LEVEL

Group 2
Objectives:

• This will help you understand the units used in level

measurements and become familiar with the most
common methods of using the various level standards.
• The formulas used in level measurements
• The difference between direct and indirect level
measuring devices
 LEVEL MEASUREMENT
• Direct Method
• Hydrostatic Pressure Type
• Electrical Type
• Microwave Level Switches
• Optical Level Detector
• Ultrasonic Level Detector
• Eddy Current Level Detector
• Servicing of Level Measuring Instruments
Level Measurement

• Level is another common process variable that is

measured in many industries. The method use will
vary widely depending on the nature of the industry,
the process and the application.

• Level Measurement- the act of establishing the height

of a liquid surface in reference to a zero point.
What is Measured?

• The measured medium can be liquid, gas, or solid and

stored in vessels(open or closed tanks), silos, bins and
hoppers.

Units of level can be expressed in:

• Feet(meters)
• Gallons(liters)
• Pounds(kilograms)
• Cubic Volume( 〖 ft 〗 ^3 or m^3)
Selection Criteria
When determining the type of level sensor that should
be used for a given application, there are a series of
questions that must be answered:
• Open tank or /Closed tank?
• Can the level sensor be inserted into the tank or
should it be completely external? Contact or non-
contact?
• Continuous measurement or point measurement?
• Direct or Indirect measurement?
• What type of materials is being measured? Liquid or
Solid? Clean or Slurry?
Methods- Direct or Indirect
(inferential)
• Hydrostatic Head
• Float
• Load Cells
• Magnetic Level Gauge
• Capacitance Transmitters
• Magnetostrictive
• Ultrasonic
• Microwave
• Laser
• Radar
• Guided Wave Radar
• Dip Stick
• Vibration
 
Direct Methods
• Direct Method sense the surface or interface of the
liquid and is not affected by changes in material density
(Specific Gravity)
• Measures the process variable directly in terms of itself.

Examples:
• Hook-Type Level Indicator
• Sight Glass
• Float Type
• Dip Sick
Hook Type Level Indicator
• When the level of liquid in an open tank is measured
directly on a scale, it is sometimes difficult to read the
level accurately because of parallel error.
Hook Type Level Indicator
Construction
• Consist of wire of corrosion resisting alloy
(such as stainless steel) about 0.063mm
diameter, bent into U-shaped with 1 arm longer
than the other
• The shorter the arm is pointed with a 60
degrees taper, while the longer 1 is attached to
a slider having a Vernier scale, which moves
over the main scale and indicates the level.
Hook Type Level Indicator
Working
• The hook is pushed below the surface of liquid whose level is
to be measured and gradually raised until the point is just about
a breakthrough the surface.
• It is then clamped and the level is read on the scale

Measuring Point
Sight Glass

Sight Glass Sight Glass for an Open Tank

High Pressure Sight Glass

Sight Glass
• Another simple direct method of measuring
liquids
• Can be used in pressurized tanks (as long as
the glass plastic tube can handle the pressure)
• Simple sight glasses may be just a plastic or
glass tube connected to the bottom of the tank
at one end and the top of the tank at the other.
• The level of liquid in the sight glass will be the
same as the level of liquid in the tank.
Sight Glass
Construction and Working
1. Consist of a graduated tube of toughened glass which is connected to the
interior of the tank at the bottom in which the water level is required.
2. When the level of liquid in the tank rises and fails the level in the sight
glass also rises and falls
3. For measured liquid level under pressure or vacuum, the sight glass must
be connected to the tank at the top of the as well as the bottom, otherwise
the pressure surface between the tank and the sight glass would cause
false reading.
4. In this case, the glass is enclosed in a protective housing and two valves
are provided for isolating the gauge from the tank in case breakage of the
sight glass.
5. The smaller valve at the bottom is provided for blowing out the gauge for
cleaning purposes.
6. The type of sight glass in high pressure tanks is used with appropriate
safety precautions.
Sight Glass

Advantages
• Direct reading is possible
• Special designs are available for use up to
316 degree Celsius and 10000
• Glassless design are available in
numerous materials for corrosion
resistance
Sight Glass
Disadvantages
• It is read only where the tank is located on the outside
of the tank the liquid in the sight liquids may freeze in
the cold weather even through the liquid inside the
tank does not, and thus, it may cause error in reading
• Heavy viscous liquids or liquid containing material
which fall out from the solution and clog the tube and
cannot be measured satisfactory by sight glass
• Overlapping gauges are needed for a long level spans
• Accuracy and readability depend on the cleanliness of
the glass and fluid
SIGHT GLASS
..\Downloads\Sight Glass Install.mp4
Float Type Level Indicator

Float-operated Lquid Level Hydraulic Transmission System for

Indicator Level Indication

Float rides the surface level to provide the measurement.

Many different styles are available.
Float Type Level Indicator
Working
1. Type of level measurement by floating ball is
very practical for continuously measurable liquid
level
2. A main component of this type is a floating ball
3. Floating ball is connected with the counter
weight (load) for measuring the level of liquid in
tank.
4. This type is not suitable for measured corrosive
liquid
Float Type Level Indicator
Advantages
• It is possible to read the liquid levels in a tank
from the ground level even if the tank is kept
below the ground level.
• Its cost low and has reliable design.
• It operates over a large temperature range.
• There is a choice of corrosion-resistant
materials to make these.
Float Type Level Indicator

Disadvantages
• They are normally limited to moderate
pressures
• They are tailored to tank geometry
WATER LEVEL FLOAT
..\Downloads\Water Level Float Switch -
Water Tank Level Indicator Float.mp4
Dip Stick

• Simple and Cheap

• Can be used with any wet materials
and not affected by density
• Can not be used with pressurized
tanks.
• Visual indication only (electronic
versions are available)

Rod Gauge similar to a dip stick found in a car, it has the weighted
line markings to indicate depth or volume.
Indirect methods (inferential)
• Indirect methods infer liquid level by
measuring some other physical parameter such
as pressure weight or temperature.
• Changing materials means a corrective factor
must be used or recalibrating the instrument.
• Measure other process variable (e.g head
pressure or weight ) in order to infer level
Hydrostatic Pressure Type
Hydrostatic Pressure Type
A. Pressure gauge Method
Construction and working
• The pressure gauge level indicator consist of a pressure gauge
connected at the lowest level of the tank
• The level at which the pressure gauge is fitted is known as the
reference level and the static pressure measured by the gauge is a
measure of the height of a liquid column and above the reference
level and hence the liquid level
• A liquid seal is connected with the piping on the tank including the
shut off valve while measuring corrosive or highly viscous liquids
• This liquid seal consist of a fluid with which the measuring system
is filled
• This filling liquids transmit the pressure head of the measure liquid
Hydrostatic Pressure Type
• The free surface of the filling liquid is kept in indirect
contact with he measure liquid.
• These 2 liquids must be not mix or react chemically

Open Tank Pressure Indicator

Hydrostatic Pressure Type
• B. Air Bellows
• Used for liquid level measurement where an indicator cannot
be conveniently located at he specified datum line.

Flexible Air Bellows A Closed box Air Bellows

Connected to the Pressure Fluid
Tank
Hydrostatic Pressure Type
B. Air Bellows
Construction and working
1. Consist of the bellow element which is connected by the tubing
with the pressure indicator
2. Air is sealed in the cavity above the bellows and inside the tubing
is the pressure indicator.
3. When the tank is empty the sealed air is uncompressed and
correspond to zero on the pressure indicator
4. As the tank is filled with liquid, the head of the liquid in the tank
flexes the bellow which compress the air above the bellows
5. The compression of sealed air is transmitted to the indicator
which is calibrated in terms of tank liquid level
6. Air bellow may be constructed for various application and ranges.
BELLOW GAUGES
..\Downloads\Bellow Gauge.mp4
Hydrostatic Pressure Type
C. Air Purge System
• Also known as the bubbler tube
• This system is one of the most popular hydrostatic pressure
type of liquid level measuring system which is suitable for an
liquid.

Air Purge System

Hydrostatic Pressure Type

Construction
• Consist of a hallow tube inserted in the liquid of the
tank.
• 2 connectors are made with the rubber tube( 1 to
regulated air supply and other to pressure gauge)
calibrated in term of liquid level
• A bubbler is connected in the air supply line which
serve simply as a visual check to the flow of the supply
air.
• A level recorder may be connected with the pressure
gauge to keep the continuous record of liquid level.
Hydrostatic Pressure Type
Working
• When there is no liquid in the tank or the liquid level in the tank
is below the bottom end of the bubbler tube the air flows out of
the bottom of the bubble tube and pressure gauge indicates zero.
• As the liquid levels in the tank increases the air flow is restricted
by the depth of liquid and the air pressure acting against a liquid
head appears as back pressure to the pressure gauge.
• This back pressure causes the pointer to move on a scale,
calibrated in terms of liquid level
• The full head of head pressure can registered as level by keeping
the air pressure fed to the tube slightly above maximum head
pressure in the tank.
Hydrostatic Pressure Type
Working(Continuation)
• The range of the device determined by the length of
the tube.
• Because air is continuously bubbling from the bottom
of the tube the tank liquid does not enter the bubbler
tube and hence the tube is said to be purged.
• The common purging fluid air but air is react with the
tank fluid or it is absorbed different gases (like carbon
or nitrogen) are chosen depending on liquid
properties.
Hydrostatic Pressure Type
Advantages
• The pressure gauge can be placed above
or below tank level and can be kept as far
away as 500 ft (12.7) from the tank with
the help of piping.
• This type of device is well suited for
measuring the level of corrosive or
abrasive liquids.
Hydrostatic Pressure Type
• When an air purge is unsuitable, because air
bubbling through liquid may interface with its
crystallization a liquid purge system is used.
• The construction and working of liquid purge
system is the same as an air purge system, the
only difference is that in place of air, water or
light material oil is used as the purge liquid.
• The nature purging liquid must be such that the
introduction of small quantities into the plant
will not affect the product on process.
Hydrostatic Pressure Type
• It should be free flowing & not vaporize at the
temperature of the pipe line,
• The purging liquid may be either soluble or
insoluble in the vessel liquid.
• The rate of flow of the purging liquid is
normally adjusted t about 1 gallon/hour.
• The supply liquid pressure is determined by the
range of liquid level to the monitored.
AIR PURGE SYSTEM
..\Downloads\Bubbler Level Measurement Working Principle.mp4
BUBBLER..\Downloads\AIR BUBBLER SYSTEM.mp4
Bubblers
• Bubblers allow the indicator to be located
anywhere. The pressure in the tube varies with
the head pressure of the height of the liquid.
Electrical Type
A. Capacitance Level Indicator
• The principle of operation of capacitance level indicator is
based upon the familiar capacitance equation of a parallel plate
capacitor given by:

C = K(A/D)
Where, C = Capacitance (Farad)
K = Dielectric constant
A = Area of plate (m2)
D = Distance between 2 plates (meter)
Electrical Type
A. Capacitance Level Indicator
• A capacitor consists of two plates separated from each
other by an insulating material called a dielectric.
• In application involving capacitance measuring
devices, one side of the process container acts as one
plate and an immersion electric is used as the other.
• The electric is either air or the material in the vessel.
• This variation produces a change in capacitance that is
proportional to level.
Electrical Type
A. Capacitance Level Indicator
When the level of liquid in tank rises, the capacitance increase.
When liquid level in the tank decreases, the capacitance also
decreases.
This increase and decrease in the capacitance is measured and is
displayed on the indicator calibrated in terms of liquid level.
Electrical Type
Advantages
• It is very useful in a small system.
• It is very sensitive.
• There are no moving parts exposed to fluid.
• It is suitable for continuous indication and/or control.
• Remote adjustment of span & zero is possible in this
of level indicator.
• It is good for use with slurries.
• Probe materials for most corrosive fluids are
available.
Electrical Type
Disadvantages
• The performance of capacitance level indicator is
severely affected by dirt & other contaminants,
because the change in temperature.
• Its sensitivity is adversely affected by changes in
temperature.
• Measured fluid must have proper dielectric qualities.
• They usually require recalibration if measured
material changes in composition or moisture content.
• Probe length & mounting must suit the tank.
CAPACITANCE LEVEL
..\Downloads\How Capacitive Liquid Lev
el Sensors Work GILLSC.com.mp4
Electrical Type
B. Radiation Level Detector
• Used where other electrical methods would not
survive.
• Also the most common reason for using a radiation
level detector is that it does not need to come in
contact with the liquid measured.
Electrical Type
Construction & Working
• It consists of gamma rays source holder on 1 side of the
tank & a gamma detector on the other side of the tank.
• The gamma rays from the source are directed towards the
detector in a thin band radiation.
• When the gamma rays penetrate the thick wall of the tank,
its energy level afterwards is greatly reduced.
• The radiation received at the gamma detector is inversely
proportional to the thickness of the tank walls & the
medium between radiation source & the detector.
• That is, the thicker the medium between source & detector,
the less radiation received by the detector & vice versa.
Electrical Type
Advantages
• There is no physical contact with the liquid.
• They are suitable for molten metals as well as liquid
for all types (corrosive, abrasive, highly viscous,
adherent)
• They are useful at very high temperatures/pressures.
• They have good accuracy and response.
• They have no moving parts.
Electrical Type
Disadvantages
• The reading is affected by density change of
liquid.
• Radiation source holders may be heavy.
• Their cost is relatively high.
RADIATION
Microwave Level Switches

