Level

Level Measurements
LEVEL
MEASUREMENTS
Level Measurements
CONTENTS
Objectives Page 3
TOP I 02.4 UPK (i) Standard Engineering Units and

their Inter-conversions Page 4
TOP I 02.4 UPK (ii) The characteristics of various

Level sensors and their selection criteria Page 8
TOP I 02.4 UPK (iii) Construction and working

Principle of direct method of level measuring devices Page 12
TOP I 02.4 UPK (iv) Construction and working

principle of displacer type Level measuring devices Page 22
TOP I 02.4 UPK (v) Construction and working

principle of hydrostatic type Level measuring devices Page 26
TOP I 02.4 UPK (vi) Construction and working

principle of capacitance type Level measuring devices Page 38
TOP I 02.4 UPK (vii) Construction and working

principle of interface Level measuring devices Page 44
TOP I 02.4 UPK (viii) Construction and working

principle of level switching devices Page 50
TOP I 02.4 UPK (ix) Applications of level measuring/

switching devices in PDO locations Page 52
TOP I 02.4 UPK (x) Calibration methods Page 53
Glossary of terms Page 56

Level Measurements
OBJECTIVES
On completion of this module, the participant will be able to: -
Evaluate the inter conversions of different level units with the given
standard engineering units table.
Explain how to select the correct level sensor for a given application with
the given characteristics of various level sensors and their selection
criteria table.
3. Explain the construction and working principle of different level

measuring / switching devices.
4. Explain the applications of level measuring/ switching devices.
5. Explain the construction and working principle of level transmitters.
6. Explain the zero check and use different Calibration devices and
methods to calibrate level transmitters to an accuracy of ±2%.
Level Measurements
TOP I 02.4 UPK (i) Standard engineering units of level and their inter-
conversions
INTRODUCTION
The measurement of level is defined as the determination of an existing

interface between two media.
These media are usually fluids, but may be solids or a combination of solid
and fluid. The interface can also exist between a liquid and a gas, a liquid
and its vapor or two liquids etc. The best method of measurement depends
upon the nature of the specific application, which must deal with:
1. The process to be measured.
2. The degree of accuracy required.
3. Dependability.
4. Economic considerations.
In the oil and natural gas industries, liquid level measurement is necessary
to achieve the following objectives.
1. Compute tank inventories of crude oil.
2. Protect equipment such as Compressors, turbines and pumps from

damage.
3. Protect operating and maintenance personnel against injury

resulting from liquid spillage.
4. Protect the environment from the spillage of liquids.
5. Control phase separation processes.

• Discuss about the measurement of level
• Discuss about the necessary of liquid level measurement
Level Measurements
STANDARD ENGINEERING UNITS OF LEVEL
Unlike pressure, temperature and Flow, which we have covered so far,

liquid level has no absolute value and is always relative to some reference
point such as the bottom of a tank. It is the height or depth of a liquid above
a reference point and is specific to a particular vessel. Hence, the normal
unit of level measurement is the meter or one of its sub-multiples. Level
measurement is expressed as a measurement of length.
Centimeter Meter Inch Feet Yard

1 0.01 0.3937 0.0328 0.0109
100 1 39.37 3.28 1.09
2.54 0.0254 1 0.0833 0.0278
30.48 0.3048 12 1 0.3333
91.44 0.9144 36 3 1
TABLE No.1 LEVEL / LENGTH CONVERSIONS
• Explain about the units of level measurement and their inter-conversions

using the given table.
Level Measurements
SELF-REVIEW
1. Convert 40 meters of level into inches.
2. Convert 25 feet of level to centimeters.
3. How would you define level?
4. What is the normal unit of Level measurement?
• Discuss the answers with the trainees.

Level Measurements
REVISION
1. Write down any two main objectives of level measurement?
a). _____________________________________.
b). _____________________________________.
2. Level measurement is always relative to some _______________ such

as the bottom of the tank.
3. One centimeter is equivalent to ________ feet.
4. Convert 50 inches of level to meters?
5. Convert 30 meters of level to feet?

Level Measurements
TOP I 02.4 UPK (ii) The Characteristics of various level sensors and
their selection criteria
Introduction
In this session, we shall discuss the characteristics of various level sensors
and their selection criteria for a particular application within PDO
locations.
Characteristics of various level sensors and their selection criteria
Measurement of liquid level is categorized into:

1 . Direct method
2 . Inferential method (indirect)
1 . Direct method
This employs the physical principles such as fluid motion, floats, and
thermal properties. Various types of level measurement under this heading
are:
1.1 Dip stick, Dip rods, and lead lines.
1.2 Sight glass.
1.3 Float operated.
2 . Inferential method (Indirect)

This employs hydrostatic head, weight, conductivity, viscosity, buoyancy
and density. Various types of level measurement under this heading are:
VARIABLE DISPLACEMENT METHOD(BUOYANCY TYPE)

2.1 Displacer.
HYDROSTATIC HEAD TYPE

2.2 Hydrostatic gauge (DP).
ELECTRICAL METHOD
2.3 Capacitance probe gauge.
• Discuss about the various types of Level measurement techniques.

Level Measurements
SENSOR TYPE APPLICATIONS LIMITATIONS

Dip stick, Dip rods, and 1. Automobile engine 1.Manual
lead lines. crank case oil level. measurement.
2. IC Engines oil level.2.Does not give
3. Oil tank level. continuous
measurement.
3. Not suitable in
pressurized tanks.
Sight Glass 1.Continuous 1. Local indication.
measurement for both 2. Possibility of
open and closed tanks. breakage.
2. Simple and reliable.
Float operated 1. Used for remote 1. Not used for foaming
transmission. liquids and liquid/gas
2. Used for switches. interface.
Displacer 1. Used for remote 1. Not suitable for wide
transmission. density fluctuations.
2. Used for interface
level measurement.
Hydrostatic gauge 1. Used for remote 1. Zero Elevation /
transmission. Suppression required
2. Used for interface depending on the
level measurement. mounting.
Capacitance probe 1. Used for corrosive 1. Scaling causes
gauge applications. errors.
2. Contain no moving 2. Temperature change
parts and easy to clean. affects change in
dielectric property.
TABLE No.2 LEVEL SENSORS SELECTION CRITERIA
• Discuss about the applications and limitations of various Level sensors.

Level Measurements
SELF REVIEW
1. What are the two types of liquid level measurement?
a) ___________________________________.
b) ___________________________________.
2. Dip stick is used to measure the liquid level under _______________

measurement.
3. Write any one type of liquid level measurement under Indirect method.
a) ____________________________________.
4. Displacer sensor is used for _________________ transmission.
• Discuss the answers with the trainees

Level Measurements
REVISION
1. Name at least two devices used for direct measurement of liquid level
a) __________________________________
b) __________________________________
2. Name any one type of device used for inferential measurement of level.
a) __________________________________
3. Write down the applications of Float operated sensor.
a) ___________________________________
b) ___________________________________
4. Which type of sensors is not suitable in pressurized tanks?
a) __________________________
b) ___________________________
c) __________________________
Level Measurements
TOP I 02.4 UPK (iii) Construction and working principle of level

measuring/switching devices
Introduction
In this session, we shall discuss the construction and working principle of
various level and interface level measuring/switching devices in detail.
1.1 Dip stick, Dip rods, and lead lines.

