Level Measurement 1A Introduction : Tevel measurement is one of the oldest methods. Liquid level Measurements are widely used to monitor as well as measure quantitatively the liquid content in vessels, reservoirs and tanks or the liquid column height in open channel streams and a variety of other cases in industrial processes, * _ The level of liquids may affect both the pressure and the rate of flow in and out of the tank or vessel. Hence, the quality can be affected. * inthis chapter different indirect methods of level measurement are discussed with their merits and demerits. 12 Methods of Liquid Level Measurement : Inthe industries two methods are used for measuring the liquid level. They are : Direct method : Ttis the simplest method of me. —imeasured directly with the help of following level indicators: ‘asuring the liquid level. In this method the level of liquid @ Hook-type level indicator teenBP industria Instrumentation (GTU) Level Measurement 73 Electrical Methods : For industrial applications it is desired to convert the liquid level position to an electrical signal ‘The measurement is done by two conversions, so that the liquid level is indirectly determined. The first conversion is liquid level to a displacement through a float in a liquid or a spring loaded plate in contact with the surface in case of granular solids. The displacement is then converted to an clectrical signal by a secondary transducer connected to float or plate. The electric transducers used for level measurements are, @ Resistive Gi) Inductive iii) Capacitive Syllabus Topic : Resistive 74 Resistive Technique for Level Measurement : It uses mercury as a conductor. Fig. 7.4.1 shows measurement of level of liquids by resistive method. Fig. 7.4.1 : Measurement of level of liquids by resistive methodjnstrumentation (GTU) 73 Level Measurement, of contact rods are inserted at various liquid levels. As the head h of liquid * the rising level of mercury above the datum will short the successive resistors i pis will directly increase the value of h advantages = qe system uses low voltage to climinate danger to the operators and to prevent arcing | the contact points. ‘The signal can be transmitted to the desired point. More contact rods can be added in cases where continuous record of level is needed. Each contact rod will have separate signal output. The transducers can be used in pressurised containers without packing glands or shafts. The unit is simple to calibrate as the distance between the levels of contact rods can be sccurately measured and the indicated value can be checked for each value that is ut 142 Disadvantages : 1 Itis not safe to use this transducer in explosive atmosphere because of arcing at the contact points. 1 The corrosive liquids corrode the contact rods. Also, the electric charges promote ‘corrosion. 4 Inorder to have a stepless indication of the liquid level, an extremely large number of contact rods are required. Any changes in the conductivity of the liquid causes serious errors. These systems present difficulties when there is saturated vapour above the liquid phase. Syllabus Topic : Inductive Techniques for Level Measurement FE.7.5.1 shows measurement of liquid level with variable permeability method.industrial Instrumentation (GTU) 74 Level Measurement Output voltage Fig. 7.5.1 : Measurement of liquid level with variable permeability method [Link] two coils L, and L, that are wound around a steel tube containing the liquid. ‘The two coils L, and L, are connected in series through a resistance. The circuit is ‘energised by an alternating current source. tially equal to about 250 4H. Coil L, acts as the search coil that can be set at a predetermined level. Its inductance changes rapidly as the conducting liquid moves into the plane of the coil. This method works well because the tape material is weakly and the liquid metal is a conductor that allows eddy currents to flow in it. ‘The inductance of each coil is ‘The relationship between the output voltage and the liquid level is non-linear. A second method uses the loading of secondary winding of the transformer. Fig. 7.5.2 shows measurement of liquid level by loading of secondary winding. ‘Secondary winding (Mercury) Fig. 75.2: Liquid level determination by loading of secondary windingInstrumentation (GTU) 7-6 Level Measurarnent oil is wound round one core of « two limbed transformer. The mercury colume 3 nding the iron core forms the secondary of the transformer resistance of the secondary winding depends on the height of the mercury column F fore, the power consumption as observed on the primary side is indicative of the Pees evel liquid “syllabus Topic : Capacitive Techniques for Level Measurement 108 itive Techniques for Level} Measurement ‘The 181 Variable Area Method : ferent methods for level measurement are as follows Serr PAE + Itisused for the measurement of level of both solids + The electrical conductin; point of the transducer. + The other point is a metal rod completely covered by insulating material inside the container. * The insulating material acts as the dielectric medium and the capacitance varies linearly with the height of material and liquids. container containing the materials is used as one connection The relation is expressed as, c = 2tehE tos.