Chapter

6
Level
Chapter Objectives This chapter will help you understand the units used in level measurements and become familiar with the most common methods of using the various level standards. Topics discussed in this chapter are as follows:

The formulas used in level measurements The difference between direct and indirect level measuring devices The difference between continuous and single-point measurements The various types of instruments available for level measurements Application of the various types of level sensing devices

Most industrial processes use liquids such as water, chemicals, fuel, and the like, as well as free flowing solids (powders and granular materials). These materials are stored in containers ready for on-demand use. It is, however, imperative to know the levels and remaining volumes of these materials so that the containers can be replenished on an as needed basis to avoid the cost of large volume storage. 6.1 Introduction This chapter discusses the measurement of the level of liquids and free flowing solids in containers. The detector is normally sensing the interface between a liquid and a gas, a solid and a gas, a solid and a liquid, or possibly the interface between two liquids. Sensing liquid levels fall into two categories; firstly, singlepoint sensing and secondly, continuous level monitoring. In the case of singlepoint sensing the actual level of the material is detected when it reaches a predetermined level, so that the appropriate action can be taken to prevent overflowing or to refill the container.

85

Copyright 2005 by The McGraw-Hill Companies, Inc. Click here for terms of use.

86

Chapter Six

Continuous level monitoring measures the level of the liquid on an uninterrupted basis. In this case the level of the material will be constantly monitored and hence, the volume can be calculated if the cross-sectional area of the container is known. Level measurements can be direct or indirect; examples of these are using a float technique or measuring pressure and calculating the liquid level. Free flowing solids are dry powders, crystals, rice, grain and so forth. 6.2 Level Formulas Pressure is often used as an indirect method of measuring liquid levels. Pressure increases as the depth increases in a fluid. The pressure is given by p = g h where p = change in pressure g = specific weight h = depth Note the units must be consistent, i.e., pounds and feet, or newtons and meters. Buoyancy is an indirect method used to measure liquid levels. The level is determined using the buoyancy of an object partially immersed in a liquid. The buoyancy B or upward force on a body in a liquid can be calculated from the equation B = g area d (6.2) (6.1)

where area is the cross-sectional area of the object and d is the immersed depth of the object. The liquid level is then calculated from the weight of a body in a liquid WL, which is equal to its weight in air (WA B ), from which we get d= W A WL area (6.3)

The weight of a container can be used to calculate the level of the material in the container. In Fig. 6.1a the volume V of the material in the container is given by
2 V = area depth = pr d

(6.4)

where r is the radius of the container and d is the depth of the material. The weight of material W in a container is given by W = gV (6.5)

Capacitive probes can be used in nonconductive liquids and free flowing solids for level measurement. Many materials, when placed between the plates of a capacitor, increase the capacitance by a factor m called the dielectric constant of the material. For instance, air has a dielectric constant of 1 and water 80. Figure 6.1b shows two capacitor plates partially immersed in a nonconductive

Level

87

Figure 6.1 Shows the relation between (a) volume of liquid and the cross- sectional area and the liquid depth and (b) liquid level, plate capacitance, and a known dielectric constant in a nonconducting liquid.

liquid. The capacitance (Cd) is given by Cd = Ca d + Ca r (6.6)

where Ca = capacitance with no liquid m = dielectric constant of the liquid between the plates r = height of the plates d = depth or level of the liquid between the plates The dielectric constants of some common liquids are given in Table 6.1; there are large variations in dielectric constant with temperature so that temperature correction may be needed. In Eq. (6.6) the liquid level is given by d= 6.3 Level Sensing Devices There are two categories of level sensing devices. They are direct sensing, in which case the actual level is monitored, and indirect sensing where a property of the liquid such as pressure is sensed to determine the liquid level.
TABLE 6.1

(Cd Ca ) r Ca

(6.7)

Dielectric Constant of Some Common Liquids Liquid Water Glycerol Acetone Alcohol (Ethyl) Gasoline Kerosene Dielectric constant 80 @ 20C 88 @ 0C 42.5 @ 25C 47.2 @ 0C 20.7 @ 25C 24.7 @ 25C 2.0 @ 20C 1.8 @ 20C