Chapter 3

Level Measurement

Objectives
After finish this lesson, you will be able
to:
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

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 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 & fuel
quantity

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Dip stick withdrawn & level read at the last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
This can darken/change color
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

 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 high-pressure
housing
1 inch thick

Gage Glass
Principles
Similar sight glass
Glass covered ports in
vessel observed
easily
Have scale mounted on
the tank
Disadvantage: shut
down process for
repair glass

Operations

Simple
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

Magnetic Gauges
Principles
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

Typical
Installatio
ns of
Magnetic
Gauge
25

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

Float Device
Principles
Cable

Weight/level
indicator

Float

Reliable of other visual

sensors
Float move by level
changes
Movement 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

THANK YOU

Capacitance
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 )

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

Conductivity
For liquid interface of
relatively high
conductivity
Include water-based
material
brine solution, acids,
caustic, certain
beverages
Limited to alarm devices
& ON/OFF system

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

 Terminals electrode
connected to relays
High-level
probe

Low-level
probe

transmit signals to
display / control device
Extends min level,
conductivity path
established through
grounded tank

Controller

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 level

Advantages

Low cost
Simple design
No moving parts
Effective for many water-based
material

Disadvantages
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)

 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
Sound
energy
absorbed
d

Soundenergy
incident
onsurface

 Value d
depend the frequency sound wave.
Influenced by surface porosity, material
thickness, rigidity
Continuous process
based on time elapses from generation of
sound wave to detection of the reflected wave

Level measurement
troubleshooting
1. Connections

DP cell sensing line connection is reversed

High operating pressure & low hydrostatic
pressure; easy to occur
Actual level , indicated level

2. Over-pressuring

3 valve manifolds on DP cell prevent overpressuring & easy to remove

Fail immediately / diaphragm become
distorted
Low / high reading

3. Obstructed sensing lines

Small diameter; clogged with particulate

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

4. 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
Sight glass
Reflex sight glass

Magnetic gage
dipstick

Ultrasonic
Cable Float

Magnetic Float

Capacitance
Side mounting
Float
Sight glass

THANK YOU