EMT 4103 SENSORS AND

TRANSDUCERS ON 15TH JULY 2020

LESSON 9
Continuation on level sensors and
transducers
 Course expectation
At the end of the lesson, understand:
•impedance probes
•Magnetic and Pneumatic Visual Level indicators.
•Bubbler System.
•Radiation
•Hydrostatic (Pressure) Transmitters
•Diaphragm.
•Sight glass level indicator
•etc
 Impedance type Level switch
• The detecting electrode will be inserted from
the top or side of a tank or hopper and then
installed inside the tank or hopper.
• When a liquid or powdery material comes in
contact with the electrode, the electrode will
detect the impedance (reciprocal of
admittance) change
 Impedance type Level switch
• between the air and object under
measurement, or between the specific object
under measurement and other object under
measurement to effect switching operation
for turning on-off the relay,
• so that the level of the liquid or powdery
material in the tank or hopper is maintained
in a given position.
 Impedance type Level switch
• Impedance type level switch is also available
with the systems of compensating the
erroneous signal transmission from the
adhering to and accumulating on the surface
of electrode
• by means of a third protection (guard)
electrode for compensation provided
between the main detecting electrode and
the grounding electrode.
 Impedance type Level switch
• Even if the distance between the detector
unit and transducer is extended, an extremely
high stability of detection is practically
obtainable by the adoption of high-grade
circuit configuration and a special cable.
• In addition, the detector unit is composed of
only metal and insulating material without
using any electrical parts,
 Impedance type Level switch
• so that the Model is usable in an extremely
wide range of temperature and pressure.
• This level switch can also be used under
radiation.
 Guard type level switch
• Signals output by common probes are
proportional to the thickness of the adhering
substance and its relative permittivity.
• In contrast, the guard type probe keeps itself
from outputting a signal until the thickness of
the adhering substance reaches a preset value.
This feature does not affect relative permittivity.
• The permissible thickness of the adhering
substance can be varied according to probe
dimension.
 Sight glass level indicator
• Put simply, a sight glass is a transparent glass
tube or window installed in a tank or boiler
system that allows an observer to view what
is happening inside the container, ensuring
optimal quality and safety.
• Sight glasses can also serve a number of
functions aside from basic viewing, but this is
the most common use.
 Sight glass level indicator
• The principle of the reflex level indicator is
based on the reflection of light.
• In the gas or steam phase, the light is
reflected by the prismatic grooves of the sight
glass so that bright indication is achieved.
• In the liquid phase, the light is absorbed,
resulting in a dark indication of the level.
Basics of Sight Glass Level Gauge
 Sight glass level indicator
• The level gauge, or sightglass is to liquid level
measurement as manometers are to pressure
measurement:
• a very simple and effective technology for
direct visual indication of process level.
• In its simplest form, a level gauge is nothing
more than a clear tube through which process
liquid may be seen.
 Magnetic level indicators
• A magnetic level indicator is an externally
mounted chamber with visual indicators that
are completely isolated from the process
liquid.
Babbitt Magnetic Level Indicators
• Babbitt Magnetic Level Indicators are a safe,
simple and reliable way to measure fluid level
inside a tank.
• These visual indicators are an alternative to sight
glasses and provide a non-invasive, low
maintenance, cost-effective level solution.
• They are especially safe for flammable, toxic,
corrosive liquids because the fluid never
contacts the indicating glass.
• Should the glass ever break, there is no
possibility of leakage.
Babbitt Magnetic Level Indicators
• Babbitt Magnetic Level Indicators, also
referred to as Level Gauges, consist of
1.a chamber,
2.a magnetic float and
3.a flipper type indicator scale mounted to the
side of the chamber.
Babbitt Magnetic Level Indicators
• Understanding the operation of the Magnetic
Level Indicator is quite simple.
• The fluid in the tank seeks its own level
inside the chamber.
• The magnetic float in the chamber rises and
falls with the fluid level.
