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
 Introduction
Measured at position (height) of interface between
phase
Direct & indirect
Vertical measurement – surface (interface) to
reference point (bottom tank)
Pressure at base ∝ height – hydrostatic pressure
P = ρgh
DP (differential pressure capsule) is most common
used
 Direct Level Measurement
• Employs physical properties – fluid motion,
buoyancy, optical, thermal, electrical properties
• Position interface – monitored visually
 Indirect Level Measurement

• Involves converting measurement – other quantity

• Determine pressure / area – height
• Temperature can affected accuracy of indirect level
measurement (substance have tendency to expand and
contract) .
• Temp changes-density changes.
• Indirect level measurement sensitive to specific
gravity, it is necessary to compensate this factor.
 Selecting Device

• Consider - operating parameter, physical & chemical

properties of raw material
• Designed to locate interface – responding to distinctive
properties of materials
• Some devices display interface visually, others use
converting measurement.
• Indirect is more accurate.
Open Tank Measurement
• Simplest application
• HP – base of tank
• LP – vent to atm
• 0% level – 4 mA
• 100% level – 20 mA
Phigh = Patm + ρgH
Plow = Patm

Differential Pressure

= Phigh – Plow = ρgH

Closed Tank Measurement
• HP – base of tank
• LP – top of tank
• Connected to DP
Phigh = Pgas + ρgH
Plow = Pgas
Differential Pressure

= Phigh – Plow = ρgH

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

• The changes in liquid density due to changes in

temperature will introduce errors.
• susceptible to dirt / scale entering tube
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 part 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
(isolated 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 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
 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
• 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
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
 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. The
waves lost kinetic energy through friction
• liquid surface are highly more reflective
Operations

• sonic level measurement

dependent on sound
wave striking live
medium & reflecting
wave
• dead media adsorb most
sound energy
• Live media will reflect
the sound waves
 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
– Low / high reading
• 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
 Sight glass
LT

Reflex sight glass

Magnetic gage