An In‐Depth Analysis of Liquid Level Measurement Techniques and Performance Evaluation Using Computational Fluid Dynamics

Liquid level measurement (LLM) systems are extensively used in industry. Although most liquid measurement systems are based on indirect measurement, flow‐based monitoring is the most used secondary measuring technique for LLM. A comprehensive review of the existing LLM techniques including optical, image‐based, capacitive, and float sensors is presented in this article. Here, we describe the classification of sensors based on their sensing principle, methods, and types. The article aims to study the effect of physical parameters on existing LLM techniques for various characteristics, such as temperature, sensitivity, measurement range, response time, and errors. The comparative analysis presented in this paper serves as a valuable resource for researchers, engineers, and practitioners seeking to understand the strengths and weaknesses of different liquid‐level sensing techniques and make informed decisions in selecting the most suitable sensor for specific applications. Further, the paper also presents the results of research work carried out to calculate the liquid level using a pressure sensor for different liquid parameters such as temperature, density, and liquid inlet velocity. This article reports the performance of a differential pressure‐based instrument (specifically an orifice sensor) used to attain reliable and accurate liquid‐level detection. Computational fluid dynamics (CFD) is used to model, design, and analyze the performance of the liquid‐level process.