Working and Construction

 
• Consists of parts; a transmitter and a receiver placed on the
outside wall of a tank or vessel, on opposite sides.
• The transmitter emits a burst of microwave energy towards the
receiver.
• This burst of energy is transmitted approximately 200 times
each second.
• If a sufficiently reflective or absorbent material interrupts the
line of sight between these two units, the energy will not reach
the receiver.
• Any loss in signal at the receiver will trigger a change of state
and operate a relay to indicate high or low condition.
Microwave Level Switches
• This example shows two
microwave switches being utilized
as blocked chute detectors.
• This range of switch will not
detect the constant falling material
under normal operating
conditions.
• This range of switch will not
detect the constant falling material
under normal operating
conditions.
• However, if the chute blocks then
the microwave signal will
decrease and the switch will detect
this change and will output an
alarm condition.
Microwave Level Switches
Features
• Non-contact principle
• High penetration and surface coating immunity
• Simple installation and set up
• Total safety for operators and site personnel
• Long ranges, non-invasive, wide temperature range.
Microwave Level Switches
Advantages
• Non-contact technology with no moving parts reduces maintenance
cost.
• Versatile technology for liquids, slurries, solids, pellets or powders.
• Long range up to 40m with adjustable sensitivity to suit most
• Simple to install and commission leading to reduced installation cost.
• Immune to coatings on tank walls improving reliability and reduces
maintenance costs.
• Non-invasive technology, with no long probes to insert, internal
product build up is reduced.
• Suitable for demanding environments such as corrosive, high dust,
high vibration and vapours
Microwave Level Switches
Applications For All Industries
• Quarry
• Water and Waste
• Process
• Chemical
• Mining
MICRO LEVEL
..\Downloads\Microwave Type Level Swit
ch KANSAI Automation Co. Ltd.mp4
Optical Level Detectors

Working & Construction

• Optical level detector make use of visible or infrared light
beams to detect the level of liquids or solids.
• A beam of light is aimed at the liquid or solids level & is
reflected back to a light-sensitive transistor, located in the same
holder as the light source
Optical Level Detectors
Working & Construction (cont.)
• By adjusting the transistor sensitivity, the unit can be
calibrated in the range of point level detection from 6.3
mm to 300 mm on reflective, opaque liquid ( e.g. milk)
or on solids services.
• When light is passing through a fixed distance in a
fluid, the intensity of light received at the detector can
be used to determine the concentration of solids in the
liquid.
• The operating temperature range is -40 degree Celsius
to 66 degree Celsius.
Optical Level Detectors
Advantages
• Use on corrosive, sticking or coating processes.
• The reflection of laser light is used in some specialized
applications such as the measurement of the thickness of
molten glass.
• The laser versions of optical level detectors provide high
precision on narrow span application.
Disadvantages
• The detector is adversely affected by changes in reflectivity of
the process.
OPTICAL
..\Downloads\Optical Liquid Level Sensor
s How they work SST Sensing.mp4
Fiber-optic Level Detectors
Working & Construction
• Use the principles of light refraction.
• Figure 2.18 illustrates the working of a fiber-optic
level detection system.
• A light beam travels through the fiber.
• When there is no liquid on the fiber, the return beam
will have the same intensity as the source beam.
• As the liquid covers the fiber, the index of refraction
increases, allowing light to escape into the liquid &
reducing the strength of the return beam.
FIBER OPTIC..\Downloads\Digital Fiber Optic
SensorAmplifier Wiring and Setting.mp4
Ultrasonic Level Detector
• No-contact direct level sensor
• Level is a function of the time it
takes an ultrasonic pulse to hit
the surface and return

