loss of weight of this body, according to Archimedes, is proportional to the level of the liquid. Such a body is called a displacer. Really, its a smart way of measuring level/ interface in varied industrial applications. Figure 3 and 4 below show a displacer removed from its nozzle and cage assembly

Fig. 3: Displacer and its nozzle and cage assembly

Fig.4: Displacer measuring level in a vessel (Nozzle and Cage) Measuring level/ interface using displacers is based on 2 equations; one for liquid level and the other for liquid interface. From Archimedes principle, 6

Weight loss by displacer (Wd) = Weight of liquid displaced (Wl) .. 1 Wd = mg .2 Where m is equal to the mass of the liquid displaced and g is the acceleration due to gravity. But Mass = density X Volume = V 3 Putting (3) into (2) Wd = gV .. 4 Where is the density of the liquid displaced, g is acceleration due to free fall, and V is the volume of the liquid displaced. The multiplication between density and acceleration due to gravity gives the weight density. So (4) can be written as Wd = V . 5 The displacer in question is usually cylindrical as shown in figure 4. Hence, the volume in question is that of a cylinder. Such that Wd = (r2L) = r2 L . 6 Equation 6 is the guiding relationship for LIQUID LEVEL MEASUREMENT using displacers. You can see from equation 6 that there is a linear relationship between the weight loss experienced by the displacer and the level of liquid measured. More liquid level submerging the displacer will result in more weight loss experienced by the displacer. Equation 6 can be expanded for liquid interface measurement. Here, there are 2 liquids involved and consequently 2 weight densities involved too. So,

Wd = r2 (1L1 + 2L2) . .. 7 Equations 6 and 7 will guide our ranging methods for displacers. They are critical equations which must be understood by instrument technicians working with displacers. Note that in equation 7, the interface level is either L1 or L2 and not both. When L1 is increasing, L2 is decreasing and otherwise. The interface level is actually the level of the liquid with the higher weight density.

4.0 RANGING DISPLACER LEVEL TRANSMITTERS: MASONEILAN DRESSER 12300

I assume that you are conversant with the difference between calibration and ranging. To range a displacer for level application, you simply follow the steps outlined below. 1. Isolate the transmitter from the process by closing the block valves on the extended upper and lower nozzles 2. Drain the level instrument cage. Be careful while doing this bearing in mind that the liquid might be pressurized. Make sure you open the drain valve first(Valve below) first until you sense the absence of pressure. Then you can open the vent valve to relief any negligible residual pressure. DRAIN SAFELY AT ALL TIMES. I have done this before wrongly with oil spills everywhere. In fact, there was a big bath. Be careful!!! 3. Having made sure that the cage is free of pressure and liquid; connect your makeshift sight glass to the drain point on the cage. Figure 5 below shows a picture of a makeshift sight glass I made with transparent hose and Swagelok fittings.

Fig. 5: Makeshift sight glass 4. Open transmitter terminal and connect hart communicator. Verify proper mounting configuration. Use flow chart below MAN CONFIG BASIC SETUP RIGHT/ LEFT

Right or left means the relative position of the transmitter head to the displacer. If the displacer transmitter is left of the displacer, then choose left.

5. MAN

Make sure the transmitter is configured to measure level not interface. Use the flow chart below CONFIG BASIC SETUP LEVEL.

6. Get to the submenu that will allow you change the specific gravity value to that of the liquid you wish to measure. Use the flow chart below MAN 7. CAL VAR SET CHG SER.

If you know the specific gravity of the liquid whose level you want to measure, then input it here under CHG SER. This means change service specific gravity. Changing the specific gravity in equation 6 is the same thing as matching the displacer loss in weight to the corresponding liquid level. 9

8. Fill the cage with the liquid of interest to the 100% percent range value(URV) while observing from the sight glass. Does your transmitter register 100% level? If yes, you have successfully ranged your transmitter. If no, then go back to the CHG SER submenu and try a different specific gravity value. From equation 6, you should know your direction of change. If your transmitter reads a higher value, say 120%, then you need to increase your SG to bring this value towards 100%. 9. A zero check is advisable. Drain your cage and see if your transmitter records 0%. If zero is not achieved, then you need to perform a specific gravity calibration according to the instrument manual. After SG calibration you need to start from step 1 again to be sure your transmitter reads the right range of your application.

