Chapter 4

LEVEL MEASUREMENT

Level Measurement Definition

Level measurement is a single

g dimension from a reference
point. As shown tank level is measured, either by Inage
method or Outage method. Each Manufacturer has a different
Instruction Set.

Level Measurement Principle

Level devices operate under three main different
principles:
1 The position (height) of the liquid surface
1.

2. The pressure head

3. The weight of the material

There are two methods used to measure the level of a liquid:

1) Direct Methods

2) Indirect or inferential Methods

1. Direct Methods (
(Visual Methods)
)
The

direct method measures the height above a zero

point by any of the following methods.
methods

Direct

methods for level measurement are mainly

used
d where
h
level
l
l changes
h
are small
ll and
d slow
l
such
h as;
Sump tanks and Bulk storage tanks.

Direct

methods are simple and reliable. There are four

types of direct level measurement devices:
1.Dip-sticks

& Dip-Rods

2.Weighted
g

g
gauge
g tape
p

3.Sight

Gauges, and

4 Floats.
4.
Floats

1.1)
) Dip-Sticks
p
& Dip-Rods
p

1.2)
) Weighted
g
g
gauge
g tape
p
Another variation is the weighted gauge tape. This is used in a
similar fashion to the dipstick
dipstick, but on deep vessels and tanks
where a solid rod would be inappropriate.

1.3)
) Sight
g
Gauges
g
There

are various types of sight gauges, the two most

common types being used are:

1 Sight
1.

glass; flat,
flat tubular and reflex

2.Magnetic
g

sight
g g
gauges.
g

The flat glass

o The flat glass type, is used for non pressurised vessels.
o It is a glass window or windows that forms part of the vessel.
o A ttypical
pi al appli
application
ation is in hot oil tanks
tanks, where
he e excessive
e essi e foam
contaminated oil may be easily detected.

Tubular Sight
g
Glasses

Light is refracted from the vapour portion of the column and is

shown generally as white colour.
colour Light is absorbed by the liquid
portion in the column and is shown generally as a dark colour.

They
h
are used
d mainly
l for
f
non-corrosive, non-toxic inert liquids
l
d
at moderate temperatures and pressures.

Reflex sight glasses

Magnetic type Sight gauges

The magnetic level gage, consisting of a magnetic float that

travels up and down on the inside of a long,
long non
non-magnetic
magnetic
(usually stainless steel) pipe. The pipe is connected to flanged
nozzles on the side of the tank.
tank The pipe column is provided
with

visual

indicator,

consisting

of

triangular

wafer

elements.
l
t

These elements flip over (from green to red, or any other

color) when the magnet in the float reaches their level. Alarm
switches and transmitter options are available with similar
magnetic coupling schemes.

Operational considerations for Sight Glasses

o

Sight glasses are usually installed with shutoff valves and a

drain valve for the purpose of maintenance, repair and
replacement.

An important safety feature of these external sight glasses is

the inclusion of ball check valves within the isolation valves.
purpose
p
of these check valves is to p
prevent the escape
p
The p
dangerous fluids if the glass breaks. Therefore it is important
that the isolation valves are left fully open when the sight glass
is in use, otherwise the operation of the check valves may be
inhibited.

Sight gauges must be accessible and located within visual

range.

They are not suitable for dark liquids.

liquids Dirty liquids will prevent
the viewing of the liquid level.

Glass
l
h
has the
h obvious
b
disadvantage
d d
off being
b
fragile
f
l and
d easily
l
damaged or broken. Therefore, this type should not be used
for measuring hazardous liquids
liquids. On safe applications,
applications tubular
gauge glasses can be used.

Reflex gauges are permissible for low and medium pressure

applications. For high-pressure applications or where the fluid
i ttoxic,
is
i armoured
d gauges with
ith magnetic
ti di
dials
l should
h ld b
be used
d
for safety reasons, gauge glass lengths between process
connections should not exceed 4 ft.
ft

1.4) Floats

Floats give a direct readout of liquid level when they are

connected to an indicating instrument through a mechanical
linkage.

A simple example of this is the weighted tape tank gauge, the

position of the weighted anchor against a gauge board gives an
indication of the liquid level in the tank.

The scale of the gauge board is in reverse order,

order i.e.
i e the zero
level indication is at the top and the maximum level indication is
at the bottom of the gauge board.
board

2. Indirect (inferential) Methods

The indirect or inferential method of

measurement uses the changing position of the
liquid surface to determine level with reference
to a datum line.

It can be used for low & high levels where the

use of the direct method instruments is
impractical.
1. Hydrostatic
H d
t ti

P
Pressure Methods
M th d

2. Displacement
3. Capacitance

devices

Level Instrumentation

4. Radiation
Radiation-Based
Based

Level Gages

2.1)
) Hydrostatic
y
Pressure Methods

A vertical column of fluid exerts a pressure due to the columns

weight. The relationship between column height and fluid
pressure at the bottom of the column is constant for any
particular fluid (density) regardless of vessel width or shape.

This principle makes it possible to infer the height of liquid in a

vessel by measuring the pressure generated at the bottom:

Where,
P = Hydrostatic pressure
= Mass density of fluid in kilograms per cubic meter
g = Acceleration of gravity
= Weight
g density
y of fluid in newtons per
p cubic meter
h = Height of vertical fluid column above point of pressure
measurement
The level of liquid inside a tank can be determined from the
pressure reading if the weight density of the liquid is constant.

Level measurement involving the

principles of hydrostatics have taken
numerous forms, including:
1.The diaphragm-box system
2H d
2.Hydrostatic
t ti diff
differential-pressure
ti l
meters
t
3 The air-bubble
3.The
air bubble tube or purge system

2.1.1) The Diaphragm-box System

Pressure sensor / transmitter can make use of this principle for liquid
level measurement. The PSE can be connected to the bottom the
vessel so that it's
it s input is related the hydrostatic pressure within the
tank.

A level can be measured using

gap
pressure g
gauge.
g These systems
y
are
employed on open vessels. They operate by giving an indication of the
pressure produced by the static head of the liquid that is related to the
actual level in the tank
tank. In this case the gauge is calibrated in units
relating to the liquid level in the tank in % value.

2.1.2) Differential
Differential-Pressure
Pressure Level Meters

Differential Pressure (DP) capsules are the most

commonly used devices to measure the pressure at
the base of a tank.

Wh
When
a DP transmitter
t
itt
i used
is
d for
f
th purpose off
the
measuring
transmitter.

level,

it

will

be

called

level

Open Tank Measurement

The simplest application is the fluid level in an open tank.

If the tank is open to atmosphere, the high-pressure side of the

l
level
l transmitter
i
will
ill be
b connected
d to the
h base
b
off the
h tank
k while
hil
the low-pressure side will be vented to atmosphere. In this
manner, the level transmitter acts as a simple pressure
transmitter.

P High
g = P atm + S . H
P Low = P atm
pressure P = P High
g P Low = S . H
Differential p
The level transmitter can be calibrated to output 4 mA when the tank is
at 0% level and 20 mA when the tank is at 100% level.

Closed tank - Dry Leg System

o

When the low-pressure impulse line is connected directly to the

gas phase above the liquid level,
level it is called a dry leg.
leg

Dry leg system usually used where the gas phase is noncondensable.

Closed tank - Wet Leg System

In a wet leg system, the low-pressure impulse line is completely filled

with liquid (usually the same liquid as the process) and hence the
name wet leg.

At the top of the low pressure impulse line is a small catch tank. The
gas phase or vapour will condense in the wet leg and the catch tank.
The catch tank,
tank with the inclined interconnecting line,
line maintains a
constant hydrostatic pressure on the low-pressure side of the level
transmitter. This pressure, being a constant, can easily be
compensated for by calibration.

2.1.3)
) Bubbler Level Measurement System
y

If the process liquid contains suspended

solids or is chemically corrosive or
radioactive,, it is desirable to p
prevent it
from coming into direct contact with the
level transmitter.
transmitter In these cases,
cases a
bubbler level measurement system,
which utilizes a purge gas,
gas can be used.
used

a) Open tank application for bubbler system:

A bubbler tube is immersed to the bottom of the vessel in

which the liquid
q
level is to be measured. A g
gas ((called p
purge
g
gas) is allowed to pass through the bubbler tube.

Consider that the tank is empty, the gas will escape freely at
the end of the tube and therefore the gas pressure inside the
bubbler tube (called back pressure) will be at atmospheric
pressure.

As the liquid level inside the tank increases, pressure exerted

by the liquid at the base of the tank (and at the opening of the
bubbler tube) increases. The hydrostatic pressure of the liquid
i effect
in
ff t acts
t as a seal,
l which
hi h restricts
t i t the
th escape of,
f purge gas
from the bubbler tube.

2.2 Displacement devices

The displacement level transmitter is commonly used for

continuous level measurement.
It works on the buoyancy principle.
The displacer has a cylindrical shape therefore each increment of
submersion in the liquid; an equal increment of buoyancy change
will result. This is a linear and proportional relationship.

When the weight of an object is heavier than an equal volume of the fluid
into which it is submerged, full immersion results and the object never
floats. Although the object (displacer) never floats on the liquid surface, it
does assume a relative position in the liquid. As the liquid level moves up
and down along
g the length
g
of the displacer,
p
, the displacer
p
undergoes
g
a
change in its weight caused by the buoyancy of the liquid. Buoyancy is
explained by Archimedes' principle, which states that: "The resultant
pressure of a fluid on a body immersed in it acts vertically upward
through the centre of gravity of the displaced fluid and is equal to the
weight of the fluid displaced".

The upward pressure acting on the area of the displacer creates the force
called buoyancy.

The immersed displacer is supported by arms or springs that allow some

small amount of vertical movement or displacement of the displacer due
to buoyancy forces caused by the change in the liquid level. This
buoyancy force can be measured to reflect the level variations.

When a b
Wh
body
d iis ffully
ll or partially
ti ll immersed
i
d in
i any liquid,
li id it iis reduced
d
d iin
weight by an amount equal to the weight of the volume of liquid
displaced.

Determining Suspended Weight for Dry Calibration:

To determine the total weight that must be suspended from the

displacer rod to simulate a certain condition of fluid level or specific
gravity, the following equation can be used:

Ws =Wd [(0.0361)(V)(Sg)]

Ws = Total suspended weight in pounds (apparent weight).

Wd = Weight of displacer, dry, in pounds (determine by weighing

displacer).

0.0361= Weight of one cubic inch of water, in pounds

(specific gravity =1.0)

V = Volume of the displacer that would be submersed at the level

required by the calibration Procedure (in cubic inches) OR,

V = /4 (displacer diameter)2 x (submerged length of displacer)

Sg = Specific gravity of the process fluid at operating temperature.

Torque
q
tube

In this method a displacer body is connected to a torque tube

which twists a specified amount for each increment of buoyancy
change.
h
As shown, the twisting force can drive a pointer, an indicator or be
transferred to a p
pneumatic or electronic system.
y
It is transferring
g
the displacer movement from the inside of pressurised vessel to
the readout mechanism, which is in atmospheric pressure.
The torque tube rotates around 4 to 6 degrees angular to
establish the 0-100% level readout.

Displacement
p
Devices Applications
pp

This type of measurement should only be used for liquids:

1. With fixed specific gravity
2. Where errors due to process variations are acceptable
3. Where a change in process conditions will not create crystallisation or
solids

If the displacer is mounted in an external still-well then the block

and drain valves should be installed for maintenance purpose. Trace
heating or insulation may by needed to maintain the temperature of
heating,
the liquid in the well.

The p
piping
p g arrangement
g
should be designed
g
to p
prevent the
formation of sediment on the bottom of the cage as eventually this
can build up and affect the displacer movement. Coating build-up or
dirt that clings to the displacer may affect the elements buoyancy
resulting in the accuracy of the measurement.

Continuous Level Displacers

Displacers are popular as level transmitters and as local level controllers,

however, they are not suited for slurry or sludge service because coating
of the displacer changes its volume and therefore its buoyant force.
They are most accurate and reliable for services involving clean liquids of
constant density.

