1.

0 SUMMARY

The purposes of the experiment were to differentiate between direct reading and indirect
reading measurement, to study the different between open tank and closed tank when there
is heat and without heat and to investigate the relationship between level and temperature.
The experiment starts by checking all the valves. Then, the experiment was started with open
tank system and closed tank system with heater off. After that both tank system was done with
the heater on. Throughout the experiment, it showed that in tank 1 with condition of closed
tank, heater on has the highest reading difference between direct-measurement (LI) than
indirect measurement (LG). It has an average different error of 4.3. Second highest different
is when open tank with heater on with difference error is about an average of 3.9. It is because
of when the heater is on, the heat helps to make the pressure excited resulting in greater
difference of LG and LI. While for heater off, Table 1 and 2 with condition of heater off have
the least average error with 3.48 and 3.5 respectively. This is because when there is no heat
applied, even though there is pressure in tank still exist but there is no excite state happen
resulting in least of error difference. This can be related to the theory, in closed tank change
of gas pressure will come a charge in transmitter output, and pressure exerted by the gas
phase is probably high that the hydrostatic pressure become insignificants. During this
experiment, there are some errors occur like the reading were not accurately record from
indirect measurement. Lastly, the temperature was affected by the surrounding.
2.0 OBJECTIVE

The objective of this experiment are:

1. To differentiate between direct reading and indirect reading measurement.

2. To study the different between open tank and closed tank when there is heat and
without heat.
3. To investigate the relationship between level and temperature.
3.0 INTRODUCTION

Level measuring instruments are used to measure fluid (liquid or gas) level either
continuously or discrete depending on the type of application. These instruments may be
indicators, which displays liquid level. Transmitters, which carries level information in the form
of ac signals for control purpose. Level switches are used to monitor high or low level of liquid
depending on the set point. Different types of level instruments work on different types of
principles. The selection of a particular level instrument depends on process parameters like
pressure, temperature, medium and environmental conditions etc.

Principles of Level Measurement

The major principles in level measurement and its classification

1. Pressure based or Differential pressure based level measurement
2. Transit time based level measurement
a) Ultrasonic based level measurement
b) Radar based level measurement
3. Attenuation based level measurement / Radiation based level measurement
4. Conductivity based measurement (Electrical measurement)
5. Capacitance based level measurement

This module covers aspects of level measurement as used in process instrumentation

and control. Level measurement addresses essential knowledge and skill elements
associated with measuring level. In this module student will conducted level measurement in
two conditions where the first condition applied on the tank i.e. closed tank and open tank and
the last condition applied on the temperature. The condition of tank either in closed or open is
to demonstrate the pressure in open system or closed system. Meanwhile the heat supplied
to the system used to demonstrate pressure of system when heat supplied. There is several
type of measurement in industry and one of it is level measurement with seals. Level
measurement with seals allows the level measurement to be removed from direct contact with
the process fluid. Remote seals are useful when:
 The process temperature is outside of the normal operating limits of the level
measurement and cannot be brought into those limits with impulse piping.
 The process is corrosive and requires frequent level measurement replacement.
 The process requires unusual materials of construction.
  The process contains numerous solids or is viscous; either condition could plug the
impulse piping.
 The application requires the use of sanitary connections.
 There exists a need for easy cleaning of the process from the connections to avoid
contamination between batches.
Seals function as an extension of the level measurement. The basic measurement of level
follows the same principle as pressure level measurements without seals: pressure is
proportional to level. The head pressure of the liquid corresponds to its height multiplied by
the specific gravity. The prudent selection of remote seals is important in maintaining a
reasonable performance expectation of the pressure level measurement.

One of the level measurement apparatus used in this experiment is bubbler tubes besides
the bourdon gauge, the bubbler tubes provide a simple and inexpensive but less accurate (±1-
2%) level measurement system for corrosive or slurry-type applications. Bubblers use
compressed air or an inert gas (usually nitrogen) introduced through a dip pipe (Figure 1-A).
Gas flow is regulated at a constant rate (usually at about 500 cc/min). A differential pressure
regulator across a rotameter maintains constant flow, while the tank level determines the back-
pressure.

Figure 1. Level measurement device

As the level drops, the back-pressure is proportionally reduced and is read on a pressure
gauge calibrated in percent level or on a manometer or level measurement. The dip pipe
should have a relatively large diameter (about 2 in.) so that the pressure drop is negligible.
The bottom end of the dip pipe should be located far enough above the tank bottom so that
sediment or sludge will not plug it. Also, its tip should be notched with a slot or "V" to ensure
the formation of a uniform and continuous flow of small bubbles. An alternative to locating the
dip pipe in the tank is to place it in an external chamber connected to the tank.
 In pressurized tanks, two sets of dip pipes are needed to measure the level (Figure 1-
B). The two back-pressures on the two dip pipes can be connected to the two sides of a u-
tube manometer, a differential pressure gage or a d/p cell/level measurement. The pneumatic
piping or tubing in a bubbler system should be sloped toward required (when the tank is full
and the vapor pressure is at its maximum). An alternative to the tank so that condensed
process vapors will drain back into the tank if purge pressure is lost. The purge gas supply
should be clean, dry, and available at a pressure at least 10 psi greater than the expected
maximum total pressure continuous bubbler is to use a hand pump (similar to a bicycle tire
pump) providing purge air only when the level is being read.

