Level Measurement

SUMMARY
The main objective of this experiment of level measurement and calibration is to measure and
differentiate the actual level (LG-sight glass with mm scale) and actual level (LI-level indicator
with mm scale) between open and closed tank based on given suggested level by using level
transmitter and indicator. As we know, level is measurement at position of interface between
phase (height) and it is a vertical measurement which measure from surface to reference point,
P=pgh where pressure at base is height minus hydrostatic pressure. Level measuring devices
in this experiment is differential device and float device. Other objectives are to measure two
type of measurement, direct measurement and indirect measurement where in indirect
measurement, involves converting measurement which is temperature that can affect the
accuracy of indirect measurement. In this experiment, it was run 5 times with different
suggested level starts with 700 mm, 600 mm, 500 mm, 400 mm, and 300 mm and the level is
measured by four parts of experiment, where Experiment 1, is to measure actual level of opened
tank with direct measurement as tank T1 as open tank, heater off . In Experiment 2, the tank
T1 is closed and the heater off as we want to observed the closed tank with direct measurement.
However, in Experiment 3, temperature is used as a factor that can affected accuracy of actual
level in indirect measurement tank where tank T1 as open tank, heater on and same goes in
Experiment 4 but the tank T1 is closed (close tank). By obtaining correct actual level at level
transmitter and indicator and using correct formula for its deviation, the result is obtained where
Experiment 1 and 2, employs with physical properties such as fluid motion, buoyancy, optical,
thermal, electrical properties and does not require compensation for changes level causes by
temperature changes. Then, in Experiment 3 and 4, temperature that are used in that
experiments are 50oC and will turn off the heater automatically, when the temperature drops
the heater will be turned on again as long stays on at the panel. So the deviation in this two
experiments shows the lowest ranges between LG and LI. Meanwhile, Experiments 2 and 4,
the pressure is open as the experiment conducted was in closed tank so that the tank is under
pressure. In closed tank system, the transmitter location is restricted by maximum allowable
distance above the lower tap. In pressurized system, the transmitter should be mounted at or
below the lower tap to ensure the transmitter always sees a positive pressure on both the
measurement and references sides. This experiment is successful because the objectives is
reached and based on the actual level(LG), actual level (LI) and the deviation is observed nearly
same with the theory.
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 (±1-
2%) 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 1-
B). 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.
THEORY
Most level measurement done is achieved through inference. Inferential level measurement
techniques obtain a level indication by monitoring the pressure exerted by the column of liquid.
The pressure exerted at the base of a column of liquid is given by
Pressure= height of column of liquid x density of liquid x acceleration due to gravity
P= pgh
In terms of weight density (N/m3), S, we can organize the above formula to read:
P=Hs
It is because the specific gravity of a liquid can be expressed as the ratio of the weight of the
volume of a liquid to that of an equivalent volume of water, in level measurement applications,
we can define level as:
Level= height x specific gravity of liquid= h x SG
Therefore, in order to determine liquid level, it is essential that the specific gravity of the liquid
be known. Level is then determined by multiplying the liquid height above the point of
measurement by the specific gravity of the liquid as indicated in the formula above. Another
point worth noting is that differential pressure transmitters are used as level transmitters to
measure level.
Open tank level measurement
Level measurement in open tanks is the simplest. The differential pressure transmitter for level
measurement is normally mounted at or below the tank connection in order to measure the
pressure of the liquid above. The pressure is sensed by the process flange and transmitted to
the high side of the sensing element of the transmitter.
Here, the level transmitter is mounted at the base of the open tank corresponding to the zero
level of measurement:
P(high)= P (atm) + (h x SG) and P (low)= P (atm)

Therefore, differential pressure, ΔP = P (atm) + (h x SG) – P (atm)= h x SG
Close tank level measurement
In a close tank level measurement installation , if a gas phase exists on top of the liquid, the
gas pressure must be compensated. This is because a change in the gas pressure will cause a
change in the level transmitter, LT, output. Furthermore, the pressure exerted by the gas may
be so high that the pressure due to the column of the liquid becomes insignificant.
A pressurized close tank application requires a reference connection. A reference connection

is a connection from the transmitter (LT) low side to the top of the tank. Its purpose is to
compensate and balance out the pressure above the liquid so that a true level measurement can
be made. If there were no reference or compensating connection, the transmitter would indicate
the level plus the tank pressure:
From the diagram above,

