Exp 2

PART PAGE
OBJECTIVE AND SUMMARY 1
INTRODUCTION 2
METHODOGICAL AND THEORY 2-3
RESULTS AND DISCUSSIONS 3-10
CONCLUSION AND 11
RECOMMENDATION
TURORIALS 11-12
REFERENCES 13
OBJECTIVE
1. To study gas volumetric flow rate measurement using orifice plate.

2. To study gas mass flow rate measurement using orifice plate and perfect gas law to
compute the gas density from the pressure and temperature measurements.
3. To study gas mass flow rate (Fm) control using PID controller.
SUMMARY
Level measurement instrument is a device that is used to detect, indicate or help control
liquid or solid levels based on the applications involved in the process. This device can be
separated into two main categories which direct or mechanical measurement and electronic
measurement. In this experiment, students were assigned to carry this experiment into two
sections, which are closed and opened tank. Furthermore, each section is divided into another
two parts with either heater is on or off. The objectives are to study gas volumetric flow rate
measurement using orifice plate, besides understanding the concept of gas mass flow rate
measurement using orifice plate and perfect gas law to compute gas density from the pressure
and temperature measurements. The third objective is to study gas mass flow rate by using PID
(proportional-integral-derivative) controller. Each set of the experiment was run five times by
manipulating the level from 700 mm until 300 mm. In order to operate the instrument, there
are certain principles of level measurement, which are necessary to obey. At the end of the
experiment, it was found that closed tank, with heater on gave larger difference in term of
pressure compared to an opened tank. Theoretically, the scenario occurred due to the rise of
pressure in open tank as the vapour was released from the chamber while in closed tank, the
pressure was maintained. Finally, several factors that contributed to errors in the experiment
are the time taken for recording the reading were varies whereas for the temperature, it was
highly influenced by the surrounding temperature.
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 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
METHODOLOGY
This experiment had been divided into some parts which are start-up procedure,
experiment 1, 2, 3 and 4, level measurement involving heater to turn off and heater to turn on,
respectively and plant shut-down. Each of these experiments (experiment 1 and 2) has open
tank and close tank to run. Experiment 3 and 4 has open tank and close to run but heater on.
The experiment was start with start-up procedure. The main power supply was switched on
while the heaters and pump were switched off. Pump suction valve and all pump discharge
valve was fully opened. Before starting the pump, by-pass valve was opened and close by-pass
valve after pump start. Air supply was set 3.0 psig from AFR. At Tank 1, top vent and overflow
valve was fully opened. Bottom globe valve was fully closed while gate valve was fully opened.
Locate the air inlet manual isolation valve is 90o to the air supply inlet tubing.
Next, experiment 1 and 2 are about level measurement. In this experiment 1 and 2, the
heater is switch off and it consists of two runs which open tank and close tank. For run I, let
the water in tank T2 to stabilize. The reading of actual temperature in tank T1 from temperature
gauge (TG) was recorded. For run II, top space of tank 1 is pressurized. The overflow valve,
vent, the bottom gate and globe valve was shut down. After that, let air flow into top space of
tank T1 by turning the air inlet manual isolation valve. The reading of actual temperature in
tank T1 from temperature gauge was recorded. In experiment 3 and 4, the heater was switched
on and it similar with experiment 1 and 2 which is consists of two runs, open tank and close
tank. Finally, after running all the experiments, the machine was shut down.
RESULTS
TABLE 1: Level Measurement (Tank T1 as OPEN tank, Heater OFF)
RUN I SET 1 SET 2 AVERAG

E
A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm) 700 700 700
C Actual Level (LI) (mm) 712.8 712.9 712.85
D Temperature (TG) (0C) 43 43 43
E Deviation = | B-C | (mm) 12.8 12.8 12.8
RUN II SET 1 SET 2 AVERAG

E
E Deviation = | B-C | (mm) 12.8 12.8 12.8

E
E Deviation = | B-C | (mm) 11.7 11.7 11.7

E
E Deviation = | B-C | (mm) 11.7 11.7 11.7

E
E Deviation = | B-C | (mm) 6.4 6.4 6.4

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

E
E Deviation = | B-C | (mm) 11.5 11.5 11.5

E
E Deviation = | B-C | (mm) 10.8 10.8 10.8
RUN III SET 1 SET 2 AVERAG

E
E Deviation = | B-C | (mm) 11.1 11.1 11.1

RUN IV SET 1 SET 2 AVERAG
E
E Deviation = | B-C | (mm) 10.7 10.7 10.7
RUN V SET 1 SET 2 AVERAG

E
E Deviation = | B-C | (mm) 9.8 9.8 9.8
2.3 TABLE 3: Level Measurement (Tank T1 as OPEN tank, Heater ON)

