Training Course for

New Employees
~Level Measurement~
28th May 2010

Plant Engineering Center

Control & Instrumentation Engineering Division
M. Sakamoto
Contents
• Overview
• Comparison Table
• Differential Pressure Type
• Displacement Type
• Float Type
• Sonic / Ultrasonic Type
• Tape (Float and Tape) Type
• Gage Type
• Radioactive (Nuclear) Type
• Bubbler (Dip Tube)
• Capacitance Type
• Conductivity Type
• Thermal Type
• Radar Type
• Beam Breaker
• Vibration Type
• Paddle Wheel Type
• Diaphragm Type
• Resistance Tape Type
• Laser Type
Comparison Table

http://www.ktekcorp.com/dnn20/default.htm
 Displacement Type
Principle of Measurement
Torque Tube Measure change of buoyancy (mechanical
force) through a torque-tube unit.
Transmitter

Application
Displacer
-Liquid Level
-Liquid / Liquid Interface
Buoyancy related
with immersed level.
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Masoneilan 12300

Application Note
-It can be mounted internally or externally. (Confirm Chamber requirement)
-Used only for liquids with fixed specific gravity where errors due to process variations are acceptable, and
where a change in process condition will not create crystallization or solids.
-Prefer to install with chamber. (to ensure material of arrangement (e.g. valve, nozzle) are compatible with the
process fluid.)
-Displacers are difficult to calibrate and have numerous mechanical components. (Easy to damage)
-Stilling will be required to prevent agitation at the liquid surface.
-The element may be affected by coating, buildup, or dirt that can cling to the displacer.
Installation Sample / Displacer
Orientation to be checked during engineering stage.
Trouble
 Float Type http://www.ktekcorp.com/dnn20/default.htm

Principle of Measurement
Float will ride freely on the surface of the
liquid. Its position is a direct indication of
Consist of level.
Hollow ball

Application
Float rides on level surface.
-Liquid Level
-Liquid Level Switch

Application Note
-Low Cost / Simple Design
-Stilling Wells are required in case of turbulent liquid surface.
-Liquid must have a fixed specific gravity to maintain the float’s accuracy. (Float will be designed with specific
gravity.)
-Float will be in contact with the process material, and buildup on the float will affect performance.
-Float material to be compatible with process.
-Same consideration as displacer type to be required.
Installation Sample / Float Type LT
100 %

Insertion direction is important

Level Indication

0%

Clearance between bottom and stage must be greater than float length.
(For Install and mantainance)
Trouble

Hard to install float.

 Sonic / Ultrasonic Type
Principle of Measurement
Transmitter converts electrical energy into
acoustical energy and a receiver converts
acoustical energy back into electrical energy.
Transmitted and return time of the pulse is
relayed electrically and converted into a level
indication.
- Sonic : 10 kHz / Ultrasonic : 20 kHz or higher.

Application
-Liquid Level
-Devices can not be sued to measure the
level of foam. (sound signal will be
Application Note absorbed by foam)

-Non-contacting, reliable, and accurate.

-No moving parts / It is unaffected by changes in density, conductivity, or composition.
-Strong Industrial noise or vibration at the unit’s operating frequency will affect performance.
-Dusts tend to give false signals.
-Deposit buildup on the probe will affect device performance.
-It will not work in vacuum service.
-Environment will affect to device performance. (Temp, Pressure, Vapor Concentration  affect to sonic speed.)
-Engineering should follow the manufacturer’s installation recommendation carefully.
 Tape (Float and Tape) / weight and cable Type
Principle of Measurement
A tape connects a float on one end and a
counterweight on the other. Counterweight
moves up an down a graduated scale located
outside the tank.
Counterweight is used to keep tension on the
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Application
-Liquid Level (Local Indication)
-Liquid Level (Transmit / Servo Type)

http://www.ktekcorp.com/dnn20/default.htm
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Application Note
-Tapes are accurate. However, they can have mechanical problems such as hang-up and friction. Also, material
buildup on the float (will affect to performance). Buildup on the tape will be cause of stack. (to be protected
from possible weather interference and process.)
-Stilling wells are often used if the vessel is agitated.
 Level Gauge Principle of Measurement
Glass Type
Glass type consists of two glass sections, in
between which is the fluid to be measured.
Reflex Type
The reflex type consists of a single glass with
cut prisms. Light is refracted for the vapor
portion of the column and is shown generally as
a light color. Light is absorbed for the liquid
portion of the column and is shown generally as
a dark color.
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Magnetic Type
Float containing a magnet is in a nonmagnetic
chamber. Float magnet will rotates wafers
180degrees as the level increases or decreases.

