LEVEL MEASUREMENT

PREPARED BY: DBA

Note: Video links are provided in some topic on this presentation. All video
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may help you to best appreciate the lesson.
 INDUSTRIAL LEVEL MEASUREMENT

The Vast amount of water used by industry, let alone all the
solvents, chemicals, and other liquids that are necessary for material
processing, make the measurement of liquid level essential to modern
manufacturing.
There are two ways of measuring level: directly by using the
varying level of the liquid as a means of obtaining the measurement;
and indirectly, by using a variable, which change with the liquid level,
to actuate the measuring mechanism.
+++…
DIRECT METHOD LEVEL MEASUREMENT
 DIRECT METHOD LEVEL MEASUREMENT

BOB AND TAPE

The simplest of the direct devices for liquid level
measurement is the bob and tape. All you need is
a bob (or weight) suspended from a tape marked
in feet and inches. The bob is lowered to the
bottom of the vessel containing the liquid, and the
level is determined by noting the point on the
tape reached by the liquid. The actual reading is
made after the tape is removed from the vessel.
Obviously this method isn’t suited to continuous
measurement.
 DIRECT METHOD LEVEL MEASUREMENT

SIGHT GLASS
Another direct means of liquid level
measurement is the sight glass. This
consists of a graduated glass Tube
mounted on the side of the vessel. As the
level of the liquid in the vessel changes,
so does the level of the liquid in the
glass tube.
Measurement is a simple matter of
reading the position of liquid level on
the scale of the sight glass tube.
 DIRECT METHOD LEVEL MEASUREMENT

FLOATS
There are many kinds of float-
operated mechanisms for
continuous direct liquid level
measurement. The Primary
device is a float that by reason
of its buoyancy will follow the
changing level of the liquid, and
a mechanism that will transfer
the float action to a pointer
 DIRECT METHOD LEVEL MEASUREMENT
DISPLACER
The displacer is similar in action to the buoyant float
described above, with the exception that its movement is
more restricted. With changes in liquid level, more or less of
the displacer is covered by the liquid. The more the
displacer is submerged, the greater is the force created by
the displacer because of its buoyancy. This force
transferred through a twisting or bending shaft to a
pneumatic or Electronic system. For every new liquid level
position, there is a new force on the shaft, causing it to
assume a new position. The pneumatic or Electronic system is
so arranged that for each new shaft position there is a new
signal or indication. The displacer float has the advantage
of being more sensitive to small level changes than the
buoyant float and less subject to mechanical friction.
INDIRECT METHOD LEVEL MEASUREMENT

ELECTRICAL LEVEL MEASUREMENT

A. Capacitance
B. Conductivity
C. Ultrasonic
D. Radar
E. Radiation
F. Tuning Fork
G. Rotating Paddle
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
A. CAPACITANCE TYPE LEVEL MEASUREMENT
When functioning as level sensors, capacitors work by processing capacitance with
reference to the dielectric constant of the material being measured and the voltage being
used to complete the circuit. These measurements are used to determine vessel levels. Higher
levels of dielectric material result in greater capacitance, meaning the former can be easily
gauged with the latter.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
A. CAPACITANCE TYPE LEVEL MEASUREMENT
WORKING PRINCIPLE
The principle of capacitive level measurement is based on change of capacitance. An insulated electrode acts
as one plate of capacitor and the tank wall (or reference electrode in a non-metallic vessel) acts as the other
plate. The capacitance depends on the fluid level. An empty tank has a lower capacitance while a filled tank
has a higher capacitance.
A simple capacitor consists of two electrode plate separated by a small thickness of an insulator such as solid,
liquid, gas, or vacuum. This insulator is also called as dielectric. Value of C depends on dielectric used, area of
the plate and also distance between the plates.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
A. CAPACITANCE TYPE LEVEL MEASUREMENT
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
A. CAPACITANCE TYPE LEVEL MEASUREMENT
APPLICATIONS
• Liquid level measurement
• Power and granular solids
• Very high temperature liquid metals
• Liquefied gases at very low temperature
• Corrosive material
• Very high pressure industrial processes
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
A. CAPACITANCE TYPE LEVEL MEASUREMENT
ADVANTAGES
• Inexpensive
• Reliable and rugged
• Versatile
• Minimal Maintenance
• Simple to use
• Easy to clean
• Good range of measurement
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
A. CAPACITANCE TYPE LEVEL MEASUREMENT
DISADVANTAGES
• Not suitable for low dielectric material
• The measurement of capacitance is hard compare to measurement of
resistance
• Sensitive to changes in environmental conditions
• Capacitive proximity sensor are not so accurate compare to inductive sensor
type.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
B. CONDUCTIVITY TYPE LEVEL MEASUREMENT
• Conductivity level switches are sensors with an electrical contact output at a specific
liquid level.
• It make use of conductivity sensing technology or conductance method for liquid level
detection.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
B. CONDUCTIVITY TYPE LEVEL MEASUREMENT
WORKING PRINCIPLE

Simply put, two metallic probes of different lengths

(one long, one short) insert into a tank. The long probe
transmits a low voltage, the second shorter probe is cut
so the tip is at the switching point. When the probes
are in liquid, the current flows across both probes to
activate the switch. One of the benefits to these
devices is that they are safe due to their low voltages
and currents. They are also easy to use and install but
regular maintenance checks must be carried out to
ensure there is no build up on the probe otherwise it
will not perform properly.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
B. CONDUCTIVITY TYPE LEVEL MEASUREMENT
ADVANTAGES:
• These switches provide an extremely cost-effective solution for liquid level
measurement.
• They are very simple to install and safe to use.
• They usually give maintenance free service.
• They generally have a rugged construction.
• They are available in different models.
• These liquid level sensors are designed in such a way that they can work with
almost all conductive mediums
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
B. CONDUCTIVITY TYPE LEVEL MEASUREMENT
DISADVANTAGES:
• Invasive
• liquids need to be conductive
• probe erosion
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
C. ULTRASONIC LEVEL MEASUREMENT
What is ULTRASONIC?
• Sonic is the sound we can hear.
• Ultrasonic is the sound above human
hearing range.
• Infrasonic is the sound below human
range.
• Humans can hear for about 20 Hz up to
20 KHz. Ultrasonic frequencies are
above 20 KHz.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
C. ULTRASONIC LEVEL MEASUREMENT
WORKING PRINCIPLE
• An ultrasonic level transmitter is mounted at the top of the tank and
transmits an ultrasonic pulse down into the tank. This pulse, travelling
at the speed of sound, is reflected back to the transmitter from the
liquid surface. The transmitter measures the time delay between the
transmitted and received echo signal and on the board
microprocessor calculates the distance to the liquid surface.
• The distance can be calculated with the following formula:
L= ½ x T xC
Where L is the distance, T is the time between the emission and
reception, and C is the sonic speed.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
C. ULTRASONIC LEVEL MEASUREMENT
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
C. ULTRASONIC LEVEL MEASUREMENT
APPLICATION

