CONTENTS

 INTRODUCTION
 TYPES OF LEVEL MEASUREMENT
 LEVEL MEAS.INST. USED IN UREA PLANT
 APPLICATIONS OF VARIOUS METHODS
 INTRODUCTION
 RF capacitance, conductance, hydrostatic tank gauging,
radar, and ultrasonics are the leading sensor
technologies in liquid level tank measurement and
control operations. Making the wisest selection for your
own application requires a basic understanding of how
these devices work.
DIFFERENT TYPES
 MECHANICAL METHODS
 PNEUMATIC METHODS
 ELECTRICAL METHODS
 NEUCLEONIC METHODS
 ULTRASONIC METHODS
 MECHANICAL METHODS
 VARIOUS METHODS ADOPTED IN MECHANICAL TYPE
MEASUREMENTS SUCH AS DIP STICK METHOD,
LEVEL GAUGES ETC.
 IN DIP STICK METHOD THE MEASURING STICK IS
INSERTED IN TO THE VESSEL AND INFERENCE OF
THE WETNESS IS OBSERVED.
 IN LEVEL GAUGES THE PHYSICAL LEVEL CAN BE
OBSERVED THROUGH THE SIGHT GLASS
 PNEUMATIC METHODS
• BUBBLER TYPE OF MEASUREMENT IS
AN EXAMPLE OF PNEUMATIC TYPE OF
LEVEL MEASUREMENT. A DIP TUBE
IS INSERTED VERTICALLY IN TO THE
VESSEL AND PURGING AIR IS GIVEN
THROUGH IT. THE BACK PRESSURE
DEVELOPED IS AN INDICATION OF
THE LEVEL IN THE VESSEL
PURGE TYPE LEVEL PG
MEASUREMENT

PURGE
TUBE
ELECTRICAL METHODS

 THERE ARE VARIOUS METHODS ADOPTED

IN THIS ALSO, SUCH AS CAPACITANCE
TYPE, RESISTANCE VARIATION METHODS
ETC.,
 CAPACITANCE TYPE
 The basis of this technique lies in the
physical properties of a capacitor and is given
by CAPACITANCE = K0A
d
 IF WE CAN VARY ANY ONE OF THE
PARAMETERS OF THIS EQUATION
ACCORDING TO LEVEL VARIATION , WE
CAN INFER THE LEVEL. THE PARAMETER
VARIED HERE IS THE DI-ELECTRIC
CONSTANT
Basic working
A
B

EQUIVALENT CIRCUIT
 NUCLEONIC TYPE
 IT CONSISTS OF A RADIOACTIVE
SOURCE, A RADIATION DETECTOR
NAD ELECTRONIC MEASURING
CIRCUITS. NORMALLY USED RADIO
ACTIVE SOURCES ARE STRONTIUM90
FOR BETA RADIATION, COBALT60 AND
CESIUM 137 FOR GAMMA RADIATIONS.
DEPENDING UP ON THE APPLICATION
THESE SOURCES CAN BE USED.
 ULTRASONIC TYPE
 THESE OPERATE ON THE PRINCIPLE OF
SONAR. SOUND WAVES ARE SEND OUT TO
THE LIQUID SURFACE UNDER
MEASUREMENT AND ARE REFLECTED BACK
TO A RECEIVING UNIT. LEVEL CAN BE
ACCURATELY DETECTED BY MEASURING
THE TIME INTERVAL TAKEN BY THE WAVES
TO TRAVEL FROM THE SOURCE TO THE
RECEIVER.
TRANSMITTER RECEIVER
TYPICAL LEVEL MEASUREMENTS
USED IN UREA PLANT

