3.

7 Displacer Level Devices

LC
D. S. KAYSER (1982) B. G. LIPTÁK (1969, 1995)

C. G. LANGFORD (2003)

Flow Sheet Symbol

Design Pressure Set by the flange rating of the chamber or by the maximum working pressure of the
displacer, usually up to 100 PSIG (7 bars, 0.7 MPa) for the flexible disc and up to
600 PSIG (41 bars, 4.1 MPa) for the diaphragm-sealed designs. The flexible shaft
unit can operate up to 1000 PSIG (69 bars, 6.9 MPa); torque-tube designs are available
up to 2500 PSIG (170 bars, 17 MPa); magnetically coupled units can be used up to
6100 PSIG (410 bars, 41 MPa). Verify ratings with the manufacturer.
®
Design Temperature Generally in the range of −50 to 451°F (−45 to 230°C). Inconel torque tubes can
operate from −350 to 850°F (−212 to 454°C). For electronic transmitters, the tem-
perature of the topworks must be kept below 180°F (82°C). If the process temperature
is above 500°F (260°C) or below 0°F (−18°C), thermal insulation barriers or torque-
tube extensions are usually recommended.
®
Materials of Construction Displacers are available in type 316 stainless steel, Monel , polypropylene, or solid
®
Teflon . The hanger cable assemblies can be obtained in type 316 stainless steel,
® ®
Monel , and Hastelloy C. The cage (chamber) is usually carbon or stainless steel.

Inaccuracy Varies widely with application and the instrument, typically 0.5% of full scale.

Range Standard displacers are available in lengths of 14 to 60 in. (0.35 to 1.5 m). The range
of special units can go up to 60 ft (18 m).

Cost Displacer-type switches cost from $200 to $500, and a 32-in. (0.81-m) electronic
transmitter costs about $2500; add $500 to $700 for an external steel chamber.

Partial List of Suppliers ABB Instrumentation Inc. (www.abb.com)

Delta Controls Corp. (www.deltacnt.com)
Dwyer Instruments Inc. (www.dwyer-inst.com)
Endress+Hauser Systems & Gauging (www.systems.endress.com)
The Foxboro Co. (www.foxboro.com)
Magnetrol International (www.magnetrol.com)
Masoneilan Operations Dresser Flow (www.masoneilan.com)
Norriseal (www.norrisel.com)
Schlumberger Measurement Div. (www.slb.com/rms/measurement)
Siemens Moore Energy & Automation (www.sea-siemens.com)
Yokogawa Corp. of America (www.yca.com)

INTRODUCTION in the apparent weight of the displacer. The simplest level

Archimedes’ (c. 290 to 212 BC) principle states that a body
wholly or partially immersed in a fluid is buoyed up by a
force equal to the weight of the fluid displaced. A level or
a density instrument is sensitive to the apparent weight of
an immersed displacer. If the cross-sectional area of the
displacer and the density of the liquid are constant, then a
unit change in level will result in a reproducible unit change
device of this type involves a displacer that is heavier than
the process liquid and is suspended from a spring scale.
When the liquid level is below the displacer, the scale
shows the full weight of the displacer. As the level rises,
the apparent weight of the displacer decreases, thereby
yielding a linear and proportional relationship between spring
tension and level. The spring scale can be calibrated as
desired.