Babbitt Magnetic Level Indicators
• As the Magnetic float rises and falls, it
changes the orientation of the flippers on the
scale providing a visual level indication.
• In addition, as the magnetic float rises and
falls, it actuates any transmitter or alarm
switches that are attached to the side of the
gauge.
Babbitt Magnetic Level Indicators
• The float construction is determined by the
process fluid, pressure, temperature and
specific gravity of the fluid.
• Magnetic Level Indicators are generally made
of 316SS, but can be made from a variety of
other materials including CPVC, Kynar,
Hastelloy, Monel or other exotic metals.
• A variety of mounting style options and
process connections are available to meet
your needs.
Bubbler system for level measurement
• A complete bubbler level measurement
system consists of a source of compressed air,
an air flow restrictor, sensing tube, and
pressure transmitter.
• Since the point of measurement has no
electrical components, the technique is a
good choice for most fluids and especially
good for fluids classified as hazardous.
Bubbler system for level measurement
 Bubbler system for level
measurement
• Let X equal the vertical distance between the
minimum and maximum measurable levels (100 in.).
• Let SG equal the specific gravity of the fluid (1.1).
• Let h equal the maximum head pressure to be
measured in inches of water.
• Let Range equal zero to h.
• Then
• h = (X)(SG)
= 100 x 1.1
= 110 in H2O
• Range = 0 to 110 in H2O
Bubbler system for level measurement
 Bubbler system for level
measurement
• The level bubbler functions by forcing a gas
(compressed air) at a near constant flow rate
out the bottom of an open tube (dip tube)
submerged in liquid.
• The back pressure in this tube is measured.
• With the liquid's density known, the level can
be calculated using the back pressure and
density.
 Merits of bubbler Tube system
• Relatively simple equipment setup.
• Intrinsically safe.
• Can be used for high temp applications.
• Suitable for use with corrosive fluids.
 Demerits of bubbler Tube system
• Requires compressed air and installation of air
lines.
• High level of mechanical wear necessitating
constant maintenance.
• Build up of materials on bubble tube not
permissible but does occur.
Radiation level measurement
techniques
Radiation level measurement techniques
Radiation level measurement techniques
 Radiation/nuclear level sensor
• The radiation/nuclear level measurement
technique is used to measure the level of fluid
or solid in a closed tank using Gamma rays. 
• Gamma radiation sources are chosen for use
in level detecting equipment because gamma
rays have great penetrating power and
cannot be deflected.
 Radiation/nuclear level sensor
• Level measurement with radiation works on
the principle of passing gamma radiation
through the material to be measured.
• As the radiation passes through this material,
the level can be determined by the amount of
attenuation.
• The wave attenuates when it passes through
materials.
 Radiation/nuclear level sensor
• The Gamma-ray is emitted from a source to the
tank and propagates through the tank.
• There is a continuous strip detector that detects
all the Gamma rays pass across the tank.
• If the continuous strip detects rays equal to the
length and it is in maximum absorption, the tank
is empty.
• As the level rises the absorption level decreases.
 Continuous level
measurement/full absorption
• In this measurement principle, the radiation is
fully absorbed. The radiation difference
between the source and the detector varies
given the image of the level.
• The radiation activity is calculated from the
pulse rate received.
• Typically the pulse rate (radiation level) at
100% level is zero, meaning the gamma rays
are completely absorbed by the medium (full
absorption).
 Continuous level
measurement/full absorption
• For example, at 50% of the full range level,
only the upper part of the detector receives
the radiation.
• Consequently the pulse rate increases.
 The source:
• The main component of this type of measuring
device is the radioactive source.
• The two common types of radioactive sources are
Caesium 137 (Cs 137) and Cobalt 60 (Co 60). 
• The activity of the radioactive substance
decreases with time. The time taken for the
activity of such a substance to halve is termed its
half-life.
• Cobalt 60 has a half-life of 5.3 years while
Caesium 137 has a half-life of 32 years.
