Level Measurement

Content:
• Importance of level measurement
• Selection criteria for level sensors
• Classification of level measuring instruments
• Direct measurement of liquid level
• Indirect method of liquid level
 Liquid Level Measurement

•Level of liquid may affect both the pressure & rate of flow
in & out of tank or vessel : hence quality may be affected.

•So great importance in industrial field.

•These devices are used to determine the level of liquid in

undergrounds, overhead tanks and also within containers.
Importance of Level Measurement
• The importance of level measurement cannot be
overstated. Incorrect or inappropriate measurements can
cause levels in vessels to be excessively higher or lower
than their measured values.
• Low levels can cause problems and damage equipment,
while high levels can cause overflow and potentially
create safety and environmental problems.
• When working in industrial settings, getting accurate level
measurements saves time and money, and optimizes the
performance of your plant and its processes.
• Process efficiency
• Accurate level measurement increases efficiency. Suppose if a tank farm needs to keep a certain amount of
material on hand at all times and the storage tanks are not filled to full capacity, the facility will incur the
unnecessary expense of purchasing and maintaining additional storage vessels. Efficient use of storage space
prevents the extra cost of needlessly acquiring more storage vessels.
• Safety
• The level is also measured for safety reasons. If a vessel is filled above its capacity, it may cause safety hazards
by spills (overflowing) in open vessels. Supposedly if the material in the container is caustic, reactive, hot,
flammable, or hazardous materials, spills or overpressure may cause catastrophic results. Monitoring levels in
tanks to make sure they are not leaking is also important for the same types of hazardous materials. Preventing
overfills and leak detection is also important for meeting environmental regulations.
• Consistent supply
• Many processes require a steady supply of inputs and outputs. A consistent supply may be difficult to maintain
if the supply is delivered at varying rates or if there are surges in the supply line. A storage vessel between the
supply and the process can act as a buffer to ensure that outflow is kept steady despite fluctuating inflow. If the
process level in the storage vessel is always maintained within an appropriate range, the supply delivery rate to
the storage vessel can rise and fall without affecting the supply delivery rate from the storage vessel to the
process. Consistent supply is directly related to product quality in coal, pulp, and paper industries.
• Inventory
• The main reason for measuring level is to keep track of inventory in terms of volume or weight. There is an
increase in the demand in the industry for control of inventory. Level measurement is one key component in a
tank gauging system for reliable and accurate inventory control.
• The other measures for inventory control are temperature, pressure and water level. Having efficient control on
your inventory is of high importance. Not only for operators using the content in a storage vessel but for the
whole company, including company executives, accounting, loss and leakage control managers and others. This
is a result of increased focus on safety, cost of ownership and the value of products stored.
 Tank Farm Overfill Hazards
• Tank farms with vessels of various forms and shapes—cylinders,
spheres, bullets and spheroids.
• These tanks can store feedstock, intermediates and final products.
• For refineries, many of these tanks are used for what are called oil
movements, which blend various products together to provide the
many grades of gasoline, diesel and other refinery products required
by the market and government regulations.
• A study of storage tank accidents for the period of 1960-2003
covered 242 tank farm accidents.
• Fifteen overfill incidents were reported, of which 13 resulted in a fire
and explosion.
• One interesting fact that arose while looking at overfill incidents is
that they mostly occurred off day shift, which is very advantageous
in regard to people occupancy/exposure, but where supervision is
typically more relaxed, and there is less general oversight.
Explosion occurred
in the early morning
(6.01 am) hours on
the weekend.
43 people were
injured

Poor Instrumentation,
Bad Practices:
The Buncefield tank
that overflowed had
both a level gauge
and an independent December 2005 a gasoline tank at the Buncefield
high-level shutdown, oil storage and transfer depot, Hemel Hempstead,
neither of which
worked. U.K., overflowed. The resulting unconfined vapor
cloud explosion was the largest ever in peacetime
Europe.
 Selection Criteria
When determining the type of level sensor that should be
used for a given application, there are a series of
questions that must be answered:

• Open tank or closed tank?

• Can the level sensor be inserted into the tank or should
it be completely external? Contact or non-contact?
• Continuous measurement or point measurement?
• Direct or Indirect measurement?
• What type of material is being measured?
• Liquid or Solid? Clean or Slurry? Interface or foamy?
Powdery or grannular?
• The measured medium can be liquid, gas or solid
and stored in vessels (open/closed tanks), silos, bins
and hoppers.

• The level measurement can be either continuous

or point values.

• Two methods are used for measuring liquid level:

1. Direct methods
2. Indirect methods
 Direct methods
• Direct methods sense the surface or interface
of the liquid and level of liquid is directly
measured on scale.

1. Hook type level indicator & dip stick

2. Sight glass
3. Float type
• Indirect methods:Indirect methods measure the liquid level
by measuring some other physical parameter such as
pressure, weight, or temperature.

1. Hydrostatic pressure type:

1. Pressure gauge method
2. Air bellows
3. Air purge system
4. Liquid purge system

2. Electrical methods
1. Capacitance level indicators
2. Radiation level detectors
 Dip Stick
Dipstick is simple and inexpensive means of
measuring level approx.
It consist of metal bar on which scale is etched.
The bar is inserted in liquid containing vessel at fixed
position. The level measurement is made by
removing the bar from vessel and reading how far up
the liquid has wetted the scale

• Simple and cheap

• Can be used with any wet material and not affected
by density.
• As human operator is required to remove and read
the scale, can only be used in small and shallow
vessels.
• Can not be used with tall or pressurized tanks
• Visual indication only (economical, but low accuracy)
• Continuous online measurement is not possible
Oil level in car engine
Direct methods : Hook type level indicator

1. Consists of wire of corrosion

resistance alloy such as SS about
¼ inch (0.063mm) diameter.
2. U shaped with one arm longer than
other.
3. Shorter arm is pointed with 60
degrees taper .
4. Longer arm is attached to slider
having vernier scale which moves
over a main scale & indicates the
liquid level.

5. Hook is pushed below the liquid

surface & raised until the point is
just break through the surface.
6. It is then clamped & the level is
read on the scale.
 Optical Dipstick
• If the level of liquid below the optical dipstick , due to total
internal reflection , the light from the source is reflected
from the mirror, passes round the chamfered end of dipstick
and enters a light detector after reflection by the second
mirror
 Sight Glass

Used for continuous indication of liquid level within a tank or

vessel.
• This is a visual method of measuring the level of fluid in
a vessel.

• A Graduated pipe made of glass is connected to a vessel.

• As the level of the fluid inside the vessel increases the
level inside the tube will increase.
• Gauge glass is light colored for clear visibility.

• A visual inspection of the tube will provide an indication

of the level inside the vessel.
• Upto 900 mm and liquid pressure of 1000 psi.
 Float type
• This method is based on Archimede’s principle
• It is used to measure liquid levels in the tank in which a
float rests on the surface of liquid and follows the
changing level of liquid.
• Float displacement- taken as measure of liquid level
• Floats are normally cylindrical for top mounted designs
& spherical for side mounted designs.
• Small diameter floats are used for high density liquids.

• Float device include following types:

1. Tape & float
2. Shaft & float
3. Float switch
 Floats
Float rides the surface level to provide the measurement.
Many different styles are available.
Float are made up of metal such as nickel plated copper

Liquid density does not affect measurement

 Tape float
• A tape connects to a float at one
end & to a counter weight on other
end to keep the tape under tension .

• The movement of float transmitted

to a pointer by this tape (ss) wound
around the pulley.

• Pointer indicates the liquid level in

the tank.
Used up to 152mm to 1.52m
 Shaft –float & Float switch

•Float switch is attached to

lever that activates the relay
at predetermined level.
•Used for Alarming/on-off
control purposes.
Level transmission up to 6.35m achieved.
 Fuel Gauge in Vehicle Fuel Tank
• As used in vehicles, the gauge consists of
two parts:
• The sensing unit - in the tank
• The indicator - on the dashboard
• The sensing unit usually uses a float
connected to  potentiometer.
• As the tank empties, the float drops and
slides a moving contact along the resistor,
increasing its resistance and the least
current is flowing, the needle points to "E"
indicating an empty tank.
• When the tank level is high and maximum
current is flowing, the needle points to "F"
indicating a full tank. 
 Indirect level measurement
• Level is measured –changes in variables like hydrostatic
pressure, electrical properties, attenuation of radioactive energy.
• Hydrostatic method
» : Pressure gauge method
• Pressure measurement : in open tanks.
• Liquid is held steady in tank: exerts pressure on walls of a tank.
• Such a pressure due to weight of liquid above certain reference :
hydrostatic pressure.
• P=hgρ h=p/gρ

• Changes in level measured: changes in hydrostatic pressure at

certain datum.
Necessary to connect the press. Gauge at the lowest level of liquid- which is inconvenient
for elevated tanks. This method is not suitable for interface level measurement.
 General Theory for Head Measurement

The Pressure exerted by the

Liquid Density (D)
Height of the liquid is:
Height (H) P = H x Density*
Pressure PSI

If the Density of the liquid is

known then
H = Density*
Pressure
*Note: For liquids other than water, use the density of water 0.0361 lb/in3 as a
reference and multiply by the SG of the liquid.
 Example
A dip stick measurement of the level of these 2 tanks indicates 30 feet of liquid in
both tanks. Calculate the pressure that each gauge will read if tank 1 contains
water (S.G. = 1) and tank 2 contains oil (S.G. = 0.85)