465
© 2003 by Béla Lipták
466 Level Measurement
This simple device is limited to applications in open tanks.
In practical industrial service, the basic problem is to seal the
process from the spring scale or other force-detecting mecha-
nism. This seal has to be frictionless and useful over a wide
range of pressures, temperatures, and corrosion conditions.
The variations in the design of this seal provide the basis to
distinguish the types of displacement detectors that are in use
and are discussed below. They are the magnetically coupled
switch, the torque tube, the diaphragm and force bar, the spring
balance, the flexible disc, and the flexible shaft design. Each
of these units operates on Archimedes’ principle but is different
as far as its seals are concerned. All of them can be used to
detect a liquid–vapor interface, a liquid–liquid interface, and,
if the level is constant, the changes in density as well. The
flexible disc unit is available as a pneumatic transmitter, and
the flexible shaft unit is available as a high-gain pneumatic
controller or as a switch. The other designs are available with
integral pneumatic or electronic transmitters or controllers.
DISPLACER SWITCH
The major difference between a float level switch and a dis-
placer level switch is that a float moves with the surface,
whereas a displacer is partially or totally immersed and moves
very little with process changes. Switching arrangements and
installation considerations are similar for the displacer and
float switches. Float-type switches are covered in the next
section, and the discussion here will be limited to the design
features of the displacer switch. Figure 3.7a shows a displacer
Testing
Cable
High Level
Flexible
Cable Displacers
Low Level
FIG. 3.7a
Displacement level switches.
© 2003 by Béla Lipták
mounted on a flexible cable attached to a support spring.
When the tank is empty, the spring must support the full
weight of the displacer. As the level rises, and the displacer
becomes immersed in the liquid, the downward force on the
support spring is reduced, and a small stem movement occurs
to activate the switch.
Figure 3.7a also illustrates how the displacer level switch
systems might be tested when installed in open tanks and
sumps, or on floating roofs. The technician or operator can
attach a testing cable as shown on the right side of Figure 3.7a.
Once the cable is attached, lifting on the cable simulates a
high-level condition, changing the state of the switch to prove
the operation of the switch and probably the wiring.
In the next section, the operation of different switching
contacts and the designs of the different float chambers are
described. Although this information is provided for float-
type switches, it is also applicable for displacer-type units.
When deciding between float-type and displacer-type level
switches, the following advantages can be noted for the latter:
1. The maximum differential between high and low set-
tings can be as much as 50 ft (15 m).
2. Level settings are adjusted by moving the displacer(s)
to a new elevation on the cable.
3. Moderate surface turbulence is less apt to cause switch
chatter, because the cable is in tension.
4. Within broad ranges, fluid density has no effect on the
displacer sizing diameter, making units interchange-
able between services of varying density simply by
changing the support spring.
5. The displacer switch is less apt to cause spurious trips
in vibrating services, because the cable is always in
tension. This is an important consideration for auto-
matic shutdown systems such as may be used at com-
pressor suction drums.
The displacer switch is available in many configurations
to achieve the desired functionality. Some have multiple
switches and can be used for multiple control functions. For
example, a single unit can be used to sequence two pumps by
actuating both pumps at high level, one at mid level, and neither
at low level. The one disadvantage of most implementations
of this style of displacer switch is that the support spring
is exposed to the process. This limits the switch to applications
that are reasonably clean, nonfreezing, and not corrosive to the
available spring materials. One way to eliminate the need for
a spring is to install the displacer horizontally and connect it
to a microswitch through a flexible shaft seal (Figure 3.7b).
TORQUE-TUBE DISPLACERS
The torque tube shown in Figure 3.7c uses a tube in torsion to
provide the spring function. The hollow torsion tube supports
the displacer, which is always heavier than the process fluid,
and also provides a frictionless pressure seal. This makes it
 3.7 Displacer Level Devices 467

Float-Arm
Extension

Flexible Shaft
11/2" NPT
Limit-Stop
Bracket

Float-Arm
Displacer
Float Formed Section
SPDT Micro Switch

FIG. 3.7b
Side-mounted displacer switch. (Courtesy of Siemens Moore Energy & Automation.)