• Wetted, non-contacting switch and transmitter for liquid

level or interface and solid level measurement; suitable for
various liquids and bulk products; not suitable for too much
surface foam, extremely high pressures and temperatures;
not applicable in vacuum service applications.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
C. ULTRASONIC LEVEL MEASUREMENT
ADVANTAGES:
• Give reliable performance, even on difficult slurry or sludge-type
services
• Absence of moving parts and the ability to measure the level
without making physical contact with the process material
• Reliability of the reading is unaffected by changes in the
composition, density, moisture content, electrical conductivity, and
dielectric constant of the process fluid.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
C. ULTRASONIC LEVEL MEASUREMENT
DISADVANTAGES:
• Ultrasonic level transmitter is just as good as the echo it receives. The echo can be
weak as a result of dispersion (which reduces sound intensity by the square of
distance) and absorption (which, in dry air, reduces its energy level by 1 to 3
dB/m).
• The energy content of the echo will be further reduced if the bin is tall, if the vapor
space is dusty, or if it contains foam or other sound absorbing materials such as
water vapors or mists.
• In addition to the problem of weak echo, another potential problem is the reflective
properties and density of the process surface. If that surface is sound-absorbing
(fluffy solids), sloping (angle of repose), or irregular, causing a diffused reflection
of the ultrasonic pulse, the result can be an error, as the round-trip time of travel
might not correspond to the vertical distance between transmitter and level.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
D. RADAR TYPE LEVEL MEASUREMENT
Radar has its origins in the first half of
the 20th century. However, radar level
measurement did not come on the scene
in use as a continuous level measurement
technology until the later part of the
20th century. Radar detect an object in
the same way as Ultrasonic waves does.
Ultrasonic uses the sound waves, and
Radar uses radio waves (microwave).
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
D. RADAR TYPE LEVEL MEASUREMENT
Working Principle:
The operation of all radar level detectors involves sending microwave beams
emitted by a sensor to the surface of liquid in a tank. The electromagnetic waves
after hitting the fluids surface returns back to the sensor which is mounted at the
top of the tank or vessel. The time taken by the signal to return back i.e. time of
flight (TOF) is then determined to measure the level of fluid in the tank.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
D. RADAR TYPE LEVEL MEASUREMENT
APPLICATIONS
• Microwave sensors are ideal for use in moist, vaporous, and dusty
environments as well as in applications in which temperatures and pressures
vary.
• Microwaves (also frequently described as RADAR), will penetrate
temperature and vapor layers that may cause problems for other techniques,
such as ultrasonic.
• Microwaves are electromagnetic energy and therefore do not require air
molecules to transmit the energy making them useful in vacuums.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
D. RADAR TYPE LEVEL MEASUREMENT
ADVANTAGES
• No media contact for vertically mounted type, so flexibility for
use on different corrosive media, thick fluids, slurries,
wastewater
• High temperature fluid compatibility for vertically mounted
types, since no sensitive components make contact with the fluid
• High accuracy due to high frequency pulse wave and precise
transit time measurement
• Sealed pressurized vessel will not affect performance
• Longer range than ultrasonic
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
D. RADAR TYPE LEVEL MEASUREMENT
DISADVANTAGES
• Foaming, splashing, vapour and humidity can affect
measurement performance
• High cost compared to other technologies
• Top mounting only
• Minimal blocking distance limits operation when in proximity
to liquid level
• Longer blocking distance than ultrasonic
• Radar passes through low dielectric constant fluids
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
E. RADIATION TYPE LEVEL MEASUREMENT
• The radiation or nuclear level measurement technique
is used to measure the level of fluid or solid in a
closed tank using Gamma rays. Gamma radiation
sources are chosen for use in level detecting
equipment because gamma rays have great
penetrating power and cannot be deflected.
• Level measurement with radiation works on the
principle of passing gamma radiation through the
material to be measured. As the radiation passes
through this material, the level can be determined by
the amount of attenuation. The wave attenuates when
it passes through materials.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
E. RADIATION TYPE LEVEL MEASUREMENT
Working Principle
• The Gamma-ray is emitted from a source to the
tank and propagates through the tank.
• There is a continuous strip detector that detects
all the Gamma rays pass across the tank.
• If the continuous strip detects rays equal to the
length and it is in maximum absorption, the tank
is empty.
• As the level rises the absorption level decreases.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
E. RADIATION TYPE LEVEL MEASUREMENT
ADVANTAGES:
• Radiation level measurement is suitable for measurement in liquid and solid.
• It gives continuous level measurement.
• It does not require contact with processed material.
• It is simple in design and construction.
DISADVANTAGES:
• Must always be mounted on the side of the vessel
• Special safety measures are required for the use of gamma radiation
• May also involve licensing requirements
• It is relatively expensive
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
F. TUNING FORK
A vibrating tuning fork liquid level switch is an instrument for monitoring the height of a
liquid and tripping a relay contact switch or transmitting a solid state relay switch output
when a maximum, minimum or intermediate level has been reached. The liquid level
switch output can then be utilized by other instrumentation to open a valve, illuminate a
warning lamp, activate an audible alarm, or switch on a pump.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
F. TUNING FORK
APPLICATIONS:

For Solid Level Detection

• Powders: tobacco, powdered cellulose, powdered clay, polystyrene powder, dry soot,
soda ash, coal ash
• Granular & Plastics: gravel, glass fine power, granular plastics, foundry sand, cements,
plastic pellets

For Liquid Level Detection

• paints, alcohols, inks drinks & beverages petroleums, oils, creams water based solutions
corrosive liquids, acids general purpose solvents
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
F. TUNING FORK
ADVANTAGES:
• Not affected by any surface disturbances such turbulence, foaming, vibration
• High temperature fluid compatibility since no sensitive components make contact with
the fluid
• Small compact size
• Sealed pressurized or evacuated vessels will not affect performance
DISADVANTAGES:
• Thick or sticky media will leave a coating on the probe which will affect vibration
frequency
• Fouling can interfere with resonant frequency causing false switch activation
• Tuning fork protruding into liquid causing obstruction, attracting fouling and hygienic
cleanliness issues
• High cost
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
G. ROTATING PADDLE
• The paddle type level switch is used for
the detection of dust level or litter material
in silo, etc. The rotating vane is continuously
rotated by a motor. When this pallet comes
into contact with the material, more force
than the rotating torque will be applied to
the pallet and rotation will stop. The level
switch detects rotation, stops and sends the
contact.
• Rotary paddle level sensors can be side or
top mounted on bins and silos. Top mounted
units can include shaft extensions to place
the rotating paddle at the point where a
high level detection is needed.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
G. ROTATING PADDLE
ADVANTAGES:
• Relatively low cost
• Easy to install
• Wide range of power supplies and accessories
• Most universal in bulk solids application
• Rugged construction
• Easy to handle and operates stable for a period of time.
 INDIRECT METHOD LEVEL MEASUREMENT - ELECTRICAL
G. ROTATING PADDLE
DISADVANTAGES:
• Drive motor failure is most common maintenance issue. Some brands more
prone than others
• Electromechanical, moving parts - Fine particles or dust must be
prevented from penetrating the shaft bearings and motor by proper
placement of the paddle in the hopper or bin and using appropriate
seals.
• Build up may occur in the paddle -If the process material becomes tacky
because of high moisture levels or high ambient humidity in the hopper.
INDIRECT METHOD LEVEL MEASUREMENT

HEAD PRESSURE MEASUREMENT

A. Guage Pressure
B. Bubbler
C. Differential Pressure
 INDIRECT METHOD LEVEL MEASUREMENT – HEAD PRESSURE
A. GUAGE PRESSURE MEASUREMENT

