KMU-KYM 437 Ölçüm ve

Kontrol Teknikleri
(2021-22 Güz)
Hafta 9
1

Doç.Dr. Suna ERTUNÇ

ertunc@eng.ankara.edu.tr
ertunc.suna@gmail.com
2 Haftalık Programı
Hafta Konu

1 Ölçüm ve Kontrol Tekniklerine Giriş

2 Temel Ölçüm ve Kontrol Sistemleri Terminolojisi
3 Ölçmenin Tarihi
4 Ölçüm Özellikleri
5 Sıcaklık Ölçümü
6 Basınç Ölçümü
7 Seviye Ölçümü
8 Arasınav
9 Akış Hızı Ölçümü
10 Konum ve Hız ölçümleri
11 Gelişen Ölçümler, Sinyal İşleme Devreleri
12 Malzeme Özellikleri Ölçümleri
13 Ölçüm Elemanı Seçimi
14 Mühendislikte Ölçüm ve Kontrol Uygulamaları
3 5.3. Level Measurements

 Level is defined as the filling height of a liquid or bulk

material, for example, in a tank or reservoir.
 We measure level for filling control, for inventory control,
and for providing safe operations to personnel and
equipment.
 Level is often measured in percent of span but may be
displayed in engineering units of feet or inches, or even
pounds if the tank geometry and material density is taken
into account.
 Level measurement technologies can be placed into one
of two groups, contact and non-contact level
measurement; level sensors in each of these groups can
be of the continuous or point variety.
 Two tasks can be distinguished:
1. continuous level measurement (level indication)
2. level switches (to detect an alarm limit to prevent overfilling)
4 5.3. Level Measurements

 Although many old and traditional methods are still used

in level control applications, it is also necessary to
create an overview of level measurement and to know
that there are different methods. Level sensors fall into
two main categories.
 Level switches used in point level measuring control
 Continuous type level sensors

 Level switches are generally contact instruments and are

used to detect the presence or absence of product in
the container at a certain point. Depending on where
they are installed, they signal when the container, tank,
tank is full, empty, or in-between.
 Continuous type level sensors are contact or non-
contact instruments.
5 5.3. Level Measurements

 Point sensing level probes only sense tank level at a discrete level. Point sensing probes
are typically used for high-high or low-low level sensing to prevent plant personnel and/or
process equipment from being exposed to harmful conditions. Point level probes are also
used in pairs in processes in which we do not particularly care what the exact level in a
tank is, only that it is between two points.

 Continuous level probes sense the tank level as a percent of span of the probes
capabilities. Continuous level probes are typically used where we need some type of
inventory control, where we need to know with some degree of confidence what the
particular level in a tank is.
6 5.3. Level Measurements

 Another classification of the level

measurement methods are ;
1. Contact Level Measurement
2. Non-contact Level Measurement
 This type of classification mainly
related with wheter the measurement
equipment contact with or without
the liquid or solid in where being
used. Both type of measurement
methods may be accomplished by the
equipments working depend on point
or continuous level measurement
fundemental.
7 5.3. Level Measurements

1. Contact Level Measurement

 As the name implies, requires that the sensing element be in contact with material being
measured. Continuous level measurements can either be direct or indirect with contact
level sensors.
 Direct contact continuous level measurement is commonly used in bulk powder storage
silos and un-agitated tanks.
 RF capacitance/resistance level sensors are the typical direct contact level sensors for
both the point and continuous level variety.
 With indirect level measurement the sensor is in contact with the material at a single
point and the tank level is inferred from this point measurement.
 Pressure transmitters measuring hydrostatic head are typically used for indirect contact
continuous level measurement. For agitated tanks indirect contact continuous level
measurement is advantageous.
8 5.3. Level Measurements

