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UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL AND BIOENGINEERING TECHNOLOGY

LAB MANUAL
CLB 21103
PROCESS INSTRUMENTATION

BACHELOR OF CHEMICAL ENGINEERING


TECHNOLOGY

EXPERIMENT 4
Level Measurement & Calibration

SEMESTER
September 2014

EXPERIMENT 4
LEVEL MEASUREMENT & CALIBRATION

1.0 EXPERIMENT PROCEDURES


1.1 Plant Start-up Procedures
1

Fill-up water in Tank T2 up to its overflow level. Make sure that drain valve is fully
closed.

At the front panel, make sure the heater and pump (P) are off.

Then switch ON the main power supply located at the front panel. The panel
instruments should all lit up.

Check that the pump suction valve and all pump discharge valves are fully open.

Open one turn of the pump by-pass valve (BV) first before starting the pump (P).
After pump start-up, close BV fully. This is a good practice to avoid any hydraulic
shock to the pump (P).

Note: During the experiment, if the water of tank T2 is at the low level, the level switch
(LS) will automatically switch off the heaters and pump (P). In this case, top up
more water into tank T2 from external water supply.

1.2 Experiment 1: Level Measurement


(Tank T1 as OPEN, Heater OFF)
1.

Refer to the start-up procedures and check that the procedures are done before the
experiment is carried out.

2.

For tank T1, fully open top vent (V) and overflow manual valves.

3.

Make sure bottom gate valve is fully open and globe valve is fully closed.

4.

Make sure air inlet manual isolation valve is closed (with 900 position at the air supply
inlet tubing). The top space of tank T1 is at atmospheric pressure, as monitored by the
pressure gauge (PG).

5.

Open one turn of the pump by-pass valve (BV) first before starting the pump (P)

6.

Start pump (P) by pressing the green pushbutton at the front panel.

7.

After pump start-up, close the pump by-pass valve (BV).

Experiment 4: Level Measurement & Calibration System

8.

Adjust the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let
the water circulate throughout tanks T1 and T2.

9.

At the sight millimetre scale (LG), observe the level in tank T1 rise until it overflows
to make sure that both of the wet legs at the Differential Pressure/Level Transmitter
(LT) is filled with water.

10. Close the manual discharge gate valve at tank T1. Stop the pump (P).
11. Run the Experiments:
Suggested Level: 700mm
Open the bottom globe valve of tank T1 to allow the water in tank T1 to
flow into tank T2 until the level at LG reads about 700mm. Close the
bottom globe valve.
Take 2 set of reading and record in the Table 1
Continue measure the level from 600mm until 300 mm.
1.3 Experiment 2: Level Measurement
(Tank T1 as CLOSED Tank, Heater OFF)
1.

Refer to the start-up procedures and check that the procedures are done before the
experiment is carried out

2.

Check that tank T1 is still operated as an OPEN tank.


Make sure that the top vent (V) and overflow manual valve are fully open.
Make sure that the manual discharge valves i.e. bottom gate valve is fully open
and globe valve is fully closed.
The pressurising air inlet manual isolation valve handle is 900 to the air supply
inlet tubing.

3. Open one turn of the pump by-pass valve (BV) first before starting the pump (P).
Start pump (P) by pressing the green pushbutton at the front panel. After pump startup, check that the pump by-pass valve (BV) is fully closed.
4. Adjust the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let the
water circulate throughout tanks T1 and T2.
5. At the sight millimetre scale (LG), observe the level in tank T1 rise until it overflows
to make sure that both of the wet legs at the Differential Pressure/Level Transmitter
(LT) is filled with water.
6. Close the manual discharge gate valve at tank T1. Stop the pump (P).
7. Open the bottom globe valve of tank T1 to allow the water in tank to flow out into tank
T2 until the level at LG reads to about 750mm. Close the bottom globe valve.
8. Then pressurise tank T1 as detailed below:

Experiment 4: Level Measurement & Calibration System

Fully CLOSE the vent (V), overflow, bottom gate valve and globe valves of
tank T1.
Pressurise the top space of tank T1 by opening the pressurising air inlet manual
isolation valve (with the valve handle in parallel to the air supply inlet tubing)
located next to the AS for air to flow into the top of tank T1.
Check that the pressure at pressure gauge is between 2.50 3.00 psig.

Note: Tank T1 is now a closed tank under pressure.


9. Run the Experiments
Suggested Level: 700mm
Open the bottom globe valve of tank T1 to allow the water in tank T1 to
flow into tank T2 until the level at LG reads about 700mm. Close the
bottom globe valve.
Take 2 set of reading and record in the Table 2
Continue measure the level from 600mm until 300 mm.
Open vent and overflow valve after experiment finish to release the
pressure in tank T1
1.4 Experiment 3: Level Measurement
(Tank T1 as OPEN Tank, Heater ON)
1.

