Magnetostrictive level gauge application tutorial. Just one article to help you understand !

Magnetostrictive level gauge measurement principle

Substances expand and contract with heat. In addition to heating, magnetic and electric fields can also cause the size of objects to elongate or shrink. Under the action of an external magnetic field, the size of a ferromagnetic substance elongates (or shortens). After the external magnetic field is removed, it returns to its original length. This phenomenon is called magnetostriction (or effect).

Based on the principle of magnetostriction, a magnetostrictive wire is installed in the non-magnetic probe, and the sensor is connected to one end of the magnetostrictive wire. The main control electronic unit sends a narrow electromagnetic pulse to the magnetostrictive line, and the electromagnetic pulse is conducted along the magnetostrictive line.

When the magnetic field generated by the pulse interacts with the magnetic field generated by the magnet in the float marking the liquid level/interface, a torsional stress wave will be generated on the magnetostrictive line, which will return to the sensor along the magnetostrictive line. Convert the captured return wave into an electronic pulse signal and send it back to the main control electronic unit.

The main control electronic unit accurately measures the time interval between the emission pulse and the return pulse through a precision circuit, and calculates the position of the float, that is, the height of the liquid level/interface.

Magnetostrictive level gauge application range

◆Power plant: reservoir, waste gas purification tank, fuel tank, etc.
◆Oil field: crude oil or product oil storage tank, three-phase separator, settling tank, sewage tank (pool), etc.
◆Petrochemical: oil pipelines, distillation towers, concentration tanks, liquefied gas tanks, ammonia tanks, oil refineries, etc.
◆Chemical industry: distillation tower, ammonia tank, toxic liquid tank, etc.
◆Water and water treatment: reservoirs, sewage tanks, water treatment tanks, sedimentation tanks, digestion towers, etc.
◆Others: food, pharmaceutical, environmental protection, papermaking and other industries

Read more about: Common Types Of Heating Oil Tank Level Sensors

Features of magnetostrictive level gauge

◆Multi-function: can measure liquid level and interface position separately or at the same time
◆High precision: measurement accuracy ±0.8mm or 0.01%FS (the larger one)
◆Wide scope of application: flexible and diversified installation methods.
◆Output mode: on-site instructions and remote electrical signal output
◆Low power consumption: two-wire loop 4-20mA output, LCD display

The principle and characteristics of the magnetostrictive level gauge are briefly introduced above.

The following content of this article will give a detailed introduction to the application of magnetostrictive level gauges. I hope you have a deep understanding of the installation and use of magnetostrictive level gauges on site after reading this article.

1.Probe form of magnetostrictive level gauge

Magnetostrictive level gauges usually have rod probes and cable probes. With different floats, the liquid level or interface can be measured.

①The probe is a rod type probe, which can measure liquid level or interface with different floats. The maximum length is 4m.

②The probe is a rod probe, which can be equipped with double floats to measure the liquid level and interface at the same time. The maximum length is 4m.

③The probe is a cable probe, which can measure liquid level or interface with different floats. The maximum length is 20m.

2.Installation method and structure of magnetostrictive level gauge

The magnetostrictive level gauge can be combined with the outer pontoon or the outer pontoon + magnetic flap into several installation methods. It is not only easy to install and maintain, but also can cooperate with the on-site flip display. Realize the on-site and remote dual output. The probe has multiple parameters to choose from. Including: installation type, connection method, probe installation type, end structure, etc.

①Installation of probe rod and magnetic flap

◆For the probe structure that is attached outside the probe. The probe rod is usually fixed on the opposite side of the connecting structure, as shown in the figure below.

◆When a magnetic flap is needed, the magnetic flap is usually fixed on the opposite side of the connection structure. At this time, the probe rod will move to any position on the left and right sides of the float, as shown in the figure below.

② Magnetostrictive level gauge probe top insertion + side/side installation method

The picture above shows the most commonly used side mounting: side-to-side mounting (the probe mounting type is for inserting the top of the probe)

Figure a. Connection mode: flange connection, bottom structure: end cover + plug
Figure b. Connection method: chuck connection, bottom structure: blind flange
Figure c. Connection method: welding, bottom structure: short pipe + drain valve
Note: There is no necessary correspondence between the connection mode and the end structure.