This is perhaps the earliest and simplest form of level measurement, still in
common use. A dip stick is essentially a stick that is calibrated to indicate
level. The dip stick is lowered vertically into a tank or vessel until it
reaches a reference point. Usually the bottom of the tank is used to ensure
that the dip stick is inserted to the correct depth. The dip stick is then
withdrawn and the level is read by determining where the interface last
made contact with the dip stick. Reading the scale on the dip stick indicates
the level measurement.
FIGURE No. 1 DIP STICK LEVEL MEASUREMENT

Dip rods may take the form of a solid round rod or a flat bar with
graduations over a length of 2.5 meters approximately. The rod is made
from non-spark metal and is inserted through a vertical guide tube until it
touches the bottom of the tank. Certain hydrocarbon liquids may contain
water, which accumulate at the bottom of the tank. The depth of water may
• Discuss about the principle of operation of Dipstick and Dip rod

Level Measurements
be measured by coating the end of the rod with a water detecting chalk,
which changes from white to blue, or a water detecting paste which
changes from green to red, if water is present. The lead line or otherwise
called manual gauging tape has replaced the dip rod as a method of
measuring liquid levels in large storage tanks. This is widely used in PDO
locations to measure storage tank levels. Obviously, dip rods over 10
meters long are too heavy to carry up to the top of large tanks and are also
too difficult to operate due to the amount of oil left sticking to the surface
during withdrawal.
The lead line consists of steel or glass fiber tape wound on a reel and a
brass weight, shaped like a plumb bob, is clipped on the free end. The bob
weight keeps the tape tight and suspended vertically inside the tank. The
tape and the bob are calibrated in meters and millimeters.
FIGURE NO. 2 MANUAL GAUGE TAPE AND BOB WEIGHT
• Discuss about the principle of operation and the advantages.

Level Measurements
1.2 Sight Glasses

Sight glasses, sometimes called gauge glasses, provide a continuous visual
indication of liquid level in a process vessel or a small tank and are,
therefore, more convenient than dipsticks, dip rods or manual gauging
tapes. However, glass elements can get dirty and are susceptible to
breakage thus presenting a safety hazard especially when hot, corrosive or
flammable liquids are being handled. There are three main types of sight
glasses, which we shall discuss now.
1.2.1 window Type Sight Glass

The drawing below shows a typical two-section window sight glass, which
is mounted directly on the side of a rectangular tank, such as a gas
compressor lubricated oil storage and circulation tank, operated at
atmospheric pressure and 60°C. This type can be seen with Borsig Gas
Compressor at Marmul location within PDO.
The slot-shaped overlapping windows are made of flat, transparent, heat

resisting glass and show the true level of oil together with any abnormal
condition such as excessive foam or turbulence. Window type sight glasses
are less likely to be damaged by an accidental knock than the more exposed
external gauge columns.
FIGURE No. 3 WINDOW TYPE SIGHT GLASS
• Discuss about the advantages and also its types.

• Explain the construction and working principle.
Level Measurements
1.2.2 Tubular type Sight Glass

The type shown below is a single tube sight glass located outside a process
vessel and connected at both ends by small bore piping unions and special
isolation valves containing safety shut-off ball check valves. In the event of
tube breakage, the sudden loss of pressure in the tube causes the pressure in
the vessel to move the balls and reseal the lines thus checking liquid or
vapour escape from the process vessel. It is essential to connect the top of
the sight glass to the vapour space of the vessel when it is operated under
pressure. Otherwise, the liquid in the glass would be blown out to
atmosphere. The externally mounted sight glass does not always indicate
the true level of the liquid inside the vessel.
If the liquid in the vessel is at high temperature and the sight glass is not
thermally insulated, the specific mass (density) of the liquid in the glass
will increase and support a higher column of lower specific mass liquid
inside the vessel. Likewise, when the liquid in the vessel is refrigerated and
the sight glass is not adequately cold insulated, the level in the sight glass
will be higher than the true level in the vessel. If the normal process liquid
is water and it becomes contaminated with light oil the average specific
mass will decrease and the sight glass level will be less than the true level
in the vessel.
The contents of the sight glass should be purged to a closed drain at regular
intervals to ensure that the lower connection is not blocked and to ensure
that the sight glass liquid is the same as that inside the vessel.
Tubular sight glasses are no longer used in high pressure, high temperature,
and hydrocarbon services because they are easily broken. However, they
are still used in utility services such as water treatment where pressures do
not exceed 1000 kPag.
• Discuss about the construction and principle of operation.

• Discuss about the limitations and applications.
Level Measurements
FIGURE NO. 4 TUBULAR TYPE SIGHT GLASS

Level Measurements
1.2.3 Flat Glass Type Sight Glasses

This type of sight glass is applicable for service with high pressure, high
temperature, and hydrocarbon liquids. It is also used with high pressure
steam at approximately 7000 kPag and 450°C and in oil / gas separation
applications at 13000 kPag and 80°C.
The sight glass element originally took the form of a one piece, u-section,
and hollow steel bar with a thick, heat resistant and shock resistant glass
plate covering the open side. The assembly being secured by a heavy
slotted cover clamped to the bar by a number of u-bolts as shown.
FIGURE No. 5 FLAT GLASS TYPE SIGHT GLASSES

• Discuss about the applications.
• Discuss about the constructional details.
• Discuss about the principle of operation.
Level Measurements
The main problem used to be inadequate illumination and two

modifications were developed to improve visual level indication namely:
Sight glass with a reflex glass panel.
Sight glass with two plain glass panels.
Both types of sight glass are illustrated, the reflex glass panel containing
prismatic grooves. When the sight glass is empty, the incident light is
reflected outwards giving the glass a bright appearance. When liquid is
present, the incident light rays are refracted from the grooves into the liquid
and the consequent reduction in reflection gives the liquid a dark
appearance. Reflex sight glasses are normally installed on vessels handling
clean, colourless and low viscosity liquids, while plain sight glasses are
used with coloured, viscous liquids.
At night, or in poorly lit locations, level observation is improved by

installing a plexiglass illuminated panel behind the double glass type units.
This accessory is important when the process vessel contains boiling liquid
and vapour condensate continuously runs down the inside of the glass.
Sight glasses on chillers become covered in frost after the surrounding air
in contact with the glass reaches its dewpoint. This problem is overcome by
fitting a transparent plastic plate on top of the sight glass.
Level Measurements
1.3 Float Operated Gauges

Devices incorporating floats have been used for a very long time for liquid
level indication, measurement and control. The device, used for liquid level
measurement in fixed roof tanks, is known as a float gauge or tape gauge
and many different types are used. All types employ measuring wires or
tapes, which are either moved by gravity counterweights, spring-powered
servomotors or electric servomotors.
A float operates on the Archimedes’ Principle, which states that when a

body is immersed in a liquid it is buoyed by an upward force, called
upthrust, equal to the weight of liquid displaced. When the weight of the
float is equal to the weight of the liquid displaced, it will remain on the
liquid surface at a constant submergence and at constant density. If the
weight of the object is greater than the upthrust on it, the object sinks. If the
upthrust of the liquid is enough to balance the weight, then the object
floats. Upward or downward motion can be used to measure the changing
level in a process vessel or a storage tank.
Tank Float Gauge

The float is connected to a counter weight by means of a cable or chain,
which is running through the groove of the pulley. The cable / chain are
kept tight enough with the help of the counterweight. The hub of the pulley
is in turn connected to an indicating device with graduations. The indicator
assumes a definite position over the scale for a definite position of the float
on the surface of the liquid and hence proportional to the liquid level in the
tank.
• Discuss about the float operated gauges

• Discuss about the principle of operation
Level Measurements
Refer to the diagram below.
FIGURE No. 6 TANK FLOAT GAUGE
Another variation in design is that where the counterweight itself acts as

the indicator moving over a graduated linear scale. (Note: This level
instrument is installed in the potable water tank opposite to the PDO Public
technical library).
In such installations, the float is placed in a stilling well or guided by guide

rods / ropes. This will prevent the float from wandering inside the tank and
only vertical displacement of the float is permitted.
• Discuss about the constructional details.
• Discuss about the principle of operation.
Level Measurements
SELF REVIEW
1. The bottom of the tank is the ______________ for correct insertion of

the dip stick.
2. Name at least one reason why lead line is preferred over dip rod.
3. Write the applications of flat type sight glass.
4. Name any two types of sight glasses used in oil industry.
a. _________________________________.
b. __________________________________.

