TSP-POGC-NIOC 1 Ø

COURSE OIL & GAS TECHNOLOGY CODE

SUBJECT LIQUID LEVEL MEASUREMENT P/TM/TRG/I.LM/001

Objectives: Upon completion of this unit, the trainees should be able to:
• Explain the principles of level measurement
• Describe most common liquid level measuring methods and instruments

Contents:
1. Level
1.1. Methods of level measurement

2. Visual level sensors

2.1. Sight glass
2.2. Float operated gauge

3. Displacement devices
3.1. The torque tube
3.2. Possible faults

4. Hydrostatic-pressure level measuring systems

4.1. Open tanks
4.2. Closed tanks
4.3. Closed tanks with a condensable vapor
4.4. Air bubble tube or purge system

Prepared by Danial Edited by A. R. Approved by C. Auge

Ghasempour Shadman
Date 05/08/00 Date 11/08/02 Date
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SUBJECT LIQUID LEVEL MEASUREMENT
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LEVEL MEASUREMENT
1. LEVEL
The surface of a liquid is the interface between the liquid and some other medium, usually
gas or vapor or sometimes, another liquid.

The engine oil and gas tank gauges of automobiles are shiny examples of liquid level
measurement devices. The measurement and control of liquid level is essential in a process
plant, where a wide variety of liquids are handled in both batch and continuous processes.
The accurate measurement of level is important for environmental protection (for example,
tank over flow to drains), plant safety, product quality, and inventory control.

Almost all liquid level devices measure according to the position or height of the liquid above
a zero or lowest point, or the hydrostatic (or head) pressure.

1.1. Methods of Level Measurement

The level measurement may be expressed either in units of length or volume, or in
percentage of total volume. There are two methods to measure a liquid level:
a. Direct method
b. Indirect or inferential method
The direct method measures the liquid height above the zero point by any of the following
techniques:
1. Direct visual observation of the height by means of a sight glass, level gauge (or
gauge glass), or dip stick.
2. A float, which is mechanically linked or electrically connected to an indicator or alarm
device.
3. An electrical probe in the liquid.
4. Reflection of sonic waves from the liquid surface or from the bottom.

The indirect or inferential method of measurement uses the changing position of the liquid
surface to determine the level.
The techniques involve:
1. The buoyancy force on a float or displacer, which is partially or completely immersed
in liquid.
2. Hydrostatic pressure of the liquid.
3. The amount of radiation passing through the liquid.
4. Electric systems by which liquid level may be inferred.
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SUBJECT LIQUID LEVEL MEASUREMENT
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2. VISUAL LEVEL SENSORS

2.1. Sight Glass
One principle of hydraulics is that, liquids that are contained in interconnected spaces find a
common level, if there is enough liquid. This principle applies to the sight (or gauge) glass.

A sight glass is a device that is connected to a tank in such a way that the liquid level in the
tank can be seen through the glass. They are very common in the process industry. There
are two types of sight glass gauges: tubular and flat glass. Sight glasses are usually installed
with shutoff valves and a drain valve, mainly for maintenance purposes, repair and
replacement. Graduations engraved on the glass or housing, help to compare the level with
a certain value (for example between 0% and 100%).

Fig. 2.1 - Sight Glass and Isolating Valves

For an open vessel, a simple open-end tubular level gauge is used. For pressure and
vacuum and vessels, the upper end of the tube is connected to the vessel to maintain
equilibrium. On open tanks, glass tubes up to 2 meters long are quite common. On high-
pressure boilers the sight glass may be limited to about 200mm in length. In every
installation, suitable guarding of the glass tube is necessary.

Flat gauges are used in industry for a wide range of pressure and temperature applications.
There are two basic designs, reflex and transparent. The reflex-type design is chosen for
non-viscous, colorless liquid. The transparent gauge is used for colored viscous liquid. In
reflex design, that part of gauge glass above the liquid surface will show bright and that part
at which liquid is present will show dark. This is due to difference between refraction indexes
of air (or any other substance above the liquid surface) and the liquid resulting in total
reflection in the upper part. If a sight glass is to be calibrated, readings shall be compared
with those obtained by a dipstick.
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SUBJECT LIQUID LEVEL MEASUREMENT
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2.2. Float Operated Gauge

Another method of direct level measurement is the “float-cable-pulley-weight” arrangement.
It operates by having a cable attached to a float passing several pulleys.
The movement of the float raises or lowers a counter weight (in the simplest form) on a scale
attached to the side of the tank. This is usually installed on storage tanks for inventory
purposes.

