CCB 3072

PROCESS INSTRUMENTATION & CONTROL LAB

Experiment 3 : Level Transmitter
Group : 2

Group Members : Aqilah binti Jazuli 15626

Mohd Afzan bin Abdullah 15472

Chang Oon Hang 15290


Che Muhammad Aiman Syazwan
bin Che Mohd Asri 15597

Cheryl Kok Hui YIng 15363



Date of Experiment : 23th June 2014






1.0 SUMMARY
Basically, the experiment is designed so that student will notice the effect and also the suitable
transmitter that can be used for the closed and open tank. There are two types of transmitter which
is flanged-mounted differential pressure transmitter and differential pressure transmitter.
The different between the open and closed in this experiment is by having open or closed the tank
from air getting inside. For the closed one, we will inert 1 bar of air pressure. From that, we calculate
the water level as a constant variable and observe the result.
However, there are still some error that need to be improved from this experiment such as
systematic error and human error. This error cant be improved by 100%, but still can reduce it so
that we can get a good result.
As for the result that we get, it have been conclude that for the open tank is suitable with
Flange-Mounted Differential Pressure Transmitter, while for the closed tank is suitable with the
Differential Pressure Transmitter.
OBJECTIVE
Calibration of a differential pressure transmitter for open-tank level measurement
Calibration of a differential pressure transmitter for closed-tank level measurement
Calibration of a flanged-mounted differential pressure transmitter for open-tank level
measurement
Calibration of a flange-mounted differential pressure transmitter for closed-tank level
measurement
Determination of the resistance and capacitance of a level process
Step response of a level process and determination of the time constant


INTRODUCTION
Different types of level transmitter are used for different types of applications. Some of the
more important types of level transmitters are the following:

i. Measurement based on hydrostatic head. Pressure and differential pressure measurement.
ii. Conductance and capacitance type probes
iii. Sonar devices
iv. Gamma Rays devices

In the current experiment, measurement based on pressure and differential pressure is used.
The liquid in a vessel exerts hydrostatic pressure which is proportional to the liquid density and head of
the liquid. For constant density the measurement of the hydrostatic pressure or pressure at the bottom
of the vessel is directly related to the level of liquid in the vessel. This principle is widely used for level
measurement because of its simplicity and low cost.

Differential pressure signifies the difference in pressure between two points. Differential
pressure measurement is useful for measuring flow or level.

In the case of flow, a device like orifice or venture tube is introduced into the flow path. This
creates a pressure drop between the upstream and down steam points of the orifice that is related to
the flow rate. Hence by measuring the pressure difference between the upstream and downstream
points of the orifice we can measure the pressure drop and hence calculate the flow rate.

For measuring level in tank the differential pressure between the bottom of the tank and the
top of the tank is measured which is directly related to the hydrostatic head created by the liquid level
which can be converted to the level using the density of the liquid.

The set up for this experiment is easy. Liquid is pumped from the sump Tank A by a pump P and
controlled by the manual MV01 and MV02. The flow rate of the liquid can be measured by the
rotameter. Liquid enters the Tank B at the top. The liquid exits from the tank through the bottom exit
and the outflow can be controlled by the calibrated ball valve MV03. MV03 is provided with a scale to
determine the % opening of the valve.

The level in the tank is indicated by a sight glass and the level can be read from the scale, which is
attached. The level is also measured by the two level transmitters. LT01 is a flange-mounted DP
transmitter while LT02 is a DP level transmitter. Both the transmitters are connected to an air pressure
source with regulator and pressure gauge. This is used to simulate pressurized closed tank conditions.
2.0 METHODOLOGY
The experimental setup consists of a cylindrical vessel of diameter d = 300 mm and height h =
1200mm. Liquid is pumped from the sump Tank A by a pump P and controlled by the manual MV01 and
MV02. The flow rate of the liquid can be measured by the rotameter. Liquid enters the Tank B at the
top. The liquid exits from the tank through the bottom exit and the outflow can be controlled by the
calibrated ball valve MV03. MV03 is provided with a scale to determine the % opening of the valve.

The level in the tank is indicated by a sight glass and the level can be read from the scale, which is
attached. The level is also measured by the two level transmitters. LT01 is a flange-mounted DP
transmitter while LT02 is a DP level transmitter. Both the transmitters are connected to an air pressure
source with regulator and pressure gauge. This is used to simulate pressurized closed tank conditions.

Part I: Determination of flow resistance
1. Valve MV03 is closed. Valves MV01 and MV02 are fully open. Pump P is started.
2. Valve MV03 is opened to 20% open.
3. Valve MV01 and MV02 are adjusted so that the level of liquid in the tank is around 100mm.
4. As the level stabilizes and remains constant, the flow rate and liquid level are recorded.
5. A minimum of FIVE (5) different levels within the range of 100mm to 500mm is selected. The
experiment is repeated the relevant data is recorded.
6. The output valve is changed to 30% open. Steps (3) to (6) are repeated. The experiment is
repeated with the valve opening of 50%.