③The bottom of the magnetostrictive level gauge probe is inserted + side/side installation method

The probe installation types in the above figure are all “insert installation at the bottom of the probe”.

Figure d. Top structure: end cover + plug
Figure e. Top structure: blind flange
Figure f. Top structure: closed
This structure is not conducive to sewage and maintenance. Therefore, when using the probe upside down, it is recommended to install the probe upside down and externally bound.

④Figure g shows the magnetostrictive level gauge probe top insertion + top/side installation
⑤Figure h shows the bottom insertion + side/bottom installation of the magnetostrictive level gauge probe
⑥Figure i shows the magnetostrictive level gauge probe top insertion + top-mounted installation + magnetic flap display
⑦Picture j is the magnetostrictive level gauge probe top insertion + side/side installation + magnetic flap display
Note: The two installation methods of ⑥ and ⑦ are suitable for occasions where the measurement position is low.

⑧Figure k Magnetostrictive level gauge probe upside-down external binding + bottom-mounted plug-in installation + magnetic flap display
⑨Figure l Magnetostrictive level gauge probe upside-down external binding + side/side installation + magnetic flap display

Note: ⑧ and ⑨ installation methods The probe installation type is the probe inverted and externally bound. These two installation methods are suitable for occasions with higher measuring positions. The end cover + plug structure or blind flange structure is selected for the bottom, which is conducive to sewage and maintenance.

The above pictures are all attached to the outside of the probe.
⑩Figure m shows the probe front-mounted external binding installation
⑪Figure n shows the probe front-mounted external binding installation
⑫Figure o shows the probe upside-down and external binding installation
The manufacturer will choose the formal installation type according to the top structure

The picture above is a schematic diagram showing the magnetostrictive level gauge with a magnetic flap.
⑬Picture p is side-mounted, side-to-side mounted, with the probe top inserted
⑭Figure q shows two views of side-mounted, side-to-side installation, the probe top is inserted and installed, and the bottom end cover + plug structure
⑮Figure r is a schematic diagram of the side-mounted, side-to-side mounted, the probe is mounted with an external binding type, the top is closed, and the bottom drain valve structure is schematic.

Typical tank application of magnetostrictive level gauge

1.Magnetostrictive liquid level gauge is used for liquid level measurement of agitated and foamed containers

When applied to occasions with stirring and foam, liquid level fluctuations and foam will affect the measurement. At this time, it is recommended to use a top-mounted probe or add a protective tube to the probe.

2.Magnetostrictive level gauge is used for liquid level measurement of small-sized containers

◆When the container to be measured is small, the use of side-to-side connection will reduce the effective measurement range. At this time, the side-to-bottom or top-to-side connection can be used to effectively increase the measurement range.

◆When the process temperature is high, you should pay attention to heat preservation, as shown in the figure on the right, you can use insulation cotton for heat preservation, or use electric heat tracing and steam heat tracing for heat preservation.

3.Magnetostrictive liquid level gauge is used for liquid level measurement of buried tank

The “buried tank” here includes a container whose main body is buried in the ground and a container whose sides are covered and cannot be installed with meters. For the measurement of this type of container, simple applications can use rod probes and cable probes. If you need on-site display, you need to use a magnetic flap + top-mounted plug-in installation type

4.Magnetostrictive liquid level gauge is used for liquid level measurement of ceiling tanks and suspended tanks

When the location of the container to be measured is high, it is difficult to install, debug, and maintain the instrument, and it is difficult to display on-site. It is recommended to use magnetic flap + bottom-mounted plug-in installation type. Or magnetic flap + bottom-mounted side-side mounting type.

Magnetostrictive level gauge installation methods and professional knowledge of typical applications are shared here.

I don’t know if you have noticed: whether there is a sudden sense of clarity when selecting the magnetostrictive level gauge based on the on-site working conditions and these installation and application examples. The selection is simply to convert the legend to the response model!

Magnetostrictive Level Gauge/Sensors for Sale

Sino-Inst offers over 10 Magnetostrictive level gauges for level measurement. About 50% of these are Magnetostrictive liquid level meters, 40% is the tank level sensor.

A wide variety of Magnetostrictive level gauges options are available to you, such as free samples, paid samples.

