Level Measurement

Concepts & Techniques

Mukund Shiroya
RIL-Hazira
 Why level measurement?

To know the inventory in the storage or process vessel for

Material stock identification
Prevention of overflow
Prevention of overload to the agitators
Prevention of under load to the agitators
Batch filling & emptying control
Operation at optimum level
 Level Measurement

Two methods of Level Measurement

Direct Measurement
Direct Measurement uses methods such as
visual Inspection
displacement of float
Tuning fork etc
Inferential measurement
Inferential measurement uses methods such as
pressure head
time of flight etc
attenuation of radiation
Change in Capacitance of material
Photoelectric
Direct Level Measurement
 Level Gauge

This is a visual method of

measuring the level of fluid in
a vessel.
A Graduated pipe is
connected to a vessel. As the
Vessel
level of the fluid inside the
vessel increases the level
inside the tube will increase.
A visual inspection of the
tube ill provide an indication
of the level inside the vessel.
 Reflex / Transparent level indicators

Reflex level indicator Transparent level

 Magnetic Level Gauges

A float containing a magnet rises and falls with the liquid. As

the float moves, this information is transferred to the
indication rail mounted on the outside of the tube. The white
and red indication flaps represent air and liquid level
respectively.
Magnet System
Each of the colored flap contains a small magnet which
rotates through 1800 when passed by the bar magnet within
the float. The bar magnet design does not lose magnet field
strength even at temperatures of 4500C guaranteeing
continuous operation in the most extreme applications.
 Float type Detectors

Most Float type detectors use

the principle of loss in weight
of a buoyant float to indicate
the level of the fluid.
The Float is selected such
that it is lighter than the fluid.
As the level of the fluid rises
the float rises. This is sensed
by the electronics assembly
to indicate the level.
 Float type Detectors

The float carries a member having a

Float-type sensors with magnetic
magnetic coupling with a transducer
coupling (a) or mechanical link (b). L =
element (coil, magnetic reed, or Hall-
level,
effect switch), that is mounted on the
1 = tank, 2 = liquid, 3 = float, 4 =
outside wall of the tank.
magnet, 5 = magnetic armature, 6 =
In some designs, the float mechanically
contacts,
links the switching mechanism through
7 = bellows, 8 = lever
the sealing in the wall (e.g., bellows).
The switching system can respond to
the restraining force developed by a
spring element connected to the float or
by an actuator of a force-balance servo
system.
 Level Measuring Technologies
* Vibrating Element
In a vibrating-element level sensor, the oscillations of a member (paddle) are
damped when it is immersed in the liquid. The attenuation of oscillations
indicates that the liquid has reached the measured level. The oscillations are
stimulated and sensed by electronic means.
 Float type Detectors

Advantages
Simple & proven techniques
Unlimited tank height
Better accuracy (depending on the float type)
Low capital,maintenance cost
Disadvantages
Subject to wear, corrosion, mechanical failure
Getting stuck due to material clogging,deposition,
material buildup
Indirect Level Measurement
 Differential Pressure
Level can be inferred from the
differential pressure ( head ) of the
fluid inside the tank.
Advantages
economical and easy to install
Online checking & maintenance possible
Disadvantages
Solid level measurement not possible
Only clean fluid cal be measured
Density variation gives error
Choking of impulse tubes possible
 Differential Pressure
Options on Differential pressure based
level measurement :
Purge type instruments
The nozzle on the vessel is continuously purged
by a medium acceptable to process & back
pressure is measured at HP & LP tapping.
Used for fluid with suspended particles or having
crystallizing nature
Chemical seal type instruments
The nozzle on the vessel is flange type instead of
threaded type.
Used when medium can chock the tapping
Cost of instrument is three times the conventional
inst.
 Time of flight - Ultrasonic
Ultrasonic instruments determine level by measuring
the length of time it takes for a sound pulse to return to a
piezoelectric transducer after bouncing off the process
material.
The sensor uses high-performance Piezoelectric crystals d
to generate short ultrasonic pulses in the form of sound L
waves. These pulses are directed toward a specific
target from where they get reflected back to the
transducer which acts as transmitter/receiver.
The transit time taken to receive the reflected pulse is
measured by the electronics.
d = Velocity of sound * time to travel
Level X = L-d
 Time of flight - Radar

Radar-based devices beam microwaves at the

process material's surface. A portion of that
energy is reflected back and detected by the
sensor. Time for the signal's return determines
the level.
Radar provides a non contact sensor that is
virtually unaffected by changes in process
temperature, pressure or the gas and vapor
composition within a vessel. In addition, the
measurement accuracy is unaffected by changes
in density, conductivity and dielectric constant of
the product or by the air movement above the
product.
 Nucleonic Level measurement

