Measurement of level in a tank using capacitive type level probe

Pre-requisite:
Before performing this experiment, student must have knowledge about
1. Working of a typical Capacitor
2. Types of Capacitors
3. Effect of various factors that affect the output of a capacitor
e.g. temperature, dielectric constant of
insulator used, distance between the plates, are of the plates used, etc.
Level measurements
In industry, liquids such as water, chemicals, and solvents are used in various
processes. The amount of such liquid stored can be found by measuring level of the
liquid in a container or vessel. The level affects not only the quantity delivered but also
pressure and rate of flow in and out of the container.
Level sensors detect the level of substances like liquids, slurries, granular materials,
and powders. The substance to be measured can be inside a container or can be in its
natural form (e.g. a river or a lake). The level measurement can be either continuous or
point values.
Continuous level sensors measure the level to determine the exact amount of
substance in a continuous manner.
Point-level sensors indicate whether the substance is above or below the sensing
point. This is essential to avoid overflow or emptying of tanks and to protect pumps from
dry run.

The selection criteria for level sensor include:

The physical phase (liquid, solid or slurry)

Temperature

Pressure or vacuum

Chemistry

Dielectric constant of medium

Density (specific gravity) of medium

Agitation (action)

Acoustical or electrical noise

Vibration

Mechanical shock

Tank or bin size and shape

From the application point of view the considerations are :

Price

Accuracy

Response rate

Ease of calibration

Physical size and mounting of the instrument

Monitoring or control of continuous or discrete levels

Level measurements are broadly classified in two groups:

Direct methods

Indirect methods

In direct methods, the level is indicated directly by means of simple mechanical

devices. The measurement is not affected by changes in material density. Few
examples are:

Dip Stick

Resistance Tapes

Sight Glass

Floats

Ultrasonic

Radar

In Indirect methods, the level is converted in a measurable signal using a suitable

transducer. Change in the material affects the measurement. A corrective factor must be
used in recalibrating the instrument. Few examples are:

Hydrostatic head methods

Load cell

Capacitance

Conductivity

Capacitance Level Measurement:

Capacitive level transducer is an example of indirect measurement of level

Capacitance level sensors are used for wide variety of solids, aqueous and organic
liquids, and slurries. The technique is frequently referred as RF as radio frequency
signals applied to the capacitance circuit. The sensors can be designed to sense
material with dielectric constants as low as 1.1 (coke and fly ash) and as high as 88
(water) or more. Sludges and slurries such as dehydrated cake and sewage slurry
(dielectric constant approx. 50) and liquid chemicals such as quicklime (dielectric
constant approx. 90) can also be sensed. Dual-probe capacitance level sensors can
also be used to sense the interface between two immiscible liquids with substantially
different dielectric constants.

Since capacitance level sensors are electronic devices, phase modulation and the use
of higher frequencies makes the sensor suitable for applications in which dielectric
constants are similar.
Working Principle:
The principle of capacitive level measurement is based on change of capacitance. An
insulated electrode acts as one plate of capacitor and the tank wall (or reference
electrode in a non-metallic vessel) acts as the other plate. The capacitance depends on
the fluid level. An empty tank has a lower capacitance while a filled tank has a higher
capacitance.
A simple capacitor consists of two electrode plate separated by a small thickness of an
insulator such as solid, liquid, gas, or vacuum. This insulator is also called as dielectric.
Value of C depends on dielectric used, area of the plate and also distance between the
plates.

Where:
C = capacitance in picofarads (pF)
E = a constant known as the absolute permittivity of free space
K = relative dielectric constant of the insulating material
A = effective area of the conductors
d = distance between the conductors
This change in capacitance can be measured using AC bridge.

Measurement:
Measurement is made by applying an RF signal between the conductive probe and the
vessel wall.
The RF signal results in a very low current flow through the dielectric process material in
the tank from the probe to the vessel wall. When the level in the tank drops, the
dielectric constant drops causing a drop in the capacitance reading and a minute drop
in current flow.
This change is detected by the level switch's internal circuitry and translated into a
change in the relay state of the level switch in case of point level detection.
In the case of continuous level detectors, the output is not a relay state, but a scaled
analog signal.
Level Measurement can be divided into three categories:

Measurement of non-conductive material

Measurement of conductive material

Non-contact measurement

Non-conducting material:
For measuring level of non conducting liquids, bare probe arrangement is used as liquid
resistance is sufficiently high to make it dielectric. Since the electrode and tank are fixed
in place, the distance (d) is constant, capacitance is directly proportional to the level of
the material acting as dielectric.