E
E Deviation = | B-C | (mm) 9.6 9.6 9.6

E
E Deviation = | B-C | (mm) 9.0 9.0 9.0

E
E Deviation = | B-C | (mm) 9.7 9.7 9.7

E
E Deviation = | B-C | (mm) 9.7 9.7 9.7

E
E Deviation = | B-C | (mm) 9.2 9.2 9.2
TABLE 4: Level Measurement (Tank T1 as CLOSED tank, Heater ON)

E
E Deviation = | B-C | (mm) 14.1 14.1 14.1

E
E Deviation = | B-C | (mm) 16.2 16.2 16.2

E
E Deviation = | B-C | (mm) 11.5 11.5 11.5

E
E Deviation = | B-C | (mm) 14.7 14.7 14.7

E
E Deviation = | B-C | (mm) 14.4 14.4 14.4

DISCUSSIONS
The objective of this experiment firstly is to differentiate the reading of the direct
measurement and indirect measurement. Then to compare these two types of measurement
between open and closed tank. For this particular experiment, there are four conditions to
compare the reading between the direct and indirect measurement. These conditions are tank
T1 as open tank heater on and lastly T1 as closed tank and heater on.
Each condition was run 5 times with each run having two sets of reading to obtain an
average reading. Based on the result, looking at only run 1 table 1, 2, 3, and 4 it shows that the
condition where tank T1 as closed tank and heater on has the highest reading difference
between the level indicator of the front panel (LI) which is the direct measurement with the
sight glass with millimetre scale (LG) which is indirect measurement.
The difference error is about an average of 7. The condition where tank T1 as closed
tank and heater off is come second place with error 4. When the heater is off, there is pressure
in tank still exist but is not in excited state. Differ from 15 when heater is on, the heat helps to
make the pressure excited resulting in greater difference of LG and LI, whereas tank T1 as
open tank and heater off have no error. The theory that if it is a closed tank, changes of gas
pressure will cause 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 T1 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 maintains its
pressure. There are some errors in this experiment which are, the reading were not accurately
recorded. The next error is, the time taken for next reading are not constant, and the temperature
is affected by surrounding temperature.
CONCLUSION AND RECOMMENDATIONS
The conclusion of this experiment is where tank T1 as closed tank and heater on has the
highest reading difference between the level indicator of the front panel(LI) which is the direct
measurement with the sight glass with millimeter scale (LG) which is indirect measurement.
The difference error is about an average of 7. The condition where tank T1 as closed tank
and heater off is come second place with error 4. T1 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.
Recommendation for this experiment would be, the sight glass level indicator should
calibrate regularly to avoid huge difference between sight glass and level indicator in the front
panel. The air pressure regulator has to check frequently so that the pressure will not fluctuate
and affect the reading
TUTORIALS
1. Level is measured in many of the processes in the industry. List and explain the most
common reasons for measuring level.
 To keep track of inventory. Essential for accurately control in terms of weight or volume
in tank gauging system.
 For custody transfer. This require high level of accuracy as it involves the amount of
material that was bought and sold which is based on level measurement converted into
weight or volume.
 Process efficiency. Good level measurement will enhance the effectiveness and efficiency
of a system to operate.
2. Name the two methods of level measurement used in the experiment.

 Indirect Level Measurement
 Open Tank Measurement
3. How the depth of a liquid does correspond to changes in liquid pressure? Can a pressure
transmitter be used to measure level?
 Certain points that align in a same vertical axis but not horizontally do affect the liquid
pressure. The deeper the point of a liquid, the higher the pressure occurred. Yes, as different
points of depth have different reading of pressure.
4. The differential pressure transmitter is used to measure level in an open tank or closed tank
system. Discuss how this is done.
 It is used in open tank system. It can detect any pressure difference in the system. It applied
capsule deflect & create motion. The top end force bar connected to detector and will
produce a 4 - 20 mA signal. Usually measure for gas pressure.
5. Discuss briefly the possible errors affecting the accuracy in pressure / level measurement
as observed in the experiment.
 The temperature of the water in the tanks or any parts of the system that can accidentally
store heat temporarily. Heat may affect a certain accuracy or sensitivity of a sensor.
6. What are the main objectives of a wet lag calibration?

 Wet leg calibration method is required for level measurement in a closed tank with hot and
intensely cold liquids.
REFERRENCES
1. Andrade, F. (2017). Differential pressure in open tank level measurement. [online]

Visaya.solutions. Retrieved from https://visaya.solutions/en/article/differential-pressure-
open-tank-level-measurement [Accessed 2 Mar. 2019].
2. Coulton (2019). Beginner's guide to Differential Pressure Transmitters. [online] Retrieved
via https://www.coulton.com/beginners_guide_to_differential_pressure_transmitters.html
[Accessed 2 Mar. 2019].
3. Dirjish, M. (2000). The Principles of Level Measurement | Sensors Magazine. [online]
Sensorsmag.com. Retrieved from https://www.sensorsmag.com/components/principles-
level-measurement [Accessed 2 Mar. 2019].
4. Schnake. J., (2007). Liquid Level Measurement, Available at:
http://www.controlglobal.com/articles/2009/guidetopressureleveltrans0902/. [Accessed on
1 Marchl 2018].
5. P. Boonsrimuang, A. Numsomran, S. Kangwanrat, Design of PI Controller using MRAC
Techniques for Coupled-Tanks Process, The World Academy of Science, Engineering and
Technology, 2010, p485-490.
6. K.K. Tan, R. Ferdous, S. Huang, Closed Loop Automatic Tuning of PID controller for
Nonlinier Systems, The Chemical Engineering Sciences 57, 2002, p3005-3011.
7. H. Canbolat, Level Measurement Technique using Three Capacitive Sensors for Liquids,
The Instrumentation and Measurement 58, 2009, p3762-3768.

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PART PAGE

OBJECTIVE AND SUMMARY 1

METHODOGICAL AND THEORY 2-3

RESULTS AND DISCUSSIONS 3-10

1. To study gas volumetric flow rate measurement using orifice plate.

Principles of Level Measurement

RUN I SET 1 SET 2 AVERAG

A Suggested Level (mm) 700 700 700

B Actual Level (LG) (mm) 700 700 700

C Actual Level (LI) (mm) 712.8 712.9 712.85

D Temperature (TG) (0C) 43 43 43

E Deviation = | B-C | (mm) 12.8 12.8 12.8

RUN II SET 1 SET 2 AVERAG

A Suggested Level (mm) 600 600 600

B Actual Level (LG) (mm) 600 600 600

C Actual Level (LI) (mm) 612.8 612.7 612.75

D Temperature (TG) (0C) 43 43 43

E Deviation = | B-C | (mm) 12.8 12.8 12.8

A Suggested Level (mm) 500 500 500

B Actual Level (LG) (mm) 500 500 500

C Actual Level (LI) (mm) 511.7 511.6 511.65

D Temperature (TG) (0C) 43 43 43

E Deviation = | B-C | (mm) 11.7 11.7 11.7

RUN II SET 1 SET 2 AVERAG

A Suggested Level (mm) 400 400 400

B Actual Level (LG) (mm) 400 400 400

C Actual Level (LI) (mm) 411.9 411.9 411.9

D Temperature (TG) (0C) 43 43 43

E Deviation = | B-C | (mm) 11.7 11.7 11.7

RUN II SET 1 SET 2 AVERAG

A Suggested Level (mm) 300 300 300

B Actual Level (LG) (mm) 300 300 300

C Actual Level (LI) (mm) 306.4 306.6 306.5

D Temperature (TG) (0C) 43 43 43

E Deviation = | B-C | (mm) 6.4 6.4 6.4

RUN I SET 1 SET 2 AVERAG

A Suggested Level (mm) 700 700 700

B Actual Level (LG) (mm) 760 700 700

C Actual Level (LI) (mm) 771.3 771.2 771.25

D Temperature (TG) (0C) 41 41 41

E Deviation = | B-C | (mm) 11.5 11.5 11.5

RUN II SET 1 SET 2 AVERAG

A Suggested Level (mm) 600 600 600

B Actual Level (LG) (mm) 600 600 600

C Actual Level (LI) (mm) 612.4 612.5 612.45

D Temperature (TG) (0C) 41 41 41

E Deviation = | B-C | (mm) 10.8 10.8 10.8

RUN III SET 1 SET 2 AVERAG

A Suggested Level (mm) 500 500 500

B Actual Level (LG) (mm) 500 500 500

C Actual Level (LI) (mm) 511.9 511.9 511.9

D Temperature (TG) (0C) 41 41 41

E Deviation = | B-C | (mm) 11.1 11.1 11.1

A Suggested Level (mm) 400 400 400

B Actual Level (LG) (mm) 400 400 400

C Actual Level (LI) (mm) 408.0 408.5 408.25

D Temperature (TG) (0C) 41 41 41

E Deviation = | B-C | (mm) 10.7 10.7 10.7

RUN V SET 1 SET 2 AVERAG

A Suggested Level (mm) 300 300 300

B Actual Level (LG) (mm) 300 300 300

C Actual Level (LI) (mm) 309.8 309.8 309.8

D Temperature (TG) (0C) 41 41 41