P (high)= P (gas) + (h x SG) and P (low)= P gas
Differential pressure, ΔP= P(high) – P(low)= (h x SG)
As seen from the calculation above, the effect of the gas pressure is cancelled and only the
pressure due to the hydrostatic head of the liquid is sensed. The low side transmitter piping that
provides the reference connection is called a dry leg connection. This connection will remain
empty if the gas above the liquid does not condense. In this closed tank application with a dry
leg condition, if the level transmitter is mounted at the base of the tank, then it can be calibrated
with 0% level= 4Ma and the 100% level=20Ma.
In condensation of the gas above the liquid does occur, then the low side of the transmitter
piping will accumulate liquid leading to potential errors in the measurement. To prevent this
from happening, the low side of the transmitter piping is purposely filled with a convenient
reference liquid (either the process liquid or some compatible material) to eliminate this
potential error. This is called a wet leg condition.
In a wet leg condition, the reference liquid will exert a head pressure on the low side of the
level transmitter. To account for this, the level must be determined and the negative effect of
the reference leg must be subtracted. The resulting calculation will result in negative
calibration.
RESULT AND DISCUSSION
The experiment is conduct to evaluate and study the measurement of level using a differential
pressure/ level transmitter and sight glass with millimetre scale. The other objectives are to
study the relation between effect of open tank and close tank and to study the effect temperature
toward open tank and close tank.
Table 1: Level measurement (Tank T1 as OPEN tank, Heater OFF)
RUN 1 SET 1 SET 2 AVERAGE

A Suggested Level (mm) 700 700 700
B Actual Level (LG)(mm) 695 695 695
C Actual Level (LI)(mm) 701 701 701
D Temperature (TG)(oC) 32 32 32
E Deviation = | B-C| (mm) 6 6 6




Based on this experiment, for Table 1 and 3 which were Open Tank; The top vent (V) and
overflow for both experiment was fully opened. The gate valve for both experiment also opened
but, the globe valve was fully closed. After start the pump (P), by-pass valve (BV) was fully
closed and the flowrate was adjusted to about 2.5m3/hr. The level of overflow in Tank 1 was
observed at the sight millimetre scale (LG) to make sure both of wet legs at Differential
Pressure/Level Transmitter (LT) is filled with water. After that, pump has been stop and gate
valve at Tank 1 was fully closed. The water level was adjusted using the bottom globe valve to
release the water from tank T1 to tank T2. The recordings were started taken when it reaches
the suggested level for each water level measurement, 700mm, 600mm, 500mm, 400mm, and
300mm. The first reading was taken from the Millimetre Scale (LG), the second reading was
taken from the Level Indicator (LI) on the front panel. The third reading was taken from the
temperature gauge (TG) mounted on tank T1. The fourth reading has to be calculated, the
deviation was calculated by subtracting the value of the Level Indicator (LI) from the
Millimetre Scale (LG) and the value obtained will then go through a modulus function by which
will end up with a positive value. Two sets of data were taken for each experiment to get the
average.
Table 2: Level measurement (Tank T1 as CLOSED tank, Heater OFF)




For experiment 2 and 4 which is CLOSED Tank, the top vent (V) and overflow for both
experiment was fully opened. The gate valve for both experiment also opened but, the globe
valve was fully closed. After start the pump (P), by-pass valve (BV) was fully closed and the
flowrate was adjusted to about 2.5m3/hr. The level of overflow in Tank 1was observed at the
sight millimetre scale (LG) to make sure both of wet legs at Differential Pressure/Level
Transmitter (LT) is filled with water. After that, pump has been stop and gate valve at Tank 1
was fully closed. The water level was adjusted using the bottom globe valve to release the water
from tank T1 to tank T2 until the level at Millimetre Scale (LG) at 750mm and the bottom
globe valve was fully closed. The vent (V), overflow, bottom gate valve and globe valve of
Tank 1 was fully closed and make sure reading at the pressure gauge is between 2.5-3.00 psig.
The recordings were started taken when it reaches the suggested level for each water level
measurement, 700mm, 600mm, 500mm, 400mm, and 300mm. The first reading was taken
from the Millimetre Scale (LG), the second reading was taken from the Level Indicator (LI) on
the front panel. The third reading was taken from the temperature gauge (TG) mounted on tank
T1. The fourth reading has to be calculated, the deviation was calculated by subtracting the
value of the Level Indicator (LI) from the Millimetre Scale (LG) and the value obtained will
then go through a modulus function by which will end up with a positive value. Two sets of
data were taken for each experiment to get the average.
Table 3: Level measurement (Tank T1 as OPEN tank, Heater ON)