2. Non-contact Level Measurement

Non-contact level measurement, as
the name implies, requires that the
sensing element not be in contact with
material being measured. The use of
non-contact level sensors eliminates
agitator interference. Non- contact
level sensing is primarily either
ultrasonic or radar/microwave.
 1. Contact Level Measurement
a. Simple sight glasses
b. Magnetic level indicator
9
c. Float sensors/ Buoy
d. Displacer switches
e. Conductive probes
f. Hydrostatic pressure level measurement
g. Level measurement with motor
10 a. Simple Sight Glasses

 A visual indication of the level can

be obtained when part of the vessel
is constructed from transparent
material or the liquid in a vessel is
bypassed through a transparent
tube.
 The liquid level then can be
observed directly in the sight glass.
 Glass gauges are cheap but aesily
broken, and should not be used with
hazardous liquid.
 The advantage of using stop valves
with the use of a bypass pipe, is the
ease in removal for cleaning.
11 b. Magnetic level indicators

 Magnetic liquid indicators work on a similar principle as the sight glasses.

 Due to the principle of combined vessels, the liquid levels in the tank and
the magnetic level gauge are the same.
 The magnet inside the float, which is placed inside the indicator body and
designed according to the buoyancy force depending on the density of
each liquid, affects the sensor elements containing the magnet inside the
indicator placed on the outer surface of the main body, and causes the
sensor elements to rotate sequentially during the rise or fall of the level.
 Thanks to the two faces of the intuitive elements in different colors, the
level information can be easily monitored from the outside of the tank.
 It is one of the most economical and common methods that can be used in
level measurement applications in high pressure tanks and boilers.
12
13 c. Float sensors/ Buoy

 There are two types of floats shown:

angular arm and the pulley
 The advantages of the float sensor
are that they are almost
independent of the density of the
liquid or soil being monitored, are
accurate and robust, and have a
linear output with level height.
 One of the significant types of float
level switch which magnetrol float
level switch which consist of a plain
float and operates via a magnetic
coupling action.
14
d. Displacer switches

 In a typical displacer switch design, a spring

is provided which is burdened with weighted
displacers.
 The displacers having weights greater than
the process fluid gets submerged in the
resulting in a buoyancy force change.
 This will cause a variation in the net force
operating on the spring. In general, the
spring will compress with the raise in
buoyancy force.
 Just like the float level switches, a magnetic
sleeve and non-magnetic barrier tube is also
incorporated in displacer switches.
 The magnetic sleeve is attached to the
spring and it moves according to the spring
movement resulting in activation of switching
mechanism.
15
e. Conductive probes
• Conductive probes are used in single
and multiple point measurements
systems.
• Low voltages is applied to the
electrodes as they are immersed in
the liquids.
• The conductive liquid completes the
electrical circuit of the control,
which activates a semiconductor
switch.
• The advantage of conductive probes
is their low cost and simple design.
• The disadvantage is that they are
limited to point measured and can
be only used with conductive liquids.
16 f. Hydrostatic pressure level measurement

• One of the oldest and most frequently used methods

of continuous measurement of the liquid level is the
measurement of the hydrostatic pressure exerted by
the liquid in the container to the bottom.
• The sensor located on the bottom surface of the tank
converts the hydrostatic pressure into a current
signal proportional to the liquid level.
• Semiconductor transducer containing silicone oil and
metal or ceramic diaphragm, It is used to increase
precision and continuity.
• In submersible level transmitters, there is an air tube
inside the hydrostatic pressure transmitter cable in
order to provide compensation with atmospheric
pressure.
• Hydrostatic pressure is the product of the height of
the liquid column and the specific gravity of the liquid.
17
g. Level measurement with motor

 It consists of the motor and the level weight at the

rope end. The weight, which is attached to the body
with a rope, moves downwards by the motor. When it
comes into contact with the solid material in the silo, it
returns to its starting position.

