Tracer Profiler Series User manual

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Tracerco Profiler –Radiological User’s Guide

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Table of Contents
1. Introduction............................................................................................................................................ 4
2. Instrument General Arrangement........................................................................................................... 5
3. Principle of Operation............................................................................................................................. 6
4. Radiation Basics .................................................................................................................................... 7
4.1. ALARA Principle - Time, Distance, Shielding ...........................................................................................................8
4.2. Time..........................................................................................................................................................................8
4.3. Distance....................................................................................................................................................................8
4.4. Shielding ...................................................................................................................................................................8
4.5. Dose Measurements.................................................................................................................................................8
4.6. Radiation Exposure and Radioactive Contamination ...............................................................................................9
5. Mechanical Installation......................................................................................................................... 10
5.1. Lifting Procedure for the Tracerco Profiler..............................................................................................................10
5.1.1. Handling........................................................................................................................................................................10
5.1.2. Detailed Lifting Procedure for the Tracerco Profiler.......................................................................................................10
5.1.3. Lifting the instrument from a horizontal position to a vertical position:...........................................................................11
5.2. Approximate weights:..............................................................................................................................................12
5.3. Dimensions of main profiler components................................................................................................................12
5.3.1. High Temperature Profiler –Shown Left .......................................................................................................................12
5.3.2. Standard Profiler –Shown Right...................................................................................................................................12
5.4. Mechanical Installation (By Site).............................................................................................................................13
5.4.1. Installation of Support Bracket.......................................................................................................................................13
5.4.2. Bolt Torquing Procedure................................................................................................................................................14
6. Radiological Safety .............................................................................................................................. 15
6.1. Source Housing and isolation .................................................................................................................................16
6.2. Arming Rod and Collimator Housing ......................................................................................................................18
6.3. Isolation of Sources ................................................................................................................................................19
6.4. Labelling and Safety Marking..................................................................................................................................20
7. Radiological Safety –WS Variant......................................................................................................... 21
8. Vessel Entry......................................................................................................................................... 22
9. Rules for Emergency Response........................................................................................................... 22
9.1. Installed sources.....................................................................................................................................................22
9.2. During installation/source removal..........................................................................................................................23
9.3. Damaged “Type A” container during transport .......................................................................................................23
9.4. Loss or theft of Radioactive Source........................................................................................................................23
9.5. Dropped source assembly......................................................................................................................................23
9.6. Mechanical damage to source................................................................................................................................24

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9.7. Contamination from abrasive action .......................................................................................................................24
9.8. Fire / Site emergency..............................................................................................................................................24
10. Rules for Disposal................................................................................................................................ 24
11. Leakage Testing................................................................................................................................... 24
12. Maintenance ........................................................................................................................................ 25
12.1. Routine Maintenance/Inspection ............................................................................................................................26
13. Document Control................................................................................................................................ 26
14. Appendix A Isodose plots..................................................................................................................... 27
15. Appendix B........................................................................................................................................... 30
15.1. Recommended Bolt Torque settings ......................................................................................................................30
16. Appendix C –Isolation of Wired Shutter / Wire operated mechanism................................................... 32

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1. Introduction
Separation vessels contain products such as gas, foam, oil, emulsion, water, and sand in different phases as
shown in Figure 1. Each phase has a different density.
The Tracerco ProfilerTM Series and Tracerco Profiler WS Series are an advanced Specialist Measurement
instrument used to identify different phases within multiphase systems. Employing award winning and patented
techniques it measures the absorption of gamma radiation through the process medium. This enables a
meaningful and accurate measurement of the vertical density distribution within vessels to be made.
Figure 1 - Typical Separation values
The instrument uses a vertical array of sources and detectors (Geiger Müller Tubes) to measure and map the
different process phases with respect to vessel height. Reliable assessment of both the interface quality and the
level of the interfaces present within the vessel are achievable.
Measurements can be separated into a maximum of six different density bands or phases. The elevation of the
various phases can be calculated and outputs given with respect to the vessel height.
The information provided can then be used to give outputs to control oil and water interface levels, control and
monitor the effects of chemical additives or establish effective sand washing regimes.