Level Measurements
TOP I 02.4 UPK (iv) CONSTRUCTION AND WORKING

PRINCIPLE OF DISPLACER TYPE OF LEVEL MEASURING
DEVICES.
2.1. Displacer Type Level measurement.
This is based on the Archemedes' principle, which states that when a

body is immersed in a liquid the resultant fluid pressure on the body acts
vertically upward through the center of gravity of the body and is equal to
the weight of the fluid that is displaced by the body.
The upward pressure acting on the area of the body creates a force and
is called BUOYANCY.
When the weight of an object is heavier than an equal volume of a liquid
into which it is submerged, full immersion results and the body never
floats. The idea is further explained by a simple experiment. The body
hereafter will be called a DISPLACER, because it displaces some amount
of liquid. A displacer is heavier than the liquid and does not float whereas
a float is lighter than the liquid and floats on the surface of the fluid.
FIG.7 PRINCIPLE OF DISPLACER

Level Measurements
In tank “A " the displacer is suspended by a spring balance that shows the
weight of the displacer in air, 3 Kg. This represents a 0 % water level in the
tank. As we increase the level in the tank to 50 %, water rises vertically and
more length of the displacer is now immersed in the water (tank " B "). You
will notice three things:
1. The weight of the displacer is reduced to 2 Kg, as indicated by the

spring balance.
2. The relative position of the displacer in the water is raised due to

the buoyancy force exerted by the water.
3. The relationship between the reductions in weight of the displacer

and the height of liquid is linear.
This is further clarified by the situation in tank “C ". As the liquid level is
increased to 100 %, the weight of the displacer further decreases to 1Kg.
The rise in level and the reduction in weight of the displacer are
directly proportional.
In industrial applications, the spring balance is not a convenient method of

indication of the level and will be replaced by a torsion spring called
“Torque tube”. Almost all manufacturers of displacement type level
measuring instruments use this unique mechanism to convert the vertical
movement of the displacer to a rotary movement in the instrument for
indication or transmission. The torque tube has two main functions
1. Transmits the motion from the displacer to the control

mechanism.
2. Provides a positive seal against the process fluid and its pressure.
• Discuss about the principle of operation of Displace type level

measurement.
Level Measurements
As mentioned earlier the design of the torque tube varies from

manufacturer to manufacturer. Here we will examine one of those types.
Shown below is a cross sectional view of one type of torque tube.
FIGURE No. 8 DISPLACER TYPE LEVEL TRANSMITTER

Level Measurements
In operation, when the displacer is freely hanging in air and the full weight
of the displacer is acting on the torque arm, this will produce a torque on
the length of the torque tube which is fixed at one end. The torque tube will
twist and when it twists the torque tube rod will also twist. Here the torque
tube is acting as a spring.
As the displacer loses its weight due to a rise in level, the twist on the
torque tube will be reduced and the torque tube rod will rotate accordingly.
This rotation is proportional to the weight of the displacer, which is also
proportional to the rise in level.
The successful application of the torque tube will depend upon the material
of construction. It should be designed to provide the necessary load
carrying ability with low operating stress. The following needs to be
considered when selecting the torque tube material.
1. Capability of the material to resist corrosion.

2. Elastic properties of the material over a wide range of
temperatures.
3. The nature of the fluid being handled.
Type 316 stainless steel (316 SS) is commonly used for temperatures up to
250 °C. Above 250 °C INCONEL (alloy) is found to be satisfactory. There
are other materials like Monel, Hastelloy C etc., which are suitable up to
250 °C. These materials have good corrosion resistance properties.
This particular instrument is designed by Fisher Controls Company and

their torque tube design is unique. Here the transmission mechanism is
pneumatic but electronic versions which produce 4 to 20 mA signal are also
available. Necessary explosion proof instrument enclosures are needed to
use the electronic versions in the oil field. The other popular design which
P.D.O. installations use is manufactured by MASONEILAN Company.
• Discuss the principle of operation of Displacer type level transmitter.

Level Measurements
TOP I 02.4 UPK (v) CONSTRUCTION AND WORKING PRINCIPLE

OF HYDROSTATIC TYPE LEVEL MEASURING DEVICES.
2.2 Hydrostatic Gauge.
Refer to the diagram given below. We can calculate the pressure at any
point in the column of liquid by using the standard formula
P=hxρ xg
Where P = Pressure in N/m2 or Pascal

h = height of the liquid from a given datum in meters.
ρ = Density of the liquid in kg/m3.
g = acceleration due to gravity in m/s2.
This equation is arrived as follows:

Pressure = Force
Area
= Mass x Acceleration
Area
= (Volume x Density) x Acceleration
Area
= (Height x Area) x Density x Acceleration
Area
= Height x Density x Acceleration
=hxρ xg
Now let’s see how the unit is arrived:

Pressure = h x ρ x g
= m x kg/m3 x m/s2
= kg
m x s2
Multiply both sides by meter and hence we get,
Pressure = kg x m = kg x m/s2 x 1/m2 = N/m2 = Pa
S2 x m 2
Also, let’s now see the relationship between density and Specific Gravity.
Level Measurements
Specific Gravity of liquid = Density of liquid

Density of water
Specific Gravity of gas = Density of gas
Density of air
We all know that density of water is 1000 kg/m3 and Specific Gravity (S.G)
is having no unit since it is the ratio of two densities. If the SG of crude oil
is 0.8, then the density of crude oil will be 800 kg/m3.
FIGURE No.9 PRINCIPLE OF HYDROSTATIC HEAD
If we calculate the pressure at the base of the vessel, this is the pressure the
pressure gauge will be measuring in this particular installation.
Level Measurements
We know that:
• Discuss about the principle of Hydrostatic head
P=h x ρ x g
Where h = 2 m
ρ = 1000 Kg / m3
g = 9.81 m / s2
Therefore P = 2 x 1000 x 9.81 = 19620 N / m2

= 19.620 kPa

Closed and pressurized vessels.

In the previous diagram we discussed the application of the hydrostatic
head principle to measure the height of the liquid in a tank. There, the
pressure above the tank was atmospheric; therefore an ordinary pressure
gauge could give us the height of the liquid in the tank. Only the dial of the
pressure gauge needs to be marked in terms of liquid height.
When a tank or vessel is closed and pressurized, the amount of pressure

inside the tank will act on top of the liquid surface. This will add to the
hydrostatic head created by the liquid height and this combined pressure is
the pressure that is measured by the pressure gauge, which is not the
pressure due to height of the liquid. This condition calls for some kind of
compensation (correction) to cancel the effect of the gas (or vapor)
pressure existing above the liquid surface.
A differential pressure measuring device can be applied in such

installations. You came across this type instrument (a D/P cell) when you
studied pressure measurements. The diagram below illustrates how the
Level Measurements
differential pressure method can be successfully used to compensate the

error that is created by the pressure above the liquid.
• Discuss about the principle of D/P type level measurement for closed
level
FIGURE No.10 D/P TYPE LEVEL MEASUREMENT FOR CLOSED VESSEL
In the above diagram the pressures involved are:
HP = P1 + P2
LP = P2
D/P cell output = HP – LP
= (P1 + P2) - P2 = P1
This is the pressure due to the hydrostatic head.

