Represented by:

measurIT technologies

New Improvements to Magnetic Level Gauge Technology

for Plants that Process and Store Fluids

Recent innovations in float design, chamber connections and quality control

deliver integrated level solutions
and support extended performance guaranties.
Co-Authored by
Carl Kull, Vice President Sales, K-TEK, Prairieville, Louisiana
Kevin Hambrice, Director of Marketing, K-TEK, Prairieville, Louisiana

Despite which direction the economy may be

heading, for process engineers responsible for plant
operations that handle fluids, these are the best of times.
Continuous research and development in the area of level
detection and its integration into process controls has
garnered tremendous gains over the past couple of years.
Spearheading the way, new improvements to magnetic
level gauge technology have wrought increased accuracy,
control, safety and reliability over older technologies such
as sight glasses, differential pressure transmitters, and
complicated pneumatic controllers. Recent innovations in
float design, float chamber connections and transmitters
have enabled the complete integration of levelling
systems into plant digital control systems (DCS), while
gains in quality control support extended warranties
and performance guaranties that are unheard of in the
industry.
A brief examination of the latest improvements to
magnetic level gauge (MLG) systems will help bring
any engineer up-to-date on the hardware that is now
available to help improve plant operations. The inclusion
of application considerations will further illustrate the
benefits of today’s modern MLG systems—benefits that
include: greater control accuracy, improved reliability,
lower installation and start-up expense, less maintenance,
eliminated fugitive emissions, and a decreased risk of
explosion.

MAGNETIC LEVEL GAUGE

TECHNOLOGY
K-TEK’s KM26 magnetic level gauge
The foundation of any level measuring system rests can be safely used to measure a wide variety of liquids,
upon the level gauge itself, and for many fluid processing including corrosive, flammable and toxic materials.

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MeasurIT Technologies Ltd.
Craan, Craanford, email: info@measurIT.com Phone: +353 (0) 53 942 8962
Gorey, Co. Wexford, Ireland www.measurIT.com Fax: +353 (0) 53 942 8963