Displacement Interface Level Measurement

Displacer level instruments may be used to measure liquid-liquid interfaces
just the same as hydrostatic pressure instruments. One important
requirement is that the displacer always be fully submerged. If this rule is
violated, the instrument will not be able to tell the difference between a
low (total) liquid level and a low interface level.
level

2.3 Capacitance Level Instrumentation

Theory of Operation
A capacitor consists of two conductors (plates) that are electrically isolated
from one another by a nonconductor (dielectric).
When
Wh
the
h two conductors
d
are at different
diff
potentials
i l (voltages),
( l
) the
h system is
i
capable of storing an electric charge. The storage capability of a capacitor is
measured in farads.
The capacitor plates have an area (A) and are separated by a gap (D) filled
with
i h a nonconducting
d
i
material
i l off dielectric
di l
i constant (K).
(K)

Capacitance (C) is calculated as:

If the area (A) and the distance (D) between the

plates of a capacitor remain constant, capacitance
will vary only as a function of the dielectric
constant of the substance filling
g the g
gap
p between
the plates.

If a change in level causes a change in the total

dielectric of the capacitance system, because (as
illustrated in Figure B) the lower part of area (A) is
exposed to a liquid (dielectric Kl) while the upper
part is in contact with a vapor
p
p ((dielectric Kv,, which
is close to 1.0), the capacitance measurement will
proportional
p
to level.
be p

Capacitance
p
Probe as a Level Switch:

In the case of a horizontally mounted level switch, a conductive probe

forms one of the plates of the capacitor (A1), and the vessel wall
(assuming it is made from a conductive material) forms the other (A2).
(A2)
An insulator with a low dielectric constant is used to isolate the
conductive probe from the housing, which is connected to the vessel
wall.
wall

The probe is connected to the level sensor via the conductive threads of
the housing.

Measurement is made by applying an supply signal between the

conductive probe and the vessel wall.

2.4 Radiation-Based Level Gages

g

An entire class of level instrumentation devices is

b
based
d on a material's
t i l' tendency
t d
to
t reflect
fl t or absorb
b
b
radiation. For continuous level gages, the most
common types of radiation used are radar
/microwave ultrasonic,
/microwave,
ultrasonic and nuclear.
nuclear

The main advantage

g of a radiation-based level g
gauge
g
is the absence of moving parts and the ability to
d t t level
detect
l
l without
ith t making
ki
physical
h i l contact
t t with
ith the
th
process fluid.

Ultrasonic level sensors

In

applications when it is not acceptable for the level

measuring instrument to come into contact with the

process material, an ultrasonic device can by used.
These

devices measure the distance from a reference

point in the vessel to the level interface, using

ultrasonic waves.
waves

Sonic sensors
o in sonic sensors, the unit uses the echo principle with a frequency in the
audible range.
g
o After each pulse, the sensor detects the reflected echo.
o Note this will only work if the surface of the liquid is a good reflector and
that the centre line of the transmitted beam is vertical.

Ultrasonic level system for innage measurement: Ultrasonic level

transmitters measure actual distance by issuing an ultrasonic
pulse and measuring the time required for the reflected echo to
be received

Level Switches

Level switches are used to detect the liquid high and

l
low
llevels.
l

The level switch outputs are used for initiating the

alarm and shutdown functions.

The outputs are also used for On/Off controls, such

as in the starting and stopping of pumps.
pumps

a)

Float Level Switches

Floats should always be lighter than the minimum expected specific

gravity (SG) of the process fluid.

They
h
can be
b made
d out off stainless
l
steel,
l Teflon,
fl
Hastelloy,
ll
Monel,
l and
d
various plastic materials.

Typical temperature and pressure ratings are -40 to 80

80C
C and up to
150 psig for rubber or plastic floats, and -40 to 260C and up to 750
psig for stainless steel floats. Standard float sizes are available from 1
to 5 inches in diameter.
diameter

Float Switches Applications

pp
& Installations

A simplex (one pump) system will use a single switch wired in

series with the motor leads so that the switch directly starts
and stops the pump motor.

side-mounted, Top-mounted, and external-mounted float

switches.

Float Level Switch Configuration

Displacer
p
Switches

Displacer remains partially or completely

submerged. The apparent weight of the
displacer is reduced as it becomes
covered by more liquid.

When the weight drops below the spring

tension, the switch is actuated.

Displacer switches are more reliable

than regular floats on turbulent, or
f
foamy
applications.
li ti

These switches are interchangeable

between tanks because differences in
process density can be accommodated
by changing the tension of the support
spring.