Level Basics

Wilockx Chris

Physical Basics of Pressure Measurement

F (force) N (Newton) P (pressure) = --------------- = ---------------- |Pa| A (surface) m2 There are different pressure units:

kPa: kilo Pascal

bar: bar kg/cm2: mmH2O: mm water

mmHg: mm mercury
atm: psi: atmosphere pound/inch2

inH2O: inch water

Physical Basics of Pressure Measurement

Pressure Quantity Absolute Pressure Atmospheric Pressure Gauge Pressure Differential Pressure Symbol pabs pamb pe dp

pabs1

pe1 > 0

dp
0%

pe = 0

pamb. pabs. 2

pe2 < 0

100%

pabs = 0
(Vacum)

Physical Basics of Pressure Measurement

Pressure is equal
in all directions

Hydrostatic Paradox
P = S.g.h S = Rho = density |Pa| = |kg/m3|.|9,81m/s2|.|m|

Pressure Measurement Pressure U - Tube

U-Tube

Pa = S.g.h + P0 |Pa| = |kg/m3|.|9,81m/s2|.|m|

Pressure Measurement Pressure Transmitters

Boudon pressure gauge

Pressure Measurement Pressure Transmitters

p - measurement

dp - measurement

Functional Principle of P and dP Transmitters

Conversion of the Physical Factor (i.e.: Deflection of Diaphragm) into an Electrical Factor: Different sensors are used:
Inductive measuring principle (coil)

Capacitive measuring principle (capacitor)

Strain Gauge measuring principle (Bridge) Piezo-resistive measuring principle (chip)

Functional principle of P and dP transmitters

inductive measuring principle:

n2 . A L = --------l

Functional principle of P and dP transmitters

capacitive measuring principle:
diaphragm

P1

P2

E .A C = --------d

C1

C2

Glass

Measuring diaphragm

Functional principle of P and dP transmitters

Strain Gauge measuring principle :
R= K x

R
Metal cores Strain gages array (bonded or made directly on the substrate)

+
Measuring diaphragm Substrate Bonding

Functional principle of P and dP transmitters

piezo-resistive measuring principle
(example 265D)

DP-Sensor

Pabs-Sensor

Measuring of resistance change via crystal lattice displacement

Functional principle of P and dP transmitters

piezo-resistive measuring principle
(e.g. 265G)

Measuring of resistance change via crystal lattice displacement

lower range value span write protect matching measuring mechanism Microprocessor based electronics

isolating diaphragm

Pe-Sensor

Main Components
terminal blocks covers housing push buttons secondary electronics integral display

display

covers
transducer gaskets

vents

bolts

flanges

Functional Specifications
General Base accuracy: ABB Model 265/266 +/- 0,04% ABB Model 264 +/- 0,075% Turn Down: 1/100 Ranges ABB Model 265 Pressure Transmitters: 60mbar - 400mbar - 2500mbar - 10bar - 30bar - 100bar 600bar Ranges ABB Model 265 dP Transmitters: 10mbar - 60mbar - 400mbar 2500mbar - 20bar 100bar

Level Measurement
Different mounting positions?
open to atmosphere

P = S.g.h

________
Dead zone

Open tank liquid measurement

Level Closed Tank

If the level to be maeasured is in a closed tank, a dp transmitter is necessary. N2

max. level
h1

Dry Leg

S = 0?

min. level Wet Leg

h2

transmitter reference line

4 mA = S . g . h2 20 mA = S . g . (h2 + h1) S = specific gravity (medium)

Level Closed Tank

If the level to be maeasured is in a closed tank, a dp transmitter is necessary.

max. level
h1

Wet Leg S1
h4

Glycol S2

min. level Wet Leg

h2

transmitter reference line

4 mA = S1 . g . h2 S2 . g . h4 20 mA = S1 . g (h1 + h2) S2 . g . h4 S1 = specific gravity (medium) S2 = specific gravity (Wet leg)

Level Closed Tank

If condensable vapours are present use the following installation.
filling tee

0
max. level
h1

S1

min. level

impuls line filled with stable fluid (Wet Leg) S2

h4

transmitter reference line

h2

transmitter reference line

4 mA = S1 . g . h2 S2 . g . h4 20 mA = S1 . g (h1 + h2) S2 . g . h4 S1 = specific gravity (medium) S2 = specific gravity (Wet leg)

Boiler-Level Measuement
Ordering data: dp transmitter with adjusted value of 300mm ... +300 mm (WC)
Actual requirement: boiler level measurement level to be monitored: -300 mm ... +300 mm

