Process Instrumentation

CHE426
Dr. Maria Mustafa
Department of Chemical Engineering
CUI, Lahore Campus
CLOs covered

• CLO1: Describe the fundamentals of Process Instrumentation

• Course contents: Level Instrumentation

Level Measurement
• Direct Sensing ; The actual level is monitored

• Indirect Sensing – using a property of liquid such as pressure

• Single Point Measurement; Presence or Absence of a liquid at a

preset level

• Free flowing solid level sensing

Direct level sensing
• Sight glass/glass gauge

• Shut off valve for

pressurized container,
flammable hazardous or
pure liquids
• Open to atmosphere for
inter liquids
Direct level sensing
Glass gauges are
• cheap, but fragile , broken
• Liquid condensation
• Leakage

• Non-magnetic material
with a magnetic gauge
Float sensors
Direct level sensing- Float sensors
• Cheap, easy to install
• Independent of liquid/solid density
• Accurate and robust and have linear output
• Can be used for liquids and free flowing solids
• BUT
• Material accumulation on the float,
• Corrosion /chemical reaction
• Friction of the pulley
• Turbulent systems
Direct level sensing
• Ultrasonics sensing
• Single point sensing or
continuous level monitoring
• A pulse of sonic waves approx.
(10kHz) or ultrasonic (more
than 20kHZ is used.

• Knowing the velocity of

ultrasonic waves 340 m/s the
level can be monitored.
• Non-contact/intrusive so
independent of the density or
corrosive and/or volatile liquids
 Direct level sensing
• Can be used under high humidity
• Have no moving parts
• Reliable accurate and cost effective
• However,
• vibrations/noise level can be a
problem
• Dust build-up on receiver or
transmitter
• Correction factor- humidity
temperature pressure
Indirect level sensing
• Using Pressure
• P= density x h x g
• The pressure can be measured by any of the methods given in the section on pressure.
• A differential pressure sensor can replace the sight glass.
• These devices are affected by liquid density and are susceptible to dirt.
• It is sometimes necessary to mount the pressure sensor above or below the zero liquid
level, as shown in Figure 8.5, in which case an adjustment to the zero point is required.
When the sensor is below the zero level, as shown in Figure 8.5(a), “zero suppression”
is required to allow for H; the distance of the measuring instrument above or below the
bottom of the container when it is above the zero level, as shown in Figure 8.5(b), “zero
elevation” is required to allow for H.
• Shutoff valves should be used for maintenance and replacement, and cleanout plugs to
remove solids. The dial on the pressure gauge can be calibrated directly in liquid depth.
Indirect level sensing
Indirect level sensing-Displacer
Buoyancy is an indirect method used to measure liquid levels. The level is determined
using the buoyancy of an object partially immersed in a liquid.
The buoyancy B or upward force on a body in a liquid can be calculated from the equation
B=g.ad
where a is the cross-sectional area of the object and d is the immersed depth
of the object.
The liquid level is then calculated from the weight of a body in a liquid WL,
which is equal to its weight in air (WA – B), from which we get
Indirect level sensing-Displacer
A displacer with force sensing is shown in Figure.

Change in buoyant force on an object to measure

the changes in liquid level.

The displacers must have a higher specific weight

than that of the liquid whose level is being
measured, and has to be calibrated for the specific
weight of the liquid.

A strain gauge measures the excess weight of the

displacer. There is only a small movement in this
type of sensor, compared to the movement in a float
sensor.
Displacers are simple, reliable, and accurate, but are affected by the
(temperature- dependent) specific weight of the liquid, and buildup on the
dispenser of coatings and depositions from the liquid.
A still well may be required where turbulence is present in the liquid .
Next Lecture

We will continue with the Level sensors and cover election criteria of Level
sensors as well.