Chapter 3:

Level
Measurement
1

Objectives
Define the level
Differentiate direct measurement &
indirect measurement
Apply the factor for selecting level
measurement device
Differentiate between open &
closed tank measurement
Understand the principle,
operation, advantages &
disadvantages of devices
2

Introducti
on
Measured at position of interface between phase
(height)
Direct & indirect
Vertical measurement surface to reference point
Pressure at base height hydrostatic
pressure

P = gh

DP (differential pressure capsule) is most common

used
Liquid level measuring devices are classified into two
groups:

(a) direct method

(b) indirect method

Direct Level Measurement

Employs physical properties fluid
motion, buoyancy, optical, thermal,
electrical properties
Position interface monitored visually
Simplicity
Not require compensation for changes
level causes by temperature changes.

Indirect Level Measurement

Involves converting measurement

other quantity
Temperature affected accuracy of
indirect level measurement (changes
density affected pressure)
Compensate sensitive specific gravity &
temperature

Open Tank Measurement

Simplest application
HP base of tank
LP vent to atm
0% level 4 mA
100% level 20 mA

Phigh = Patm + gH
Plow = Patm

Differential
Pressure
= Phigh Plow = gH

Closed Tank Measurement

HP base of tank
LP top of tank
Connected to DP

Phigh = Pgas + gH
Plow = Pgas
Differential Pressure
= Phigh Plow = gH
The effect of gas pressure is
cancelled and only pressure due
to hydrostatic head of the liquid is
sensed.

Level Measuring
Devices

Differential Pressure (DP)

Principles

Known hydrostatic
Based on height of liquid head
(pressure)

Operations
the top & bottom tank is
connected to DP
the top LP
the bottom HP
system sensed both high & low
side
high side sensed pressure
exerted by height of liquid

 each sides exposed same

pressure -system pressure
cancelled & differential pressure
indicates liquid level
problems vapor may
condensate & fill LP tap
condensate liquid produces its
own static head - can affect
accuracy

DP Advantages
easy to install, has wide range, faster
response time
modification - can measure hard to
measure fluids (viscous, slurries,
corrosive)
simple & accurate
calibration is simple, no special tools
required

DP Disadvantages
affected changes density used
fixed specific gravity liquid
require constant head maintain at
reference leg
susceptible to dirt / scale entering
tube

Dip Stick
Principles
oldest form
essential stick/rod
commonly used oil
level (internal
combustion engines)&
fuel
quantity(underground
storage tanks

Operations
lowered vertically into tank until
reach reference point
bottom tank reference point to
ensure correct depth
dip stick withdrawn & level read at the
last interface contact
reading indicate level

Lead
Line

Principles

same way dip

stick
steel measuring
tape attach
weight
more capable
than dip stick

Operations
measuring clear liquid applied
special chemicals to the sticks or
line.
this can darken/change color
when immersed in liquid.
chemical not react with the process

Advantages
Compact, easy
Accuracy 0.1% up to range 20
ft
Accurate, reliable, dependable

Disadvantages

only measure open system

safety precaution caustic &
toxic process
not possible for continuous
representation

Sight
Glasses
Principles

visual measurement
transparent tube of glass/plastic
mounted outside vessel
level inside vessel = level sight
glass

Operations
Principle - equal pressure on the
surfaces of two connected columns
causes liquid to seek same level
one leg represent process, another
transparent tube
fluctuates; level changes- true
representation of the process level

 tube have a scale indicator for

direct reading
can be adapted to open / closed
tank
closed-tank sight glass used in both
pressurized & atmospheric process
Application on pressurized vessels boiler drum, evaporators,
condensers, distillation column &
stills
Low & high pressure process

Low pressure
sight
glass
clear round tube
fitted between service
valve
equipped with ball
checks, inserted
within valve chamber
shut off flow if
leak/rupture
Ball checks permit
free flow of fluid when
level changing

High pressure
sight
glass
Contain liquid under high
pressure reflex sight
glass used
Is armored; permit it
tolerate higher temp &
pressure
Viewing glass
install in protective highpressure housing
1 inch thick

Gage Glass
Principles
similar sight glass
glass covered ports in
vessel observed easily
have scale
mounted on the tank

Operations
simple and reliability
transmitter fail; it still can be used
Limited function
Disadvantages :
very often inaccessible - difficult to
measure
vulnerable to breakage release to
environment
hot, corrosive, caustic - spills could be
serious
careful when install at the risk
breakage is possible
shut down process for repair glass

25

Principles

Magnetic
Gauges

used the attraction between 2

magnet to follow a liquid level (1
magnet enclosed in a float ring & 1
inside a nonmagnetic tube
magnet follower)
tube made from nonmagnetic
metal / PVC pipe
Magnet balance by counterweight;
fall & rise easily

Operations
ring-shaped
floating magnet fits
around the outside
of the tube &
follows any change
in the liquid level.

 the magnet inside the tube follows

the floating magnet & moves the
indicator along calibrated scale
tank sealed liquid not leave the
tank
cannot used to measure liquid if
floating is stick to tube
tube material should withstand the
temperature, pressure & chemical
action

Typical
Installatio
ns of
Magnetic
Gauge
30

Float Device
Principles

Weight/level
indicator

reliable of other
visual sensors
Cable float move by
level changes
movement
Float
convey a level
measurement
rises & falls with
level; position
sensed outside
the vessel

