OBJECTIVE

To evaluate and study the measurement of level using the following.

1

A differential pressure / level transmitter (ABB model 621ED)

A sight glass with millimetre scale.

SUMMARY
The purpose of level measurement and calibration experiment was to evaluate and
study the measurement of level using differential pressure or level transmitter and sight glass
with millimetre scale This experiment is conducted under two different conditions which is
the first one is open tank and heater off while the other one is closed tank and heater off.. The
reading of actual level (LI) is slightly different with the actual level (LG) because there is
parallax error while set the level on the suggested level as the position of the sight glass with
millimetre scale is high. There are small different between reading on the sight glass and the
level indicator. This is because sight glass reading was taken manually by human eye contact
while level indicator was taken by sensor indicator. So, the level indicator is more accurate
than the sight glass. The sight glass less accurate because of human errors while read the
readings.

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 (12%) 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 1B). 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 a 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.

RESULTS
Table 1 : Level measurement (Tank T1 as OPEN tank, Heater OFF)
RUN 1
SET 1
SET 2
A
Suggested Level (mm)
700
700
B
Actual Level (LG)(mm)
700
700
C
Actual Level (LI)(mm)
703
703
o
D
Temperature (TG)( C)
32
32
E
Deviation = | B-C| (mm)
3
3

AVERAGE
700
700
703
32
3

A
B
C
D
E

RUN 2
Suggested Level (mm)
Actual Level (LG)(mm)
Actual Level (LI)(mm)
Temperature (TG)(oC)
Deviation = | B-C| (mm)

SET 1
600
600
604
32
4

SET 2
600
600
604
32
4

AVERAGE
600
600
604
32
4

RUN 3
Suggested Level (mm)

SET 1
500

SET 2
500

AVERAGE
500

B
C
D
E

Actual Level (LG)(mm)

Actual Level (LI)(mm)
Temperature (TG)(oC)
Deviation = | B-C| (mm)

500
507
32
7

500
507
32
7

500
507
32
7

A
B
C
D
E

RUN 4
Suggested Level (mm)
Actual Level (LG)(mm)
Actual Level (LI)(mm)
Temperature (TG)(oC)
Deviation = | B-C| (mm)

SET 1
400
400
402
32
2

SET 2
400
400
402
32
2

AVERAGE
400
400
402
32
2

A
B
C
D
E

RUN 5
Suggested Level (mm)
Actual Level (LG)(mm)
Actual Level (LI)(mm)
Temperature (TG)(oC)
Deviation = | B-C| (mm)

SET 1
300
300
302
32
2

SET 2
300
300
302
32
2

AVERAGE
300
300
302
32
2

Table 2 : Level measurement (Tank T1 as CLOSED tank, Heater OFF)

RUN 1
SET 1
SET 2
A
Suggested Level (mm)
700
700
B
Actual Level (LG)(mm)
700
700
C
Actual Level (LI)(mm)
704
704
D
Temperature (TG)(oC)
32
32
E
Deviation = | B-C| (mm)
4
4

AVERAGE
700
700
704
32
4

A
B
C
D
E

RUN 2
Suggested Level (mm)
Actual Level (LG)(mm)
Actual Level (LI)(mm)
Temperature (TG)(oC)
Deviation = | B-C| (mm)

SET 1
600
600
604
32
4

SET 2
600
600
604
32
4

AVERAGE
600
600
604
32
4

A
B
C
D
E

RUN 3
Suggested Level (mm)
Actual Level (LG)(mm)
Actual Level (LI)(mm)
Temperature (TG)(oC)
Deviation = | B-C| (mm)

SET 1
500
500
503
32
3

SET 2
500
500
503
32
3

AVERAGE
500
500
503
32
3

A
B
C
D

RUN 4
Suggested Level (mm)
Actual Level (LG)(mm)
Actual Level (LI)(mm)
Temperature (TG)(oC)

SET 1
400
400
402
32

SET 2
400
400
402
32

AVERAGE
400
400
402
32

Deviation = | B-C| (mm)

A
B
C
D
E

RUN 5
Suggested Level (mm)
Actual Level (LG)(mm)
Actual Level (LI)(mm)
Temperature (TG)(oC)
Deviation = | B-C| (mm)

