The Complete Guide to Industrial Level Measurement: Choosing the Right Siemens Level Sensor

• Level Measurement
• Continuous vs. Point Level Measurement
• Comparison Table
• Common Industrial Applications
• Radar Level Measurement

• Ultrasonic Level Measurement
• Hydrostatic Level Measurement
• Capacitance Level Measurement
• FAQ

Whether you're monitoring a water reservoir, wastewater lift station, chemical storage tank, grain silo, or process vessel, selecting the right level measurement technology is critical to keeping your operation running safely and efficiently. The right instrument helps prevent overflows, protects equipment, improves process control, and provides operators with the reliable information they need to make informed decisions. However, with technologies such as radar, ultrasonic, hydrostatic, capacitance, and point level switches available, knowing where to start can be overwhelming.

This guide explains the most common types of industrial level measurement, how each technology works, and where it performs best. We'll also introduce Siemens level measurement solutions available through EB Horsman & Son, helping you understand which products are best suited for water and wastewater treatment, mining, manufacturing, chemical processing, and other industrial applications. Whether you're specifying instrumentation for a new project or replacing an existing device, this guide will help you make a more informed decision.

What Is Level Measurement?

Level measurement is the process of determining how much liquid, slurry, powder, or solid material is contained within a tank, vessel, silo, or open channel. The information collected can be used for process control, inventory management, safety, regulatory compliance, and equipment protection.

Almost every industrial facility relies on level measurement in some form. Water and wastewater treatment plants monitor reservoirs and wet wells. Mining operations measure slurry tanks and ore bins. Food and beverage facilities track ingredients and finished products, while manufacturers use level sensors to automate production and prevent costly interruptions.

Although the goal is always the same—to determine how much material is present—not every application requires the same technology. Factors such as the product being measured, the process conditions, and the level of accuracy required all influence which sensor is the best fit.

Continuous vs. Point Level Measurement

Continuous level measurement provides a constant reading of the material inside a vessel. Instead of simply indicating whether a tank is full or empty, it continuously reports the current level, allowing operators to monitor inventory, control pumps, optimize processes, and identify trends over time.

Point level measurement works differently. Rather than measuring the entire contents of a vessel, it detects whether material has reached a specific location. Point level sensors are commonly used for high-level alarms, low-level alarms, overflow prevention, dry-run protection, and pump control.

Both technologies are widely used, and many facilities rely on a combination of continuous and point level devices throughout their process.

No single technology is ideal for every application. Siemens offers several level measurement technologies, each designed to perform under specific process conditions.

Comparison Table

Radar level measurement is used across many industries because of its versatility and reliability.

Typical applications include:

• Water reservoirs and storage tanks
• Wastewater lift stations and wet wells
• Chemical storage tanks
• Slurry tanks
• Clarifiers
• Digesters
• Bulk solids silos
• Aggregate bins
• Cement storage
• Mining process vessels
• Food and beverage storage tanks
• Oil and fuel storage

Radar is often the preferred choice for applications involving changing temperatures, high humidity, dust, foam, or vapour, where consistent and reliable measurements are critical.

• Radar Level Measurement: Radar level measurement is one of the most accurate and reliable methods for continuously measuring the level of liquids and bulk solids in industrial applications. Because it uses microwave signals rather than physical contact with the material, radar technology performs exceptionally well in demanding environments where other measurement methods may struggle.
• How Radar Level Measurement Works: Radar level transmitters emit high-frequency microwave signals toward the surface of the material inside a tank, vessel, or silo. These signals travel through the air until they reach the product surface, where they are reflected back to the sensor.

  The transmitter measures the time it takes for the signal to return and calculates the distance between the sensor and the material. Knowing the dimensions of the vessel, the instrument accurately determines the current level and continuously updates the measurement in real time.

  Since the sensor never comes into contact with the product being measured, radar level measurement is considered a non-contact technology. This minimizes wear, reduces maintenance requirements, and provides reliable performance even in harsh operating conditions.

• Advantages of Radar Level Measurement: Radar has become one of the preferred technologies for industrial level measurement because it delivers accurate, repeatable measurements across a wide range of applications.
  
  

  Some of the key advantages include:

  • High measurement accuracy for liquids, slurries, and bulk solids
  • Non-contact measurement that reduces maintenance and eliminates sensor wear
  • Reliable operation in tanks containing steam, vapour, dust, or condensation
  • Excellent performance over long measuring distances
  • Suitable for both indoor and outdoor installations
  • Minimal maintenance due to the absence of moving parts
  • Continuous level measurement for improved process control and inventory management

  Modern 80 GHz radar technology also provides a narrow beam angle, allowing measurements in narrow tanks, vessels with internal obstructions, and applications where piping, mixers, or ladders could interfere with other sensing technologies.

• Limitations of Radar Level Measurement: Although radar is one of the most versatile level measurement technologies available, it is not always the best solution for every application.

  Some considerations include:

  • Higher initial investment compared to some ultrasonic or pressure-based technologies
  • Proper installation is important to avoid interference from internal tank structures such as agitators, ladders, or support beams
  • Certain products with extremely low dielectric constants may require careful product selection and application review

  Despite these considerations, advances in radar technology have significantly expanded the range of applications where radar can be used successfully.

• Siemens Radar Level Measurement Solutions: EB Horsman & Son offers a range of Siemens SITRANS radar level transmitters designed to provide reliable level measurement for water and wastewater treatment, mining, manufacturing, chemical processing, and other industrial applications.

  Depending on your application, Siemens offers solutions including:

  • SITRANS LR110 – Compact 80 GHz radar transmitter designed for water and wastewater applications, pump stations, and storage tanks.
  • SITRANS LR120 – Ideal for process vessels and industrial tanks requiring accurate, continuous level measurement.
  • SITRANS LR140 – Designed for hygienic and chemical process applications requiring high measurement accuracy.
  • SITRANS LR150 – Suitable for industrial process tanks where reliable non-contact level measurement is required.
  • SITRANS LR250 – A versatile radar transmitter for liquid level measurement in demanding industrial environments.
  • SITRANS LR560 – Engineered for long-range measurement of bulk solids in silos, hoppers, and mining applications.

  With advanced 80 GHz radar technology, Siemens level transmitters deliver dependable measurements even in challenging environments while integrating seamlessly with plant automation and control systems.

Ultrasonic level measurement is commonly used throughout municipal and industrial facilities, especially where clean or relatively clean liquids are being monitored.

Typical applications include:

• Clean water storage tanks
• Wastewater wet wells
• Lift stations
• Pump stations
• Open channels
• Reservoirs
• Equalization tanks
• Irrigation systems
• Stormwater collection systems
• Process water tanks

Many wastewater treatment plants also use ultrasonic sensors with flumes and weirs to measure flow in open channels by monitoring the liquid level.

• Radar Level Measurement: Ultrasonic level measurement is a proven, cost-effective technology for continuously measuring the level of liquids in tanks, wells, and open channels. Like radar, ultrasonic sensors are non-contact devices, meaning they measure the level of a product without touching it. This makes them ideal for applications where minimizing maintenance and preventing sensor contamination are important.

  Ultrasonic level transmitters have been widely used for decades in water and wastewater treatment facilities, pumping stations, and industrial storage tanks because they are reliable, easy to install, and require very little routine maintenance.

• How Ultrasonic Level Measurement Works: Ultrasonic level transmitters measure level by emitting high-frequency sound waves toward the surface of the material being measured. The sound waves travel through the air, reflect off the liquid surface, and return to the sensor.

  The transmitter calculates the time it takes for the sound wave to travel to the surface and back. Using this information, it determines the distance between the sensor and the product. Since the dimensions of the tank or channel are known, the transmitter continuously calculates the current level.

  Because the sensor is mounted above the material and never comes into contact with the process, ultrasonic measurement is considered a non-contact technology. This design helps reduce wear, simplifies maintenance, and makes installation easier than many contact-based measurement methods.

• Advantages of Ultrasonic Level Measurement: Ultrasonic technology offers several benefits for liquid level monitoring, particularly in clean or lightly contaminated applications.

  Key advantages include:

  • Non-contact measurement with no moving parts
  • Reliable continuous level measurement
  • Simple installation and commissioning
  • Minimal maintenance requirements
  • Cost-effective solution for many applications
  • Suitable for tanks, wells, and open channels
  • Excellent choice for water and wastewater applications

  Ultrasonic transmitters are particularly effective in applications where liquids have relatively calm surfaces and environmental conditions remain consistent.

• Limitations of Ultrasonic Level Measurement:

  While ultrasonic level measurement is an excellent solution for many applications, it can be affected by environmental conditions that interfere with the transmission of sound waves.

  Performance may be reduced in applications involving:

  • Heavy steam or vapour
  • Significant dust
  • Dense foam on the liquid surface
  • Strong turbulence or splashing
  • Large temperature fluctuations
  • High-pressure vessels

  These conditions can weaken or deflect the ultrasonic signal, reducing measurement accuracy.

  In applications where steam, condensation, dust, or challenging process conditions are common, radar level measurement is often the preferred choice. Radar transmitters use microwave signals rather than sound waves, making them much less susceptible to these environmental factors.

• Radar vs. Ultrasonic: Which Should You Choose?  Both radar and ultrasonic technologies provide accurate, continuous, non-contact level measurement, but each has its strengths.

  Ultrasonic level measurement is often the ideal choice for clean water, wastewater, open channels, and general industrial applications where environmental conditions are stable and a cost-effective solution is desired.

  Radar level measurement is generally recommended for more demanding applications involving vapour, steam, foam, dust, high temperatures, pressure, or bulk solids. It also provides excellent performance in narrow vessels and applications with internal obstructions.

  The best technology ultimately depends on your process conditions, required accuracy, and operating environment.

• Siemens Ultrasonic Level Measurement Solutions:  EB Horsman & Son offers Siemens ultrasonic level transmitters designed to provide reliable and accurate level measurement across a wide range of industrial and municipal applications.

  Depending on your application, Siemens solutions include:

  • SITRANS Probe LU – A versatile ultrasonic transmitter designed for level, volume, and open channel flow measurement in water and wastewater applications.
  • SITRANS LU150 – A compact ultrasonic level transmitter ideal for smaller tanks, pump stations, and storage vessels.
  • SITRANS LU180 – Designed for reliable level measurement in industrial process tanks and municipal water applications.

  Siemens ultrasonic level transmitters are trusted worldwide for their ease of installation, dependable performance, and seamless integration with modern automation and control systems, making them an excellent choice for many everyday level measurement applications.

Hydrostatic level measurement is best suited for liquids where pressure can be directly related to liquid height. It is commonly used in municipal infrastructure, industrial facilities, and environmental monitoring applications.

Typical applications include:

• Deep wells
• Groundwater monitoring
• Water reservoirs
• Elevated storage tanks
• Wastewater basins
• Lift stations
• Wet wells
• Pump stations
• Clarifiers
• River and lake level monitoring
• Chemical storage tanks
• Fire water storage tanks

These applications often require dependable level measurement over long periods with minimal maintenance, making hydrostatic transmitters an effective solution.

• Hydrostatic Level Measurement: Hydrostatic level measurement is a proven and dependable method of continuously measuring the level of liquids by monitoring the pressure created by the liquid itself. Unlike radar or ultrasonic technologies, which measure the distance to the liquid surface, hydrostatic transmitters determine level based on the weight of the liquid column above the sensor.
  
  

  Because of its simplicity and reliability, hydrostatic level measurement has been used for decades in water and wastewater treatment facilities, reservoirs, storage tanks, and deep wells where accurate liquid level monitoring is essential.

• How Hydrostatic Level Measurement Works: As the level of liquid inside a tank or basin rises, the pressure at the bottom increases. A hydrostatic pressure transmitter installed near the bottom of the vessel measures this pressure and converts it into a level measurement.
  
  

  The principle is straightforward: the greater the height of the liquid above the sensor, the greater the pressure exerted on the transmitter. Since the density of many liquids—such as water—remains relatively constant, the instrument can accurately calculate the liquid level based on the measured pressure.

  Hydrostatic transmitters may be installed directly inside a tank, suspended in a deep well, or submerged in a reservoir or basin. They continuously monitor changes in pressure and provide real-time level information to plant operators and control systems.

• Advantages of Hydrostatic Level Measurement: Hydrostatic level measurement remains a popular choice because it offers reliable performance, simple installation, and accurate measurements in many liquid applications.
  
  

  Some of its key advantages include:

  • Continuous and accurate liquid level measurement
  • Simple measuring principle with proven long-term reliability
  • Ideal for deep tanks, wells, and reservoirs
  • Suitable for submerged installations
  • Performs well in applications where the liquid surface may be turbulent
  • Compact design with few moving parts
  • Cost-effective solution for many water and wastewater applications
  • Easy integration with plant automation and SCADA systems

  Since hydrostatic transmitters measure pressure rather than the liquid surface, they continue to provide stable measurements even when waves or surface agitation are present.

• Limitations of Hydrostatic Level Measurement: Although hydrostatic level measurement performs well in many liquid applications, there are some factors to consider when selecting this technology.
  
  

  Because the transmitter calculates level based on pressure, changes in liquid density can affect measurement accuracy. Liquids with varying concentrations, temperatures, or specific gravities may require recalibration or compensation.

  Hydrostatic transmitters are also contact sensors, meaning they are installed directly in the liquid. In applications involving corrosive chemicals, heavy sludge, or materials that may coat the sensing element, selecting the appropriate wetted materials and performing periodic maintenance is important.

  For applications involving heavy vapours, foam, dust, or complex tank geometries, non-contact radar level measurement may offer a better long-term solution.

• Hydrostatic vs. Radar: Which Should You Choose?  

  Both hydrostatic and radar technologies provide continuous level measurement, but each has advantages depending on the application.

  Hydrostatic level measurement is often preferred for deep wells, reservoirs, water tanks, wastewater basins, and other liquid applications where a simple, reliable, and economical solution is required.

  Radar level measurement is generally better suited for applications where the liquid density changes significantly, where non-contact measurement is preferred, or where challenging process conditions such as steam, condensation, foam, or corrosive products are present.

  Choosing the right technology depends on the process conditions, installation requirements, maintenance expectations, and desired measurement accuracy.

• Siemens Hydrostatic Level Measurement Solutions:  

  EB Horsman & Son offers Siemens hydrostatic level transmitters designed for reliable level measurement in municipal, industrial, and environmental applications.

  Depending on your application, Siemens solutions include:

  • SITRANS LH100 – A compact hydrostatic transmitter designed for continuous level measurement in water, wastewater, wells, and storage tanks.
  • SITRANS LH300 – A high-performance submersible pressure transmitter suitable for demanding industrial applications requiring accurate and dependable liquid level measurement.

  Siemens hydrostatic transmitters are built to withstand harsh environments while providing reliable performance in reservoirs, pump stations, wastewater treatment facilities, and industrial process applications.

  Best For

  • Deep wells
  • Water reservoirs
  • Wastewater basins
  • Lift stations
  • Pump stations
  • Storage tanks
  • Groundwater monitoring
  • Applications requiring a reliable submerged level measurement solution

Capacitance level measurement is widely used in industries that process liquids, powders, and granular materials.

Typical applications include:

• Chemical storage tanks
• Water and wastewater treatment
• Food ingredient silos
• Flour and grain storage
• Plastic pellet hoppers
• Cement and lime silos
• Powder processing systems
• Pharmaceutical manufacturing
• Oil and lubricant storage
• Bulk material handling equipment

Because capacitance sensors can detect many different types of materials, they are frequently used where a single technology must accommodate varying products.

