260, —E——_—— pe Ee Level Measuremen, 85 Co, "trol Instrumentation ~ | ASUREMENT vents, chemicals, urate measurement LEVEL ME. which use many s0 steam and Ih Other; Oder 4 er ligui ™ Manufacturing indus! Fliquig i i in power plants which use vast ‘amount of water, the acc is ve ae FY essential ALI i QUID LeveL MEASUREMENT S e enerally, there are wo methods used in industries for measuring liguld level. The s! Direct Method ~ Indirect M fethod mean of obtaining the Direct method use the varying level of the liquid as a Fh the liquid level to meas; ee Sa and the indirect method use a variable that changes witl te the measuring mechanism. 1. DIRECT METHOD ~ _This is the simplest method of measuring liquid level. In this method, the level of the liquid is measured directly by means of the following level indicators i. Sight Glass / Gauge Glass ii, _ Float Type / Float - Operated Level Gauges Torque Tube Displacer / Float Displacement Type Level Gauges i. SIGHT GLASS / GAUGE GLASS for the continuous indication of liquid level within a tank or vessel. Sight glass is used ich is connected {A sight glass instrument consists of a graduated tube of toughened glass whi to the interior of the tank at the bottom in which the water level is required Sight-glass Tube High-pressure tank ee «; High-pressure piping [Protective housing \ ‘Scale Ty Sightolass ~ y) Uiuid a simple sight glass for an open tank in which the liquid level in the el of liquid in the tank. As the level of liquid in the tank rises and lass also rises and falls accordingly, Thus, by mess1 ©1602 Process Control Insumenvie” , sight glass, it is not necessary in ease 1 eat Jin the tank 6 MEANT Ais0 can be usec si vel of liquid 1 Seok Tue eso Fatieien inte tank. Any other desired ligt andere jiquid under pres When evel with the ise the pressure 1 measure a liquid Ie vrromn; otherwise the p the sight Beth connected i the tap un well a2 ct C2 bee Mh he ale differen sc Be Between the tank andthe sight glass WOU! CTT. provided for isolating the Bibs enclosed in a protective housing and two Y*™ Bauuge fom the tank in case of breakage of sight glass reading easurement 15 made by Jags in high pressure have a small inside which m This type of sight 8 ye must Fig 1.4.2 shows a high pressure sight glass 1" the position of the liquid level on the calibrated scale ‘Tanks is used with appropriate safety precautions, The glass tubs diameter and a thick wall. ore than 900 mm length. In The standard practice is not to go in for a glass tube of m ‘ease the height of the tank is more than 900 mm, two or more sight glass level gauges are provided at different levels. This type of gauge is made to withst ‘steam pressure at 252°C (500°F) or 1000 psi liquid pressure Advantages '* Direct reading is possible _ © Special designs are available for use up to 316°C and 10000 psi ® Glassless designs are available in numerous materials for corrosion resistance. Disadvantages © Itis read only where the tank is located, which is not always convenient. * Since glasses are located on the outside of the tanks, the liquid in sight glass may ‘freeze in cold weather even though the liquid inside the tank does not, and thus, it “may cause error in the reading, ‘Heavy viscous liquids or liquid containing materials which fall out of solution and ‘the tube cannot be measured satisfactorily by a sight glass. yping gauges are needed for long level spans ¢y and readability depend on the cleanliness of glass and fluid, and pressure of 350 psi of OAT OPERATED LEVEL MEASUREMENT GAUGES Jevel measurement by floats, the primary device is afloat which b meus : changing level of the liquid, the movement of the float i Tae g Gg fe Se some Suitable mechanism. The various types of Bs ‘ + eylinder shaped ceramic floats and disc-shaped. floats _ LiL) for Continuous direct 11S Wound around a Pulley : niet ead on a scale whichstr Level Measure; Sumentation — 1 aes ‘ ; Vel, the f the tank. The advantage of this method is that it is possible to read ) leVel of tiquid in tanks which are below the ground level WwolcaroR py gre not Fig it Simple modification of this arrangement can be as shown in fig 1.ii.2. It does not Permit a wide range of level measurement, but it does have mechanical advantages that make it excellent for control and transmitter applications. In another arrangement shown on fig 1.ii.3, the float is used to move a magnet. As the magnet moves, it attracts a follower magnet connected by a cable to the indicator, thus providing a reading of liquid level measurement. A float guide tube is inserted downward into the vessel and is mounted with flange and gasket to the top of the tank, the lower end of the tube is closed and the inside of the tube is thus completely sealed off from the tank. Concentricity of float to tube is maintained by guide surfaces to ensure vertical motion and proper magnetic