LEVEL MEASUREMENT

Level sensors are not only used in

Industrial and Chemical Applications
Common household items use them as
well
These sensors range from simple
mechanical devices to electronic or
radiating tools with +0.1%.

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 Tunning Method of Controlller
The original Ziegler-Nichols tuning methods published in
1942 aimed for a super-fast speed of response at the
expense of control loop stability.

However, with a slight modification of their tuning rules, the loop

stability can be improved. This comes at the expense of a
slight reduction in the speed at which a control loop
responds to a disturbance or set point change.

However, most process experts will agree that control loop

stability is more important than speed.

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LEVELS SENSORS ON CAR

Cars contain two of the main

kinds of level sensors:
1)Float sensor(based on
buoyant and displacement
types)
2)Visual sensor
Eg. The float sensor is found in
the gas tank and visual sensors
under the hood of the car.
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 GAS TANK FLOAT SENSOR

• Initially, the float is at top of tank

• The attached wiper is closer to negative side of terminal
– Less resistance
– More current
– Hotter Heating coil
– Pulls Bimetallic strip so dashboard gauge displays full
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 As fuel leaves tank, float lowers
Wiper moves further down resistor
More resistence
Less current
Coil cools
Strip pulls with contracting metal
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Finally, after float hits bottom of tank, wiper is
pulled to far right:
Highest resistance
Lowest current
Coolest heating coil
Strip pulled gauge to empty

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 Gas Tank Float Sensor
• Pros:
– Relatively simple mechanical design
– Good for estimating level of fuel
– Economical

• Cons:
– Inaccurate when:
• Tank is completely full
• Tank is near empty
– Doesn’t measure precise tank volume
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 Types

• Point level Sensorsindicate cetain level of

product in tank),shows high n low
Eg Capacitance Sensors,optical sensors
converting light waves for oil in low level
measurement.

• Continuos Level Sensors indicates the

continus level of product when it rises and
falls eg ultrasonic and radar
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 Dipsticks

Dipstick is inserted into • Similary to the fuel

engine tank float meter:
Then removed with oil – Good for estimating
residue on tip
Tip is marked with “full” fluid level
and “add oil” markings – Not a precise
Checking transmission measurement of
fluid is similar volume 20
Methods ---- Direct or Indirect (inferential)

1. Float Swithes
2. Gauge glass
3. Differential
pressure type
4. Load Cells
5. Capacitance
Transmitters
6. Ultrasonic
7. Microwave
8. Radar
9. Dip Stick etc

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For Liquids

Dip Stick

• Simple and cheap

• Can be used with any wet
material and not affected by
density.
• Can not be used with
pressurized tanks
• Visual indication only
(electronic versions are
available)

RodGauge - similar to a dipstick found in a car, it has weighted line

markings to indicate depth or volume(used in trnsportation and stationary
engines) 23
For Liquids

Sight Glass
Another simple direct
method of
measuring liquids.
Can be used in
pressurized tanks
(as long as the
glass or plastic
tube can handle
the pressure)

Good for applications where non-contact measurement is needed (like

beverages) 24
Hydrostatic Head Level Sensors

• These methods infer level by measuring the

hydrostatic head produced by the liquid
column.

• A pressure sensing element is installed at the

bottom of the tank and pressure is converted
to level.

• Different liquid densities or closed tank

applications must be accounted for.

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Hydrostatic Head Level Sensors

General Theory for Head Measurement

The Pressure exerted by the

Height of the liquid is:
Liquid
Height (H) Density (D) P = H x Density*
Pressure
PSI

If the Density of the liquid is

known then
H= Pressure
Density*
*Note: For liquids other than water, use the density of water 0.0361 lb/in3
as a reference and multiply by the Specific gravity of the liquid. 26
Hydrostatic Head Level Sensors (Cont‘d)

Practical Considerations when using

head type instruments
The reference point of the tank vs instrument
input must be considered.

Liquid Liquid
Height Density (D) Height (H) Density (D)
(H) Pressu
re PSI
Pressur
e PSI

This may not be practical in some applications where the tank elevation is below
grade or where a remote visual reading is required.

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 Example
A dip stick measurement of the level of these 2 tanks indicates 30 feet of
liquid in both tanks. Calculate the pressure that each gauge will read if
tank 1 contains water (S.G. = 1) and tank 2 contains oil (S.G. = 0.85)

Water Oil
Height
Density
Height
(H)
Density
(H)
(D) (D)
Tank Tank
1 PSI 2 PSI

P = H x Density P = ? psi

= 30 ft x 0.0361 lbs/in3
= (30 x 12) x 0.0361
= 13 psi
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For Liquids

Floats(Bouncy Methods)
Float rides the surface level to provide the
measurement. Many different styles are
available. Usually used for pump control,
high/low level alarms and emergency
shut-off

Liquid density does not affect measurement

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Magnetic Level Sensor

Used where the sight

glass level gauge
can not be used.
Magneto-resistive
types can provide
an electrical output.

Liquid/liquid interface (such as water and oil) can be measured by changing

the buoyancy of the magnetic float

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Displacers
• Not the same as a float.
• The displacer is immersed in the tank and
the buoyant force of the liquid produces a
torque which is proportional the amount of
liquid level. (F=W) where F force or wt to
be supported and W weight of displacer.

The output force

can be converted
to provide a
proportional
pneumatic or
electrical
continuous output
of tank level.
F=W-V*G/D 32
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1) UltraSonic Level Measurement

• Non-Contact direct level

sensor
• Level is a function of
the time it takes an
ultrasonic pulse to hit
the surface of liquid and
return(from the
transmitter to receiver)
Limitations include:
• Surface foam absorbs signal, agitation create
reflections
• High Pressure & High Temperatures affect the
signal speed 34
• Vapour and condensate create false echo’s
2) Radar Level Sensors (Microwave)

Similar to ultrasonic
but at a much higher
frequency (6.3 GHz)
Various designs
-- Frequency Modulated
Continuous Wave
-- Pulsed Wave
-- Guided Wave

These sensors have better performance in

applications where vapour, dust or uneven
surfaces exist. 35
3) Load Cells

Tank level is determined by

the weight of the quantity
of material
Load Cells (strain gauge
transducers) placed at the
bottom of the tank
measure the weight and
then convert it to an
electrical signal.

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 4) d/P Cell Transmitter
The differential pressure cell is one of the most common
methods of measuring level.

4 – 20 mA

24 VDC mA To PLC
or
Controller

Lo side open to
atmosphere

Open Tank Measurement

• Lo side of the d/P cell is left open to atmosphere.
• Hi side measures the hydrostatic head pressure which is proportional to the
height of the liquid and its density.
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5) Capacitance Level Detection (RF Level Probes)

RF Capacitance level sensors are similar in operation to conductivity

sensors and are typically used when non-conductive liquids are
measured.

The only variable is the dielectric of the tank material that varies
in proportion to the level.
Conductive liquids like mineral water will short out the probe to the tank
wall.Good for solids 40
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 Summary

• Level is measured by locating the

boundary between two media, called the
interface
• Level can be measured directly or
indirectly
• Noninvasive devices are preferred when
the material is corrosive, hazardous,
sterile, or at a high temperature or
pressure
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