Now let's look at the glass level gauge. There's a lot of firebrick on either side of the glass channel, so it may be necessary to drill holes in the firebrick to reduce its thickness. This will cause the temperature on the outside to rise, so the detector must be water-cooled to bring the internal temperature of the electronics down to the normal range.
There are three geometries that can be used in continuous gamma level measurement. The most common is a point source that is collimated to produce a right-triangle-shaped beam with the 90º angle at the top of the detector. Next is a strip source that is characterized to produce a similar shaped beam, but with the apex of the triangle at the point detector (Figure 3). Third, there is the geometry of a strip source and a strip detector. This geometry is often used for highly precise level measurement on small diameter vessels or pieces of pipe, such as vertical risers.
In point level applications (Figure 4), the source produces a narrowly collimated conical beam that is aimed across the vessel at the point detector. In most point level applications, the reason a gamma gauge is being used is because the inner walls of the vessel are subject to vibration, corrosion, abrasion, or fouling or coating with material. Fly ash hoppers are classic examples of this kind of application. The energy activity of the source must be sized, so that the point level gauge continues to work correctly through a reasonable thickness of fouling or coating, perhaps as much as a couple of inches.
How to Measure a Tank of Tomato Paste
Larry Fontes, maintenance and production supervisor at Ingomar Packing Co. (www.ingomarpacking.com) in Los Banos, Calif., uses a gamma level gauge on a very difficult food industry application. "We were using a dual remote diaphragm seal system with chemical T diaphragm seals and a 4-20 mA DC HART transmitter to control a valve, which would control the level in a holding tank," Fontes says. "The holding tank is 38 in. (nominal 1 m) in diameter and about 30 ft (9.1 m) tall. The product inside the tank is tomato paste with a specific gravity of about 1.134 at 210 ºF to 215 ºF (a little over 100 ºC) at a flow rate of approximately 250 gallons per minute."
"After a 100-day processing season," Fontes continues, "the diaphragm seals would become coated due to the temperature of the product, and the level indication would begin to drift as the diaphragm was unable to pick up the change in pressure as the level changed."
Fontes reports that the problem became so severe that product spilled out the vent on top of the tank, while the transmitter reported little or no change in percent level.
Fontes looked into other level technologies, including radar. "I was looking for a level system that wouldn't be affected by the properties of the product due to the thermal processing," he says. "We had used a [gamma] device to measure soluble solids from Berthold Technologies, so I was somewhat familiar with the technology. Berthold worked with the consulting engineer we had contracted for the expansion of our aseptic processing system. [Process Resource Inc.. www.processresource.com]
"Berthold provided onsite start-up and training for myself and several of our operators," Fontes goes on. "The installation was made much easier with the help of all the individuals from Berthold. We operate the gauge under the general license in the Code of Federal Regulations."
And how has it worked out? "Since the installation of the Berthold level gauge (Figure 5) in 2007," Fontes reports, "we have had instances during a couple of processing seasons that would have resulted in the same issues as before. The dual diaphragm system level indication began to drift, while the gamma level gauge remained constant."
Fontes concludes, "The Berthold level gauge installation was part of a $1.3 million expansion to the flash cooler, which is part of our aseptic processing.
The Business of Using Gamma Level Gauges
Similar to every other device that uses nuclear byproduct material, even the smoke detectors in your house, gamma level gauges are required to be licensed. This means that applications, paperwork and rules have to be known, understood, followed and kept current. However, once you are set up to do this, licensing can be relatively simple and not too onerous.
"Many gamma level gauges can be distributed under the general license in most states in the United States," says Berthold Technologies' radiation safety officer (RSO), Mark Morgan, "but the general license does not exist in other countries, and the U.S. NRC plans to do away with it in one to three years anyway, in favor of specific licensing. The NRC plans to make the specific license procedure simpler and more streamlined."
The general license has less paperwork, but has restrictions on gauge geometry, exposure levels, shielding, and other environmental health and safety issues. The other kind of license, used globally as well as in the United States is called a "specific license." This means that you, as the gauge owner, are licensed to do several specific things with the gamma level gauge you own.
So what does this mean for operations and maintenance? Maintenance on the electronics, including the detector, can be done by any plant-qualified instrument tech or maintenance tech. No license is required by persons doing that level of maintenance. Since a gamma energy source is basically a steel-jacketed lead box with a capsule the size of a horse-pill inside of it, maintenance on source housings is minimal. A trained, licensed person is required to change the geometry of the gauge or to move it.
And when you aren't using it anymore, you are required to dispose of it properly—not just send it to a junkyard. Most manufacturers of gamma gauging instruments will accept a returned source, take title to it (so you and your management don't have to keep track of it forever), and send you a document saying that you are no longer responsible for it.
Knowing these simple rules in advance can mitigate management's reluctance to undertake a new regulatory duty.
So There You Have It
Gamma level gauges are a good long-term solution to many of the most difficult level applications you will run into. They will operate with fewer maintenance headaches and, in some cases, operate where nothing else will.