Level Measurements
Differential pressure method of hydrostatic head measurement is popularly

used both in pressurized tanks and vented tanks. When used for vented
tanks, the LP side of the D/P cell is also vented to the atmosphere.
Complications can arise when the space above the liquid is under pressure
and contains the vapor of the liquid itself. This vapor remains as vapor
within the tank at the process operating temperature. But when it is tapped
outside of the tank, this vapor may condense back to liquid. This will create
problems for successful measurement. Let us examine how.
Refer to the drawing below.
FIGURE No.11 D/P TYPE WITH OUTSIDE WET LEG
The vapor of the liquid when connected to the LP impulse line and taken to
the ambient temperature will condense to liquid and remain as liquid inside
the LP impulse line. In this situation the LP side is fully or partially filled
Level Measurements
with liquid and therefore it is wet. The LP side is then referred to as

WET LEG.
The amount of liquid condensed inside the LP side can also vary due to the
rate of condensation. This will create a hydrostatic head in the LP side. All
these factors contribute to inaccuracy in measurement. In such applications
where wet leg is encountered the measurement of liquid level is not
accurate and correction (compensation) is required.
Another problem with this kind of measurement arises when the measuring
instrument is located below the zero level (datum). The error due to this
problem can arise for both DRY and WET LEG applications. We will
discuss them in detail and also the methods employed to compensate for
the errors.
Consider an installation as given below.

Level Measurements
FIGURE No.12 D/P CELL MOUNTED BELOW DATUM
The D/P cell is located below the datum level (zero level). When the liquid
level is at the zero percentage (lower range value), we expect the D/P cell
to produce an output either 4 mA or 20 kPa, depending upon the type of
transmission. But in this case when the level is actually at 0%, the HP side
measures the hydrostatic head produced by the liquid height "X". This
will make the transmitter send a signal, which is more than 4 mA or 20
kPa. The information given by the transmitter is not true from the
measurement point of view but this error is a definite (fixed) error because
the liquid trapped inside the HP leg remains there all the time. Since the
signal given out by the transmitter is more than zero, this needs to be
corrected for. This type of correction is termed as ZERO SUPPRESSION.
This means that to bring the increased transmitter output back to zero,
(4mA or 20 kPa), to represent the 0% of the measurement (level).
The example on the next page explains the point further.

Level Measurements
Level Measurements
Distance "A" = 2 meter

Distance "B" = 6 meter
Distance "C" = 1 meter
S.G. of liquid = 0.92
1. Find the range and span of measurement in kPa.

2. Find the amount of pressure that needs to be suppressed for the
transmitter to read zero when the level is at the datum.
• Discuss
Solution 1 about the Zero suppression.
Range of measurement = 0 m to 2 m (0% to 100% level).

Head created by 0% level = 0 kPa (LRV).
Head created by 100% level = 2 x9.81x 0.92x1000 Pa.
= 18050.4 Pa.
= 18.0504 kPa (URV).
Therefore range of measurement = 0 to 18.0504 kPa (Ans).
Span of measurement = URV - LRV.
= 18.0504 - 0 = 18.0504 kPa (Ans).
Solution 2
When the level is at datum, the transmitter measures a hydrostatic head

created by the column of liquid inside the HP impulse line. This line has a
vertical distance of 1 meter (C).
Therefore the pressure due to this height = 1x9.81x0.92x 1000

= 9025.2 Pa
= 9.0252 kPa (Ans)
Level Measurements
This is the amount of pressure that needs to be suppressed in the transmitter

so that when the transmitter measures 9.0252 kPa it has to send 4 mA (0%
signal) to the level indicator to show that level is at the 0% of
measurement.
Provisions are given in all D/P transmitters to fit suppression kits (parts) for
this biasing. Bias means add or subtract by a fixed value.
In the previous example we considered a dry leg application. Using the

same example, when the LP side becomes a WET LEG the problem is
different. Let us examine how different it is.
• Discuss about how to find the range and span of measurement in kPa.
• Discuss about how to find the amount of pressure that needs to be
suppressed for the transmitter to read zero when the level is at the datum.
Level Measurements

WITH OUTSIDE WET LEG
Note the changes in this drawing. Now let us assume that the level is at the
datum point, and the outside wet leg is completely filled with the same
liquid as in the tank.
The hydrostatic head seen by the HP side = C x ρ x g = 9.0252 kPa.

The hydrostatic head seen by the LP side = B x ρ x g = 54.1512 kPa.
Looking at the above pressures we can see that the LP side has more
pressure than the HP side when the level is at the datum point. This will
drive the transmitter zero below 4 mA. Also even if the level rises in the
tank the transmitter cannot produce any positive output because the LP side
will always have more pressure than the HP side.
To compensate for this type of error ZERO ELEVATION IS REQUIRED

in the transmitter. This means to apply bias as in the case of dry leg
installation. Let us now see how this can be done by looking at the
pressures involved.
The net pressure seen by the LP side of the transmitter, when the level is at
the datum point is:
{(B x ρ x g) - (C x ρ x g)} = (B-C) x (ρ x g)
= 5x 0.92 x 1000 x 9.81
= 45.126 kPa
The pressure due to height "C" in Hp side is also there in LP side. These
two pressures cancel each other. The remaining height of liquid in the LP
Level Measurements
side is creating the 45.126 kPa. This is the pressure, which is measured by
the LP side, and drives the transmitter zero below 4 mA.
Zero elevation kits can be fitted to the transmitter to cancel the effect of
such pressures, and make the transmitter read 4 mA when the level is at
0%.
• Discuss about how Zero elevation can be achieved in the transmitter.
SELF REVIEW
1. Write the formula inter-relating pressure, height of the liquid column,

density and acceleration due to gravity.
2. A pressure gauge is mounted in a tank 30 feet below the datum line of

the tank. The specific gravity of the process liquid is 0.80.What is the
pressure on the gauge in psi? (1 psi = 6.895 kPa; 1 ft = 0.3048 m)
Level Measurements
3. The zero suppression is used to bring the increased transmitter output

back to zero due to the definite error caused when the D/P level is located
below the datum level. True/False?
4. Convert 5 kPa into inches of water column using the formula
TOP I 02.4 UPK(vi) CONSTRUCTION AND WORKING

PRINCIPLE OF CAPACITANCE TYPE OF LEVEL MEASURING
DEVICE.
2.3 Capacitance type liquid level measurement.