There are several types of indirect

level measuring devices that are
operated by Pressure. Any rise in the
level causes an increase of pressure,
which can be measure by the gauge.
The gauge scale is marked in units of
level measurement (feet or inches).
 INDIRECT METHOD LEVEL MEASUREMENT – HEAD PRESSURE
B. BUBBLER SYSTEM
The Air – bubbler system is a system of indirect level
measurement especially suitable for liquids that are corrosive,
viscous, or contain suspended solids.
The pressure caused by the liquid column is used in the bubbler
method of level measurement. A pipe is installed vertically in
the vessel with its open end at the zero level. The other end of
the pipe is connected to a regulated air supply and to a
pressure gauge. To make a level measurement the air supply is
adjusted so that the pressure is slightly higher than the pressure
due to the height of the liquid. This is accomplished by
regulating the air pressure until bubbles can be seen slowly
leaving the open end of the pipe. The gauge then measures the
air pressure needed to overcome the pressure of the liquid. The
gauge is calibrated in feet or inches of level.
 INDIRECT METHOD LEVEL MEASUREMENT – HEAD PRESSURE
B. BUBBLER SYSTEM
APPLICATIONS:
• The level bubbler can be used to monitor in-take screens for debris and initiate an airburst
backwash. This is done by placing a dip tube on each side of the screen and when the
pressure differential between the two reaches a certain point, a backwash can be initiated to
clean the screens. This system is a called a Differential Level Bubbler.
• The level bubbler can be used to measure the level of the wet well to control the intake
pumps.
• The level bubbler can be used to measure levels in all types of liquids such as sanitary waste
stations.
• The level bubbler can be a retrofit replacement for ultrasonic level transmitters.
 INDIRECT METHOD LEVEL MEASUREMENT – HEAD PRESSURE
B. BUBBLER SYSTEM
ADVANTAGES:
• Immune to surface foam, pH, conductivity, temperature, turbulence, and solids content.
• Reliability is better than other level measurement methods because the dip tube is the
only part of the system in contact with the liquid being measured.
• The sensor is not in direct contact with liquid, offering long life and greater calibration
stability.
• The instrument panel can be located up to several hundred feet from what is being
measured.
• Suitable for applications with corrosive, acidic, hazardous, volatile, molten, cryogenic,
or radioactive liquids.
• The purge gas (compressed air) provides complete isolation from the measured liquid.
• Minimal Maintenance when an Auto Blow Down system for the dip tube is purchased
and integrated with the Level Bubbler.
 INDIRECT METHOD LEVEL MEASUREMENT – HEAD PRESSURE
B. BUBBLER SYSTEM
ADVANTAGES:
• Applicable to pressurized tanks, but only up to the pressure of the available air
supply
• Accuracy depends on the readability of the pressure indicator and a constant,
repeatable air supply
• Fluid density changes create level measurement errors
Installation cost (labor) is high
• May not work well in viscous or sticky process fluids that tend to clog the dip tube
• Regular preventative maintenance is required
If air supply fails, the process material can enter the dip tube and damage
instrumentation
• Exhausted air can pick up volatile materials from the process fluid that should not be
released into the environment
 INDIRECT METHOD LEVEL MEASUREMENT –
HEAD PRESSURE

C. DIFFERENTIAL PRESSURE TRANSMITTER FOR

LEVEL MEASUREMENT
 DIFFERENTIAL PRESSURE TRANSMITTER
LEVEL MEASUREMENT BY D.P. TRANSMITTERS
To determine the level of a liquid in an open tank, connect the high side
of the Transmitter to a tap at the bottom of the tank. Vent the low side
of the transmitter to the atmosphere. The pressure represents the height
of the liquid in the tank multiplied by the specific gravity of the liquid;
therefore, the output of the transmitter will be proportional to the liquid
level above the transmitter. If the tank is located above the transmitter,
the zero must be readjusted to elevate the range.

To determine the liquid level in a closed tank, steps must be taken to

compensate for tank pressure generated above the top of the liquid
and the top of the tank. This is accomplished by placing a tap at the
top of the tank and connecting it to the low side of the transmitter.
When this has been done, the differential pressure measured by the
Transmitter is proportional to the height of the liquid in the tank
multiplied by the specific gravity of the liquid. If the liquid has a vapor
that could condense in the piping connected to the top of the tank, the
piping should be filled with he measured liquid. This will exert a head
pressure on the low side of the transmitter and must be zeroed out.
 DIFFERENTIAL PRESSURE TRANSMITTER

Definition
A d/p transmitter is an instrument
that senses the difference in
pressure between two ports and
produce an output signal with
reference to a calibrated pressure
range.

