Level Gauge

CONTENT

OBJECTIVES 1

1.0 INTRODUCTION 1

1.1 Background of Instrumentation 1

1.2 Level Measurement 1

1.3 Level Gauge 2

2.0 CLASSIFICATION OF LEVEL GAUGE 3

2.1 Tubular glass level gauge 3

2.2 Transparent level gauge 3

2.3 Reflex level gauge 4

2.4 Magnetic level gauge 5

3.0 GAUGE GLASS MATERIAL 6

4.0 DESIGN FEATURES 6

5.0 GAUGING INACCURACIES 7

6.0 ACCESSORIES 8

7.0 CONCLUSION 8

REFERENCES 9
OBJECTIVES
On completion of this analysis, the following objectives will be achieved:
1. To explain how to select the correct level gauge for a given application with the
given characteristics of various level gauges.
2. To understand the construction and working principle of different types level
gauges

1.0 INTRODUCTION
1.1 Background of Instrumentation
There have been significant developments in the field of instrumentation in recent
times. It is highly used in systems like power plants, process industries, automatic
production machines, various control/manipulation and safety devices etc. It is cost
effective as it contributes significantly in evolving better quality control, higher plant
utilization, better man power productivity, material and energy savings, and speedier and
accurate data reductions.
Detailed specifications of the functional characteristics of any instrumentation are
termed its performance characteristics. These are in general, indicative of the capabilities
and limitations of the instrumentation for a particular application. Therefore, the
knowledge of the performance characteristics is quite important as it enables us to have
quantitative estimates of the positive as well as the negative points of various
commercially available instrumentations. Consequently, one can select the optimum type
of instrumentations for the given application.

1.2 Level Measurement

Level is the filling height of a liquid or bulk material, for example, in a tank or
reservoir. Generally, the position of the surface is measured relative to a reference plane,
usually the tank bottom. If the product’s surface is not flat (e.g., with foam, waves,
turbulences, or with coarse-grained bulk material) level usually is defined as the average
height of a bounded area.
The measurement of level is defined as the determination of an existing interface
between two media. These media are usually fluids, but may be solids or a combination
of solid and fluid. The best method of measurement depends upon the nature of the
specific application, which must deal with:
1. The process to be measured.
2. The degree of accuracy required.
3. Dependability.
4. Economic considerations.
In the oil and natural gas industries, liquid level measurement is necessary to achieve the
following objectives.
1. Compute tank inventories of crude oil.
2. Protect equipment such as compressors, turbines and pumps from damage.
3. Protect operating and maintenance personnel against injury resulting from
liquid spillage.
4. Protect the environment from the spillage of liquids.
5. Control phase separation processes.

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1.3 Level Gauge
Level gauge operate by connecting a measuring chamber in parallel to the vessel
being monitored so as to directly indicate the level visually or by the use of a magnetic
indicator or transducer. The configurations of glass-type gauges comprise tubular glass,
flat glass-transparent (circular and long-form), reflex, and magnetic gauges. The level in
the gauge follows the level in the vessel, as illustrated in Figure 1.3.

Figure 1.3: A level gauge (on right) is mounted in parallel to the vessel, extending over
the range of level to be indicated. A circular gauge is mounted at the level of interest
(left).

Level gauges are often used in process vessels as well as storage vessels. In level
gauges providing direct visual indication, the accuracy is limited by the readability of the
meniscus of the liquid in the indicating area of the gauge. The readability can be reduced
when monitoring foaming, boiling, or inhomogeneous liquids. A single chamber has
multiple gauge covers stacked along the length of the measuring chamber. There are
small spaces over which the view of the level is blocked by the top and bottom edges of
the individual gauge covers.
Magnetic gauge can provide better accuracy because it has high resolution and
continuous indication is available through the entire range.

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2.0 CLASSIFICATION OF LEVEL GAUGE
2.1 Tubular glass level gauge
A simple tubular glass gauge comprises a transparent glass tube, seals, end blocks,
and guard rods to protect the glass. It is positioned parallel to the vessel along the
elevation over which the level is to be indicated and mounted with suitable fittings to
retain the pressure as well as to seal the ends of the sight tube. This construction, however,
is not well suited for use with dangerous process fluids.

Figure 2.1: The traditional tubular glass level gauge is not recommended for most
industrial applications.

An important consideration in gauge selection is that of maintaining the safety of

personnel and associated equipment. The difficulty is evident when the process vessel,
storage tank, pipeline, and so on are used with high-temperature, high-pressure, corrosive,
or other dangerous fluids or steam. If a sight glass tube sustains a fracture of the glass or
a leak at the seals, the dangerous fluid can escape and create the potential for a hazardous
condition. The single tube design is not recommended for use with toxic materials,
pressures above 1 bar (0.1 MPa or 14.5 psig), or temperatures above 100°C.

2.2 Transparent level gauge

Transparent level gauge measuring chamber retains the fluid and accepts the glass
and covers, which are secured with bolts. One or more vision slots are machined into the
chamber to allow viewing of the level. Tie bars are areas that may be left (i.e., not
machined out) in the vision slot so as to provide higher strength. Gasket material is
compressed between the chamber and the glass to prevent direct contact and to provide a
seal. Cushions are placed between the glass and the covers to prevent direct glass-to-
metal contact. The chamber, glass, and gaskets are wetted by the process. Shields can be
optionally installed to protect the glass from the process fluid and/or from the ambient
environment (e.g., windblown sand).

