Level measurement
In refining and petrochemical processing, precise level and pressure measurement is essential for safe, stable and compliant operation. From feedstock conditioning and separation to downstream conversion and storage, reliable measurement technology ensures consistent process conditions, protects critical assets and supports high product quality.
VEGA provides maintenance free level, interface and pressure instrumentation designed to perform reliably under extreme temperatures, pressures and aggressive media. As the global leader in radar level measurement, VEGA combines advanced sensor technology with decades of application expertise to support petrochemical operators in optimising processes, reducing operational risk and meeting the highest safety and regulatory standards.
The following application examples demonstrate how advanced level, interface and pressure measurement technologies support demanding petrochemical processes where stable feed conditions, precise phase separation and long term reliability are critical.
In petrochemical plants, pressure measurement plays a key role in protecting equipment such as pumps, filters and feed systems operating at elevated temperatures. A U.S.-based OEM supplying high temperature filtration systems required pressure sensors capable of withstanding harsh thermal conditions while meeting strict delivery timelines.
Previous solutions failed due to insufficient temperature resistance and long lead times, resulting in production delays and reduced planning reliability.
VEGA supplied the VEGABAR 83 pressure transmitter, designed for process temperatures up to 200 °C (392 °F) with a long term accuracy of 0.075 %. Short delivery times and strong application support enabled fast integration and reliable operation.
Effective feedstock preparation is a prerequisite for reliable petrochemical conversion processes. In crude oil desalting – a critical step before distillation and downstream processing – precise control of the oil water interface is essential to remove salts and residual water. This prevents corrosion, fouling and catalyst degradation further downstream.
However, fluctuating crude oil compositions lead to varying densities and dielectric constants, making interface measurement particularly challenging at operating temperatures of around 130 °C.
VEGA’s advanced radar and pressure sensors deliver accuracy and reliability under extreme conditions.
A German refining company implemented the VEGAFLEX 86 guided wave radar sensor with an extended reference section. The sensor delivers reliable interface measurement independent of density and dielectric variations and operates under extreme conditions up to 450 °C and 400 bar.
Its ceramic components, robust mechanical design and advanced steam compensation ensure stable performance even in high vibration environments.
Over an 18 month test period, the system delivered reliable measurements with zero malfunctions despite continuously changing feedstock qualities. Following this success, a second desalter was equipped with VEGAFLEX 86, confirming its suitability for demanding petrochemical feed preparation.
In particularly challenging applications – such as vessels with multiple fluid layers, unstable emulsions or highly variable feedstocks – even advanced radar technologies can reach their limits. VEGA’s Multi Point Density Array (MDA) addresses these challenges using non contact radiometric density measurement.
Multiple externally mounted detectors measure density at different heights within the vessel, creating a complete real time density profile. This enables precise monitoring of oil, water and emulsion layers and supports stable feed preparation upstream of sensitive petrochemical units.
Because the system is non intrusive, it is unaffected by pressure, temperature or aggressive media and eliminates buildup related measurement errors. MDA is therefore ideally suited for separation and feed conditioning processes where stable inlet conditions are essential to protect reactors, furnaces and catalysts.
Where other technologies fail, the Multi-Point Density Array ensures reliable multi-phase interface and emulsion control.
By combining innovative measurement technology with deep process knowledge, VEGA helps petrochemical operators stabilise feedstock quality, optimise plant performance and ensure safe, compliant operation – even under the most demanding conditions.
PIN 27.2 Apr/May 2026
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