Model 3201

Liquid Level Controller

The Model 3201 Liquid Level Controller is ideal for oilfield • Field Reversible Action - The Model 3201 design
scrubber and separator applications. Its rugged and versatile makes reversing the controller action simple. Requires
design make it the preferred choice of production operators for no additional parts or special tools.
reliable service in a wide variety of applications. Available in
caged and cageless configurations with a variety of displacer • Liquid Interface Control - The Model 3201 is well-suited
sizes, materials, and vessel connection options. for liquid-liquid interface detection.

• Displacers - Mallard offers a variety of displacer

materials and designs to satisfy your application
Features: requirements. Standard material offerings are PVC,
Acrylic, and 316 Stainless Steel.
• Pneumatic Non-bleeding Pilots - The Model 3201 can be
fitted with either of two non-bleeding pilots: a snap pilot for • NACE - The Model 3201 is available with wetted materials
on/off service or a throttle pilot for modulating service. The that meet NACE MR-01-75 specifications for sour service.
controller can be quickly and easily converted from snap to
throttle or vice versa.

zMallard Control Company, Inc. 2003; All Rights Reserved 4/03

 Page 2

Specifications:

Available End Connection Sizes Seal Temperature Ratings

Threaded: 1.5" or 2" Buna: -20 to 180°F (-29 to 82°C)
Butt Weld: 1.5" or 2" Viton: -20 to 400°F (-29 to 204°C)
Flanged: 2", 3", 4", 6", or 8"
Displacer Pressure Ratings
End Connection / Pressure Ratings1 See Table 2
MNPT / 6000 psig (414 bar)
150# RF / 275 psig (19 bar) Minimum Allowable Fluid Specific Gravity
300# RF / 740 psig (51 bar) See Table 3
600# RF / 1480 psig (102 bar)
600# RTJ / 1480 psig (102 bar) Materials of Construction
900# RF / 2220 psig (152 bar) Body: Steel
900# RTJ / 2220 psig (152 bar) Case & Cover: Die Cast Aluminum
1500# RF / 3750 psig (259 bar) Pilots: Aluminum with SST Internals
1500# RTJ / 3750 psig (259 bar) Pilot Gaskets/Diaph.: Buna
2500# RF / 6170 psig (426 bar) Viton (optional)
2500# RTJ / 6170 psig (426 bar) Gauges: Bronze
316 SST (optional)
Pilot 316 SST LF (optional)
Snap (on/off), 0-20 / 0-30 psig output Shaft: 303 SST
Throttle (modulating), 3-15 / 6-30 psig output 316 SST (optional)
Bearing Blocks: 303 SST
Supply Pressure Requirement 316 SST (optional)
3-15 or 0-20 psig output: 20-30 psig min. Bearings: 440C SST
6-30 or 0-30 psig output: 35-40 psig min. Seals: Buna
Viton
Supply & Output Connections Displacer: PVC
1/4" fnpt Acrylic (optional)
316 SST (optional)
Operating Temperature Limits Displacer Arm: 302 SST
See Table 1 Vertical Hanger (swivel): 316 SST
Vertical Displ. Ext. Chain: 302 SST

1. Maximum pressure ratings @ 100°F (38°C)

 Page 3

Table 1. Operating Temperature Limits

Temperature Limits
Body Material Seals Displacer Material
°F °C
C.S. Buna PVC -20 to 140° -29 to 60°
C.S. Buna Acrylic -20 to 180° -29 to 82°
C.S. Buna 316 SST -20 to 180° -29 to 82°
C.S. Viton PVC -20 to 140° -29 to 60°
C.S. Viton Acrylic -20 to 200° -29 to 93°
C.S. Viton 316 SST -20 to 400° -29 to 204°

Table 2. Displacer Pressure Ratings

Maximum Pressure
Material
Psig Bar
PVC 6170 426
Acrylic 6170 426
316 SST 2000 @ 180°F, 1595 @ 400°F1 138 @ 82°C, 110 @ 204°C1

1. For applications requiring higher pressure ratings for SST displacers, consult Factory or your local Mallard representative.