relationship between inner and outer magnets, The follower magnet inside the tube seeks a position corresponding to that of the float, thus moving the cable. The cable winds on a drum located at the top end of the float guide tube. The cable is kept taut by a spiral wound spring. corrosion- resistant materials to make theseion= I psirumental El 602 Process Control 1" Disadvantages © Normally limited to mode te pressures © They are tailored to tank geometty il, FLOAT DISPLACEMENT TYPE Level Et -socording 10 WilCH Ry ciple : nodes prineiDle °°" displaced liquid, and the i These instruments work on the Archin ‘gh ei in a liquid is buoyed up by a force equal tothe We eh of pe evel of uel eee ‘ i ue iy proportion seals parent change in weight of the body Is direaly OPeMEEME gully Hollow cylindrical in ments working on alled a displacet 8” ots filled into it. Sever? fering in the method emplo’ al types of instran it is placed. The body immersed is yed to weigh @ ae swith small amounts of lead sh is principle are available, each dif convert its weight into liquid-level measurement + this purpose. The displacer is used for read out/control. The nnected with the tabular be which restricts its he float and Torque tube is the most commonly used device fo attached to a torque tube assembly whose rotary motion 18 torque tube consists of @ metal tube with a shaft inside of which is co! floats shown in fig 1.iii.1. The displacet is suspended from the torque tu! movem ents to prevent contact with any part of the vessel in which it is placed. POINTER ce DISPL ACER (TUBULAR FLOAT) Fig Litt. "It is designed Me en ee the weight of the float with liquid in its o ‘ get oa direction, When liquid level rises ae val a Hee ined in quid alse eet eal 0 the ae - pe la desired, the size of the float ae of a y ‘ ind its wei Fi splacer, a to a jum level read the torque ae s weigh gee eee wie the displacer to the ie ons (eae iinimize friction | i is desi Fete: anc ented lnife edge besrng Baetash iy revented ays pulls in the same direction on th lash is prevented 1e torque tube. AsLevel Measurement d of the tube el ened to the inner en\ ; ee ide of the vessel. The i ‘Thus the interior of Nee the small rotator shaft wh the to oie tation of the inner end accurately tot iY TIE tube ig ata “aSKeted and clamped rigidly to the vessel wall. PSHHI Pressure and no packing Is required for it tis in \dent on the density of rat! © note that the apparent change in weight of float is a 2 "quid should noe Tiquid and the weight of the float, Therefore, it is essential 4 se Slurri o. Shange, Obviously this instrument should not be used in tank ¢ ig UtTies, he; " » Neay vat. NY viscous liquids, or liquids which form erystals that will deposit on the floa Seana "Se, this instrument is rugged and simple in construction and reliablegm POSSIbIe to pees eeSetion of suitable material for float, float cage, and torque tube, it's NSe this instrument over a wide range of pressure and for many liquids. Advantages High accuracy Reliable in clean liquids Can be mounted intemally or extemally (extemal mounted unit can be disconnected for maintenance) ‘* Adaptable to liquid interface measurement Disadvantages * Limited range, devices exceeding 1.2m in length are bulky and difficult to balance _* Cost increases appreciably for externally mounted units as pressure ratings increase _ © External units may require stilling chambers 2. INDIRECT METHODS Following are the indirect methods of liquid level measurement generally used in industries. Hydrostatic pressure type Electrical methods ‘Ultrasonic level sensor J Fe HYDROSTATIC PRESSURE TYPE ¢ Tiguid in tank at rest exert a force on the walls of the tank, mas hydrostatic pressure, and is proportional to the dep static pressure methods used for liquid level measu This force in a liquid at th (height) of the liquid in itement are listed below, XxXLevel Measureme f sation ~ E1602 Process Control Insitute E oD iy pressure GAUGE METH! oe jest method used f ank is Hiquid in an open tank! This is the simp! Hydrostatic pressure of any p- pressure p=hp (often called head) h- Height of liquid p- Density of the liquid Hydrostatic pressure in a closed tank is given by p=hp+external pressure ontiquid yottom of the tank containing @ liquid of known o the height or level of liquid in the tank. ¢ for liquid level instrument. ressure gauge connected at the ge is fitted is known as the ‘measure of the height of the cted Therefore pressure measured at the b density and specific gravity is directly proportional t This principle is utilized in pressure gauge instrument The pressure gauge level indicator consists of @ P 1 at which the pressure ga the gauge is a liquid level. A liquid seal is conne 1g a corrosive or highly lowest level of the tank. The level reference level and the static pressure measured by liquid column above the reference