Patent Publication Number: US-2017370760-A1

Title: Radar level gauge system with modular propagation device

Description:
TECHNICAL FIELD OF THE INVENTION 
     The present invention relates to a radar level gauge system and to a method of installing a radar level gauge system at a tank. 
     TECHNICAL BACKGROUND 
     Radar level gauge (RLG) systems are in wide use for determining the filling level of a product contained in a tank. Radar level gauging is generally performed either by means of non-contact measurement, whereby electromagnetic signals are radiated towards the product contained in the tank, or by means of contact measurement, often referred to as guided wave radar (GWR), whereby electromagnetic signals are guided towards and into the product by a transmission line probe acting as a waveguide. The probe is generally arranged to extend vertically from the top towards the bottom of the tank. 
     An electromagnetic transmit signal is generated by a transceiver and propagated towards the surface of the product in the tank, and an electromagnetic reflection signal resulting from reflection of the transmit signal at the surface is propagated back towards to the transceiver. 
     Based on a relation between the transmit signal and the reflection signal, the distance to the surface of the product can be determined. 
     Radar level gauge systems are ubiquitous in application areas involving handling, shipping and storing of products as well as, for example, in the chemical process industry. 
     A radar level gauge system is often mounted on a so-called nozzle at the top of the tank. (The nozzle may typically be a pipe that is welded to the tank and fitted with a flange at its upper end to allow attachment of an instrument, such as a radar level gauge system, or a blind flange. The inner diameter of the nozzle may typically be between 0.1 and 0.2 m, and a typical length may be around 0.5 m.) 
     To prevent the nozzle from influencing non-contacting filling level measurements, it is desirable for the antenna (such as cone antenna or horn antenna) to extend to the lower end of the nozzle. 
     Nozzles are, however, not standardized and different tanks may have nozzles of different lengths, requiring different antenna dimensions. 
     So far, this issue has been addressed through the manufacture of customized antennas, such as by welding an extension pipe of suitable length to the antenna supplied together with the radar level gauge system. This may, however, be a relatively costly and time-consuming procedure, which may involve relatively difficult seam welding due to the thin material in the walls of the antenna and extension pipe. 
     Also for radar level gauge systems with other types of propagating devices, such as various transmission line probes, it may be desirable to facilitate adaptation to the tank at which the radar level gauge system should be installed. 
     SUMMARY OF THE INVENTION 
     In view of the above, a general object of the present invention is to provide an improved radar level gauge system. In particular, it would be desirable to provide for facilitated adaptation of a radar level gauge system to the properties and/or dimensions of the tank at which the radar level gauge system should be installed. 
     According to a first aspect of the present invention, it is therefore provided a radar level gauge system for determining the filling level of a product in a tank, comprising: a transceiver for generating, transmitting and receiving electromagnetic signals; an elongated propagation device connected to the transceiver for propagating an electromagnetic transmit signal in a longitudinal direction of the propagation device towards a surface of the product and for returning an electromagnetic reflection signal resulting from reflection of the electromagnetic transmit signal at the surface back towards the transceiver; and processing circuitry coupled to the transceiver for determining the filling level based on a relation between the transmit signal and the reflection signal, wherein the propagation device comprises: a first propagation device part comprising a cuff portion; and a second propagation device part comprising an end portion inserted in the cuff portion of the first propagation device part and joined together with the cuff portion by at least a first fastening arrangement, wherein the first fastening arrangement comprises: a tab formed in one of the cuff portion of the first propagation device part and the end portion of the second propagation device part; and a recess formed in the other one of the cuff portion of the first propagation device part and the end portion of the second propagation device part, the tab being received by the recess to interact with the recess to prevent relative movement between the first propagation device part and the second propagation device part at least in the longitudinal direction. 
     The “transceiver” may be one functional unit capable of transmitting and receiving electromagnetic signals, or may be a system comprising separate transmitter and receiver units. 
     It should be noted that the processing circuitry may be provided as one device or several devices working together. 
     The electromagnetic transmit signal may advantageously be a microwave signal. For instance, the transmit signal may be frequency and/or amplitude modulated on a carrier in the microwave frequency range. 
