Level Measurement To assure the safety and profitability of processes, it is often essential to be equipped with instruments providing reliable

and precise measurements of level. A level measurement can be categorized in :

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A top-down or bottom up measurement

A top-down measurements may or may not contact the process fluid. A top-down measurement poses less potential for leakage A bottom-up measurement typically contacts the process fluid . Level devices that use pressure transmitters are bottom-up measurement systems.

Direct and indirect measurement - Direct measurement - indicates that level is measured directly. For example, when you use a dipstick to check the oil level in your car, you are making a direct measurement. A direct measurement is independent of any other process parameters

- Indirect measurement, also known as inferred measurement, indicates that a variable other than level is first measured and then used to determine a level measurement. For example, pressure transmitters use mass and the fluids specific gravity to calculate level Continuous ,Single-Point or Multipoint Measurement: A continuous level-measurement system monitors the height of product within a range of points within the tank at all times. Continuous measurement is used for precise control, to maintain the level of a material at a particular point, and to ensure a consistent supply, like in a batch reactor. Single-point measurement indicates whether a product is at least as high or low as a certain point, usually the high- or low-level limit. They are typically used to prevent overflow. A common example is a toilet tank float. In multipoint measurements, level indication is observed at two or more discrete points in the tank. Two single-point measurement devices may sound alarms or operate equipment at high and low limits. Several single-point devices located throughout the vessel could approximate a continuous level-measurement system

CONTACTING VS. NONCONTACTING

In a contacting measurement, some part of the measurement system is in direct contact with the contents of the vessel. Examples of contacting measurement techniques include floats and dipsticks. In a noncontacting measurement, no part of the measurement system directly contacts the contents of the vessel.

There are several types of level measurement technologies - point level - pressure-based - ultrasonic non-contact - and radar based. I will start to explain in detail how each device works.

POINT LEVEL DETECTION Point level detection can either be single point or multipoint measurement and is normally used where either high or low alarm levels are to be indicated. The most common application is for over-fill protection, and is frequently used in addition to continuous level measurement systems where additional back up or high integrity alarm signals are required. Multipoint measurement is commonly used for automatic pump control for filling or emptying vessels, where separate start and stop levels are required for the pump.

ULTRASONIC LEVEL SWITCHES Ultrasonic level switches are used in most industrial processes applications to detect high and low levels. Operation is achieved using the time-proven principle of ultrasonic transmission between two crystals. Liquid presence is detected by virtue of its bulk. Liquid droplets, condensation, or foaming are ignored. Typically an ultrasonic gap sensor is operated at a nominal frequency of 1 MHz. Sensor electronics are set to respond to the gain or the attenuation due to the lack of liquid in the sensor gap

Generally, gap sensors are designed for fail safe low level duty. A special Hi-sens type sensor is used for fail safe high level duty.

Advantages of ultrasonic gap switches:

No moving parts, no maintenance Simple installation Hazardous area use Immune to foam Unaffected by: RF interference Conductivity Droplets Most coatings Liquid color/opacity

MAGNETIC FLOAT-OPERATED SWITCHES

Magnetic float-operated switches usually fall into two categories, - horizontal - vertical-operated configurations. In most applications it is common to have the float switch directly mounted to the tank or vessel via a stand-off nozzle and flanged connection. In certain cases, especially in the process industries where temperatures and pressures, installed in a separate Figure below. vessels may be at high the float switch device may be chamber or bridle as shown in

Horizontal Type Level Switches The horizontal level switch typically employs a two magnet principle to provide the switching action. The main advantage of this design is that the internal float is mechanically isolated from the electrical switching mechanism via the magnetic coupling through the non-magnetic flange of the switch body. In this figure it is shown how the horizontal magnetic two-magnet principle operates.

One permanent magnet forms part of a float assembly which rises and falls with changing liquid level. A second permanent magnet is positioned within the switch so that the adjacent poles of the magnet repel each other through a non-magnetic diaphragm. A change of liquid level which moves the float through its permissible travel causes the float magnet to move and repel the switch magnet to give the snap action operation.

Vertical Type Level Switches The float in a vertical type level switch carries a stainless steel sheathed permanent magnet which rises and falls in the glandless pressure tube with changing liquid level. A switch mechanism is mounted inside the enclosure adjacent to the pressure tube. Switching is achieved with a unique three-magnet system, giving snap action latch-on switching.