Torque Tube Torque of a knife-edge bearing support. A limit stop prevents acci-
Torque
Flange Rod dental overstressing of the torque tube by limiting the down-
Arm
Torque ward motion of the torque arm. The angular displacement of
Torque
Arm Tube the torque tube and torque arm are the same at the knife edge
Block end of the tube. At the flange end, the tube is anchored in
place and does not rotate, but the torque rod is free to rotate
the same amount as it did at the knife edge. The angular
displacement, which amounts to about 5° or 6°, is linearly
proportional to the apparent weight of the displacer and thus
to the level or density. With the pressure sealing problem
solved, it is a simple matter to convert the angular displace-
Limit
Stop
ment to a usable electronic or pneumatic analog signal. The
®
standard torque-tube material is Inconel , but the torque tube
Knife ® ®
Edge
Nozzle is also available in stainless steel, Hastelloy , Monel , nickel,
or Durimet. Note that the mechanical design requires the
Flapper technician to be knowledgeable and careful in doing main-
Displacer tenance or repairs.

Sizing of Displacers

FIG. 3.7c
Torque tube displacer level detector.
possible to transfer the changes in the apparent weight of the
displacer through the wall of the pressure vessel into a mea-
suring device. Figure 3.7c is a schematic presentation of the
displacer and torque tube. The displacers are typically cylin-
drical and can be furnished in a wide selection of plastic and
alloy materials. Although any length displacer up to 60 ft
(18 m) can be obtained, the most common lengths cataloged
are 14, 32, 48, and 60 in. (0.3, 0.8, 1.2, and 1.5 m). The
3 3
volume of a standard displacer is 100 in. (1638 cm ), and
the diameter is reduced as the length increases.
The torque arm connects the displacer to the torque tube
and absorbs any lateral forces. Friction is minimized by use
The technique given below for determining the desirable
displacer diameter is applicable for all types of buoyant-force
detectors, not just the torque-tube design. The displacer diam-
eter sets the weight change of the displacer per level incre-
ment. The torque tube is designed to twist a fixed amount for
each increment of buoyancy change. Therefore, in selecting
the displacer diameter, the torque-tube characteristics, the
density of the process fluid, and the level span must be
considered. For purposes of this discussion, it will be assumed
that the motion of the torque rod will be used to operate a
proportional band controller. Proportional band (PB) refers
to the response sensitivity of the controller, and it determines
the percentage change in output signal in response to a 1%
change in the level. A 100% apparent proportional band
setting means that the level in the tank has to cover the
displacer completely to generate a full output signal, and that