Refer to the start-up procedures and check that the procedures are done before the
experiment is carried out.

2.

For tank T1, fully open top vent (V) and overflow manual valves.

3.

Make sure bottom gate valve is fully open and globe valve is fully closed.

4.

Make sure air inlet manual isolation valve is closed (position 900 at the air supply inlet
tubing). The top space of tank T1 is at atmospheric pressure, as monitored by the
pressure gauge (PG).

5.

Open one turn of the pump by-pass valve (BV) first before starting the pump (P).
Start pump (P) by pressing the green pushbutton at the front panel. After pump startup, close the pump by-pass valve (BV).

6.

Adjust the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let
the water circulate throughout tanks T1 and T2.

7.

At the sight millimetre scale (LG), observe the level in tank T1 rise until it overflows
to make sure that both of the wet legs at the Differential Pressure/Level Transmitter
(LT) is filled with water.

8.

Switch ON the heater on the front panel.

9.

Let the water to circulate throughout tanks T1 and T2 until the water temperature
reaches to about 600C.
Note:
TIC has an ON/OFF alarm with hysteresis of 0.50C.

Experiment 4: Level Measurement & Calibration System

10.

Say the temperature set point is at 60.00C, the heater is switched ON until the
water temperature reaches 60.00C. TIC will then switch the heater OFF. The
water temperature will continue to rise and then drop to below 60.00C.
Once the water temperature drops below 59.50C, TIC will switch the heater ON
again to heat the water up to the set point temperature again.
This will continue throughout as long as the heater switch at the front panel
stays ON.
Switch the heater OFF.

11.

Close the manual discharge gate valve at tank T1. Stop the pump (P).

12.

Run the Experiments


Suggested Level: 700mm
Open the bottom globe valve of tank T1 to allow the water in tank T1 to flow
into tank T2 until the level at LG reads about 700mm. Close the bottom
globe valve.
Take 2 set of reading and record in the Table 3.
Continue measure the level from 600mm until 300 mm

1.5 Experiment 4: Level Measurement


(Tank T1 as CLOSED Tank, Heater ON)
1. Refer to the start-up procedures and check that the procedures are done before the
experiment is carried out.
2. Check that tank T1 is still operated as an OPEN tank.
Make sure that the top vent (V) and overflow manual valve are fully open.
Make sure that the manual discharge valves i.e. bottom gate valve is fully open
and globe valve is fully closed.
The pressurising air inlet manual isolation valve handle is 900 to the air supply
inlet tubing.
3. Open one turn of the pump by-pass valve (BV) first before starting the pump
(P).Start pump (P) by pressing the green pushbutton at the front panel. After pump
start-up, check that the pump by-pass valve (BV) is fully closed.
4. Adjust the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let
the water circulate throughout tanks T1 and T2.
5. At the sight millimetre scale (LG), observe the level in tank T1 rise until it overflows
to make sure that both of the wet legs at the Differential Pressure/Level Transmitter
(LT) is filled with water.
6. Switch ON the heater on the front panel.Let the water to circulate throughout tanks
T1 and T2 until the water temperature reaches to about 600C.
Note:

a. TIC has an ON/OFF alarm with hysteresis of 0.50C.

Experiment 4: Level Measurement & Calibration System

b. Say the temperature set point is at 60.00C, the heater is switched ON until
the water temperature reaches 60.00C. TIC will then switch the heater OFF.
The water temperature will continue to rise and then drop to below 60.00C.
c. Once the water temperature drops below 59.50C, TIC will switch the heater
ON again to heat the water up to the set point temperature again.
d. This will continue throughout as long as the heater switch at the front panel
stays ON.
7. Switch the heater OFF.
8. Close the manual discharge gate valve at tank T1. Stop the pump (P).
9. Open the bottom globe valve of tank T1 to allow the water in tank to flow out into
tank T2 until the level at LG reads to about 750mm. Close the bottom globe valve.
10.

