level measurement - apex innovations · 2014-07-20 · apex innovations 26-11-2009 im331.doc page 2...
TRANSCRIPT
26-11-2009 Im331.doc Page 1
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: [email protected] 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: [email protected]
Web: www.selecindia.com
Delear:
Sham Traders, Kolhapur