Point/ Liquid Level Switch Measurement and Detection

Systems
Point level measurement sensors are used for the purpose of marking a single liquid
height or for presetting a level condition. Usually, this sensor works as a high alarm that
measures the overflow conditions in tanks through liquid level sensors, or works as a
marker to note down the low alarm conditions. Point level sensors only indicate whether
the substances is above or below the sensing point. The different types of sensors are
given below:

Float Sensor
Capacitance Sensors
Conductivity Probes

1. Level Detection and Measurement by Using a Float Sensor

Level Detection Using a Float Sensor

Float sensors are so called because of its main system that appears to float in
the body of certain liquid substance.

Principle of Operation: A liquid level control system by using a float sensor works on
the principle of buoyancy, which states, A float immersed in a liquid is buoyed
towards upward direction by an applied equal force to the weight of the displaced
liquid. As a result, the body drives partially and gets submerged upon the liquid surface
and covers the same distance the liquid level moves.

Construction: A level measurement float system consists of a oat, a sensor stem, a

magnet, a reed switch and a weight suspended on the outside of the open tank. A
scale is fixed on the outside of the tank, and the contents of the tanks level are
indicated by the position of the weight along the scale.
Working: Level detection of liquids is often
done with a oat-type liquid level switch. The
oat transfers on a mechanical arm or sliding
pole and activates a switch when the level moves
towards upward direction. Sometimes the oat
itself contains a small magnet that varies the
state of a switch when the liquid level gets
moving up and moves into the original position.
This type of level sensor comes with many
advantages like it is very simple, highly accurate,
and best suitable for various products. The weighted float principle remains one of the
most direct, reliable and economical means of sensing liquid interfaces like chemical
emulsions, slurries and other layered liquids.

The disadvantages of this sensor are that it requires various mechanical equipment,
especially the pressure vessels.

Primary Areas of Float Sensor Application: In view of the requirements pertaining to

the increase in usage of sealed tanks, the current industrial systems make use of this
type of oat method for precise reading and accuracy, which is a good example of
electronics and mechanical engineering, making it the most accurate level-measuring
system for various applications in very large storage tanks.

2. Level Detection and Measurement by Using Capacitance

Sensor

Level Detection Using Capacitance Sensor

 Capacitance level sensors are made available for wide range of solids, aqueous,
organic liquids and slurries. This technique is frequently stated as the radio-frequency
signals applied to a capacitance circuit. The capacitive sensors are designed to sense
material with dielectric constants as low as 1.1 for coke and fly ash, and as high as 88 for
water or other liquids.

Principle of operation: The principle of capacitive level measurement is based on the

change of capacitance. There are two plates in capacitive sensor: one plate acts as an
insulated electrode and the other plate acts as a tank wall. The capacitance depends on
the liquid level. An empty tank has low capacitance while a filled tank has higher
capacitance. A simple capacitor consists of two electrode plates separated by a small
thickness of an insulator such as solid, fluid, gas, or vacuum.

The Value of C depends on dielectric constant used, area of the plate and also on the
distance between the plates.

C=E(KA/d)

Where: C = Capacitance in Pico farads (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 by using an AC Bridge.

Construction and Working: The

measurement of liquid level is done by
applying a Radio Frequency signal
between the conductive probe and the
vessel wall. The Radio Frequency
signal results in a very-low current
which flows through the dielectric
process material in the tank from the
probe to the vessel wall. If the liquid
level in the tank drops, then the
dielectric constant decreases, which
leads to the drop in capacitance
reading as well as minute drop in
current flow.

This change can be detected by the liquid-level switchs internal circuitry and translated
into relay state changes of the level switch in case of a point level detection.

The main advantages of these capacitance systems include easy installation, broad
application range, good accuracy suitable for variety of applications and highly
recognized and well -proven technology.
The disadvantages include sensitivity to changes in the measurable properties such as
dielectric constant and conductivity which creates an issue; furthermore, it is an intrusive
system.

Primary Areas of Capacitance Sensor Application: Capacitance level sensor probes

are used for measuring the levels of:

Fluids
Liquid metals at very-high temperature range
Dissolved gases at very-low level of temperature
Very-high density industrial processes.

3. Level Detection by Using Conductivity Probes

Level Detection by Using Conductivity Probes

Principle of operation: The principle used in this system states that the presence of a
product will make a change in the resistance between the two conductors.

Construction and Working: This system is applicable for level measurement in

conductive liquids. The conductivity of the insulated material can be varied if the probe
is covered or not covered within the conductive product. There are two electrodes: one
is used as a metal wall of the tank, and the other electrode is inserted into the tank. This
principle can be explained with a practical application.

A Conductive probe is used as a liquid level indicator for measuring the level of
electrically conductive products in a metal water tank, or other container, which can be
obtained by means of a probe isolated from the container and a conductivity amplier.
When the product is not in connection with the probe, the electrical resistance is
relatively high or infinite between the probe and the metal tank wall. If the level of the
liquid rises completely between the probe and the tank wall, then the resistance
gradually decreases.

This method is advantageous as it is very simple, low cost and well suited for dual or
multiple point control.

The method is disadvantageous as the probe must not get contaminated with grease
or any other deposits and has limited suitability for products of varying conductivity.

As a practical example of this detection here we have shown figure of intelligent

overhead tank water level indicator with block diagram which uses conducting probes
for detecting the water in tank. This system is built by using priority encoder, BCD-seven
segment decoder, seven segment display and other miscellaneous components.

Intelligent Overhead Tank Water Level Indicator

The probes are connected to +5V and the return or ground terminal is kept at the
bottom of the tank. Nine active-low inputs of priority encoder are converted to active-
low BCD output by internal circuitry and then the water level is indicated in seven
segment display interms of percentage of water. As the water level is increases probes
get shorted and correspondingly priority encoder gives BCD values and later the
information is displayed on seven segment display through BCD to seven segment
decoder IC.