Level measurement
• Measurement of levels is also an important activity in any chemical process
industries
• Industries are required to store several liquids (Water, Solvents, Fuel) in large
containers
• It is required that industries keep a track of how much liquid or how much
solvents, water etc is there in the large containers at any given point of time.
So, that replacement can be done, whenever it is required.
• Basically two types of measurements
• Direct measurement
• Indirect measurement
Direct Measurement
• The simplest method of measuring liquid level directly is to
use ordinary sight glass or gage glass on the vessel
• The level of liquid in the sight glass will be the same as the
level of liquid in the tank
• This method is quite effective for clean coloured liquids
Advantages Disadvantages
Direct reading is possible • It is read only where the tank is located, which is not always
convenient
Special designs are
available for use up to • Since sight glasses are located on the outside of the tanks, the liquid
316 0C and 10,000 psi in the sight glass may be effected by ambient temperatures and
pressures, and thus, it may cause error in the reading
• Accuracy & readability depend on the cleanliness of glass and fluid
• When E1 is not in contact with the conductive liquid, the
electrical circuit is open, and no current flows between
electrodes E1 and E3.
• When E1 is in contact with the conductive liquid, the circuit
closes due to the conductive fluid completing the circuit
between E1 and E3.
• Relay X operates and switches to the a side.
• By connecting the relay X to a contactor, the pump can be
turned ON and OFF.
• The use of electrodes is limited since continuous measurement of level requires a
large number of electrodes
• This method is limited by the characteristics of the liquids, some are non-conducting,
some are corrosive, some contain solids which deposit on the electrodes
Float and Tape/Chain method
Float-operated Liquid
Level Indicator Hydraulic Transmission
System for Level Indication
*** Float rides the surface level to provide the
measurement. Many different styles are
available.
• It is majorly employed in open vessels only
• The float is usually of Nickel-plated copper, rests on the surface of liquid
• The float is made with sloping top in order to avoid building of solid material
on top of the float, thereby changing its weight
• These instruments work on the Archimedes principle according to which a
body when placed in a liquid is buoyed up by a force equal to the weight of the
displaced liquid, and the apparent change in weight of the body is directly
proportional to the level of liquid in which it is placed.
• The float is connected to counter weight for measuring the level of liquid in
tank.
• Range is 4 inch to 60 ft and not suitable for measured corrosive liquid.
• Hydraulic transmission system usually employed for high pressure (up to
1000 psi) closed systems and 750 0C
Indirect Measurement
• Indirect methods “infer” liquid level by measuring some other physical
parameter such as pressure, weight, or temperature.
• Measures another process variable (e.g. head pressure or weight) in order to
infer level.
• Examples:
Hydrostatic Pressure Type (Pressure gauge method, Air bellows, Air purge
system, Liquid purge system)
Electrical Type (Capacitance level indicators, Radiation level detector)
Pressure Gauge Method
• The simplest method used for liquid level measurement in the open tank
P=ρgh (for open tank)
P=ρgh + external pressure on liquid (for closed tank)
• The pressure gauge level indicator consists 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 &
the static pressure measured by the
gauge is a measure of the height of
liquid column above the reference level
& hence the liquid level
• A liquid seal is connected with the piping on the tank including a shut-off
valve while measuring corrosive or highly viscous liquids
• This liquid seal consists of a fluid with which the measuring system is filled
• This filling liquids transmits the pressure head of the measured liquid
Air Purge System
• Also known as bubbler tube.
• This system is 1 of the most popular
hydrostatic pressure type of liquid level
measuring system which is suitable for
any liquid.
• Consists of a hollow tube inserted in
the liquid of the tank.
• 2 connectors are made with the bubbler tube (1 to regulated air supply & the
other to a pressure gauge), calibrated in terms of liquid level.
• A bubbler is connected in the air supply line which serves 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. (Figure)
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 & the pressure gauge indicates zero.
• As the liquid level in the tank increases, the air flow is restricted by the depth of
liquid and the air pressure acting against 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 range of head pressure can be registered as level by keeping the air
pressure fed to the tube, slightly above maximum head pressure in the tank.
• The range of the device is 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 if air reacts with the tank fluid or is
absorbed, different gases (like carbon or nitrogen) are chosen depending on
liquid properties.
• The pressure gauge can be placed above or below the tank level & can be kept as
far away as 500 ft (12.7m) from the tank with the help of piping
Liquid Purge System
• When an air purge system is unsuitable, because air bubbling through liquid may
interface with its crystallization, a liquid purge system is used.
• The construction & 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 of the purging liquid must be such that the introduction of small
quantities of it into the plant will not affect the product on process.
• 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 to about 1 gallon/hour.
• The supply liquid pressure is determined by the range of liquid level to the
monitored.
Diaphragm box method
• The diaphragm box liquid level meter is shown in figure consist of two flanges
in between which is contained a diaphragm element made of rubber or oil
resistant synthetic composition (neoprene fabric)
• The system is filled with air
• The diaphragm is usually suspended in the vessel by a chain to a fixed support
• The box is connected to the pressure receiver
• Can be used up to 500 ft
• Limited for corrosive liquids. For corrosive liquids liquid seal can be used
• Diaphragm boxes are made of cast iron, bronze
• It is essential that the complete system should be airtight since loss of air would
prevent the operation
Air-trap system
• The air-trap system is very similar to diaphragm-box system except that no
diaphragm is used (lack of suitable material for few kinds of corrosive liquids)
• The pressure receiver operates from the pressure of the trapped air and all other
details are same as diaphragm box system.