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 The gauge is called transparent because there are glass panels both in front of and
behind the measuring chamber, with respect to the observer who is reading the gauge.
Accordingly, the liquid level indication is illuminated by light coming from behind. This
configuration is useful to allow visual inspection of the liquid for color and presence of
particles, for example, in addition to indicating the level. One drawback is that it requires
the availability of some light from behind. Lighting panels (called illuminators) are
available for providing this illumination when it is not available from the ambient
lighting. Because of the process fluid viewing capability, transparent gauges can be used
in applications that require the indication of the interface between two liquids.

Figure 2.2: Transparent level gauge construction, front view (left), and cutaway view
(right). The front view shows two covers attached to one chamber, and shows the
distinction between visible length and visible glass.

2.3 Reflex level gauge

Greater visibility of the transition between the liquid level and the gas or vapor
above it is provided by the reflex-type glass gauge. The construction, shown in Figure 2.3,
incorporates a glass element in front of the measuring chamber housing, but not behind it.
Illumination is only from the front, and level visibility is aided through the use of grooves
in the glass where it contacts the liquid being monitored.
When viewing a transparent or semi-transparent liquid in a reflex gauge, the
liquid will appear black or dark because the light is not reflected back to the viewer from
the prism area. The column above the liquid will appear silvery, because the light is
reflected back from the glass-to-gas interface at the prism area (e.g., there will be a dark
column below the indicated level and a silvery column above the indicated level).
Because of the reflection of light back to the viewer, reflex gauges are well suited to
viewing with a flashlight in low-light areas.
Because of the front illumination and the prismatic glass, reflex gauges are
recommended for use only with clean, clear, process fluids and when there is no liquid–
liquid interface to be viewed. Because of its irregular shape, shields cannot be installed
against the prismatic glass, so corrosive fluid service is limited to those with little or no
effect on the glass.

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 Figure 2.3: Construction of a reflex glass level gauge.

2.4 Magnetic level gauge

Because the magnetic level gauge does not require direct viewing of the level (i.e.,
there is no need for glass), the measuring chamber can be opaque, and welded metal
construction is normally used. This substantially widens the operating temperature range
and increases the ruggedness as compared to chambers using gauge glass. The wide
temperature range is possible, because the measuring chamber can have approximately
the same coefficient of thermal expansion as the vessel, and there is no glass to interface
with the metal chamber.
To allow the magnetic system to operate properly, the chamber metal must be of a
nonmagnetic type - usually an austenitic stainless steel such as AISI 316 SS. Because the
float in the chamber of a magnetic gauge incorporates a permanent magnet, any reliable
method of detecting the location of a magnetic field can be used to show the location of
the float and, thus, the level.
One limitation in magnetic gauges is that the float must have a comparatively
thick wall to operate at higher pressures. Due to the related weight, it is more difficult to
measure process fluids of low SG (e.g. less than 0.45) when the pressure is high (e.g.
over 200 bars/20 MPa).

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3.0 GAUGE GLASS MATERIAL
Borosilicate glass is the most common type of gauge glass. It has good chemical
resistance up to about 300°C. In addition, transparent shields can be mounted between the
glass and the process fluid to protect the glass from corrosive media in transparent level
gauges (e.g., the shields can be made of mica or PCTFE).
Borosilicate glass is usually tempered to improve its resistance to thermal shock.
The tempering process comprises the heating of the glass to the glassy transition point,
followed by rapid cooling. This is done during manufacture of the glass to induce
mechanical compressive stress in the outer layer, resulting in an increase in the ultimate
tensile strength (UTS). The tensile strength is increased; because the compressive stresses
must be offset by tensile stresses before cracks can propagate (cracking is required before
breakage of the material).
Aluminosilicate glass has a lower coefficient of linear thermal expansion than
borosilicate glass, but it can be used at higher process temperatures of up to 425 °C.
Quartz glass has the highest temperature rating (up to 530 °C) and also has the lowest
coefficient of linear thermal expansion. It can be used in transparent gauges but is not
available in reflex gauges, because it would be difficult to form the grooves. The
materials of construction other than quartz determine the maximum operating
temperature of a quartz gauge assembly. Extremely flat gasket and cushion seating
surfaces are required when using quartz glass to avoid bending and torsional or point
stress.

