Experiment No.

Title: Level measurement using Differential Pressure Transmitter (DPT)

Aim: To study DPT level measurement technique and perform level measurement using DPT.

Apparatus: DPT level measurement trainer, digital multi-meter.

Theory:

An electronic device that measures the height of material-typically liquid-inside a tank or

other vessel is called the level measurement sensor. Level measurement is an important task
in various industries. Incorrect or inappropriate measurements can cause levels in vessels to
be excessively higher or lower than their measured values. Low levels can cause pumping
problems and damage the pump, while high levels can cause vessels to overflow and
potentially create safety and environmental problems. Vessels operating at incorrect
intermediate levels can result in poor operating conditions and affect the accounting of
material.

Level measurement sensors fall into two main types:

 Point level measurement
 Continuous level measurement

Point level measurement sensors are used to mark a single discrete liquid height at preset
level condition. Generally, this type of sensor functions as a high alarm, signaling an overfill
condition, or as a marker for a low alarm condition. Continuous level sensors are more
sophisticated and can provide level monitoring of an entire system. They measure fluid level
within a range, rather than at a one point, producing an analog output that directly correlates
to the level in the vessel. To create a level management system, the output signal is linked to a
process control loop and to a visual indicator.

The level of a liquid in a vessel can be measured directly or inferentially. Examples of direct
level measurement include float, magnetic, retracting, capacitance, radar, ultrasonic and laser
level measurement technologies. Weight and differential pressure technology measure level
inferentially. We are using the differential pressure level measurement technique for level
measurement.

Differential Pressure level measurement:

The differential pressure level measurement uses a differential pressure detector connected
to bottom of the tank being monitored. The higher pressure caused by the fluid in the tank is
compared to lower reference pressure which is generally atmospheric pressure. This
comparison takes place in differential pressure detector. Figure 1 illustrates the typical
differential pressure level measurement system.

The tank is open to atmosphere; therefore it is necessary to use only high pressure connection
on the differential pressure transmitter. The low pressure side is vented to atmosphere;
therefore the pressure difference is hydrostatic head, or weight of the liquid in the tank. The
maximum level that can be measured can be determined by the maximum height of the liquid
above the transmitter. The minimum level that can be measured is determined by the point
where the transmitter is connected to the tank.

Figure 1: Differential pressure level measurement

Differential pressure transmitter construction:

A differential pressure transmitter has three functional parts.

Direct Pressure sensing element (located in the lower housing):

The majority of industrial DP Transmitters are fitted with diaphragm as the pressure sensing
element. This diaphragm is a mechanical device. It is placed in between the two pressure inlet
ports. The diaphragm will be deflected by the applied pressure. This is clarified in figure 2.
This deflection is converted into an electrical signal. This is normally done by the sensors. The
commonly used sensors are (a) Strain Gauge (b) Differential Capacitance (c) Vibrating wire.
The sensor output is proportional to the applied pressure.

Figure 2: Differential pressure transducer internal structure

Electronic Unit:

The electrical signal generated at the lower chamber by the sensor is in the range of milli-volt
only. This signal is to be amplified to 0-5V or 0-10V range or is to be converted to 4-20mA for
onward transmission to a remote instrument. This upper housing is the Transmitter portion
of the DP Transmitter which houses the Electronic Unit. See figure 2 for further clarifications.

2-Wire 4-20mA Current Transmitter:

A DC output current is generated which is directly proportional to the pressure range of the
Differential Pressure Transmitter. The lower range is 4mA, and the upper range is 20mA. This
controlled current output is not affected by load impedance variation and supply voltage
fluctuations.

Procedure:

1 Close drain cock at bottom of measuring level tank.

2 Fill tank with clean water.

3 Insure the mains supply is 230 v .

4 Connect the mains supply & turn On. Observe digital indicator read 0.00.

5 Fill the measuring tank till o.oomm

6 Connect the multimeter to banana socket & measure Transmitter current.

7 Fill level tank to 100mm level wait for 2 min to stabilize level

8 Measure transmitter current & observe digital level indication.

9 Repeat exercise for next level at increment of 100mm till level reaches to top of tank.

10 Repeat observation from top level to 0.00 mm level by adjusting drain value.

11 Repeat entire exercise if required.

Level calculation formula:

Level = measured current (ImA) – 4 mA * (higher range) / 16.

Observation Table:

No. Glass level (mm) Digital indicator (mm) Current (mA) Level by calc. (mm)

1 0

2 50

3 100

4 150

5 200

6 250

7 300

8 350

9 400

10 450

11 500

Conclusion:

We have measured the level of water using DPT level measurement device and verified it.