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LEVEL MEASUREMENT

Instruction manual

Contents

1 Description

2 Specifications

3 Installation requirements

4 Installation Commissioning

5 Troubleshooting

6 Components used

7 Packing slip

8 Warranty

9 Experiments

10 Components‟ details

APEX INNOVATIONS

Product Code

331

Apex Innovations

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Level measurement setup is designed

to demonstrate principles of liquid level

measurement a) by air purge method

and b) by use of differential pressure

transmitter. The set up consists of Air

pump, air purge tube, manometer,

transparent process tank marked with

graduated scale, supply tank, pump for

water circulation, differential pressure

transmitter (DPT) and level indicator.

The process tank is and provided with

drain valve. The level in the tank is

displayed on digital indicator. The DPT

is powered by the digital indicator and

provision is made to tap and measure

the loop current. The units are fitted on

support housing designed for tabletop

mounting.

Manometer

Air Pump Process Tank

N

Level Transmitter

Pump

Product Level Measurement

Product code 331

Manometer Range 100-0-100 mm, Box type

Air pump Capacity 2.5 LPM

Differential pressure

transmitter

Type Capacitance, smart series with inbuilt digital local

indicator, two wire, Range 0–200 mm, Output 4–20

mA,

Process tank Acrylic, transparent with graduated scale 200 mm.

Level indicator Digital, Range 0-200mm, Supply 230VAC

Pump Capacity 1200LPH

Supply tank Capacity 7 Liter, SS304

Overall dimensions 650Wx475Dx540H mm

Shipping details

Gross volume 0.2m3, Gross weight 41 kg, Net weight 16 kg

Specifications

Description

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Water

Clean water 7 liters

Support table

Size: 800Wx800Dx750H in mm

Electric supply

230 V, 50Hz, 1 ph AC.

Place the supply tank on support table. Fill with clean water. Place the pump in

the supply tank. Connect the drain pipe piece at the outlet of the drain valve.

Place the set up on support table. Connect the PU tube at the pump delivery and

insert other end in to the process tank.

Loosen the DP Transmitter (DPT) clamping bolts, lift the DPT upwards and insert

one Support Plate below the DPT.

Ensure supply voltage as L-N 230 +/- 10 V AC and L-E 1-5 VAC and then connect

Electric supply to the setup.

Switch on the electric supply, MAINS and PUMP and fill up the Process Tank and

switch off the pump.

Remove air from DPT by loosening the air vent plug on “H” side. Gently tighten

the air vent after removing the entrapped air.

Fill up the water in the Manometer (using ink dropper/syringe) up to zero mark.

Switch on AIR PUMP and adjust needle valve and set the air bubble rate @ 2-3

bubble/sec.

Check display value on Level Indicator. Check manometer reading.

Drain water from the tank and check the values in between.

Now set up is ready for experimentation.

Installation Commissioning

Installation requirements

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Shutting down the set up

Switch off the main supply.

Drain process tank in to supply tank.

For longer shut down remove water from supply tank.

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Note: For component specific problems refer components‟ manual

Problems Possible causes / remedies

Level is not correctly

indicated

Ensure Supply 24VDC from indicator.

Remove air from the H side of the DPT.

The Zero adjustment is excessively turned. Fill up

the water in the tank so that level is visible at

some point. Readjust the Zero to match the level

reading.

Level indicator parameter setting disturbed.

Manometer reading not

correct

Adjust air purge pipe immersion height.

Excessive bubbling rate.

Level indicator not

working

Check electric supply.

Check Wiring connections.

Components Details

DP Transmitter Make Yokogawa, Model EJA110-EMS-5A-92NN,

Calibration range 0-200 mm H2O, Output linear with

digital local indicator.

Level indicator Make Selectron, model PIC 152–B2, 85 to 270VAC

Pump Make Tullu Model THS 3000

Box

No.1/1

Size W675xD500xH560 mm; Volume:0.2m3 Gross weight: 41kg

Net weight: 16kg

1 Set up assembly consisting of supply tank,

pump, PU tube, drain pipe, transmitter support

plates (2 Nos).

1 No

2 Instruction manual CD (Apex) 1 No

3 Instruction manual CD (For DP transmitter) 1 No

Packing slip

Components used

Troubleshooting

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This product is warranted for a period of 12 months from the date of supply against

manufacturing defects. You shall inform us in writing any defect in the system

noticed during the warranty period. On receipt of your written notice, Apex at its

option either repairs or replaces the product if proved to be defective as stated

above. You shall not return any part of the system to us before receiving our

confirmation to this effect.

The foregoing warranty shall not apply to defects resulting from:

Buyer/ User shall not have subjected the system to unauthorized alterations/

additions/ modifications.

Unauthorized use of external software/ interfacing.

Unauthorized maintenance by third party not authorized by Apex.

Improper site utilities and/or maintenance.

We do not take any responsibility for accidental injuries caused while working with

the set up.

Apex Innovations Pvt. Ltd.

E9/1, MIDC, Kupwad, Sangli-416436 (Maharashtra) India

Telefax:0233-2644098, 2644398

Email: support@apexinnovations.co.in Web: www.apexinnovations.co.in

Warranty

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Theory:

Level measurement by air purge method:

When a small stream of air is continuously purged in the liquid column, the back

pressure generated is proportional to hydrostatic head (i.e. x g x h where is liquid

density, g is acceleration due to gravity and h is the liquid height of liquid column

above purge point). If the back pressure is measured and if the liquid density is

known the height of the liquid column above purge point can be calculated.

Level measurement using DP transmitter:

1 The DPT mainly consists of Pressure detector assembly and transmitter assembly.

The pressure detector assembly houses capsule assembly. The electronic circuit is in

transmitter assembly.

2 The DPTs have two process connections for measurement of differential pressure.

The higher pressure is to be connected to “H” side and lower pressure to be

connected to “L” side. For measurement of level in open tanks the pressure conne

“L” connection of DPT is open to atmosphere. In case of level measurements in the

closed vessels, the additional connection from the top of tank needs to be connected

to “L”.

3 The smart series DPTs can be calibrated for different ranges by using Hand held

programmer (Optional). (Conventional old type DPTs were provided with SPAN

adjustment knob for changing the calibration range). This is also cal is The span

(range) adjustment can be done

4 The Signal form DP is in the range of 4-20 mA which is proportional to hydrostatic

head (i.e. x g x h where is liquid density, g is acceleration due to gravity and h is

the liquid height above DP).

5 For measurement of level (using hydrostatic head) the DPT needs to be mounted at

the bottom of the vessel. The position of the DP can be raised / lowered and same

can be compensated by adjusting ZERO on the DPT. However it is recommended that

position of DPT should not be above minimum tank level.

Experiments

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Experiment No. 1: Level measurement by Air purge method

Procedure

Prepare the set up as described in “Installation Commissioning”.

Switch on AIR PUMP.

Fill water up to 50 mm in the process tank by using pump and drain valve.

Note the manometer reading.

Repeat the observation at different levels in the process tank.

Observations

Sr. No. Process tank level mm Manometer reading mm

1 50 51

2 100 100

3 150 150

4 190 190

Conclusions

1 The manometer reading tallies with process tank level throughout the range.

Self study

Use this set up to measure the density/specific gravity of liquid.

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Experiment No. 2: Level measurement using DP transmitter

Procedure

Ensure that one transmitter support plate is inserted below the DPT. The zero

level of the process tank and centre of the DPT is approximately at same level.

Fill water up to 50 mm in the tank.

Note the reading on LEVEL INDICATOR (It is assumed that air entrapped is

removed initially).

Turn the zero adjustment knob so that indicated reading matches with process

tank level.

To measure loop current of the transmitter connect multi-meter to “CHECK mA”.

The reading in % is indicated on the local display of the transmitter.

Fill the water in steps of 50 mm and note the indicated reading, current in ma

and process tank level. (Note that this DPT is pre-calibrated for range of 200 mm

of H2O)

Repeat the procedure by draining the water in steps of 50 mm.

Plot the graphs of indicated reading Vs actual level and Current in MA Vs Actual

level and note accuracy and Hysteresis.

Observations

Sr. No. Process tank level mm Indicated reading mm Loop current mA

1 10 9.8 4.79

2 50 49.9 8.02

3 100 100.2 12.06

4 150 150.7 16.13

5 190 189 19.20

Conclusions

1 The indicated reading fairly tallies with actual level.

Self study

The Signal form DPT is proportional to hydrostatic head and it is calibrated to 200

mm of H2O.Use this set up to measure the density/specific gravity of liquid.

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Experiment No. 3: Level measurement by raising/lowering the DPT

(Zero adjustment of DPT)

Procedure

Ensure that one transmitter support plate is inserted below the DPT. The zero

level of the process tank and centre of the DPT is approximately at same level.

Fill water up to 100 mm in the tank.

Note the reading on LEVEL INDICATOR (It is assumed that air entrapped is

removed initially).

Loosen the DPT clamping bolts. Raise/lower the DPT by adding/removing support

plate below the transmitter. The centre of the DPT is above/below the bottom of

the tank.

Note that indicated reading does not match with actual level.

Turn the zero adjustment knob clockwise / anticlockwise to match the indicated

reading matches with process tank level.

Change the level in steps of 50 mm. Note actual level and indicated reading.

Conclusions

1 With initial Zero adjustment the indicated reading tallies with actual level

throughout the range.

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Experiment No. 4: Range adjustment of DPT

Procedure

(Important note: It is recommended that this experiment should be conducted

under guidance of experts who are aware of “Range calibration of DPT” and

“Programming of Level indicator (PIC152)”. If the range calibration is disturbed it is

not possible to conduct earlier experiments unless the range is reset to 200 mm.)

The DPT is calibrated for 200 mm range. With range setting arrangement on

the display unit, it can be changed to some other value say 150 mm. Refer

instruction manual of DPT.

Initially change the display setting of the level indicator d.SC.H to 150 mm

(the value to which the range is to be changed)

Fill up the water in the process tank to say 190 mm and in range setting mode

turn the “Zero “setting so that the display on the transmitter is 100%.

Repeat above step by lowering the level in the process tank by 10 mm till

finally the Display value is 100% for 150 mm level. Exit the setting mode.

The Level indicator shows 150 mm level. Check the linearity for intermediate

level values. (Adjust the “Zero” if required for offset correction)

Change the range to 200 mm and level indicator display setting to 200 before

closing this experiment.

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Differential Pressure Transmitter Introduction

The model EJA110A pressure transmitter measures the flow rates

and the pressure of the liquids, gases, and steam, and also liquid

levels.

Technical specifications

Model EJA110A-DMS5A-92NN

Make Yokogawa

Output signal 4 – 20mA DC with digital

communication (Linear)

Measurement span 1 to 100kPa (100 to 10000mmH2O)

Calibration range 0 – 200, 0 – 500 mmH2O

Wetted parts material Body – SCS14A, Capsule – SUS316L

Process connections without process connector (1/4BSP body connection)

Bolts and nuts material SCM 435

Installation Horizontal impulse piping left side high pressure

Electrical connection 1/2NPT female

Cover „O‟ rings Buna-N

Supply 10 to 24VDC

Process temperature limit -40 to 120 0C

Housing Weather proof

Weight 3.9Kg

Manufacturer’s address

If you need any additional details, spares or service support for this unit you may

directly communicate to the manufacturer / Dealer / Indian Supplier.

Yokogawa Electrical Corporation

2-9-32, Nakacho,

Musashino-shi,

Tokyo, 180-8750, Japan.

Indian supplier:

Yokogawa Blue Star Ltd.

40/4 Lavelle Road,

Bangalore – 560 001.

Components‟ Manuals

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LEVEL INDICATOR

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Manufacturer’s address

If you need any additional details, spares or service support for this unit you may

directly communicate to the manufacturer / Dealer / Indian Supplier.

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Selectron process controls Pvt. Ltd.

E-121/120/113, Ansa Industrial Estate,

Saki Vihar Road, Andheri,

Mumbai – 400 072.

E-mail: selnet@bom3.vsnl.net.in

Web: www.selecindia.com

Delear:

Sham Traders, Kolhapur