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2. Instrument General Arrangement
A diagram of a single High Temperature detector system is shown below. The Profiler is typically located on a
flange at the top of a vessel and consists of 3 main components that make up the outer instrument housing.
These are the dip-pipes, neck and dome. Only the neck and dome are visible out of the top of the vessel. Figure
2shows a variant with a heat sink located between the dome and the neck.
Figure 2 - General Representation (T240-X-4 Variant)
The dip-pipes project into the separator through the vessel flange. The dip-pipe tubes comprise a source tube
and detector tube(s).
The source tube is the narrowest of the dip-tubes and holds the source rod in the collimator. This source rod
contains a series of sources distributed along its length. The rod is attached to an arming mechanism allowing
the user to isolate the sources within the device.
The collimator has a series of small holes, which align with each source position when the rod is in the open
position. This allows narrow beams of radiation to be directed towards the detectors in the adjacent detector
tube(s). When the arming mechanismis locked inthe shut position the alignment ofthe sources andthe collimator
is such that the sources are isolated and the radiation from the gauge is at a safe level.
The dip-pipes are effectively a sleeve and datum for the instrument components and provide the pressure seal
with the vessel flange. They also permit the use of low energy Americium-241 sources enabling small changes
in product density to be detected, thus providing more information with regard to phase dispersion than a standard
instrument.
Heat
sink

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3. Principle of Operation
With sources loaded and the arming rod in the open position, the process medium present between the source
and detector dip pipes will attenuate theradiation seen by each Geiger Müller (GM) tube within the detector array.
This attenuation is related to the density of the intervening material / phase.
Representative pulses from the GM tubes are counted in the Signal Processor unit and made available for
analysis via the fibre optic link and a RS485 converter.
The PLC or Control system collects informationfrom each individual GM tube via the fibreoptic link and calculates
the density of the material. This enables a density or interface profile of the vessel to be constructed. Density
bands are allocated for each of the six phases (Sand, Water, Emulsion, Oil, Foam and Gas). The top level of
these phases can then be calculated with respect to vessel or instrument height.
Figure 3 - System Representation - Two probes
The measured interface levels can be used for control or shutdown purposes via hardwired outputs or
communications via the PLC or control system.
A Galvanic Isolator, normally fitted in the main panel, powers each detector probe. Communication between the
probe and the PLC or controller is achieved using Modbus protocol. For safety, communications in the field is
Source
Rod
Probe
Gamma
Sources
Gamma
Detector
s
Probe
A
Fiber optic connection &
Patch boxs
Probe
B
Intrinsically safe
Fiber Converters
PLC or T229
Controller
Intrinsically safe
power supplies &
connections
Optional HMI

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over a fibre optic cable. The Fibre optic signal is converted to an electrical signal in the main panel using a Fibre
optic converter.
4. Radiation Basics
Elements such as Americium-241, Caesium-137 and Cobalt-60, which emit ionizing radiation, are known as
Radioisotopes. They emit electromagnetic energy in the form of gamma radiation, which is very similar to light
and in fact forms part of the same Electromagnetic Spectrum. Unlike light, gamma radiation readily penetrates
solid and opaque materials and can pass through steel and other dense materials. It is this ability to penetrate
materials which is used in the measurement of process variables such as Level, Interface and Density. A change
in the amount of detected radiation passing through the material indicates a change in a process variable.
Ionizing Radiation is harmful to the human body when absorbed at an excessive rate. As an analogy, consider
a radiating energy source such as heat. The extent of injury from a heat source depends on several factors such
as:
•The temperature of the heat source,
•The distance from the heat source to any part of the body,
•The portion of the body in contact with the heat source,
•The presence or absence of insulating material between the heat source and the body.
Similarly, possible injury to the body caused by exposure to a radioactive source is dependent upon factors such
as:
•The activity of the source,
•The distance from the source,
•The percentage and portion of the body receiving the radiation,
•The amount of shielding between the source and body.

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4.1. ALARA Principle - Time, Distance, Shielding
The goal of any radiation safety program is to keep personnel exposures As Low As Reasonably Achievable
(ALARA). This principle can be governed by the following three factors:
Figure 4 - Time, Distance Shielding
4.2. Time
The dose of radiation that a person receives is directly proportional to the amount of time spent in a radiation
field. An effective way to reduce total dose is to minimize the amount of time spent in a radiation field.
4.3. Distance
The distance from a source of radiation is a crucial factor in keeping exposures low. The strength of the radiation
field decreases in proportion by the square of the distance from the source (an effect known as the Inverse Square
Law). Moving just a few feet from a source of radiation can have a significant impact on reducing the exposure.
4.4. Shielding
Shielding the radioactive source greatly reduces the radiation field. Radioactive sources supplied by Tracerco
are contained in source holders that shield the radiation to a very low level, except where the radiation to be
measured must pass through the process medium and vessel wall(s). All series of Tracerco source holders have
a shutter or other mechanism to close off the aperture through which radiation is emitted, or to otherwise isolate
the sources. This shields the source(s) for installation or maintenance purposes, or for emergencies.
4.5. Dose Measurements
It is important to have some method of quantifying the dose of ionizing radiation. The term of interest to most
users is the tissue absorbed dose quantity, which defines the amount of absorbed radiation energy within the
body. The term for this dose quantity is the Sievert in international units and Rem in older, previously used units.