High Pressure Port Low Pressure Port

 DIFFERENTIAL PRESSURE TRANSMITTER
Since level measurement depends on hydrostatic pressure alone, a d/p
transmitter is used to remove any bias caused by other pressure
variables. The Level and Pressure relationship is shown below:

Where:
PL = Hydrostatic Pressure
h = Liquid Level/Height
ρ = Density
g = acceleration due to
h PL gravity
 DIFFERENTIAL PRESSURE TRANSMITTER
Using Pressure Gauge:
Where:
VP = Vapor Pressure
PL = Hydrostatic Pressure (Liquid Pressure)
PM= Measured Pressure
Vp
PM = PL + VP must be
removed

PM The measured pressure should be equal to the

hydrostatic pressure to get the accurate height of
PL the liquid. In this case, the vapor pressure adds to
the hydrostatic pressure causing a bias in the level
measurement.
 DIFFERENTIAL PRESSURE TRANSMITTER
Using Differential Pressure Tx:
Where:
VP = Vapor Pressure
PL = Hydrostatic Pressure (Liquid Pressure)
Vp PM = Measured Pressure
Vp HP = High Pressure Side
LP = Low Pressure Side
PM = HP - LP
= (VP + PL) - VP
PM
PM = PL
PL Since the measured pressure is equal to the
HP LP hydrostatic pressure, the level can now be
calculated accurately.
 DIFFERENTIAL PRESSURE
TRANSMITTER CONFIGURATION
 D/P TRANSMITTER CONFIGURATION
Dry Leg Configuration

The dry leg configuration is

comprised of the Differential Vp
Pressure Transmitter, where the Reference Leg

high pressure side is connected to

the point of measurement and the
low pressure side is connected to a Point of Measurement

reference leg. The reference leg is

used to compensate for the vapor PL
pressure. HP LP
 D/P TRANSMITTER CONFIGURATION
Dry Leg Configuration

The disadvantage of the dry leg

configuration however is that
condensate tends to build up at the Vp Condensate
w/ unknown
reference leg causing errors in level Reference Leg height and
measurement. pressure

PM = HP - LP
= (VP + PL1) - (VP + PL1 PL2
PL2)
must be HP LP
PM = PL1 - PL2 removed
 D/P TRANSMITTER CONFIGURATION
Wet Leg Configuration

The wet leg configuration is then used to

prevent the error caused by the condensate
if dry leg configurations were to be used.
This is done by introducing a seal pot filled
with fluid with known height and density, thus Vp Seal Pot
Seal Fluid
w/ known
its pressure can be calculated. The excess height and
pressure can be corrected through pressure
calibration

PM = HP - LP
= (VP + PL) - (VP + PL PSF
PSF)
PM = PL1 - PSF HP LP
may be removed
through calibration
 DIFFERENTIAL PRESSURE
TRANSMITTER INSTALLATION
 D/P TRANSMITTER INSTALLATION
Zero Elevation
-is a type of installation where the
instrument is placed above the
point of measurement.

Datum Line (0%)

Implemented because:
* it protects the instrument from
hydrostatic pressure due to high
level measurements.
*it causes the instrument to stay
clear of obstructions.
Point of measurement Obstruction
 D/P TRANSMITTER INSTALLATION
Zero Suppression
- is a type of installation where the
instrument is placed below the point
of measurement.

Implemented because:
* it provides ease of access.
*protects the instrument from abrasive Seal Fluid
fluids by filling the high pressure side
with a sealing fluid.

Point of measurement
Datum Line (0%)
LEVEL CALCULATION FOR DP TRANSMITTER
LEVEL CALCULATION FOR DP TRANSMITTER
LEVEL CALCULATION FOR DP TRANSMITTER
LEVEL CALCULATION FOR DP TRANSMITTER
LEVEL CALCULATION FOR DP TRANSMITTER
LEVEL CALCULATION FOR DP TRANSMITTER
END