AHMAD „AKIF BIN ADAM

ULTRASONIC INSTRUMENTATION SYSTEM FOR DETECTING LIQUEFIED

PETROLEUM GAS LEVEL IN 14 KILOGRAM CYLINDERS

AHMAD „AKIF BIN ADAM

A thesis submitted in fulfilment of the

requirements for the award of the degree of

Master of Engineering (Gas)

Faculty of Petroleum and Renewable Energy Engineering

Universiti Teknologi Malaysia

JUNE 2015

iii

Dedicated to my beloved parent, ummi and abah,

and all my lovely siblings,

thanks for your love and encouragement

iv

ACKNOWLEDGEMENT

First of all, I would like to thank Allah The Almighty for giving me the strength

and opportunity to finish this research study. In completing this project, I was in contact

with many people, researchers, and academicians. They have contributed towards my

understanding and thoughts.

In particular, I wish to express my sincere appreciation to my research supervisor,

Dr. Mariani Idroas, for encouragement, guidance, critics and motivation towards the

completion. Without her continued support and interest, this thesis would not have been

the same as presented here. A remarkable honor to Associate Professor Ir. Dr. Zainal

Zakaria, my co-supervisor, for his knowledge sharing and thoughtful ideas.

My sincere appreciation also extends to all my colleagues especially to Advanced

Microprocessor Research (AMIR) Laboratory members and others who have provided

assistance at various occasions. I am also grateful to all my family members. Their views

and tips are useful indeed. May Allah S.W.T. rewards and blesses us all.

v

ABSTRACT

Liquefied Petroleum Gas (LPG) is commonly stored in highly pressurized cylinder

tank and needs to be measured using a non-invasive way. This approach has been

constructed to facilitate the process of LPG level measurement inside a cylinder tank.

Currently, liquid level of LPG inside a cylinder is measured using a weighing scale. In this

research, a new method is developed by using a non-invasive ultrasonic instrumentation

system for monitoring LPG level in the 14 kilogram cylinder. The instrumentation system

was integrated with the designed experimental rig. Module ultrasonic sensors Truma.LC-

V1.15 were attached vertically outside of the cylinder wall on the sensor holder of the

experimental rig. The ultrasonic sensors emit the ultrasonic signals and the signals will

then propagate through the cylinder wall. The reflected signal was recorded again by the

ultrasonic sensors. The reflection of the ultrasonic signal depends on the type of the

medium's impedance. The generated signals from the transceiver type of sensors were sent

to the Pico Scope Data Acquisition System (DAQ) for data reading. The output voltage

signals were processed by the computational data process system, giving a result of the

LPG liquid level inside the cylinder. An image of the LPG liquid level in the cylinder was

constructed using javascript based programming. The image showed the liquid level in

percentage value and html software was used as the interface in this program. The

developed instrumentation system was also tested on 18-L testing cylinder and 14-kg LPG

cylinder with various LPG liquid levels and it was able to detect the amount of LPG in the

cylinders, with the maximum error of 5.68%.

vi

ABSTRAK

Petroleum Gas Cecair (LPG) biasanya disimpan di dalam silinder bertekanan tinggi

dan perlu diukur dengan cara tanpa musnah. Cara ini telah dibina untuk memudahkan

proses pengukuran aras LPG di dalam tangki silinder. Pada masa kini, aras cecair LPG di

dalam silinder diukur menggunakan alat penimbang berat. Dalam kajian ini, satu kaedah

baru dibangunkan menggunakan sistem peralatan ultrasonik tanpa musnah untuk

memantau aras LPG di dalam silinder simpanan berkapasiti 14 kilogram. Sistem peralatan

ini disepadukan dengan rekaan pelantar eksperimen. Modul deria ultrasonik Truma.LC-

V1.15 telah dipasang pada pemegang sensor pelantar eksperimen. Deria ultrasonik

tersebut dipasangkan secara menegak di luar dinding silinder. Deria ultrasonik

memancarkan isyarat ultrasonik dan isyarat telah tersebar menembusi dinding silinder.

Isyarat pantulan dirakam semula oleh deria ultrasonik. Pantulan isyarat ultrasonik

bergantung kepada jenis galangan bahan perantara. Isyarat yang dihasilkan dari deria jenis

penghantar-terima telah dihantar ke Pico Scope Data Sistem Perolehan (DAQ) untuk

membaca data. Isyarat voltan keluaran diproses oleh sistem proses data perkomputeran

untuk memberikan aras kandungan cecair LPG di dalam silinder. Pembinaan imej aras

LPG dalam silinder dibina menggunakan pengaturcaraan berasaskan javascript. Imej

tersebut menunjukkan imej aras LPG di dalam nilai peratusan dan perisian html digunakan

sebagai perantara muka pada program ini. Sistem peralatan yang dibangunkan diuji pada