Part II: Level measurement in open and closed tanks
1. Valve SV06 is kept open (open tank level measurement).
2. MV03 is kept 50% opened.
3. MV01 and MV02 are fully opened. Pump P is started.
4. By adjusting the valves MV01 and MV02, the level is adjusted to 100mm. All relevant data
available are recorded.
5. A minimum of FIVE (5) levels within the range of 100mm to 500mm is selected by increasing the
flow rate correspondingly. Relevant data at each level is recorded.
6. The experiment is repeated by reducing the flow in steps until the lowest flow rate is achieved.
7. Valve SV06 is closed. A pressure of 1 psi is set by adjusting the air pressure regulator connected
to the top of the tank (closed pressurized tank). MV03 is kept open. Steps (4) to (6) are
repeated.
8. The experiment is repeated for tank top pressure equal to 0.5psi.
The air pressure is controlled by controlling the air regulator and SV06 when increasing or
decreasing the flows to the pressurize tank, so that the pressure in the pressurized tank will remain
constant.

Part III: First order tank level dynamics
1. Valve SV06 is kept open. MV03 is set for 30% opening.
2. The values of the flow rates corresponding to tank level equal to 300mm and 500mm are
determined. These flow rates are let to be equal to F1 and F2 respectively.
3. The flow rate is set equal to F1. The level is let to come to steady state.
4. The flow is suddenly changed to F2 by opening the valve MV02.
5. The change in level is recorded as a function of time using the two transmitters and the
recorded. The response is recorded.
6. A graph similar to Fig. 5 is obtained. From the graph, values of K and T are determined.
The values of the theoretical value of the time constant are determined as follows.

3.0 RESULTS

Determination of Flow Resistance

Level (mm)
Flow Rate (L/min)
30% 50%
100 8.5 20.0
200 9.5 23.0
300 10.5 25.0
400 12.5 26.0
500 13.0 28.0
4.0 Table 1: Flow resistance of valve
Level Measurement In Open Tank Level With 30% Opening

Tank top
pressure
(psi)
Flow rate
(L/min)
Sight glass
reading
(mm)
Differential
pressure
transmitter
Flange-mounted
differential
pressure
transmitter
Level increasing Level increasing
0
19.0 100 102 103
21.5 200 202 208
24.0 300 305 317
27.0 400 412 432
28.0 500 510 537
5.0 Table 2: Calibration of open tank level (30% open) increasing level
6.0 Table 3: Calibration of open tank level (30% open) decreasing level
Tank top
pressure
(psi)
Flow rate
(L/min)
Sight glass
reading
(mm)
Differential
pressure
transmitter
Flange-mounted
differential pressure
transmitter
Level decreasing Level decreasing
0
28.0 500 510 537
27.0 400 406 422
25.0 300 304 316
23.0 200 207 211
19.0 100 104 103
Level Measurement of Closed Tank Level with 30% Opening and 0.5 psi

Tank top
pressure
(psi)
Flow rate
(L/min)
Sight glass
reading
(mm)
Differential
pressure
transmitter
Flange-mounted
differential
pressure
transmitter
Level increasing Level increasing
0.5
20.0 100 104 440
21.5 200 207 650
24.0 300 312 786
27.0 400 412 867
28.0 500 510 990
7.0 Table 2: Calibration of open tank level (30% open) increasing level
8.0 Table 3: Calibration of open tank level (30% open) decreasing level


Tank top
pressure
(psi)
Flow rate
(L/min)
Sight glass
reading
(mm)
Differential
pressure
transmitter
Flange-mounted
differential pressure
transmitter
Level decreasing Level decreasing
0.5
28.0 500 510 990
27.5 400 410 878
24.0 300 312 780
22.5 200 208 689
20.0 100 104 410
y = 81.081x - 575.68
R = 0.973
y = 51.075x - 946.24
R = 0.9704
0
100
200
300
400
500
600
0 4 8 12 16 20 24 28 32
L
e
v
e
l

(
m
m
)

Flow Rate (L/min)
Level vs. Flow Rate
30% Open
50% Open
Linear (30% Open)
Linear (50% Open)
0
100
200
300
400
500
600
0 100 200 300 400 500 600
S
i
g
h
t

G
l
a
s
s

R
e
a
d
i
n
g

(
m
m
)

Level (mm)
Flanged-Mounted Pressure
Transmitter
Increasing
Decreasing
QUESTION
1. Based on your data, use appropriate plots to determine the flow resistance of the
calibrated flow valve.




