Float operated gauges have the same limitations. Because the float follows the liquid
surface, the liquid surface should be kept fairly smooth. In many vessels, agitation and
surging occurs and this does give problems to float operated gauges. To help counter these
effects, floats of various shapes have been designed. Baffle plates, guide tubes and cages
are also used to help to overcome these problems.

The float movement can be transmitted electronically or more simply, through mechanisms,
to an indicating pointer, which moves on a scale.

Fig. 2.2 - Float Operated Gauge

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Many different arrangements suitable for open or sealed tanks are available. In most cases,
the objective is to provide some form of useful mechanical motion when there is a change of
level. How the motion is utilized depends on the installation requirements and type of
instrument. One common type of float-operated unit used on process vessels is a float
operated magnetic switch. A float moves a magnet up or down inside a non-magnetic tube.
On the outside of the tube is a magnetic follower (magnetically attractive material) mounted
on a pivot. As magnet inside the tube gets nearer to the follower, the follower overcomes
spring tension and is pulled towards the magnet. Hence there is mechanical motion due to a
change in the level. The motion can be used to position a mercury type electrical switch, to
move a flapper or to move a small pneumatic pilot valve, etc.

Fig. 2.3 - Float Operated Magnetic Switch

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SUBJECT LIQUID LEVEL MEASUREMENT
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3. DISPLACEMENT DEVICES
The displacement level transmitter is commonly used for continuous level measurement. It
works on the buoyancy principle of Archimedes, which states that a body immersed in a
liquid will be buoyed up by a force equal to the weight of the liquid displaced. The displacer
body has a cylindrical shape. As a result for each increment of submersion depth, an equal
increment of buoyancy force will result. This gives a linear, proportional relationship. The
displacer should not be confused with a float although sometimes it is referred to as float. A
float is a surface follower and therefore stays on the liquid surface. In industrial level
measurement units, a displacer will not float! If allowed, it will sink to the bottom of the
vessel.

Fig. 3.1 - Displacer Type Unit

When the vessel is empty, the free end of the displacer arm carries the whole weight of the
displacer. This causes a turning moment (torque) equal to the product of the weight of the
displacer and the effective length of the displacer arm. This torque is applied to the end of a
torque tube. The turning moment or torque is balanced by the torsion stress set up in the
torque tube therefore the angle through which the tube spindle is turned will be proportional
to the apparent weight of the displacer. As the liquid level in the vessel rises, the apparent
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weight of the displacer becomes less and so turning moment or torque on the torque tube
becomes less. The torsion stress on the torque tube will then rotate the spindle to a new
angle proportional to the apparent weight of the displacer. In other words, as level around
the displacer changes, the effective weight of the displacer changes. This apparent change
of weight causes mechanical motion on the tube spindle. The result is, mechanical motion
due to a change in level. That motion can be used to drive a pointer on a chart or to position
a flapper in relation to a nozzle in a pneumatic transmitter or pneumatic controller.

The up-thrust on the displacer depends on the density of the liquid in the vessel. Therefore
the displacer unit will only function accurately if it is in the liquid, which it is designed or
calibrated.

Length of the weighted displacer determines the range covered by a displacer unit. The
displacer unit cannot measure levels above or below the displacer.

3.1.The Torque Tube

This device is used in buoyancy instruments because of the small amount of rotation
involved. It allows the vertical up and down movement of the displacer to be changed to a
rotary motion without the use of glands and consequent problems associated with glands.
The rotary motion can be used to move a flapper, pointer, pen, etc.