Table 3. Minimum Allowable Fluid Specific Gravity

Top Level Control Liquid-Liquid Interface Level Control

Horizontal Displacer Vertical Displacer Horizontal Displacer Vertical Displacer
Pilot Pilot
Standard1 Standard2 Std1 Special3 Std2 Special3
Snap 0.28 0.21 Snap 0.28 0.030 0.21 0.050
Throttle 0.56 0.42 Throttle 0.56 0.060 0.42 0.100

1. Based on 1.88" dia. x 12" displacer with 12.5" displacer arm.

2. Based on 1.88" dia. x 12" displacer with 15" displacer arm.
3. Special displacer and displacer arm configurations required - consult Factory or your local Mallard representative.
 Page 4

Theory of Operation
The operation of the Series 3201 Liquid Level Controller is
based upon the "Force Balance Principle", illustrated in
Figure 1. The weight of a displacer-type level sensing
element produces a force which is applied to one side of
the Torque Bar through a series of shafts and levers. This
force is balanced by the opposing force of a compressed
spring on the other side of the Torque Bar. As the level
rises, the increased immersion of the displacer in the liquid
causes the relative weight of the displacer to decrease, due
to the buoyancy force being produced. This, in turn, results
in a decrease in force applied to the Torque Bar. The
Torque Bar then rotates until the forces are again balanced.
Torque Bar rotation is detected by the pilot through a fulcrum
mounted on a lever (Flapper Bar) to affect the desired
controller output. The output signal can be a pneumatic
on/off signal by using the snap pilot, a pneumatic modulating
signal by using the throttle pilot.
Figure 1.
Controller Action
Controller action is determined by the installation of the
Flapper Bar, as shown in Figure 2. Control is considered
"Direct-Acting" when the controller output changes in the
same direction as the liquid level. For example, the
Flapper bar
controller output signal will increase when the liquid level
the controller is sensing increases, and vice versa. Control
is considered "Reverse-Acting" when the controller output Pivot
changes in the opposite direction as the liquid level. For a
direct-acting controller, the Flapper Bar pivot point is on the
same side as the spring. For a reverse-acting controller, the
Flapper Bar pivot point is on the opposite side as the spring.
Fulcrum
Proportional Band
Proportional band is the ratio of used displacer length
versus the total length of the displacer to achieve a desired
output signal.

EXAMPLE: If six inches of liquid level change will develop

the required output signal (such as 3-15 psi) and a 12" long
vertical displacer is used, then the level controller is said to Flapper bar DIRECT ACTING
have a 50% proportional band. Sliding the fulcrum on the
Pivot
flapper bar away from the pivot pin toward the snap ring
decreases proportional band (increases sensitivity), while
sliding the fulcrum on the flapper bar away from the snap
ring toward the pivot pin increases proportional band
(decreases sensitivity). A desired output signal (such as
Fulcrum
3-15 psi or 6-30 psi) may be accomplished over any portion
of the displacer by adjusting the fulcrum as described above.

REVERSE ACTING

Figure 2. Controller Action

 Page 5

Snap Pilot Operation

The snap pilot (Figure 3) is made up of two valves: one to
admit system supply pressure and one to exhaust system
pressure. Ball "X" controls the flow of supply gas into the
X
pilot and is held closed on the pilot seat by force exerted by
the supply pressure acting upon the seating area of the ball. SUPPLY

When force transmitted from the flapper bar to the thrust

pin "Y" becomes sufficient to overcome the force holding
ball "X" seated, ball "X" snaps off the pilot seat allowing
supply gas to flow past ball "X" and through the output port
of the pilot. The spherical seating end of the thrust pin "Y" Y OUTPUT
seats and closes the exhaust port simultaneously when ball
"X" snaps open. The seating area of the thrust pin is smaller
than the seating area of ball "X"; therefore, the thrust pin
must remain seated against the supply pressure until force
on the thrust pin from the flapper bar diminishes.

A simultaneous action occurs as force from the flapper bar

on the thrust pin "Y" is removed. When this happens, the EXHAUST
supply pressure will unseat the thrust pin and open the
exhaust port in the pilot and ball "X" will reseat and close off
the supply port. The difference in seating areas gives this Figure 3. Snap Pilot
pilot its "snap" action.

Throttle Pilot Operation

The throttle pilot (Figure 4), like the snap pilot, is also made
up of two internal valves. In addition, the throttle pilot
utilizes a resilient diaphragm "Z" in conjunction with the
valves to create a Force Balance Pilot.

The pilot output supply pressure acts upon the diaphragm

"Z" so that the diaphragm pushes back with the same force
being applied to the thrust pin by the flapper bar, thus the SUPPLY
term Force Balance.

The throttle pilot functions in a similar manner as the snap

pilot except that the output pressure is proportional to the X
amount of force applied to the lower seat by the flapper bar. OUTPUT
An increase in force on the thrust pin produces a
proportionate increase in pilot output pressure.
Z
As forces change on the thrust pin, the pilot seeks a new
balance point by exhausting the supply output at valve "Y"
or unseating valve "X" to increase output pressure. Supply
Y
gas does not flow while the pilot is in balance.

