Ultrasonic Level

Transmitter Working
Principle

An ultrasonic level transmitter is mounted on the top of the tank and

transmits an ultrasonic pulse down into the tank. This pulse, travelling at
the speed of sound, is reflected back to the transmitter from the liquid surface.
The transmitter measures the time delay between the transmitted and
received echo signal and the on-board microprocessor calculates the
distance to the liquid surface using the formula.

Distance = (Speed of sound in air x time delay) / 2

Once the transmitter is programmed with the bottom reference of the
application – usually the bottom of the tank – the liquid level is calculated by
the microprocessor. The basic equation for calculating the tank level is
Level = Tank Height – Distance

Basic Concept and Elements of the Ultrasonic Level Measurement

Minimum measuring distance (Xm): (also known as the “Dead Band”) is a

feature common to all ultrasonic level meters. This is a short range in front of
the sensor within which the ultrasonic device cannot measure.

Maximum measuring distance (XM): The longest range under ideal

condition within which the device can measure. No measurement is possible
beyond this distance.

Ultrasonic level transmitter, which performs calculations to convert the

distance of wave travel into a measure of level in the tank. The time lapse
between firing the sound burst and receiving the return echo is directly
proportional to the distance between the transducer and the material in the
vessel. The medium is normally air over the material’s surface but it could be
a blanket of some other gases or vapours. The instrument measures the time
for the bursts to travel down to the reflecting surface and return. This time will
be proportional to the distance from the transducer to the surface and can be
used to determine the level of fluid in the tank. This basic principle lies at the
heart of the ultrasonic measurement technology and is illustrated in the
equation: Distance = (Velocity of Sound x Time)/2. These noncontact
devices are available in models that can convert readings into 4–20 mA
outputs to DCSs, PLCs, or other remote systems.

The frequency range for ultrasonic methods is in the range of 15…200

kHz. The lower frequency instruments are used for more difficult applications;
such as longer distances and solid level measurements and those with higher
frequency are used for shorter liquid level measurements.

For practical applications of ultrasonic measurement method, a number of

factors must be considered. A few key points are:

 The speed of sound through the medium (usually air) varies with the
medium’s temperature. The transducer may contain a temperature
sensor to compensate for changes in operating temperature that would
alter the speed of sound and hence the distance calculation that
determines an accurate level measurement. Temperature compensation
is provided to account for uniform temperature variances of the sound
medium. The temperature sensor is placed inside the transducer and the
signal is sent to the transceiver via the transducer’s wiring. Optionally, an
alternate temperature sensor can be used to provide a temperature input,
rather than by using the integral temperature sensor. If the temperature of
the sound medium is to remain constant, instead of using either the
integral temperature compensation or the remote sensor, the desired
temperature may be entered during the transceiver configuration.
 The presence of heavy foam/dust on the surface of the material can
act as a sound absorbent. In some cases, the absorption may be
sufficient to preclude use of the ultrasonic technique. To enhance
performance where foam/dust or other factors affect the wave travel to
and from the liquid surface, some models can have a beam guide
attached to the transducer.
 Extreme turbulence of the liquid can cause fluctuating readings. Use
of a damping adjustment in the instrument or a response delay may help
overcome this problem. The transceiver provides damping to control the
maximum changing rate of the displayed material level and fluctuation of
the mA output signal. Damping slows down the rate of response of the
display especially when liquid surfaces are in agitation or material falls
into the sound path during filling.
 Non Contact RADAR
Level Transmitter
Principle

A radar transmitter should be mounted on the top of a

tank, chamber/cage or standpipe. The transmitter sends out microwaves
via the antenna, which then travel down to the product surface. At the
product surface, they are reflected back to the antenna of the radar
transmitter. The propagation velocity of microwaves in free space is the speed
of light (~300,000 km/s).
Two different principles are used to measure the extremely short transmission
times: Frequency Modulated Continuous Wave (FMCW) and pulse
technology. The FMCW method emits microwaves continuously over a
narrow frequency sweep. The frequency of the return reflection is slightly
different from the frequency currently being transmitted, and the frequency
difference is proportional to the distance. Because of multiple reflections,
there are several signals mixed together. Therefore an FFT calculation has
to be done internally by the radar transmitter to determine all the
different single frequencies. This information is used to calculate an echo
curve, from which the system can calculate the distance.
The method consists of the emission of microwave energy pulse. The
time that needs to receive a return reflection is measured. This time is the
image of the level (i.e. level = velocity × time). Because of the high
propagation speed (300,000 km/s) the radar transmitter can repeat this
several million times in a second without having any interference between the
individual signals. These signals are periodical. So the sensor sees the same
echo curve several million times during one second. A special sampling
method makes it possible to expand the time of this fast echo curve into a
slower time range.