A capacitor is an electrical component that consists of two conductors
separated by a dielectric or insulator. Capacitance value is measured in
farads. This value is determined by the area of the conductors (usually
called plates), the distance between the plates and the dielectric constant of
the insulator between the plates.
For capacitance type of level measurement, one plate is usually the probe
and the other plate is usually the tank. The dielectric is the material in the
tank. The relationship between the capacitance, plate area, the distance
between them and the dielectric constant is given by the equation;
C = K xA
Level Measurements
Where: C = Capacitance
K = Dielectric constant
A = Area of the plates
D = Distance between the plates
In most of the applications, the area of the plates and the distance between
the plates are fixed values. The dielectric varies with the level in the tank
and this variation is used to produce a signal, which is proportional to the
level. Industrial application of the capacitance type of level measurement is
confined to ON-OFF control purposes (point measurement, switching).
Best measurement results are obtained when the difference between the
dielectric constants of the two media is relatively high. This is because the
change in capacitance with the variation in level is a direct function of the
dielectric constant, and is greater when the height of the measured medium
with a high K (liquid) replaces a medium with a low K (gas).
• Discuss the principle of measurement of capacitance type liquid level
measurement.
It should be noted that the dielectric constant of liquid varies with
temperature. An increase in media temperature results in a decrease in
dielectric constant. Since level variations are inferred from variations in
dielectric, the changes in temperature will affect the accuracy of
measurement. Therefore suitable temperature compensation is required
when significant variations in media temperature are anticipated.
Two typical situations of capacitance measurement are:

1) Non conducting liquids.
2) Conducting liquids.
Non conducting liquids.

When measuring the level of a non-conducting liquid, a bare metal probe
can be used. The total (effective) capacitance of the system is given by the
equation:
C e = C1 + C 2 + C 3
Level Measurements
Refer to the drawing below.
FIGURE No.15 CAPACITANCE TYPE FOR NON CONDUCTING LIQUIDS
• Discuss about the types of capacitance measurement

• Discuss
Conducting about how to calculate the effective capacitance
liquids
For applications where the medium is a conducting liquid, insulated probes
are used. The total capacitance of the system is given by:
C2C4 C C
C e = C1 + + 3 5
C 2 C 4 C 3 + C5
+
Level Measurements
FIGURE No.16 CAPACITANCE TYPE FOR CONDUCTING LIQUIDS
• Discuss about how to find the effective capacitance of conducting

liquids.
Capacitance measurement techniques

As seen earlier the total capacitance Ce varies with the liquid level in the
tank. This change in capacitance can be measured by using an a/c
wheatstones bridge. A typical wheatstones bridge is given below.
Level Measurements
R1 R3
Detector
Voltage Source
a.c. G
C
2
R
2
Ce
Rx
FIGURE No.17 CAPACITANCE MEASUREMENT BRIDGE
The bridge is said to be balanced when the ratio of the impedances is equal.
It can be mathematically shown that the effective capacitance is equal to:
R1 C 2
Ce =
R3
Where Ce is the probe capacitance and R1, C2 & R3 are bridge

components. The detector can be calibrated to read level in suitable units.
By knowing the capacitance to level relationship of the probe, the level
values can be calculated by substituting the component values in the
equation.
Example:- A capacitance probe with a 5µF /m characteristic is used in a

• application.
level Discuss about theother
The techniques
bridgeofcomponents
capacitanceare
measurements.
C2 = 100µF, R1 = 10
kΩ, R2 = 100 kΩ, R3 = 50 kΩ. Find the level on the probe. (Ans = 4 m).
Level Measurements
Some advantages of capacitance level devices are:

1. They contain no moving parts.
2. Can be used for corrosive applications.
3. Easy to clean.
4. They can be designed for explosion proof service.
Some disadvantages of capacitance level devices are:
1. Measurement is subjected to error caused by changes in dielectric

constant due to variation in temperature.
2. Scaling deposited on the probe, while in use, causes changes in
dielectric constant and causes errors in measurement.
3. On site calibration is often required for best results.
• Discuss about the advantages and disadvantages of capacitance level devices.
SELF REVIEW
1. What is the function of capacitor?

Level Measurements
2. Write the relationship between the capacitance, plate area, the distance
between them and dielectric constant.
3. Mention at least two advantages of Capacitance type of level

measurement.

TOP I 02.4 UPK(vii) CONSTRUCTION AND WORKING
PRINCIPLE OF INTERFACE LEVEL MEASURING DEVICES.
INTERFACE LEVEL MEASUREMENTS

Level Measurements
DEFINITION: The measurement of level is defined as the determination

of the position of an existing INTERFACE between two media.
These media are usually fluids, but may be solids or a combination of solid
and fluid. The interface can exist between a liquid and a gas, a liquid and
its vapour, two liquids etc. Interface measurement of two media (liquid /
liquid) is encountered in industry when two liquids of different specific
gravities meet. Because of the difference in densities they do not mix
together. They are called IMMISCIBLE LIQUIDS. In liquid / liquid applications,
the border between the two liquids form an interface and measurement of
the position of this border in a tank or vessel containing these liquids
become important for successful process operation and economy.
Various methods are used to measure interface levels in industry depending

upon the process conditions and applicability. This discussion will be
confined to two types of widely and successfully used methods in P.D.O.
1. BUOYANCY TYPE.
2. DIFFERENTIAL PRESSURE TYPE.
BUOYANCY TYPE.
The previous discussion on displacer operation showed the displacer
suspended in two fluids with the displacer weight being a function of the
interface position.
The magnitude of displacer travel depends upon:-

a. THE CHANGE IN INTERFACE
b. THE DIFFERENCE IN SPECIFIC GRAVITY BETWEEN THE
UPPER AND LOWER FLUIDS
Level Measurements
FIGURE No.18 DISPLACER TYPE INTERFACE LEVEL MEASUREMENT
When both fluids are liquids, the displacer is always IMMERSED in liquid. Let
us consider a vessel containing two immiscible liquids such as NGL and
WATER. The specific gravity of NGL is 0.75 and of water is 1.0. A
displacer is placed in this vessel to measure the interface between water
and NGL. With the displacer completely immersed in NGL the weight of
the displacer is 1.4 lb. (600 gm.).
The weight of the displacer in air is 3.0 lb. (1.4 Kg). When the water level
in the vessel is increased to half of the length of the displacer, the displacer
weight is reduced to 1.2 lb. (540 gm).
This decrease in weight of the displacer is due to change in buoyancy.

When the water level is increased further the displacer weight is further
reduced to 1.0 lb. (450 gm). This further reduction in weight is again due to
greater portion of the displacer is immersed in heavier liquid, which is
water.
• Discuss about the principle of Displacer type interface measurement.

Level Measurements
From this example it can be seen that the weight of the displacer is a
function of the position of interface. When the displacer weight varies,
the rotary motion of the TORQUE TUBE also varies proportionally and
hence the output.
2 . DIFFERENTIAL PRESSURE METHOD

As discussed earlier, differential pressure method can be used for level
measurements. By this method we infer the level position by measuring the
hydrostatic head governed by the relationship:
P = hρg
As can be seen by the formula, the pressure (hydrostatic head) is dependent

on the liquid specific gravity (density). The example given below will
describe how differential pressure method can be successfully used in
interface level measurements.
FIGURE No.19 D/P METHOD OF INTERFACE MEASUREMENT

Level Measurements
• Discuss the principle of D/P method interface measurement.
Given:-
Vessel - Horizontal drum with a weir height = 8 ft = 2.5 m.
Measuring device - flange mounted DP transmitter.
HP connection - 0.9 in (0.2 m) above the drum bottom.
LP connection - from the top of the drum (dry leg).
Specific gravities = 0.85 for heavier liquid (GH).
= 0.60 for lighter liquid (GL)
g = Acceleration due to gravity = 9.81 m/s2
Formulas for calculation:
Pmax = h ρ g = transmitter differential at maximum interface.