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Typically, for absorbed dose we talk in terms of milliRem (mRem) or microsieverts (μSv), units of radiation dose
resulting from very small exposures. Dose rate is therefore measured in milliRem per hour (mRem/hr) or
microSieverts per hour (µSv/hr).
4.6. Radiation Exposure and Radioactive Contamination
Radiation Exposure and Radioactive Contamination must betreated as two very different phenomena. Exposure
occurs when a person spends time in a radiation field, and implies subjection to external radiation. A sealed
Caesium-137 source produces gamma radiation which is of sufficient energy to penetrate the body. Shielding
the radiation source with dense material such as lead or steel greatly reduces the radiation field. Limiting
exposure to a radiation field is the primary safety concern for nuclear gauge users.
Contamination implies direct contact with, inhalation, ingestion, or absorption of radioactive materials. For
example, for a nuclear gauge containing a Ameriscium-241 source, contamination occurs only if a breach of the
source capsule occurs and radioactive material leaks out. If such a breach occurs, a person is not only exposed
to gamma radiation from the source, but they could also experience contamination from direct contact with the
actual Ameriscium-241 radioactive material that was inside the source capsule. This is potentially very dangerous
because ifthe radioactive material isin direct contact withthe skin, or manages toget inside the body, the distance
from the person’s tissues to the radiation emitter is virtually zero and the radiation field in contact with the bodily
tissues is therefore very high.
In addition, the body’s organs can suffer internal damage through absorption of the radioactive material.
However, it must be stressed that Tracerco only utilize sealed, doubly-encapsulated radioactive sources which
have undergone stringent type testing and conform to ANSI/ISO standards. The likelihood of contamination from
leaked radioactive material is therefore extremely low.

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5. Mechanical Installation
There are three main aspects of the profiler installation:
•Radiological
•Mechanical
•Electrical and Communications
This document is concerned primarily with the radiological, mechanical and its safety aspects with respect to
operational and maintenance of the Profiler.
The mechanical components are generally shipped as the following components:
1. Assembled Profiler unit consisting of probes, dip pipes, neck, dome, collimator
2. Support bracket
3. Fibre optic breakout boxes.
4. Sources, in arming rods and A type container
5.1. Lifting Procedure for the Tracerco Profiler
5.1.1. Handling
Detector dip-pipes: The dip-pipe assembly which houses the detectors will be packaged in a sturdy wooden
crate. The crate will be suitable for handling by a forklift truck or a suitable hoist and slings and will clearly display
lifting information, centre of gravity, etc. To unpack the system, remove the lid of the crate and lift the Profiler out
using the lifting lugs attached to the flanges. The tube is thin-walled and care should be taken not to bend it on
removal or installation.
Source Arrays: The source arrays will be shipped in Type ‘A’ containers. The containers should only be opened
in the presence of a qualified Tracerco engineer.
5.1.2. Detailed Lifting Procedure for the Tracerco Profiler
The detector arrays should be lifted by fixing lifting shackles through the lifting lugs fitted to the titanium flange.
It is recommended that the lifting shackle is a 2 tonne rated large 'D' shackle (BS 3032 1958). Two shackles
should be inserted into two of the holes at the top of the can opposite each other, as indicated in the sketch below.