Water Oil
Density (D)
Density (D) Height
Height
(H)
(H)

Tank 1 Tank 2
PSI
PSI

P = ? psi P = ? psi
 Example
A dip stick measurement of the level of these 2 tanks indicates 30 feet of liquid in
both tanks. Calculate the pressure that each gauge will read if tank 1 contains
water (S.G. = 1) and tank 2 contains oil (S.G. = 0.85)

Water Oil
Density (D)
Density (D) Height
Height
(H)
(H)

Tank 1 Tank 2
PSI
PSI

P = H x Density P = ? psi

= 30 ft x 0.0361 lbs/in3
= (30 x 12) x 0.0361
= 13 psi
 Example
A dip stick measurement of the level of these 2 tanks indicates 30 feet of liquid in
both tanks. Calculate the pressure that each gauge will read if tank 1 contains
water (S.G. = 1) and tank 2 contains oil (S.G. = 0.85)

Water Oil
Density (D)
Density (D) Height
Height
(H)
(H)

Tank 1 Tank 2
PSI
PSI

P = H x Density x SG P = H x Density x SG
= 30 ft x 0.0361 lbs/in3 x 1 = 30 ft x 0.0361 lbs/in3 x 0.85
= (30 x 12) x 0.0361 = (30 x 12) x 0.0361 x 0.85
= 13 psi = 11 psi
• In closed tanks:
• P=hgρ+Pa (external pressure)
• Since these sensors sense increasing pressure with depth
and because the specific gravities of liquids are different,
the sensor must be properly calibrated for each
application

Liquid seal is used so as

to avoid the contact of
corrosive process liquid
with press. Gauge
elements
Air Bellows
1. Air bellows lowered into the
liquid.
2. Air filled capillary connects
bellows to pressure gauge.
3. As the liquid level changes, its
hydrostatic pressure changes,
due to which bellows gets
deflected.
4. This deflection changes the air
pressure inside capillary
5. Thus pressure gauge reading
changes which is calibrated in
terms of liquid level.
Air Purge or air bubbler method
 Bubblers
Advantages: Instrument
P input does not
matter
-- Easy installation
Regulated purge
-- Continuous reading providing system
analogue or digital signal (air or nitrogen)

-- No moving parts

-- Good accuracy and

repeatability
Bottom of tube
determines
reference point
 Bubblers
Instrument
P input does not
Limitations: matter

-- Not suitable for pressurized Regulated purge

tanks system
(air or nitrogen)

-- Sediments may block tube or

probe

Bottom of tube
-- Tanks must be freely vented determines
reference point
 Closed Tank Applications
P (atmospheric)

Open tanks are vented to atmosphere so the

pressure at the bottom of the tank is only
due to the head pressure of the liquid.

P Head = h x D

Closed tanks are not vented to atmosphere

so the pressure at the bottom of the tank
P vapour is due to the head pressure of the liquid +
the vapour pressure above the surface.

P Head = (h x D) + P vapour
 Using a d/P Cell Transmitter
The differential pressure cell is one of the most common methods
of measuring level.

4 – 20 mA

24 VDC mA To PLC or
Controller

Lo side open to
atmosphere

Open Tank Measurement

• Lo side of the d/P cell is left open to atmosphere.
• Hi side measures the hydrostatic head pressure which is proportional to the height of the
liquid and its density.
 Using a d/P Cell Transmitter
In a closed tank, the Low side of the d/P cell is connected to the
top of the tank and will cancel the effects of the vapour
pressure above the surface. (ex. Boiler drum)

4 – 20 mA

24 VDC mA To PLC or
Controller

H L

Closed Tank Measurement

• Lo side of the d/P cell measures the vapour pressure above the surface.
• Hi side measures the hydrostatic head pressure which is proportional to the height of the
liquid and its density + vapour pressure
• So output of differential cell transmitter corresponds to hydrostatic pressure only.
Capacitance Level Indicator
• The principle of capacitive level measurement is based on change of
capacitance.
• An insulated electrode acts as one plate of capacitor and the tank wall
(or reference electrode in a non-metallic vessel) acts as the other plate.
• The capacitance depends on the fluid level. An empty tank has a
lower capacitance while a filled tank has a higher capacitance.
• A simple capacitor consists of two electrode plate separated by a
liquid medium such as solid or liquid. This is also called as dielectric
medium.
• Value of C depends on dielectric medium used, as area of the plate
and distance between the plates remains constant.
•  C=ε0 εr A/d Cα εr
• As the liquid level changes, means dielectric medium change and that
causes the change in capacitance and vice versa.
• This change in capacitance is measured and calibrated in terms of
liquid level.
• Advantages:
• Useful in small systems.
• It is very sensitive
• No moving parts exposed to fluid.
• Suitable for continuous indication & control.
• Good for slurries also.