Conducting Material:
In conducting liquids, the probe plates are insulated using thin coating of glass or plastic
to avoid short circuiting. The conductive material acts as the ground plate of the
capacitor.
Proximity measurements (Non-contact type measurements):
In Proximity level measurement is the area of the capacitance plates is fixed, but
distance between plates varies.
Proximity level measurement does not produce a linear output and are used when the
level varies by several inches.
Advantages of Capacitive level measurement:
1. Relatively inexpensive
2. Versatile
3. Reliable
4. Requires minimal maintenance
5. Contains no moving parts
6. Easy to install and can be adapted easily for different size of vessels
7. Good range of measurement, from few cm to about 100 m
8. Rugged
9. Simple to use
10. Easy to clean

11. Can be designed for high temperature and pressure applications.

Applications:
Capacitance Level Probes are used for measuring level of
1. Liquids
2. Powered and granular solids
3. Liquid metals at very high temperature
4. Liquefied gases at very low temperature
5. Corrosive materials like hydrofluoric acid
6. Very high pressure industrial processes.
Disadvantages:
Light density materials under 20 lb/ft3 and materials with particle sizes exceeding 1/2 in.
in diameter can be a problem due to their very low dielectric constants (caused by the
large amount of air space between particles).

Guided-wave radar level sensors

There are two main types of radar level sensors: through-air and guidedwave. Both technologies are very versatile, but guided-wave designs have
some useful advantages.
Control Engineering Explains
Learn about radar level sensors

Guided-wave technology sends the radar pulse down a probe that extends into the tank contents,
either liquid or solid. Typically, theyre mounted from the tank top hanging down. The pulse hits
the surface and is reflected back up the probe to the sensor, where the transit time is translated
into a distance. This is very similar to through-air radar, which accomplishes the same action
without the probe.

This technology gives a very precise continuous reading, is energy efficient (a consideration for
potential battery-powered wireless connectivity), and can operate in difficult situations where
other approaches fail.
The probe concentrates the energy pulse much as speaking through a tube concentrates the
sound. This is particularly useful under certain conditions where a through-air pulse is less
reliable:

Liquids that have low dielectric values (e.g., propane, butane);

Low specific gravity liquids;

Turbulent liquids;

Internal physical obstructions (e.g., baffles);

Heavy foam layers; and,

Problematic solids.

A guided-wave probe is often much smaller than a through-air antenna, which

allows it to be mounted through a smaller opening or where equipment is more
congested. While the probe helps with the signal, it can introduce its own problems:

In some extreme cases no product contact is permitted, which demands

another technology entirely.

A unit can only measure as far as the probe extends. There is no theoretical
limit, but there are practical issues when they get very long.

Probes can be either rigid or flexible, determined by practicality. An

application with solids may not be suitable for a flexible probe. Similarly,
liquid with high turbulence may cause a flexible probe to move around.

Sticky material can build up on a probe. Various designs can see through this
to a point, but eventually it will interfere with an accurate reading.

In some cases, probes have been bent to read around corners. This is tricky,
though, and you should consult with your provider as to practicality.

The probe does not have to be the full length of the tank unless you need
readings all the way to the bottom. If the process only needs readings in the
upper half of the tank, thats all the length you need.

Ultrasonic Transmitters vs. Guided-Wave Radar for Level

Measurement
Ultrasonic level sensors have been on the market for years and are still considered a trusted
technology throughout the process measurement industry. Ultrasonic transmitters are
noncontacting and offer a cost-effective choice for most straight-walled tank-level applications.
Over the years, however, newer level measurement devices have emerged that are capturing
market share from older technologies that use sound or echo-based measurement. Technologies
such as guided-wave radar (GWR) are comparably priced and have proven to be a more reliable
choice in difficult sensing conditions. Guided-wave radar is suitable for both liquid and solid
applications and operates independent of process conditions.
Ultrasonic Technology
Ultrasonic transmitters operate by sending a sound wave generated
from a piezoelectric transducer to the surface of the process material
being measured. The transmitter measures the length of time it takes
for the reflected sound wave to return to the transducer. A successful
measurement depends on the wave, reflected from the process material
and moving in a straight line back to the transducer. Because factors
such as dust, heavy vapors, tank obstructions, surface turbulence,
foam, and even surface angles can affect the returning signal when
using an ultrasonic level sensor, you must consider how your operating
conditions can affect the sound waves.
Other important aspects of ultrasonic transmitters include:

Sound wavesSound must travel through a medium, usually

air, making the transmitters unsuitable for use with vacuum
applications where the absence of air molecules prevents the
propagation of sound waves.

