Level Control

Instructor: Dr. Ammar Hasan

Example level control system

Instructor: Dr. Ammar Hasan

 Example level control system
• It is a liquid solvent distribution system
located in a factory.
• Its purpose is to release the solvent into
the system after the product in a batch
process vessel has been emptied.
• As the solvent flows through connecting
pipes, tubes, and vessels, it cleans the
system in preparation for the next batch.
Instructor: Dr. Ammar Hasan
 Example level control system
• Before some type of automatic control can be
implemented, it is necessary to determine the level
with a mechanical or electronic sensing detector.
• The control function is initiated by a signal from the
sensing device, which indicates the actual level of the
batch process vessel.
• The solvent is transferred from a storage reservoir
that functions as the source, through pipes that serve
as the path, to the process vessel which is the load.

Instructor: Dr. Ammar Hasan

 Example level control system
• Until the solvent level reaches the sensor, the controller
keeps valve 1 open to allow the fluid to pass through.
• When the level reaches the sensor, valve 1 is shut off.
The controller is programmed to keep the solvent in the
vessel for a period of time while the chemical reaction
by the liquid performs the necessary cleaning action.
• After the required time has elapsed, the controller
opens valve 2 to enable the solvent to drain into and
clean the distribution system.

Instructor: Dr. Ammar Hasan

 Power Sources
• Sources that provide the force required to
transfer materials include pumps, static pressure
-tanks, and angers.

Pumps
A pump is primarily used to move liquids a
required distance, or to an elevated level. The
pump is powered by an electric motor, a
combustion engine, or a hydraulic system.

Instructor: Dr. Ammar Hasan

 Power Sources
Static Pressure Tanks
• Static pressure tanks are employed to transfer liquids
and solids a required distance, or to a lower level.
• The tank stores the material.
• Valves located near the output ports of the tank open
and close the pathway, which controls the flow of
material as needed.
• The pressure from the tank provides the force that
moves the material.
• Gravity adds to the force if the flow is vertical.

Instructor: Dr. Ammar Hasan

Power Sources: Tanks

Instructor: Dr. Ammar Hasan

 Power Sources
Augers
• The auger is used to move powders or
granules in an upward vertical
direction. The auger is driven by an
electric motor, a combustion engine,
or a hydraulic system.

Instructor: Dr. Ammar Hasan

 Power Sources
Transfer Systems
• There are various types of
distribution systems that
serve as the pathway for
materials to be transferred
from one location to
another.

Instructor: Dr. Ammar Hasan

Power Sources: Transfer systems

Instructor: Dr. Ammar Hasan

 Power Sources
Pipes
A pipe is the primary vehicle used for
transporting solids and liquids which
need to be moved upward, downward,
and horizontally.

Instructor: Dr. Ammar Hasan

Power Sources: Pipes

Instructor: Dr. Ammar Hasan

 Power Sources
Conveyor Systems
The conveyor belt is often used to transfer solid materials.
The belt is powered by a motor. The movement is
horizontal, or on an upward or downward slope.

Instructor: Dr. Ammar Hasan

Power Sources: Conveyer systems

Instructor: Dr. Ammar Hasan

Power Sources : Conveyer systems

Instructor: Dr. Ammar Hasan

 Methods of Measurement
• Level is measured by locating the boundary between
two media, called the interface.
• The media can be liquid and gas, liquid and liquid,
liquid and solid, or solid and gas.
• An example of a liquid and gas medium is water making
contact with air in an open vessel.
• A liquid and liquid medium is two liquids that do not
mix, such as oil floating on top of water.
• An example of a solid and gas medium is powder in
contact with air in an open vessel.

Instructor: Dr. Ammar Hasan

 Methods of Measurement
• Level can be measured directly or indirectly.
• Direct measurement devices are also referred to
as invasive devices because the sensor is in
direct contact with the material.
• The indirect method, also known as inferred
measurement, means that a variable other than
level is measured and used to infer; or indicate, a
level measurement through some conversion
method.

Instructor: Dr. Ammar Hasan

 Methods of Measurement
• For example, the level of a vessel can be
determined by weight, pressure, volume,
buoyancy, or electrical properties.
• Indirect measurement devices are also referred
to as noninvasive devices, because no part of the
sensor comes in contact with the material.
• Noninvasive devices are preferred when the
material is corrosive, hazardous, sterile, or at a
high temperature or pressure.

Instructor: Dr. Ammar Hasan

 Point level Measurement
• Point level measurements detect if the
interface/level is at a predetermined point.
• Generally, this type of detection is used to signal
either a low-level limit when a vessel needs to
be refilled, or a high-level alarm to warn of an
overfill condition.
• The output of point level measurement devices
typically produces On-Off, or 1 and 0 state digital
signals.