4.0 DESIGN FEATURES

It is typical for all glass level gauges to have a reduction in pressure rating as the
temperature increases. Manufacturers list representative charts for general guidance in
selecting the type of construction and components to meet the application requirements.
Once the complete gauge model has been specified, including chamber model, glass type,
shields, and so forth, it is important to verify with the manufacturer the resulting
temperature vs. pressure curve for that particular configuration.
Transparent and reflex gauges are normally limited to a maximum single-gauge
length of up to 1.5 m. If a greater total visible length is required, multiple gauges will
have to be installed. Overlapping is suggested to allow viewing of levels that would
otherwise be blocked by the top and bottom edges of the covers.
To reduce problems from boiling or foaming process fluids, a larger-diameter
measuring chamber (approximately 50 mm) can be used as shown in the top row of
gauge cross sections illustrated in Figure 4.0.
In cryogenic service, the view of the level in standard glass gauges may be
blocked by ice accumulation. A non-frosting lens can be added that consists of a T-
shaped plastic lens held against the glass by the cover and extending out in front of the
glass. The plastic lens has a relatively low thermal conductivity and is not as cold on the
front viewing surface as the face of the gauge glass, which reduces frosting.
Heating or cooling of the gauge may be required to keep it at approximately the
same temperature as the process fluid in the vessel. The appropriate device may be added
externally or mounted in the bore of the chamber.

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 Figure 4.0: Special level gauge designs and cross sections.

5.0 GAUGING INACCURACIES

Gauge error usually depends on the resolution of graduations on the scale, if
provided. Readability can be degraded by foaming, boiling, and other effects that alter
density or reduce visibility. The indicated level can be affected by a difference between
the temperature of the gauge and the vessel. If the gauge is cooler than the vessel, the
liquid within the gauge may be denser and therefore indicate low. This can be eliminated
by using a heater on the gauge and controlling the gauge temperature to match the vessel
temperature. Conversely, the gauge temperature can be reduced, if needed, by adding a
cooler in a similar manner.
In a gauge with a magnetic follower, some error is due to the strong magnetic
attraction required between the float magnet and the follower magnet, which induces
friction on the walls between them.
Foaming or boiling can show false high readings because of an apparent lower
specific gravity (SG) of the fluid in the gauge compared to the fluid in the vessel (if the
vessel fluid has less foaming or boiling). This can be reduced by using a gauge with a
larger chamber diameter, as was shown in Figure 4.0. Internal condensation can cause
readings to become blurred. To prevent this, a heater can be added inside or outside the
chamber.

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6.0 ACCESSORIES
Gauge support brackets are used with long gauges, where the distance between
supports is about 1.5 m or longer, to reduce the load placed on nipples and valves. Steel
brackets are welded directly to the measuring chamber and then bolted to a support plate
on the vessel. On a reflex gauge, the bracket can be welded to the back of the chamber
(between sections to avoid interference with cover bolts). On a transparent gauge,
suitable welding locations include the right or left side of the chamber, between sections.
The brackets are normally welded on at the factory according to customer specifications.
Valves and fittings are also needed, of course, for the installation of level gauges.
Fittings can be any of several types, including spherical union, flanged, socket weld, solid
shank, or NPT union. Valves are normally factory assembled to the gauge. The fitting of
unions to the vessel side of the gauge valve will facilitate the initial connection of the
gauge. The gauge can be removed without depressurizing the vessel if valves are
included on both the gauge and vessel sides of the unions.
An illuminator can be used with transparent gauges to increase visibility in lower-
light areas. A lamp is used with a diffuser to illuminate the entire visible glass area.
Explosion- proof versions are available for use in hazardous areas.
Scales can be engraved or etched in the desired units and are attached to the gauge
cover. If the installed scale does not accurately indicate the actual level in the vessel, a
calibration can be undertaken. The calibration data can be used to derive a conversion
factor between the indicated reading and the actual vessel volume.
Boiler and steam/water gauges must be reliable to ensure the safety of personnel
and equipment. High pressures and temperatures require attention to the specification and
application of all parts and materials of the gauge, valves, and fittings. Saturated steam
tables should be consulted to ensure that the operating pressure and temperature for the
application are within the range shown in the tables provided by the gauge manufacturer.
Standard glass level gauges may not be suitable for use with steam.
Shields (usually mica) should be used to protect against etching of the glass (the
etching is also called frosting, but this is different from frosting due to accumulation of
ice in cryogenic systems). Transparent gauges are used because shields cannot be applied
to the prismatic surface of reflex glass.

7.0 CONCLUSION
The various types of glass level gauges provide a means to view the level of the
liquid. For accurate level indication, foaming and boiling must be minimized. The
process fluid in the gauge should be at the same temperature (and density) as that in the
vessel.
Tubular glass gauges are not recommended for hazardous applications such as
toxic liquids, high temperature, and high pressure. Magnetic level gauges can provide a
higher safety margin when direct viewing of the liquid is not required. Magnetic level
gauges yield the lowest errors, where power is available, at a higher cost.

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REFERENCES

1. Nakra BC and Chaudhry KK (2004). Instrumentation, Measurement and

Analysis.2nd ed. Tata McGraw-Hill: New Delhi

2. Bela G. Liptak (2003). Instrument Engineers’ Handbook – Process Measurement

and Analysis Volume 1. 4th ed. CRC Press: US

3. Level Measurements retrieved from www.scribd.com

4. Level retrieved from www.scribd.com

5. Boiler Drum Level Measurement and Control by David C. Farthing retrieved

from www.scribd.com

6. Instrumentation Engineers Handbook by Vehicular Instrumentation/Transducer

Committee, Telemetry Group and Range Commanders Council retrieved from
www.scribd.com