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5.1.3. Lifting the instrument from a horizontal position to a vertical position:
Following the diagrams below, use a crane appropriately connected to the two eyebolts. An operative should
support the end of the dip-pipe while the instrument is lifted in order to avoid excessive strain on the end of the
assembly. The operative should take care to monitor any swing on the assembly as the crane lifts.
Step 1: Step 2:
Step 3:

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5.2. Approximate weights:
The approximate weight for a 4m long profiler is as follows:
6” 300# dual dip pipe profiler = Approximate 75Kg (165 lb)
8” 300# dual dip pipe profiler = Approximate 85Kg (187 lb)
Accurate measured weights can only be supplied once the instrument design is finalized and manufactured.
5.3. Dimensions of main profiler components
5.3.1. High Temperature Profiler –Shown Left
Height of Dome and neck arrangement
= 1200mm
Width of dome and neck arrangement
= 360mm
Length of dip pipes from top of dip pipe flange to
bottom of dip pipes
= 1000mm > Length < 1800mm
5.3.2. Standard Profiler –Shown Right
Height of Dome and neck arrangement
= 680mm
Width of dome and neck arrangement
= 360mm
Length of dip pipes from top of dip pipe flange to
bottom of dip pipes
= 1000mm > Length < 1800mm
The size of the flange and the dip pipes will vary from application to application. Typical
range of nozzle will be 10” to 4” nozzle.

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5.4. Mechanical Installation (By Site)
Ensure that the flange face of vessel nozzle is clean and place the joint gasket on the nozzle flange. Using a
suitable lifting hoist and as detailed in sections 6.1.2 and 6.1.3, lift the dip-pipe assembly out of its crate and into
position above the vessel nozzle.
Carefully lower the dip-pipe assembly through the nozzle and into the vessel. When the dip-pipe is approximately
200mm from the vessel nozzle, carefully remove the fixing bolts that hold the profiler neck and dome to the
titanium flange. The neck and dome supported continue to lower the dip-pipe assembly until it mates with the
vessel nozzle, ensuring that the dip-pipe passes through the bottom support bracket, if fitted (see 6.2.1 below).
The integrity of the titanium dip-pipe assembly must be protected by a suitable sized relief valve fitted to the
vessel.
5.4.1. Installation of Support Bracket
The support bracket is an option that is not used in all profiler applications. On applications where the support
bracket is used, each project will be issued with job specific mechanical drawings that include a General
Arrangement drawing and a Lower Support Arrangement drawing (if required).
Affix bottomsupport tosuitable internal clipsor local internal support at theheight shown on General Arrangement
drawing. Ensure that the arrows on the base are aligned in the direction of liquid flow.
Insert the dip-pipe in to the vessel following review of installation information below. Pass the dip-pipe through
the annulus of the bottom support, tightening the bolts fix the dip pipe in place.
Torque dip-pipe flange bolts to the correct settings (refer to section 6.2.2 and Appendix C).
Figure 5 - Bottom Bracket

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5.4.2. Bolt Torquing Procedure
Please refer to project specific pressure vessel calculations for suggested gasket type and bolt torque settings.
•All nuts to be capable of being run down their respective bolts by hand.
•Ensure threads are suitably lubricated.
•Assemble the joint and secure all nuts by hand.
•
Refer to APPENDIX B for recommended bolt torque settings.

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6. Radiological Safety
It is our normal practice to supply all equipment as specified except the radioactive sources. These will normally
be shipped to site prior to commissioning by Tracerco Services engineers. The sources will be shipped in a
suitable type “A” container. This ensures that the sources are safely packed and shielded for transport. When
shipped to site, the sources should be kept in a safe area (e.g. Radiographer’s store) until the arrival of Tracerco
Services Commissioning Engineers, who will install the source array into its dip-pipe. Prior to arrival of the
sources, the site license should be amended to include the additional sources. Tracerco’s Radiation Safety
Officer (RSO) or Radiation Protection Advisor (RPA), may be contacted for advice with regard to licenses,
registration, etc. Please note local radiological rules must apply and additional local advice may be required.
Figure 6 –Neck and dome (Standard Profiler)
The system specified is designed to meet regulatory requirements, reducing the emission of radiation from the
source array to a safe level. The Profiler contains Americium-241 sources. The sources emit a low energy
(60keV) gamma ray that is easily shielded. When the Profiler is operational there will be no measurable dose
rate outside of the vessel from the sources even when the vessel is empty.