Sino-Inst is a globally recognized supplier and manufacturer of Magnetostrictive level measurement instrumentation, located in China.

1. Introduction

In order to grasp the operation information of the storage tank in real time and accurately. For example the level, density, pressure, temperature, volume, and quality of the storage medium in the storage tank. To ensure the safety of the storage tank, many oil storage tanks have been studied at home and abroad. Detection and measurement methods and devices. Such as static pressure method, liquid level meter, hybrid method, etc., designed to a variety of measurement technologies, such as pressure type, servo type, radar type, magnetostrictive type, float steel belt type, etc.

Due to many factors such as technology, economy, and use. The monitoring, measurement, and safety management of oil storage tanks in our oil depots mainly rely on manual rulers, manual measurements, and manual inspections. Its measurement accuracy, reliability, maintainability, and real-time performance are difficult to meet the development needs of oil depot informatization construction.

An oil tank level gauge based on magnetostrictive measurement technology has a simple structure and high measurement accuracy. It can measure liquid level, boundary level, multi-point temperature, and other advantages at the same time.

This year, it has been applied more and more in the monitoring and measurement of oil storage depots, such as Sinochem Nantong Oil Depot. Therefore, the magnetostrictive level gauge is applied to the information system of the product oil storage tank oil depot. Real-time monitoring and metering management of refined oil storage tanks. Not only can real-time collection, storage, and management of oil depot receiving, sending, and storing information. It can also reduce staff to increase efficiency and improve oil depot management.

2. Working principle of the magnetostrictive level gauge

2.1 The composition of the magnetostrictive level gauge

The magnetostrictive level gauge is mainly composed of a float (with a magnetic ring inside), a transmitter (or an electronic warehouse is composed of a pulse generator and a receiver), a waveguide equipped with a magnetostrictive wire and a temperature detector. . The transmitter (electronic warehouse) is equipped with a magnetostrictive wire waveguide and temperature detector are integrated structure. The transmitter and temperature detector adopt a modular and integrated design.

2.2 Working process of the magnetostrictive level gauge

The working principle of the magnetostrictive level gauge is mainly to use the combination of magnetic effect and super-generating effect to achieve the purpose of measurement. Magnetic effect and Weidmann effect and Villari effect.

When the transmitter is powered on, the pulse generator and receiver start to work. The pulse generator in the electronic head of the level gauge first applies an electrical pulse signal to the magnetostrictive waveguide wire. This electrical pulse is accompanied by a circular magnetic field. When the magnetic field encounters the longitudinal magnetic field generated by the magnet in the float at the speed of light. It will be vectorially superimposed to form a spiral magnetic field.

According to the Weidmann effect, when the magnetic field of the magnetostrictive material changes. The weak size of the magnetostrictive material itself will also change accordingly. Therefore, when the synthetic magnetic field changes to form a spiral magnetic field, the magnetostrictive waveguide wire will be twisted and deformed. This excites the torsional wave (or return pulse).

The torsion wave will be transmitted back to the induction coil in the sensor head in the form of ultrasonic waves along the waveguide wire and will change. When the coil in the sensor, it will be converted into transverse stress.

According to the Villari effect, when a magnetostrictive material is physically deformed. Will cause changes in the magnetic field strength in the magnetostrictive material. Therefore, the magnetic flux passing through the sensor coil will change, and an induced electromotive force that can be detected will be generated at both ends of the sensor coil. The propagation speed of the supergenerated torsion wave is only related to the elastic modulus and density of the magnetostrictive waveguide filament, which is a constant.

Therefore, the time difference from the moment the current pulse is emitted to the detection of the induced electromotive force is multiplied by this fixed velocity V. The position of the magnet (float) can be accurately calculated. Its liquid level height L=V*(t1-t2).