This technique utilizes the

attenuation of radiation taking
place while it passes through
physical matter, to indicate
the level inside a vessel.
The assembly consists of a
Radioactive source which
emits radiation and a
detector which detects the
attenuated radiation and
converts it into a percentage
of actual level I = I0*e-d
 Nucleonic Level measurement

Type of Radioactive detectors

Geiger Counter
The most common radiation detection instrument is the Geiger counter. This instrument is a
gas-filled detector that works on the principle that as radiation passes through air or a specific
gas, ionization of the molecules occur. When a voltage is connected across the gas chamber,
a current will flow as the positive ions are collected at the cathode and the negative ions are
collected at the anode. This current can be used to power a meter to quantify the radiation.
The GM detector is a good sturdy detector
used for the detection of beta and gamma
radiation. It will detect most beta, gamma,
and x-ray radiation used in the research
environment as well as the strong gamma
and x-ray radiation used in industrial
radiography.
 Nucleonic Level measurement

Scintillation Detectors
Scintillation crystals and photo-multipliers are
used to detect and measure gamma and x-ray
radiation. These detectors are especially useful
in the research environment for detecting the
low-energy photons emitted from I-125. The
detectors can either be hand-held or well-
counters. The well-counters are used to count
samples in a low background shielded cavity
 Nucleonic Level measurement

Actual Instrument :
Continuous Detector :
Extremely rugged and reliable even in harsh environments.
The LJC is a continuous level detector utilizing ion-chamber
technology.

Features & Benefits:

- Available in ranges up to 19 feet (6 meters)
- Frequency output to the Ohmart/VEGA Smart Pro, Pro Pac,
or to a PLC/DCS

Applications:
- Standard vessels & tanks
- Areas in need of a rugged detector housing
 Nucleonic Level measurement

Advantages of Neuclonic Instruments :

Low Maintenance & High Reliability
Non invasive to vessel
No exposure to corrosion, abrasive, high pressure or high
temperature process conditions
No moving parts
Detectors employ no moving parts to wear, bind, corrode or fail on
process
Proven technology
Nuclear measurements have proven reliable over time in thousands
of applications
 Nucleonic Level measurement

Low Installation Cost

Gauge installed without process shutdown
No alterations are required to the vessel interior for gauge
installation in a standard application
No intrusions in to the vessel required
With no intrusions necessary in a standard installation, no
changes to coded vessels required
High first time success rate
With nuclear level systems, there is a high
success rate on the first installation.
Time and money are not wasted trying multiple
level technologies
 Nucleonic Level measurement

Solves Difficult & Extreme Applications

High temperature
Process temperature has no effect on measurement
High pressure or vacuum
Measures in all process pressures
Corrosive
Non contact technology allows use in the most aggressive services
Volatile or biohazard
Non invasive nature eliminates process connections and leak paths
Agitators, baffles, coils & other obstacles
Internal obstructions are inconsequential to the measurement with properly
configured systems
Build up on vessel interior
Process build up upon the vessel interior can be compensated for by special gauge
configurations
 Photoelectric

Photoelectric level sensors operate in transmittance or reflection modes. In the

transmittance mode, a sensing system, including a light beam source and a photo
detector, responds to the interruption or the attenuation of the light beam when the liquid
breaks the beam path from the source to the detector. In the reflection mode, an optical
prism mounted inside a tank changes the reflectance of the light when it is immersed in
the liquid. The construction of the transducer is arranged so that a light source and photo
detector for sensing the change in the light's intensity are mounted on the outside wall of
the tank. The light beam passes through and is reflected from the faces of the prism.

Transmittance-mode (a) and

reflectance-mode (b) photoelectric
level sensors. L = level, 1 = tank, 2 =
liquid, 3 = light source, 4 =
photodetector, 5 = prism.
 Capacitive-Level Sensors

Radio frequency (RF), based on capacitance

or admittance, can handle a wide range of
process conditions. Process temperature and
pressure are limited only by the material of the
sensing element. Level transmitters of this type
sense the change of electrical impedance that
occurs with the change of level on the sensor.
RF devices ignore material buildup on sensor
and work with all types of process material. It is
an intrusive technology.
 Typical examples of loops

Typical Measurement Loop

Process Sensor Transmitter Control System

 Typical examples of loops
Typical Control Loop

Process Sensor Transmitter Control System

Final Control Element