( $) © : Permittivity of insulator h : Height of material, m 4, : Diameter of metal rod, m 4, : External diameter of insulator, m The container must be earthed to avoid danger of el where, jectric shock to the personnel and Prevent any errors due to external metallic objects. Ma Capacitive Voltage Divider Method : “ r i Mie conductivity of a liquid is high, then its surface area can be used a8 one electrode 1. S8Pacito DG is tirade iss fsed reference plate parallel tothe suntge Industrial Instrumentation (GTU) 76 Levwok Measuirorrens a * Fig. 7.6.1 shows capacitive voltage divider method for measurement of level of igs conductivity liquid. P (Mitary ance) MMU Fig. 7.6.1 : Capacitive voltage divider method for measurement of level of high conductivity liquid © Ituses an auxiliary electrode P, placed at a fixed distance above the reference electrode P,. The electrodes P, and P, are electrically insulated from each other. © Amac, voltage is applied between the liquid and electrode P,. The potential of electrode | P, with respect to earth is, q W=VxXGGG VY © The capacitance C, is inversely proportional to the distance between the liquid surface and P,, © Thus, the output voltage decreases with rise of liquid level. The relation between the output voltage and liquid level is non-linear. 7.6.3 Variable Dielectric Constant Method : [Link] Principle of Operation of Liquid Level Measurement : The electrical capacitance of the sensing probe varies with the level of material and hence level changes can be recorded in terms of the electrical capacitance of the probe i.e. higher the liquid level greater is the capacitance,Fig, 7.6.2(b) : Measurement of liquid level using capacitive transducer As shown in Fig. 7.6.2(a), the insulated metal electrode is fixed near and parallel to the wall of the metal tank. If the liquid is nonconductive, the electrode and the tank wall form the plates of the parallel plate capacitor and the liquid between them acts as the dielectric, te tigi condutive the ede he ai form the lates of he apc, ‘he insulation between them is dielectric.Industrial Instrumentation (GTU) 78 Level Manaureriag dds on the height of dielectric between the plates, © The capacitance of the capacitor depen: pacitance, Thus, the capacitance is proportional The greater the height, greater is the ca to the height of the liquid in the tank. liquid level using capacitive transducer when © Fig, 7.6.2(b) shows the measurement of nsulated electrodes are kept at a fixed distance the task is not of metal. In this case the it apart. © The two insulated electrodes will behave as the plates of the parallel plate capacitor. The: higher the liquid level in the tank, greater is the capacitance. Thus, any change in the liquid level can be measured in terms of the change in capacitance. [Link] Advantages and Disadvantages of Liquid Level Measurement : | Advantages : 1. Itcan be used for common liquids, powdered or granular solids, liquid metals, liquified gases, corrosive materials like hydrofluoric acid is very high pressure processes. 2. They have high sensitivity. Disadvantages : 1. Any change in liquid composition requires recalibration of the indicator. 2. Liquid should be pure as the presence of contaminants affects the capacitance. ‘Syllabus Topic : Ultrasonic Methods 7.7___Ultrasonic Level Detection Method : Principle : Ultrasonic level detectors use the principle of reflection of an acoustic wave from a liquid-to-a vapour plane i.e. itis based on the law of reflection of ultrasonic oscillations from the solid or liquid surface or the interface between two immiscible liquids. The time taken by the wave for its travel from the transmitter to the liquid surface and back to be receiver, can be taken as the measure of the liquid level. Construction and Working : The ultrasonic level detectors operate by absorption of acoustic energy as it travels from source to receiver or by the attenuation of a vibrating diaphragm face, oscillating at 35 to 40 KHz. d, An ultrasonic transmitter is mounted at the top of the as 331 m/s at 0°C.41 instrumentation (GTU) = sravel time indicates the depth of * g1he ultrasonic transmitter is mounted at the bottom of the tank then the time of travel + epicts the depth of liquid in the tank