Extended reading: Fuel-Diesel-Water Tank Level Sensor Monitoring

2.3 Technical characteristics of the magnetostrictive level gauge

The petrochemical industry has gradually paid attention to the monitoring of oil levels. According to the working principle, it can be roughly divided into the following types:

• Mechanical float level gauge. The price is low, but its accuracy is low, and it cannot meet the requirements for use as a measuring instrument. And the failure rate is high, and the steel belt is prone to jam.
• Capacitive liquid level gauge. The price is moderate and the measurement accuracy is acceptable. However, due to its large temperature drift, its stability is insufficient, the accumulated error is large, and the measured value is not accurate.
• Light guide type liquid level gauge. The price is moderate, but the measurement accuracy is low and the stability is poor.
• Radar level gauge. The price is expensive, the liquid level accuracy, reliability, and stability are all ideal, the installation is also very convenient, and different media are practical.
• Magnetostrictive liquid level gauge. The price is more expensive, the stability is better, and it is easy to install. But it cannot be used in heavy oil with high viscosity and high density. Of course, the magnetostrictive level gauge has many other outstanding advantages. Specifically in:

① The work is very reliable. Because the second son telescopic level gauge uses the waveguide principle to work. Therefore, there are no mechanical moving parts inside the device, and there are no defects such as wear. The entire converter is enclosed in a stainless steel tube. No contact with the measured medium. Therefore, the sensor works reliably and has a long life span.

②Multi-parameter measurement. Another major feature of the magnetostrictive level gauge is that it integrates measurement of liquid level, water interface, temperature and other parameters. Because the electronic components in the magnetostrictive level gauge can detect the continuous magnetic waves generated by the same emission pulse. Therefore, two or more magnetic floats can be installed on the same sensor. Just ensure that the weight of the float corresponds to the specific gravity of the medium. The liquid level and interface can be measured at the same time, realizing multi-parameter measurement.

③High measurement accuracy. Because the magnetostrictive level gauge uses waveguide pulses to achieve measurement. During work, the displacement of the measured liquid surface is measured by the time difference between the excitation pulse and the induction pulse. Therefore, the accuracy is extremely high, which is a measurement accuracy that is difficult to achieve with other sensors. At roughly the same or lower cost, magnetostrictive level gauges have higher accuracy and better economic benefits than other measuring systems that use capacitance, pressure, mechanical, ultrasonic or servo devices.

④ Good safety performance. The explosion-proof grades of magnetostrictive level gauges are generally flameproof and intrinsically safe. Suitable for working in various flammable, explosive, high temperature, high pressure and other dangerous places. No need to manually open the filling cap during measurement. Avoid the hidden danger of insecurity caused by manual measurement.

⑤ Easy to install and maintain. Since the magnetostrictive level gauge adopts flange connection, the installation is extremely simple. Moreover, the core components are not in contact with the medium, and the product has a modular structure. Intelligent design, no need for regular maintenance and regular calibration, which brings great convenience to users.

⑥Easy to realize networking. The output of the magnetostrictive level gauge is a standard signal. It is convenient for crisis management and can better cooperate with computer. It is also easy to make long-distance transportation possible.

Of course, the change of medium density will have a certain impact on the accuracy of the magnetostrictive level gauge. But it can be installed by installing a suitable float. Reduce the immersion of the float, reduce the outer diameter of the float, and overcome and avoid it to the greatest extent through temperature compensation. After on-site testing, the magnetostrictive level gauge is the same as the radar level gauge, with blind spots and inaccurate measurement of tank bottom oil.

Extended reading: Radar Oil Tank Level Sensor

3. Application of magnetostrictive level gauge in Sinochem Zhuhai Phase II product oil tank

At present, Sinochem Zhuhai Phase II Chenpin Oil Depot with a total of 412,000 m3 has been completed. Among them, the online liquid level monitoring system involving 12 light product oil tanks totaling 192,000 m3 uses magnetostrictive level gauges. The liquid level system consists of a magnetostrictive liquid level gauge, H-500 field display, H-1000 (oil depot) 10.4 inch color touch screen controller and YSMK-YK oil depot information monitoring and management system.