     The cuff portion of the first propagation device part may be arranged at an open end of the first propagation device part. 
     The “tab” is an elongated piece of material that can be angled or bent. The tab may also be referred to as an elongated tongue of material. 
     Moreover, the recess may be a blind hole or a through-going hole in the cuff portion or the end portion. The recess may advantageously be shaped and dimensioned to accommodate the tab. For example, the outline of the recess may be a scaled (slightly enlarged) replica of the outline of the tab. 
     In embodiments of the radar level gauge system according to the present invention, the propagation device may be a radiating antenna, such as a cone antenna or a horn antenna. These embodiments, for instance, provide for facilitated installation of the radar level gauge system at a tank having a tubular mounting structure (often referred to as “nozzle”) extending vertically upwards from the roof of the tank. Following a simple measurement of the length of the nozzle, an antenna extension part can be selected among a set of antenna extension parts of different lengths, or a long antenna extension part can be shortened based on the measurement. Thereafter the selected or customized antenna extension part can be attached to the original antenna of the radar level gauge system without the need for welding or special tools. This will facilitate installation of the radar level gauge system, and provides for a reduction in the installation time, which in turn saves installation cost and facilitates installation planning. 
     In other embodiments of the radar level gauge system according to the present invention, the propagation device may be a coaxial transmission line probe. These embodiments, for instance, provide for facilitated delivery and installation of the radar level gauge system. The outer conductor of the coaxial transmission line probe may be provided in propagation device parts, each having a cuff portion and an end portion configured to be received by a cuff portion of another propagation device part. Hereby, the coaxial transmission line probe can be transported and delivered in parts and easily assembled on site. As for the above-described antenna embodiments, different lengths may be provided and/or one or several propagation device parts may be shortened on site. 
     Also these embodiments of the present invention will facilitate installation of the radar level gauge system, and provide for a reduction in the installation time, which in turn saves installation cost and facilitates installation planning. 
     According to various embodiments of the present invention, the tab may be an integral portion of one of the cuff portion of the first propagation device part and the end portion of the second propagation device part. 
     Furthermore, the tab may extend along a periphery of the propagation device. 
     According to various embodiments, the radar level gauge system of the invention may further comprise a second fastening arrangement, peripherally spaced apart from the first fastening arrangement. This will facilitate secure mechanical connection between the first and second propagation device parts. 
     The second fastening arrangement may advantageously comprise a tab formed in one of the cuff portion of the first propagation device part and the end portion of the second propagation device part; and a recess formed in the other one of the cuff portion of the first propagation device part and the end portion of the second propagation device part, the tab being received by the recess to interact with the recess to prevent relative movement between the first propagation device part and the second propagation device part at least in the longitudinal direction. 
     According to embodiments, the tab comprised in the first fastening arrangement may extend along the periphery of the propagation device in a first peripheral direction; and the tab comprised in the second fastening arrangement may extend along the periphery of the propagation device in a second peripheral direction, different from the first peripheral direction. 
     Different peripheral directions of the first and second tabs (and the corresponding recesses) may facilitate the correct joining of the propagation device parts. Furthermore, rotation of the propagation device parts in relation to each other can be prevented, or at least restricted. 
     According to various embodiments, the radar level gauge system of the invention may further comprise a third fastening arrangement, including: a tab formed in one of the cuff portion of the first propagation device part and the end portion of the second propagation device part; and a recess formed in the other one of the cuff portion of the first propagation device part and the end portion of the second propagation device part, the tab being received by the recess to interact with the recess to prevent relative movement between the first propagation device part and the second propagation device part at least in the longitudinal direction, wherein: the tab comprised in the third fastening arrangement extends along the periphery of the propagation device in the first peripheral direction. 
     The first and third fastening arrangements may advantageously be peripherally spaced apart and the first direction may be substantially perpendicular to the longitudinal direction. 
     To minimize the influence of the fastening arrangements on the signal propagation through the elongated propagation device, each of the tab comprised in the first fastening arrangement, and the tab comprised in the second fastening arrangement may be formed in the end portion of the second propagation device part. 
     The second propagation device part may advantageously be arranged between the transceiver and the second propagation device part. 
     Moreover, in non-contacting radar level gauging embodiments in which the propagation device is an antenna, the second antenna part may comprise a first portion exhibiting an increasing cross-sectional area with increasing distance in the longitudinal direction from the transceiver, and a second portion exhibiting a substantially constant cross-sectional area along a longitudinal extension of the second portion, the first portion being located between the transceiver and the second portion. For instance, the second antenna part may thus be a cone antenna with a cylindrical end portion. 
     The first antenna part may be provided as an antenna extension part, and may exhibit a substantially constant cross-sectional area along a longitudinal extension of the first antenna part. In the cuff portion of the first antenna part, the inner cross-sectional area may, however, be locally enlarged to allow the cuff portion to receive and accommodate the end portion of the second antenna part. Accordingly, the inner diameter of the first antenna part (having a circular cross-section) in the cuff portion may be slightly larger than the outer diameter of the second antenna part (having a circular cross-section). The inner diameter of the first antenna part outside the cuff portion may be substantially equal to the inner diameter of the second antenna part in the end portion thereof. 
     According to a second aspect of the present invention, it is provided a method of installing a radar level gauge system at a tank having a tubular mounting structure extending vertically upwards from a roof of the tank, the method comprising the steps of: providing a radar level gauge system including a transceiver for generating, transmitting and receiving electromagnetic signals; and an antenna for radiating electromagnetic signals transmitted by the transceiver; measuring a distance indicative of a distance from a top end of the tubular mounting structure to a potential source of a disturbance echo; determining a desired total antenna length based on the measured distance, the desired total antenna length being such that the disturbance echo is substantially eliminated; determining a desired antenna extension length based on the desired total antenna length and a length of the antenna comprised in the radar level gauge system; providing an antenna extension having the desired antenna extension length; attaching the antenna extension to the antenna of the radar level gauge system to form an extended antenna; and mounting the radar level gauge system, with the extended antenna, on the top end of the tubular mounting structure. 
     The above-mentioned potential source of a disturbance echo may element in the tank that may result in a disturbance echo close to the ceiling of the tank. For instance, the lower end of the tubular mounting structure may be such a potentially disturbing source, due to the abrupt impedance change at the lower end of the tubular mounting structure. Other examples of disturbing sources may include other metal structures in the tank, such as beams, inlets, heaters, agitators etc. 
     For instance, the desired total antenna length may thus be such that the end of the extended antenna protrudes from the tubular mounting structure, towards an interior of the tank. 
     In various embodiments of the method according to the present invention, the step of attaching may comprise the steps of partially inserting one of the antenna and the antenna extension into the other one of the antenna and the antenna extension to provide an overlapping portion in which the antenna and the antenna extension overlap; and deforming one of the antenna and the antenna extension in the overlapping portion to interlock the antenna and the antenna extension through the deformation. 
     Advantageously, one of the antenna and the antenna extension may comprise a tab in the overlapping portion, and the other one of the antenna extension may comprise a recess in the overlapping portion; and the step of deforming may comprise bending the tab in such a way that the tab is received by the recess. 
     Before bending the tab, the antenna extension may be moved in relation to the antenna to align the tab and the recess. For instance, the antenna extension may be rotated in relation to the antenna. 
     The steps of various methods according to the present invention need not necessarily take place in the order mentioned in the claims, but may take place in a different order unless a particular sequence is explicitly or implicitly indicated as being necessary. Furthermore, it may be possible to carry out several steps simultaneously. 
     Further effects and variations of the present second aspect of the invention are largely similar to those described above with reference to the first aspect of the invention. 
     In summary, the present invention thus relates to a radar level gauge system for determining the filling level of a product in a tank, comprising a transceiver, an elongated propagation device, and processing circuitry coupled to the transceiver for determining the filling level. The propagation device comprises a first propagation device part comprising a cuff portion; and a second propagation device part comprising an end portion inserted in the cuff portion and joined together with the cuff portion by at least a first fastening arrangement. The first fastening arrangement comprises: a tab formed in one of the cuff portion and the end portion; and a recess formed in the other one of the cuff portion and the end portion. The tab is received by the recess to interact with the recess to prevent relative movement between the first propagation device part and the second propagation device part at least in the longitudinal direction. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing a currently preferred embodiment of the invention, wherein: 
         FIG. 1  schematically shows a level measuring system comprising a radar level gauge system according to a first example embodiment of the present invention; 
         FIG. 2  is a block diagram schematically illustrating the radar level gauge system in  FIG. 1 ; 
         FIG. 3  schematically illustrates the radar level gauge system in  FIG. 1  with a propagation device in the form of an extended antenna inside the tubular mounting structure; 
         FIG. 4  schematically illustrates a radar level gauge system according to a second example embodiment of the present invention in  FIG. 1  with a propagation device in the form of a modular coaxial transmission line probe; 
         FIGS. 5 a - c    schematically illustrate a first example configuration of the connection between two propagation device parts; 
         FIGS. 6 a - c    schematically illustrate a second example configuration of the connection between two propagation device parts; 
         FIG. 7  is a block diagram schematically illustrating an installation method according to an embodiment of the present invention; and 
         FIGS. 8 a - e    are schematic illustrations of the method according to  FIG. 7 . 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION 
     In the present detailed description, various embodiments of the radar level gauge system according to the present invention are mainly discussed with reference to a battery-powered radar level gauge system with wireless communication capabilities. 
     It should be noted that this by no means limits the scope of the present invention, which equally well includes, for example, radar level gauge systems that are loop-powered or powered with dedicated power lines. 
       FIG. 1  schematically shows a level measuring system  1  comprising a tank arrangement  17  according to an example embodiment of the present invention, and a host system  10  illustrated as a control room. 
     The exemplary tank arrangement  17  comprises a radar level gauge  2  of non-contacting type and a tank  4  having a tubular mounting structure  13  (often referred to as a “nozzle”) extending substantially vertically upwards from the roof of the tank  4 . 
     The radar level gauge  2  is installed to measure the filling level of a product  3  contained in the tank  4 . The radar level gauge system  2  comprises a measuring electronics unit  6  arranged outside the tank  4 , and a propagation device in the form of an elongated extended antenna  7  for radiating an electromagnetic transmit signal S T  in a longitudinal direction of the antenna  7  towards a surface  11  of the product  3  and for returning an electromagnetic reflection signal S R  resulting from reflection of the transmit signal S T  at the surface  11 . 
     By analyzing the transmit signal S T  and the reflection signal S R , the measurement unit  6  can determine the distance between a reference position (such as a feed-through between the outside and the inside of the tank) and the surface  11  of the product  3 , whereby the filling level can be deduced. 
     With reference to  FIG. 2 , the radar level gauge system  2  in  FIG. 1  comprises a measurement unit (MU)  20 , a wireless communication unit (WCU)  21  and a local energy store in the form of a battery  22 . The wireless communication unit  21  may advantageously be compliant with WirelessHART (IEC 62591). As is schematically indicated in  FIG. 2 , the MU  20  comprises a transceiver  23  and a measurement processor  24 . The transceiver  23  is controllable by the measurement processor  24  for generating, transmitting and receiving electromagnetic signals having frequencies defining a frequency bandwidth, such as 24 GHz to 27 GHz. The measurement processor  24  is coupled to the transceiver  23  for determining the filling level in the tank  4  based on a relation between the transmit signal S T  and the reflection signal S R . 
     As is schematically indicated in  FIG. 2 , the measurement unit  20  comprises a first output  26 , a second output  27 , and a first input  28 . The first output  26  is connected to a first input  30  of the wireless communication unit  21  through a first dedicated discreet line, the second output  27  is connected to a second input  31  of the wireless communication unit  21 , and the first input  28  is connected to a first output  32  of the wireless communication unit  21  through a second dedicated discreet line. The second output  27  of the measurement unit  20  and the second input  31  of the wireless communication unit  21  may be configured to handle bidirectional data communication according to a serial or a parallel communication protocol to allow exchange of data between the measurement unit  20  and the wireless communication unit  21 . The communication between the measurement unit  20  and the wireless communication unit  21  using the different inputs/outputs is described in more detail in U.S. patent application Ser. No. 13/537,513, which is hereby incorporated by reference in its entirety. 
     The above example of a wireless and locally powered configuration is intended to give the skilled person a detailed example of how various aspects and embodiments of the radar level gauge system according to the present invention can be implemented. It should, however, be noted that there are many other ways of powering and interfacing a radar level gauge system. Such other ways are widely accessible to one of ordinary skill in the art and can be implemented without excessive experimentation or undue burden. 
       FIG. 3  is a schematic illustration of the top portion of a first embodiment of the radar level gauge system  2  in  FIG. 1 , with a propagation device in the form of an elongated extended antenna  7  inside the tubular mounting structure  13 . 
     Referring to  FIG. 3 , the extended antenna  7  comprises a first propagation device part (in the context of this first embodiment sometimes referred to as a first antenna part or an antenna extension)  35 , and a second propagation device part (in the context of this first embodiment sometimes referred to as a second antenna part or an antenna)  36 . The first antenna part  35  comprises a cuff portion  38  at an upper end thereof, and a lower end of the second antenna part  36  is inserted in the cuff portion  38  of the first antenna part  35 . 
     The first antenna part  35  and the second antenna part  36  are joined together by at least one fastening arrangement  40  provided at the cuff portion  38  of the first antenna part  35 , where there is an overlap between the first antenna part  35  and the second antenna part  36 . 
     In  FIG. 3 , the at least one fastening arrangement  40  is schematically indicated by a simple box. To provide for a robust fastening of the antenna extension  35  to the cone antenna  36  of the radar level gauge system  2 , the antenna  7  may be provided with several fastening arrangements, which may be distributed circumferentially along the periphery of the antenna  7 , in the overlap between the cuff portion  38  of the first antenna part  35  and the end portion of the second antenna part  36 . 
       FIG. 4  is a schematic illustration of the top portion of a second embodiment of the radar level gauge system  2  in  FIG. 1 , with a propagation device in the form of an elongated coaxial transmission line probe  37 . Although not explicitly shown in  FIG. 4 , it should be understood that the transmission line probe  37  extends towards and into the product in the tank  4 , advantageously practically all the way to the bottom of the tank  4 . The coaxial transmission line probe  37  comprises an inner conductor  39  and an outer conductor  41 . To allow the product level to be the same between the inner conductor  39  and the outer conductor  41  as outside the coaxial transmission line probe  37 , the outer conductor  41  is provided with holes  43 . 
     Referring to  FIG. 4 , the outer conductor  41  of the elongated coaxial transmission line probe  37  comprises a first propagation device part (in the context of this second embodiment sometimes referred to as a first outer conductor part)  35 , and a second propagation device part (in the context of this second embodiment sometimes referred to as a second outer conductor part)  36 . The first outer conductor part  35  comprises a cuff portion  38  at an upper end thereof, and a lower end of the second outer conductor part  36  is inserted in the cuff portion  38  of the first outer conductor part  35 . 
     The first outer conductor part  35  and the second outer conductor part  36  are joined together by at least one fastening arrangement  40  provided at the cuff portion  38  of the first outer conductor part  35 , where there is an overlap between the first outer conductor part  35  and the second outer conductor part  36 . 
     In  FIG. 4 , the at least one fastening arrangement  40  is schematically indicated by a simple box. To provide for a robust interconnection of the first outer conductor part  35  and the second outer conductor part  36  of the radar level gauge system  2 , the propagation device (antenna  7  or transmission line probe  37 ) may be provided with several fastening arrangements, which may be distributed circumferentially along the periphery of the propagation device, in the overlap between the cuff portion  38  of the first propagation device part  35  and the end portion of the second propagation device part  36 . 
     Two different example configurations of the fastening arrangement  40  will be described below with reference to  FIGS. 5 a - c    and  FIGS. 6 a - c   . Thereafter, an example method of installing the above-described first embodiment of the radar level gauge system  2  at the tank  4  will be described with reference to the flow chart in  FIG. 7  and the illustrations in  FIGS. 8 a   - e.    
       FIGS. 5 a - c    schematically illustrate a first example configuration of the propagation device in  FIG. 3  and  FIG. 4 . Referring to  FIGS. 5 a - c   , the fastening arrangement  40  comprises tabs  42   a - b  integrally formed in the first propagation device part  35 , and recesses  44   a - b  integrally formed in the second propagation device part  36 . As is schematically shown in  FIGS. 5 b - c   , the first  35  and second  36  propagation device parts are joined together by pushing each tab  42   a - b  into its corresponding recess  44   a - b  so that the tabs  42   a - b  are deformed and interact with the recesses  44   a - b  to prevent relative movement of the first propagation device part  35  in relation to the second propagation device part  36 , at least in a longitudinal direction (along the symmetry axis  45  of the propagation device). 
       FIGS. 6 a - c    schematically illustrate a second example configuration of the propagation device in  FIG. 3  and  FIG. 4 . Referring to  FIGS. 6 a - c   , the propagation device according to the second example configuration comprises four fastening arrangements  40   a - d  distributed along the circumference of the propagation device at the overlap between the first propagation device part  35  and the second propagation device part  36 . As is shown in  FIGS. 6 a - c   , each fastening arrangement  40   a - d  comprises a tab  46   a - d  integrally formed in the second propagation device part  36 , and a recess  47   a - d  integrally formed in the first propagation device part  35 . The tabs  46   a - c  of the first to third fastening arrangements  40   a - c  extend along a first peripheral direction, here substantially perpendicular to the longitudinal extension of the elongated propagation device, and the tab  46   d  of the fourth fastening arrangement  40   d  extends along a second peripheral direction, here substantially parallel to the longitudinal extension of the elongated propagation device. 
     An embodiment of the method according to the invention of installing a radar level gauge with an extended elongated antenna at a tank will be described below with reference to the flow-chart in  FIG. 7  and the schematic illustrations in  FIG. 3 ,  FIG. 6 a - c    and  FIGS. 8 a   - e.    
     In a first step S 1 , a radar level gauge system  2  comprising a measurement electronics unit  6  and a cone antenna  36  is provided. 
     In a second step S 2 , the length of the tubular mounting structure (nozzle)  13  is measured. 
     Thereafter, in a third step S 3 , an antenna extension  35  is provided, having a length (longitudinal extension) being related to the measured length of the tubular mounting structure  13 . The length of the antenna extension  35  will be dependent on the length of the tubular mounting structure  13  and the length of the cone antenna  36 , and should be selected such that the extended elongated antenna  7  extends into the tank  4  beyond a lower end of the tubular mounting structure  13 , as is schematically indicated in  FIG. 3 . 
     In a fourth step S 4 , the end portion of the cone antenna  36  is inserted into the cuff portion  38  of the antenna extension  35  as is schematically indicated in  FIG. 8 a   . The insertion can take place by moving either of the cone antenna  36  and the antenna extension  35 , or both simultaneously. 
     Following insertion of the end portion of the cone antenna  36  into the cuff portion  38  of the antenna extension, the horizontal tabs  46   a - c  are (in step S 5 ) aligned to the horizontal recesses  47   a - c  to allow access to each tab  46   a - c  through its corresponding recess  47   a - c , as is schematically shown in  FIG. 8   b.    
     Referring to  FIG. 8 c   , each of the horizontal tabs  46   a - c  is then, in the following step S 6 , deformed (bent) so that the tab is received by its corresponding recess  47   a - c . Following this step, relative movement in the longitudinal direction between the cone antenna  36  and the antenna extension  35  is prevented. 
     To complete the attachment of the antenna extension  35  to the cone antenna  36 , the antenna extension  35  is (in step S 7 ) rotated to align the vertical tab  46   d  with its corresponding, vertically oriented, recess  47   d  as illustrated in  FIG. 8 d   , and (in step S 8 ) the vertical tab  46   d  is deformed (bent) so that the tab is received by its corresponding recess  47   d  as illustrated in  FIG. 8   e.    
     Finally, in step S 9 , the radar level gauge system  2 , with the extended antenna  7 , is mounted on the tubular mounting structure  13 . 
     The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.