Vertical movement of the float magnet in the pressure tube simultaneously actuates the secondary and tertiary magnets in the switch mechanism to operate the contacts

DISPLACERS
The displacer element, typically made of stainless steel, is suspended on a stainless steel cable from a spring. The element is always heavier than its equivalent volume of the liquid in which it operates, so it always creates tension on the spring. In free air, the spring will be extended to a known length, controlled by a mechanical stop to prevent overstressing. Fixed to the spring is the float rod and magnet assembly, free to move up and down as the spring extends or contracts, andt the switch mechanism is outside the pressure tube in the usual manner.

As liquid rises to cover the displacer element, a force is created equal to the weight of the liquid displaced. This force is sensed by the spring as a reduction in weight, causing the spring to contract, moving the magnet upwards inside the pressure tube, and actuating the switch mechanism

TUNING FORK LEVEL SWITCHES

The tuning fork type of level switch typically comprises a sensor consisting of a pair of tines that act like a tuning fork plus associated electronics that provide either a solid state electronic output or simple relay contact. Tuning fork tines are oscillated at their natural resonant frequency of typically 1300 Hz by a piezoelectric crystal located near the head of the fork. When the sensor is in the vapor space, the natural resonant frequency is maintained at 1300 Hz.

When the sensor tines become immersed in liquid, the sensors natural frequency is reduced. Typically electronics are set to respond when the natural frequency drops by approximately 200Hz to 300Hz

ADVANTAGES - Temperature range 40 F to +300 F (-40 C to 150 C)

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High pressures up to 1500 psi (100 bar~)

Ultrasound

ULTRASONIC SIGNALS
An ultrasonic signal is generated by driving a piezo-electric crystal with a high voltage AC signal. The crystal tries to oscillate but is unable to because it is bonded to the inside face of the transmitter. As a result, the whole assembly oscillates at the crystals natural frequency and an ultrasonic signal is transmitted. Ultrasonic level transmitters are non-contacting instruments installed over a liquid that may be in a tank, wet-well, or open air reservoir. An ultrasonic pulse is emitted by the transmitter toward the liquid surface.

Ultrasonic level transmitters typically send a signal directed toward the liquid surface about once every second. The signal travels at the speed of sound and is reflected back as an echo towards the transmitter when it hits the liquid surface. The transmitter knows the instant in time when the signal was sent and also the instant in time when the echo is received back, so the overall journey time is known.

Because the transmitter knows both the speed of sound and time taken, the distance to the target is calculated using the basic equation:
Distance = Speed x Time

BLANKING DISTANCE & RING-DOWN TIME

All transmitters have a blanking distance, sometimes called a blocking distance or dead zone, in which no measurements can be made. The time it takes for the oscillation to spread is known as the ring-down time. The ring-down time can be used to calculate the distance to the surface, since in ultrasonics time equals distance.

If the liquid surface is too close to the transmitter face, an echo is received before the transmitter oscillation decays, which makes it extremely difficult to detect the echo among other noise. To avoid this situation, manufacturers stipulate a minimum blanking distance based on the ring-down time of the transmitter. ATTENUATION OF ULTRASONIC SIGNALS Ultrasonic signals can be affected by vapors, condensation, foam, and various other factors

Vapors This error can usually be overcome by programming a speed of sound correction factor. Condensation Heavy condensation is best avoided. Foam Correct positioning of the transmitter above this foam-free area usually solves the problem. Turbulence Turbulent liquid surfaces can also be problematical but a stilling tube can minimize excessive agitation.

Use of Pressure Transmitters is a another way o level measurement

when -The process is corrosive and requires frequent transmitter replacement -the placement of the tank doesnt allow to put the pressure transmiters directly on the tank in contact with the process fluid Pressure transmitters with remote seals are used so this kind of system allow transmitter to be removed from direct contact with the process fluid. Seals function act as an extension of the transmitter.

