Replacing Displacer Type Level Measurement with Guided Wave Radar: A Project Experience
In industrial process control, precise and reliable level measurement is essential, especially when monitoring interface levels between immiscible liquids. Recently, we successfully transitioned from a displacer type level measurement system (Fisher) to a Guided Wave Radar (GWR) level transmitter (Rosemount) in one of our critical process tanks.
This upgrade not only addressed recurring maintenance challenges but also resulted in significant improvements in process efficiency and yield due to more precise process control.
Project Background
Our previous displacer system faced several challenges:
- Frequent Failures: Mechanical linkages of the displacer were prone to breaking or dislocating, causing inaccurate measurements.
- Process Interruptions: These failures led to unplanned downtime and disrupted production schedules.
- Maintenance Burden: Recurrent breakdowns increased operational costs and maintenance hours.
To address these issues, we opted for the Rosemount Guided Wave Radar (GWR) level transmitter, a robust and non-mechanical alternative designed for challenging interface level measurement applications.
Why Rosemount Guided Wave Radar (GWR)?
The Rosemount GWR offered several key advantages:
- High Precision: Ideal for interface measurement, leveraging dielectric constant (DK) differences between liquids to provide accurate readings.
- Non-Mechanical Design: Eliminated failures associated with moving parts in the displacer system.
- Custom Chamber Design: Rosemount provided a new chamber tailored specifically for the GWR, replacing the old displacer chamber.
- Advanced Signal Processing: Ensured stable and reliable measurements even in dynamic process conditions.
- Ease of Integration: Equipped with HART communication for seamless setup and integration into existing control systems.
Photo and Product Link
- Product Link: Rosemount Guided Wave Radar Level Transmitter
- Photo:
Implementation Process
1. Compatibility Assessment
The first step involved ensuring that the GWR was compatible with the process liquids and application:
- Dielectric Constant (DK) Measurement:
- Conducted DK testing for both liquids to determine the feasibility of interface measurement.
- Confirmed that the DK difference exceeded the GWR’s minimum threshold for accurate interface level detection.
2. Chamber Replacement
The existing displacer chamber was unsuitable for the GWR’s operational requirements. Rosemount designed a custom chamber that met process and installation needs.
3. Planning and Installation
- Conducted a comprehensive review of the existing setup, including piping, instrumentation, and control requirements.
- Removed the old displacer system and chamber, ensuring the tank remained contamination-free.
- Installed the new chamber and mounted the GWR transmitter with precision.
4. Calibration and Testing
- Configured the GWR using HART communication tools to input DK values and application-specific parameters.
- Verified measurement accuracy through manual interface level checks and process simulations.
Post-Implementation Benefits Table
| Benefit | Details |
|---|---|
| Improved Reliability | – Eliminated mechanical failures from the displacer system. |
| – Significantly reduced unplanned downtime. | |
| Enhanced Accuracy | – Achieved precise interface and total level measurements. |
| – Ensured better process control and optimized production quality. | |
| Improved Process Yield | – Minimized product losses by precisely controlling interphase levels. |
| – Enhanced resource utilization and efficiency. | |
| Reduced Maintenance | – Robust GWR design and custom chamber reduced maintenance frequency. |
| – Lowered operational and maintenance costs. | |
| Seamless Integration | – Integrated smoothly into the existing control system. |
| – Enhanced overall process efficiency through advanced communication (e.g., HART protocols). |
Key Insights
- Thorough Planning: Ensuring compatibility through DK testing and designing a custom chamber were critical to the project’s success.
- Collaborative Efforts: Close collaboration with Rosemount ensured the design and installation met all process requirements.
- Long-Term Benefits: The switch to GWR not only addressed immediate issues but also provided lasting improvements in reliability and yield.
Disclaimer: This post is not a product advertisement. It aims to share practical insights and experiences from a real-world project to help industry professionals understand the benefits and considerations of transitioning from displacer-type level measurement to guided wave radar technology.