 The Strip Detector:
• The detector for continuous measurement is a
type of scintillation counter and
photomultiplier.
• This type of sensing has the advantage of the
high sensitivity of the scintillation crystals
(compared to Geiger counters) coupled with
the safety and economy of a point source.
 Advantages:
• Suitable for a variety of products
• Mounted without obstruction
• Can be mounted external to the vessel
 Disadvantages:

• Must always be mounted on the side of the

vessel
• Special safety measures are required for the
use of gamma radiation
• May also involve licensing requirements
• Expensive
 Hydrostatic pressure transmitter
level
• Hydrostatic pressure sensors are used for the
measurement of level or filling height of a liquid.
• Hydrostatic pressure measurement is suited for
level measurement due to the hydrostatic effect
of non-flowing fluids.
• This physical principle describes the effect of the
weight force of a stationary, meaning non-flowing,
liquid on a measuring point. This weight force is
usually described as “hydrostatic pressure’’.
 Hydrostatic level sensors
• Hydrostatic level sensors are using the
principle of hydrostatic pressure in a liquid
column to measure the height of the level in a
tank.
• These sensors are actually pressure sensors
that measure the hydrostatic pressure at a
certain depth in the liquid, and then use the
formula Phydro = ρgh to calculate the filling
height (h) of the tank.
 Hydrostatic level sensors
• Hydrostatic level transmitters are used for level
measurement in open or vented vessels where
the gas phase on top of the liquid is at ambient
pressure, and for sealed or gas-tight vessels
where the pressure above the liquid is variable.
• The sensors are equipped with a relative
pressure measuring cell of which one side is
exposed to the hydrostatic pressure and the
other side is connected to:
 Hydrostatic level sensors
1. the ambient pressure, in the case of open
vessels,
2. the variable pressure on top of the liquid, in
the case of sealed vessels.
• In this way, the pressure acting on the liquid
surface is automatically compensated.
 Displacer level transmitter
principle
• A displacer level transmitter is intended for
liquid applications.
• The displacer rod is immersed in the liquid
and hanging on a spring or a torque tube.
• It always has a higher density than the liquid,
so it doesn’t float.
• When the vessel is completely filled and thus
the displacer rod is fully immersed, there will
still be a downward force on the spring.
 Displacer level transmitter
principle
• The operation of a displacer level transmitter
is based on the Archimedes' principle that
• states that the upward buoyant force that is
exerted on a body immersed in a fluid,
• whether fully or partially submerged, is equal
to the weight of the displaced fluid.
• In this case, the buoyant force is acting on the
displacer rod, pushing it upwards.
 Displacer level transmitter
principle
• When the liquid level rises, the buoyant force
will increase, reducing the apparent weight
of the displacer rod.
• This reduces the length of the spring while
the displacer moves upwards.
• The up and down movement of the displacer
rod is measured by sensors in the head of the
transmitter and converted into an output
signal.
Displacer level transmitter principle
 Servo level transmitter principle

• A small displacer hangs on a cable that is

rolled up on a wire drum.
• The wire drum is magnetically coupled with a
weight balance and is driven by a bidirectional
servo motor.
• When the displacer is lowered into the vessel
and reaches the liquid surface, its apparent
weight will decrease under the influence of
the buoyant force.
 Servo level transmitter principle
• The weight loss is detected by the weighing
balance which then sends a signal to the
control unit to stop the servo motor.
• The length of the unwound cable is calculated
by counting the number of revolutions of the
wire drum by means of a set of Hall effect
sensors and multiplying it by the known
circumference of the drum.
 Servo level transmitter principle
• Subtracting the result of this calculation from the
total height of the vessel gives the height of the
liquid in the tank.
• When the level changes, the weighing balance
will reposition the displacer until a new
equilibrium is reached.
• The servo level gauge is based on the Archimedes’
principle as it uses the buoyant force during the
measurement, and can therefore only be used for
liquid level measurements.
