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Few measurements are as common and widespread in terms of application, operation, and variety as is
level. This measurement is defined as the determination of the position of an existing interface between
two media. These media are usually fluids, but they may be solids or a combination of a solid and a fluid.
The interface can exist between a liquid and a gas, a liquid and its vapor, two liquids, or a granular or
fluidized solid and a gas.
Many techniques are available for the measurement of these interfaces, each with its own trade-offs of
advantages and limitations. The best selection depends on the nature of the specific application,
including the process to be measured, the degree of accuracy and dependability desired, and economic
considerations and constraints. The design engineer must have a working knowledge of the various
types of measuring devices available as a guide for the selection and implementation of a system best
suited for a particular application. Following is a list of level-measuring methods in present use:
Visual
Hydraulic head
Variable displacer
Capacitance
Conductance
Head level-measurement
Many level-measurement techniques are based on the principle of hydrostatic head measurement. From
this measurement, a level value can be inferred and is usually calibrated in a linear measurement, such
as feet or inches, and the level is read directly, therefore eliminating the need for conversions. Such
level-measuring devices are common in a wide variety of industries.
When level is elevated in a tank, the force created by this head pressure is applied to the measurement
side of the transducer, resulting in an increase in the instrument output. This instrument response
caused by the head pressure is used to infer a level value. Changes in atmospheric pressure will not
affect the measurement because these changes are applied to both sides of the pressure transducer.
The specific gravity of a fluid must be considered to establish the relationship between level and
pressure. If the fluid is lighter, the pressure exerted by a specific column of liquid is less. The pressure
will be greater for heavier liquids.
delay between transmit and reception - indicates the distance, which directly infers the level.
The low power of the beam permits safe installation for both metallic and non-metallic vessels. Radar
sensors can be used when the process material is flammable and when the composition or temperature
of the material in the vapor space varies.
Contact radar measuring devices send a pulse down a wire to a vapor-liquid interface, where a sudden
change in the dielectric of the materials causes the signal to be partially reflected. The time of flight is
measured, and the distance traversed by the signal is calculated. The non-reflected portion of the signal
travels to the end of the probe and gives a signal for a zero reference point. Contact radar can be used
for liquids and small granular bulk solids. In radar applications, the reflective properties of the process
material will affect the transmitted signal strength. Liquids have good reflective qualities, but solids
usually do not. When heavy concentrations of dust particles or other such foreign materials are present,
these materials will be measured instead of the liquid.
Tank atmosphere
The radar signal is reflected directly on the liquid surface to obtain an accurate level measurement. Any
dust or mist particles present must have no significant influence, as the diameters of such particles are
much smaller than the 3-cm. radar wavelength. For optical systems with shorter wavelengths, this is not
the case. There can be slight measurement errors for a few specific products in the vapor space of the
tank; this is especially true when the composition may vary between no vapor and fully saturated
conditions. For these specific products, pressure and temperature measurement may be required for
compensation. Such compensation is made by the software incorporated in the tank intelligence system
provided by the equipment manufacturer.
End-of-the-probe algorithm
End-of-the-probe algorithm can be used in guided-wave radar when there is no reflection coming back
from the product. This new technology innovation provides a downward-looking time of flight situation,
which allows the guided-wave radar system to measure the distance from the probe mounting to the
material level. An electromagnetic pulse is transmitted and guided down a metal cable or rod, which acts
as a surface wave transmission line. When the surface wave meets a discontinuity in the surrounding
medium, such as a sudden change in dielectric constant, some of the signal is reflected back to the
source, where it is detected and timed. The portion of the signal that is not reflected travels on and is
reflected at the end of the probe.
use for comparison of actual performance. Such issues as instrument location and mounting, differences
in the expression of terms, the amount of detail and completeness given, and the methods used to obtain
instrument data should be considered.
Installation considerations are very important in non-contact level measurement applications, and the
following recommendations are listed to help the overall performance of measuring systems:
Material characteristics can have adverse effects on the measurement quality of the measurement
system operation.
Turbulent surface conditions should be avoided, and stilling basins should be considered in severe
turbulent situations.
Dust and dirt build-up at the sensor can reduce the transmitted and/or received signal strength.
The conditions at the liquid surface that affect reflectivity of the energy beams can result in error. For
radar systems, this is dependent on the dielectric constant, which should be above 10. Levels below
1.5 can preclude the use of radar applications.
The vapor space is considered to be transparent to the energy of the transmitted and reflected
energy beam. Materials in the vapor portion of the vessel that are translucent to the traveling
waveform can affect the energy level and the speed of the waveform.
The velocity of an ultrasonic wave is dependent on the pressure, temperature, and composition of the
vapor. Compensation or changes in the vapor is at times necessary. The condition of the vapor
should be constant. For example, when the conditions change during start-up, shutdown, and normal
operation, and appropriate compensation is not made, error can result.
The vessel geometric design and other conditions can affect the performance of a measuring system.
The configuration of the transponders and material entering or leaving the vessel can result in
measurement error. The formation of solids at various points along the beam path should be avoided.
Parasitic echoes and erratic energy reflection caused by internal tank structures should be discounted
by the measuring system. Moving parts like agitators can produce false reflections that can be sensed as
level measurement. The wetted portion of the sensor should be mounted perpendicular to the liquid
surface. Condensation forming on the sensor should be avoided. Multiple reflections caused by cones,
nozzles, and other geometric shapes of the vessel should be avoided by proper mounting and
compensation of false echoes.
Donald Gillum has more than 40 years of experience as master instructor, department chair, and
division director of instrumentation control systems and automation at Texas State Technical College in
Waco, Texas. Prior to this, he spent 10 years at a petrochemical facility as an instrumentation and
analyzer engineering technician. Gillum spent two terms on the ISA Executive Board, served as program
evaluator and commissioner for ABET, and currently sits on the board of directors for ABET. He wrote
the ISA book, Industrial Pressure, Level and Density Measurement, Fourth Edition. He obtained a B.S.
from The University of Houston and is a registered professional engineer in control systems engineering.
Gillum has considerable experience in industrial training and development.
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