EXHAUST

Figure 4. Throttle Pilot

 Page 6

Dimensions:

1. 16.15" dimension based upon standard vertical service configuration of 15" arm with a 12" lg. displacer. Other arm lengths and displacer sizes are available upon
request. 24.50" dimension based upon standard horizontal service configuration of 12.50" arm with a 12" lg. displacer. Other arm lengths and displacer sizes are
available upon request.

Dimension "F"
Body Size
Vessel Connection
2.00 3.00 4.00 6.00 8.00
Butt-Weld Sch. 40 6.00 - - - -
Sch. 80 6.00 - - - -
Sch. 160 6.00 - - - -
Sch. XXH 6.00 - - - -
Slip-on 6.00 - - - -
Screwed Male NPT 6.00 - - - -
Grooved 6.00 6.88 6.94 6.04 *
150# RF 6.50 6.56 6.56 6.50 *
300# RF 6.81 6.75 6.88 6.94 *
600# RF 7.19 7.12 7.50 11.0 *
600# RTJ 7.25 7.31 7.56 11.0 *
900# RF 8.00 9.63 10.13 * *
900# RTJ 8.06 9.69 10.19 * *
1500# RF 8.00 10.25 10.63 * *
1500# RTJ 8.06 10.31 10.69 * *
2500# RF 8.50 11.06 11.75 * *
2500# RTJ 8.56 11.13 11.81 * *

* Consult Factory
 Page 7

Information Required for Proper Selection of the 3201 Liquid Level Controller:

1. Fluid Media
2. Fluid Temperature: Maximum & Minimum
3. Operating & Design Pressure
4. Body Connection Size & Type
5. Displacer Orientation: Horizontal or Vertical
6. Displacer Arm Length: Arm length is figured from the centerline of the controller case to where the displacer attaches to the
arm. Standard arm lengths are 12.5" for Horizontal displacers and 15" for Vertical Displacers. Other arm lengths are
available upon request.
7. Determine mounting orientation (See Figure 5).

LEFT-HAND MOUNT RIGHT-HAND MOUNT

Figure 5. Controller Mounting

Mounting
The Series 3201 Liquid Level Controller can be set up as vessel, then it is considered "right-hand". If the controller is
right-hand mount or left-hand mount. The orientation of the to be mounted on the left side of the vessel, then it is
level controller mounted to the vessel, while facing the front considered "left-hand". The mounting orientation can be
of the controller, determines the mounting style (Figure 5). If easily reversed in the field.
the controller is to be mounted on the right side of the
 Page 8

Model Number Information

Sample Model Number: 3201 - 20 MS 0 - S RD B - S A
END CONNECTION CODE
1.5” 15
2” 20
3” 30
4” 40
6” 60
8” 80
END CONNECTION TYPE CODE
Screwed MNPT MS
Butt-Weld, Sch. 80 B8
Butt-Weld, Sch 160 B1
Raised Face Flange RF
Ring Type Joint Flange RJ
Special - to be specified SP
PRESSURE RATING CODE
MNPT (6000 psig) 0
ANSI 150 ( 275 psig) 1
ANSI 300 ( 740 psig) 3
ANSI 600 (1480 psig) 6
ANSI 900 (2220 psig) 9
ANSI 1500 (3750 psig) 5
ANSI 2500 (6170 psig) 2
MATERIALS OF CONSTRUCTION CODE
Body Shaft Brg. Block
1018 / A105 C.S. 303 SST 303 SST -
1018 / A105 C.S. 316 SST 316 SST A
1018 / A105 C.S. (NACE) 316 SST 316 SST N
PILOT CODE
Snap (Pneumatic on/off) S
Throttle (Pneumatic Modulating) T
MOUNTING / CONTROLLER ACTION CODE
Left Hand / Direct LD
Left Hand / Reverse LR
Right Hand / Direct RD
Right Hand / Reverse RR
SEAL MATERIAL CODE
Buna B
Viton V
Special - to be specified X
GAUGE TYPE CODE
0-30 psi, Brass Internals S
0-60 psi, Brass Internals T
0-30 psi, 316 SST Internals 3
0-60 psi, 316 SST Internals 6
0-30 psi, Brass Internals, Liquid-Filled A
0-60 psi, Brass Internals, Liquid-Filled B
0-30 psi, 316 SST Internals, Liquid-Filled C
0-60 psi, 316 SST Internals, Liquid-Filled D
CONTROLLER CASE CODE
Standard A

While this information is presented in good faith and believed to be accurate, Mallard Control Company does not guarantee results based upon such information.
Mallard Control Company reserves the right to change the design or specifications of these products without notice.

Mallard Control Company, Inc.

4970 Washington Boulevard
Beaumont, Texas, USA 77707
409 842-5392 Phone
409 842-8165 FAX
www.MallardControl.com