• The main limitation is the possibility of slow loss
of air trapped in the system
• For this reason, an auxiliary tap should be
provided for filling the air as frequently as may be
necessary
Pneumatic balance displacement float gauge
• The force caused by the float is balanced by the
Pneumatic servo system
• The range of this kind of gauge may be as low as
2 in. and as high as 60 ft (depends on float
length)
• The accuracy of the method is similar to other
methods as long as the specific gravity of the liquid is not low.
• The deposition of solids on the float is source of error
Level measurement by Weighing
• The simplest and most obvious way to measure the level of a liquid or a dry
material is to weigh the contents of the entire vessel
• When the area of vessel is known, the level can be determined
• This is done for dry materials where other methods fail. However, it is
expensive when large and heavy equipment involved
• This method is more accurate if the weight is an important factor than density,
level or volume
Level of dry materials
• This is used for measuring a specified level in the
bin/vessel
• The device operates from a light, flexible diaphragm
which mechanically positions a switch
• The weight of dry material in the bin acts against the
diaphragm when the material in the bin reaches a
desired level
• These devices are satisfactory for all dry bulk materials of sufficient weight or
density
• Probe or contact type electric indicators may also be used.
• In most cases it is necessary to select different types based on the material
characteristics
Electrical Type
Radiation Level Detector
• The most common reason for using a
radiation level detector is that it does
not need to come in contact with the
liquid being measured
• 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 of 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.
• When the tank is empty, the gamma rays pass only through the 2 tank walls & the
air or vapour in the empty tank.
• When liquid enters the tank & its level rises, the radiation beam passes through a
path in the liquid, as well as the tank walls.
• The liquid in the tank reduces the radiation received by the detector.
Advantages Disadvantages
There is no physical contact with the liquid. The reading is affected by density change of
liquid.
They are suitable for molten metals as well as
liquids of all types (corrosive, abrasive, highly Radiation source holders may be heavy.
viscous, adherent)
Their cost is relatively high.
They are useful at very high
temperatures/pressures.
They have good accuracy & response.
They have no moving parts.
Ultrasonic Level Detector
• Non-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 Detectors
• 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 returned to 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.
Density measurement
• The measurement of density or specific gravity may be accomplished by 2
methods
The pressure at the bottom of a column liquid/gas is proportional to density
The weight of a given volume of liquid/gas is proportional to density
• The head h1 is held constant in the
measuring tank or vessel by an overflow
arrangement
• The head h0 in the reference chamber is
constant providing the liquid is non-
volatile
• Therefore the differential pressure measured by the manometer is that due to
the difference in densities of two liquids
• The system is calibrated to accommodate the different heads in the tank and
reference chamber by adding sufficient mercury to the manometer to bring the
float to the zero position when the densities of two liquids are equal
• Density can be continuously measured if the flow of liquid through the
measuring tank is continuous.
• The pressure in each chamber is measured by means of the bubbler system
• Temperature corrections (usually done manually after manometer readings) are
necessary if the temperature of the flowing liquid varies
• To avoid necessity of temperature corrections a thermostatic heater can be used
to maintain constant temperature of the flowing liquid
• The density measurement using weight method
is shown in Figure
• The liquid flows continuously in and out of the
displacer chamber at a rate about 3 gpm. The
upward force on the balance beam is due to the
displaced volume of liquid. This force is
balanced by the pneumatic servomechanism
• As a result the pressure is transmitted to the receiver is proportional to the liquid density
• The equipment can be used for liquids having S.G of 0.5 and higher. The densities of
corrosive liquids can be measured, providing suitable materials of construction are
selected. Also, the densities under pressure may be measured.
• Temperature corrections are necessary if the temperature of the flowing liquid changes
• To avoid necessity of temperature corrections a thermostatic heater can be used to
maintain constant temperature of the flowing liquid
Hydrometer method
• The hydrometer method can be used for continuously
measuring specific gravity of liquids (Figure)
• The level of liquid is maintained constant at the overflow tube
• The hygrometer sinks or rises in the liquid as the specific
gravity varies (Buoyancy - Archimedes principle)
• The lower end of the hydrometer supports an armature in an
inductance coil and the specific gravity/density can be
remotely indicated
• Specific gravity meters for gases generally operate on the same
principles as meter used for liquids
• Another common method for measuring specific gravity of gases is to compare the weight
of a column of the gas with the weight of column of air at the same height
Viscosity measurement
• A quantity expressing the magnitude of internal friction in a fluid
• It can be measured by measuring the friction, i.e. shear force
• Figure shows a bowl containing the liquid (viscosity to be measured)
• The bowl is rotated at constant speed by connecting it to the motor
• A paddle wheel is supported in the bowl and is free to turn with in the liquid, the rotation
of the paddle wheel is opposed by the spring
• For low viscosity fluids the shear or drag forces are low, and the pointer deflects a small
amount
• For high viscosity fluids the forces are greater and the pointer is deflected a large amount
• Since viscosity is greatly affected by temperature, the bowl is enclosed by a housing which
has thermostatic temperature control
Continuous viscosity meter
• Since the flow rate of a fluid in a variable area meter (rotameter) is dependent on
viscosity, this is used to measure the viscosity of fluid
• A tapered tube through which the fluid flows, contains two floats. The lower float
is shaped so as to be immune to viscosity changes
• The flow rate through the tube is controlled to a constant value so that the lower
float remains at the flow setting mark.
• Since the flow is constant the upper float which is sensitive to viscosity changes
or actually is acted on by the viscous drag forces, changes position with changing
the fluid viscosity.
• Therefore the distance between the floats is proportional to the viscosity of the
fluid at the existing temperature.