This system can display liquid level, interface height and temperature with H-500 on-site display in the field. In the control room, the H-1000 (oil depot) controller is used to display data in real-time with three-dimensional graphics and digital methods. Use sound and light alarm to prevent oil spill and oil shortage. Therefore, the detailed functions of the system are as follows:

• Accurate real-time measurement of oil level, water level and temperature. Using 10.4 color LCD screen, the number of storage accuracy points is not limited. It can be customized according to the customer’s volume meter, and the oil height, water height, temperature, volume, and remaining volume can be displayed in graphical and digital ways.
• Alarm function. The system has multiple alarm functions such as high liquid level (pre) alarm, low liquid level (pre) alarm, and high water level alarm. Use sound and light alarm to prevent oil spill and oil shortage.
• Self-diagnosis, management and equipment failure alarm.
• Oil intake report. It is possible to compare the liquid level before and after oil intake. Automatically calculate and save the amount of oil in and out.
• Communication function. The system is connected to the sensor through a 485 interface for data collection. At the same time, it can provide a built-in Ethernet interface, 2 RS-232 interfaces and an open protocol. Data communication with the local system and remote server.
• Product lightning protection design. With internal lightning protection and external lightning protection functions. In the event of a lightning strike, the internal circuit automatically discharges the strong lightning current and will not detonate or ignite combustible gas. The external wiring steel pipe is connected to the protective grounding system of the storage tank.
• Active communication and timing transmission data settings. The system can use external equipment to achieve active communication settings. Be able to set the target server IP address, port, user name, password and data sending time. And upload the data to the target server at the specified time and shift shift.
• Leak detection function. Due to the high measurement accuracy, the static and dynamic liquid level of the oil tank can be monitored in real time. It can also realize pipeline leakage monitoring in accordance with pipeline leakage testing procedures.

Extended reading: Oil Level Measurement Solutions for the Oil & Gas Industry

Since Sinochem’s Zhuhai Phase II oil depot currently does not have the oil intake conditions, the instrument and system cannot be fully tested and verified. But through other petrochemical companies have used the magnetostrictive level gauge as an oil tank level monitoring system for in-depth understanding. The above-described functions can all be realized, and the measurement accuracy function is carefully compared with the manual ruler. It is found that the accuracy is very high, basically reaching the level of measurement.

In summary, the magnetostrictive level gauge has outstanding advantages such as high reliability, high accuracy, low failure rate, and multi-parameter measurement. It has been regarded by experts in the petrochemical industry as the preferred instrument for liquid level and boundary level measurement. It is an ideal choice for metering and process-level monitoring. Especially in applications where the dielectric constant of the medium is low, the medium is volatile, and the measurement interface is required. Because the magnetostrictive characteristics are not affected by factors such as dielectric constant, temperature, pressure, and meteorological conditions, it has become the first choice for users. Under the trend of industrial production integration and large-scale production. Magnetostrictive level gauges will have a broader application space in future level measurement.

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The liquid level of the liquid ammonia storage tank is accurately measured, which can eliminate potential safety hazards.

This article analyzes the application problems of several common liquid ammonia storage tank level measuring instruments. So as to provide a basis for the selection of measuring instruments.

About Liquid Ammonia Storage Tank

Liquid ammonia is a common chemical raw material. To facilitate transportation and storage, gaseous ammonia is usually pressurized or cooled to obtain liquid ammonia. When liquid ammonia is dissolved in water, ammonium ion NH4+ and hydroxide ion OH- are formed, and the solution is alkaline. Liquid ammonia is mostly stored in pressure cylinders or steel tanks. Liquid ammonia is widely used in industry, is corrosive and easily volatile, so its chemical accident rate is very high.

Read more about: 7 Level Senors for Tank Level Measurement

Application Analysis of Common liquid Ammonia Storage Tank Level Measuring Instruments

External liquid level sensor

The external level gauge is an instrument that uses the sonar ranging principle and “micro-vibration analysis” technology to measure the level from the outside of the container. No need to make holes on the tank wall, no flanges, no fire, no tank cleaning. Do not touch the liquid and gas in the tank. It can realize online installation and maintenance. It is a completely non-contact isolated instrument.

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The external liquid level sensor continuously and accurately measures the liquid level in the tank from outside the tank. No contact with the liquid and gas in the tank at all, realizing a true isolation measurement. Therefore, the characteristics are as follows:

1. Isolated non-contact liquid level measurement technology is very safe.
2. Installation and debugging, thereby reducing construction and maintenance costs.
3. It is more reliable and durable. There are no mechanical moving parts in the measuring probe and host, and it is strictly sealed, isolated from the outside world, and will not be worn or corroded.
4. Pass the “functional safety integrity” level certification.

Differential pressure transmitter

One end of the differential pressure transmitter is connected to the liquid phase, and the other end is connected to the gas phase. The liquid level of the liquid ammonia storage tank can be measured using the principle of hydrostatics.

In the process of applying this instrument and equipment, it is necessary to strictly control the installation height of the equipment.

Generally, it needs to be installed below the lower interface of the liquid level pressure interface of the container under test. And choose easy to maintain and observe. At the same time, it is also close to the pressure taking part.

Taking into account the low boiling point and easy vaporization of liquid ammonia, it is necessary to use a double flange differential pressure transmitter to ensure the stability of the measurement signal.

If this device is used, the installation of the device will only be limited by the length of the capillary tube.

Specifically, it is necessary to take corresponding protection and insulation measures, and ensure that the bending radius of the capillary is greater than 50mm. When using this measuring instrument, if the installation elevation changes, the output value of the device will be affected.

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From the application effect point of view, the differential pressure transmitter has the characteristics of easy calibration and a wide range of popularization. At the same time, the price of this type of equipment is low, and it has a certain cost-effective advantage.

However, when installing the device, it is necessary to reserve mounting holes. At the same time, due to the close relationship between the equipment and the density change of the medium, the measurement operation will cause the material of the instrument diaphragm to be corroded by the corrosive medium. After a long time of operation, the equipment is prone to deformation of the capsule.

In the application process, if there is no indication, the indication is too large or too small and the indication remains unchanged. It is also necessary to check the power supply, safety barriers, circuit boards, diaphragm capillaries and pressure valves. And appropriately replace the equipment components and open the equipment pressure valve in time.

Magnetic flap level gauge

The application of the magnetic flap level gauge follows the law of float and the principle of magnetism, and needs to be connected to the tank through a flange.

During the measurement, the two-color cylindrical magnetic float inside the device will change under the influence of the magnetic field, and the float junction is the actual liquid level of the storage tank.

In the process of installing the equipment, it is necessary to avoid magnetic materials around the equipment, and determine the heating temperature according to the medium condition. In the case of large gas-liquid-phase opening connections, a flange needs to be installed in the middle of the level gauge.

In the process of equipment debugging, a magnetic steel corrector is needed to adjust the magnetic column to white, and then open the gas phase stop valve and the liquid phase stop valve successively, and observe the liquid level rise and fall.

The magnetic flap level gauge can measure the liquid level and interface of any medium, and the equipment itself has the characteristics of convenient and intuitive installation.

However, if there are too many impurities in the medium, the magnetic column will not flip and the measurement will fail.

At the same time, the application of this device is prone to the problem of magnetic column jamming, which will lead to the failure of remote transmission instructions. However, the price of this equipment is low, and installation holes need to be reserved during installation.

The magnetic flap level gauge is prone to problems such as no signal output from the transmitter, no change in the output signal and the range cannot be adjusted to the corresponding value during the application process. In the application process, the power supply voltage, cables, terminal pins and safety barriers need to be checked.

Cable guided wave radar liquid level sensor

The application of the cable guided wave radar level gauge follows the principle of travel time, and it is necessary to measure the distance from the reference point to the surface of the liquid ammonia by transmitting and receiving high-frequency pulse signals.

When installing the equipment, it is necessary to avoid the liquid ammonia inlet to prevent false reflections from the equipment.

When installing the sensor, it cannot be installed in the center of the tank, and the sensor must be kept away from the tank wall.

When installing the cable probe, the distance between the probe and the smooth metal wall should be greater than 50mm, the distance between the end of the probe and the bottom of the container should be greater than 0mm, and the diameter of the short tube should not be greater than 0mm. In addition, depending on the installation position, the offset of the cable probe may increase.

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The cable-type guided wave radar level gauge has the characteristics of direct contact with the medium and small measurement blind area, and the measurement accuracy is high.

However, this equipment is not suitable for measuring pressure vessels, and the price is relatively high. It is necessary to reserve mounting holes on the top of the equipment during installation.

From the point of view of application failures, the equipment may have failures such as incorrect DCS system configuration, cable probe failure, and unstable DCS display value.

In the application process, it is necessary to carry out on-site measurement before calibration, and it is not necessary to check whether the DCS configuration data is consistent with the actual measurement result in order to obtain the real data.

Before measurement, you need to clean the probe and increase the height of the empty tank appropriately to eliminate the effect of echo.

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