 CAPACITANCE TYPE
 NUCLEONIC TYPE
 LEVEL TROLS
 CAPACITANCE TYPE
THE CPACITOR USED IN THE LEVEL
MEASUREMENT GENERALLY TAKES THE FORM
OF A VESSEL ITSELF AND A PROBE THAT
EXTENDS IN TO THE VESSEL. THE VESSEL WALL
AND THE PROBE FORM THE TWO ELECTRODES.
THE DISTANCE BETWEEN THE ELECTRODES
AND THE SURFACE AREA REMAIN CONSTANT.
THE VARIABLE IS THE DEAPTH OF THE MATERIAL
BEING USED.WHICH REPRESENTS THE DI-
ELECTRIC BETWEEN THE ELECTRODES
AIR HAS DI-ELECTRIC CONSTANT EQUAL
TO ONE AND THE SOLUTION MEASURED
(UREA) HAS A DI-ELECTRIC CONSTANT
GRATER THAN ONE.THE CAPACITANCE OF
THE MATERIAL THEN DEPENDS ON HOW
MUCH MATERIAL LIES BETWEEN THE
PROBE AND THE WALL. THIS
CAPACITANCE VARIATION MEASURED TO
GET THE LEVEL OF THE LIQUID IN THE
VESSEL. THE CAPACITANCE IS MEASURED
BY FEEDING A HIGH FREQUENCY
VOLTAGE AT A CONSTANT FREQUENCY TO
THE PROBES.
THE HIGHER THE CAPACITANCE OF THE
CAPACITOR THE GREATER THE HIGH
FREQUENCY CURRENT THROUGH IT.
THE AMPLIFIER CARD CONVERTS THIS
HIGH FREQUENCY CURRENT IN TO A
FREQUENCY PROPORTIONAL TO THE
LEVEL. THIS FREQUENCY IS THEN
CONVERTED IN TO 4-20mA.
 FEATURES
• Usable with all Kotron probes for application
flexibility.
• Remote mounting up to 45 m (150 ft) with no
preamplifier on the probe ensures protection
from high process temperatures or heavy
vibration.
• LED shows the status of the relay and aids in
calibration and trouble-shooting.
• Cast aluminum, anti-corrosive painted enclosure
is rated CENELEC (IP 65), NEMA 4X (type 4
CSA), NEMA 4X/7/ 9.
• Conformally coated circuit boards reduce circuit
problems due to moisture and fungus.
• 4-20 mA current output, utilizes 24 VDC
 ADVANTAGES
 CAN BE USED FOR ANY TYPE OF
LIQUIDS /SOLIDS / SLURRIES/ CHEMICALS/
HYDROCARBONS/ACIDS/SALTS ETC
 CAN BE USED UP TO 500 DEG C & 5000 PSI
PRESSURE
 LOW MAINTENANCE
 RESPONSE TIME LESS THAN 0.1S
 LOW COST
 NUCLEONIC TYPE
 BASIC PRINCIPLE
 ROD SOURCE
 SCINTILLATION COUNTER/DETECTOR
 LB-323 GAUGE
 FEATURES
 RADIATION EXPOSURE LIMITS
 BASIC PRINCIPLE
BASED ON PHYSICAL LAW OF
ATTENUATION OF NUCLEAR
RADIATION AS IT PASSES THROUGH
MATTER. THE ABSORBTION OF GAMMA
RADIATION FOLLOWS AN
EXPONENTIAL LAW.
 A BEAM OF RAYS WITH THE
ORIGINAL INTENSITY I0 IS
WEAKENED AS IT PASSES THROUGH
THRE MATTER HAVING THICKNESS
“d” AND DENSITY “ρ”,