Then pressurise tank T1 as detailed below:


Fully CLOSE the vent (V), overflow, bottom gate valve and globe valves of
tank T1.
Pressurise the top space of tank T1 by opening the pressurising air inlet manual
isolation valve (with the valve handle in parallel to the air supply inlet tubing)
located next to the AS for air to flow into the top of tank T1.
Check that the pressure at pressure gauge is between 2.50 3.00 psig.
Note: Tank T1 is now a closed tank under pressure.
11. Run the Experiments
Suggested Level: 700mm
Open the bottom globe valve of tank T1 to allow the water in tank T1 to
flow into tank T2 until the level at LG reads about 700mm. Close the
bottom globe valve.
Take 2 set of reading and record in table 4
Continue measure the level from 600mm until 300 mm.
1.6 Plant Shut-down Procedures
After all of the experiments have been completed, do the following:
1. Make sure that all the heaters and pump (P) are switched OFF.
2. Make sure that the air inlet manual isolation valve handle is in 900 position at
the air supply inlet tubing. The top space of tank T1 is at atmospheric
pressure. Check the pressure gauge (PG) as well.
3. Fully open the overflow manual valve and the top vent (V) valve of tank T1.
4. Drain out all of the water in tank T1 by opening the manual discharge valve
i.e. the gate valve. After that, fully close both the gate valve and globe valve.
5. Drain out all of the water in tank T2 by opening its manual drain valve.
6. Switch OFF the main power supply.

Experiment 4: Level Measurement & Calibration System

2.0

RESULTS

2.1

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

A
B
C
D
E

RUN I
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
700

SET 2
700

AVERAGE
700

A
B
C
D
E

RUN II
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
600

SET 2
600

AVERAGE
600

A
B
C
D
E

RUN II
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
500

SET 2
500

AVERAGE
500

A
B
C
D
E

RUN II
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
400

SET 2
400

AVERAGE
400

A
B
C
D
E

RUN II
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
300

SET 2
300

AVERAGE
300

REMARKS:
B: Read from the sight glass with millimetre scale (LG).
C: Read from the level indicator (LI) on the front panel.
D: Read from the temperature gauge (TG) mounted on level tank T1.

Experiment 4: Level Measurement & Calibration System

2.2 TABLE 2: Level Measurement (T1 as CLOSED tank, Heater OFF)


A
B
C
D
E

RUN I
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
700

SET 2
700

AVERAGE
700

A
B
C
D
E

RUN II
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
600

SET 2
600

AVERAGE
600

A
B
C
D
E

RUN III
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
500

SET 2
500

AVERAGE
500

A
B
C
D
E

RUN IV
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
400

SET 2
400

AVERAGE
400

A
B
C
D
E

RUN V
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
300

SET 2
300

AVERAGE
300

REMARKS:
B: Read from the sight glass with millimetre scale (LG).
C: Read from the level indicator (LI) on the front panel.
D: Read from the temperature gauge (TG) mounted on level tank T1.

Experiment 4: Level Measurement & Calibration System

2.3 TABLE 3: Level Measurement (Tank T1 as OPEN tank, Heater ON)


A
B
C
D
E

RUN I
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
700

SET 2
700

AVERAGE
700

A
B
C
D
E

RUN II
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
600

SET 2
600

AVERAGE
600

A
B
C
D
E

RUN III
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
500

SET 2
500

AVERAGE
500

A
B
C
D
E

RUN IV
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
400

SET 2
400

AVERAGE
400

A
B
C
D
E

RUN V
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
300

SET 2
300

AVERAGE
300

REMARKS:
B: Read from the sight glass with millimetre scale (LG).
C: Read from the level indicator (LI) on the front panel.
D: Read from the temperature gauge (TG) mounted on level tank T1.

Experiment 4: Level Measurement & Calibration System

2.4 TABLE 4: Level Measurement (Tank T1 as CLOSED tank, Heater ON)


A
B
C
D
E

RUN I
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
700

SET 2
700

AVERAGE
700

A
B
C
D
E

RUN II
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
600

SET 2
600

AVERAGE
600

A
B
C
D
E

RUN III
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
500

SET 2
500

AVERAGE
500

A
B
C
D
E

RUN IV
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
400

SET 2
400

AVERAGE
400

A
B
C
D
E

RUN V
Suggested Level (mm)
Actual Level (LG) (mm)
Actual Level (LI) (mm)
Temperature (TG) (0C)
Deviation = | B-C | (mm)

SET 1
300

SET 2
300

AVERAGE
300

REMARKS:
B: Read from the sight glass with millimetre scale (LG).
C: Read from the level indicator (LI) on the front panel.
D: Read from the temperature gauge (TG) mounted on level tank T1.

Experiment 4: Level Measurement & Calibration System

3.0 QUESTIONS
1. Level is measured in many of the processes in the industry. List and explain the most
common reasons for measuring level.
2. Name the two methods of level measurement used in the experiment.
3. How the depth of a liquid does correspond to changes in liquid pressure? Can a
pressure transmitter 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.
5. Discuss briefly the possible errors affecting the accuracy in pressure / level
measurement as observed in the experiment.
6. What are the main objectives of a wet lag calibration?

4.0 REFERENCE
1. Experiment Manual LMC 200. QDR Marketing Sdn Bhd

Experiment 4: Level Measurement & Calibration System

Experiment 4: Level Measurement & Calibration System