Distance between connection pipes: h = 1000mm

hhigh

Density water Tuper.: +200 C (Sup= 865 kg/m3) Tref.: +30 C (Sref= 996 kg/m3)

hlow (hlow) = 200mm hhigh (hhigh) = 800mm hlow

NN

+300 mm
h - 300 mm

Density steam Tsteam.: +200 C (Ssteam = 7.9 kg/m3)

Boiler-Level Measuement
DP Transmitter with an adjusted value of: -300 ... +300 mm (WC)

+300 mm
hh P1 (-300mm) P2 (+300mm)
h

= (-h* Sref * g + hl * Super. * g + [h-hl] * Ssteam * g) * 102 = = (-1 * 996 * 9.81 + 0.2 * 865 * 9.81 + 0.8 * 7.9 * 9.81) * 102 = -80.1 mbar = (-h* Sref * g + hh * Super. * g + [h-hh] * Ssteam * g) * 102 = = (-1 * 996 * 9.81 + 0.8 * 865 * 9.81 + 0.2 * 7.9 * 9.81) * 102 = -29.7 mbar

Adjusted value: -80.1 ... -29.7 mbar

hl

- 300 mm

Remote Seals
Protect Transmitters from
High temperature Corrosive components

Useful for
Prevention of deposits in the process Connection

Media with high viscosities

Media with tendency to

Adaptation to various process

connections

polymerization

Level Open Tank

e.g.: a seal transmitter flange mounted on the high pressure side of the transmitter is recommended in case of dirty liquid fluid or process temperature > 107 C

transmitter reference line

P=S.g.h

Level Closed Tank

N2

max. level

h1

e.g.: a seal transmitter flange mounted on the high pressure side of the transmitter is recommended in case of dirty liquid fluid or process temperature > 107 C

min. level

h2

min. level may not be below this line

transmitter reference line

Level Closed Tank

low side seal reference line Sg

max. level

filled capillary
h1 h4

Sc min. level

h2

S
h3

high side seal reference line

4 mA = S . g . h2 + Sg . G .(h4-h2) Sc . g . h4 20 mA = S . g . (h1 + h2) Sc . g . h4 S Sg Sc = specific gravity (medium) = specific gravity (gas above fluid) = specific gravity (filling oil capillary tube)

transmitter reference line

Level Transmitter 265D

Compact Version

Remote Seals Design

..... with Flush or Extended Diaphragm in Flange design DN 25 Pressure Rating PN 10...PN 250

DN 50 / DN 80 Pressure Rating PN 16...PN 100 DN 1 DN 2 / DN 3 Pressure Rating 150 psi...1500 psi Pressure Rating 150 psi...600 psi

Remote Seals
.... via Capillary Tube to Transmitter

Remote Seals Design

.... with Flush or Extended Diaphragm in Sandwich Design

DN 50 / DN 80

Pressure Rating up to PN 400

DN 2 / DN 3

Pressure Rating up to 2500 psi

Remote Seals Design

Corrosion Resistant Materials
Stainless Steel

Hastelloy C
Monel 400 Tantal FEP coated Gold plated Ect

Capillary tube stainless steel, with PVC protective cover as an option

Remote Seals Design

Filling liquids depending on the application
Silicon Oil as Standard

Carbon Fluoride
White Oil High Temperature Oil

for Oxygen Service

for Food and Beverage up to 400 C

Vacuum proof design with special liquid for use down to an absolute pressure of 5 mbar abs.
ABB is a recognized leader in the all welded technology where Remote Seals System can be welded at every junction.

Application Limits

Filling Liquid

Id 20C (68F)

Pressure rating in mbar abs. 100C (212F) 150C (302F) 200C (392F) 250C (482F) 400C (752F) > 500 > 1000 > 500 > 1000 > 25 > 500 > 1000 > 500 > 1000 > 38 > 750 --> 750 > 1000 > 50 > 1000 --> 1000 > 1000 ------> 1000 -----

Silicone Oil Carbon Fluoride High-temperature Oil White Oil Vacuumproof Design

IC L IH WB IC-V

> 500 > 1000 > 500 > 500 >5

Application Limits

Seals Design Performance

Accuracy is primarily affected by Fill volume change due to temperature Capillary length Diaphragm stiffness

Low fill volume and low stiffness of diaphragm is required for high accuracy

Questionaire

Questionaire for P-/DP-Transm. with remote seals

Level Measurement

air supply
regulator

dP

Bubble measurement

Liquid Level (example oil on water)

S2 S3 range of interface level h interface level S1 LT

S1 = H2O S2 = oil 4 mA = 20 mA =

S2 . 9,81 . h S1 . 9,81 . h

(only oil) (only H2O)

(simplified illustration; without the influence of capillary tube S3)

Interface level measurement

Density

S1 = low specific gravity S2 = higher specific gravity S3 = specific gravity of filling oil in capillary tube