18-L silinder ujian dan 14-kg LPG silinder yang berbeza aras cecair LPG dan sistem ini

berjaya mengesan jumlah LPG dalam silinder dengan ralat maksimum 5.68%.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF ABBREVIATIONS xiv

LIST OF SYMBOLS xv

LIST OF APPENDICES xvii

1 INTRODUCTION 1

1.1 Project Background

1.2 Problem Statement

1.3 Objective

1.4 Scope of Study

1.5 Thesis Outline

1

4

6

7

7

2 LITERATURE REVIEW 9

2.1 Introduction

2.2 Overview of Liquid Level Measurement

2.3 Types of Liquid Level Measurement

9

9

10

viii

2.4 Liquid Level Measurement

2.5 Use of Ultrasonic in Liquid Level Measurement

2.6 Current Method of LPG Cylinder Measurement

11

12

18

3 METHODOLOGY 19

3.1 Introduction

3.2 Overview of the Instrumentation System

3.3 Instrumentation Rig Configuration

3.3.1 Development of Platform

3.3.2 Development of Sensor Holder

3.4 Cylinder Specification

3.5 Sensoring System Optimization

3.5.1 Transmission and Reflection Effect

3.5.2 Ultrasonic Sensoring System

3.5.3 Arrangement of Ultrasonic Sensors

3.5.4 Image Grid Configuration

3.6 Development of Ultrasonic Instrumentation System

3.6.1 Module Sensor

3.6.2 Pico Scope Data Acquisition System (DAQ)

3.6.3 Computational Data Process

3.6.4 Image Generation

3.7 Experimental Procedures

3.7.1 Initial Testing on 18 L Cylinder

Experimental Procedure

3.7.2 Calibration Testing on 14 kg LPG Cylinder


3.7.3 Measurement of 14 kg Cylinder


19

20

21

23

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36

36

41

42

44

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48

49

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51

52

52

53

54

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4 RESULTS AND DISCUSSIONS 56

4.1 Introduction

4.2 Sensors Testing and Calibration of 18 L Testing

Cylinder

4.2.1 Level Measurement of the 18 L Cylinder

4.2.2 Calibration Graph of 18 L Cylinder Level

Measurement

4.2.3 Discussions

4.3 Sensors Testing and Calibration of LPG Cylinder 14

kg

4.3.1 Data Collection of LPG Cylinder

Measurement

4.3.2 Calibration Graph of LPG Cylinder Level

Measurement

4.3.3 Discussions

4.4 Experimental Tests on LPG Cylinders

4.4.1 Data of Case 1




4.4.5 Discussions

4.5 Image of LPG Level

56

57

57

64

65

67

67

68

69

71

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74

75

76

77

5 CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusions

5.2 Recommendations

80

80

81

REFERENCES

Appendices A

83

87-104

x

LIST OF TABLES

TABLE NO. TITLE PAGE

3.1 Specification of both cylinders 35

3.2 Level and percentage fill relation information 47

4.1 Data collection of level measurement at 23.0 cm 58

4.2 Overall data collection of level measurement on testing

cylinder 18 L

63

4.3 Level measurements for the actual level and from indicator

sensor

66

4.4 LPG cylinder 14 kg measurement testing data collection 68

4.5 Table of weight, volume, level and its percentage from

weight measurement

70

4.6 Comparison table of weight measurement and sensor

measurement

70

4.7 Experimental data of empty cylinder (17.0 kg) 72

4.8 Experimental data of partially filled cylinder (21.7 kg) 73

4.9 Experimental data of partially filled cylinder (27.2 kg) 74

4.10 Experimental data of fully filled cylinder (30.5 kg) 75

xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Cylinders with LPG 3

1.2 Manifold LPG system 4

1.3 Weighing measurement of LPG cylinder 6

2.1 The gas cylinder with liquid inside and the mechanical

model of mass density

12

2.2 Block diagram of generation, propagation, and reception

of lamb waves of tank wall

15

2.3 The arrangement of the prototype level sensing using

lamb wave at the tank wall

15

2.4 Measuring level method 17

3.1 Overall setup of ultrasonic instrumentation system 19

3.2 Photo of Ultrasonic instrumentation system 20

3.3 Instrumentation rig diagram 22

3.4 Actual photo of instrumentation rig 22

3.5 Mechanical design of platform (side and top view) 24

3.6 Real image of the platform 24

3.7 Installed wheels and its mechanical design 25

3.8 Stopper and its mechanical design 25

3.9 Platform surface arrangement 26

3.10 Sensor holder 27

3.11 Vertical mounting of sensor on a sensors holder 28

3.12 Actual fabricated sensor holder 28

3.13 Design of sensor with casing 29

3.14 Image of sensor with casing 29

xii

3.15 Mechanical design of stand 30

3.16 Housing base of the instrumentation rig 31

3.17 Connector 31

3.18 Testing cylinder of 18 L capacity 33

3.19 Dimension of testing cylinder 33

3.20 Dimension of LPG cylinder tank 34

3.21 LPG cylinder of 14 kg 35

3.22 Ultrasonic signal transmission and reflection 37

3.23 Illustration on different medium of cylinder content 41

3.24 Sensors arrangement 42

3.25 Sensors touch to the cylinder wall 43

3.26 Photograph of sensor arrangement 44

3.27 Cylinder fraction due to sensor arrangement 45

3.28 Graphical illustration of ellipsoidal bottom cylinder 46

3.29 Process flow of ultrasonic instrumentation system 47

3.30 Ultrasonic Instrumentation system 48

3.31 Ultrasonic Truma.LC-V1.15 module sensor 49

3.32 Pico Scope DAQ 50

3.33 Image of percentage cylinder filling 51

4.1 Voltage signal at sensor 1, S1 = 3.53 V 59










4.11 Graph of output voltage (V) for S1 to S10 at 23.0 cm water

level

62

4.12 Graph of actual water level against measured water levels 64

4.13 Graph of LPG cylinder calibration 69

xiii

4.14 Image interface of Case 1 with 8.14% 77




xiv

LIST OF ABBREVIATIONS

ASTM - American Society for Testing and Materials

CFC - Chloro Fluoro Carbon

DAQ - Data Acquisition System

DC - Direct Current

GMB - Gas Malaysia Berhad

HHV - Higher Heating Value

HTML - Hyper Text Markup Language

LHV - Lower Heating Value

LPG - Liquefied Petroleum Gas

MSDS - Material Safety Data Sheet

NDT - Non Destructive Testing

PC - Personal Computer

PZT - Lead Zirconium Titanate

PVC - Poly Vinyl Chloride

STP - Standard Temperature and Pressure

TOF - Time of Flight

UT - Ultrasonic Testing

xv

LIST OF SYMBOLS

π - Pi, 3.14

ρ - Density

a - Depth of Head or Bottom

θ - Angle

atm - Atmospheric Pressure

avg - Average

c - Speed of Light

cm - Centimeter

D - Diameter

g - Gram

h - Height of Liquid Level

kg - Kilogram

J - Joule

kHz - Kilohertz

L - Length

m - Meter

mm - Millimeter

MHz - Megahertz

MJ - Megajoule

r - Radius

R - Reflection Coefficient

Rayl - Rayleigh

S - Sensor Number

t - Time

T - Transmission Coefficient

xvi

V - Voltage

υ - Volume

W - Weight

Z - Acoustic Impedence

° - Degree

°C - Degree Celcius

°F - Degree Fahrenheit

E - Wave Energy

S - Sensor

T - Transmitter

C3H8 - Propane

C4H10 - Butane

% e - Percentage of Error

xvii

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Technical Drawing of Ultrasonic Instrumentation Rig 87

CHAPTER 1

INTRODUCTION

1.1 Project Background

Oil and gas are natural resources that contribute as the source of fuel to most of the

countries in the world for its economic expansion. Many nations depend on these natural

resources for growth and development of their countries. It is necessary to ensure that the

natural resources can be transported safely from its original plant or storage to the

consumers throughout the countries (Bannon, 2003).

The transmission process and storage technique of oil and gas must be in control

because of its natural characteristic that is highly volatile and flammable. There are many

methods used to transfer these oil and gas supply to the market such as tanker, pipeline

barge, rail and truck.

Liquefied petroleum gas (abbreviated as LPG) is a chemical compound that usually

used as a fuel for cooking, combusting and burning tool and also used for transportation

energy source. This inflammable mixture is widely used as an aerosol propellant and a

2

refrigerant. The LPG replaced CFC in an effort to reduce the effect of green house and

protect the ozone layer (Bejan, 1999).

There are various types of LPG mixture available in the market and the mixture of

their composition are different for each country and depend on the seasonal weather of the

country. There will be more propane in winter while more butane in summer (Totten,

2003). There are types of mixes which are mainly propane (C3H8), and mainly butane

(C4H10). The mostly common mixes were the mixture of both propane and butane in a

certain percentage.

Substance of propylene and butylenes are normally present but in a little

concentration. LPG is basically in gas or liquid phase which is odourless and colourless.

Therefore, it is difficult to detect whether there are any existence of LPG or not. The

odorant like ethanethiol, is incorporated with LPG so that leaks can be recognize easily. In

the United States, thiophene known also as amyl mercaptan is an approved odorants

(Mahalingam, 2012). Figure 1.1 shows the example of LPG cylinders commonly used

today.

3

Figure 1.1 Cylinders with LPG

LPG will be vaporise when exist in room temperatures and pressures. LPG is

pressurized in a special designed cylinder that is capable of storing large pressure content.

The cylinder also designed appropriately in order to fulfil the supply and demand on

market daily use. Typically percentage of filling is between 80% to 85% of their storage

capacity. This would allow the thermal expansion of the LPG (Zakaria et al, 2006).

Unlike natural gas, LPG is heavier than air, thus will flow along floors and tend to

settle in lower spots, such as basements. (Soundarya et al, 2014). Large amounts of LPG

usually stored in a bulk cylinders typically aboveground, underground or mounded.

Periodic inspection and testing of the storage must be done to ensure safety standards are

maintained.

4

1.2 Problem Statement

Liquefied Petroleum Gas (LPG) becomes the most popular source for household

and commercial uses. Basically, when compared to other liquid fuels, LPG is flexible to

handle and having lesser pollution with minimum space used for storage. LPG will be

delivered to the customer either by using cylinder, bulk tank or pipeline. There are several

ways of LPG distribution to customers depends on the type of customer i.e. whether it is

domestic, commercial or industry. Figure 1.2 shows an example of manifold LPG system

installation for commercial use.

Figure 1.2 Manifold LPG system (Primagas, 2009)

LPG consumption for every customers were different depending on the rate of use.

There were consumers who used LPG daily at a high rate such as the laundries that uses

for the purpose of drying clothes. Numbers of users only use a small amount of LPG for

home cooking. The different on LPG consumption rate of consumers carries variation of

usage among consumer thus requiring friendly LPG cylinder measurement. This idea was

not as important for some consumers, but it was very significant for customers who

utilized the LPG on a large scale basis especially for those who use it for commercial

purposes.

5

Therefore, this research study is intended to develop an ultrasonic instrumentation

system to measure the LPG residual in the cylinder in a better way using ultrasonic

sensors. This study focused on the ability of the developed system in monitoring the

presence of LPG and its level. This is the initial study to detect the LPG level imposed on

the household LPG cylinders of a 14 kg capacity.

Most of LPG users, especially among commercial and industrial field were used

weighing instrument in order to obtain the exact contents of LPG inside the cylinder.

Some of them measured the amounts of LPG inside the cylinder by checking the content

pressure. This method was often used by the refilling plant because this is the fastest way

of measurement. This pressure type measurement was conducted in a rapid process

because the filling process and the pressure readings were taken simultaneously. Figure

1.3 shows the example of weighing instrument for LPG cylinder. This machine was

designed completed with the gas filler tool for LPG refilling process.

Figure 1.3 Weighing measurement of LPG cylinder (Siraga, 2008)

6

Ultrasonic instrumental technique was an acceptable way to monitor the LPG

content in the LPG cylinder. This method is proposed because it can help the process of

measurement in easy way using non-invasive procedure.

1.3 Objectives

The objectives of this project are:

i. To develop a non-invasive ultrasonic instrumentation system for detecting

the LPG content in LPG cylinder storage.

ii. To monitor LPG residual inside the cylinder.

1.4 Scopes of Study

In order to achieve the objectives of this project, the scopes are:

i. Understanding the principal of ultrasonic measuring method on liquid level

measurement.

ii. Development of instrumentation rig of LPG cylinder measurement.

iii. Performing the study on sensoring system optimization

iv. Setting up the ultrasonic instrumentation system including module sensor,

Pico Scope DAQ, computational data process and image reconstruction.

7

v. Carry out preliminary experiment on testing cylinder 18L and LPG cylinder of

14 kg for instrumentation system calibration and accomplish the experimental

measurement on four different types of LPG cylinder.

vi. Analyzing data receive from Pico Scope DAQ using computational data

process system.

vii. Generating the percentage of LPG content information using html based

programming.

1.5 Thesis Outline

Chapter 1 briefly presents the background information about oil and gas industry

around the world. LPG is one of oil and gas product which is essential in our daily needs

for household use, industry and transportation. LPG characteristics, transmission and

storage system have been briefly defined. This chapter includes the problem statement,

objectives and the scopes of the project. Chapter 2 explains the literature review about the

measurement of LPG storage on recent industrial usage. The configuration systems of

measurement and the suitable type of sensors are described in more detailed. Chapter 3

describes the methodology on LPG instrumentation system based on ultrasonic sensors to

detect the LPG level. The outcome signals are explained to show the LPG level in suitable

image. Chapter 4 presents results obtained from the experiments. Specific justifications

and explanations about the output results are explained to validate and verify the

correctness of the experiment. Chapter 5 combines the overall conclusions and some of

recommendations for future improvements.

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AHMAD „AKIF BIN ADAM