I=I0e -μρd
THE MASS WEAKENING CO-EFFICIENT
μ DEPENDS ON THE TYPE OF
RADIATION SOURCE USED.
 ROD SOURCE

 TYPE : CONSTRUCTED AS ROD

 LENGTH : 1040MM IN ONE PART AND
 INACTIVE PART AT THE
 BOTTOM 800 MM.
 MATERIAL : COBALT 60
 RANGE : 35 mCurie
 SHIELDING
THE SHEILDING CONSISTS OF A LEAD
CYLINDER WITH A RADIATION EXIT SLOT, THE
CYLINDER IS WELDED IN TO A STEEL TUBE
THAT IS SHIELDED WITH A STEEL COVER.
THE CYLINDER IS MOUNTED IN SUCH A
STRUCTURAL FRAME THAT BY TURNING IT
THRO’ 90 DEG ADDITIONAL SHIELDING IS
PROVIDED FOR EFFECTIVE RADIATION BEAM
BY THE STRUCTURAL FRAME
 SCINTILLATION COUNTER
THE RADIATION DETECTOR CONSISTS
OF A SCINTILLATION COUNTER WITH
HIGH SPECIFIC SENSITIVITY TO
GAMMA RADIATION
THE NaI CRYSTAL CONVERTS THE GAMMA
QUANTA EMITTED BY THE RADIO ACTIVE
SOURCE IN TO LIGHT FLASHES,THE
QUANTITY OF WHICH IS PROPORTIONAL TO
THE INCIDENT RADIATION INTENSITY.THE
CRYSTAL IS OPTICALLY COUPLED WITH A
PHOTOMULTIPLIER IN WHOSE
PHOTOSENSITIVE LAYER THE LIGHT
FLASHES RELEASE ELECTRONS.
AN HV SUPPLY APPLIED TO THIS LAYER
ACCELARATES THE ELECTRONS
TOWARDS THE ANODE WHERE THEY
RELEASE FURTHER ELECTRONS AS
THEY IMPINGE ON A DYNODE SYSTEM.
THUS HIGH AMPLITUDE PULSES ARE
PRODUCED AND SUBSIQUENTLY
CONVERTED IN TO STANDARD PULSES
OF APPROX. 10V BY A SERIES AMPLIFIER.
 THE GAUGE
 THE LEVEL GAUGE LB-323 IS A
MICROPROCESSOR CONTROLLED SYSTEM
THAT ALSO SUPPLIES THE OPERATING &
CONTROL VOLTAGE TO SCINTILLATION
COUNTER.THE STANDARD PULSES SUPPLIED
BY THE DETECTOR IS PROCESSED BY THIS
SYSTEM AND CALCULATES THE AVERAGE
COUNT RATE AND COMPUTES FINAL RESULTS
ON THE BASIS OF PRE PROGRAMMED
PARAMETERS. IT GIVES AN OUTPUT OF 4-20
mA .
 FRONT PANEL OF LB-323

CODE DISPLAY LVEL DISPLAY

10 75

COMPUTE CODE
LOCKED

PROBE FAILED
MEASURE ENTER
I
O

POWER
SWITCH
 FEATURES
 Non contact, continuous level measurement
 independent of pressure, temperature and chemical
properties of the product
 use of rod sources enables linearization of measuring
signal even at the beginning of the measuring range
 adaptable for all shapes of vessel (cylindrical, conical, etc)
 simple to calibrate (only one measuring point is needed)
 source design for output signal proportional to product
level or volume
 measuring range of several meters possible (more than 10
m)
 automatic decay compensation
 minimal source activity through the use of scintillation
counters
 indication in % level or millimeters
 RADIATION EXPOSURE LIMITS
 UP TO 0.2 Sv  No Effect evident

 Up to 1.0 Sv  Slight changes of blood structures but

no serious damage is likely to occur

 Radiation hangover, vomiting, serious

 Up to 2.0 Sv illness possible, good chances of
recuperation

 More than 6 Sv  No chance of survival

 The above limits are for the whole

body exposure to radiation for a short
time , but permanent exposure to
radiation will cause much damage due
to regenerative capacity of living
organism.
 Radio active decay
 The decay of radio active sample is statistical in
nature and it is impossible to predict when a
particular atom will transform. The radio activity
in a sample decreases with time, in manner
shown in graph and follows an exponential law
 A=A0e-λt

Where A0 = initial activity

A= activity after time t
λ = transformation or decay constant
 HALF LIFE
 THE RATE OF TRANSFORMATION OF A RADIO
ISOTOPE IS USUALLY GIVEN IN TERMS OF ITS
HALF LIFE, THE TIME REQD. FOR ONE HALF OF
THE ATOMS ORIGINALLY PRESENT TO DECAY.
 t1/2 = 0.693 /λ
R
a
d
i
o

a
c
t
i
v
i
t
y
half life time
 LEVEL TROLL WORKING

 Works on archimedean principle . According to this

principle the displacer body undergoes an apparent
loss in weight equal to the weight of liquid it
displaces.
 20 mA point