Bubblers do consume inert gases, which can later accumulate and blanket processing
equipment. They also require maintenance to ensure that the purge supply is always available
and that the system is properly adjusted and calibrated. When all factors are considered, d/p
cells typically are preferred to bubblers in the majority of applications.
3.0 RESULTS AND DISCUSSION

TABLE 1: Level Measurement (Tank T1 as OPEN tank, Heater OFF)

RUN I SET 1 SET 2 AVERAGE

A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm) 700 700 700
C Actual Level (LI) (mm) 701.1 701.1 701.1
D Temperature (TG) (0C) 39.9 39.9 39.9
E Deviation = | B-C | (mm) 1.1 1.1 1.1

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm) 600 600 600
C Actual Level (LI) (mm) 602 602 602
D Temperature (TG) (0C) 39.8 39.8 39.8
E Deviation = | B-C | (mm) 2 2 2

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm) 500 500 500
C Actual Level (LI) (mm) 504 504 504
D Temperature (TG) (0C) 39.7 39.7 39.7
E Deviation = | B-C | (mm) 4 4 4

RUN VI SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm) 400 400 400
C Actual Level (LI) (mm) 405 405 405
D Temperature (TG) (0C) 39.6 39.6 39.6
E Deviation = | B-C | (mm) 5 5 5

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm) 300 300 300
C Actual Level (LI) (mm) 305 305 305
D Temperature (TG) (0C) 39.4 39.4 39.4
E Deviation = | B-C | (mm) 5 5 5
TABLE 2: Level Measurement (T1 as CLOSED tank, Heater OFF)
RUN I SET 1 SET 2 AVERAGE
A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm) 700 700 700
C Actual Level (LI) (mm) 702 702 702
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 2 2 2

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm) 600 600 600
C Actual Level (LI) (mm) 603 603 603
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 3 3 3

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm) 500 500 500
C Actual Level (LI) (mm) 504 504 504
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 4 4 4

RUN IV SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm) 400 400 400
C Actual Level (LI) (mm) 404 404 404
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 4 4 4

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm) 300 300 300
C Actual Level (LI) (mm) 305 305 305
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 5 5 5
TABLE 3: Level Measurement (Tank T1 as OPEN tank, Heater ON)
RUN I SET 1 SET 2 AVERAGE
A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm) 700 700 700
C Actual Level (LI) (mm) 702 702 702
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 2 2 2

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm) 600 600 600
C Actual Level (LI) (mm) 603 603 603
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 3 3 3

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm) 500 500 500
C Actual Level (LI) (mm) 503 503 503
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 3 3 3

RUN IV SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm) 400 400 400
C Actual Level (LI) (mm) 405 405 405
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 5 5 5

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm) 300 300 300
C Actual Level (LI) (mm) 306 306 306
D Temperature (TG) (0C) 32 32 32
E Deviation = | B-C | (mm) 6 6 6
TABLE 4: Level Measurement (Tank T1 as CLOSED tank, Heater ON)
RUN I SET 1 SET 2 AVERAGE
A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm) 700 700 700
C Actual Level (LI) (mm) 701 701 701
D Temperature (TG) (0C) 38.1 38.1 38.1
E Deviation = | B-C | (mm) 1 1 1

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm) 600 600 600
C Actual Level (LI) (mm) 604 604 604
D Temperature (TG) (0C) 38.1 38.1 38.1
E Deviation = | B-C | (mm) 4 4 4

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm) 500 500 500
C Actual Level (LI) (mm) 505 505 505
D Temperature (TG) (0C) 38.1 38.1 38.1
E Deviation = | B-C | (mm) 5 5 5

RUN IV SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm) 400 400 400
C Actual Level (LI) (mm) 405 405 405
D Temperature (TG) (0C) 38.1 38.1 38.1
E Deviation = | B-C | (mm) 5 5 5

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm) 300 300 300
C Actual Level (LI) (mm) 306 306 306
D Temperature (TG) (0C) 38.1 38.1 38.1
E Deviation = | B-C | (mm) 6 6 6
 The objectives of this experiment are to differentiate between direct reading and
indirect reading measurement. Besides that, it is also to study the different between open tank
and closed tank when there is heat and without heat. Lastly, to investigate the relationship
between level and temperature. During this experiment, 4 sets of reading were taken which
are open tank when heat on, open tank when heat off with pressure of 30 psig, close tank
when heat on and close tank when heat off with pressure 30 psig. Two sets of reading of each
run were taken to get an average reading.