Limitations include:
• Surface foam absorbs signal, agitation create reflections
• High Pressure & High Temperatures affect the signal
speed
• Vapour and condensate create false echo’s
Ultrasonic Level Detector
• Operate on the basic principle of using sound waves to
determine liquid solid/slurries level or distance.
• A sensor would normally be mounted at the top of a tank and
direct a sound wave down towards the surface of the product.
• When the sound wave hits the product it is reflected and return
the sensor.
• The greater the distance between the sensor and the product,
the longer it will take for the sound wave to travel down and
back up again.
• The sensors calculate this time interval and give a signal
proportional to the distance.
• They also compensate for the changes in the speed of sound
due to changes in temperature.
Ultrasonic Level Detector
• Ultrasonic sensors are not
suitable for use in all
applications.
• If the product gives of vapours
then this can affect the
measurement, and if there is
foam on the surface then the
sound wave will not receive a
signal that it is able to process
accurately.
• Ultrasonic level sensor emits
high frequency (20-200kHz)
acoustic waves.
Ultrasonic Level Detector
Advantages
• Non-contact type measurement technique.
• They have ability to measure level without making
physical contact with the process material.
• They have no moving parts.
• The reliability of the reading is unaffected by changes
in the composition, density, moisture content,
electrical conductivity, or dielectric constant of the
process fluid.
Ultrasonic Level Detector
Disadvantages
• Temperature compensation is essential in
ultrasonic level measurement.
• The dirt, irregular and slope surface affect the
accuracy of measurement.
• An ultrasonic transmitter is subject to many
interferences, which affect the strength of the
echo it receives. The echo can be weak due to
dispersion & absorption.
ULTRASONIC
..\Downloads\Ultrasonic Level Sensor Bea
m Width Explained.mp4
Eddy Current Level Measurement
Sensors
• Use eddy-current principle to
measure the level of molten
(liquid) metals or other
conducting liquids in a tank.
• It consists of 3 coils – 1
primary coil (C­­P) & 2
secondary coils (C­­S1­ & CS2).
• Secondary coils are located on
either side of the primary coil
Eddy Current Level Measurement
Sensors
• When a high frequency (5okHz) current is applied to the
CP a high frequency magnetic field is generated.
• In response to this, an eddy current is generated in the
molted metal liquid in the tank & voltages are induced in
the CS1 & CS2 of the sensor.
• The difference in these voltages, which can be detected
by the sensor, corresponds to changing distance between
the sensor & the surface of the liquid in the tank.
• This changing distance can be calibrated to read level of
the liquid in the tank.
Eddy Current Level Measurement
Sensors
Advantages
• Eddy-current level sensors are non-contact type
measurement technique.
• Blanco no moving parts.
• These sensors are small & light with a wide
measurement range.
• They are highly stable with little thermal driff.
• They use differential method, which minimizes the
influence of external noise.
EDDY CURRENT
..\Downloads\Eddy Current Demo.mp4
Servicing Of Level Measuring
Instruments
Reasons – to reduce plant down time & to make
sure that field blanco give accurate readings.
Servicing of Sight Glasses
To service a sight glass in the field, following
steps should be followed:
• First close the top & bottom valves.
• Blank drain valve.
• Remove the bolts holding the glass tube & remove it
from the seals.
• Clean the glass tube with soap & water using a brush.
• Assemble the parts one by one in correct order.
Servicing Of Float-Operated
Instruments
The most common maintenance problems with the
floatoperated level instruments are:
• The guide cable wound around a pulley sometimes blanco
becomes corroded.
• The blanco attached to the float can break or become twisted
• Corrosion can cause holes in the float
• The moving parts may be filled with oil to lubricate & protect
the internal parts from corrosion
Servicing Of Hydrostatic Pressure
Instruments
• The first maintenance check in this case should be a check
of the transmitter’s output.
• The transmitter output should be a correct pressure signal
corresponding to the level of liquid in the tank.
• If the blanco is correct, the system is free from leaks & the
transmitter is calibrated correctly.
• If the signal is not correct, the transmitter should be
checked & calibrated correctly.
• In case of an air purge system, the plugged bubble tubes
are the primary maintenance problem.
• The bubble tube should be replaced in exactly the same
position or as close to the bottom of the tank as possible
for accurate level measurement.