Instructor: Dr. Ammar Hasan

Point level Measurement

Instructor: Dr. Ammar Hasan

 Continuous level Measurements
• Continuous level measurements locates the interface
point within a range of all possible levels at all times.
• The output of continuous level measurement devices
typically produces an analog signal between 4 and 20
mA, which is both proportional and linear to the
level.
• The electrical signal can be converted into
information that represents various quantitative
values used to indicate levels.

Instructor: Dr. Ammar Hasan

Continuous level Measurements

Instructor: Dr. Ammar Hasan

 Level Measurement Methods
• Level measurements are made by a number of instruments
that use different methods to make the readings.
• The instruments are classified as
–Visual observation systems
–Float and displacement systems
–Purge systems,
–Hydrostatic head systems
–Differential pressure systems
–Weight method
–Electrical and Ultrasonic systems

Instructor: Dr. Ammar Hasan

 Selection of Level Measurement Method

• The selection of a specific method of measuring

level is often based on the following
considerations:
–Material
–Accessibility
–Cost
–Turbulence
–Accuracy
–Pressure

Instructor: Dr. Ammar Hasan

 Visual Methods
• Visual method simply means that a
direct measurement is taken by
observing the location of the material’s
top surface in the container.
• Include:
– Rod gauge
– Sight glass

Instructor: Dr. Ammar Hasan

 Visual Methods: Rod Gauge
• A rodgauge is a dipstick that is inserted into the material
being measured.
• It is the same type of device used to indicate oil level in a
car.
• It has weighted line markings which indicate depth for
volume.
• This device is very accurate and is often used during the
calibration of other level measurement devices.
• It is not used to measure hazardous materials, to produce
remote indication, or in vessels that are pressurized.

Instructor: Dr. Ammar Hasan

Visual Methods: Rod Gauge

Instructor: Dr. Ammar Hasan

Visual Methods: Rod Gauge

Instructor: Dr. Ammar Hasan

 Visual Methods: Sight glass
• The sight glass is a transparent tube connected to the
side of a vessel.
• As the tank level changes, so does the level in the sight
glass.
• This device provides a direct, local, and continuous
measurement.
• Sight glasses are used for high pressure applications
and for hot or corrosive fluids.
• They are not useful when foam or viscous liquids are
used, because visual quality is obscured.

Instructor: Dr. Ammar Hasan

Visual Methods: Sight glass

Instructor: Dr. Ammar Hasan

Visual Methods: Sight glass

Instructor: Dr. Ammar Hasan

 Other Methods
• Rodgauges and sight glasses give visual
indication of level.
• However, they do not produce a feedback
signal in automated control applications.
• Now we will focus on techniques that can
provide feedback information through
mechanical linkages or electrical signals.

Instructor: Dr. Ammar Hasan

 Float Method
• The float-type level indicator is a spherical or
cylindrical element that rides on the surface of
the liquid as a means of detecting the level.
• A float is a direct, invasive method that provides
either point or continuous measurement.
• By using different types of linkage connections
between the float and the indicating device, such
as the gauges a continuous measurement reading
can be taken.

Instructor: Dr. Ammar Hasan

Float Method

Instructor: Dr. Ammar Hasan

 Float Method
• Float devices can also be used for automatic control.
• By connecting the float element to the stem of a flow control
valve with a linkage, it will allow-water to replenish a vessel if
the level becomes too low.
• An example is the float mechanism used in a household toilet
tank.
• To provide more accurate control, a linkage can connect the
float to the potentiometer of an electronic computing device.
• Small diameter floats are used to measure higher density fluids.
• Larger-floats are used for liquid-liquid interface detection or for
reading lower density materials.

Instructor: Dr. Ammar Hasan

Float and Displacement Methods: Buoyancy
Method

Instructor: Dr. Ammar Hasan

Float Method

Instructor: Dr. Ammar Hasan

 Float Method
• Float devices can also be used for automatic control.
• By connecting the float element to the stem of a flow control
valve with a linkage, it will allow-water to replenish a vessel if
the level becomes too low.
• An example is the float mechanism used in a household toilet
tank.
• To provide more accurate control, a linkage can connect the
float to the potentiometer of an electronic computing device.
• Small diameter floats are used to measure higher density fluids.
• Larger-floats are used for liquid-liquid interface detection or for
reading lower density materials.

Instructor: Dr. Ammar Hasan

 Displacement Method
• The displacement level sensor is somewhat
different from a float sensor in that its probe is
weighted so it actually sinks in the measured fluid.
• However, the probe has buoyancy, meaning it
tends to float as the liquid rises up over it.
• Displacement level sensors operate on the
Archimedes Principle: a body immersed in a liquid
loses weight equal to the weight of the volume of
liquid it displaces.

