LEVEL SYSTEMS

One of the most frequent uses of industrial instrumentation is to measure and frequently control
the level of materials in storage and processing containers such tanks, wells, reservoirs, bins, and
hoppers. Level systems have been around for well over a century and reflect a succession of
mechanical, pneumatic, electrical, and electronic measurement and regulating techniques.
Although several level systems that are currently in use have been updated, the fundamental idea
has remained mostly unchanged. The use of relatively recent technology created during the
previous few decades is represented by other level systems. Level measurement and control have
also been significantly impacted recently by solid-state electronics and digital approaches,
similar to other industrial instrumentation systems.
Classification of level systems
System Objectives
Depending on how level data are used, either a single fixed level, a series of numerous fixed levels, or a
continuous range of levels between low and high levels will be felt. In order to ensure an even supply of
material to a process without issues of overfeeding or underfeeding, the primary need may be for
information on a continuous or periodic basis, as in the case of inventory control. Alternatively, the
primary need may be for controlling a level, which entails maintaining a proper dynamic balance between
numerous vessels in a continuous process. One fluid, two fluids, or more fluids that are fundamentally
immiscible may also require information or control, and the efficiency of a particular operation may
depend significantly on where the fluid interfaces are located.
Characteristics of Measurands and Process Environment
Chemical composition (corrosiveness), viscosity (for liquids), flowability (for solids), and the process
environment (temperature, pressure, absence or presence of agitation, among others) are all significant
factors that affect not only the choice of the level measuring method but also the design and location of
the sensing devices. Interfaces include those between liquid and gas (often air), liquid and foam, liquid
and liquid, liquid and granular solids, solid floating on a liquid, solid beneath a liquid, and vapor and
liquid. Frequently, in selecting the most appropriate level measurement technique, this is the most
convenient starting point. Suppliers of equipment tend to fall into measurement technique categories.
Direct and Inferential Methods
In direct methods, the distance (usually height) between the material level and a datum line is directly
measured. Direct methods include (1) direct visual observation of distance on a suitably calibrated scale,
as with a gage stick, hook gage, or gage glass; (2) determination of the position of a detecting member
which rides on the material surface, such as a ball or other type of float (liquids) or a plumb bob (solids);
(3) contact of electrode probes with the material; (4) interruption of a light beam to a photoelectric cell;
and (5) reflection of radio and radar frequency waves or of sonic and ultrasonic energy from a material
surface.
Inferential methods utilize effects other than the changing position of a material surface for determining
the level in a vessel. Inferential methods include (1) measurement of the fluid or hydrostatic head
developed by the material (liquids); (2) measurement of the buoyant force created when a detecting
element is partially or completely immersed (liquids); (3) attenuation of radiation; (4) utilization of
electrical properties of materials, such as capacitance, conductance, and resistivity; and (5) utilization of
thermal and other physical differences between the material and the gas or vapor space above the
material.
In contrast to direct methods of measurement, most inferential methods have in common certain inherent
errors because of changes in density due to varying composition and temperature, among other factors.
Importance of level control in process operation
The specific level of liquid in each vessel can be crucial to the proper operation of many processes
utilizing liquids contained in vessels, such as distillation columns, reboilers, evaporators, crystallizers,
and mixing tanks. For instance, a level that is excessively high could disturb reaction equilibria, harm
equipment, or result in the leakage of priceless materials. Too low of a dose could also have detrimental
effects. Together with these fundamental factors, one benefit of continuous processing is that storage
space is reduced all along the process. While this lowers the initial cost of the equipment, less storage also
highlights the importance of precise level management. Effective measurement and control of level can
usually be justified in terms of economy and/or safety. To the operator, knowledge of this variable
provides data on the (1) quantity of raw material available for processing, (2) available storage capacity
for products being manufactured, and (3) satisfactory or unsatisfactory operation of the process. In the
following paragraphs, a few examples are given.
Efficient Operation of Equipments
Control at One Height - the level must be maintained accurately at a predetermined height, irrespective of
load conditions on the process.
Proportional (Wideband) and Averaging Level Control - In such process applications, control of the level
at a constant height is not always desirable. It is more important that the outflow of the storage vessel
does not change suddenly and cause an upset in the subsequent process stage. Any sudden increase in
input to the storage vessel should be absorbed in the vessel. To accomplish this, “averaging” liquid-level
control is used, wherein a wideband proportional-plus-reset mode of control is incorporated in the level
control instrument.
Level Control Permits Smaller Vessels - The use of level measurement and control is advantageously
utilized to keep the capacity of processing vessels within reasonable bounds in basic single-capacity
systems. It's possible for a mixing or reaction vessel to be small if level measurement and control are
employed.
Protection of Centrifugal Pumps - Where it is desired to maintain a head pressure against the suction of a
centrifugal pump, the level of the liquid in the storage tank must be maintained at an optimum value.
Product Quality Control - it is a process through which a business seeks to ensure that product quality is
maintained or improved. Quality control requires the company to create an environment where
management and employees strive for perfection.
Cost Accounting - The flowmeter, weighing scale, and liquid-level gage are the process cost accountant’s
principal tools for obtaining facts concerning quantities of liquid raw materials and finished products in
storage, and of liquids in process.
LEVEL MEASUREMENT SYSTEM MATHEMATICS
Important to the engineer who designs and specifies liquid-level instrumentation systems are such factors
as (1) the relationship of flow to level in vessels, and (2) capacity versus level height in variously shaped
vessels.
Constant Head for Steady Process Flow

Q=CA √ 2 gH
where
Q = quantity, ft3/s
C = orifice constant
A = area of flow, ft2
g = acceleration of gravity, 32.2 ft/s2
H = height of liquid, ft
Relationship of Flow to Level in Process Vessels

Qi=Q 0=0.897 C A 0 √ 2 gH
where
Qi = flow rate into vessel, gal/min
Qo = flow rate out of vessel, gal/min
C = orifice constant or coefficient
A0 = orifice area, in2
g = acceleration of gravity, 32.2 ft/s2
H = height of liquid level above top of outlet orifice, in
Capacity versus Level Height in Various Vessels
Many processing and storage vessels where liquid-level measurement is a factor are cylindrically shaped
and mounted vertically on end. Thus, the content for any level height can be simply calculated by:
Content = cross section area x level height
Spherical Tanks
Volume Determinations:
The volume measured is independent of liquid density.
V=A× H
where
V = volume of vessel
A = area of vessel
H = height of level
The volume measurement depends on the density of the liquid.
A×P
V=
D
Where:
V = volume in vessel at given level
P = pressure due to hydrostatic head
D = density of liquid in vessel
Weight Determinations:

W =H × D× A= A × P
where
W = weight of liquid in vessel
H = height of level
D = density of liquid
A = area of vessel
P = pressure due to hydrostatic head
Thus, the measurement is independent of liquid density.
If direct measurement of level height is used, then
W =A × D × H
and the weight measurement depends on knowing the density of the liquid.
Errors in Measurement of Quantities in Storage Tanks:
1. The tank may not be perfectly round (if cylindrical) or geometrically true (if some other shape).
2. The tank wall is stretched, owing to hydrostatic pressure.
3. The fluid is not at its reference temperature.
Necessity for Corrections
Error for Tanks “Out of Round” (Fig. 5)

Error Due to Pressure Expansion (Fig. 6)

Error Due to Temperature (Fig. 7)