level and hence the ‘with the piping on the tank including a shut off valve while measurin Pa fluid with which the measuring system is filled. ‘viscous liquid. This liquid seal consist of This filling liquid transmits the pressure head of the measured liquid. The free surface of the th the measured liquid. These two liquids must not filling liquid is kept in indirect contact wit ‘mix or react chemically. Fig 2.1.0.1 shows an open tank pressure indicator for measuring liquid level. / Maximum Level Pressure gauge mounted ‘on same level as the minimum tank level chosen carefully, sinc . will affect the cel any sicineein)Level Measurements Process OO strimansation - 1 isadvantage a k. This dai evel in the tan ss omer nt nstument must be mounted at same Jevel as the minimum es control room. In eee Meonvenient, as a Pe nny pe located at certain height above ne of the 1 ne coed HS Case, the level indicat Jd show an error equivalent to the hete control room, icator would s b. AIR PURGE SYSTEM pressure types of ydrostatic Tiquid as shown in fig 2-4-1 Air purge (bubbler tube) is one of the most popular hy liquic ‘ iquid measuring system which is suitable for aY e f pressure Indicator #)| To Recorder Air Flow Control (@r 0 Rec oo Regutator| Valve A: ae \ subbier Air Supply 5 Liquid ~ Fig. 2.i.b.1 ‘An air purge system consists of a hollow tube inserted in the liquid of the tank. Two ‘connections are made with the bubbler tube, one to the regulated air supply and the other fo & pressure gauge, calibrated in terms of liquid level. A bubbler is connected in the air supply Tine which serves simply 2s a visual check to the flow of the supply air. A level recorder may bbe connected with the pressure gauge to Keep the continuous record of liquid level as shown in fig 2.i.b.1. ‘When there is no liquid in the tank or the liquid in the tank is below the bottom end of the bubbler tube and the pressure gauge indicates zero. In other words, if there is no back sure because the air escapes to the atmosphere, As the liquid level in the tank increases, flow is restricted by the depth of liquid anc ir pressure acting against liquid head back pressure to the pressure gauge. Thi pressure causes the pointer to move calibrated in terms of liquid level. full range of head pressure can be Jevel by keeping the air pressure fed to the tube, slightly above the maximum The range of the device is determined by the length of the tube. Because ail ubbling from the bottom of ube, the tank liquid does not Ee ence the tube is said to be purging. The common purging fluid i euler, the, oF is absorbesutalEMt eases (C2/N) are g fluid is air, but, if chosen depending onE1602 Process Control Instrumentation — 1 Aay, =. pane tank level and ean be Kept as far 1 belo’ ; » help of PIPING: © Pressure gauge can be placed above © 7m) from the tank Ww! away as 500 ft (12 © Well - suited fo 1 BOX METHOD & DIAPHRAC s shown in fig 2.i.c.1 and consist of two cnt made of rubber or oil resistant 1 to be measured and an air filled ‘the diaphragm produced by the vel meter | xd a diaphragm cle™ sed in the liquid tne deflection 0} The diaphragm box liquid le flanges in between which is conta synthetic composition. The box is immer capillary extends from it to the instrument. T s Yi ips causes a compression of the air in the connection capillary. The capillary tubing, ‘on the other end is connected to a secondary instrument which through the air from the capillary tube indicates the liquid head exerted by the liquid on the diaphragm. The capillary ‘connecting tube, which enters the top flange, is extended into the diaphragm box and is bent to one side, to prevent its being sealed by the diaphragm ‘An alternative method known as air trap method (fig 2i.c.2) is used when a diaphragm box cannot be used. Here a box without diaphragm is inserted into the tank. In ‘effect the box comprises an iron pipe which is inserted into the tank. The upper end of the pipe is sealed and connected to the secondary instrument through capillary tubing and the bottom end is exposed to the liquid in the tank. When the liquid level rises, the air in the capillary tube is compressed and the instrument responds accordingly. Here it is important that the liquid should be free from the solids, which otherwise might plug the capillary. t ‘ToPRESSURE SENSING INSTRUMENTLed Mea 22 Pr Bess C, ‘ontrol Instrumentation — ! Advantage E m om, the box may be ciate ere it is necessary to prevent contact b/w liquid and diag wean age 1a well outside the tank and the well is communicated 10 the Piping. . ng. The impulse piping and the well are filled with an inert liquid. Disadvantage i : et up the line The main disadvantage is that the head developed is not ne a meet UP imited. losses 4S Well as for a satisfactory indication. Hence ranges are quite qd. FORCE BALANCE TYPE 4.1, When the hydrostatic Pneumatic