9.6. LEVEL SWITCHES |
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9.6Level switches
A level switch is one detecting the level of liquid or solid (granules or powder) in a vessel. Level switches often use floats as the level-sensing element, the motion of which actuates one or more switch contacts.
Recall from section 9.1 that the “normal” status of a switch is the resting condition of no stimulation. A level switch will be in its “normal” status when it senses minimum level (e.g. an empty vessel). For a level switch, “normal” status is any fluid level below the trip threshold of the switch.
Level switch symbols
Normally-open |
Normally-closed |
(NO) |
(NC) |
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CHAPTER 9. DISCRETE PROCESS MEASUREMENT |
9.6.1Float-type level switches
Some level switches use a float to sense the level of a liquid surface, actuating an electrical switch by the motion of the float. The electrical schematic symbol for a level switch is actually based on this type of mechanism, with a round “ball” float drawn as the actuating element:
Level switch symbols
Normally-open |
Normally-closed |
(NO) |
(NC) |
An example of this technology is a level switch manufactured by Magnetrol, with two such switches shown in the following photograph of a steam boiler. These switches sense water level in the steam drum of the boiler:
9.6. LEVEL SWITCHES |
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The Magnetrol float switch mechanism uses a mercury tilt bulb, tilted by a magnet’s attraction to a steel rod lifted into position by a float. The float directly senses liquid level, positioning the steel rod either closer to or farther away from the magnet. If the rod comes close enough to the magnet, the mercury bottle tilts to change the switch’s electrical status:
Tilt switch
Connection to vessel
Connection to vessel
Magnetic |
Magnet |
rod |
|
Float |
Process |
liquid |
Float |
Process |
liquid |
A feature of this design is complete isolation between the electrical components and the “wet” components sensing the liquid level. The steel rod moves inside a non-magnetic metal tube, with the tube sealing process fluid pressure from escape while still allowing the magnetic tilt switch to sense float position.
Simpler float switch designs also exist for direct installation in open (vented) process vessels, resembling the float valve assembly on a water-flush toilet. Any “limit” style switching element will work here, including inductive proximity switches, to sense the float’s position in an environment where no isolation need exist between the switch and the process fluid(s):
Switch |
Switch |
Float |
|
|
|
Float |
|
|
Process liquid |
|
Process liquid |
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9.6.2Tuning fork level switches
This level switch uses a metal tuning fork structure to detect the presence of a liquid or solid (powder or granules) in a vessel:
An electronic circuit continuously excites the tuning fork, causing it to mechanically vibrate. When the prongs of the fork contact anything with substantial mass, the resonant frequency of the fork decreases. The circuit detects this frequency change and indicates the presence of mass contacting the fork. The forks’ vibrating motion tends to shake o any accumulated material, such that this style of level switch tends to be resistant to fouling.
It should be noted that the previous photograph of the tuning-fork style level switch is complete: the fork “paddles” are only a couple of inches long and require no physical extensions in order to properly detect liquid or solid material at that point.
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9.6.3Paddle-wheel level switches
A more primitive variation on the theme of a “tuning fork” level switch is the rotating paddle switch, used to detect the level of powder or granular solid material. This level switch uses an electric motor to slowly rotate a metal paddle inside the process vessel. If solid material rises to the level of the paddle, the material’s bulk will place a mechanical load on the paddle. A torque-sensitive switch mechanically linked to the motor actuates when enough torsional e ort is detected on the part of the motor. A great many level switches of this design sold in the United States under the trade-name Bindicator (so-called because they detected the level of solid material in storage bins).
A “Bindicator” style of level switch appears in this photograph (painted black, against a whitepainted hopper), used to detect the presence of soda ash powder in a hopper at a water treatment plant: