instrumentation , ultrasonic level meter

Main points that covered in the course :

1- We will present some types of level measurement instruments. 

There are two main categories: 

- Point level instruments, which produce digital signals and are used to detect a specific level (such as full or empty). 

- Continuous level instruments, which produce analog signals and measure the level across a range.

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2- Case study tutorial :

How to measure fluid level of open vessel using ultrasonic level (non contact sensor)

Open vessel : Tank level control system is widely used in automation , common application in industry .

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3- we have 4 points in open vessel application :

a. Features and conditions of the open vessel – understanding the design and environment of the tank. 

b. Mounting the ultrasonic sensor and installation conditions – where and how to properly install the sensor. 

c. Entering variables into the transmitter – this step is known as programming or commissioning.

d. how to  connect the sensor  &  the transmitter using terminal blocks and electrical wiring. Proper wiring ensures accurate signal transmission and safe operation.

main points of course :

1. physical quantities: know the physical quantities measured by the sensor.

2.physical theories : understand  the different types of sensors, the physical theories behind them, their operating principles, and how they function.

3. Application: Indicates where the instrument should be installed for example at  (a pipe , open channel ,lake ,river ,vessel ,tank , etc      )

4. Installation :  Describes the appropriate installation location for the instrument.

5. Configuration / programming : Edit the device parameters, such as maximum and minimum levels, tank shape, and nominal pipe size, inside diameter, wall thickness .

6. operation.

7. Commissioning:  involves installing the system, verifying its operation, performing necessary tests, and delivering the fully functional system to the client.

8. Tenders and bids: include the preparation of technical specifications, identification of product features and requirements, evaluation of different types of equipment, and selection of the most suitable solution."

9. integration with plc

10. Output control

11. Communication

Level sensors divided in to 2 classifications :

1.Point level measurement as level switch , level electrode , float switch :

give digital signal to plc.

Capacitive , optical , float , conductive.

Invasive to a product :they must touch the product.

2. Continuous level measurement as level meter , :

Give certain level measurement such as 5 m , 45 ft , 22 inches.

Non-contact sensor / non-invasive : don’t touch the product.

Continuous level transmitters can be installed for the following applications:

Flumes or weirs.

Ponds/ rivers/lakes.

Open or closed vessel /tank.

Case study  :

How to measure fluid level of open vessel using ultrasonic level (non contact sensor)

We show u how to install/mount level sensor in top of the vessel , ultrasonic type .

Uses level switches / level transmitters to detect the water level.

Notice the following features/ conditions of vessel:

you have to know these info about the interested tank

Product type : liquid , paste like, solids

Tank shapes :

Process conditions : specify the product conditions

blocking distance:

mode : level / ullage

filling inlets/holes

overflow holes at high level

Zero point /min : fixed reference point near the bottom of the vessel.

variables of vessel 1:

use meter tape to get these values/ documents such as P&ID diagram for this vessel

product : water

tank shape: flat ceiling

Hight of vessel : 6 m from zero reference point

Diameter /width : 4 m

Installed pipe of a pump: about 1 m from zero reference of vessel, supply pump / draw pump

to install level switches on pipe of pump to avoid dry running of pump & keep liquid level above this point by level transmitter .

No overflow hole

supply inlet pipe: at 3 m from zero reference point

Empty E : 5.4 m from zero reference point

Full F/ span : 5.1 m from zero reference point

the distance from the minimum level to the maximum level

Bd (block distance)  : 0.3 m from sensor membrane.

Max level according to process needs : 1.85 m relay activated to start a pump via plc/transmitter itself

Min level according to process needs: 1.14 m relay deactivated to stop pump

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variables of vessel 2:

Hight of vessel : 6 m from zero reference of vessel,

Diameter /width : 8 m

Supply inlet pipe : at 2 m from zero reference of vessel,

Installed pipe of a pump: about 1.5 m from zero reference of vessel, supply pump / draw pump

to install level switches on pipe of pump to avoid dry running of pump & keep liquid level above this point by level transmitter .

Overflow hole : at 4.5 m

Empty E : 5.4

Full F : 5.1 m

Bd (block distance) : 0.3 m

desired level according to process needs : 4.4 m relay activated to start alarm

desired level according to process needs : 4.3 m relay deactivated to stop alarm/horn

Installation conditions for on vessel for level measurement

Installation conditions for flow measurement.

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1. Mounting FDU 9x sensor on a vessel: go to the attached catalogue of sensor , called (installation)

with link :fdu91.pdf

go to page number 15 .

Ultrasonic level sensor is fixed at top of tank filled with liquid , the reference point for all measurements is the bottom of tank, zero reference point.

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2. Power supply for ultrasonic sensors/ connecting to transmitter FMU:

go to the attached catalogue of sensor , called (commissioning)

with link :  fmu90 comission.pdf

go to page number 24.

We have 2 versions ,so u can power with 220/24 volts

Fuse will be 400/ 2.