2. Based on your data,
a. Develop the Calibration curve of Flange-mounted Transmitter in Open Tank













Figure 1 Level vs. Flow rate
Figure 2 : Calibration curve of Flanged Mounted Pressure Transmitter in open tank with 30%
valve opening
0
100
200
300
400
500
600
0 100 200 300 400 500 600
S
i
g
h
t

G
l
a
s
s

R
e
a
d
i
n
g

(
m
m
)

Level (mm)
Differential Pressure Transmitter
Increasing
Decreasing
0
100
200
300
400
500
600
0 200 400 600 800 1000 1200
S
i
g
h
t

g
l
a
s
s

r
e
a
d
i
n
g

(
m
m
m
)

Level (mm)
Flanged-mounted Pressure
Transmitter (closed tank)
Increasing
Decreasing

b. Develop the Calibration curve of Differential Pressure Transmitter in Open Tank




















c. Develop the Calibration curve of Flange-mounted Transmitter in Closed Tank


Figure 3 Calibration curve of Differential Pressure Transmitter in open tank with 30% valve
opening
Figure 4 Calibration curve of Flanged-Mounted Pressure Transmitter in close tank with 30%
valve opening
0
100
200
300
400
500
600
0 100 200 300 400 500 600
S
i
g
h
t

g
l
a
s
s

r
e
a
d
i
n
g

(
m
m
)

Level (mm)
Differential Pressure Transmitter
(closed tank)
Increasing
Decreasing

d. Develop the Calibration curve of Differential Pressure Transmitter in Closed Tank



Figure 5 Calibration curve of Differential Pressure Transmitter in close tank with 30% valve
opening
4.0 DISCUSSION
For this experiment, measurement based on pressure and differential pressure was used. For constant
density (liquid) the measurement of the hydrostatic pressure or pressure at the bottom of the tank is
directly related to the level of liquid in the tank.
From the results obtained during the experiment, it was observed that the resistance of the flow
was an inverse proportional to the outlet valve opening. For this experiment the same level of liquid was
hold in the tank and resistance flow was recorded with valve opening of 20% and 30% respectively
resulting in higher flow with more percentage of valve opening. In other words, the resistance of flow is
reduced with the opening of the valve as it can be referred in the table 1.
As for the next experiment the level was measured reading from two different types of
transmitters, the differential pressure transmitter and a flanged mounted differential pressure
transmitter respectively. The tank was kept open during this experiment. It can be observed that the
flanged-mounted differential pressure transmitter read high level readings compare to the differential
pressure transmitter.
On the other hand, as the same experiment was conducted only that this time the tank was kept
closed, an out of range reading was observed in the flanged-mounted differential pressure transmitter
could no pick the different reading and the same reading of 990 was read for different flow rates.
However, the differential pressure transmitter was able to read precise level readings for different flow
rates.
With all the above observed both differential pressure and flanged-mounted differential
pressure transmitters respectively responded during the open tank experiment whereas the flanged-
mounted differential pressure transmitter failed during the closed tank experiment.

Errors:

1. Systematic error : The reading of Differential Pressure and Flanged-Mounted Differential
Pressure Transmitter keep fluctuating during the experiment. So, the readings taken may not be
accurate.
2. Human error : Some of the valves may not close and open properly. Besides, some air also may
trap inside the tank that affects the readings of the transmitter.
3. Parallax error : The flow rate of the liquid and the level of liquid in the tank may not be accurate
since the position of the eye is not perpendicular to the scale when taking readings.
4. Zero error : This error involved the incorrect reading of the instruments such as transmitter. The
transmitters are too sensitive to any changes in the environment and may slightly affect the
result of this experiment.
Recommendations:
1. In order to improve the results, the experiment should be repeated several times and get the
average values.
2. Before taking readings, make sure that no air are trapped inside the tank and make sure all the
valves close or open properly.
3. Keep the eye perpendicular to the scale during taking the reading of the level of liquid.
5. To avoid zero error ,repeat the experiment at least three times to get the average result.

5.0 CONCLUSION
We can conclude from the experiment that the resistance of the flow is inversely
proportional to the outlet valve opening. This is because the pressure in the tank led by the
increasing the flow rate of water in the tank. For open tank, the flanged-mounted differential
pressure transmitter records high level readings compared to the differential pressure
transmitter.However,the differential pressure transmitter was able to read more precise and
accurate level readings for different flow rates for close tank.
Hence, for calibration of pressure for the open tank is suitable with Flange-Mounted Differential
Pressure Transmitter, while for the closed tank is suitable with the Differential Pressure Transmitter.

6.0 REFERENCES

Flow and Level Measurement, Retrieved on 20

June 2014, from
http://www.omega.com/literature/transactions/volume4/T9904-07-DIFF.html#diff_1
Level Measurement using Pressure Transmitter, Retrieved on 20

June 2014, from http://blog.impress-
sensors.co.uk/tag/differential-pressure-transmitter
Rosemount 2024 Differential Pressure Transmitter. Retrieved on 20 June 2014, from
http://www2.emersonprocess.com/siteadmincenter/PM%20Rosemount%20Documents/00809-0100-
4592.pdf