Based on the result, on table 1, 2, 3 and 4 shows that in tank 1 with condition of closed
tank, heater on has the highest reading difference between direct measurement (LI) than
indirect measurement (LG). It has an average different error of 4.2. Second highest different
is when open tank with heater on with difference error is about an average of 3.8. When the
heater is on, the heat helps to make the pressure excited resulting in greater difference of LG
and LI. Table 1 and 2 with condition of heater off have the least average error with 3.42 and
3.6 respectively. This is because when there is no heat applied, even though there is pressure
in tank still exist but there is no excite state happen resulting in least of error difference.

From the theory, in closed tank change of gas pressure will come a charge in
transmitter output, pressure exerted by the gas phase maybe so high that the hydrostatic
pressure become insignificants. From the result, it shows that the two condition which Tank 1
as closed tank gives larger difference that T1 as open tank because of pressure rise. This is
due to atmospheric pressure in open tank while in closed tank only pressure exists inside the
tank. In open tank, the vapour being released from the chamber while closed tank is vapours
being released and maintain its pressure. During this experiment, there are some errors occur
like the reading were not accurately record from indirect measurement. Lastly, the temperature
was affected by the surrounding.
5.0 CONCLUSION AND RECOMMENDATION

In conclusion, this experiment was running for 4 sets of reading were taken which are open
tank when heat on, open tank when heat off with pressure of 30 psig, close tank when heat
on and close tank when heat off with pressure 30 psig. Two sets of reading of each run were
taken to get an average reading. An average different error is 4.2. Second highest different is
when open tank with heater on with difference error is about an average of 3.8. When the
heater is on, the heat helps to make the pressure excited resulting in greater difference of LG
and LI, but the reading on the condition of heater off have the least average error with 3.42
and 3.6.

For recommendation, there are some errors occur like the reading were not accurately record
from indirect measurement. So, sight glass that was used. In order to measure the liquid level
measurement in the tank. Physically, its visual measurement should be always equal to
another to achieve exact analysis. Lastly, another error is the closed tank pressure was not
accurate therefore, it is recommended that the pressure for the closed tank is set properly
before the experiment can be run.
6.0 TUTORIALS

1. Level is measured in many of the processes in the industry. List and explain the
most common reasons for measuring level.
 The level of measurement help to decide how to explain the data from variable values
and help to decide statistical analysis. Level is measured for the purpose of process
efficiency, inventory, safety, consistent supply of materials and custody transfer. It is
also a very simple systems employ external sight glasses or tubes to view the height
and hence the volume of the fluid.

2. Name the two methods of level measurement used in the experiment.

 dip stick
 Sight glasses

3. How depth of a liquid does correspond to changes in liquid pressure? Can a

pressure transmitter be used to measure the level?
 The pressure became greater when the deeper into water due to the weight of water
pressing down on it. Hence, the higher the depth the higher the change in liquid
pressure. Yes, pressure transmitter can be used to measure level.

4. The differential pressure transmitter is used to measure level in an open tank or

closed tank system. Discuss how this is done.
 We can get the measurement by rising the water until it overflows. A differential
pressure transmitter is located somewhere near the bottom of the vessel. These
transmitters have both a low pressure and a high pressure connection in order to make
them a differential pressure transmitter. The high pressure side is connected to the
port near the bottom of the vessel to sense the weight of the material above it in the
vessel. In non-pressurized vessels the low pressure side may simply be vented to
atmosphere but pressure vessels require that the low pressure side be connected to
the vapor space above the level. The difference in pressure between the high and the
low side causes the diaphragm of the pressure cell to move. In order for the weight to
level conversion to be accurate, the density of the material being measured must
remain constant,
5. Discuss briefly the possible errors affecting the accuracy in pressure/ level
measurement as observed in the experiment.
 Connections
 High pressure and low hydrostatic pressure easy to occur
 Actual level high and indicated level is low

 Over-pressuring
 fail immediately or diaphragm become distorted
 low and high reading

 Obstructed sensing lines

 Small diameter , clogged with particulate inaccurate reading
 Sluggish respond to level changes
 To overcome periodic draining and flushing

 Draining sensing line

 To remove debris
 Leaking

6. What are the main objectives of a wet lag calibration?

 To vaporised liquid which will be condensate by atmosphere level
7.0 REFERENCES

1. Automation forum (2018) OPEN & CLOSED LEVEL MEASUREMENT [ONLINE]

Available at: https://automationforum.co/open-closed-level-measurement/

2. Eurotherm (2018) Calibrating and testing control [ONLINE] Available at:

https://www.eurotherm.com/calibrating-and-testing-control-components-on-your-heat-
process

3. Instrumentationtoolbox (2017) Introduction to level measurement with differential

pressure transmitters [ONLINE] Available at:
https://www.instrumentationtoolbox.com/2012/12/introduction-to-level-measurement-
with.html

4. COULTON (2017) The difference between re-ranging / dry calibration / wet calibration
- for differential pressure transmitters [ONLINE] Available at:
https://www.coulton.com/difference_between_range_calibration.html