LEVEL SENSOR

LEVEL SENSOR
• Level sensors detect the level of liquids and other
fluids and fluidized solids, including slurries, granular
materials, and powders that exhibit an upper free
surface. The substance to be measured can be inside
a container or can be in its natural form. The level
measurement can be either continuous or point
values.
 CLASSIFICATIONS OF LEVEL SENSOR
• Point level measurement - Point level
measurement indicates when a product is present
at a certain point.
• Continuous level measurement - measure level
within a specified range and determine the exact
amount of substance in a certain place
Point level measurement
 Capacitance Level Sensor
• Capacitance Level Sensor - capacitance level sensor is a
proximity sensor that gives off an electrical field and detects
a level by the effect on its electrical field. These sensors are
small, less expensive, than other sensors, invasive to the
product, accurate, have no moving parts. However, they
must be calibrated and will only detect certain liquids like a
water treatment facility that has storage tanks would be an
ideal use for a capacitance sensor.
Capacitance Level Sensor
 Optical Level Sensor
• Optical sensors work by converting light rays into electrical signals which
measure a physical quantity of light then translate it into a measurement.
– These sensors have no moving parts
– They are not affected by high pressure or temperature
– They are small in size
– They can be used in liquid applications
• However, if the lens gets coated or dirty they would require cleaning.
They can be used as low-level indicators to prevent run dry conditions
when using oil, coolant, or hydraulics.
Optical Level Sensor
 Conductivity (Resistance) Level Sensor
• A conductivity or resistance sensor uses a probe to read conductivity. The probe has a pair of
electrodes and applies alternating current to them. When a liquid covers the probe its electrodes
form a part on an electric circuit, causing current to flow which signals a high or low level.
• advantages
– There are no moving parts
– They are low cost
– Fairly easy to use
• disadvantages
– They are invasive (meaning they must touch the product being sensed)
– They only sense conductive liquids
– The probe will erode over time
• Appropriate use for these sensors would be for signaling high or low levels.
Conductivity (Resistance) Level Sensor
 Vibrating (Tuning Fork) Level Sensor
• They use a fork-shaped sensing element with two tines. The fork vibrates at its
natural resonant frequency. As the level changes, the frequency of the fork will
change detecting the level. These sensors are:
– Cost effective and compact
– Invasive to the product, meaning they have to touch the material to sense the
level
– Easy to install
– Essentially maintenance-free
• They have unlimited uses based on the material that they can sense. Mining, food
and beverage, and chemical processing industries use these sensors for their
applications.
Vibrating (Tuning Fork) Level Sensor
 Float Switch
• The last point level sensor that we will talk about is a float switch. Float switches use a float, a
device that will raise or lower when a product is applied or removed, which will open or close a
circuit as the level raises or lowers moving the float.
• advantages
– They are non powered device
– They provide a direct indication
– They are inexpensive
• disadvantages
– They are invasive to the product
– They have moving parts
– They can be large in size
• Float switches will only give an indication for a high or low level, they cannot measure a variable
level. A great use for float switches is in liquid storage tanks for high or low-level indication.
Float Switch
Continuous Level Measurement Sensors
 Ultrasonic Level Sensor
• Ultrasonic level sensors work by emitting and receiving ultrasonic waves. The time it takes for the
waves to reflect back is how distance is measured.
• advantage
– These sensors have no moving parts
– They are compact
– They are reliable
– Non-invasive (Non-contact)
– Unaffected by the properties of the material they are sensing
– Self-cleaning because of the vibrations they give off
• disadvantage
– They can be expensive
– In some situations, the environment can have a negative effect on them
• An example application is a hot asphalt tank in a shingle manufacturing plant. The ultrasonic sensor
would be placed in the top of the tank away from the hot asphalt and used to sense the level in order
to send a fill request for the tank.
Ultrasonic Level Sensor
 Radar Level Sensor
• Radar or microwave is also a continuous level sensor.
• These sensors transmit microwaves by an antenna on the radar sensor. The product that is being sensed
reflects these microwaves back to the antenna and the time from emission to reception of the signal is
proportional to the level of the product.
• advantages
– They are not affected by temperature, pressure or dust
– They can also measure liquids, pastes, powders, and solids
– They are very accurate and require no calibration
– They are non-invasive because they do not have to touch the product that it is sensing
• disadvantages
– They are expensive
– They have a limited detection range
• If we go back to our shingle manufacturing plant example a Radar level sensor could be an ideal solution.
Much like the ultrasonic sensor, radar sensors are ideal for hot liquid storage tanks.
Radar Level Sensor
Other Classification of level sensor
 Point and continuous level detection for solids

• Rotating paddle - Rotating paddle level sensors are a

very old and established technique for bulk solid point
level indication. The technique uses a low-speed gear
motor that rotates a paddle wheel.
• Admittance-type - An RF admittance level sensor uses a
rod probe and RF source to measure the change in
admittance.
 Point level detection of liquids
• Magnetic and mechanical float - The principle behind magnetic, mechanical, cable,
and other float level sensors often involves the opening or closing of a mechanical
switch, either through direct contact with the switch, or magnetic operation of a reed.
• Pneumatic - used where hazardous conditions exist, where there is no electric power
or its use is restricted. These sensors are suitable for use with highly viscous liquids
such as grease, as well as water-based and corrosive liquids.
• Conductive - Conductive level sensors are ideal for the point level detection of a wide
range of conductive liquids such as water, and is especially well suited for highly
corrosive liquids such as caustic soda, hydrochloric acid.
• State dependent frequency monitor - A microprocessor controlled frequency state
change detection method uses a low amplitude signal generated on multiple sensor
probes of differing lengths.
 Continuous level measurement of liquids
• Hydrostatic pressure - Hydrostatic pressure level sensors are
submersible or externally mounted pressure sensors suitable for
measuring the level of corrosive liquids in deep tanks or water in
reservoirs.
• Air bubbler - An air bubbler system uses a tube with an opening below
the surface of the liquid level. A fixed flow of air is passed through the
tube.
• Gamma ray - A nuclear level gauge or gamma ray gauge measures level
by the attenuation of gamma rays passing through a process vessel.
 Continuous level measurement of liquids
• Magnetostrictive - similar to float type sensors in that a permanent
magnet sealed inside a float travels up and down a stem in which a
magnetostrictive wire is sealed.
• Resistive chain - Resistive chain level sensors are similar to magnetic
float level sensors in that a permanent magnet sealed inside a float
moves up and down a stem in which closely spaced switches and
resistors are sealed.
• Magnetoresistive - Magnetoresistance float level sensors are similar to
float level sensors however a permanent magnet pair is sealed inside
the float arm pivot.