Pmin = h ρ g = Transmitter differential at minimum interface.
Transmitter span = Pmax - Pmin kPa
h = height of measurement in meters.
To find
1. Transmitter span in kPa and in inches of water.
2. If suppression / elevation of zero required?
3. If required the magnitude in kPa and in inches of water?
Establishing values;
Specific gravity of heavier liquid = 0.85

Specific gravity of lighter liquid = 0.60
Height of measurement “h” = 2.5 - 0.2 = 2.3 meters
Density of water (ρ ) = 1000 Kg / m3
Level Measurements
Head seen by the DP transmitter

when the interface is maximum = 2.3 x 850 x 9.81 =19178.55 Pa
=19.178 kPa
19.178 x 4.016 =77.018 " H2O
Head seen by the DP transmitter
when the interface is minimum = 2.3 x 600 x 9.81 =13537.8 Pa
= 13.537 kPa
13.537 x 4.016 = 54.364 ' H2O
Therefore span = 19.178 - 13.537 = 5.641 kPa = 22.654 " H2O

Transmitter range =13.537 kPa to 19.178 kPa
When interface is at the minimum (zero interface level), the DP cell will
measure a hydrostatic head of 13.537 kPa and will produce an output
greater than 4 mA. But the transmitter should produce 4 mA when the
interface level is ZERO. This means that the transmitter zero should be
brought down (suppressed) for an amount of pressure equal to 13.537 kPa.
Level Measurements
SELF REVIEW
1. Mention the two common methods used to measure interface level.
2. The specific gravity of NGL is __________________________.
3. The decrease in weight of the displacer is due to change in

__________________.
Level Measurements
TOP I 02.4 UPK(viii) CONSTRUCTION AND WORKING

PRINCIPLE OF LEVEL SWITCHING DEVICE.
Construction and Working Principle of Level Switches
In PDO locations, MAGNETROL type of float switches are widely used,
although many other types like flexible tube type, magnetic repelling type
are also available.
In this type of instrument the float, which is in the shape of a ball or a dish-
ended cylinder, senses the level change and positions a magnetic piston or
sleeve, which is attached to the float rod. The sleeve (or piston) moves up
and down inside the enclosed, pressure tight non-magnetic tube. Outside
the non-magnetic tube there is a permanent magnet fixed on a pivot, which
actuates a mercury or micro switch. A simplified diagram is given below.
For detailed sketches, refer to the product literature of "MAGNETROL"
level switches, which are widely used in the P.D.O. interior locations. This
instrument is also installed on V - 0020 and T - 0020 in HIBAH station.
electrical connections
Mercury pellet NO = normally open

NC = normally closed
Com
Com = common
NC NO
hermetically sealed glass case
Non magnetic
Pressure tight pivot
Tube
spring support
magnetic sleeve magnet spring
float rod
liquid level
FIGURE No.20 MAGNETROL LEVEL SWITCH

For high and high-high level switch applications normally closed contact is
being used, while for low and low-low level switch applications normally
• Discuss the construction and working principle of level switches.

Level Measurements
open contacts are being used. This is because of getting a closed contact
under normal conditions to safeguard the tank or vessel in the event of
loose connections in the circuit, which is otherwise called as fail-safe
condition.
SELF REVIEW
1. What is the most commonly used type of level switch used in PDO
locations?
2. For high and high-high level switch applications __________

__________contact is being used.
3. For low and low-low level switch applications ________

________________ contact is being used.
Level Measurements
TOP I 02.4 UPK (ix) APPLICATIONS OF LEVEL MEASURING /

SWITCHING DEVICES.
Introduction
In this session, we shall discuss the applications of various types of level
measuring/switching devices in PDO locations.
Applications
Lead lines are widely used by production operators in MAF Tank farm area
and interior locations to take the inventory of tank levels.
Sight glasses of the different types discussed are used for local indication in
many applications.
Displacer type transmitters are widely used to measure oil level and
interface level in crude oil storage tanks, C.P.I., separators etc. The
hydrostatic head type level transmitters of DP type are the most widely
used level transmitters in the interior locations.
Capacitance type level measuring devices are used for on-off control in the
dehydration tanks in the interior and crude oil storage tank in MAF Tank
farm area for draining water that is settled down.
Magnetrol level switches are widely used for safeguarding the tanks,
separators, C.P.I’s in association with logic circuits.
Level Measurements
TOP I 02.4 UPK (x) LEVEL CALIBRATION METHODS.

Introduction
We have seen the calibration of DP type of transmitters in the previous
module. Hence, in this session, we shall concentrate the calibration of dry
weight calibration of displacer type of level transmitters on a typical
application of MARMUL T-2412 Oil Level and Interface Level.
MMPS T-2412
TAG No. : 24-LEA-258HH
SERVICE : OIL
(a) DISPLACER DETAILS
Length of the displacer (L) = 35.6 cms
Diameter of the displacer (D) = 4.24 cms.
Volume of the displacer (V) = πD²L = 22 x 4.24 x 4.24 x 35.6
4 7x4
= 502 cubic cms.

Displacer Hanger Extension length = 319.8 cms.
(b) SPECIFIC GRAVITY

Specific Gravity of Oil (ρ1) = 0.911
(c) CALCULATION
Weight of the displacer + Hanger in air (W) = 1600 gms.
Loss of weight in 100% Oil (W1) = (V x ρ1) =457.322 gms.
Weight of the displacer in 100% Oil = W – W1 =1142.678 gms.
2
(d) CALIBRATION
INST. READING WEIGHT TRANSMITTER

Level Measurements
(%) (GRAMS) OUTPUT (mA)

0 1600 4
50 1371.339 12
100 1142.673 20
MMPS T-2412
TAG No. : 24-LEA-259LL
SERVICE: INTERFACE (OIL / WATER)
(a) DISPLACER DETAILS
Length of the displacer (L) = 35.6 cms

Diameter of the displacer (D) = 9.8 cms.
Volume of the displacer (V) = πD²L = 22 x 9.8 x 9.8 x 35.6
4 7x4
= 2686.38 cubic cms.

Displacer Hanger Extension length = 1063.6 cms.
(b) SPECIFIC GRAVITY

Specific Gravity of Oil (ρ1) = 0.911
Specific Gravity of Water (ρ2) = 1.005
(c) CALCULATION
Weight of the displacer + Hanger in air (W) = 4000 gms.
Loss of weight in 100% Oil (W1) = (V x ρ1) =2447.29 gms.
Loss of weight in 100% Water (W2) = (V x ρ2) =2699.81 gms.
Weight of the displacer in 100% Water = W – W2 =1300.19 gms.
Weight of the displacer in 50% Oil +
50% Water = (W- W1) + (W- W2)
2
= 1426.45 gms.
d) CALIBRATION
Level Measurements
INST. READING WEIGHT TRANSMITTER

(%) (GRAMS) OUTPUT (mA)
0 1552.71 4
50 1426.45 12
100 1300.19 20
SELF REVIEW
1. Write the formula used in calculating the volume of the displacer
2. Calculate the Volume (V) of the displacer if the Length (L) and Diameter
(D) of the displacer are 11.8 cms and 5.7 cms respectively.
3. Calculate the loss of weight in 100% oil (W1) using the following details
a) Volume of the displacer (V) = 425 cubic cms.
b). Specific Gravity of Oil (ρ1) = 0.911
4. Calculate the loss of weight in 100% Water (W2) using the following
details
a). Volume of the displacer (V) = 444 cubic cms.

Level Measurements
b). Specific Gravity of Water (ρ2) = 1.005

Glossary of terms
ARCHIMEDES’ PRINCIPLE – The principle that when a body is wholly
or partly immersed in a fluid it experiences an up thrust equal to the weight
of fluid it displaces; the up thrust acts vertically through the center of
gravity of the displaced fluid.
BUOYANCY – The apparent loss in weight of a body when wholly or

partly immersed in a fluid.
CAPACITANCE – The ratio of the charge on one of the conductors of a

capacitor (there being an equal and opposite charge on the other conductor)
to the potential difference between the conductors.
DIELECTRIC - Substance, solid, liquid or gas, which can sustain a steady

electric field, and hence an insulator. It can be used for cables, terminals,
capacitors and similar devices.
DISPLACER- It is a long narrow closed cylinder, which is half submerged

in the liquid at normal level. It is heavier than the liquid and does not float.
IMMISCIBLE – Liquids of different densities that do not mix together.

INFERENTIAL – Indirect means.
INTERFACE - Sharp contact boundary between two phases, either or both

of which may be solid, liquid or gas.
LEAD LINE – Also called as a Manual Gauging Tape used to measure

level manually.
Level Measurements
PLUMB BOB – A weight, which moves up and down vertically in an

aligned manner.
PRISMATIC GROOVES- Grooves in the shape of prism that are

transparent glass whose faces are triangles.
PULLEY – A wheel with a flat, round, or grooved rim which rotates on a

shaft and carries a flat belt, vee belt, rope or chain to transmit motion and
energy.
SERVOMOTOR – A motor, electric or hydraulic, for use in an automatic

control system for e.g. the operation of a large valve by a governor of small
power.
SIGHT GLASS – A device on the outside of a separator that allows the
operator to check liquid levels inside the vessel.
TORQUE TUBE – Displacer is suspended from a torque tube that

measures the buoyancy force acting upwards on the cylinder at varying
depths of submergence caused by movement of liquid level.
VAPOUR – A gas, which is at a temperature below its critical temperature

and can therefore be liquefied by a suitable increase in pressure.
WEIR – A dam like structure which maintains a liquid level.
ZERO ELEVATION – This is required to compensate for zero of the

transmitter when the LP side becomes the wet leg.
ZERO SUPPRESSION – This is required to compensate for zero of the

transmitter especially in case of level transmitter when it is mounted below
the bottom of the tank.
Level Measurements
Learning Session Plan

Unit : I 02
Element : I 02.4
UPK (i) : Standard engineering units of level and their inter-
conversions.
UPK (ii) : The characteristics of various level sensors and their selection
criteria.
Learning Objective:
The participant will be able to evaluate the inter-conversions of different
level units with the given standard engineering units table and explain how
to select the correct level sensor for a given application with the given
characteristics of various level sensors and their selection criteria table.
Total Session Time:
1 period
Time Activity Resources
10 min Introduction TRANSPARENCIES

VIDEO CASSETTE
REF. NO:TVAR 1186.88
20 min Explain the standard TRANSPARENCIES
engineering units of level and
their inter-conversions.
20 min Explain the characteristics of TRANSPARENCIES
various level sensors and their
selection criteria.
Level Measurements
15 min Self review
15 min Revision

Unit : I 02
Element : I 02.4
UPK (iii) : Construction and working principle of direct method of level
measuring devices.
Learning Objective:
The participant will be able to explain the construction and working
principle of direct method of level measuring devices
Total Session Time:
3 periods
60 min Explain the construction and TRANSPARENCIES

working principle of dip
sticks, dip rods & lead lines.
working principle of sight
glasses.
working principle of float
operated gauges.
Level Measurements
15 min Self review
15 min Revision

Unit : I 02
Element : I 02.4
UPK (iv) : Construction and working principle of displacer type level
measuring devices.
Learning Objective:
The participant will able to explain the construction and working principle
of displacer type level measuring devices.
Total Session Time:
1 period

working principle of displacer VIDEO CASSETTE
type level measuring devices. REF. NO:TVAR 1186.88
15 min Self review

Level Measurements
15 min Revision

Unit : I 02
Element : I 02.4
UPK (v) : Construction and working principle of hydrostatic type level
measuring devices.
Learning Objective:
principle of hydrostatic type level measuring devices.
Total Session Time:
4 periods
10 min Introduction OHP

TRANSPARENCIES
280 min Explain the construction OHP

and working principle of TRANSPARENCIES
hydrostatic type level
measuring devices.
Level Measurements
15 min Self review
15 min Revision

Unit : I 02
Element : I 02.4
UPK (vi) : Construction and working principle of capacitance type level
measuring devices.
Learning Objective:
principle of capacitance type level measuring devices.
Total Session Time:
2 periods

TRANSPARENCIES
120 min Explain the construction and OHP

working principle of TRANSPARENCIES
capacitance type level
measuring devices.
Level Measurements
15 min Self review
15 min Revision

Unit : I 02
Element : I 02.4
UPK (vii) : Construction and working principle of interface level
measuring devices.
Learning Objective:
principle of interface level measuring devices.
Total Session Time:
2 periods

TRANSPARENCIES

working principle of interface TRANSPARENCIES
level measuring devices.
Level Measurements
15 min Self review
15 min Revision

Unit : I 02
Element : I 02.4
UPK (viii) : Construction and working principle of level switching
devices.
Learning Objective:
principle of level switching devices.
Total Session Time:
1 period

TRANSPARENCIES

working principle of level TRANSPARENCIES
switching devices.
Level Measurements
15 min Self review
15 min Revision

Unit : I 02
Element : I 02.4
UPK (ix) : Applications of level measuring/switching devices in PDO
locations.
UPK (x) : Calibration methods.
Learning Objective:
The participant will be able to explain the zero check and use different
Calibration devices and methods to calibrate level transmitters to an
accuracy of ±2% and explain the applications of level measuring/switching
devices in PDO locations.
Total Session Time:
1 period

Level Measurements
20 min Explain the applications of TRANSPARENCIES

level measuring/switching
devices.
20 min Explain the calibration TRANSPARENCIES
methods for level measuring
devices.
15 min Self review
15 min Revision
Q & A FOR LEVEL MEASUREMENTS
1. Convert 40 meters of level into inches.
1 meter = 39.37 inches
40 meters = 40 * 39.37 = 1574.8 inches
So, 40 meters of level is equivalent to 1574.8 inches
2. Convert 25 feet of level to centimeters.
1 feet = 30.48 centimeters.
25 feet = 25 * 30.48 = 762 centimeters.
So, 25 feet of level is equivalent to 762 centimeters.

Level Measurements
3. How would you define level?
The measurement of level is defined as the determination of an existing

interface between two media.
4. What is the normal unit of Level measurement?
The normal unit of level measurement is the meter or one of its sub-
multiples.
5. Write down any two main objectives of level measurement?
a) Compute tank accessories of crude oil.
b) Protect equipment such as Compressors, turbines and

pumps from damage.
6. Level measurement is always relative to some reference point such as

the bottom of the tank.
7. One centimeter is equivalent to 0.0328 feet.

