LEVEL MEASUREMENT

BY

Aftab Ahmed Mazari

Level Measurement Based

on Buoyancy Force of Liquid
Floats & displacers are always in direct

contact with the liquid being measured.

Both use to measure the level on Buoyancy

principle.

Float and displacer, both are hollow objects

Floats ride near the surface of liquid
Displacers are built with additional weight
so they submerge as the level rises.

Level Measurement Based

on Buoyancy Force of Liquid
Float movement is vertical.
Displacer movement is so slight that it is

difficult to see. Small change in position is

proportional to any change in level.

Float has the weight less or equal to the

weight it displaces, when fully submerged.

Displacer has weight more than the liquid

it displaces when fully submerged.

Definition of Some Points

Datum point:
Buoyancy:

A fixed reference point from

which level is measured
Upward force exerted by liquid
on an object
submerged &
floating in it

Buoyant force: Net upward force exerted by

liquid on
submerged or floating
object equal the weight
of the
displaced liquid.

Level Measurement by Float

A float, cable, sliding pointer arrangement.

A fixed scale is mounted on the exterior of
the tank

A cable connects the float with the pointer

through two pullies.

Pointer move up and down and also serve

as counter weight.

Float type level indicators are installed on

the open tanks and the tank of the
atmospheric pressure.

Level Measurement by
Displacer
Displacer do not ride on the surface of the
liquid but they are design to submerge as the
level rises.
Displacer mechanism transfer the slight
mechanical motions due to loss of weight
which can be used in instruments to indicate
level.

Torque Tube Displacers

The most common type of displacer

mechanism is a torque tube displacer.

Torque tubes are useful when level
measurement is needed on the liquid
under pressure.
As the liquid level changes, the
buoyant force moves the displacer
slightly and twist the torque tube.
The motion of the torque tube makes
the pointer move to indicate the
liquid level on the scale.

Torque Tube Displacers

Amount of rotation depends on the size
1. shape
2. weight of the float
3. length of the support arm
4. stiffness of the torque tube
5. density of the liquid.

Torque Tube Displacers

Pointer total rotation is 2 to 7 (approximate).
Suppose full range is 18 at a specific gravity

1.0 as the liquid rises the displacer becomes

lighter by the amount the liquid displaced
With no water the torque tube pointer at X
when water filled at the full range 18 the
pointer will go to maximum position Y.
Suppose kerosene(SG 0.8) replace the water in
this tank. In this case pointer will not move from
X to Y with full range of 18 but it is required
22.5 for full range. 18/0.8 =22.5 inches.

Torque Tube Displacers

Displacer will displace the same amount of

kerosene as water but the kerosene is lighter

than the water. Greater volume of displaced
kerosene is required to produce the same
buoyancy force as water
If the liquid is dense the new displacer should
have a greater diameter and vise versa.
Diameter of the displacer should be
proportional to the square root of the densities
Mechanical motion of torque tube to be
detected by the pneumatic or electronic
transmitter for controlling and recording
purpose.

Bubbler Method Of Liquid

Measurement
An air purge system used to measure corrosive,
abrasive or hard to handle liquids.

Usually this system is used for the underground tanks.

Air continuously bubbling out of the tube and the
instrumentation read back pressure

Where air have an undesirable effect on the fluid, a

liquid purge system is substituted.

no liquid in tank the air flows out of the bottom of the

tank and their will be no back pressure.

Bubbler Method Of Liquid

Measurement
As the liquid level increases, the air flows
is restricted by the depth of the liquid
covering the tube.

Suppose level to be measured is 15Ft, with

a fluid having specific gravity 1.9 then the
range of the transmitter or gauge will be
P = h * PCF *SG = 15*.433*1.9 =12.3 Psi

PCF = Pressure Conversion Factor (PSI/Ft)

one foot change of water level will give a
change of .433 PSI.

Bubbler Method Of Liquid

Measurement
Supply of purge air should be higher than
the static head.

Where air have an undesirable effect on the

fluid, a liquid purge system is substituted.

In liquid purge system normally, the purge

liquid is used at a rate of about 1 gal/hr.

Hydrostatic Pressure
A water tank that is open at
the top. The water in the tank
is at rest
A pressure gage is at the
bottom.
the liquid exerts a force on
the bottom.
This force is proportional to
the depth of the liquid.
force at any point in the tank
varies with the elevation of
the liquid
HYDROSTATIC PRESSURE is
the term used to describe this
force in a liquid at rest.