4 mA = 20 mA =

(S1 . h S3 . h) . 9.81 (h * SG2 h * SG3) * 9.81

Density measurement

Level measuement in a spheric tank

output (volume) Input [%] (Level = h) 0.00 3.75 7.75 11.75 16.75 22.00 28.00 35.25 45.75 55.00 65.00 72.25 78.50 83.75 88.25 92.50 96.25 100.00 Ouput [%] (Volume) 0.00 0.41 1.71 3.82 7.48 12.39 19.13 28.52 43.64 57.48 71.82 81.17 88.12 92.94 96.18 98.40 99.59 100.00

v = 1/3 pi * h2 (3r h)

input (level = h)

Level measuement - warning

Pressure (vacuum) Temperature Medium Foam Agitator Flow inlet

Intelligent Transmitters
A E

4 ... 20 mA

Conventional 1965

HART 1987

A E+#

4 ... 20 mA + superimposed, digital communication

FSK-Modem

Fieldbus 1985/95/97/99

A #

Intelligent Transmitters

Fieldbus Functionality
More values Multi variabel High resolution Diagnostic data Quality signal Status Decentral Functions Distributed Control Bi-directional Asset Optimization Graphics

HART Traditional
Value Device Parameter SMART Fieldbus

Value 4-20mA

Time

Intelligent Transmitters
Value (measuring) Status Scaling Filter time Alarm / warn limits Alarm summary TAG Device diagnostic
Cyclic services (Analog value)

Acyclic services (Hart)

Spontaneous services Acyclic services

Manufacture specific parameter

Intelligent Transmitters
Analog Technology
400 mbar

Bus Technology

Basic range value

200 mbar

20 mA

Sensor range limits

0 mbar

4 mA

-400 mbar

Floating Point 32 bit

Communication mode: Point-to-Point

2600T

e.g. power supply FSK modem

US > 10.5 ... 45 V DC (HART)

R > 250 Ohms

Communication mode: FSK Bus

2600T

TZN 128 e.g. power supply FSK modem

TZN 128

FSK modem

SmartVision

SmartVision

SmartVision

Communication Requirements
Connecting cable Communication between transmitter and PC/laptop requires

shielded and twisted pair lines.

The minimum wire diameter should be: - 0.51 mm for lines up to 1500 m

- 0.81 mm for lines longer than 1500 m

The maximum line length is limited to: - 3000 m for twin-core cable - 1500 m for multicore cable

Electrical Safety - Explosion Protection

The areas where this can occur are classified depending upon the probability that gas/vapour, in dangerous combination with air, is present. In Europe and some part of the world, except the American continent, the classification is as follows, according to IEC Publication 79-10: ZONE 0: an area in which an explosive gas-air mixture is present continuously or for long periods. ZONE 1: an area in which an explosive gas-air mixture is likely to occur in normal operation. ZONE 2: an area in which an explosive gas-air mixture is not likely to occur in normal operation, and if it occurs, it will exist only for a short time.

Electrical Safety - Explosion Protection

In North America, the classification refers to only two divisions, which may be briefly defined as follows, according to NEC article 500: Division 1: hazard may be present in normal operation.

Division 2: hazard may be present only in abnormal operation.

Therefore the following rough equivalence apply:
CONTINUOUS HAZARD (> 100 h / y) EUROPE (IEC) ZONE 0 INTERMITTENT HAZARD (1 - 100 h / y) ZONE 1 ABNORMAL CONDITIONS (0.01 - 1 h / y) ZONE 2

North America *

DIVISION 1

DIVISION 1

*Note: The Zone classification like IEC is now possible also for North America according to article 505 of the NEC/Edition 1996, ANSI/NFPA70

Electrical Safety - Explosion Protection

The various gases/vapours are grouped considering their "likeness" in terms of ignition energy. Each group has a "representative gas". Representative gases and relevant minimum ignition energy (microjouls) are shown here below:
Representative Gas Acetylene Hydrogen Ethylene Propane IEC / CENELEC (EUROPE) II C II C II B II A NORTH AMERICA Class I Group A Class I Group B Class I Group C Class I Group D Minimum Ignition Energy [micro joules] 20 J 20 J 60 J 180 J

Note: according to IEC classification II means surface industries (as an alternative to mining atmosphere)

Electrical Safety - Explosion Protection

The temperature classification relates to the maximum attainable temperature of the transmitter, or part of it (normally assuming a 40 C ambient), to the ignition temperature of a gas / vapour.
Max. Temp. [ C] 200 180 165 160 North America T3 T3A T3B 135 T3C 100 T5 T6 T4 Max. Temp. [ C] IEC/CENELEC (EUROPE)

450
300 200

T1
T2 T3

135

T4

85