Instructor: Dr. Ammar Hasan

Displacement Method

Instructor: Dr. Ammar Hasan

 Displacement Method
• The probe is suspended from a scale.
• When the level is below the displacer, the scale
shows the full weight of the displacer.
• When the level rises, there is a loss of weight of
the displacer.
• The weight change causes the displacer to move,
thereby yielding a linear and proportional signal.
• The change in displacer movement is small in
comparison to the change in liquid level.

Instructor: Dr. Ammar Hasan

 Displacement Method
• This device is limited to applications in open
tanks and is capable of transmitting electronic
signals for remote readings.
• Displacement sensors are especially
appropriate for measuring liquid-liquid
interfaces, that is, two liquids that do not mix
together, such as oil and water, different
chemicals in the same container, and slurries.

Instructor: Dr. Ammar Hasan

 Displacement Method
• Displacement systems are very accurate,
relatively simple, easily understood, and
can be used at high temperatures and in
pressurized vessels.
• Their disadvantages are that they
require the density of the liquid to be
constant to make accurate readings.

Instructor: Dr. Ammar Hasan

 Purge Method
• Purge is one of the oldest methods of level
determination.
• This type of system can measure such materials as
water, oil, corrosive liquids, molten metal, pulp, and
fine powders.
• It consists of a dip tube vertically immersed in the fluid
of a tank with an open end placed close to the bottom.
• A tee connection joins the supply line, the bubbler
pipe, and a pressure gauge.

Instructor: Dr. Ammar Hasan

Purge Method

Instructor: Dr. Ammar Hasan

Purge Method

Instructor: Dr. Ammar Hasan

 Purge Method
• To make a level measurement, the air
supply regulator must be adjusted so that
its pressure is at least 10 psi higher than
the highest hydrostatic pressure to be
measured.

Instructor: Dr. Ammar Hasan

 Purge Method
• As the liquid rises, there is more static head
pressure above the outlet of the tube.
• Therefore, backpressure at the bottom of
the bubbler tube increases.
• The increase in backpressure allows less air
flow through the bubbler tube and an
increase in pressure at the gauge, causing a
larger deflection.

Instructor: Dr. Ammar Hasan

 Purge Method
• Purge instruments are popular level
detectors in the paper industry because
they are self-cleaning and do not allow the
pulp, measured in a vat, to clog the orifice.

Instructor: Dr. Ammar Hasan

 Hydrostatic Pressure Method
• The hydrostatic head level detector is a
pressure detector that determines level in
an open container using the indirect, or
inferred, measurement technique.
• It operates on the principle that any
column of material exerts a force at the
bottom of the column due to its own
weight.
Instructor: Dr. Ammar Hasan
Hydrostatic Pressure Method

Instructor: Dr. Ammar Hasan

 Hydrostatic Pressure Method
• This force is called hydrostatic
pressure, or head pressure.
• Hydrostatic pressure is
determined by the following
formula:
Pressure = Height * Density
Instructor: Dr. Ammar Hasan
 Hydrostatic Pressure Method
• As the height ofthe material changes, there
is a proportional change in pressure.
• By placing a pressure gauge at the bottom
of the vessel, the level of material can be
determined using the following formula:
Height = Pressure .
Density

Instructor: Dr. Ammar Hasan

Hydrostatic Pressure Method

Instructor: Dr. Ammar Hasan

 Differential Pressure Method
• Hydrostatic pressure measurements
determine the liquid level in an open
container where the top is exposed to the
atmosphere.
• When a liquid level inside a pressurized
tank is determined using this method, the
gauge will measure not only the fluid, but
the pressure above the liquid as well.

Instructor: Dr. Ammar Hasan

 Differential Pressure Method
• The vessel pressure in the vapor space
above the liquid can be compensated for
by using a differential pressure transducer.

Pressure measurement = Hydrostatic Head + Vessel Pressure

Instructor: Dr. Ammar Hasan

 Weight Method
• The level of a material in an unpressurized container
can be determined by obtaining an inferred
measurement value of weight.
• This method is both noninvasive and very accurate.
• To measure the weight, devices such as mechanical
springs are placed under the container and onto a
supporting surface.
• As the springs compress, a linkage device connected to
a pointer deflects to a calibrated position that indicates
the weight.

Instructor: Dr. Ammar Hasan

 Weight Method
• Weight is also detected by electronic
sensors.
• The signals from these devices can easily
be connected electronically to proportional
weight, volume, and level readings for
display.
• Weight level measurements can be used
for solids and liquids.
Instructor: Dr. Ammar Hasan
 Weight Method
• Contents weight = measured weight – container weight

• Volume = contents weight / density

• Level = volume / surface area

Instructor: Dr. Ammar Hasan

 Electronic level sensors
• Electronic level sensors are devices that
use a change in level to change an
electrical property.
• There are three main types of electronic
level sensors:
–conductive probes
–capacitive probes
–ultrasonic sensors

Instructor: Dr. Ammar Hasan

Electronic level sensors: Conductive probes

• Conductive probe sensors are used in single or

multiple point measurement systems to detect
the presence of a conductive liquid.
• It also contains a controller.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Conductive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Conductive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Conductive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Conductive probes

• A low AC voltage is applied to the electrodes

as they are immersed in the liquid.
• The conductive liquid completes the
electrical circuit of the control, which
activates a semiconductor switch.
• if the level drops below the shortest
electrode, the circuit opens, and the current
flow stops.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Conductive probes

• The advantage of conductive probes is their

low cost and simple design.
• The disadvantage is that they are limited to
point measurements and can only be used with
conductive liquids.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes
• They are used for-continuous level measurement.
• The principle of operation is based on the theory of
capacitance.
• According to this theory, the value of a capacitor can change
by varying the size of one or more plates, or by changing the
dielectric.
• The probe and the metal wall of the tank form the two plates
of a capacitor, and the contents in the tank is the dielectric.
• When a non metallic tank is used, a second electrode—
referred to as a counter electrode—is used.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

• When the tank is empty, the dielectric is

the air.
• As the tank fills, the nonconductive
liquid and the air become the dielectric.
• As the level varies, the dielectric
constant changes and causes the
capacitance to change.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

• If the medium is conductive, the probes must

be coated with an insulating material, usually
Teflon, that becomes the dielectric.
• The wall is not coated, which causes the liquid
to become the other plate of the capacitor.
• As the level varies, the size of the capacitor
plate becomes larger or smaller and causes the
capacitance to change.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

• If the walls of the vessel are not parallel, the

side of the container cannot be used as one of
the plates.
• In this situation, a second probe must be used.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

Instructor: Dr. Ammar Hasan

Electronic level sensors: Capacitive probes

• Capacitive level probes are simple to

use and are relatively inexpensive.
• A limitation is that their accuracy is
dependent on the liquid.
• The presence of solids in the liquid, or
exposure to a large temperature
change, will cause the dielectric to vary.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic
• Ultrasonic sound waves (above the frequency
heard by humans) are developed by an oscillator.
• They are emitted by a transmitter toward the top
surface of the medium and are reflected back to
the ultrasonic signal receiver.
• The time it takes the waves to travel from the
transmitter to the target surface and back to the
receiver is measured.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic
• The time lapse between transmission
and detection is proportional to distance.
• This data is calculated electronically and
converted into a liquid-level
measurement.
• The auto-focus mechanism of a camera
works on the same principle.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic
• The ultrasonic sending unit consists of a piezoelectric
crystal sandwiched between two metal plates.
• An AC voltage with a frequency of 20 K to 100 kHz is
applied to the plates.
• Because of its atomic structure, the side of the crystal
connected to one polarity expands, and the other side
contracts when the opposite polarity is applied.
• The high-frequency expansion and contraction of the
crystal causes the surrounding air to emit ultrasonic
waves.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic
• By replacing the AC source with a voltage amplifier, a
second assembly, made of the same components as
the transmitter, can operate as an ultrasonic receiving
unit.
• The incoming ultrasonic waves cause the diaphragm to
vibrate. The result is that the piezoelectric crystal
expands and contracts, which creates a high-frequency
AC voltage between the plates.
• The output current produced by the ultrasonic. sensor
is proportional to the distance it measures.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic
• Ultrasonic sensors should not be used in applications
where a mist is present in the vapor space above the
liquid.
• The reason is that sound travels through a mist at a
different speed than it does through dry air.
• Inaccurate readings are also made if a layer of foam on
the surface is detected.
• The advantages of ultrasonic sensors are that they are
noninvasive, they have a long sensing range, and they
have a long lifespan because there are no moving parts.

Instructor: Dr. Ammar Hasan

Electronic level sensors: Ultrasonic

Instructor: Dr. Ammar Hasan

 SELECTING A LEVEL SENSOR
• When selecting the most appropriate level
measuring device for a particular application, the
following considerations should be made:

1. What are the physical properties of the medium?

–Is it a solid or a liquid?
–Will foam, vapors, or a mist be present?
–Does the material contain chunks or voids?
–Is the material prone to density changes?

Instructor: Dr. Ammar Hasan

 SELECTING A LEVEL SENSOR
2. What are the chemical and thermal properties?
–Corrosive
–Flammable
–Caustic
–Sterile

• These factors are considered along with

reliability, cost, and safety.

Instructor: Dr. Ammar Hasan