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6.1. Source Housing and isolation
The sources areall contained within a single arming rod, which is locked into place to thecollimatorwith a padlock
or older designs by a screw in the bottom of the collimator. Both methods lock the arming rod to the collimator.
The collimator is then screwed and also locked to the dip pipes via the Locking post (x), the dip pipes in turn are
bolted to the vessel. These padlock(s) must only be removed by an authorised person. The lever is bolted to the
collimator and restricts the vertical movement and allow the sources to be isolated or open.
For source removal, the source housing, lever, locks and screws must all be removed before the arming rod can
be retracted from the vessel to alloy removal of the sources. Tracerco recommend this is only performed by a
Tracerco engineer.
Sources will occasionally require isolation, e.g. for vessel entry. This is achieved by pushing down on the lever
at the neck of the profiler and inserting a padlock into the locking hole (Z) provided. This action withdraws the
sources behind a shield and reduces the dose rate to less than 7.5 micro-Sieverts/hr at a distance of 10cm.
Because it is not possible to receive an effective body dose > 7.5 micro-Sieverts/hr, it is not necessary to
designate a radiation controlled area.
The lever must not be locked in the open position but may be wired or pinned to prevent accidental operation
shut off.
Figure 7 - Source Arming Rod and Isolator Mechanism
Item in Blue is the arming rod
mechanism.
Item in Red is the collimator.
Items in Green (Y) is the quick
release mechanism.
Figure 7 shows the items in grey
which are the neck and dip pipes.
These are bolted to the vessel
flange in blue at the bottom.
The isolation lever is shown with
the arrow indicating the isolation
direction.
In normal operation the sources are held fixed in the ‘Open’position with a locking thumb screw tightened onto
the quick release mechanism (Y). This quick release mechanism can be knocked out to quickly allow isolation.
For vessel entry during shutdown, the arming rod can be isolated and locked shut with a padlock into the locking
hole (Z) provided.
Z) Locking hole for
Isolation Padlock
X) Locking
post for
Source
Padlock
Y) Quick
Release
Mechanism
W) Isolation
Lever

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Figure 8 - Source isolation mechanism
Figure 9 - Thumb Screw and Gaiter
Thumb
screw
Quick Release Mechanism (Z)
Rubber Gaiter
to prevent water
ingress
Isolation
Lever

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6.2. Arming Rod and Collimator Housing
The arming rod is locked into the collimator tube using a padlock as shown in Figure 10. The arming rod has a slot cut in
its length to allow movement of the sources inside the tube thus exposing or isolating the sources. A second locks the
collimator to the dip pipe.
Figure 10 - Arming Rod locked into collimator
The sources sit inside the arming rod holes shown in Figure 11. These sources sit on a ledge inside the holes and are
secured into place with circlips to prevent movement. Special circlips and circlip pliers are required to fix the sources in
place.
Figure 11 - Arming rod and collimator section (Open Position)
Locking post hole
for second lock
Source holes
Collimator holes
Holes

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6.3. Isolation of Sources
The sources are isolated by removing the quick release mechanism and pressing down on the lever, as shown in Figure 8.
The Isolation lever should not be locked in the open position using a padlock in the Locking Hole (z). The locking
hole (z) must only be used to lock the sources in the ‘close’ positon when isolating the sources for vessel entry. The locking
thumb screw will firmly fix the sources in an open position (exposed).
This lifts the holes containing the sources in the arming rod out of alignment with the holes in the collimator tube. The entire
arrangement sits inside a sealed dip pipe and contains the sources and mechanism. Should a radiation leak occur then the
radiation substance should remain in the dip tubes.
Figure 12 - Source Rod and Collimator (Open Position)
Figure 13 - Source Rod and Collimator (Closed Position)
Due to the nature of Americium 241 sources, this is a weak energy radiation and does not require much shield to greatly
reduce the radiation beaming through the pipe.
Various hole shapes are allowed in the collimator tube. The diameter of the arming rod, collimator tube and the holes for
each source will be different depending on the source capsule type used.
However, the operation and arrangement of the various radiological components is the same for all Tracerco Profiler series
variations.
Source
Source arming rod
Collimator tube
Outer source dip-pipe
Detector dip-pipe
Blocked Radiation
beam

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Figure 14- Arming Rod and Collimator Section –(Closed Position)
6.4. Labelling and Safety Marking.
The profiler has a metal label attached, screwed or tie wrapped (metal type) to
the dome. Detailing the Radioactive details of the installation, these Include:
•ISO Trefoil label denoting a radioactive material is contained in the
installation.
•Manufacture’s name, address and Model of the container / instrument.
•Unique Serial number of container.
•Date of manufacture of the container / instrument.
•Dose Rate measured at 1m and date taken.
•The radioactive isotope and nominal activity of each source.
•Total nominal activity of all the sources.
•Source Model Number and ISO classification.
•Individual serial number of all the sources contained in the installation.
Additional marking may also be attached to the dome or neck detailing the
sources, certification marking and site tag number that are not relevant to the
radiation source installation.