Process Instrumentation - Level
Process Instrumentation - Level
Module 3
Level Detectors
Level Detectors TABLE OF CONTENTS
TABLE OF CONTENTS
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
LEVEL DETECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gauge Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ball Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chain Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Magnetic Bond Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Conductivity Probe Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Differential Pressure Level Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DENSITY COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Specific Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reference Leg Temperature Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressurizer Level Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steam Generator Level Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remote Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environmental Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LIST OF FIGURES
LIST OF TABLES
NONE
REFERENCES
Kirk, Franklin W. and Rimboi, Nicholas R., Instrumentation, Third Edition, American
Technical Publishers, ISBN 0-8269-3422-6.
Academic Program for Nuclear Power Plant Personnel, Volume IV, General Physics
Corporation, Library of Congress Card #A 397747, April 1982.
Fozard, B., Instrumentation and Control of Nuclear Reactors, ILIFFE Books Ltd., London.
Rhodes, T.J. and Carroll, G.C., Industrial Instruments for Measurement and Control,
Second Edition, McGraw-Hill Book Company.
TERMINAL OBJECTIVE
1.0 Given a level instrument, RELATE the associated fundamental principles, including
possible failure modes, to that instrument.
ENABLING OBJECTIVES
1.1 IDENTIFY the principle of operation of the following types of level instrumentation:
a. Gauge glass
b. Ball float
c. Chain float
d. Magnetic bond
e. Conductivity probe
f. Differential pressure (∆P)
1.2 EXPLAIN the process of density compensation in level detection systems to include:
a. Why needed
b. How accomplished
1.3 STATE the three reasons for using remote level indicators.
1.4 Given a basic block diagram of a differential pressure detector-type level instrument,
STATE the purpose of the following blocks:
a. Differential pressure (D/P) transmitter
b. Amplifier
c. Indication
1.5 STATE the three environmental concerns which can affect the accuracy and reliability
of level detection instrumentation.
LEVEL DETECTORS
Liquid level measuring devices are classified into two groups: (a) direct method,
and (b) inferred method. An example of the direct method is the dipstick in your
car which measures the height of the oil in the oil pan. An example of the
inferred method is a pressure gauge at the bottom of a tank which measures the
hydrostatic head pressure from the height of the liquid.
Gauge Glass
A very simple means by which liquid level is measured in a vessel is by the gauge glass method
(Figure 1). In the gauge glass method, a transparent tube is attached to the bottom and top (top
connection not needed in a tank open to atmosphere) of the tank that is monitored. The height
of the liquid in the tube will be equal to the height of water in the tank.
Figure 1 (a) shows a gauge glass which is used for vessels where the liquid is at ambient
temperature and pressure conditions. Figure 1 (b) shows a gauge glass which is used for vessels
where the liquid is at an elevated pressure or a partial vacuum. Notice that the gauge glasses in
Figure 1 effectively form a "U" tube manometer where the liquid seeks its own level due to the
pressure of the liquid in the vessel.
Gauge glasses made from tubular glass or plastic are used for service up to 450 psig and 400°F.
If it is desired to measure the level of a vessel at higher temperatures and pressures, a different
type of gauge glass is used. The type of gauge glass utilized in this instance has a body made
of metal with a heavy glass or quartz section for visual observation of the liquid level. The glass
section is usually flat to provide strength and safety. Figure 2 illustrates a typical transparent
gauge glass.
Another type of gauge glass is the reflex gauge glass (Figure 3). In this type, one side of the
glass section is prism-shaped. The glass is molded such that one side has 90-degree angles which
run lengthwise. Light rays strike the outer surface of the glass at a 90-degree angle. The light
rays travel through the glass striking the inner side of the glass at a 45-degree angle. The
presence or absence of liquid in the chamber determines if the light rays are refracted into the
chamber or reflected back to the outer surface of the glass.
When the liquid is at an intermediate level in the gauge glass, the light rays encounter an
air-glass interface in one portion of the chamber and a water-glass interface in the other portion
of the chamber. Where an air-glass interface exists, the light rays are reflected back to the outer
surface of the glass since the critical angle for light to pass from air to glass is 42 degrees. This
causes the gauge glass to appear silvery-white. In the portion of the chamber with the
water-glass interface, the light is refracted into the chamber by the prisms. Reflection of the light
back to the outer surface of the gauge glass does not occur because the critical angle for light
to pass from glass to water is 62-degrees. This results in the glass appearing black, since it is
possible to see through the water to the walls of the chamber which are painted black.