Gauge measures
pressure which is
proportional to
depth of liquid

Depth of
liquid
PI

Hydrostatic Pressure
Place a pressure gauge at a surface of the

liquid, it will read 0 psig

Pressure at the surface equals the atmospheric
pressure.
Place the pressure gauge at various points on
the side of the container, it will give different
readings for every location.
These readings depend on the depth of the
liquid at that point and is independent of the
shape of the container
For example, the pressure exerted by a depth of
1 foot of water in an open tank is 0.433 psi, no
matter what the size of the container.
This shows that hydrostatic pressure is
proportional to liquid height.

Density / Specific Gravity

In industry there are hundreds of process liquids,

different from water in their behavior and physical

properties.
To measure the level of any liquid, we must know
its density.
D = m / v D =density , M=mass, v = volume
Specific gravity : The ratio of a any liquids density
to waters density
The pressure exerted by a liquid column depends
on :
1. The height of the liquid above the point at which
the measurement is taken.
2. The density (specific gravity) of the liquid.

Pressure Head
The hydrostatic pressure of liquid in an open tank is
P = PCF x h x sg. (PCF=pressure conversion
factor=0.433 psi/ft)

10 ft of head means that an elevation of 10 ft of

liquid above a certain reference point. The pressure

at the reference point is ;
P = .433 x 10 x S.gr.

Pressurized Fluids

The difference in pressure

between any point and the datum

point in a tank depends upon the EXTERNAL PRESURE APPLIED TO TANK
difference in their elevations.
Air
external pressure on the surface
Pressure
of the liquid, corresponding
10-ft level
increase in pressure at every
point in the tank.
A closed tank filled with water up
to a height of 10 feet. A pressure
of 50 psi is applied at the surface
0-ft level
of the liquid. pressure at the
bottom of the tank will be 0.433 x
10 + 50 =54.33 psi.
Therefore for pressurized fluids
P = (0.433 x 10 x S.gr.) + external
pressure on liquid.

50 psi
Pi indicates the pressure
exerted by the 10-ft depth
of water plus the extrnal
pressure of 50 psi
PI

Pressure Gauge (Liquid Seal)

open tank containing Nitric

acid
Piping is done as shown in
the figure-3
Liquid seal is used so that
acid does not enter the
instrument line and the
pressure indicator
install the pressure indicator
in elevation above or below
the minimum level of the tank
will affect the reading
It is advisable that the piping
size should be at least equal
to inch.

OPEN TANK PRESSURE INDICATOR

Maximum level

Nitric
Acid

PI must be mounted on
same level as minimum
tank level

liquid seal
PI

Minimum level

Pressure Gauge (Liquid Seal)

Liquid seal should not contribute any
significant amount of head pressure.

Suppose maximum tank elevation is 125

inches.

Tank is filled up to its maximum level, then

pressure at the bottom would be
P = PCF x h x s.g.
P = .433 x 125/12 x 1.5=6.76 psi

Level is 50% i.e. 62.5 in, pressure would be;

P = .433 x62.5/12 x 1.5 = 3.38 psi

Pressure Gauge (Liquid Seal)

Level is half, the pressure is also half of that
at maximum level.

This means that pressure is directly

proportional to h as is also given by the

equation.
P = .433 x h x s.g.
P = K x h (since s.g is constant for any
liquid and.433psi for one foot of water is also
constant.).

Modify pressure gage to read in terms of

height or level

Air Bellows
Install a pressure gauge at the same elevation as

the minimum level in the tank.

Suppose a tank is located 50 ft above the control
room.
An indicator located in the control room would
then show an error equivalent to 50 ft head of
water because of elevation of water in the tubing.
Where a pressure indicator cannot be located at
the minimum level, an AIR BELLOWS can be used.
Bellows must be located at the minimum level
height

Air Bellows
Tubing from the bellows element is connected

to the pressure gauge

Air is sealed in the cavity above the bellows
and inside the tubing to the pressure indicator
When the level is at the minimum level, there
is no pressure on the sealed air inside the
tubing and hence no pressure is indicated on
the gauge
As the level in the tank increases, the
pressure head increase and flexes the bellows
upwards. sealed air is transmitted to the
pressure indicator which is calibrated in terms
of tank level.