© 2003 by Béla Lipták

468 Level Measurement

the level has to drop to the bottom of the displacer to generate
the minimum output. A controller set to a PB of 100% can
be used as a transmitter if the process fluid is water. At 50%
apparent proportional band, a level variation of 50% of the
displacer length produces minimum to maximum output, and,
at 25% setting, a level variation of 25% will generate the min-
imum to maximum output.
The term apparent proportional band is necessary to dis-
tinguish the actual band setting on the instrument based on
water density at standard temperature from the resulting
apparent band related to the density of the process fluid being
measured. Figure 3.7d shows the relationship between the
two terms as a function of process liquid density. It can be
seen from Figure 3.7d that, if the band setting on the instru-
ment is 50%, the output of the controller will change 50%
of the level change with a liquid gravity of 1. It will change
100% with a gravity of 0.5, and, with a specific gravity of
0.1, the output will equal 10 times the level change. The
process fluid density thus affects the apparent gain of the
controller in an inverse linear fashion.
Because the weight change per unit level change gener-
ated by the displacer is balanced by the torsion spring con-
stant, the characteristics of the torque tube must be consid-
ered. The range of a standard torque tube matches the buoyant
3 3
force generated by a 100 in. (1638 cm ) displacer in water
for a band setting of 100%. This is equivalent to a force range
of 0 to 3.6 lbf (0 to 1.6 kgf). Table 3.7e below lists the force
Actual (Water Based)
Proportional Band
100 SG = 1.0 SG = 0.25
SG = 0.1
SG = 0.5
80
SG = 0.2
60
40
20
0
100 200 300 400 500 600 800
FIG. 3.7d
Relationship between apparent and actual proportional band.
ranges of standard and thin-wall torque tubes for one design
at various proportional band settings. The thin-wall tube
requires one-half as much force for full range operation as
the standard-wall tube. Review the technical literature for the
actual device used to confirm the actual numerical constants
to use. The calculations here are only examples.
Interface Measurement
In most liquid level measurement applications, the specific
gravity of the liquid is 0.5 (or greater), and it generates
sufficient force on the torque tube for a full range of output
signals, even with the use of a standard volume displacer,
unless a very narrow proportional band is required. This may
not be true for liquid–liquid interface applications. Difference
in buoyant forces is generated only by the density difference
between the two fluids, and the displacer must be completely
submerged for meaningful readings. Therefore, available
forces are smaller, and the sizing of displacers for liquid–liquid
interface is more difficult and requires more attention.
On interface applications, it is advisable to select a dis-
placer diameter to result in a 100% apparent proportional
band when the actual band setting is 20%. This leaves addi-
tional adjustment capability to the operator who, if required,
can reduce the actual band to 10% (the minimum recom-
mended) to achieve a reduction in apparent band to 50%. An
example will illustrate this.
Assume an installation in which the specific gravity of
the light fluid is 0.98 and of the heavy fluid is 1.02, and the
required displacer is 32 in. (812 mm) long. Furthermore, it
is desired to generate full controller output over a level inter-
face change of 16 in. (406 mm). To select a displacer diameter
suitable for these requirements, it is necessary to calculate
the displacer volume that will generate the force range
required by a thin-wall tube when the level variation is 16 in.
(406 mm). A thin-wall tube at an actual band of 20% requires
a full-range force of 0.36 lbf (0.16 kgf). The calculation of
displacer volume to generate this force is as follows:
Apparent Volume for 16 in. length
Proportion
1000
Band = (torque tube force)/( ∆SG)(wt. of 1 in.3 H 2O)
= 0.36/(0.004)(0.036) = 250 in.3 3.7(1)

Diameter = (( 4V )/(πL))1/ 2 = [(( 4)(250))/((π )(16))]1/ 2 = 4.5 in.

TABLE 3.7e 3.7(2)
Force Ranges of Standard and Thin-Walled Torque Tubes
Actual PB Force Range for Force Range for
If it is required to broaden the actual proportional hand
Setting (percent) Std.-Wall lbf (Kgf) Thin-Wall lbf (Kgf) to 40%, full controller output will result from a 32-in.
100 0–3.60 (0–1.6) 0–1.8 (0–0.8)
(812-mm) change in the interface. If the band is narrowed
to 10%, full controller output will correspond to a level
50 0–1.80 (0–0.8) 0–0.720 (0–0.32)
change of 8 in. (203 mm). If a standard-wall torque tube had
20 0–0.72 (0–0.32) 0–0.36 (0–0.16)
been selected for the above example, the diameter of the tube
10 0–0.36 (0–0.16) 0–0.18 (0–08) would have worked out to about 6.5 in. The sizing method

© 2003 by Béla Lipták

 3.7 Displacer Level Devices 469

Pressure Vessel
2" or Larger Nozzle

" Gate Valve (Vent)

2" Gate Valve
or Plug Gate Valve
2" or 3" Standpipe Automatic Gage Cocks
or Tees
" Gate Valve (Vent)
or Plug
1 " or Larger 1 " or Larger Screwed
Gate Valve or Flange Connections