For experiment 3 and 4 where the heater ON, the heater switched on and let the water
circulate in the tank until the temperature reach 500C. if the water temperature drop to the
49.90C TIC will switch the heater on to heat up water in the tank to the set point temperature.
The gate valve at Tank 1 was fully closed and the pump has been stop. The bottom globe valve
of Tank 1 was opened to allow water flow into the Tank 2 until the level at Millimetre Scale
(LG) at 700mm and the bottom globe valve was fully closed. This experiment was continued
with 600mm, 500mm, 400mm and 300mm reading of water level at Millimetre Scale (LG).
Table 4: Level measurement (Tank T1 as CLOSED tank, Heater ON)





There are some errors occurred during this experiment was being conducted. First, parallax
error occurred during taking the reading of the Millimetre Scale (LG). Next, the experimenter
does not alert or forgot to open the overflow valve after setting the tank to pressurise tank or
close tank. 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.
Summarized results:
Experiment Run 1 Run 2 Run 3 Run 4 Run 5 Average

deviation
(mm)
Open tank 6 8 8 4 7 6.6
Heater off
Closed tank 7 8 13 7 7 8.4
Heater off
Open tank 13 5 5 7 10 8.0
Heater on
Closed tank 7 8 13 10 9 9.4
Heater on
All the reading was recorded and the deviation (actual level ǀLG – LIǀ) (mm) for each
experiments was calculated by using the formula given. The average deviation for Experiment
1 for all runs is 6.6mm. Next, the average for all runs in Experiment 2 is 8.4mm and for
Experiment 3 is 8.0mm. Lastly, the average deviation for Experiment 4 is 9.4mm.
CONCLUSION
In conclusion, the objectives of the experiment were to evaluate and study the measurement of
level using a differential pressure/level transmitter ( ABB model 621ED ) and sight glass with
millimetre scale. Based on the results obtained, it can deduce that the best measurement
equipment is the differential pressure or level transmitter because the reading is more accurate
but there will be the sight glass with millimetre scale act as the most accurate equipment due
to when the sensor or level of the differential pressure or level transmitter being damaged. As
a results, there were difference between reading on the sight glass and the level indicator. The
highest deviation that had been acquired is 13 while the lowest deviation is 5. This is because
the sight glass reading was taken manually by human eye contact while level indicator was
taken by computer sensor. It can be concluded that the level indicator is more accurate than the
sight glass. The sight glass less accurate because of the human errors. The open tanks that carry
out concept of open systems shows the effect of temperature drop is very frequent to due the
heat transfer is higher rather than the close systems. The close tank that carry out the concept
of open systems shows the effect of the temperature drop is very frequent due to the heat
transfer is higher rather than the close systems. The close tank that relate to the close systems
show the heat that have been kept in the thermal tank that make the rate of heat being transferred
is lower than in the open systems but the matter or volume or mass of water doesn’t decrease
at all due to in close system concept that only have exchange in energy (heat) but no change in
matter or mass.
RECOMMENDATION
Some recommendations need to be taken for improvement and accuracy of data taken in the
future. Recommendation for this experiment is the sight glass with millimetre scale should
locate an analogue level instead of watching the water level to increase or decrease by own eye
to avoid the parallax error. Small changes will affect the entire result. Next, another
recommendation is the place on alarm system on tank 1 to avoid overflow when the
experimenter forgot to open the overflow valve after setting the tank to pressurise tank ot close
tank. Lastly, the concept of the experiment needs to be understand before ad while the
experiment was being conduct.
TUTORIALS
1. Level is measured in many of the processes in the industry. List and explain the most
common reasons for measuring level.
1. Carpenter's spirit level