4 mA point
• One of the oldest and most common methods of
measuring liquid level is to measure the pressure
exerted by a column (or head) of liquid in the vessel.
The basic relationships are:
• P = mHd
• or:
• H = mP/d (3)
• where, in consistent units:
• P = pressure
• m = a constant
• H = head
• d = density
ULTRASONIC LEVEL MEASUREMENT
 The non-contact ultrasonic level sensors consist of the
following elements: sensor, analog signal processor,
microprocessor, binary coded decimal (BCD) range
switches, and an output driver circuit. The
microprocessor generates a series of transmit pulses
and a transmit gate signal that are routed through the
analog signal processor to the sensor. The sensor
transmits an ultrasonic beam to the surface level, and
the returned echo from the surface is detected by the
sensor and routed to the microprocessor, which
processes the signal into a digital representation of the
distance between the sensor and the surface level. The
microprocessor stores the distance value and, by
means
of a moving average technique built into the
software program, compares it to the value of
others stored in memory. If the value does not
correspond to prior signals or new signals being
received, it is rejected. Incorporation of a
moving average technique and a non-linear
digital filter ensures rejection of spurious signals
and noise. The microprocessor constantly
updates and reviews the signals received,
creating new averaged values which are
indications of the actual fluid level in the tank.
 Continuous Sensors
 For continuous sensors, the averaged
value from the microprocessor is
converted into an analog 4 to 20 mA signal
which is linear with the liquid level. In an
empty pipe or low level condition, when
the echo from the level does not return to
the sensor for more than 8 seconds, the
output signal from the system drops below
the minimum 4 mA.
Manual Level Measurement Methods
Method Description
Dipstick A common method of level
measurement, all car owners are
familiar with. This method
provides a manual method of
detecting level.
Hook Gauge The hook gauge is another form of
Dipstick method providing greater
level accuracy.
Sight Glass Another common manual method
of level measurement. The liquid
level is directly displayed against
a scale.
Uses
Measurements of liquid
with slow changes in
level. (e.g. Oil Sump).
Measurement of liquids
as with the Dipstick
where smaller changes in
level are required to be
measured.
Liquid level measurement
of vessels where level is
not required to be
recorded.
Electrical Level Measurement Methods

Method Description Uses

Pressure Measuring the differential pressure Can be used for

between the surface of the liquid measurement of
and the bottom of the liquid can liquids in open or
be used to provide a level. closed vessels.
Blubber The blubber method uses a pipe Liquids and slurries
submersed into the liquid (to the (including
bottom of the vessel). This pipe is corrosive liquids).
connected to a pressure
transducer and constant air
supply. The pressure instrument
measures the level, the higher the
level the greater the back
pressure on the pressure
transducer.
Weight Simple method, mounting the vessel Systems mounted on
onto weigh scales or load cells. weigh cells can be
The greater the level the greater used for liquids
the weight. (including
corrosive), slurries
Conductive Conductivity can be used to Used to switch at level
measure level giving discrete points giving discrete
readings of the level. signals at level points
The system uses two electrodes, (e.g. High and Low Level
one immersed into the liquid the detection).
second to the switching point. The
liquid must be conductive, when
the level covers both probes a
current flows between the
electrodes.
The current flowing is detected
providing the level switch.
Resistance The resistance level measurement The resistance gauge
method is basically two elements can be used for solids
that are mounted vertically into and liquids.
the vessel. One strip is made up of
chained resistors. As the level
rises in the tank the elements are
shorted together and the
resistance reduced. The lower the
resistance the higher the level.
Capacitance The capacitor method used two Level
cylinders that are mounted vertically in measurement of
the tank. These act as the plates of two liquids (including
capacitors in parallel, one with air corrosive and high
between the plates and the second with temperatures) can
the liquid. As the level changes the total be achieved
capacitance is changed. accurately with the
capacitance
gauge.
Ultrasonic The ultrasonic method uses a The use of
transmitter and receiver. The ultrasonic level
transmitter emits pressure waves at measurement can
approximately 20kHz. The ultrasonic be used for liquids
waves reflect off the material the level (including
is being measured. The level is corrosive) and
determined from the time it takes for solids.
the emitted waves to be reflected and
detected by the receiver. The higher the
level the quicker the waves are
reflected to the receiver.