" Coupling 6000 LB

\ Tapped One End Only

FIG. 3.7f
Side-mounted displacer. (Courtesy of Siemens Moore Energy &
Automation.)
given can be used for all displacer applications including
density detection. Standard displacer diameters are 3, 4, and
6 in. (76, 102, and 152 mm), but special sizes and designs
are also available (Figure 3.7f). Carefully review the engi-
neering specifications or check with the manufacturer for the
details that apply to the specific instrument being considered.
In a large vessel, the interface may have a very slow but
substantial wave motion if the difference between densities
is small. The gravity forces are small, and the fluids have
little friction to damp out any fluid motion. If no sight port
is located so as to make this motion visible, the operator will
have the impression that the signal or the control is cycling.
Rag Layer
Another cause of measurement doubt and confusion is the
common situation of a rag layer of material, lighter than the
heavy layer and heavier than the light layer, that will accumu-
late between the two desired layers. If there is no mechanism
or procedure to remove this material, it will become ever deeper
until it suddenly appears in the upper layer outlet. In continuous
processes, even tiny amounts of undesired materials will
always accumulate wherever conditions make this possible.
Features and Installation
Torque-tube level devices can be mounted internally or exter-
nally to the vessel. Internal displacers are used where it is
possible to drain the tank for level detector maintenance. If
the displacer is to be internally mounted, it is good practice
to install it inside of a stilling well, which may be fabricated
from a piece of pipe. To avoid errors, the standpipe must have
a number of vertical slots or holes along its length to permit
a free but restrained flow of liquids, and it should have a stop
bar across the bottom to prevent the displacer from falling to
Overlapping
Gage Glasses
1 " or Larger
Gate Valve
Reducer to " Pipe
" Gate Valve (Drain)
These Assemblies
May be Elbows
FIG. 3.7g
The installation of an external cage displacer on a standpipe with
two level gauge sections. (Courtesy of the American Petroleum
Institute, API RP 550.)
the bottom of the vessel if it becomes disconnected from the
torque tube.
For installations in which the vessel cannot be opened
and drained to perform maintenance on the displacer, it may
be installed in a level chamber mounted outside of the tank
and isolated from the process by means of lockable valves.
Local safety rules must be observed. A single barrier between
vessel and the environment may require special precautions.
It has been typical practice to install a level gauge to
approximately match the span of the displacer to provide
visual observation of the level. Figure 3.7g shows the instal-
lation of a displacer transmitter and level gauge mounted on
a standpipe or level chamber. Note that the two units have
independent isolation and drain valves. Some users prefer to
eliminate the installation of breakable sight glasses for envi-
ronmental and safety reasons.
When an external chamber is used, it may be necessary
to heat-trace and insulate the level chamber for freeze or fire
protection. The density measurement is for the liquid in the
chamber and may not represent the vessel contents density
if the level chamber temperature is not the same as the vessel
bulk temperature. For liquid–liquid interface applications, the
standpipe must have three connections to the vessel: one in
the heavy liquid layer, one in the light liquid layer, and one
in the vapor space that vents back into the vessel.
Special torque-tube and displacer designs are available
for operating pressures up to 2500 PSIG (17 MPa). For high-
temperature installations, the torque-tube material may be the