• Disadvantages:
• Performance affected by dirt or contaminants.
• Sensitivity affected by change in temperature.
• Probe length & mounting must suit the tank.
 Radiation Level Indicator

Cobalt 60,
1. Change in liquid level can be
Cesium 137
measured in terms of change in
intensity of radioactive
radiations.
2. Radiation source such as cobalt
60, cesium 137 is located one
side of tank and radiation
detector such Geiger-Mueller
detector on other side of tank.
3. As the liquid level changes, the
amount of radioactive
radiations received by receiver
changes.
4. The intensity of radiations
varies inversely with the liquid
medium inside the vessel.

The accuracy of most radiation level gages is around 1% of range.

• Advantages:
• Absence of moving
• No physical contact with the process fluid: suitable for
molten metals , corrosive, viscous fluids.
• Good accuracy & fast response.
• Useful at very high temperature & pressure.

• Disadvantages:
• They require a gamma radiation source and are relatively
expensive.
• Cost is relatively high.

• This method is suitable for corrosive, abrasive, viscous

liquids because of non-contact type.
 Ultrasonic Level Detector (20KHZ-200KHZ)

The distance to an object is calculated and then converted by the

ultrasonic radar level sensor to 4-20 mA signal.
https://www.youtube.com/watch?v=7bjh3_dMcrY
https://www.youtube.com/watch?v=DRxTevCBhIQ
https://www.youtube.com/watch?v=EMotg3BQjlI
https://www.youtube.com/watch?v=ylhwPcyieTc
 Working principle:
• Ultrasonic detectors use sound waves (wavelength greater than 20 kHz) to
measure distance.

• A sensor would normally be mounted at the top of a tank and direct a

sound wave down towards the surface of the product.
•
• When the sound wave hits the product it is reflected and returned to the
sensor.

• The greater the distance between the sensor and the product, the longer it
will take for the sound wave to travel down and back up again.

• The sensors calculate this time interval and give a signal proportional to
the distance.

• They also compensate for the changes in the speed of sound due to
changes in temperature, pressure & moisture .
• Stagnant, un-agitated liquids and solids consisting of large and
hard particles are good reflectors.

• Turbulence, foam, and loose dirt are poor reflectors.

• Dust, mist, vapors or humidity in the vapor space tend to
absorb the ultrasonic pulse.

• variations in concentration cause changes in the amount of

energy in the sound wave that is reflected back to the sensor

• Non-contact level sensing of highly viscous liquids, as

well as bulk solids.
 Acoustic Liquid Level Measurement for
flowing gas well
• CSG (coal seam gas) is a significant source of energy
• Many accidents have occurred in coal mines due coal-gas outbursts
• The exploitation of coal seam gas can reduce the gas content and
pressure in coal.
• CSG is produced by lowering the pressure within the coal seam so that
Methane (CSG) is released from the coal in the form of gas and then
brought to the surface accompanied by the water
• In coal seam gas (CSG) wells, water is periodically removed from the
wellbore in order to keep the bottom-hole flowing pressure at low
levels, facilitating the desorption of methane gas from the coal bed.
• However, improper water and gas production at the initial stage may
result in permeability damage and further induce the change in
productivity.
• Therefore, it is of great significance to accurately monitor the liquid level
in order to calculate gas flow rate and well performance for optimizing
gas production of CSG wells.
Types of flowing gas wells
• Principles of Acoustic Liquid Level Determination:
• An acoustic gun attached to the wellhead of the annulus is used to
emit an acoustic pulse, and then the acoustic pulse spreads across
the annulus from surface to bottom.
• When the acoustic wave encounters restrictions, such as tubing
coupling and subsurface safety value, a partial acoustic wave will
be reflected to the wellhead and received by the acoustic sensor.
• Specially, as soon as the acoustic wave reaches the liquid level, all
the wave will be completely reflected by the interface, and the
acoustic sensor will receive a reflected wave of high intensity later.
• By identifying the reflected signal from the liquid level, the round-
trip (surface-liquid level-surface) travel time of the acoustic wave
can be determined.
• And then the depth of the liquid level z t will be obtained from the
following equation
• Where t, W –travel time and
• propagation velocity of acoustic wave
• The acoustic travel time in the
annulus can be obtained by
computing the interval from
initiating the acoustic pulse to
receiving the pulse reflected.
• The frequency of the acoustic
signal is mainly concentrated
in the area beyond the
frequency of 20 Hz, namely,
its energy is focused on the
low frequency.
• This is because the high
• frequency portions of the
signal are absorbed by the
medium in the annulus during
propagation
Oil Separator: Displacer
Oil Separator: Differential pressure