A third type of gauge glass is the refraction type (Figure 4). This type is especially useful in
areas of reduced lighting; lights are usually attached to the gauge glass. Operation is based on
the principle that the bending of light, or refraction, will be different as light passes through
various media. Light is bent, or refracted, to a greater extent in water than in steam. For the
portion of the chamber that contains steam, the light rays travel relatively straight, and the red
lens is illuminated. For the portion of the chamber that contains water, the light rays are bent,
causing the green lens to be illuminated. The portion of the gauge containing water appears
green; the portion of the gauge from that level upward appears red.
Ball Float
The ball float method is a direct reading liquid level mechanism. The most practical design for
the float is a hollow metal ball or sphere. However, there are no restrictions to the size, shape,
or material used. The design consists of a ball float attached to a rod, which in turn is connected
to a rotating shaft which indicates level on a calibrated scale (Figure 5). The operation of the
ball float is simple. The ball floats on top of the liquid in the tank. If the liquid level changes,
the float will follow and change the position of the pointer attached to the rotating shaft.
The travel of the ball float is limited by its design to be within ±30 degrees from the horizontal
plane which results in optimum response and performance. The actual level range is determined
by the length of the connecting arm.
The stuffing box is incorporated to form a water-tight seal around the shaft to prevent leakage
from the vessel.
Chain Float
The differential pressure (∆P) detector method of liquid level measurement uses a ∆P detector
connected to the bottom of the tank being monitored. The higher pressure, caused by the fluid
in the tank, is compared to a lower reference pressure (usually atmospheric). This comparison
takes place in the ∆P detector. Figure 9 illustrates a typical differential pressure detector attached
to an open tank.
The tank is open to the atmosphere; therefore, it is necessary to use only the high pressure (HP)
connection on the ∆P transmitter. The low pressure (LP) side is vented to the atmosphere;
therefore, the pressure differential is the hydrostatic head, or weight, of the liquid in the tank.
The maximum level that can be measured by the ∆P transmitter is determined by the maximum
height of liquid above the transmitter. The minimum level that can be measured is determined
by the point where the transmitter is connected to the tank.
Not all tanks or vessels are open to the atmosphere. Many are totally enclosed to prevent vapors
or steam from escaping, or to allow pressurizing the contents of the tank. When measuring the
level in a tank that is pressurized, or the level that can become pressurized by vapor pressure
from the liquid, both the high pressure and low pressure sides of the ∆P transmitter must be
connected (Figure 10).
The high pressure connection is connected to the tank at or below the lower range value to be
measured. The low pressure side is connected to a "reference leg" that is connected at or above
the upper range value to be measured. The reference leg is pressurized by the gas or vapor
pressure, but no liquid is permitted to remain in the reference leg. The reference leg must be
maintained dry so that there is no liquid head pressure on the low pressure side of the transmitter.
The high pressure side is exposed to the hydrostatic head of the liquid plus the gas or vapor
pressure exerted on the liquid’s surface. The gas or vapor pressure is equally applied to the low
and high pressure sides. Therefore, the output of the ∆P transmitter is directly proportional to
the hydrostatic head pressure, that is, the level in the tank.
Where the tank contains a condensible fluid, such as steam, a slightly different arrangement is
used. In applications with condensible fluids, condensation is greatly increased in the reference
leg. To compensate for this effect, the reference leg is filled with the same fluid as the tank.
The liquid in the reference leg applies a hydrostatic head to the high pressure side of the
transmitter, and the value of this level is constant as long as the reference leg is maintained full.
If this pressure remains constant, any change in ∆P is due to a change on the low pressure side
of the transmitter (Figure 11).
The filled reference leg applies a hydrostatic pressure to the high pressure side of the transmitter,
which is equal to the maximum level to be measured. The ∆P transmitter is exposed to equal
pressure on the high and low pressure sides when the liquid level is at its maximum; therefore,
the differential pressure is zero. As the tank level goes down, the pressure applied to the low
pressure side goes down also, and the differential pressure increases. As a result, the differential
pressure and the transmitter output are inversely proportional to the tank level.
