LEVEL MEASUREMENT

• Sensing liquid levels fall into two categories; firstly, single-point sensing
and secondly, continuous level monitoring.

• In the case of single-point sensing the actual level of the material is

detected when it reaches a predetermined level, so that the
appropriate action can be taken to prevent overflowing or to refill the
container.

• Continuous level monitoring measures the level of the liquid on an

uninterrupted basis. In this case the level of the material will be
constantly monitored and hence, the volume can be calculated if the
 LEVEL SENSING DEVICES
• There are two categories of level sensing devices.
They are direct sensing, in which the actual level
is monitored, and indirect sensing where a
property of the liquid such as pressure is sensed
to determine the liquid level.
 DIPSTICK
Dipsticks

• Dipsticks offer a simple means of measuring level approximately.

The ordinary dipstick is the cheapest device available.

• This consists of a metal bar on which a scale is etched. The bar is

fixed at a known position in the liquid-containing vessel.

• A level measurement is made by removing the instrument from the

vessel and reading off how far up the scale the liquid has wetted.

• As a human operator is required to remove and read the dipstick,

this method can only be used in relatively small and shallow vessels.
 OPTICAL DIPSTICK
O

• It allows a reading to be obtained without removing the dipstick

from the vessel, and so is applicable to larger, deeper tanks.

• Light from a source is reflected from a mirror, passes round the

chamfered end of the dipstick, and enters a light detector after
reflection by a second mirror.

• When the chamfered end comes into contact with liquid, its
internal reflection properties are altered and light no longer
enters the detector.
 OPTICAL DIPSTICK
• By using a suitable mechanical drive system to
move the instrument up and down and measure
its position, the liquid level can be monitored
 SIGHT GLASS
The Sight glass
• It is the simplest method for direct visual reading with the sight glass

normally mounted vertically adjacent to the container. The liquid level

then can be observed directly in the sight glass.

• The ends of the glass are connected to the top and bottom of the tank via

shutoff valves, as would be used with a pressurized container (boiler) or a

container with volatile, flammable, hazardous, or pure liquids.

• In cases where the tank contains inert liquids, such as water, and

pressurization is not required, the tank and sight glass both can be open to
SIGHT GLASS CONFIGURATIONS
 FLOAT SENSORS
• There are two types of floats : the angular arm and the pulley.

• The float material is less dense than the density of the liquid, and floats

up and down on top of the material being measured.

• A float with a pulley can be used with either liquids or free-flowing

solids. With free-flowing solids, agitation is sometimes used to help

level the solids.

• The advantages of the float sensor are that they are almost

independent of the density of the liquid or solid being monitored, are

accurate and robust, and have a linear output with level height.
 FLOAT SENSORS
• However, accuracy can be affected by material accumulation on the float,

corrosion, chemical reactions, and friction in the pulleys.

• If the surface of the material being monitored is turbulent, causing the float

reading to vary excessively, some means of damping might be required, such as a

stilling well.

• A ball float is attached to an arm, and the angle of the arm is measured to indicate

the level of the material. A spherical float shape is used to provide maximum
buoyancy, and it should be one-half submerged for maximum sensitivity, and to
have the same float profile independent of angle.

• The fuel gauge shows the output voltage from a potentiometer driven by the

float. Although very simple and cheap to manufacture, the angular float sensor
FLOAT SENSORS
 LIQUID LEVEL PROBES

• Probes for measuring liquid levels fall into three

categories, i.e., conductive, capacitive, and
ultrasonic.
 CONDUCTIVE PROBES
• These are used for single-point measurements in liquids that are conductive

and non volatile as a spark can occur.

• Two or more probes as shown can be used to indicate set levels. If the liquid

is in a metal container, the container can be used as the common probe.

• 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.

• Thus, probes can be used to indicate when the liquid level is low and to

operate a pump to fill the container. Another or a third probe can be used to

indicate when the tank is full and to turn off the filling pump.
CONDUCTIVE PROBES
 CAPACITIVE PROBES
• These are used in liquids that are nonconductive and have a high and can be

used for continuous level monitoring.

• The capacitive probe consists of an inner rod with an outer shell; the
capacitance is measured between the two using a capacitance bridge. In the
portion out of the liquid, air serves as the dielectric between the rod and outer
shell. In the immersed section, the dielectric is that of the liquid that causes a
large capacitive change, if the tank is made of metal it can serve as the outer
shell.

