UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

CLB 21303
PROCESS INSTRUMENTATION & CONTROL

BACHELOR OF CHEMICAL ENGINEERING

TECHNOLOGY

EXPERIMENT 3
Level Measurement & Calibration

SEMESTER
Sept/Oct 2022

Experiment 3: Level Measurement & Calibration System

 EXPERIMENT 3

LEVEL MEASUREMENT & CALIBRATION

1.0 EXPERIMENT PROCEDURES

1.1 Plant Start-up Procedures

1 Fill-up water in Tank T2 up to its overflow level. Make sure that drain valve is
FULLY CLOSED.

2 At the front panel, make sure the heater and pump (P) are OFF.

3 Then switch ON the main power supply at the front panel. The panel instruments
should all lit up.

4 Check that the pump suction valve and all pump discharge valves are FULLY
OPEN.

5 Open ONE TURN of the pump by-pass valve (BV) first BEFORE starting the pump
(P). After pump start-up, FULLY CLOSE BV. This is a good practice to avoid any
hydraulic shock to the pump (P).

Note: During the experiment, if the water of tank T2 is at the low level, the level switch
(LS) will automatically SWITCH OFF the heaters and pump (P). In this case,
TOP UP more water into tank T2 from external water supply.

1.2 Experiment 1: Level Measurement

(Tank T1 as OPEN, Heater OFF)

1. Refer to the START-UP procedures and check that the procedures are DONE before
the experiment is carried out.

2. For tank T1, FULLY OPEN top vent (V) and overflow manual valves.

3. Make sure bottom gate valve is FULLY OPENED and globe valve is FULLY
CLOSED.

4. Make sure air inlet manual isolation valve is CLOSED (with 900 position at the air
supply inlet tubing). The top space of tank T1 is at atmospheric pressure, as
monitored by the pressure gauge (PG).

5. Open ONE TURN of the pump by-pass valve (BV) first BEFORE starting the pump
(P)

Experiment 4: Level Measurement & Calibration System

 6. Start pump (P) by pressing the GREEN pushbutton at the front panel.

7. After the pump already starts, CLOSE the pump by-pass valve (BV).

8. ADJUST the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let
the water circulate throughout tanks T1 and T2.

9. At the sight millimetre scale (LG), OBSERVE the level in tank T1 rise until it
overflows to make sure that both of the wet legs at the Differential Pressure/Level
Transmitter (LT) is filled with water.

10. CLOSE the manual discharge gate valve at tank T1. STOP the pump (P).

11. Run the Experiments:

 Suggested Level: 700mm
 OPEN the bottom globe valve of tank T1 to allow the water in tank T1 to
flow into tank T2 until the level at LG reads about 700mm. CLOSE the
bottom globe valve.
 Take TWO (2) sets of reading and record in Table 1
 REPEAT step 2 and continue measure the level from 600 mm until 300
mm.

1.3 Experiment 2: Level Measurement

(Tank T1 as CLOSED Tank, Heater OFF)

1. Refer to the START-UP procedures and check that the procedures are DONE before
the experiment is carried out

2. Check that tank T1 is still operated as an OPEN tank.

 Make sure that the top vent (V) and overflow manual valve are FULLY
OPENED.
 Make sure that the manual discharge valves i.e. bottom gate valve is FULLY
OPENED and globe valve is FULLY CLOSED.
 The pressurising air inlet manual isolation valve handle is 900 to the air supply
inlet tubing.

3. Open ONE TURN of the pump by-pass valve (BV) first BEFORE starting the pump
(P). Start pump (P) by pressing the GREEN pushbutton at the front panel. After
pump start-up, check that the pump by-pass valve (BV) is FULLY CLOSED.

4. Adjust the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let the
water circulate throughout tanks T1 and T2.

5. At the sight millimetre scale (LG), observe the level in tank T1 rise until it
OVERFLOWS to make sure that both of the wet legs at the Differential Pressure/Level
Transmitter (LT) is filled with water.

6. CLOSE the manual discharge gate valve at tank T1. STOP the pump (P).

Experiment 4: Level Measurement & Calibration System

 7. OPEN the bottom globe valve of tank T1 to allow the water in tank to flow out into
tank T2 until the level at LG reads to about 750mm. CLOSE the bottom globe valve.

8. Then PRESSURIZE tank T1 as detailed below:

 FULLY CLOSE the vent (V), overflow, bottom gate valve and globe valves
of tank T1.
 PRESSURIZE the top space of tank T1 by OPENING the pressurising air inlet
manual isolation valve (with the valve handle IN PARALLEL to the air supply
inlet tubing) located next to the AS for air to flow into the top of tank T1.
 Check that the pressure at pressure gauge is between 2.50 – 3.00 psig.