SET 1
300
300
303
32
3

SET 2
300
300
303
32
3

AVERAGE
300
300
303
32
3

Summarized results ;
Condition
Run 1
Open tank
Heater off
Closed tank
Heater off

Run 2

Run 3

Run 4

Run 5

Average
deviation
3.6

3.2

3.7
3.6
3.5
3.4
3.3
3.2
3.1
3
open tank

closed tank

Graph 1 : Standard deviation for heater off method

DISCUSSION
Calibration is the process of evaluating and adjusting the precision and accuracy of
measurement equipment. Proper calibration of an instrument allows people to have a safe
working environment and produce valid data for future reference. Calibration refers to the act
of evaluating and adjusting the precision and accuracy of measurement equipment. Instrument
calibration is intended to eliminate or reduce bias in an instrument's readings over a range for
all continuous values.
This experiment is conducted under two different conditions which is the first one is
open tank and heater off while the other one is closed tank and heater off. Based on data
tabulated on table 1 and table 2, a summarization of data is tabulated in graph 1. From the
graph, we can see that in heater off condition open tank contribute the most to the value of
deviation at 3.6 rather than closed tank at 3.2. Basically, when the temperature inside tank is
changed, the density of water is also changed. Based on theory, as the temperature increased,
the density of liquid is decreased. Because density influences pressure of a liquid, this will
make the accuracy of pressure level indicator to drop. So, the change in the accuracy will
increase the standard deviation which is difference between readings from the sight glass with
the reading from the level indicator. The measurement for heater off, which is sighted glass, is
not affected by changes in density of the liquid as during run the experiment, the level of

water inside the tank should be set at the suggested level by monitored the reading at the
sighted glass.

CONCLUSION
The two type of measurement have been compare between open and closed tank. The
tank as open tank and heater has the highest reading difference of the level indicator and
direct with indirect measurement. When the heater off condition and open tank contribute the
most to the value of deviation at 3.6 rather than closed tank at 3.2. It is because, density
influence pressure of liquid. Hence, the change in the accuracy will increase the standard
deviation which is difference between readings from the sight glass with the reading from the
level indicator. We can conclude that, closed tank system with heater off give less deviation
than open tank system.

RECOMMENDATION
For the recommendation, during take of reading, at sight glass with millimetre scale
(LG) which is the indirect measurement, the eye should sharp to the level. During the closed
tank, the pressure is adjusted to increase the level of pressure rises there of many error. In
addition, we also must check or ensure there are no troubles shooting before run the

experiment. Connection between high operating pressure and low hydrostatic pressure easy to
occur, so we must check the connection before run the experiment. Obstructed sensing lines
and draining sensing line also must be check. Hence, to get the accurate result, we must avoid
the error and double check for the trouble shooting error.

TUTORIAL
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.

3.

dip stick
Sight glasses
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

REFERENCES
i.

Schnake.

J.,

(2007).

Liquid

Level

Measurement,

Available

at:

http://www.controlglobal.com/articles/2009/guidetopressureleveltrans0902/.
[Accessed on 15 April 2015].
ii.

Omega Transaction in Measurement & Control Series, (1995). Pressure or Density

Level

Instrumentation,

Available

at:

http://www.omega.com/literature/transactions/volume4/t9904-12-press.html.
[Accessed on 15 April 2015].
iii.

David R. Caprette (2000). All about Instrumentation [Online] Available at:

http://www05.abb.com/global/scot/scot206.nsf/veritydisplay/bb949b50a265ef08c1257
bf6004ccab3/$file/TI_266-EN_B-09_2013.pdf [15 April 2015]

iv.

Third Edition; Bela G. Liptak Instrument Engineer Handbook Process Control

v.

Idaho State Universitys College of Technology, (1992). Level Measurement.

Available

vi.

at:

http://www.isu.edu/estec/ic-ed-modules/Module-9-Level-

Measurement.pdf. [Accessed on 15 April 2015].

Instrumentation & Control Chulalongkorn University, (2014). Level Instrumentation.
Available at: https://canteach.candu.org/Content%20Library/20053318.pdf. [Accessed
on 15 April 2015].