Fig. 3.2 - Torque Tube

3.2. Possible Faults

The most possible faults of the displacement level measurement systems are:
- Build up of dirt on the displacer, restricting free movement and causing calibration
errors.
- Damaged torque tube assembly causing zero and / or range error.
- Dirt, wear and friction on indicating, recording or transmission mechanism.
- Leaks and blockage on associated pipe works.
- Damaged displacer.
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4. HYDROSTATIC-PRESSURE LEVEL MEASURING SYSTEMS

This method uses the measurement of pressure exerted by the liquid. Consider a tank filled
to a depth of one meter; there will be a pressure on the bottom because of the height of the
column of liquid being supported by each unit area. If the tank is filled to a depth of two
meter, there will be a column twice as high to be supported by each unit area, so the
pressure will have been doubled. A pressure gauge connected at the bottom of the tank will
indicate the pressure that is directly proportional to the weight of the column of water liquid
above it and, thus, proportional to the depth. Therefore, the pressure indicated by the
instrument is directly proportional to the height of the column of liquid above the gauge. The
relationship for open-vessel pressure gauge level system is:

P = SG × D × H
Where:
P = hydrostatic pressure (head), (Kg/cm2)
SG = Specific gravity of the liquid
D = Density of water (kg/cm3)
H = Height of liquid above the reference point (Cm)

Fig. 4.1 - Hydrostatic Pressure Level Sensor

The dial of the pressure gauge can be calibrated in units of length. This application is the
simplest of all hydrostatic pressure methods. An instrument commonly used for this purpose
is the differential pressure transmitter. Different techniques are used to measure the level in
open or closed vessels.

4.1. Open Tanks

On vented tanks (tanks open to atmosphere), the high-pressure side of the instrument is
connected to the lowest measuring point while the low-pressure side is kept open to
atmosphere. The instrument will then respond to changes in the static head.
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Fig. 4.2 - D.P. Cell Connected to an Open Tank

4.2. Closed Tanks

As with the open tanks, the high-pressure side of the instrument is connected to the lowest
measuring point. The low-pressure side must be connected to a point above the highest
liquid level and will contain only gas or vapor. This connection is often referred to as a “Dry
leg”. The method of connection allows the instrument to compensate for any pressure
changes that may occur above the liquid. As pressure inside the vessel is acting on both
sides of the ∆P instrument, only changes in liquid head will affect the instrument output.

Fig. 4.3 - D.P. Cell Connection To A Closed Tank

If the instrument is mounted below the vessel, when the tank is empty, there will be a high
indication due to the liquid in the pipe work connection. Fitting a zero suppression kit to the
transmitter to depress the reading to zero can offset this error.
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Fig. 4.4 - D.P. Cell Mounted Below the Vessel

4.3. Closed Tank with a Condensable Vapor

It is normal practice to connect the high-pressure side of the instrument to the lowest
measuring point. The low-pressure side must be connected to a point above the highest
liquid level. However, if the vapors in a tank are condensable, the upper connection line
must be kept full of condensate at all times. This method of connection is often referred to as
a “Wet Leg”. If this wet leg arrangement is not used, vapors could condense and cause a
change of liquid level in the leg that results in instrument reading error. Filling the
low-pressure side with liquid will consequently affect the instrument “Zero”. To overcome this
problem a zero elevation kit is fitted to the ∆P instrument and adjusted to compensate for
head pressure in the wet leg or balance line.

Fig. 4.5 - D.P. Cell With “Wet Leg” Connection

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SUBJECT LIQUID LEVEL MEASUREMENT
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4.4. Air Bubble Tube or Purge System

If an open-ended tube is submerged in the liquid, a constant air flow is injected into it, and its
pressure is regulated at a value slightly greater than maximum head of the liquid in the tank,
air pressure in the system will be equal due to the hydrostatic head of the tank liquid at any
level because any excessive pressure will bubble air out at the bottom of the tube.

This system is also called a purge system because air or some other gas (such as nitrogen),
is continuously bubbling from the bottom of pipe keeping the liquid out. It is very well suited
to measuring the level of corrosive liquids, viscous liquids, or liquids that contain entertained
solids.

Fig. 4.6 - Bubble Tube Level Sensor