© 2003 by Béla Lipták

470 Level Measurement
limiting factor. The spring characteristics of the tube will
change at sufficiently high temperatures. Low temperatures
have little effect on the spring characteristics of the tube. For
®
torque-tube materials, Inconel is suitable for temperatures
between −350 and 850°F (−212 and 454°C). All other mate-
rials are limited to 500°F (260°C) except bronze, which is
rated at 300°F (150°C). Torque-tube extensions will provide
substantial thermal isolation for the instrument case. Installa-
tion details will also affect the instrument temperature. When
the process is at a temperature above 500°F (260°C), finned
extensions are recommended; when it is below 0°F (−18°C),
plain extensions may be used. The extensions should not be
insulated. Additional thermal insulation or thermal radiation
barriers can be used to protect the indicating and transmitting
portions of the instrument. Note that pneumatic transmitters
may have a higher allowable temperature than the electronic
version. Jacketed displacer chambers are available for hard-
to-handle services if field-applied tracing is judged to be inad-
equate. The process connections on external chamber displac-
ers are normally 1.5 or 2 in. (38 or 51 mm) and often flanged,
so they may be used in mildly dirty services. Consider blow-
down or drain valves where appropriate and permissible. It is
preferred not to use external chambers if there is a likelihood
of plugging because of solids accumulation.
The torque-tube displacer can be furnished with pneu-
matic or electronic transmitters or with local control. Con-
trollers are available with gain, integral, and/or derivative
control action. An output gauge should be installed on the
transmitter signal to indicate level and for troubleshooting.
It may also be good practice to install an independent level
gauge. The torque tube and displacer design has an excellent
field record for accuracy and reliability. Over time, accumu-
lated noncondensable and solids may compromise accuracy,
and some verification of proper performance is desirable. The
torque-tube seal is virtually trouble-free if properly specified
to meet the process requirements. In processes in which level
setpoint changes are infrequent, or where speed of response
is a concern, displacer units are often used as local level
controllers, even if a sophisticated control system is used.
The units may also be furnished with transmitter/controller
combinations, allowing the advantage of local control with
remote process indication.
SPRING-BALANCE DISPLACER
This instrument is similar to the torque-tube unit except that
the spring function of the torque tube is replaced by a con-
ventional range spring, and the isolation of the process from
the instrument is by means of a magnetic coupling. As illus-
trated in Figure 3.7h, the displacer is suspended in the liquid
by means of an extension range spring. As the level in the
vessel rises or falls, the buoyancy force on the displacer changes,
causing the spring to extend and contract. A magnetic attracting
ball attached to the displacer rod rises and falls in response
© 2003 by Béla Lipták
Magnet Nozzle Air
Attraction Pilot
Output
Ball
Air
Enclosing
Supply
Tube
Range
Spring
Magnetic Coupling with
Electronic Output
Displacer
FIG. 3.7h
The old spring balance, magnetically coupled displacer.
to the displacer movement. The movement is about 1 in.
(25 mm) full range. The ball is centered within the enclosing
tube, and its movement is nearly frictionless. A follower
mechanism moves with the magnetic ball for indication and
signal transmission.
Other design features and accessories are similar to the ones
discussed in the section on torque-tube design. The spring-
balanced displacers are also available with corrosion-resistant
wetted parts and are suitable for operating temperatures
between −250°F (−157°C) and 600°F (316°C). Because the
interior-to-exterior motion is magnetically coupled, units
with very high pressure ratings to 6000 PSIG (41 MPa) are
available. The merits and disadvantages of the spring-balanced
design are similar to those of the torque-tube units, except
that the movement of the displacer is greater, and the range
spring is exposed to the process. Greater movement almost
always causes faster wear at pivot points. The range spring
exposure creates difficulty in installations where vapor space
condensation, polymerization, or crystallization is expected,
because material buildup on the spring will interfere with
proper operation. Inert gas purging of the spring chamber has
been used to prevent the process vapors from entering the
chamber, but the large flow rates required make this solution
impractical.
FORCE-BALANCE DISPLACER
The basic mechanism of the classic differential-pressure trans-
mitters illustrated in the previous section can be adapted to
produce another family of displacer level devices. Figure 3.7i
shows the force-balance type of top-mounted design. Level
variations in the vessel cause a proportional change in buoyant