Surface conditionFoam and other debris collected on the

surface of the liquid can absorb the sound waves and impede
their return to the sensor.

Angles of incidence and reflectionSound waves must be sent

and received in a straight line and reflective surfaces must be
flat (i.e., nonagitated/nonturbulent condition).

Operating temperatureUltrasonic units are typically plastic with a maximum operating

temperature of 60C. Also, varying process temperatures may generate inaccurate level
readings.

Operating pressuresUltrasonic devices are not intended for extreme pressure limits;
maximum working pressures should not exceed 30 psig.

Figure 1. Ultrasonic transmitter

mounted on top of tank

Environmental conditionsVapor, condensing humidity,

and other contaminants can change the speed of sound
through air and greatly affect the accuracy of the return
signal. As a result, ultrasonic devices should be mounted
in a predictable environment.

The most popular benefit of through-air measurement

technologies such as ultrasound, radar, and laser measurement is
that the measuring device never comes in contact with the
product being measured (Figure 1), although at some point the
measuring signal must come in contact with the liquid surface
before it begins its return trip back to the sensor. This explains
why the air quality between the sensor and liquid surface can be
problematic and why the quality of the liquid surface needs to be
accounted for. Every disturbance the signal picks up on its way
to the liquid surface and back will affect the level measurement
information in the signal.
Ultrasonic transmitters provide a sensible level measurement
solution when properly applied. Remember, an ultrasonic
transmitter is only as good as the echo it receives.
Guided-Wave Radar (GWR)
Guided-wave radar (GWR) is a contacting level measurement
method that uses a probe to guide high-frequency
electromagnetic waves from a transmitter to the media being
measured (Figure 2).

Figure 2. GWR technology measuring liquid

level in process vessel

GWR is based on the principle of time domain reflectometry (TDR). With TDR, a low-energy
electromagnetic pulse is guided along a probe. When the pulse reaches the surface of the medium
being measured, the pulse energy is reflected up the probe to circuitry that then calculates the
fluid level based on the time difference between the pulse being sent and the reflected pulse
received. The sensor can output the analyzed level as a continuous measurement reading via an
analog output, or it can convert the values into freely positionable switching output signals.
Unlike older technologies, GWR offers measurement readings that are independent of the
chemical or physical properties of the process media with which it is in contact. Additionally,
GWR performs equally well in liquids and solids.
GWR is suitable for a variety of level measurement applications including those that involve:

Unstable process conditionsChanges in viscosity, density, or acidity do not affect

accuracy.

Agitated surfacesBoiling surfaces, dust, foam, and vapor do not affect device
performance. GWR also works with recirculating fluids, propeller mixers, and aeration
tanks.

High temperatures and pressuresGWR performs well in temperatures up to 315C and

can withstand pressures up to 580 psig.

Fine powders and sticky fluidsGWR works with vacuum tanks filled with used
cooking oil as well as tanks holding paint, latex, animal fat, soybean oil, sawdust, carbon
black, titanium tetrachloride, salt, and grain.

One of the most common misconceptions about GWR is how product build-up on the probe
affects the level measurements. One would think that if you have a mass of product stuck to the
probe, or a coating of product over the probe's entire length, that the signal would misidentify the
true liquid surface (Figure 3). This is not the case. The GWR radar signal has a very large
detection area360 and extending out several feetaround the probe. When the
electromagnetic pulse comes in to contact with a mass of product on the probe, the signal is
returned and analyzed to see whether it reflects the true liquid level (Figure 4). Because the true
liquid level always has a larger return signal than the return signal generated from the smaller
mass sticking to the probe, the sensor can easily identify the liquid surface. Algorithms
developed over the last decade have made this contacting form of level measurement an
excellent choice for even the stickiest of fluid-level applications.

Figure 3. Sticky product covered over a 2 in. length of 1/4 in. o.d. rod probe

Figure 4. Sound energy pulse advances outward from the probe surface

Comparison Points
The chart in Figure 5 compares some important comparison points between ultrasonic and GWR
transmitters:
Figure 5. A comparison between ultrasonic and GWR transmitters

Ultrasonic transmitters

Guided-wave radar transmitters

Measurement Principle

Sound waves

High-frequency radar impulses

Contact Type

Noncontact measurement

Contact measurement
Operating Limits

Limited operating pressures and temperatures

High temperatures and pressures do not affect

device performance

Mounting
Top-mounted

Top-mounted
Environmental and Application Conditions

Conditions affect measurement performance

Not affected by environmental and application

conditions

Overall Performance
Acceptable
Performance is based on strength of the
reflected sound wave or echo

Exceptional
Performs well independent of process
conditions