• Capacitance Level Measurement: Capacitance level measurement is a versatile technology used to detect the level of liquids, powders, granular materials, and some bulk solids. Unlike radar and ultrasonic sensors, which measure the distance to the material surface, capacitance sensors detect changes in the electrical properties surrounding the sensing probe.
  
  

  This technology is commonly used for both continuous level measurement and point level detection in industrial processes where reliable performance, compact installation, and the ability to measure a wide range of materials are important.

• How Capacitance Level Measurement Works: Capacitance technology offers excellent flexibility and can be used in applications involving liquids, powders, pellets, and other bulk materials.

  Some of its key advantages include:

  • Suitable for both continuous level measurement and point level detection
  • Measures liquids, powders, granules, and many bulk solids
  • Compact design for installation in tanks, vessels, and silos
  • Reliable performance in challenging process conditions
  • No moving mechanical parts, reducing maintenance requirements
  • Can detect product interfaces between two liquids with different dielectric properties
  • Suitable for high-pressure and high-temperature applications when properly selected
  • Compatible with a wide range of process materials

  Its versatility makes capacitance technology a practical choice for many industrial applications where multiple material types are handled.

• Advantages of Capacitance Level Measurement: Hydrostatic level measurement remains a popular choice because it offers reliable performance, simple installation, and accurate measurements in many liquid applications.
  
  

  Some of its key advantages include:

  • Continuous and accurate liquid level measurement
  • Simple measuring principle with proven long-term reliability
  • Ideal for deep tanks, wells, and reservoirs
  • Suitable for submerged installations
  • Performs well in applications where the liquid surface may be turbulent
  • Compact design with few moving parts
  • Cost-effective solution for many water and wastewater applications
  • Easy integration with plant automation and SCADA systems

  Since hydrostatic transmitters measure pressure rather than the liquid surface, they continue to provide stable measurements even when waves or surface agitation are present.

• Interface Measurement: One unique advantage of capacitance technology is its ability to perform interface measurement.

  In some industrial processes, two different liquids naturally separate into layers, such as oil floating on water or hydrocarbons above wastewater. Since each liquid has different electrical properties, a capacitance sensor can detect the boundary between them and accurately identify the interface.

  Interface measurement is commonly used in:

  • Oil and water separation systems
  • Chemical processing
  • Wastewater treatment
  • Storage and settling tanks
  • Industrial separation processes

  This capability helps improve process efficiency, reduce product loss, and support automated control of separation systems.

• Limitations of Capacitance Level Measurement: Although capacitance technology is highly versatile, selecting the correct sensor for the application is essential.

  Because the sensor measures changes in electrical properties, the material being measured must have suitable dielectric characteristics. Significant changes in product composition or dielectric constant can affect measurement accuracy and may require recalibration.

  Since the probe is installed directly in the process, applications involving heavy product buildup or coatings on the sensing element may require periodic inspection and maintenance. Proper probe selection and installation can help minimize these effects.

  For applications requiring completely non-contact measurement or those involving heavy vapours, foam, or challenging tank geometries, radar level measurement may be a better alternative.

• Siemens Capacitance Level Measurement Solutions: EB Horsman & Son offers Siemens capacitance level measurement solutions designed to provide dependable performance across a wide range of industrial applications.

  Depending on your process requirements, Siemens solutions include:

  • Pointek CLS200 – A compact capacitance switch for point level detection in liquids and solids.
  • Pointek CLS300 – Designed for reliable level measurement in industrial process vessels and storage tanks.
  • Pointek CLS500 – A versatile capacitance sensor suitable for demanding applications involving powders, bulk solids, liquids, and interface detection.

  These Siemens capacitance sensors provide reliable level monitoring in chemical processing, water and wastewater treatment, manufacturing, food processing, and many other industrial applications.

  Best For

  • Liquids
  • Powders
  • Plastic pellets
  • Grain and flour
  • Chemical storage tanks
  • Bulk solids
  • Interface measurement
  • Point level detection
  • Applications requiring a compact contact sensor