Seal & Fulcrum
Force Bar
Hanger Rod
Displacer
FIG. 3.7i
Force balance, diaphragm sealed displacement level transmitter.
(Courtesy of The Foxboro Co.)
force of the displacer, reducing the apparent weight on the
force bar as the level increases. In the side-mounted version,
the process is sealed by a diaphragm, which also serves as
the fulcrum of the force bar. The buoyant force is transmitted
to the balancing rod, which pivots on the range wheel. An
increase in level causes a minute movement that, it turn, is
detected by the transmitter, which in the past generated a
pneumatic signal. Today, the signal is electronic, in the form
of either an analog signal or digital data communicated over
the bus or network of the plant.
This instrument is available with the displacer mounted
either inside the vessel or in an external chamber. The latter
is used where maintenance must be performed while the tank
is under pressure. The limitations of this device are similar
to those of the torque-tube design, but the diaphragm seal is
not as rugged as the torque tube, and the operating pressure
is limited to 600 PSIG (4.1 MPa) with operating temperatures
to 400°F (204°C). A variety of materials are available to meet
requirements of corrosive services (see Table 3.7j).
The displacer sizing procedure for density, interface, or
level detection follows the same basic method outlined for
the torque-tube units, except that the buoyant force range
involved is different. The buoyant force span for one standard
unit is 2.90 lbf (1.29 kgf) or more; for the narrow design, it
is 1.45 lbf (0.65 kgf) or more. The formula to calculate tile
buoyant force is:
F = (0.36)(SG)(V)(Lw)/L 3.7(3)
where
F = buoyant force in pounds
SG = specific gravity difference
© 2003 by Béla Lipták
3.7 Displacer Level Devices 471
V = displacer volume in cubic inches
Lw = working length of displacer in inches
L = total length of displacer in inches
This instrument is available for mounting either inside the
vessel or in an external chamber. The latter is used where
maintenance must be performed while the tank is under pres-
sure. The limitations of this device are similar to those of the
torque-tube design but, in addition, the diaphragm seal is not
as rugged as the torque tube, limiting operating pressures to
600 PSIG (4.1 MPa) and operating temperatures to 400°F
(204°C).
FLEXIBLE DISC DISPLACER
In case of the flexible disc design, as rising liquid level
reduces the apparent weight of the displacer, a force balance
mechanism detects this change in weight while maintaining
equilibrium. The output signal is directly related to the level
in the vessel. Span adjustments are made by changing the
total length of the float arm.
The float arm is supported by the flexible disc. As a result
of the force-balance principle of operation, all components
maintain their predetermined position with essentially no
movement. This protects the flexible disc from fatigue due to
bending. The weight of the displacer and float arm is carried
by the flexible disc, and the static pressure in the vessel acts
upon the thrust pivots. Limit stops keep the float arm motion
within the elastic limits of the disc when the vessel is empty.
This design has the same limitations as the other displacer
units but has a narrower range of application, because the
flexible disc seal limits its use to 100 PSIG (0.7 MPa) oper-
ating pressure. At higher pressures, the unit becomes inaccu-
rate, and an increase in error of ±1% of full scale can be
expected per 100 PSIG of process pressure. The flexible disc
is normally made of stainless steel, but it is also available in
®
Monel and nickel. The displacer can be made of a wide
variety of materials. The performance of this unit is generally
inferior to the other designs covered in this section.
FLEXIBLE-SHAFT CONTROLLERS
This unit moves too much to be simply classified as a displacer
and too little to be simply a float device. But the limited float
motion makes it more nearly a displacer, so it is considered
as such here. As with the other displacer designs, the flexible-
shaft unit detects the buoyant force of the float with practically
no motion involved approximately 1/32 in. (0.8 mm) travel.
As shown in Figure 3.7k, the shaft is tubular, with a flattened
center section that moves easily in the vertical direction but
resists horizontal motion. In the pneumatic-controller version,
the extension tongue transmits the float motion to an air pilot.
472 Level Measurement

TABLE 3.7j
Data on Displacer Materials, Sizes, and Other Features (Typical)*
Metric Displacer Data