5.0 RANGING INTERFACE LEVEL TRANSMITTERS: MASONEILAN DRESSER 12300

1. Follow steps 1 to 4 in RANGING LEVEL TRANSMITTERS above 2. Ensure that transmitter is configured for interface level measurement and not level measurement. Use the flow chart below MAN CONFIG BASIC SETUP INTERFACE.

3. Get to the submenu that will allow you change the specific gravity value to that of the liquid you wish to measure. Use the flow chart below MAN CAL VAR SET CHG SER.

4. Put in the specific gravity values for both the lower and upper liquids. Changing the specific gravities in equation 7 is the same thing as matching the loss in weight of the displacer to the interface level. Note that the interface level is the level of the liquid with the higher specific gravity.

5. Fill the cage with the lower SG liquid to full range. Does your transmitter read 0%? If yes, then the LRV ranging is successful. If not, then change the lower SG to achieve a zero percent from the transmitter. If the transmitter reads below 0%, then you should decrease your SG in small increments . The direction of the change is determined from equation 7. 6. Fill the cage with the higher SG liquid to full range. Does your transmitter read 1000%? If yes, then the URV ranging is successful. If not, then change the 10

lower SG to achieve a 100 percent from the transmitter. The direction of the change is determined from equation 7. 7. Repeat steps 5 and 6 at least once to be sure your range is correctly executed.

6.0 SPECIAL CASES

1. DIFFERENT LIQUIDS IN ACTUAL USE: This happens when the liquids you use to range the transmitter are different from the actual liquids in the vessel of interest. Are you surprised that this can happen? Dont be because I have seen it several times in which case the transmitter reports the wrong level. It could be a frustrating experience for an instrument technician. In interface applications, I would advice that you line up your nozzle and cage assembly accordingly for your ranging. After draining the cage and isolating it form the process vessel, you can fill the cage with the lower SG liquid by opening the top nozzle only. The same applies for the higher SG liquid with the opening of the bottom nozzle only. For level applications, you can drain as much of the liquid from the vessel of interest for your use or get a sample to your laboratory to confirm the SG.

2. EMULSIONS: Emulsions occur when two liquids mix together. In this case, the resultant liquid combines the specific gravities of the 2 liquids. Interface applications using displacers suffer from emulsions. Practically, displacer transmitters specify the minimum difference between the lower and higher specific gravities. For masonelian dresser transmitters, the least difference is about 0.1. The transmitter goes to high alarm or unpredictable response if this difference goes smaller than that. A vessel with a layer of emulsion contains 2 interfaces which confuses your transmitter to start spiking between the LRV and URV. Make sure there are no emulsions in your vessel before attempting to range your displacer transmitters!!! Whenever emulsions appear in your vessel, displacer transmitters move out of control. So watch out for these symptoms on Oil and water separators.

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3. EMPTY UPPER NOZZLE: Displacers required to measure interface level must be completely immersed in both liquids. The upper nozzle must be completely filled with the lower SG liquid else the displacer cannot differentiate between a low interface level and an empty upper nozzle. I have once ranged an interface level transmitter expected to measure the interface level between fuel oil condensate and glycol. Guess what? After the job, the transmitter measured falsely because there was no condensate in the vessel. Condensate was expected to flash off from the glycol in the running process. But this never happened!!!! Its important that you pay close attention also to the process in which your displacer is a part of.

7.0 A LAST WORD

Compared with other methods of level/ interface measurement in process industries, displacers offer an expensive yet reliable and simple application. Knowing the specific gravities alone may not be all there is to properly ranging displacers. Sometimes factory tolerances require some minor changes to the true specific gravities to ensure accurate level measurement. Also, the mounting configuration can hinder the successful ranging of displacer transmitters. Finally, process condition affects the success a technician can achieve in ranging displacers from one application to another. For your comments and enquiries, please send your mails to Akan.Archibong@gmail.com

ABOUT THE AUTHOR

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Archibong A., is an instrument technician with a 5 year experience in both manufacturing and oil and gas industries. He is currently pursuing a CCST/ CAP with international society for Automation.

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