Level Measurements
8. Convert 50 inches of level to meters?
1 inch = 0.0254 meters
50 inch = 0.0254 * 50 = 1.27 meters
So, 50 inches of level is equivalent to 1.27 meters.
9. Convert 30 meters of level to feet?
1 meter = 3.28 feet
30 meter = 30 * 3.28 = 98.4 feet
So, 30 meters of level is equivalent to 98.4 feet.
10. What are the two types of liquid level measurement?
a) Direct method.
b) Indirect method.
11. Dip stick is used to measure the liquid level under direct measurement.
Level Measurements
12. Write any one type of liquid level measurement under indirect method.
a) Displacer.
13. Displacer sensor is used for remote transmission.
14. Name at least two devices used for direct measurement of liquid level.
a) Dip stick
b) Sight glass
15. Name any one type of device used for inferential measurement of level.
a) Hydrostatic gauge(DP)
Level Measurements
16. Write down the applications of Float operated sensor.
a) Used for remote transmission.
b) Used for switches
17. Which type of sensors is not suitable in pressurised tanks?
a) Dip stick
b) Dip rods
c) Lead lines
18. The bottom of the tank is the reference point for correct insertion of the
dip stick.
19. Name atleast one reason why lead line is preferred over dip rod.
Dip rods are too heavy to carry up to the top of large tanks.
Level Measurements
20. Write the applications of flat type sight glass.
It is applicable for service with high pressure, high temperature and

hydrocarbon liquids.
21. Name any two types of sight glasses used in oil industry.
a) Window type sight glass.
b) Tubular type sight glass.
22. Write the formula inter-relating pressure, height of the liquid column,
density and acceleration due to gravity.
P= h * ρ* g
Where P = Pressure
h = height of the liquid from a given datum
ρ = density of the liquid
g = acceleration due to gravity
Level Measurements
23. A pressure gauge is mounted in a tank 30 feet below the datum line of
the tank. The specific gravity of the process liquid is 0.80.What is the
pressure on the gauge in psi? (1 psi = 6.895 kPa ; 1 ft = 0.3048 m)
P=h*ρ*g
= (30 * 0.3048) * 800 * 9.81 N/m2
= 71762.112 N/m2
= 71762.112 psi
1000 * 6.895
= 10.4078 psi
24. The zero suppression is used to bring the increased transmitter output
back to zero due to the definite error caused when the D/P level is located
below the datum level. True/False?
True.
25. Convert 5 kPa into inches of water column using the formula.
P=h*ρ*g
5 * 1000 =h * 1000 * 9.81
h = 5000 = 0.5096 meters
9810
= 0.5096 * 39.37 inches
= 20.06 inches
26. What is the function of capacitor?
A capacitor is an electrical component that consists of two conductors

separated by a dielectric or insulator.
Level Measurements
27. Write the relationship between the capacitance, plate area, the distance
between them and dielectric constant
C = K xA
D
Where: C = Capacitance
K = Dielectric constant
A = Area of the plates
D = Distance between the plates
28. Mention at least two advantages of Capacitance type of level

measurement.
a) They contain no moving parts.

b) Easy to clean.
29. Mention the two common methods used to measure interface level.
a) Buoyancy type.
Level Measurements
b) Differential pressure type.
30. The specific gravity of NGL is 0.75.
31. The decrease in weight of the displacer is due to change in buoyancy.

Level Measurements
32. What is the most commonly used type of level switch used in PDO
locations?
MAGNETROL
33. For high and high-high level switch applications normally closed
contact is being used.
34. For low and low-low level switch applications normally open contact
is being used.
Level Measurements
35. Write the formula used in calculating the volume of the displacer.
Volume of the displacer = (πD2 L) / 4
36. Calculate the Volume (V) of the displacer if the Length (L) and
Diameter (D) of the displacer are 11.8 cms and 5.7 cms respectively.
Volume of the displacer = (πD2 L) / 4 = (3.14 x 5.7 x5.7 x 11.8) / 4
= 300.95 cubic cms.
37. Calculate the loss of weight in 100% oil (W1) using the following
details
a) Volume of the displacer (V) = 425 cubic cms.
b). Specific Gravity of Oil (ρ1) = 0.911
Loss of weight in 100 % oil (W1) = (V x ρ1) = (425 x 0.911 )
= 387.175 gms.
38. Calculate the loss of weight in 100% Water (W2) using the following
details
a). Volume of the displacer (V) = 444 cubic cms.
b). Specific Gravity of Water (ρ2) = 1.005
Loss of weight in 100 % water (W2) = (V x ρ2) = (444 x 1.005)
= 446.22 gms.
Level Measurements

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Level Measurements

TOP I 02.4 UPK (i) Standard Engineering Units and

TOP I 02.4 UPK (ii) The characteristics of various

TOP I 02.4 UPK (iii) Construction and working

TOP I 02.4 UPK (iv) Construction and working

TOP I 02.4 UPK (v) Construction and working

TOP I 02.4 UPK (vi) Construction and working

TOP I 02.4 UPK (vii) Construction and working

TOP I 02.4 UPK (viii) Construction and working

TOP I 02.4 UPK (ix) Applications of level measuring/

TOP I 02.4 UPK (x) Calibration methods Page 53

Glossary of terms Page 56

On completion of this module, the participant will be able to: -

3. Explain the construction and working principle of different level

4. Explain the applications of level measuring/ switching devices.

5. Explain the construction and working principle of level transmitters.

The measurement of level is defined as the determination of an existing

1. The process to be measured.

2. The degree of accuracy required.

1. Compute tank inventories of crude oil.

2. Protect equipment such as Compressors, turbines and pumps from

3. Protect operating and maintenance personnel against injury

4. Protect the environment from the spillage of liquids.

5. Control phase separation processes.

STANDARD ENGINEERING UNITS OF LEVEL

Unlike pressure, temperature and Flow, which we have covered so far,

Centimeter Meter Inch Feet Yard

TABLE No.1 LEVEL / LENGTH CONVERSIONS

• Explain about the units of level measurement and their inter-conversions

1. Convert 40 meters of level into inches.

2. Convert 25 feet of level to centimeters.

3. How would you define level?

4. What is the normal unit of Level measurement?

• Discuss the answers with the trainees.

1. Write down any two main objectives of level measurement?

2. Level measurement is always relative to some _______________ such

3. One centimeter is equivalent to ________ feet.

4. Convert 50 inches of level to meters?

5. Convert 30 meters of level to feet?

Characteristics of various level sensors and their selection criteria

Measurement of liquid level is categorized into:

2 . Inferential method (Indirect)

VARIABLE DISPLACEMENT METHOD(BUOYANCY TYPE)

HYDROSTATIC HEAD TYPE

• Discuss about the various types of Level measurement techniques.

SENSOR TYPE APPLICATIONS LIMITATIONS

TABLE No.2 LEVEL SENSORS SELECTION CRITERIA

• Discuss about the applications and limitations of various Level sensors.

1. What are the two types of liquid level measurement?

2. Dip stick is used to measure the liquid level under _______________

4. Displacer sensor is used for _________________ transmission.

• Discuss the answers with the trainees

3. Write down the applications of Float operated sensor.

4. Which type of sensors is not suitable in pressurized tanks?

TOP I 02.4 UPK (iii) Construction and working principle of level

1.1 Dip stick, Dip rods, and lead lines.

FIGURE No. 1 DIP STICK LEVEL MEASUREMENT

• Discuss about the principle of operation of Dipstick and Dip rod

FIGURE NO. 2 MANUAL GAUGE TAPE AND BOB WEIGHT

• Discuss about the principle of operation and the advantages.

1.2 Sight Glasses

1.2.1 window Type Sight Glass

The slot-shaped overlapping windows are made of flat, transparent, heat