Level Measurement Using

Differential Pressure
When a vessel contains a liquid under

Instruments
pressure

Pressure measurement of liquid level

becomes more difficult

Differential pressure measurement is suited

to level measurement in closed vessels

We will now discuss various applications of

differential pressure instruments in liquid
level measurement

Level Measurement Using

Differential Pressure
When liquid level is measured in an open
Instruments
tank, piping from the lower end of the tank is
connected to the high pressure side of the
transmitter and the low pressure side is
vented

When liquid level is measured in a closed

tank the effect of tank pressure is

compensated by connecting a line from the
top of the tank to the low pressure side of
the differential.

Pressure transmitter. The pressure due to the

height of the liquid is a measure of its level.

Open Tank Or Closed Tank With Dry

Leg
Span
= (x) (GL)
Closed Tank
With Dry Leg

Open Tank

Min
level

Max level

L
dP
Cell

Max level

Hw at minimum level = (y) (GL)

Hw at maximum level = (x+y)
(GL)
where
GL = Specific gravity
Hw= equivalent head of water
EXAMPLE
x= 150 in, y = 15 in, GL = 1.5
Span = 225 in.
Hw at min. level = 15x1.5 =
22.5
Hw at max. level = (150+15) x
1.5 = 247.5
Calibrated Range 22.5 to 247.5
inches head of water.

vent

Min
level

Dry
Leg
H

L
dP
Cell

Open Tank Or Closed Tank

With Dry Leg
If the tank liquid should not come in contact with the
transmitter.

The transmitter lines can be filled with a suitable seal

liquid

This seal liquid should be heavier than the tank liquid

Must be immiscible with it
Must not react chemically with it.

Open Tank Or Closed Tank

Span = (x) (GL)
With
Dry
Leg
Hw at minimum level = z(Gs)+y
CLOSED TANK WITH
DRY LEG

Max level

Dry leg

Min level
H

L
d/p
cell

vent

(GL )
Hw at maximum level = z(GS)+
(x+y) (GL) where
GL = specific gravity of tank liquid
Gs = specific gravity of seal liquid
Hw = Equivalent Head of water.
Example:
Open tank with x = 80 inches
Y = 5 inches, and z = 10 inches
Z
GL = 0.8, GS = 0.9
Span = (80) (0.8) = 64 inches
Seal liquid
HW at minimum level = (10) (0.9)
+ (5) (0.8) = 13 inches
HW at maximum level = (10) (0.9)
+ (5+80) (0.8) = 77 inches
Calibrated Range = 13 to 77
inches head of water

Seal liquid

L
d/p
cell

Closed Tank With Wet Leg

C LOSED

WITH

WET

Min level

H
Seal liquid

LEG

Constant
head leg

Max level

TANK

Span
= (x) (GL)
HW at minimum level =
(d) (GS) - (y) (GL)
HW at maximum level =
(d) (GS) - (x+y)
(GL)
Example:
Closed tank with x = 2.0 m, y = 0.4 m, and d =
2.5 m.
GL = 0.8
GS = 0.9
Span = (2.0) (0.8) = 1.6 mH2O
HW at minimum level
= (2.5) (0.8) - (0.4)
(0.8) = 1.93 mH2O
HW at maximum level = (2.5) (0.9) - (0.4 + 2.0)
(0.8) = 0.33 mH2O
Calibrated Range = 1.93 to 0.33 mH2O.
(Note that this inverted range indicates that
high pressure should be applied to low pressure
side of transmitter)

L
d/p
cell

Closed Tank With Wet Leg

Sometimes it is necessary to fill both sides of
the transmitter with the seal liquid

This is required for condensing corrosive fluids

Closed Tank With Wet Leg

Span =
(x) (GL)
C LOSED

WITH

WET

Min level

H
Seal liquid

LEG

Constant
head leg

Max level

TANK

Span =
(x) (GL)
HW at minimum level = (y) (GL) - (d) (GS)
HW at maximum level = (x+y) (GL) - (d)
(Gs)
Example: Closed tank with x = 70 inches
Y = 20 inches, and d = 100 inches
GL = 0.8
GS = 0.9
Span = (70) (0.8) = 56 inches
HW at minimum level =
(20) (0.8) - (100) (0.9) = - 74 inches
HW at maximum level =
(70+20) (0.8) - (100) (0.9) = - 18 inches
Calibrated Range = - 74 to 18 inches head
of water.
(Minus signs indicate that the higher
pressure is applied to the low pressure side
of the transmitter.)

