A LEVEL PERSPECTIVE
LEVEL
MEASUREMENT
TECHNOLOGIES
In The Process Control Industry
Few things are as ubiquitous in the process control industry as According to the Health and Safety Executive that investigated the
the need to measure the level of a process material in a blast, “the tank was full, but gauges and safety devices did not
container. Whether that material is water, waste water, work.”1 A high level switch that should have detected the petrol level
petroleum, sugar, or any other form of liquid or solid, and cut off flow to the tank failed to operate and workers didn’t notice
level that the tank was overflowing2. This resulted in a 32-hour inferno
measurement which injured 43 people and left many families homeless.
accuracy can Because of the importance of accurate level measurement and
be a the myriad of different process materials requiring level
determining measurement, an almost equal number of unique methods for
factor in both detecting level have been developed. Selecting the correct level
profit margins measurement technique for a particular application can seem like a
and safety. On daunting task in the
December face of so many options. All
11th 2005, level measurement
malfunctioning Instances of level systems rely upon
level gauges certain characteristics of the
were partially measurement and control process material,
responsible for such failure... can lead to tragic as density,
a massive costly capacitance,
explosion at consequences.... temperature, etc.,
the and each has its own
Hertfordshire particular advantages and disadvantages. It is important to
Oil Storage understand the fundamental mechanics of the level measurement
Terminal in technologies being considered in order to correctly specify the
Hertfordshire, appropriate method (or methods in the case of redundant systems)
England. for the application.
10
Categorizing Level
Measurement
How to
Narrow Down
Technologies Options
A good way to reduce the number
of level measurement options is to
categorize them into two broad
categories: contact and non-contact.
Then you can filter choices by the type
of material they can measure.
Contact Non-Contact
Contact and Non-Contact
The characteristics of the process material being
measured, such as tank size and shape, the pressure and
temperature that the process requires, amount of material
agitation, available power, etc., must be taken into account
when determining if a contact or non-contact approach is the
right option. One must consider whether the material is
corrosive or tacky and could possibly cause damage to the
measuring device, whether it is volatile and a contact sensor
might create a safety hazard, whether the agitation,
temperature, or pressure of the process material could affect
the reading of or damage the contact sensor, and any other
troublesome possibility. On the other hand, non-contact
solutions may be outside of the budgetary constraints of the
project or not provide the necessary level of precision.
Type of Material Measured
Process materials that need level measurement can
generally be classified as liquids, granular solids, slurries, and
interfaces. Liquids vary greatly in density and can be under a
wide range of pressures and temperatures, depending on the
Liquids Granular Interfac Slurrie
process. These factors influence the types of level sensors that s
Materials e s
can be used. Interface level, or the point at which two liquids of
different densities meet, requires special consideration over Materials A Semiliqu
that are in that are in surface id
typical liquid level measurement. A lot of the sensor technology a
that can be successfully employed in measuring liquid will be a solid boundar mixtures
unwieldy or simply unusable when measuring granules such state and y of liquid
liquid state
as loam and stone dust, or slurries such as cement. For these small betwee
reasons, it is important to understand the type of process
material (at all stages of the process) you are dealing with prior
to looking into level measurement options.
1
An Overview of
Level Measurement
Technologies
Because for the sheer number of
level measurement technologies, the
following overview is not meant to be
all-inclusive nor is it meant to cover
every intricacy of the technology in
question. It is meant instead to give a
very high-level synopsis of some of the
different types of technology available
and how each functions as a
measurement device. More detailed
information regarding a specific
measurement device can be found in
the manufacturer’s documentation and
should always be consulted prior to
purchase as every device uses level
measurement methodology differently.
That being said, a broad understanding
of how each technology category is
meant to function will give you a proper
head start when specifying level
measurement sensors.
Contact Sensors on measurement accuracy3. When
measuring an interface, the top opening of
retraction of a connected cable. This type of
sensor, in principle, requires no power to
the gauge must be submerged at the level of operate but is susceptible to failure from
Level Sight Gauge the top liquid and the bottom opening must float jamming or clinging.
be at the level of the denser liquid or else
the level measurement will be incorrect. Displacer
Level sight gauges can only be used when
measuring liquids, as granules and slurries
cannot move fluidly through the gauge.