Operations
common uses ; connected to a
pulley by a chain / flexible cable
rotating pulley, turn, connected to
indicating device
float moves, counterweight
moves along scale

 perforated tape can be used to drive

a dial indicator
as the raise / lower in level, weight
will also raise / lower by pulley
arrangement
installing scale on the tube / guide,
level can be determine
application: closed tank /
atmospheric pressure

Cable

Float
Drum indicator

Figure 3.13: Float and spring-loaded drum

 more sophisticated; a steel tape &

spring-loaded drum
level raises / lowers, drum winds in
the steel tape / lets it out
a window spring-loaded drum
housing allows operator view
graduation; determine level
advantage: reading can be at
ground level

 float & tape commonly used;

reliable, little maintenance &
calibration
Usage : local indication &
auxiliary / backup
limited to liquid-gas interface
not accurate for foaming liquid

Capacitan
ce
electrical device that store
energy & electricity
consists 2 plates separates by
insulating material; dielectric
connecting plates to power
supply, electrons attracted from
one
plate to the other
capable storing & holding the
charge until discharge

Operations

Plate 2
Plate 1

Dielectric

Plate 2
Plate 1

Dielectric

one side of process

container acts one
plate & immersed
electrode is other side
dielectric; air /
material inside vessel
area & distance
between 2
plates is
fixed values

amounts of charge stored determined

by 3
factors; area, distance, type of dielectric

relationship

KA
C
D

where:
C = capacitance; farad (F)
K = dielectric constant
A = area of plates
D = distance between plates

 Dielectric varies
with level
changes in
capacitance
proportional with
level

if the wall nonconductive, a

single probe contain 2 electrode
can be used -horizontally

 terminal of electrode connected

to measuring device
interface passes between
electrodes, capacitance
changes because the different
in dielectric constant
conductive material; insulate
probe is used (teflon-coated)
continuous measurement,
probe install vertically

 changes capacitance direct

function of dielectric constant
dielectric constant air & most
gases = 1
temperature cause dielectric
constant of liquid vary (T , K
)

Barrel (side mount) and

probe (top mount) formats
Basic full/empty type level
indication set by mounting
position
Accurate switching even
with heavy residue build-up
High reliability due to no
moving parts
Can often be used with
liquids and powder or
granular product

44

Advantages
simple design, no moving parts,
minimal maintenance
availability of corrosive resistant
probe

Disadvantages

temperature will effect error

reading
probe coated with a
conductive material, errors
may occur

 for liquid interface

of relatively high
conductivity
include waterbased material:
brine solution,
acids, caustic,
certain beverages
limited to alarm
devices & on/off
system
Conductivity

Principles
2 electrodes positioned in a tank
(extends min & max level)
Cable grounded & functions as
common electrode
Stilling well provided to ensure
interface not disturbed & prevent
false measurement

High-level
probe

Controller

Low-level
probe

terminals electrode
connected to relays;
transmit signals to
display / control device
extends min level,
conductivity path
established through
grounded tank
level falls below
electrode, path
interrupted,
showed
gas / vapor is
nonconductive

 level condition
activate device to
sound alarm control
to operate pump /
feed controller that
adjust level
current will flow
through electrodes &
tank
relay detect high

 Uses stainless steel

probes (1m) to provide
sensing for up to 3 switch
points
Can only be used with
conductive fluids
Used in conjunction with a
level control relay to set &
monitor switching points
Once installed switching
points can be easily adjusted

50

Disadvantages
Advantages
low cost
simple design
no moving
parts
effective for
many waterbased
material

System must be
conductive
Only point
detection can be
measured
Possibility
sparking;
prohibitive for
explosion &
flammable
substances

Ultrasonic & Sonic

Sensors
Principles
Measuring device not contact
with process material
measures distance from one
point in vessel to level interface
operate on the echo principles
different ultrasonic & sonic;
operating range (US: 20kHz & S:
10kHz /below)


Ultrasonic sound pulses
are reflected by the surface of the
liquid
Non-contact level sensing of
water, emulsions, oils, chemicals
and effluent
Provides proportional indication
of level via a 0/4-20mA or 0-10V
output
Typical range 0.25 to 10m
Provides accurate level
indication, but can be affected

54

 can be used continuously

sonic conductivity precise; depend
the density & characteristic of
surface
sound waves tend to pass through
most gases.
waves lost kinetic energy through
friction
liquid more reflective
gas more adsorb

Operations
sonic level
measurement
dependent on
sound wave striking
live medium &
reflecting wave
dead media adsorb
most sound
energy
Soundenergy
absorbed
d
Soundenergy
incident
onsurface

 value d; depend the

frequency sound
wave.
influenced by surface
porosity, material
thickness, rigidity
continuous, based on
time elapses from
generation of sound
wave to detection of
the reflected wave

Level measurement
troubleshooting
Connections
DP cell sensing line connection is
reversed
High operating pressure & low
hydrostatic pressure; easy to occur
Actual level , indicated level

Over-pressuring
3 valve manifolds on DP cell
prevent over-pressuring & easy to
remove
Fail immediately / diaphragm become
distorted

Obstructed sensing lines

Small diameter; clogged with

particulate inaccurate reading
Sluggish response to level changes
To overcome: periodic draining &
flushing

Draining sensing lines

To remove debris / particulate settle
on the bottom vessel / in line
Close tank; remove condensate
prevent fluid pressure build up in
LP impulse line
Leaking / drained wet leg false
high level indication

Lead line

LT

Reflex sight glass

Ultrasonic
Cable Float

Magnetic Float

Capacitance

Sight glass

Side
mounting
Float

End

63