So in a open OPEN TANK - SINGLE SEAL SYSTEM with transmitter above the tap : the head pressure of the liquid is measured to infer a level measurement. Remote seal systems consist of external sensing diaphragm seals that are connected to the transmitter with oil-filled capillaries. The oil used in the capillaries is not compressible. Any column of liquid exerts a force at the base of the column because of its own weight. This force, called hydrostatic pressure or head pressure, can be measured in pressure units. Hydrostatic pressure is determined by the following equation:
Hydrostatic Pressure = Height x Specifics Gravity

in a open OPEN TANK - SINGLE SEAL SYSTEM with transmitter below the tap The difference is that the distance between the tap and the transmitter must be calculated with the specific gravity (S) of the fill fluid instead of the process fluid. Note this is the vertical distance, not the capillary length

CLOSED-TANK LEVEL MEASURement

In closed systems, the transmitter location is restricted by the maximum allowable distance above the lower tap. In pressurized systems, this is the same as the 1 atmosphere equivalent seen previously. In sub-atmospheric systems (vacuum systems), the transmitter should be mounted at or below the lower tap. This ensures the transmitter always sees a positive pressure on both the measurement and the reference sides. Because Differentel Pressure transmitter is used, changes in the overall vessel pressure affect the high- and low-pressure taps of the transmitter equally, so the effects of pressure variation are canceled out. When using DP level-based technology for a closed-vessel application, customers have traditionally used one of this methods:

Dry leg system Wet leg system Remote seal/capillary system

Wet and Dry Leg Systems

In a wet/dry leg configuration, impulse piping is used to connect the DP transmitter to the high and low pressure taps on the vessel. The user then must fill the low-side impulse piping with a suitable gas (dry leg) or liquid (wet leg) to endure that a suitable reference pressure is applied on the low side of the DP transmitter sensor. Dry leg configurations are used when the gas in the vapor space of the vessel cannot condense (e.g., nitrogen). Wet leg configurations are used when the vapor gas can condense, such as steam. Remote seal systems consist of external sensing diaphragm seals that are connected to the transmitter with oil-filled capillaries. The oil used in the capillaries is not compressible, and thus they offer significantly better performance than wet/ dry leg configurations. In The most used two seal systems, the distance between the taps becomes the reference offset from zero. The calculations are the same regardless of where the transmitter is mounted.

Hydrostatic Tank Gauging

Hydrostatic tank gauging (HTG) uses a multipoint system to measure mass, volume, density, level, and temperature for liquid inventory and process applications .

Hydrostatic pressure is the pressure created by a height of liquid above a given point. HTG works on the principle that the hydrostatic head pressure of a column of liquid is directly proportional to the height of that column.

Mass is equal to the pressure difference between the bottom and top transmitters multiplied by the average area of the tank. The tank area is based on the current product level (determined by the pressure difference) and strapping table data.

Density is equal to the pressure difference between the middle and bottom transmitters divided by the distance between them. Density cannot be calculated when the product volume is below the middle transmitter

Level is equal to the difference between the bottom and top pressure measurements divided by the density plus the heel. The heel is the height of the process fluid from the bottom transmitter to the floor of the tank A temperature measurement is taken between the bottom and middle pressure transmitters. The temperature measurement, combined with the products measured density and density correction factors, is used to calculate standard density and standard volume values.

Level Measurement using RADAR technology Radar (radio detection and ranging) technologies transmit a continuous microwave signal from a radar device mounted on top of a vessel to the surface of the material held inside. The transmitted signal is reflected back to the device and the gauge measures the distance (and determines the level) by differentiating the transmitted and returned signals. It is similar like in ultrasound measurement.

The level measurement is determined by using the reference height of the gauge minus the distance to the surface.

Radar level devices are available in two basic versions: free radiating and guided wave. Both free radiating and guided wave radar provide a top-down direct measurement where they measure the distance to the surface. Free radiating radar sends a signal through the vapor space that bounces off the surface and returns to the gauge. Free radiating radar can frequently be used in vessels with agitators.

Guided wave radar sends a low energy pulse down a probe or cable that bounces off the surface and back to the device

It should not be used in applications with sticky fluids.the main advantage of the GWR is that can be used in tight vessels due to bypass.

A key advantage of radar is that no compensation is necessary for changes in density, dielectric, or conductivity of the fluid. Changes in pressure, temperature, and vapor space conditions have no impact on the accuracy of radar measurements
The most important differences between Guided-wave radar and ultrasonic are 1. Measurement Principle point of view

Ultrasonic systems are using sound waves and Guided-wave radar High-frequency radar (radio)
impulses

2. From Operating Limits point of view

Ultrasonic systems have Limited operating pressures and temperatures values but Guided-wave
radar can operate in High temperatures and pressures environment.