d/p
cell

Zero Elevation
1. For elevated-zero range, the measured variable
zero is above the lower range valve
2. It is done by biasing the zero output signal to
raise the zero to a higher starting point
3. It is used in liquid level measurement for starting
measurement above the vessel connection point

Zero Suppression
For a suppressed zero range
The measured variable zero is below the lower range
value

Biasing the zero output signal to lower the zero to a

lower starting point

It is normally used in level measurements involving

wet leg calculations

Level Measurement On
Electrical Properties Of Liquid
Continuous level measurement may be accomplished

by several methods
Capacitance Level Probes
Dielectric is a substance having a little or no electrical
conductivity.
The operation of capacitance probe in dielectric fluid,
in a metallic tank.
The tank and rod act as the two plates of a capacitor.
The dielectric liquid in the tank rises and falls between
the rod and the side of the metal of the metal tank.

Level Measurement On
Electrical Properties Of Liquid
When the level rises, more of the capacitance probe is

surrounded by the liquid and the capacitance increases.

C = K(A/D)
D = distance between plates
A = Area Of The Plate
K = dielectric constant
C = capacitance
An electronic circuit is required to measure the
capacitance accurately, amplify it and display it as a
level.

Level Measurement In Vessel Like

Boiler Drum
Level measurement in high pressure, high

temperature vessel are same as level

measurement in wet leg closed tank. Only
there is one exception that in steam drum
and the impulse line of DP transmitter there
are very much difference in densities of
water and steam

Let suppose the boiler which produce KS

(510C steam) and drum operating pressure

is 107 kg/cm2

Level Measurement In Vessel Like

Boiler Drum
Densities at said pressure are as under
1.

Saturated steam (Inside drum) : 0.0588 Kg/liter

2.

Saturated water (Inside drum) : 0.683 Kg/liter

3. Sub cooled water (Outside drum in

transmitters leg) : 0.975 Kg/liter

Level Measurement In Vessel

a)
water head
in low pressure
leg
Like
Boiler
Drum
of transmitter.
: 0.975*1100
= 1073 mmWc
b) water head in high pressure leg
of transmitter
: 0.975*400
= 390 mmWc
c) water head in high pressure
side due to water inside drum:
0.683*700 = 478 mmWc
d) steam head on low pressure
side:
0.0588*700 = 41 mmWc
span / Range
DP at zero drum level:
a-b =1073-390 = 683 mmWc
dp at 100 % drum level: a-b-c
= 1073-390-478 = 205 mmWc
Span 683 205
: 478 mmWc
Range: 683 mmWc to 205 mm
Wc

700 mm

1100 mm
400 mm

TX

Gauge measures
pressure which is
proportional to
depth of liquid

Depth of
liquid
PI

EXTERNAL PRESURE APPLIED TO TANK

10-ft level

Air
Pressure

50 psi
Pi indicates the pressure
exerted by the 10-ft depth
of water plus the extrnal
pressure of 50 psi

0-ft level

PI

OPEN TANK PRESSURE INDICATOR

Maximum level

Nitric
Acid

PI must be mounted on
same level as minimum
tank level

liquid seal
PI

Minimum level

FLEXIBLE AIR BELLOWS

PiPI

Tube bent at 90
deg. to prevent
bellows from
sealing it off when
in the extreme
compressed
position

With no liquid
pressure head acting
on bellows, air
pressure in tube is
atmospheric
pressure

Air

liquid level

With pressure
head acting on
bellows, air is
compressed in
sealing tube

Closed Tank
With Dry Leg

Open Tank
Max level

Min level

L
Y

Min level
Y

Dry
Leg

Max level

dP
Cell
vent

L
dP
Cell

CLOSED TANK WITH

DRY LEG

Max level
Dry leg

Min level

Seal liquid

L
d/p
cell

vent

Seal liquid

L
d/p
cell

C LOSED

WITH

WET

Min level

H
Seal liquid

LEG

Constant
head leg

Max level

TANK

L
d/p
cell

SPAN

20mA
zero suppression
zero elevation

4mA

0
-70
-80

-50
-60

-10

-30
-40

-20

10

30
20

40

measured variable

90

70

50
60

80

700 mm

1100 mm
400 mm

TX