ICPC20 – Industrial Instrumentation

July-Dec 2023 Session

Level Measurement: Part-3 – Electrical type

Level Gauges

Dr. Sri Ram Shankar R.

Assistant Professor, Dept. of ICE,
NIT-Tiruchirappalli
srir@nitt.edu
1. Conductive Probes
Conductive probes are used for single-point measurements in liquids that are
conductive and nonvolatile as a spark can occur.

Two or more probes used to indicate set levels. When the

liquid is in contact with two probes the voltage between
the probes causes a current to flow indicating that a set
level has been reached.
If the liquid is in a metal container, the container can be
used as the common probe.

Thus, probes can be used to indicate when the liquid level is low and to operate a pump
to fill the container.

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2. Resistance type Level Gauge
Measures level changes by the
change in resistance of a partially
submerged electrical element.

The electrical sensing element

consist of a precision-wound
helix resistor that has about 28
contacts per foot. An outer jacket
of flexible protective material
also acts as a pressure receiving
diaphragm.

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• The pressure of the liquid in the tank acts upon the jacket-diaphragm and causes the
resistance element to contact the steel base trip.

• Below the surface of the liquid, the resistor is shorted. The resistor remains unshorted
above the surface, and it is this portion that is metered to provide the level reading.

• Two wires from the sensor top transmit an electrical resistance signal that is related to the
distance from the tank top to the surface of the liquid. Typically 1 Ω corresponds to 1 cm

• The sensor strip remains fixed in position has no moving parts and provides a continuous
indication of resistance.

• The windings of these sensors are purely resistive, they cannot store or release electrical
energy. Thus resistance sensors qualify as intrinsically safe devices and can be used with
explosive liquids and dust.

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3. Thermal Level Measurement
A fine resistance wire is stretched vertically in a tank and heated
electrically.
Varying resistance of the wire if the liquid level inside the tank
changes.
Part immersed in liquid : cooler
→ lower resistance per unit length (r1)
Part exposed to gas: hotter
→ higher resistance per unit length (r2)

𝑉
𝑅 = = 𝑟1 𝑥 + 𝑟2 𝑙 − 𝑥
𝑖
𝑅 = 𝑟1 𝑥 1 − 𝛼 + 𝛼𝑙

where 𝛼 = 𝑟2 /𝑟1 ; 𝛼 > 1

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 4. Capacitance Level Measurement
Wide variety of solids, aqueous and organic liquids, and slurries.
Designed to sense material with dielectric constants as low as 1.1 (coke and fly
ash) and as high as 90 (quick lime) or more.

Dual-probe capacitance level sensors can also be used to sense the interface
between two immiscible liquids with substantially different dielectric constants.

Phase modulation and the use of higher frequencies (RF) signals makes the
sensor suitable for applications in which dielectric constants are similar.

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Capacitance Level Measurement Device
An insulated electrode acts as one plate of capacitor and the tank wall (or reference
electrode in a non-metallic vessel) acts as the other plate. The capacitance depends on
the fluid level. An empty tank has a lower capacitance while a filled tank has a higher
capacitance.

C =Kε0A/d

Relative Permittivity or
Dielectric Constant: K or εr

C = 0.225 K (A/d )
C is the capacitance in pF.
A = Area of plates in sq. inches. in2
d = Distance between the plates in inches
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Measurement of Conductive liquids
Conductive liquids
Capacitive level probes designed for
conductive liquids are coated with plastic
or some other dielectric substance, so the
metal probe forms one plate of the
capacitor and the conductive liquid forms
the other:

Variables are permittivity (ε) and distance (d),

since a rising liquid level displaces low-
permittivity gas and essentially acts to bring the
vessel wall electrically closer to the probe.

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Measurement of non-conductive liquids
Non-Conductive liquids
If the liquid is non-conductive, it may be used as
the dielectric itself, with the metal wall of the
storage vessel forming the second capacitor plate.

Variable is permittivity (ε), provided the liquid has

a substantially greater permittivity than the vapor
space above the liquid.

Capacitive level instruments may be used to measure

the level of solids (powders and granules) in addition to
liquids.
In these applications, solid substance is almost always
non-conductive.

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 Composition Probe
Good accuracy in capacitance measurement only if the relative permittivity is known.

A compensating probe (also known as “Composition Probe”) is used to measure and

compensate for changes in liquid permittivity. Installed below the LRV point in the vessel
that will always be submerged in liquid.

→ Since this compensating probe is always immersed, and always experiences the same
A and d dimensions, its capacitance is purely a function of the liquid’s permittivity (ε).

In case of solids, variations in moisture content and granule size in the solid may
greatly affect permittivity. Solid level measurement through capacitance probe is not
very accurate due to sensitivity to changes in process permittivity and errors caused
by stray capacitance in probe cables.
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 Capacitance Modelling

Setup with the Still tube

Capacitance without considering the Capacitance considering the

permittivity of vapour phase: ?? permittivity εv of vapour phase: ??
Derive : Homework
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Capacitance Modelling

Setup without the Still tube

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Measurement of Change in Capacitance
This change in capacitance can be measured using AC bridge.
Measurement is made by applying an RF signal between the conductive probe and the
vessel wall. The RF signal results in a very low current flow through the dielectric
process material in the tank from the probe to the vessel wall.

When the level in the tank drops, the dielectric constant drops causing a drop in the
capacitance reading.

Relay Output
Output
Scaled Analog Signal

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Capacitance Measurement Circuit

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Proximity type Capacitance Level Measurement Gauge

The level sensing electrode is normally a flat plate mounted parallel to the surface
of the material. The material, if conductive, acts as the ground plate of the
capacitor. As level rises to the sensor plate, the effective distance between plates is
decreased, thus causing an increase in capacitance.

The area is fixed, but distance varies.

In nonconductive materials, the vessel acts as the ground plate and the mass of
material between the plates is the variable.

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Installation of Capacitance Level Sensors

Measurement of Level in solids Measurement of Level in liquids

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Inductive
Conductive liquid
Level
Gauging

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 How to derive the expression of capacitance?

The formula for the cylindrical capacitor is

Where,
C= capacitance of the cylinder
L = length of the cylinder
a = inner radius of the cylinder,
b = outer radius of the cylinder https://byjus.com/question-answer/what-is-the-derivation-for-
capacitance-of-a-cylinder/
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Materials Referred to:
Tony.R. Kuphaldt, Lessons in Industrial Instrumentation, Version 2.02, April 2014
Patranabis D, Principles of Industrial Instrumentation, Tata McGraw Hill, 3rd Edition, 2010.
Fundamentals of Industrial Instrumentation and Process Control, William Dunn
Notes on Industrial Instrumentation from Sathyabama Inst. Sci Tech. and
Notes on Industrial Instrumentation by Prof. Saraswathi, SCSVM.

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