foree-balance type Pressure acts on the bottom side of the diaphragm, the valve port closes sufficiently to develop a back pressure on the upper side of diaphragm wyigh would be indicated PY the gauge. For hydrostatic pressure dve to fixed level in the sac the diaphragm will come in equilibrium when pressures on both sides are equal, For any change, the ‘valve port will either ef ro and « new balance will be obtained. gauge is shown in fig 24 ‘The force balance method is well adopted for liquid level control. Level guage Restriction << Air Supply Pressure regulator & seal Fig 2.i-d.1 RICAL METHODS OF LEVEL MEASUREMENT al methods consist in bu cony. liquid levels int i otri i lo electri i ctrical/electronic means, Commonly used electrical nie aa signals and s areLevel Measuremony E1602 Process Control strumentation = “ type LEVEL GAUGE od, a scheme of which is ype. A mercury column is ed, decrease with inoreasing Ris re eo inserted the column as fo that 1/R 8 8 linear function of the a. RESISTANCE TYPE tive meth The simplest form of the electrical t « is also known 3 shown in fig 2iia.1. 7 operated by the liquid co level, A no. of resistances shown in fig. resistances evel, But the level variation gives ® ie to liquid - column I XLevel Fig 2.ii-a.1 Application This method is used .: Be contact fe ie ell of the liquid whose level is to bs a BE cont na cae mounted in the tank. For a fairly larg nee cre nbs: of, Be directly mouaied glee conductive Be 8 sed in oe eas Higuicl gin nag with ae ineral processing Units to disignen les, e layers i ipply of water, se bed in these eal sewage, or sea water has high condi¥ Level Measuremeng 02 Proc, AS Control Instrumentation ~ 1 b. y NDUCTiVE LeveL GAUGE Pee eica Indi fc stals which are good electrical Uctive level gauging is suitable for liquid me Mt east feebly magnetic. It condy Ictors, The o 5 gnet he container of the liquid must be non-magne two coils wound on it May be a fg 2ii 1, wil and @ ide tbe to the actual container as shown in fig 2b.) WILT og, by sliding. el rence scheme, The position of the coils may be alter an i changes a Which jg pdtid moves up, inductance of one of the coils changes a *Scdirectly related to the required height is measured, .d unbalance in bridge Fig2ibb.t © CAPACITIVE TYPE LEVEL GAUGE, Capacitance methods are the most extensive ones for liquid level measurement in Tecent years. They are the most suitable for non conducting liquids like oils, gasoline or liquid gases, for corrosive acids and high pressure process liquids. The liquid acts as the dielectric material of the capacitor. The electrodes are arranged in the form of a pair of concentric cylinders in the tank. With the level rising, the capacitance of the capacitor b/w the electrode pair increases as the gas phase has less dielectric constant than the liquid. The basic scheme of the system is shown in fig 2ijic.1. At the bottom, a hole is provided for the liquid to enter into the electrode assembly. If the dielectric constant of the vapour phase ¢,, is very small compared to that of the liquid phase s, and the dimensions are as shown, the capacitance is given by the relation c= eels zin@fr,)Level Measure, nod E1602 Process Control Insurers sueand # vapour Phase oF length Taki it the dielectric constant of the vapo ng into account the die Be hs value of the capa icitance 1 = T=, the approximate outs + tends 1. sly torte py Sele tte = Fins +e) Bain p,) oma jatay capacitance effects. This means 0 fxm 8 Saale ote 1 in a tank of © ental vlinder is generally The outer that for measurement of the liquid level of ein etrde oi Se form electrode is unnecessary. The tank serves this purpose ‘ot an ideal dielectric but has @ concentric pair. It is further assumed that the liquid i ‘5 aA vo inserted Oxon gaat The central electrode ™ Teaka, stance of a large value. The central ¢ i cylinder and a probe Bs. gic fee a worst ease, it is generally enclosed in @ ae YI Pl is formed, ve ili, ULTRASONIC LEVEL S neon. Door detectors use the prin ection of an acous iors use the principle of reflection of ment is shown in figures 2.ii, Ultrasonic level liquid to vapour plane or vice versa. The schematic arranger and 2.iii.2. ae. Ourpae Fig 2.iii.1 Fig 2. Ultrasonic wave sent by the transmitter T is reflected at the interface and received back by the receiver crystal R. As level changes fiom 1 to Ip, transit time also changes. Measurement can be made on the basis of the time required by the echo to reach by the receiver or on the basis of change of phase of the wave during this time, For phase measurement, a phase sensitive detector is used. The method of time measurement is quite common and such a meter is known as the Fathometer and has an accuracy of about 0.1% of full scale. The liquid phase method is used in storage tank of oil and chemicals and for ar-craft or marine equipment tanks, Th : in mines, oil-wells, shafs, et. ( . The vapour phase method is used for employed for avoiding spurigy, Ea itude by a factor of 10° ystal oscillations. The received «i i aplide {7° 10"t0 10° and hence must be amplified signal reduces in i re Se a——————s —_,,. XN 885 C, PMOL Instrumentation 1 Level Measuremen, B. OLD LeveL, perECTORS ieee the increasing applications of continuous processing, not only the fluid handling the impa ge tt 180 to those inisties which handle large quantities of solid materials in buy, Ce Of measuring and controlling methods for solid level is growing. Solid Level detectors fll into two principal categories: BPSSOMEUGg Which provides a continuity of meesurement frm the low to high end gf their scale, 1. Fixed — point, which provides measurement only at one or several specific levels, ie ‘Various types of solid level detectors in common use are 1. Gamma Ray Absorption Method 2. Weighing Device _ 3. Electrical Capacitance 4. Diaphragm Method, 5. Rotating Paddle 6. Balanced Paddle ___ 1. GAMMA RAY ABSORPTION METHOD The working of this device (fig B.1.1) is based on the principle that the amount of y = radiation from a fixed source varies with thickness of solid between source and detector. This device is most ideally used in solid bins and can operate under condition of high pressure and temperature. It could be designed to give either continuous indication or annunciation at some fixed point values, The advantage is that it does not require any jing or connection through vessel wall. This instrument can also be used to determine density of fluidized bed with known height of bed.Level Measure, en E1602 Process Control nero" 2, WEIGHING ppvick ever f sible and gives result most gst possible device WHEN?” ale levers or other types of ¢ simple : ng the solid is support’ mn SC F hydraulic, or electric. This bry expensive particularly This is probably contain accurately, The bin force balancing 99 device can operate for large bins where SUPP" CAL CAPACITANCE | continuously based on principle of talled in the bin. The ently ins undings changes in direct e is detected by suitable indication or alarms at high and low set ding and control in both bins ‘ethod are affected by the as etc, caus 3. ELECTR ures the solid leve vertical rod 18 fh the material i ge of capacitanc In a device which meas an insulated ¥ electrical capacitance, electrical capacitance of this rod wit proportion to the level of material, The chan} electrical device which cou! points. This device is suitable and process vessels. It may be noted fore, to some extent by tempe perma 1 its surrol 1d either give continuous for continuous indication, recor that level readings in this m ature also. density of material and there! 10 BECTRICAL INSTRUMENT vEsset DIAPIRAGH: ELECTRODE SID LEVEL TURN Bie FigB3.1 4, DIAPHRAGM METHOD This device (fi it i ig B4.1) is b ety required 1 dete evel stern neine for levels, If intemmediane (oe ne used. late levels are r detect ei Thus ae level at one particular point will be it also to be detected, alee to detect both units may be602 5 Process Control Instrumentation ~ I Level Measuremen S. ROTATING PADDLE tee rotation, a a paddle i attached t0 a shaft driven by synchronous motor, When ee area mete, moter por une a horizon inetd auianic switches which may be used to operate or shut off conveyor, This le only for top — level detection, TO INDICATOR OR ALARM DRIVE MECHANISM AND SWITCHES PADDLE GUARD PADDLE WHEEL FigB.5.1 : SOLID BALANCED PADDLE device is designed to measure level of hot catalyst at temperatures upto 550°C id response. The device is capable of giving indication at fixed point only. Js device a balanced paddle extends into the vessel through a diaphragm seal on horizontal arm. It is balanced by pneumatic balance transmitter. When the solid level of paddle and contact it, the balance is disturbed and the arm in ce transmitter is unbalanced, which is indicated by an indicator attached to——————————_ Level Measure 21 602 Process Coniat Instrument | C. LEVEL swiTCHES the working of flost switch ‘i one. The most commonly used level switch is a float Pe Oe con js used for alarm or on 4s that they ride or flost on the changing liquid level and the: ~ off functions. Float switches utilize 2 float that follows liquid ievels and st Ome POSE WARS FANge Of travel, it actuates 2 switch. Most of the float switches are cesigned fe relatively Short travel. tn tans, both high 2nd low levels are of COST The low level Boat saaien Usually remains submerged while the high level When level Feaches past the central line of float, then the lo hollow and made of brass or stainless steel. MERCURY SWiTcH FigC1 Fig C1 shows the working of « mercury switch attached aflame Sool re tone ‘sleeve pull magnet iowards itself, which tits the mercury switch rhe ew cp amhantialiaaideyrss sre expected, dry type micto