Note: Tank T1 is now a CLOSED TANK under pressure.

9. Run the Experiments

 Suggested Level: 700mm
 OPEN the bottom globe valve of tank T1 to allow the water in tank T1 to
flow into tank T2 until the level at LG reads about 700mm. CLOSE the
bottom globe valve.
 Take TWO (2) sets of reading and record in Table 2
 REPEAT step 2 and continue measure the level from 600 mm until 300
mm.
 OPEN vent and overflow valve AFTER experiment to release the
pressure in tank T1

1.4 Experiment 3: Level Measurement

(Tank T1 as OPEN Tank, Heater ON)

1. Refer to the START-UP procedures and check that the procedures are DONE before
the experiment is carried out.

2. For tank T1, FULLY OPEN top vent (V) and overflow manual valves.

3. Make sure bottom gate valve is FULLY OPENED and globe valve is FULLY
CLOSED.

4. Make sure air inlet manual isolation valve is CLOSED (position 900 at the air supply
inlet tubing). The top space of tank T1 is at atmospheric pressure, as monitored by
the pressure gauge (PG).

5. Open ONE TURN of the pump by-pass valve (BV) first BEFORE starting the pump
(P). Start pump (P) by pressing the GREEN pushbutton at the front panel. After
pump start-up, CLOSE the pump by-pass valve (BV).

6. Adjust the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let
the water circulate throughout tanks T1 and T2.

7. At the sight millimetre scale (LG), observe the level in tank T1 rise until it
OVERFLOWS to make sure that both of the wet legs at the Differential
Pressure/Level Transmitter (LT) is filled with water.

Experiment 4: Level Measurement & Calibration System

 8. Switch ON the heater on the front panel.

9. Let the water to circulate throughout tanks T1 and T2 until the water temperature
reaches to about 500C.

Note:
 TIC has an ON/OFF ALARM with hysteresis of 0.50C.
 Say the temperature set point is at 50.00C, the heater is switched ON until the
water temperature reaches 50.00C. TIC will then switch the heater OFF. The
water temperature will continue to rise and then drop to below 50.00C.
 Once the water temperature drops BELOW 49.50C, TIC will switch the heater
ON again to heat the water up to the set point temperature again.
 This will CONTINUE throughout as long as the heater switch at the front panel
stays ON.

10. Switch the heater OFF.

11. CLOSE the manual discharge gate valve at tank T1. STOP the pump (P).

12. Run the Experiments

 Suggested Level: 700mm
 OPEN the bottom globe valve of tank T1 to allow the water in tank T1 to
flow into tank T2 until the level at LG reads about 700mm. CLOSE the
bottom globe valve.
 Take TWO (2) sets of reading and record in Table 3.
 REPEAT step 2 and continue measure the level from 600 mm until 300 mm.

1.5 Experiment 4: Level Measurement

(Tank T1 as CLOSED Tank, Heater ON)

1. Refer to the START-UP procedures and check that the procedures are DONE before
the experiment is carried out.
2. Check that tank T1 is still operated as an OPEN tank.
 Make sure that the top vent (V) and overflow manual valve are FULLY
OPENED.
 Make sure that the manual discharge valves i.e. bottom gate valve is FULLY
OPENED and globe valve is FULLY CLOSSED.
 The pressurising air inlet manual isolation valve handle is 900 to the air supply
inlet tubing.

3. Open ONE TURN of the pump by-pass valve (BV) first BEFORE starting the pump
(P).Start pump (P) by pressing the GREEN pushbutton at the front panel. After
pump start-up, check that the pump by-pass valve (BV) is FULLY CLOSED.

4. Adjust the flowrate by using Variable Area Flowmeter (FI) to about 2.5m3/hr. Let
the water circulate throughout tanks T1 and T2.

Experiment 4: Level Measurement & Calibration System

 5. At the sight millimetre scale (LG), observe the level in tank T1 rise until it
OVERFLOWS to make sure that both of the wet legs at the Differential
Pressure/Level Transmitter (LT) is filled with water.

6. Switch ON the heater on the front panel. Let the water to circulate throughout tanks
T1 and T2 until the water temperature reaches to about 500C.

Note:
a. TIC has an ON/OFF ALARM with hysteresis of 0.50C.
b. Say the temperature set point is at 50.00C, the heater is switched ON until
the water temperature reaches 50.00C. TIC will then switch the heater OFF.
The water temperature will continue to rise and then drop to below 50.00C.
c. Once the water temperature drops BELOW 49.50C, TIC will switch the
heater ON again to heat the water up to the set point temperature again.
d. This will continue throughout as long as the heater switch at the front
panel stays ON.

7. Switch the heater OFF.

8. CLOSE the manual discharge gate valve at tank T1. STOP the pump (P).

9. OPEN the bottom globe valve of tank T1 to allow the water in the tank to flow out
into tank T2 until the level at LG reads to about 750mm. CLOSE the bottom globe
valve.

10. Then PRESSURIZE tank T1 as detailed below:

 FULLY CLOSE the vent (V), overflow, bottom gate valve and globe valves
of tank T1.
 PRESSURIZE the top space of tank T1 by OPENING the pressurising air inlet
manual isolation valve (with the valve handle IN PARALLEL to the air supply
inlet tubing) located next to the AS for air to flow into the top of tank T1.
 Check that the pressure at pressure gauge is between 2.50 – 3.00 psig.

Note: Tank T1 is now a CLOSED TANK under pressure.

11. Run the Experiments

 Suggested Level: 700mm
 OPEN the bottom globe valve of tank T1 to allow the water in tank T1 to
flow into tank T2 until the level at LG reads about 700mm. CLOSE the
bottom globe valve.
 Take TWO (2) sets of reading and record in Table 4
 REPEAT step 2 and continue measure the level from 600 mm until 300
mm.

1.6 Plant Shut-down Procedures

After ALL of the experiments have been completed, do the following steps:

1. Make sure that BOTH the heater and pump (P) are switched OFF.

Experiment 4: Level Measurement & Calibration System

 2. Make sure that the air inlet manual isolation valve handle is in 900 positions at
the air supply inlet tubing. The top space of tank T1 is at atmospheric
pressure. Check the pressure gauge (PG) as well.

3. FULLY OPEN the overflow manual valve and the top vent (V) valve of tank
T1.

4. DRAIN out all of the water in tank T1 by OPENING the manual discharge
valve i.e. the gate valve. After that, FULLY CLOSE BOTH the gate valve
and globe valve.

5. DRAIN out all of the water in tank T2 by OPENING its manual drain valve.

6. Switch OFF the main power supply.

2.0 RESULTS

2.1 TABLE 1: Level Measurement (Tank T1 as OPEN tank, Heater OFF)

RUN I SET 1 SET 2 AVERAGE
A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN IV SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

Experiment 4: Level Measurement & Calibration System

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

RUN I SET 1 SET 2 AVERAGE

A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN IV SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

Experiment 4: Level Measurement & Calibration System

 2.3 TABLE 3: Level Measurement (Tank T1 as OPEN tank, Heater ON)

RUN I SET 1 SET 2 AVERAGE

A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN IV SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

Experiment 4: Level Measurement & Calibration System

 2.4 TABLE 4: Level Measurement (Tank T1 as CLOSED tank, Heater ON)

RUN I SET 1 SET 2 AVERAGE

A Suggested Level (mm) 700 700 700
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN II SET 1 SET 2 AVERAGE

A Suggested Level (mm) 600 600 600
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN III SET 1 SET 2 AVERAGE

A Suggested Level (mm) 500 500 500
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN IV SET 1 SET 2 AVERAGE

A Suggested Level (mm) 400 400 400
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

RUN V SET 1 SET 2 AVERAGE

A Suggested Level (mm) 300 300 300
B Actual Level (LG) (mm)
C Actual Level (LI) (mm)
D Temperature (TG) (0C)
E Deviation = | B-C | (mm)

REMARKS:
B: Read from the sight glass with millimetre scale (LG).
C: Read from the level indicator (LI) on the front panel.
D: Read from the temperature gauge (TG) mounted on level tank T1.

Experiment 4: Level Measurement & Calibration System

3.0 QUESTIONS

1. Level is measured in many of the processes in the industry. List and explain the most
common reasons for measuring level.

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

3. How the depth of a liquid does correspond to changes in liquid pressure? Can a
pressure transmitter 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.

5. Discuss briefly the possible errors affecting the accuracy in pressure / level
measurement as observed in the experiment.

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

4.0 REFERENCE
1. Experiment Manual LMC 200. QDR Marketing Sdn Bhd

Experiment 4: Level Measurement & Calibration System

Experiment 4: Level Measurement & Calibration System