 The advantages of motorized level switches are that they are not affected by
dust and can operate at high temperatures. Rotor pedals are one of the oldest
level sensors. These sensors stand out with their easy-to-use, reliable and
applicability for level measurement of all types of dry bulk (sawdust, grain, pulses,
etc.).
 While the shaft can rotate easily, there is no contact with the material. When
the pedals come into contact with the material, the shaft slows down or comes to
a complete stop.
 More advanced models not only detect the presence or absence of material, but
also warn the user in case of electrical connection failure or power outage.
 2. Non-Contact Level Measurement
18 a. Ultrasonic Level Sensors
b. Radar/Microwave Sensors
c. RF Capacitive Probes
d. Nuclear Level Sensor
19
a. Ultrasonic Level Sensors

 Ultrasonic level sensors use sound waves to detect the level.

 The piezoelectric crystal in the transducer placed on the top of
the tank converts electrical signals into sound energy that
moves ripples in the medium at a certain frequency and
constant speed.
 Sound waves propagate and return to the transducer as an
echo.
 The device simply measures the time elapsed between when the
wave begins to propagate and when it bounces off the surface
and returns.
 This time is directly proportional to the distance between the
transducer and the surface of the material to be measured and
can be used to measure the level of the material.
 Ultrasonic level switches are an alternative method especially
for point level measurements of low viscosity liquids.
 It detects whether there is any material between the converter
crystal on one side of the switch and the receiver crystal on the
other side, by the method of transmission of sound waves.
20 a. Ultrasonic Level Sensors - cont.

 Ultrasonic or sonic devices can be used for

single point or continuous level measurement
of a liquid or a solid
 A pulse of sonic waves (approximately 10
kHz) or ultrasonic waves (more than 20 kHz)
from the transmitter is reflected from the
surface of the liquid to the receiver, and the
time for the echo to reach the receiver is
measured.
 The time delay gives the distance from the
transmitter and receiver to the surface of the
liquid, from which the liquid level can be
calculated, knowing the velocity of ultrasonic
waves (approximately 340 m/s)
21
b. Radar/Microwave Sensors

 Radar, or microwave level

measurement operates on similar
principles to ultrasonic level probes,
but instead of sound waves
electromagnetic waves in the 10GHz
range are used. When properly
selected, radar can overcome many of
the limitations of ultrasonic level
probes.
 Radar can:
• Be unaffected by temperature
changes in the tank air space.
• See through heavy foam to detect the
true material level.
• See through heavy vapor in the tank
air space to detect true material level.
22
c. RF Capacitive Probes

 They are used for continuous

measurements
 The value of the capacitance can
be change by varying the dielectric.
 The probe and the metal wall of the
tank form the two plates of a
capacitor, and the contents in the
tank is the dielectric.
 When the tank is empty the
dielectric is the air.
 As the level changes the dielectric
constant changes and causes the
capacitance change.
23 d. Nuclear Level Sensor
 Continuous nuclear level detection is typically used
where most other technologies are unsuccessful.
 Different radioactive isotopes are used, based on
the penetrating power needed to pass through the
tank. Radiation from the source is detected on the
other side of the tank. Its strength indicates the level
of the fluid.
 Point, continuous, and interface measurements can
be made. As no penetration of the vessel is needed
there are a number of situations that cause
nucleonic transmitters to be considered over other
technologies.
 These applications generally involve high
temperatures / pressures or where toxic or corrosive
materials are within the vessel. Placing the source
and / or detector in wells within the vessel can
reduce source sizes.
24 d. Nuclear Level Sensor- cont.

 An extension of this is to use a moving source within the

vessel; this facilitates the unique ability to combine density
profiling with accurate tracking of a moving interface.
 Nuclear level detection has some drawbacks.
 One is high cost, up to four times that of other technologies.
Others are the probable requirement for licenses,
approvals, and periodic inspections; and the difficulty and
expense of disposing of spent radiation materials.
 Another factor to consider is that the radiation symbol found
on these devices can cause concern to plant personnel.
 From a psychological standpoint, the radiation symbol found
on these controls is frequently the cause of unfounded
concern with uninitiated plant personnel.
 Plant Management is usually required to ensure that
appropriate education is given to any staff likely to be
involved with this measurement technology.
25