Application Note
-Level Gauges must be accessible and located within visual range.
-In certain services, such as steam drum service, glass gages must conform to local code requirements.
-Magnetic Type to be used for dark liquids and dirty fluid. (Toxic / Hazardous liquid also : Glass gages can be
easily damaged or broken.)
-For safety reasons, the length of glass gages between process connections should not exceed 4 ft (1.25m).
-When installing such devices, good lighting is required. Sometimes an illuminator may be required in dark
areas.
-Level gage range shall cover Level Transmitter range.
Installation Sample / Magnetic Type
100 %

Insertion direction is important

Level Indication

0%

Clearance between bottom and stage must be greater than float length.
(For Install and mantainance)
 Radioactive (Nuclear) Type
Principle of Measurement
A radioactive source radiates through the
vessel. Te gamma quantum is seen by the
radiation detector (such as a Geiger counter)
and is transformed into a signal.
(When the vessel is empty, the count rate is
high.)
The strength of the sensed radiation depends on
the thickness of the vessel wall, the distance
between the source and detector, and the
density and thickness of the measured material.
The radiation source generally has a half-lie of
30 years; therefore, corrections for source decay
are rarely required.

Application Note
-External to the vessel. It can be added or removed without disturbing the process.
-Highly reliable, non-contacting device with no moving parts.
-Unaffected by temperature, pressure, and corrosion and their mode of failure is limited and predictable.
-Expensive to install and operate in order to maintain their compliance with regulations.
-Special care must be exercised when installing them, which drives their cost up. And they are difficult to
calibrate.
-Special license and training are required.
-It will be applied where other types of measurement can not be used/
 Bubbler (Dip Tube) Type
Principle of Measurement
The pressure that is required to force air
bubbles from the bottom of the tube is liquid
head above the end of the tube.
i.e. Air pressure = Liquid Head (Level)

P&ID Hookup

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Application
Generally 3 inches (75mm) -Pit Level

Application Note
-Low cost / easy maintenance.
-It can operate without electrical power, and it can be used on pressurized or unpressurized vessels.
-Variations in density will affect the bubbler’s readout, and bubblers can become coated or plugged by process
fluid residue or dirt.
-Purge gas can introduce unwanted components into the process. (It shall be selected carefully.)
-This measuring devise is not an off-the-shelf item; some engineering is required.
-Bubbler, Purge-set, etc.
 Capacitance Type Principle of Measurement
Measures the changing electrical capacitance
that occurs within the devices as the level in the
vessel varies.
It can be used for conductive or nonconductive
fluid, but the dielectric constant of the fluid
being measured must remain constant, unless a
unit is used that compensates for dielectric
variations.
(Note: dry, nonconductive material with a
moisture content may become conductive.)

Application
-Level Switch
-Level Indication
-High Temperature Application
(with Ceramic coating)
Application Note
-No moving parts / unaffected by nonconductive buildup, and can be used for pressurized or unpressurized
vessels.
-Calibration may be time consuming.
-The unit is affected or changed to the material’s dielectric constant and thus requires temperature
compensation.
-Conductive residue coating will affect the unit’s performance.
-Prove shall be contacted with tank walls.
 Conductivity Type Principle of Measurement
Conductivity level measurement works..
When material contacts the prove, a low voltage
electrical path is completed between the
container wall and the probe, which actuates a
relay. For nonconductive containers, the path is
between the level probe and a reference probe.

Application
-Level Switch

Application Note
-Easy to install / No moving parts / relatively simple / low cost
-Can be used for pressurized or unpressurized vessels.
-Unit may cause sparking as the liquid level rises to reach the probe. I.S. designs are available if they are
required.
 Thermal Type
Principle of Measurement
Thermal Devices consist of a heater element
next to a temperature switch. When the liquid
rises above the switch, it dissipates the heat,
and the temperature switch activates.

Application Note
-Low cost, no moving parts.
-Sensitive to coating or caking materials, and they provide point measurement only.
 Radar Type
Principle of Measurement
Same principle as sonic type, but operates at a
frequency of about 24 GHz.

-Horn Antenna
-Guide Wave
-Rod Type
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Application Note
- Easy to install / Non contact
- Dielectric constant limitation
- Installation to be followed manufactured recommendation.
- It shall not be installed on centre of vessel.
- To consider prevention of build up on sensor.

