Instrumentation and Control

Systems

THISARA GANEGODA
B. Tech Engineering (Hon’s).AE(ECSL).AM(IESL)
What is a Level Sensor?

• A level sensor is a device that is designed to monitor, maintain, and measure

liquid (and sometimes solid) levels.

• Once the liquid level is detected, the sensor converts the perceived data into an
electric signal.

• Level sensors are used primarily in the manufacturing and automotive industries,
but they can be found in many household appliances as well, such as ice makers
in refrigerators.
Main types of level sensors

• 1.) Point level sensors

Point level sensors are designed to indicate whether a liquid has reached a
specific point in a container.

• 2.) Continuous level sensors

Continuous level sensors, on the other hand, are used to render precise liquid level
measurements.
The Magnetic Level sensor
• The magnetic level indicator working principle is widely used in level instrumentation.

• The interaction between float magnets inside the chamber and magnetic flags outside
the chamber provide virtually maintenance-free, continuous level information.

• This type of level indicator doesn’t require power, making it ideal for a variety of
applications across industries.
Magnetic Level sensor
The Magnetic Level Indicator Working Principle
• The working principle behind a magnetic level indicator is that the measuring
instrument shares the same fluid — and therefore, the same level — as the vessel.

• The level indicator is attached to the vessel and connects directly with the fluid to be
measured. Within the chamber is a float with a magnet assembly inside.

• This float rests on the fluid’s surface. As the fluid level rises or falls, so does the float. As
the float moves up or down, the magnet assembly rotates a series of bi-color magnetic
flags or flaps, changing the visual indicators mounted just outside the chamber from
one color to the other.
Cont…
www.youtube.com/watch?v=vZs4E2WQPBI
Measurement principle
• The Magnetic Level Indicator (MLI) is a simple, rugged instrument designed to
indicate level or interface.

• It indicates level using a float magnetically coupled to an index or a column of

rotating flaps. It is ideal for aggressive media stored in vessels when the PTFE
lining option is used.
Cont…
• The float is equipped with a ring system of permanent magnets for transmission
of liquid level to the indicator. The indicator is linked magnetically to the magnet
system in the float.

• For the purpose of design, the minimum level in the measuring tube is given by
the lower lateral flange connection axis i.e. liquid level zero is the centreline of
the lower connecting flange.
Cont…
• Magnetic level Indicators (MLI) are preferred Level Indicator (compared with glass or
reflex indicators) because of safer performance against external explosions and high
pressure application.

• There is a difference between the true liquid level and the indicator position because:
float is immersed to a certain depth depending on the product density and float
type
float magnets are positioned below the float centreline in order for the float to
have good stability.
Cont…
• Since the magnetic level indicator working principle relies on the interaction between
magnets, these level measuring instruments do not need a power source. They are also
virtually maintenance-free. An additional advantage: The indicator’s magnetic force can
affect optional switches or transmitters mounted outside of the chamber.

• The colored flags are easy to see, even from a distance, and are paired with a scale for
precise readings. As for any level instrumentation, the size and material of the float are
chosen according to the media, temperature, pressure, and density of the process
media.
Two Types of electro magnetic sensors

• 1.) Magnetic Float

• 2.) Magnetostrictive
Magnetic Float Level sensor

• Float level sensors are continuous level sensors featuring a magnetic float that rises
and falls as liquid levels change. The movement of the float creates a magnetic field
that actuates a hermetically sealed reed switch located in the stem of the level sensor,
triggering the switch to open or close.

• The working principle behind magnetic float level switches is to utilize a magnetic field
to open or close a circuit as the level of a liquid within the chamber rises or falls.
The stainless steel float within operates on the basic buoyancy principle that the force
on a buoyant object is equal to the mass of liquid displaced by the object.
Cont…

• Partially submerged within the liquid surface, the float moves within the chamber
when the liquid level moves, thereby accurately tracking the liquid surface
motion.

• Utilizing magnetic fields to open and close switch points in many float level
switches is common and used in many industries. It’s a simple, smart technique
for level measurement and maintenance.
Cont…

• As the float moves with the liquid level, it moves a magnetic sleeve into or out of
the field of a magnet that actuates a switch, causing switch operation. A non-
magnetic barrier tube effectively isolates the switch mechanisms from the
controlled liquid.
MAGNETIC LIQUID LEVEL SWITCH

• A magnetic liquid level switch consists of two main components: a magnet

embedded inside a float, and a reed switch placed in an enclosure. The single
unit or multiple reed switch units are housed tightly in a stainless steel or an
engineering plastic stem and a permanent magnet is sealed inside a float whose
rise and fall causes the opening or closing of a mechanical switch, either through
direct contact or in proximity of a reed switch due to the magnetic field.
Cont…

• It may not be too hard to imagine a magnet placed inside a float, nor does the
concept of harnessing magnetic fields to work in liquid level switches. However,
it’s a little harder to understand a reed switch. A reed switch consists of two
ferromagnetic contact tips called, ‘reeds,’ that are encased in a glass tube. As the
magnet passes by the contacts in the encased reed switch, they are drawn or
touch and complete a signal circuit between the two lead wires.
Magnetostrictive Sensor

• Magnetostrictive transducers: electromechanical devices that use

magnetostriction, an effect found in some ferromagnetic materials that
changes dimension in response to the application of a magnetic field.
How do Magnetostrictive sensors work?