industries the new platform of choice is the magnetic level
gauge. Almost half of all MLGs sold to engineers today are
used to replace older sight glass units.
In the past, a sight glass was felt to be simpler because
it does not have a float. Yet, close scrutiny reveals that a
slight glass can possess as many as 50 separate parts.
Additionally, the continuous maintenance required to
remove and clean the glass is quickly forcing them out of
favour. Some users have indicated a six to twelve month
payback in maintenance savings alone by replacing
their sight glasses with magnetic gauges. The fact that
the cushions and gaskets used to seal the glass can be
permanently deformed by compression—resulting in
possible leaks, stress points, and even potential breakage—
is likely the ultimate reason for the demise of sight glasses.
This older technology clearly represents a substantial risk
for environmental and personnel safety.
A quick review of how MLGs operate helps to further
point out the reason for their increasing acceptance.
Whereas a sight glass indicates level by visually
displaying fluid level through direct contact against a
measuring grid, MLGs display level through a separate
tube that does not contain the process fluid, hence they
are sometimes referred to as bypass level indicators.
An MLG is still a visual indicator of liquid level, but it
utilizes magnetic transmission to couple the position of a
float (housed within an external “float” chamber alongside
the process fluid vessel) to a moving shuttle (indicator)
housed in a closely approximated separate tube that is
totally isolated from the fluid. As the fluid level is repeated
in the float chamber, so is it represented in the indicator
tube.
Since the visible shuttle/indicator avoids direct contact
with process liquids, problems with coating, plating,
fouling, fugitive emissions and hazardous material leaks
are completely eliminated. This ensures safe levelling of
liquids that are toxic, corrosive, or flammable. Magnetic
coupling also makes it easier to determine the level of
colorless fluids.
NEW REFINEMENTS TO AN ALREADY
SUCCESSFUL PACKAGE
The current status of magnetic level gauges as the
preferred choice of level measuring and control has been
brought about by a series of incremental, but important,
improvements. Today’s state-of-the-art MLGs provide
the highest levels of accuracy and longterm reliability, an
achievement that can be attributed to treating each part
within the gauge as an individually engineered design,
and not as an off-the-shelf commercial product.
MeasurIT Technologies Ltd.
Craan, Craanford,
Gorey, Co. Wexford, Ireland
Represented by:
measurIT technologies
An engineered approach to float design
The float, which is also known as the buoyancy device, acts
as the heart of any MLG. Ideally, each float is designed to
the specifications of each particular application. The best
representatives contain up to 15 rod-magnets, arranged
around the circumference of the float and held in place
with flux rings to evenly distribute the magnetic pull.
Taking into account the specific gravity of the fluid,
the ideal buoyancy—ranging from 75 to 200 grams—is
incorporated during the design prior to the float being
manufactured. This positive buoyancy ensures that the
float stays at the level of the fluid despite the buildup
of contaminants that would ordinarily cause a zero-
buoyancy device to sink. Positive-buoyancy (maintained
via a hermetic seal) floats also are proving superior to the
old vented-tube designs, which sink to the bottom of the
chamber when they eventually fill with condensed vapour
Additionally, the float material often deserves
application-specific consideration. For instance, for fluids
with a very low specific gravity, titanium represents a good
choice. If there is a heavy hydrogen sulfide or chloride
content, then C-276 might serve better.
Combined, these engineering efforts provide an exact
linear duplication of the fluid level onto the indicator.
No offset curve is required for calibration, as is the case
for some older-design floats that attempt to meet all
applications with a single configuration.
New strides in chamber design
Since the float chamber must house a small amount
of the process liquid, it must be almost as strong as the
vessel it is measuring. Today’s leading MLG chambers
are manufactured from a variety of materials including
PVC, alloy, titanium, and stainless steel, allowing them
to withstand process extremes from -320 to 1000 °F and
full vacuum to 4,500 psig. Sturdy materials, such 316 SS
allow MLGs to operate accurately within highly corrosive
environments, such as in offshore operations.
However, the most beneficial gains in chamber design
stem from a recent breakthrough in connecting the float
chamber to the process or storage vessel. Currently, only
one North American gauge manufacturer utilizes this new
connection technique, referred to as extruded-outlet. With
extrusion outlet welding, the bead is placed well outside
the lumen of the float chamber. Because there are no
internal distortions within the chamber, the float can move
freely and accurately reproduce levels without hanging
up.
The previous use of saddled and bevelled outlet pipes
often left an unusable float chamber because of sink-in
and bowing after welding, which ultimately interfered with