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Selection Criteria
 Beam Breakers
Principle of Measurement
Its basic components are a light source and a
receiver (photocell) that accepts the light beam
and measures it. The light travels in a straight
line until it is intercepted by an object (such as
the liquid level in a tank).

Application Note
- Low cost / can be used for pressurized or unpressurized vessels.
-Beam breakers have a limited range and are affected by changes in reflectivity.
-Simple construction / Unaffected by gravity.
-Sensitivity adjustment is available only in some units and residue coating will affect the beam breaker’s
performance.
-To consider liquid drop and condensation.
-Clear liquid may difficult to sense level.
-Receiver may required shield the light receiver from outside light source.
 Vibration Type http://www.ktekcorp.com/dnn20/default.htm

Principle of Measurement
-Vibration devices consists of a tuning fork that
vibrates at its natural resonant frequency by a
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-Tuning fork contacts a material, either dry or in
suspension, the vibration frequency is altered,
which switches a relay.

Application
- Limit detection (Liquid / Solid)

Application Note
- Vibration units have no moving parts, are rugged and reliable are good for low-density materials, and require
little maintenance.
-They will not be used in vibrating bins, especially if the two frequencies are close.
-Product buildup will affect the performance of vibration units. The switch setting cannot be readily changed,
and vibration units typically required protection from materials that are charged from the top.
 Paddle Wheel Type
Principle of Measurement
In a paddle wheel a motor keeps the paddle
rotating. When the material rises and prevents
the paddle’s rotation, a switch is actuated.

Application
- Solid Point detection

Application Note
- A paddle wheel is inexpensive, simple, and reliable.
-It is susceptible to shock, vibration, and damage by falling material.
-Paddle wheels generally require some protection from material charging from the top.
-Hang-ups or material buildup on the paddle will affect the device’s performances, and material bridging around
the switch will give erroneous state.
 Diaphragm Type
Principle of Measurement
- The diaphragm is a point measurement device.
The process materials (or hydrostatic pressure)
apply pressure on a diaphragm, which in turn
actuates a switch.

Application Note
- The diaphragm is reliable, easy to maintain, and available for different applications.
-Coating may affect the flexing of the diaphragm, and abrasive material may affect its performance.
-The accuracy of the unit is affected by changes in specific gravity.
-The diaphragm must be in contact with the material. It should be at least 2 to 3 in. above any sediment in the
vessel bottom to prevent dirt from building up at the diaphragm.
 Resistance tape Type
Principle of Measurement
Resistance tape function as follows,
As the level rises in the tank, the resistance
element is shorted to the conductive probe,
affecting loop resistance. The unit measures the
loop resistance and provides an indication of
level.

Application Note
- A resistance tape will handle corrosive liquids and slurries.
-It must contact the material and is susceptible to moisture getting inside the tape. (Desiccant to be used.)
-Resistance tape devices are affected by changes in specific gravity, are not suitable for flammable
atmospheres, and are neither accurate nor rugged.
-They require careful engineering and careful installation.
-Plants may need to use stilling if turbulence exists.
 Laser Type
Principle of Measurement
Pulsed type laser
Its transmitter emits a continuous series of the
pulses at a target. The time taken by each pulse
to travel from the transmitter to the target and
back is measured and converted into distance.

Continuous wave laser

Consists of a transmitter that emits a continuous
laser beam at the target. When the beam hits the
target, phase-shifting occurs. Based on the
degree of phase shift and on other constant
parameters such as wave frequency, the device
determines the distance of the target and
therefore level.

Application Note
- Laser transducers mounted outside a metal vessel can measure level through a process-rated sight glass.
-Laser unit can be accessed without having to interrupt the process.
-Laser type level instrument uses an extremely short wavelength and produces a very narrow beam.
-Food accuracy and non-contact measurement for difficult application.
-Expensive
 Engineering for
Level Instrument Design
• To select the best level instrument for an
application, engineer shall consider following
points.
– Process Condition
• Fluid Property
• Measuring Range
– Purpose of Measuring
• Control
• Indication
• Alarm
– Installation
• Construction
• Maintenance
– Cost
Input / Output to/from Instrument
Department
• Input
– Project Specification
– P&ID
– Instrument Process Data
– Piping Material Specification
– Vessel Engineering Drawing
• Output
– P&ID (Instrument Type and Arrangement)
– Vessel Engineering Drawing
 References
General Principle
http://www.engineeringtoolbox.com/flow-meters-d_493.html
http://www.omega.com/literature/transactions/volume4/T9904-07-DIFF.html

Endress + Hauser (Applicator)

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