It is used to get horizontal and vertical surfaces square and provides a reference for
parts of a building. Whether the roof is level to the horizon, the door is vertical to
the horizon and so on. As it uses gravity, the reference is really a line to the
gravitational centre of the earth. The spirit level operates square to this line. The
reason is so that all the vertical parts are the same direction, making it easier to fit
components in between them. In building and construction work another level is
provided by a laser leveller or water in a hose. This can be used to get two points
in different places at the same height.
2. Water level
The water level in a tank could be the difference between some reference point like
empty or full, in meters, or maybe litres. This is to know how full it is, and can
work out other things about usage.
3.Ground level
The ground level across a field on a farm may be adjusted by making a specific
slope toprovide a controlled flow of runoff water.
4.Signal level
Signal level might be in a radio receiver or a sound recording studio. The receiver
levelcan be an indication that the system is working properly, as the level (strength)
of thesignal is "normal". The sound studio, the level (strength) of the signal is
adjusted so it won't overload the recording media. If it is too weak background noise
becomes anissue, too strong and distortion follows.
2. Name the two methods of level measurement used in the experiment.
1. Sight glass
2. Magnetic gauges
3. How the depth of a liquid does correspond to changes in liquid pressure? Can a
pressure transmitter be used to measure level?
The pressure of a column of liquid is directly proportional to the pressure. Yes, a

pressure transmitter can be used to measure level. For example, the DP Transmitter
device is used to measure level as an inferential measurement.
4. The differential pressure transmitter is used to measure level in an open tank or closed
tank system. Discuss how this is done.
OPEN TANK CLOSE TANK

The high pressure side of the level Should the tank be closed, and a gas
transmitter is connected to the base of the phase exist on top of the liquid, the gas
tank while the low pressure side is vented pressure must be compensated for. A
to change in the gas pressure will cause a
atmosphere. change in transmitter output. The
pressure exerted by the gas phase may be
Phigh =Patm + S . H so high that the hydrostatic pressure of
Plow = Patm the liquid column becomes insignificant
Differential pressure ΔP =Phigh - Plow Compensation can be achieved by
=S.H applying the gas pressure to both the
high and low pressure sides of the level
The level transmitter can be calibrated to transmitter.
output 4 mA when the tank is at 0% level
and 20 mA when the tank is at 100% level. We have: Phigh = Pgas + S . H
Plow= Pgas
AP = Phigh - Plow = S . H
The effect of the gas pressure is canceled

and only the pressure due to the
hydrostatic head of the liquid is sensed.
When the low pressure impulse line is
connected directly to the gas phase
above the liquid level, it is called a dry
leg.
5. Discuss briefly the possible errors affecting the accuracy in pressure / level
measurement as observed in the experiment.
The possible errors affecting the accuracy in pressure / level measurement as observed
in the experiment:
1. Temperature Influence:
For every 18 °F (10 °C) shift in temperature from which the gauge is calibrated, the
user can experience up to a ±0.4% additional error. The cause is the change in the
elasticity or spring rate of the Bourdon tube element with temperature. While it is
difficult to circumvent the influence of ambient temperature, we can address the
influence of process temperature. In steam service, the common practice is to install
coil syphons or pigtail syphons to dissipate process heat. Another common practice
is to install a diaphragm seal with capillary to separate the gauge from the high heat
source. There are many options available with fill fluid in the seal and capillary
system to withstand temperatures up to 600 °F. In severe cold ambient conditions,
many users elect to heat trace their instrumentation via electric or steam trace. Process
and ambient temperature is an important consideration when selecting and applying
pressure gauges.
2. Vibration Influence:
Vibration due to pumps, motors, and other rotating equipment can cause excess wear
and possible premature failure of internal working parts of a pressure gauge, which
include the Bourdon tube and the movement or gear mechanism. Vibration also
causes difficulty in accurate reading of the gauge, due to pointer oscillation. One of
the most common causes of pressure gauge failure is exposure to continuous
vibration. The most widely accepted remedy is to utilize a liquid filled pressure gauge.
The fill fluid of choice is either glycerine or silicone. Liquid filled gauges address not
only pointer oscillation, but also serve to protect and lubricate the internal geared
movement.
3. Pulsation Influence:
Process pulsation can occur around the discharge of pumps as well as quick operating
valves. Many users assume that liquid filling a pressure gauge will fully address
pulsation. Although a liquid filled gauge helps to dampen the effects of pulsation, it
often does not fully address this process condition. Pulsation dampeners are installed
upstream of the gauge socket and they can be a piston-type snubber, a sintered metal
snubber, or a threaded in-flow restrictor in the socket of the gauge. A needle valve
installed upstream of the gauge that is "pinched down" or slightly opened, is another
common practice to address pulsation. It is not recommended to rely solely on a
needle valve to address pulsation, due to the fact that the user could inadvertently
open the valve, and thereby negate flow restriction. In clean fluids (gases or clean low
viscosity liquids) a threaded orifice/flow restrictor or a sintered metal snubber is the
least costly way to address pulsation. In dirtier and higher viscosity fluids a piston
snubber is usually installed.
6. What are the main objectives of a wet lag calibration?
Wet leg is filling the impulse lines of the differential pressure transmitter with a
different fluid (usually heavier) than the process fluid. When using a differential
pressure transmitter if the fluid measured can evaporate and condensate, we use the
wet leg measurement so that the condensate fluid does not affect the readings to give
false indications. If the fluid cannot evaporate and condensate, we use the much easier
to maintain and calibrate than the wet leg.
REFERENCE
1. Experiment Manual LMC 200. QDR Marketing Sdn Bhd
2. https://www.bayt.com/en/specialties/q/17469/what-is-dry-leg-and-wet-leg-
measurement/
3. http://www.powerplantinterview.com/instrument-4.html
4. http://www.noshok.com/reference_process_conditions.shtml
5. https://answers.yahoo.com/question/index?qid=20100311022637AAmn2PK

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SUMMARY

Principles of Level Measurement

The major principles in level measurement and its classification

This module covers aspects of level measurement as used in process instrumentation

Figure 1. Level measurement device

Pressure= height of column of liquid x density of liquid x acceleration due to gravity

Level= height x specific gravity of liquid= h x SG

Open tank level measurement

P(high)= P (atm) + (h x SG) and P (low)= P (atm)

Close tank level measurement

A pressurized close tank application requires a reference connection. A reference connection

From the diagram above,

Differential pressure, ΔP= P(high) – P(low)= (h x SG)

Table 1: Level measurement (Tank T1 as OPEN tank, Heater OFF)

RUN 1 SET 1 SET 2 AVERAGE

RUN 2 SET 1 SET 2 AVERAGE

RUN 3 SET 1 SET 2 AVERAGE

RUN 4 SET 1 SET 2 AVERAGE

RUN 5 SET 1 SET 2 AVERAGE

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

RUN 1 SET 1 SET 2 AVERAGE

RUN 2 SET 1 SET 2 AVERAGE

RUN 3 SET 1 SET 2 AVERAGE

RUN 5 SET 1 SET 2 AVERAGE

RUN 1 SET 1 SET 2 AVERAGE

RUN 2 SET 1 SET 2 AVERAGE

RUN 3 SET 1 SET 2 AVERAGE

RUN 4 SET 1 SET 2 AVERAGE

RUN 5 SET 1 SET 2 AVERAGE

RUN 1 SET 1 SET 2 AVERAGE

RUN 2 SET 1 SET 2 AVERAGE

RUN 3 SET 1 SET 2 AVERAGE

RUN 4 SET 1 SET 2 AVERAGE

RUN 5 SET 1 SET 2 AVERAGE

Experiment Run 1 Run 2 Run 3 Run 4 Run 5 Average

1. Carpenter's spirit level

2. Name the two methods of level measurement used in the experiment.

The pressure of a column of liquid is directly proportional to the pressure. Yes, a

OPEN TANK CLOSE TANK

The effect of the gas pressure is canceled

6. What are the main objectives of a wet lag calibration?

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