Servo level transmitter principle
Weight and cable level transmitter
principle
• The operation of electromechanical level
transmitters, as they are sometimes called, is
very similar to servo level transmitters.
• The difference is mainly in the control of the
probe and the internally used sensors.
• Although the technique is used primarily for
solids, also liquid level can be measured by
replacing the weight with a floating probe.
 Magnetostrictive principle
• A magnetostrictive level sensor consists of a
float that slides along a vertical ferromagnetic
rod (also called the waveguide) during the rise
and fall of the level.
• A permanent magnet is located inside the
float at a precise location which corresponds
to the level of the liquid.
• If the exact position of this magnet could be
measured, then the level of the liquid could
be calculated.
 Magnetostrictive principle
• At the start of the measurement, the
transmitter sends a short current pulse down
the waveguide and starts a timer from the
moment the pulse leaves the transmitter.
• As the current pulse is flowing through the
waveguide, it creates a small circular
magnetic field around the rod.
• When the pulse arrives at the float, its
circular magnetic field will intersect with the
magnetic field of the permanent magnet.
 Magnetostrictive principle
• The interaction between the two magnetic
fields causes a mechanical torsional force in
the waveguide, as if the rod is locally twisted.
• This torsional force is propagated along the
waveguide as an acoustic torsional wave and
flows back to the transmitter with a constant
speed close to the speed of sound.
 Magnetostrictive principle
• At the top of the waveguide, a pick-up coil or
a piezo crystal will detect the torsional wave
and convert it into a corresponding electrical
signal.
• At the same time, the timer is stopped and
the time delay from the excitation of the
waveguide to the reception of the
corresponding acoustic wave is calculated.
 Magnetostrictive principle
• From this time delay, knowing that the
acoustic wave travelled at a constant speed,
we can now calculate the position of the float.
• The system for the time interval measurement
is similar to the time of flight principle in
ultrasonic level sensors.
Magnetostrictive principle
 Laser level sensors
• Distance measurement using lasers is done with
one of the following techniques:
1.Pulsed lasers
2.Frequency modulated continuous wave lasers
3.Triangulation lasers
• Although it is perfectly possible to measure level
with all three techniques, only pulsed lasers are
used for industrial applications.
 Laser level sensors
• This is because they are better suited to
penetrate dust and steam.
• Continuous wave and triangulation lasers are
more into short-range measurements,
• whereby continuous wave lasers are used in
highly accurate laboratory equipment and
• triangulation lasers are used in positioning
applications and robotics.
 Laser level sensors
• The principle of a pulsed laser level
transmitter is again based on the time-of-
flight technique.
• The laser diode sends out a light pulse with a
very sharp beam angle of less than 0,3°.
• The reflection that comes off the surface of
the process medium is captured by the
receiver.
 Laser level sensors
• A very precise timing circuit measures the time
delay between the transmitted and received
pulse and sends the result to the
microprocessor which calculates the distance
to the surface using the formula:
• Distance =(speed of light * time of flight)/2
• Once this distance is known, the level can be
found by making the difference between the
height of the tank and the distance to the
surface.
Laser level sensors
 Load cell principle
• A load cell is a force transducer for measuring
weight. Its output signal is proportional to the
weight being measured.
• Tanks and silos can be mounted on one or
multiple load cells so that their entire weight
can be measured.
• There are mainly 3 different technologies as:
1. Hydraulic
2. Pneumatic
3. Electronic
 Load cell principle
• In order to determine the level, the weighing
system must first be tared with an empty
tank so that only the net content of the tank is
measured.
• The filling level is then determined by
evaluating the measurement data.
• The conversion to fill level can only take place
if the density of the product is constant.
 Load cell principle
• The calculation uses a strapping table in which
weight and level are paired in steps.
• When the measured weight is between two
steps, the level is determined by
interpolation.
Load cell principle