Figure – Radar pulse principle

FMCW and pulse technologies produce the same result: an echo curve.
In the past, the lower power consumption of ‘pulse’ technology has been an
advantage for building a loop‐powered radar transmitter. Nowadays, both
technologies deliver the same performance. There are no longer any major
differences between these two measuring principles when it comes to
accuracy, dynamic range, measuring range or response time.
Radar transmitters are available with different operating frequencies. For the
measurement of liquids, there are low frequencies (between 4.5 – 10 GHz)
sensors and high frequency (24 – 27 GHz) sensors.
 Basics of Differential
Pressure Level
Transmitters
The importance of level measurement cannot be overstated. Incorrect or
inappropriate measurements can cause levels in vessels to be excessively
higher or lower than their measured values. Low levels can cause pumping
problems and damage the pump, while high levels can cause vessels to
overflow and potentially create safety and environmental problems. Vessels
operating at incorrect intermediate levels can result in poor operating
conditions and affect the accounting of material.

The level of a liquid in a vessel can be measured directly or inferentially

(indirect). Examples of direct level measurement include float,
magnetostrictive, retracting, capacitance, radar, ultrasonic and laser level
measurement technologies. Weight and differential pressure technology
measure level inferentially. All have problems that can potentially affect the
level measurement.
Differential pressure level measurement technology infers liquid level by
measuring the pressure generated by the liquid in the vessel. For
example, a water level that is 1000 millimeters above the centerline of a
differential pressure transmitter diaphragm will generate a pressure of 1000
millimeters of water column (1000 mmWC) at the diaphragm. Similarly, a level
of 500 millimeters will generate 500 mmWC. C
alibrating this differential pressure transmitter for 0 to 1000 mmWC will allow it
to measure water levels of 0 to 1000 millimeters.

Note that this example presumes that the liquid is water. Liquids with other
specific gravities will generate other differential pressures and cause
inaccurate measurements. Continuing with the previous example, the same
500-millimeter level of another liquid with a specific gravity of 1.10 at operating
conditions in the above vessel will generate 550 mmWC of pressure at the
transmitter. As such, the differential pressure transmitter calibrated for water
would measure 50 millimeters higher than the actual 500 millimeter liquid
level. Conversely, if the liquid has a specific gravity that is lower than that of
water, this transmitter will measure lower than the actual level. This example
illustrates that differential pressure technology does not measure level, but
rather infers level.

Open Tank DP Level

Transmitter Calculations
In any process industry, level measurement is very important for safety and
process purpose.

Level can be measured by two methods.

1. Direct method
2. Indirect method
Here we discuss about indirect method and which is using DP transmitter for
level measurement.

A Differential pressure transmitter is a common and well understood

technology for liquid level measurement. If the tank is closed or
pressurized, a DP measurement must be made to compensate for the
vessel pressure.
DP Transmitter Level Measurement for Open Tank
Suppose there is a open tank in which a DP transmitter installed for the
measurement of level then HP leg of the DP transmitter is connected with
bottom of tank and LP leg is open in atmosphere. Assume process fluid
specific gravity in the tank is 1.0

Definition of specific gravity: Specific gravity is a measure of density relative to

the density of a reference substance. Reference substance is taken water.

For DP Transmitter Configuration, we have to find out Zero Level & Span
Level. Accordingly we have to configure Lower Range Value (LRV) and Upper
Range Value (URV) using HART communicator.
DP Transmitter installed at the exact HP tapping point

At Zero level = 0 mmwc

At Span level = H x Specific gravity
= 500 x 1.0

= 500 mmwc

Then Range = 500 – 0 = 500 mmwc

So, we have to set Lower Range Value (LRV) = 0 mmwc and Upper Range
Value (URV) = 500 mmwc in the DP Transmitter using HART communicator.
DP Transmitter Installed Below Tapping Point for Open Tank
If transmitter is installed below the tank then it’s called zero suppression then
calculation is below:
When zero suppression is used then H1 height always filled with process fluid.
At zero level (LRV) = H1 x specific gravity
= 100 x 1.0

= 100 mmwc

At 100% level (URV) = (H1 + H2) x specific gravity

= (100 + 500) x 1.0

= 600 mmwc

Range = URV – LRV = 600 – 100 = 500 mmwc

So, we have to set Lower Range Value (LRV) = 100 mmwc and Upper Range
Value (URV) = 600 mmwc in the DP Transmitter using HART communicator.
 Closed Tank Level
Measurement using DP
Transmitters
Hydrostatic head instruments for measuring liquid level in vessels operating
above atmospheric pressure uses the full capability of the differential pressure
instruments with both sides of the measuring element connected to the
vessel.