• The capacitance change is directly proportional to the level of the liquid. The

dielectric constant of the liquid must be known for this type of measurement.
The dielectric constant can vary with temperature so that temperature
CAPACITIVE PROBES
 ULTRASONICS PROBES
• Ultrasonic level measurement is one of a number of
noncontact techniques available.
• It is used primarily to measure the level of materials
that are either in a highly viscous liquid form or in solid
(powder or granular) form.
• The principle of the ultrasonic level gauge is that energy
from an ultrasonic source above the material is
reflected back from the material surface into an
 ULTRASONICS PROBES
• Measurement of the time of flight allows the level
of the material surface to be inferred.
 ULTRASONICS PROBES

Level = Speed of sound in air x Time delay / 2

 ULTRASONICS PROBES
• An ultrasonic level transmitter is fixed at the top of a
tank half filled with liquid. The reference level for all
measurements is the bottom of the tank.
• Level to be detected is marked as “C”, and “B” is the
distance of the ultrasonic sensor from the liquid
level. Ultrasonic pulse signals are transmitted from
the transmitter, and it is reflected back to the sensor.
• Travel time of the ultrasonic pulse from sensor to
target and back is calculated. Level “C” can be found
by multiplying half of this time with the speed of
sound in air. The measuring unit final result can be
 ULTRASONICS PROBES

• Ultrasonic level transmitter has no moving parts,

and it can measure level without making physical
contact with the object.
• This typical characteristic of the transmitter is useful
for measuring levels in tanks with corrosive, boiling
and hazardous chemicals.
 ULTRASONICS PROBES
• Ultrasonic techniques are especially useful in measuring the
position of the interface between two immiscible liquids
contained in the same vessel or measuring the sludge or
precipitate level at the bottom of a liquid-filled tank.
• In either case, the method employed is to fix the ultrasonic

transmitter–receiver transducer at a known height in the

upper liquid. This establishes the level of the liquid/liquid or
liquid/sludge level in absolute terms.
ULTRASONICS PROBES
 SELECTION CONSIDERATIONS
Distance to be measured
• The type of ultrasonic device must be able to cover the
distance required. This is usually included in its specification
sheets. Note that the general specifications are for clean air
and a flat surface.
• The reason for variation in range is simply that a system
designed for high accuracy and short distances will not be
powerful enough for longer distances. Similarly a more
powerful system may be too strong for short distances and
cause too much echo and induced noise.
• It should be noted that new systems do have automatic
variable gain to compensate for this. Temperature changes or
dust, dirt and condensation on the sensor hamper the
 SELECTION CONSIDERATIONS
Surface of material
• It is a fundamental requirement in this type of measuring system
that part of the transmitted signal is reflected back from the
surface of the product to be measured. The more distinct the
measuring surface, then the more accurate and reliable the
measured value.
• The clarity of the surface can be obscured by:
- layer of foam on a liquid surface
- fine granules on bulk material
 SELECTION CONSIDERATIONS
Environmental conditions
• Since the ultrasonic signal must pass through the air where it is
installed, such factors as dust, steam, pressure, temperature
and gas need to be considered.

Acoustic noise

• A common form of acoustic noise occurs when a truck tips a

load of ore into a storage bin or hopper. The noise generated
from the transfer of ore can affect and degrade the return
 SELECTION CONSIDERATIONS
Pressure
• In general, ultrasonic measurement systems are not affected
by pressure variations. The only limitations that are imposed
are due to the mechanical constraints of the equipment,
and in the case of low pressure, the ability to transmit sound
energy.
• One limitation with pressurised vessels are that since they
are fully enclosed there may be a problem with second or
 SELECTION CONSIDERATIONS
Temperature
• Changes in temperature affect the speed of the sound
wave and ultimately the transit time. The temperature
sensor makes corrective adjustments. Errors can occur in
situations where there is a varying temperature gradient
over the distance of the measurement.

• Operation of ultrasonic equipment can be up to 170 with

the limitation being due to the transducer construction
 SELECTION CONSIDERATIONS
Mounting
• Since the ultrasonic device is intended to measure the
level, it requires an unobstructed path so that the only
signal reflected is that of the material to be measured.
• The path of falling product, and reflections from
surfaces of the holding vessel should be avoided. The
bottom surface needs to be angled so that the
reflected signal is directly back to the transmitter for a
valid measurement.
• If the bottom of the vessel is at an angle so that the
signal is reflected from a number of walls, the output
from the device can be unpredictable.
 SELECTION CONSIDERATIONS
Self-cleaning
• In applications where splashing can occur, self
cleaning probes may be required.
• Condensation, liquid and dust are atomised on
contact with the highly active transducer face. This
makes self cleaning probes resilient to build up
reducing routine maintenance.
 INDIRECT LEVEL SENSING
• The most commonly used method of indirectly measuring a
liquid level is to measure the hydrostatic pressure at the
bottom of the container.
• The depth can then be extrapolated from the pressure and
the specific weight of the liquid can be calculated.
• The dial on the pressure gauge can be calibrated directly in
liquid depth. The depth of liquid can also be measured using
bubblers, radiation, resistive tapes, and by weight