Summary
The different types of level instruments presented in this chapter are summarized below.
In the gauge glass method, a transparent tube is attached to the bottom and top
(top connection not needed in a tank open to atmosphere) of the tank that is
monitored. The height of the liquid in the tube will be equal to the height of
water in the tank.
The operation of the ball float is simple. The ball floats on top of the liquid in
the tank. If the liquid level changes, the float will follow and change the
position of the pointer attached to the rotating shaft.
The operation of the chain float is similar to the ball float except in its method
of positioning the pointer and its connection to the position indication. The float
is connected to a rotating element by a chain with a weight attached to the other
end to provide a means of keeping the chain taut during changes in level.
The magnetic bond mechanism consists of a magnetic float that rises and falls
with changes in level. The float travels outside of a non-magnetic tube which
houses an inner magnet connected to a level indicator. When the float rises and
falls, the outer magnet will attract the inner magnet, causing the inner magnet to
follow the level within the vessel.
DENSITY COMPENSATION
If a vapor with a significant density exists above the liquid, the hydrostatic
pressure added needs to be considered if accurate transmitter output is required.
Specific Volume
Before examining an example which shows the effects of density, the unit "specific volume" must
be defined. Specific volume is defined as volume per unit mass as shown in Equation 3-1.
1
Specific Volume (3-2)
density
Specific volume is the standard unit used when working with vapors and steam that have low
values of density.
For the applications that involve water and steam, specific volume can be found using "Saturated
Steam Tables," which list the specific volumes for water and saturated steam at different
pressures and temperatures.
The density of steam (or vapor) above the liquid level will have an effect on the weight of the
steam or vapor bubble and the hydrostatic head pressure. As the density of the steam or vapor
increases, the weight increases and causes an increase in hydrostatic head even though the actual
level of the tank has not changed. The larger the steam bubble, the greater the change in
hydrostatic head pressure.
A condensing pot at the top of the reference leg is incorporated to condense the steam and
maintain the reference leg filled. As previously stated, the effect of the steam vapor pressure is
cancelled at the ∆P transmitter due to the fact that this pressure is equally applied to both the low
and high pressure sides of the transmitter. The differential pressure to the transmitter is due only
to hydrostatic head pressure, as stated in Equation 3-3.
Summary
If a vapor with a significant density exists above the liquid, the hydrostatic
pressure that it will add may need to be considered if accurate transmitter output
is required.
- Electronic circuitry
- Pressure detector input
- Instrument calibration
Remote Indication
Level measurements may be taken at locations far from the main facility
The level to be controlled may be a long distance from the point of control
The level being measured may be in an unsafe/radioactive area.
location. Using relays, this system provides alarms on high and low level. It may also provide
control functions such as repositioning a valve and protective features such as tripping a pump.
Environmental Concerns
Density of the fluid whose level is to be measured can have a large effect on level detection
instrumentation. It primarily affects level sensing instruments which utilize a wet reference leg.
In these instruments, it is possible for the reference leg temperature to be different from the
temperature of the fluid whose level is to be measured. An example of this is the level detection
instrumentation for a boiler steam drum. The water in the reference leg is at a lower temperature
than the water in the steam drum. Therefore, it is more dense, and must be compensated for to
ensure the indicated steam drum level is accurately indicated.
Ambient temperature variations will affect the accuracy and reliability of level detection
instrumentation. Variations in ambient temperature can directly affect the resistance of
components in the instrumentation circuitry, and, therefore, affect the calibration of
electric/electronic equipment. The effects of temperature variations are reduced by the design
of the circuitry and by maintaining the level detection instrumentation in the proper environment.
The presence of humidity will also affect most electrical equipment, especially electronic
equipment. High humidity causes moisture to collect on the equipment. This moisture can cause
short circuits, grounds, and corrosion, which, in turn, may damage components. The effects due
to humidity are controlled by maintaining the equipment in the proper environment.
Summary
The density of the fluid, ambient temperature changes, and humidity are three factors which can
affect the accuracy and reliability of level detection instrumentation. Level detection circuit
operation is summarized below.
There are three major reasons for utilizing remote level indication:
- Level measurements may be taken at locations far from the main facility.