Maximum
Working
Pressure English Displacer Data
Approximate Relative Permissible Process
OD bar or Maximum Working Density of Displacer Liquid Relative
Material L (mm) (mm) MPa kg/cm L(in.) OD (in.) Pressure (PSI) (Specific Gravity) Density Limits (SG Term)
316 SS 356 76 6.9 69 14 3 1000 2.95 0.42 and 1.6
610 51 10.3 103 24 2 1500 2.52 0.56 and 2.2
610 76 6.9 69 24 3 1000 1.69 0.25 and 0.98
813 51 10.3 103 32 2 1500 2.28 0.42 and 1.6
813 76 6.9 69 32 3 1010 1.22 0.18 and 0.7
1016 51 10.3 103 40 2 1500 2.38 0.33 and 1.4
1219 42 10.3 103 48 1.66 1500 2.27 0.39 and 1.6
1270 51 7.6 76 50 2 1100 1.90 0.27 and 1.0
1524 38 10.3 103 60 1.5 1500 2.41 0.39 and 1.6
1524 76 10.3 103 60 3 600 1.31 0.10 and 0.4
1829 33 10.3 103 72 1.31 1500 2.58 0.42 and 1.7
2134 32 10.3 103 84 1.25 1500 2.60 0.40 and 1.6
2438 27 10.3 103 96 1.05 1500 2.96 0.49 and 2.0
2540 32 10.3 103 100 1.25 1500 2.43 0.34 and 1.4
2743 27 10.3 103 108 1.05 1500 2.80 0.44 and 1.8
2743 51 6.7 67 108 2 975 1.64 0.12 and 0.5
3048 25 10.0 100 120 1 1450 2.47 0.44 and 1.8
3810 25 10.0 100 150 1 1450 2.44 0.35 and 1.4
®
Monel 356 76 6.9 69 14 3 1000 1.63 0.42 and 1.6
610 76 6.5 65 24 3 950 1.69 0.25 and 0.98
813 51 10.3 103 32 2 1500 2.28 0.42 and 1.6
1524 51 6.9 69 60 2 1000 1.88 0.22 and 0.89
2134 33 10.3 103 84 1.31 1500 2.60 0.36 and 1.5
3658 25 5.2 52 144 1 750 2.47 0.37 and 1.5
Solid PTFE 356 76 10.3 103 14 3 1500 2.28 0.42 and 1.6
813 51 10.3 103 32 2 1500 2.28 0.42 and 1.6
1219 41 18.3 183 48 1.6 2650 2.28 0.42 and 1.6

*Courtesy of The Foxboro Co.

Mounting
An increase in level moves the tongue, gradually closing the
Float Flange
Flexible vent of the pilot and increasing the output signal to the control
Arm
Shaft valve. By turning the mounting flange 180°, the control pilot
action can be reversed so that an increase in level will be
Float accompanied by a decrease in the signal to the valve. The unit
can also be provided as an on–off switch with either pneu-
Extension matic or electric output.
Limit-Stop
Tongue As with other displacer designs, this device can be used
Bracket
to control interface or fluid density, but it is very limited in
FIG. 3.7k adjustment flexibility as compared to the torque-tube design.
Flexible shaft level controller. (Courtesy of Siemens Moore Energy The flexible shaft unit has a narrow and fixed proportional
and Automation.) band without integral action. The ball float has a throttling

© 2003 by Béla Lipták


range of approximately 0.5 in. (12.7 mm), depending on arm
length. This high sensitivity limits application in many ser-
vices. The flexible shaft level controller can be furnished with
pressure ratings to 1000 PSIG (0.9 MPa) and temperature
ratings to 700°F (371°C). Construction materials include
® ®
stainless steel, nickel, Monel , Hastelloy , and others. The
flexible shaft design is generally used in services where near
on–off control action is desired. Cost is less than for the
torque-tube devices.
CONCLUSION
The external-cage-type displacement level transmitters and
controllers are very popular in power plants and chemical
processes. Applications include close control of level in high-
temperature and high-pressure vessels and where the process
cannot be shut down for instrument replacement or mainte-
nance. They have lost some ground to electronic level sensors,
partly because they are limited to use on clean fluids, because
dirt and material buildup on the displacer cannot be tolerated,
and partly as a result of cost considerations. They are not
confused by foam, vapors, and changes in vapor density of
the devices used, the torque-tube type continuous units up to
60 in. (1.5 m) and the displacement-type switches are the
most popular.
© 2003 by Béla Lipták
3.7 Displacer Level Devices 473
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