• When a ferromagnetic material — such as iron, nickel, or cobalt — is subjected to

an external magnetic field, the magnetic domains within the material align,
creating internal stresses that cause the material’s shape or dimensions to
change.

• This phenomenon is referred to as magnetostriction. Conversely, when a

magenetostrictive material is subjected to a stress, its magnetic properties will
change. This is known as the Villari effect.
Cont…

• Another manifestation of magnetostriction is the Wiedemann effect: When a

wire is subjected to a magnetic field oriented parallel to its length, and a current
is passed through the wire, the wire experiences torsional strain at the location
where the magnetic field occurs.
Cont…

• All ferromagnetic materials experience magnetostriction, but in some materials,

the magnitude of the dimensional change is too small to be of practical use. For
example, when a magnetostrictive bar or rod is placed in a magnetic field
oriented parallel to the length of the bar, the bar will change length. However, the
length change for materials used in linear magnetostrictive sensors is very small
— typically on the order of 10-6 m/m
Cont…

• In magnetostrictive sensors, the wire, or bar, is referred to as a waveguide. It is

typically made from an iron alloy and is mounted to a stationary part of the
machine. The magnetic field is provided by a magnet, referred to as a position
magnet, which is attached to the moving part being measured. Short pulses of
current (1-3 μs) are applied to a conductor attached to the waveguide.
The basic components of a magnetostrictive
sensor
Cont…

• As the Wiedemann effect states, torsional strain (twist) is induced in the

waveguide, due to the interaction of the magnetic field caused by the current and
the magnetic field caused by the position magnet. Because the current is applied
as a pulse (referred to as an interrogation pulse), the twist travels down the wire
as an ultrasonic wave, moving at approximately 2850 m/s. This twist, or
mechanical pulse, is detected by a signal converter (also referred to as a strain
pulse converter), which relies on the Villari effect to create a voltage pulse
indicating receipt of the mechanical strain wave.
Cont…
Cont…
• The time between the initial current pulse and the detection of the mechanical
pulse indicates the location of the position magnet, and therefore, the position of
the moving part being measured. The interrogation rate, or update rate, can
range from one time per second to over 4000 times per second, with the
maximum update rate determined by the length of the waveguide.
• Magnetostrictive sensors provide absolute position information and, unlike
incremental encoders, do not need to be re-homed when there is a loss of power.
They can also use multiple position magnets with one waveguide, making them
well-suited for applications that require position information for multiple
components along the same axis, such as the knives on a slitting machine.
Cont…

• In addition to being non-contact, magnetostrictive designs enclose the waveguide

in an extruded aluminum housing or stainless steel tube, so they are virtually
impervious to contamination. They can also operate when there is a barrier
between the position magnet and the waveguide — as long as the barrier is non-
magnetic, such as ceramic, plastic, aluminum, or stainless steel.
Magnetostrictive level measurement technique

• A Magnetostrictive level equipment measures the level by measuring the time of

flight of a wave between the instrument and the material interface.

• Main components of the magnetostrictive level instruments are:

Sensor

Magnetic float

Waveguide: Rod, which has the full length of the vessel

Cont…
Cont…
• The main part of the magnetostrictive instrument is the Float centred around a
long metal rod, which is called as the waveguide. The waveguide is hung from the
top of the vessel, which is long enough to from the top to bottom. An electric
pulse is sent periodically from top to bottom through the waveguide.

• Unlike the echo technology in the ultrasonic and guided radar system, From the
top of the waveguide, an electric pulse is sent through the waveguide. The float
positions at the liquid level, the electric pulse pass throughout the waveguide.
Cont…

• Source: forumautomation.com
Cont…

• A magnetic pulse is produced due to the electric pulse. This magnetic pulse produced
by the electric pulse, combined with the magnetic flux of the magnetic float generates
a torsional stress pulse exactly at the float position. This torsional pulse travels through
the rod to either end with a speed of sound. Though it reaches the sensor too, at the
bottom end there is Dampener to the absorb the mechanical wave.

• The sensor detects the torsional wave. To be clear, we are not sensing the reflected
wave, the torsional wave is a mechanical wave produced at the float contact.
Cont…

• The microprocessor circuit attached to the sensor calculates the time elapsed
between the electric pulse generation and receiving the torsional pulse. The time
delay is strictly a function of the distance between the float and the sensor as we
know the speed of the signal is constant.
Applications
• Refinery and chemical industries

• Energy and power plant technology

• Feed water heaters and boilers

• Oil and gas industries

• Offshore exploration and drilling

• Pipeline compressor applications

• Pulp and paper