float movement. Attempts to re-straighten the chamber
after welding often resulted in unnecessary bends and
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occasional code violations. Fillet welds, weld-o-lets and
butt weld tees often cause additional distortion and
alignment problems of their own.
The new standard of extruded outlets eliminates all
distortion problems by providing a smooth radius on the
inside, while also guaranteeing a stronger connection. For
example, a 2” outlet on a 2” schedule 10 pipe has a pressure
rating 1000 psig. Extrusion welds meet ANSI B31.1, B31.3
and Section VIII standards.
Improvements in Indicators
Nowadays, the best indicator tubes are hermetically
sealed. Some manufacturers nitrogen-purge a glass or
polycarbonate tube and then put ryton (to avoid corrosion)
caps on each end to ensure air-tightness. This hermetic
seal eliminates the possibility of any moisture entrapment
and build-up that could negatively impact the indicator
movement and travel. This allows a smooth path for the
indicator, which tracks the float to represent the exact level
against a calibrated scale.
In some instances, a bar graph is required. Even here,
gains have been made.
In the past, many bar graphs were housed in an
aluminium channel with a flat glass front. However, metal
and glass expand and contract at different rates, so it is not
possible to maintain a hermetic seal. Moisture laden air
then reaches the metal pivot points, leading to corrosion
that causes the flags to hang up and yield inaccurate
readings. But newer designs take advantage of ryton pivot
points that do not corrode, and hermetically sealed tubes
that prevent moisture from entering in the first place.
NEW OPTIONS FOR UNIQUE
APPLICATIONS
Interface measuring
In some cases, two separate fluids are contained within
the same vessel—as when oil floats on top of water, for
instance. Understandably, measuring the interface could
ordinarily prove very difficult.
Modern magnetic level gauges cope with this situation
through floats that are specifically designed to float with
half their volume in the upper fluid and half in the lower
fluid. By dialing in the specifications of the fluids at the
MLG factory, interface differences as low as 0.03 SG can be
accurately measured.
To go one step further, the use of two floats— and
a third connection point from the float chamber to the
process vessel—allows some MLGs to also measure the
total level of upper fluid, in addition to the interface level
(between the upper and lower fluid).
MeasurIT Technologies Ltd.
Craan, Craanford,
Gorey, Co. Wexford, Ireland
Represented by:
measurIT technologies
Top mounted applications
When levels need to be detected in underground tanks
and sumps, the gauge must be located above the vessel
instead of at the more traditional location alongside the
vessel. In the case of top mounted MLGs, rods are attached
to the floats. Again, accurate engineering of the float,
magnets and the rod can allow grade level observation of
tanks that span up to 14 feet underground.
Extreme temperatures
The latest MLGs can provide accurate levelling of fluids at
temperatures up to 1000 °F through the use of factory-
supplied high temperature insulation jackets. The most
effective jackets consist of two layers: an inner ceramic
fiber insulation blanket, and an outer fiberglass cloth jacket
that is silicone impregnated for weather resistance. This
not only helps the gauge withstand high temperatures,
but it provides moisture resistance and increased operator
protection.
At the other end of the spectrum, many low
temperature fluids are clear, or create excessive frost, and
cannot be reliably indicated by a sight glass.
To counteract this dilemma, some manufacturers
use foam-glass insulation with mastic and an openweave
fiberglass cloth vapour barrier, along with a smooth
aluminium jacket for protection. This cryogenic insulation is
then furnished with a clear frost extension (made of Lexan)
on the indicator so that the level is visible on the outside
of the thick insulation. To maintain accurate tracking of the
indicator through all of this insulation, even more powerful
magnets are built into the float, allowing some modern
MLGs to accurately indicate levels at –320 °F.
In some cases, precise temperature control of the
process fluid is necessary for “freeze” protection. The idea
is to heat liquids above their pour point, and to prevent
paraffin build up as seen in oil production applications. In
the past, gauges have been heated using steam or electric
heat tracing within narrow trace tubes which parallel
the gauge. However, this does not provide a uniform
distribution of heat. Instead, the latest MLGs employ a
steam or electric heat jacket that completely surrounds
the entire float chamber to ensure the maintenance of a
constant temperature.
Highly volatile fluids
Of course, when highly volatile fluids—encountered
during ethylene production and also in propane chillers,
for example—create their own “steam,” a different
approach must be taken. If an old-style gauge is used in
an application where the fluid is operating near its vapour
pressure, the level indication may be erratic because
vapour from the boiling fluid cannot pass the float quickly
enough.. Modern MLGs sidestep this hindrance by building
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an oversized float chamber that allows the vapors to pass
around the narrower float. Built-in guide-rods within the
chamber itself help to keep the float pressed close to the
indicator tube, thus insuring no loss in accuracy.
Suspended particles
Oversized float chambers are also increasingly indicated
for use in measuring fluids with suspended particles.
When the particles are metallic, even more specific
measures can be taken. To illustrate: rusty piping systems
and vessels will occasionally bring about faulty readings
when the rust particles find their way to the float, causing
it to stick. However, this problem is now solved through the
installation of magnetic traps that catch the rust.
ADVANCEMENTS IN SYSTEM
INTEGRATION
One of the major advantages of today’s MLG technology
is that since the vessel contents are totally contained within
the float chamber, the same magnetic levelling can be used
to actuate limit switches or continuous level transmitting
devices without having to disturb existing piping or vessels.
Installation and modification can be undertaken while the
plant is on-line. This paves the way for easy integration
of levelling technology into plant digital control systems
(DCS).
For instance, level transmitters can pipe continuous
level readings via common industry protocols such as
4-20 mA, HART, Honeywell DE, Foundation Fieldbus, while
deriving their source of power from the control loop.
Electronic innovations in transmitter technology are
quickly replacing older mechanical means such as reed-
switch transmitters and pneumatic controllers. Leading-
edge magnetostrictive transmitters, for example, feature
only one moving part. The transmitter detects the position
of the float within the float chamber by using “time of
flight” technology to calculate distance. The resulting, non-
contact, level measurement is accurate to 0.01% of full
scale or 0.050 inch.
Guided wave radar transmitters (no moving parts) are
also very popular devices used in conjunction with MLGs
to achieve a redundant level measuring system particularly
harsh conditions such as paraffin wax build up in crude oil
applications.
This same technology allows for the hand-in-hand
integration of control switches. Alone, or in combination
with a magnetostrictive transmitter, high and low tier
switches can easily be configured to shut a pump off or
close a valve, for example. For some of these switches, the
trip point can be adjusted by simply loosening the clamps
and repositioning the switch.
MeasurIT Technologies Ltd.
Craan, Craanford,
Gorey, Co. Wexford, Ireland
Represented by:
measurIT technologies
QUALITY GAINS
It should come as no surprise that all of these
technological accomplishments have been accompanied
by improvements in quality and reliability. At a minimum,
ISO 9000 certification is becoming more common. Fully
assembling, function testing and calibrating all gauges
and accessories at the gauge factory further optimize
quality control. Continuing on, though, one MLG provider
even has on-site ASME certification, permitting an “S”, “U”
or “UM” certification stamp on its gauges. Most of these
gauges, transmitters and switches are FM, CSA and Cenelec
certified. Along with a PED and ATEX certification, this
equipment can be used anywhere in the world.
A SUCCESSFUL OUTLOOK FOR PROCESS ENGINEERS
A few installation examples serve to illustrate the
outcome of all of these accomplishments.
At one processing plant, the replacement of the an
old sight-glass instrument bridle—with a new MLG, three
electric switches and two pneumatic switches— eliminated
15 valves, 42 pipe fittings, 103 threaded joints and two
sight glasses including 16 U-bolts and nuts. The difference
in replacement costs resulted in a savings of $2,795 while
decreasing maintenance costs.
One level system for an industrial boiler originally
resorted to an inconsistent sight glass for local indication,
an unreliable conductivity “spark plug” system for remote
indication, and separate float-operated switches for safety
shutdown. The fitting of an easy-to-read local MLG indicator,
with reliable non-contact switches to operate the remote
indication panel lights and non-contact switches for safety
shutdown, resulted in a much more integrated system that
proved far easier to maintain.
And finally, at a Pulp Mill in South Africa, an MLG was
fitted with a magnetostrictive transmitter to monitor boiler
drum level that operated at 600F @ 1500 psig. The combo
level systems were successful in replacing an unreliable
sight glass and bridle system.
Such successful installations of new magnetic levelling
technology are increasingly being recreated throughout
all manner of industries that process and store liquids. For
those engineers that reap the benefits of these innovations,
the future is bright indeed.
We provide a complete family of point and continuous level
products including magnetically coupled level gauges,
magnetostrictive level transmitters, laser transmitters, guided
wave radar transmitters and ultrasonic transmitters.
For more information please contact MeasurIT Technologies
at + 353 (0)53 942 8962, email: info@measurIT.com
or sales@measurIT.com, www.measurIT.com.
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email: info@measurIT.com Phone: +353 (0) 53 942 8962
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