The differential pressure transmitter, enables an automatic subtraction of

the pressure on the LP side, from the total pressure appearing at the HP
side. This is accomplished as shown in diagram above, where the LP is
connected above the maximum predicted level. With this arrangement, each
increment of pressure above the liquid surface is applied to both capsule
assemblies of the transmitter, and since they are in opposition, the increment
is cancelled. Only the hydrostatic pressure, which is applied to the HP, is
effective in causing any response to the transmitter, which is
proportional to the level.
The DP transmitter have inbuilt pressure sensors like Diaphragm,
capsules, strain gauges etc to measure the differential pressure. The
pressure sensor converts the measured pressure into parameters like
millivolts, capacitance, resistance etc depending on the type of pressure
sensor we are using inside the DP transmitter. Generally a Wheatstone
bridge will be used to convert resistance, capacitance or inductance type of
pressure sensor outputs into electrical signal like millivolts or volts which is
proportional to the pressure, then transmitter converts the pressure into
equivalent Level Signal accordingly.

The tank bottom tapping point is High pressure (HP) tapping point and Tank
top tapping is Low Pressure (LP) tapping point. The DP Transmitter is
connected at these HP & LP tapping points accordingly.

The DP Transmitter calibration parameters will vary depending on installation

& seal system also. Generally we can see three possibilities of installation of a
transmitter in the field.

They are :

1. Transmitter installed Exactly at HP tapping point ( Ideal & preferred way

of installation)
2. Transmitter installed above HP tapping point ( Not preferable, Chance of
bubble formation in the impulse line)
3. Transmitter installed below HP tapping point (Error can be compensated
effectively)
So we have to calibrate the transmitter depending on the type of installation in
the field. The calibration formula will vary slightly depending on the
installation.Every transmitter have two important parameters, they are
Lower Range Value (LRV) & Upper Range Value (URV). We have to
calculate the LRV & URV values based on type of installation. The below
figures with formulas dictates the calculations. After calculating the values,
configure the same parameters in the transmitter using HART communicator.

Here we are discussing two types : Wet Leg & Dry Leg

Wet Leg : if LP impulse line is filled with liquid like water, glycol, glycerin
or liquid inside tank

Dry Leg : if LP impulse line is filled with air, gas or any other gases.
The hydro static pressures applying on DP transmitters will vary depending on
wet leg or dry leg. so we have to consider these & calibration formula also
varies accordingly.

We can only decide for a particular DP transmitter is having Wet leg or Dry leg
from the field installation & its process application. Sometimes we can make a
dry leg installation into wet leg by filling water into the LP impulse line also.
Transmitter mounted leveled with the min. level

With wet leg ;

Span = ρp • g • H , or, = SGp • h

With dry leg ;

Span = ρp • g • H , or, = SGp • h
Transmitter mounted above the min. level

With wet leg ;

Zero Elevation = − (ρf • g • x)

Span = ρp • g • H

With dry leg ;

Not preferable

Therefore, for calibration;

4mA (LRV) = Min. Head + Zero Elevation

20mA (URV) = Span + Zero Elevation

Transmitter mounted below the HP tap ;

With dry leg ;

Pw at min. level = (SGf • x)

Pw at max. level = (SGf • x) + (SGp • H)

Span = SGp • H

With wet leg ;

Zero Suppression = − (ρf • g • h) ,or, = − (SGf • h)

Span = ρp • g • H , or, = SGp • H

Therefore, for calibration;

4mA (0%) = Zero Elevation

20mA (100%) = Span+Zero Suppression

With wet leg ;
Pw min = (SGp • y) − (SGf • d)

Pw max = (SGp)(x + y) − (SGf • d)

Span = ρp • g • x , or = SGp • x

With dry leg ;

Pw at min. level = (SGf • z) + (SGp • y)

Pw at max. level = (SGf • z) + (SGp)(x+y)

Span = SGp • H

NOTE:

ρp = density of process liquid in the tank

ρf = density of fill-liquid in the tubing
ρu = density of upper liquid
ρl = density of lower liquid
SGp = std. gravity of process liquid.
SGf = std. gravity of fill liquid
SGu = std. gravity of upper liquid
SGl = std. gravity of lower liquid
Pw = equivalent head of water