Muhammad Waris

Ammad Iqbal
Write in your own word (Hand-written)
LEVEL SENSORS
Level sensors are used to measure the level of the free-flowing substances. Such substances
include liquids like water, oil, slurries, etc as well as solids in granular/powder form (solids
which can flow).
Principle
These substances tend to get settled in the container tanks due to gravity and maintain their
level in rest state. Level sensors measure their level against a pre-set reference.
Principle of Operation
Distance over which charge is stored is shown in diagrams below and depends on the
medium measured. If the medium is non-conductive then it provides a large change in the
dielectric constant. If the medium is conductive then an insulated probe is used and the
capacitor is formed by the outer surface of the insulation (shorted to the wall) and the
electrode.

Level Measurement Sensor Selection

Key questions to ask before selecting a level measurement sensor:

Are you measuring a liquid or solid?

What are the temperature and pressure ranges of application?
Is point level or continuous measurement required?
What level measurement range do you need?
Ease of calibration or programming
Is the measured material electrically conductive?
Will the material coat or build up on surfaces?
Does turbulence, foam, or vapour occur at the surface of the liquid?
Will you need contact or non-contact level measurement?
What kind of output do you need analogue, relay, digital display, etc.
CLASSIFICATION-BASED ON SENSING POINTS

Depending upon the number of location where presence of a fluid (or fluidic solids) is to be
sensed, level sensors can be broadly classified under three categories. And each category
further classified.
1.

2.

Single Point Level

Sensors

These sensors are used

only at single location.

where fluid level is to be sensed

Multi-point Level Sensors

These sensors are used
number of locations single

3.

where fluid level is to be sensed at

location.

Continuous Level Sensors

These sensors are used where fluid level at all locations is

sensed.
For example,
For point and continuous level detection for solids, the level sensors are:
Vibrating point, rotating paddle, admittance-type

Point level detection of solids, the level sensors are: Magnetic and
mechanical float, pneumatic, conductive.

Sensors for both point level detection or continuous monitoring:

Ultrasonic, capacitance, optical, microwave.

Continuous level measurement of liquids: Magnetostrictive, resistance

chain, magnetoresistive, hydrostatic pressure, air bubble, gamma ray.[6]

CLASSFICATION-BASED ON SENSING PRINCIPLES

A wide variety of sensing principles are used are used for measurement of liquids, fluidic
solids, slurries, etc. These are explained below

Floats
Floats work on the simple principle of placing a buoyant object with a specific gravity
intermediate between those of the process fluid and the headspace vapour into the tank, then
attaching a mechanical device to read out its position. The float sinks to the bottom of the
headspace vapour and floats on top of the process fluid.
Early float level transmitters provide a simulated analogue or discrete level measurement
using a network of resistors and multiple reed switches, meaning that the transmitter's output
changes in discrete steps.
Advantage
Floats work well with clean liquids and are accurate and adaptable to wide variations in fluid
densities
Limitations

Unlike continuous level-measuring devices, they cannot discriminate level values

between steps.

Floats are affected by changes in product density since the displacement of the body
(its weight loss) is equal to the weight of the fluid displaced. If the specific gravity
changes, then the weight of the displaced material changes, thus changing the
calibration.

 Ultrasonic
These devices, which gauge levels by measuring the duration and intensity of echoes from
short bursts of energy, share the same capabilities as lasers and offer flexibility in mounting
and outputs. The technology is ideal for many types of liquids, but performance drops off in
applications involving foam. Range is more limited than laser offerings and alignment of the
emitting/detection and reflection components is also critical.

Advantage

Ultrasonic technology is inherently non-contact and is therefore impervious to

challenging application factors that can negatively impact level sensor performance
such as corrosive & ultrapure liquids, coating, scaling, dirt, density, dielectric or
conductivity.

Limitation
The factors to avoid with ultrasonic are extreme foam, vapour, turbulence and installations in
flange fittings with tall risers. Foam, vapour and turbulence can absorb and/or deflect away a
substantial portion of the return signal. Tall installation fittings can disrupt the acoustic signal
path

Laser

This technology offers the broadest availability of offerings, flexibility, ease of set-up and
alignment, and cost. While lasers work well for bulk and liquid, continuous, and switching
applications, its not as well-suited for clear materials, foam (light loss due to dispersion), or
sticky fluids (lens contamination).

Capacitance
Capacitance level sensors operate with a variety of solids, liquids, and mixed materials. There
are also a wide range of device types, some of which can be attached outside the vessel.
Users need to be cautious when selecting a device, as not every capacitance senor works with
every type of material or vessel. In addition, some capacitive probes can give continuous
output much the way guided microwaves or conductive probes do, but need to be calibrated
to the material being measured.
Advantage

Capacitance techniques are capable of operation at extremes of temperature and

pressure. They work well for materials that wont leave a coating. Usually only a
single tank penetration is required.

Limitation

Capacitance systems are intrusive. Have problems with varying dielectric materials
and those medias that coat the sensing element. Thus users are normally limited to
water-like media. Even acids and caustics that dont appear to coat the sensing
element are so conductive that the thin film they leave can cause serious errors in
measurement

Applications

Level sensors have been a part of manufacturing processes for several decades, in industries
as diverse as food and beverage, semiconductors, and pharmaceutical.

Liquid level measurement is important in household applications for devices such as

automated coffee machines, water dispensers, juice squeezers, water evaporators,
steamers, fridges and freezers, boilers, heating systems, dishwashers, washing machines,
steam irons, etc.
They are used in Pharmaceutical industry for slurry level control.
Level sensors are used to detect fill level of dry and wet cereals in food and packaging
industries.
Level sensors are used paints and pigments industries to check the fill level of fluids.
Level sensors are used chemical industries to check the fill level of substances.