There is also no way to incorporate any type
The first type of level measurement
of automation into the process using this
device to be considered here is also the
type of measurement device.
simplest. A level sight gauge typically
consists of a tube connected at openings Displacers are dissimilar from float
near the top and bottom of the tank. The Float devices in that they are denser than the
tube has a transparent face so an operator process fluid and suspended by a spring.
can see the level of the process material. They rely on Archimedes’ Principle to detect
This is technically a non-contact changes in buoyancy force, which is equal
measurement because there is no sensor to the weight of the displaced fluid, caused
making contact with the process material. by a rise or fall in level. A sensor at the top of
However, many of the same concerns about the gauge measures the change in apparent
contact sensors should be taken into Other devices, such as floats and weight of the displacer body. The level
account, such as agitation, corrosiveness, displacers, rely on the material’s specific measurement is therefore a product of the
tackiness, temperature, pressure, etc., gravity (density) to measure level. They often length of the displacer body covered by the
which could damage or obscure the viewing use a gauge similar to the sight level (a tube process material and the specific gravity of
area. connected to the side of the tank towards the the material4. Both displacers and floats
top and bottom).. Magnetic floats, a specific require much of the same considerations as
Though this method of level type of float level sensor, typically rely on mentioned previously with level sight
measurement may be considered the reed relays placed lengthwise within the tube. gauges and special considerations for
most trustworthy because the material When the float passes these relays the interface measurement.
level can actually be seen by the operator, magnetic field trips them. Therefore, the
pressure or temperature differentials accuracy of such a sensor is limited by
between the tank and the viewing area can
have an effect the number of reed relays placed in the
gauge. Other float sensor types rely on the
measurement of the extension and
1
Bubble Tube Resistance Tape will vibrate at its resonant frequency
when not submerged in process
material. If the frequency is dampened,
the material has reached the level of the
The mechanical force of a process
liquid can be used to measure level
Bubble tube level measurement
relies on the specific gravity of the
process material as well. With this type
of contact sensor, a tube is submerged
switch. This technique works with liquids,
into the process fluid and air or nitrogen
slurries, and granules, although
is pumped through the opening, near
using what is known as resistance tape. consideration should be made for
the bottom of the tank. The resulting
Two wires, one attached to a voltage coating or corrosive materials. Vibrating
back pressure is proportional to the
source and the other to a precision level switches will typically only be used
liquid level and density5. In instances
resistor, are contained within a for point level measurement, as opposed
where submerging a tube into the
shielded, flexible probe. Hydrostatic to continuous level measurement, and
process liquid is impractical, air can be
pressure pushes on the probe body and trigger high and/or low alarms. The
pumped in through an entry at the side
shorts out the submerged length of sensors themselves tend to be fragile
of the tank. This type of sensor can only
wire. The change in resistance is because of the level of precision
be used to measure the level of liquids.
correlated with the level of the process necessary10.
If the process liquid in which the tube is
liquid. These types of contact probes
submerged remains at a constant level,
tend to be very delicate and changes in
any change in backpressure is due to a
density can have a minor effect. They
change in density or interface level, thus
are typically used to measure liquids
allowing for measurement of these and slurries9.
variables6.
Contacting Ultrasonic
RF Capacitance
point-measurement level switches or
continuous level measurement.
Variations of this technique can be used
Vibrating or ultrasonic level switches
to measure liquids, granular solids,
work under the principle that the sensor
slurries, and interface levels8.
mA mA
Non-
Conductive
RF Capacitance level sensors use the same operating principle as an electronic capacitor in order to gauge level. An
electronic capacitor consists of two conductive metal plates separated by some kind of insulating material. Capacitance is the
measurement of the amount of energy a capacitor can store. Level
UsingMeasurement
a method that is very similar to that of an electronic
capacitor, the capacitance of a process material can also be measured and then correlated to the level.
Using RF Capacitance
If measuring a non-conductive material, that material is used as the insulator part of the capacitor and the tank wall acts as
the second conductive plate; if measuring a conductive material, the probe body is shielded with an insulator and the
mA
material acts as the other conductive plate7. In either case, a rise in the level will correlate with an increase in the
measured capacitance (over that of air). This technology can be used for either
Conducti
ve
Contact and Non-
Contact Level
Measurement
Comparison
yutabtSliii
Material Measurement
Corrosiveness
Tackiness
Granular
Agitation
Continuo
oatlFGguaeSghitvLeel
Single-P
Liquids
Slurries
Interface
Level
Level
ypeT
● ● ●
● ● ● ●
● ● ●
Contact
● ● ● ●
● ● ● ● Uosanrtl ● ●
● ● ● ●
● ● ● ●
● ● ● ● ● ● ● ●
Non-Contact
Nucealr
● ● ● Cellsod ● ● ● ●
aL
● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ●
Recommended
applications
the direction of an object, waiting for that
Non-Contact Sensors pulse to reflect off the object and return
to the source, and measuring its time-of-
All level measurement Radar flight. The distance between the pulse
systems rely upon certain source and the object can be calculated
characteristics of the as the product of one-half the time-of-
process material... flight and the speed of light.
For use in level measurement, a
radar transceiver is suspended from
Radar is a technology which the top of the tank and measures the
was first extensively developed and distance to the top of the process
deployed during the second World material. The overall length of the tank
War as a means of detecting aircraft, body can then be used to calculate the
ships, and other large objects. Since level. As a non-contact sensor, radar
the technology was introduced to the has the distinct advantage of not being
civilian sector, many peacetime affected by the process material’s
usages of the technology have been state, such as agitation, corrosiveness,
established, including level tackiness, temperature, pressure, etc.
measurement. Radar typically works Radar can be used to measure liquids,
by emitting electromagnetic pulses in slurries, and granular
1
solids. However, materials with high the material, it is typically only used
conductivity tend to be better candidate when all other options have been
for radar level measurement because exhausted due to the dangers and
they reflect more of the emitted radio expense of using radioactive material
signal. As such, conductive materials and the stigma associated with it.
other than the process material within
the tank, such as agitators, can cause Nuclear type level sensors use
interference with the radar signal. radioactive isotopes, typically either Summary
cobolt-60 or caesium-137, to emit The technologies described here
gamma radiation into a storage barely scratch the surface of those
Non-Contacting Ultrasonic container and sensors on the opposite available to the industry (not to mention
side to measure the attenuation, or variations of these technologies). Due to
change in frequency modulation, of that the nearly countless number of process
radiation. Isotopes are atoms that have materials and conditions in all of the
the same chemical behavior as one industries that require level
another but a different number of measurement for their processes, an
neutrons. Radioactive isotopes are almost equal number of methods for
Non-contact ultrasonic level sensors
those isotope variations which are measuring level have been devised.
use a very similar method as radar
unstable under normal conditions and However, understanding the differences
sensors to measure level. However,
decay into other elements. When these between and limiting factors attributed to
instead of using radio waves they use
atoms decay, they emit three different contact and non-contact sensors, as
sound waves and the distance is
kinds of radiation (alpha, beta, and well as the fundamental operating
calculated as the product of one-half the
gamma) which can be picked up and principles of some of the more common
flight time and the speed of sound.
measured by special sensors. Gamma level sensor technologies, should help
Unlike the speed of light, the speed of
radiation is used for the purposes of when specifying what technique is best
sound is temperature dependent, so the
level measurement because, of all suited for a particular application.
temperature of the tank must also be
three kinds, it is the best at penetrating Instances of level measurement and
measured and taken into account11. Like
materials13. control failure, such as the events that
radar, they can also be used to measure
liquids, slurries, and granular solids. This technology can be used in both unfolded at the Hertfordshire Oil Storage
Process materials that produce a single-point and continuous level Terminal, can lead to tragic and costly
stronger sonic reflection are more applications. In single-point consequences that could have been
applicable to this type of measurement. measurement, such as high and low avoided. A level perspective is vital to
Condensation, dust buildup, and alarms, a sensor is typically installed maintaining accurate process control
presence of additional objects within the parallel to the source of radiation on the and ensuring continuous safety.
tank can all cause measurement opposite side of the tank and any
inaccuracies12. change in frequency modulation over a
certain threshold triggers an alarm.
Load Cells Since radiation is released from all
by Simon Paonessa - Technical Writer
directions from a radioactive element, Precision Digital Corporation
continuous level measurement involves
using sensors along the length of the
tank on the opposite side. Using the
attenuation detected through an empty
tank as a baseline, any change
detected by a sensor is attributed to 7. Magnetrol, Kotron® RF Capacitance, 2009,
Load cells, sensors normally used 1. Buncefield tank 'was overflowing', BBC News, 9 May
<http://www.magnetrol.com/v2/pdf/MII/50-100.pdf>
8. Lipták, 430
to measure weight, can be used to 2006, <http://news.bbc.co.uk/2/hi/uk_news/4752819.
9. Lipták, 526
stm>
gauge tank level. These sensors are
attached to the support columns of a
tank and measure the downward force
applied on them by the mass of the
container above. By taking into account
the weight of the tank when empty and References
2. How Buncefield fire unfolded, BBC News, 13 July 10. Ibid., 413
assuming that the tank has straight 2006, <http://news.bbc.co.uk/2/hi/4525504.stm> 11. Magnetrol, Ultrasonic Non-Contact Transmitters,
sides, any change in the weight 3. Lipták, Béla G., et al., Instrument Engineers' <us.magnetrol.com/Technologies_Individual.
Handbook, Fourth Edition, Volume One: Process aspx?id=23>
measured by the load cell can be Measurement and Analysis, CRC Press, 2003, 413 12. Lipták, 412
correlated with a change in level. Load 4. Ibid., 465 13. Ibid., 515
5. Ibid
cells can be used to detect the level of 6. Foxboro, Bubble Tube Installations for Liquid Level,
liquids, slurries, and granular solids, but Density, and Interface Level Measurements,
September 1988,
require the process material to be of <http://resource.invensys.com/instrumentation/
constant density. Load cells typically documentation/eib/mi/mi020328.pdf>
are not used to measure interface level. the level being at or above that sensor.
Though this technique is affected little
Nuclear by the physical state and properties of