and speed of travel is a function of what the liquid is. For water. the ultrasonic pulse travels at the speed of 1,496 m/s. fig. 7.7-1 shows an ultrasonic level detector. Fig. 7.7.1 : Ultrasonic level detector + Inultrasonic level measurement temperature compensation is necessary. This is because the velocity of sound is proportional to the square root of temperature. For air, it changes by about 0.6 m/s for per °C change in temperature. + To measure the travel time of echo in an electronic pulse, some sonic energy must be reflected. Solids and liquids with hard and large particles are good reflectors. Dirt has poor reflecting characteristic. It absorbs the sonic pulse. The angle of incidence is equal to the angle of reflection, Hence, it is desired that the reflecting surface must be flat. If the surface is sloping and an ultrasonic pulse is reflected, then the echo will not be directed back to the source. The round trip travel time cannot be accurately found. Inegular surface result in diffuse reflection. In such cases only small parts of the total cho travel vertically back to the source. The ultrasonic level measuring devices can be used for continuous as well as point Measurements, Point measuring ultrasonic detectors are used for measurements of gas/liquid, liquidAiquid or gas/solid interfaces.BF indus Instrumentation (GTU) 7.7.1 Advantages : 1. They have no moving parts. 2. The reading reliability is unaffected by changes in the composition density, mois content, electrical conductivity or dielectric constant of process fluid. 3. They are non-contact type measurement techniques. They have the ability to mes evel without making physical contact with the process material. 7.7.2 Disadvantages : 1, Temperature compensation is needed. Dirt, irregular and slope surfaces affect the accuracy of measurement. An ultrasonic transmitter is subject to many interferences, that affect the strength echo it receives. The echo can be weak because of dispersion and absorption. Syllabus Topic : Radiation Methods 7.8 Radiation Level Detection Method : Radiation level detectors are used in conditions when the electrical methods do work. Radiation level detector does not need to come in contact with the liquid that is measured, Construction and working : To indicating instruments Fig. 7.8.1 : Radiation level detector © Fig. 7.8.1 shows a radiation level detector. © It comprises of gamma rays source holder on one side of the tank and a gamma on the other side of the tank.instrumentation (GTU) 1 Measurement ‘the gamma rays from the source are directed towards the detector in a thin band of radiation. when the gamma rays penetrate the thick wall of the tank, their energy level decreases. ape radiation received at the gamma detector is inversely proportional to the thickness ofthe tank walls and the medium between the radiation source and detector. ‘re thicker the medium, the lesser is the radiation and vice-versa. ifthe tank is empty, the gamma rays will pass through two tank walls and the air or * apour in the empty tank. As soon as liquid enters the tank its level rises, The radiation ‘ beam passes through a path in the liquid and the tank walls. +The liquid in the tank decreases the radiation received by the detector, + The amount of radiation is inversely proportional to the amount of liquid between the madiation source and the detector. The difference in the amount of radiation will correspond to the liquid level in the tank. + Ifthe liquid level in the tank increases, the amount of radiation that is received decreases and vice-versa. The radiation loss received by the tank walls is constant. 781 Advantages : No physical contact with the liquid. They are useful at very high temperatures/pressures, They have good accuracy and response. They have no moving parts. They are suitable for molten metals and liquids of all types. M2 Disadvantages : The reading is affected by density change of liquid. Cost is high,(7h nati revarrintin GT) 7 _——— Syllabus Topic : Air Purge System (Bubbler Method) 9 Air Purge System (Bubbler Method) Principle : © Ituses a hydrostatic pressure type method for the measurement of liquid level © In this method a liquid in a tank at rest exerts a force on the walls of the tank. This force ina liquid at rest is called as “hydrostatic pressure”, It is proportional to the depth of the liquid in the tank, © Air Purge (Bubbler tube) system is suitable for the measurement of any liquid. Prossure Indicator Fig. 79.1 : Air purge system Construction : © It consists of a hollow tube or bubbler tube. This tube is inserted in the liquid of the tank. ‘© Two connections are made with the bubbler tube, one to the regulated air supply and other to a pressure gauge that is calibrated in terms of the liquid level. * A bubbler is connected in the air supply line. It acts as a visual check to the flow of supply air. * A level recorder can be connected with the pressure gauge to keep the continuous record of the liquid level.7 If there is no liquid in the tank the air flows out of the bottom of the bubble tube and the pressure gauge indicates zero. As the air escapes to the atmosphere, there is no back eee {as soon as liquid enters the tank, the air flow i sir pressure that acts against the liquid head gauge. ibe beck pressure causes the pointer to move tn a scalé, that is Calibrated in terms of the jiquid level The complete range of head pressure can pressure fed to the tube, above the maximum s restricted by the depth of the liquid. The appears as back pressure to the pressure be recorded as level by keeping the air head pressure in the tank. + The range of the device is determined by the length of the tube. As air is bubbling from the bottom of the tube, the tank liquid does not enter the bubbler tube. Hence, the tube is said to be purged. Advantages : 1. _ Itis well-suited for measuring the level of corrosive or abrasive liquids. 2 The pressure gauge can be placed above or below the tank level from the tank with the help of piping. 7.91: A capacitive transducer with two quartz diaphragms of area 750 mm? separated by a distance of 3.5 mm. The capacitance is 370 pF when no pressure is applied to the diaphragm. A pressure of 900 KN/m? when applied to the top diaphragm produces a deflection of 0.6 mm. Find the value of capacitance after applying the pressure. Soin, : Let C, and C, be the capacitances Tespectively before pressure is applied. Let di and d2 te the values of the distance between the diaphragms for the corresponding pressure conditions, C, = Gand cA Gag es, ieee 4 Qe axe d, = 3.5mmd, = d,~06 4, = 35-06 =2,9 mm a5 4G, = 30x55 C, = 446.5 pF Ex.7.92: A pressure moasuring instrument uses @ capacitance transducer having a spacing 4 mm betwoon its diaphragms and pressure of 600 KN/m’ produces an favorage deflection of 0.3 mm of the diaphragm of the transducer. The tranaducer which has a. cepactiance of 800 pF belore application of pressure ‘and is connected in an oscillator circuit having a frequency of 100 KHz. Determine the change in frequency of the oscillator after the pressure is applied to the transducer. Soin. : ‘The resonant frequency, 1 "= Gefic ‘The inductance is constant, but capacitance is variable. 1 2nJLC, 1 fe = AE fw. fo, q But cia and C,= ie _ VE artes The frequency of oscillator after the application of pressure is, a x fa = it EE 0 fon = 962KHz + Change in frequency of oscillator fy =795 Gb pus Instrumentation (STU) 7-15 AC type Bourdon tube made up of moud metal. The dimensi 1=36.5 mm, x= 16 mm, y = 3 mm and t = 0.35 mm. Calculate the displacement of free end if a pressure of 1500 KPa is applied. The modulus of elasticity of moud metal is 180 GN/m* ‘The equation of displacement of tip is, = aostt (2 eps oa :: Aa apa _ 0.05 x wx 36.5 x 10" x 1500x 10° (3 180 x 10" ( 6. 02 /16)033 16)" 5, «(2 (ss a =mr for Bourdon tube) 0.02 m = 20mm Aa Soin. : Ex 7.9.4: ‘The maximum stress A fat circular diaphragm of mild steel has a diameter of 15 mm. For mild steel, young's modulus = 200 GN/m* and poisson's ratio « = 0.28. Find the thickness of the diaphragm if the maximum stress is not to exceed 300 MN/m* when the applied pressure is 300 KN/m”. Find the deflection at the centre for a pressure 150 KN/m?, Also calculate the natural frequency of the diaphragm if the density of mild steel is 7800 Kg/m® 3D’P 160 3D’ . Thickness of diaphragm = t = 16 Sy, 0.205 x 10-* m 16 x 300 x 10° ports =e t = 0.205 mm The deflection at the centre for a pressure of 150 KN/m’ is 3P. 256 Et Geeee Industrial Instrumentation (GTU) 7-16 Level Measurement ON The natural frequency is, 6 20.0205 «107 [200x107 = DP \3pd-—)> asxlo) \V) 3%7800(1 -0.28 0, = 55492,86 rad/s ®, f = 5f = 8.831 KHz 7.10 University Questions and Answers : Dec. 2011 @.1 Explain working of Ultrasonic level detector. (Section 7.7) (7 Marks) Dec. 2012 @. 4(a) State and explain various principles of operation of Capacitive Transducers for level measurements. (Sections 7.6.1 and 7.6.2) (7 Marks) May 2014 Q. 4(a) State and explain various principles of operation of Capacitive Transducers for level measurements. (Sections 7.6.1 and 7.6.2) (7 Marks) Dec. 2014 Q. 4(b(OR) Explain measurement of liquid level using capacitive transducer. (Section [Link]) (7 Marks) May 2015 Q. 4(a) State and explain various principles of operation of Capacitive Transducers for level measurements. (Sections 7.6.1 and 7.6.2) (7 Marks) Dec. 2015 Q. 3(b) State and explain various principles of operation of capacitive transducer for level measurements. (Sections 7.6.1 and 7.6.2) (7 Marks) a aga RATE: