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Instruction: For Liquid Level, Density, and Interface Level Measurements
Instruction: For Liquid Level, Density, and Interface Level Measurements
September 2013
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Contents
Introduction .............................................................................................................................. 5
Abbreviations ....................................................................................................................... 5
Principle of Operation .......................................................................................................... 5
Alternative to Bubble Tubes ................................................................................................. 6
Reference Instructions .......................................................................................................... 6
Formulas for Specific Gravity Conversions ........................................................................... 7
For Liquids LIGHTER than Water ................................................................................. 7
For Liquids HEAVIER than Water ................................................................................. 7
For All Liquids ................................................................................................................ 7
Calibration ........................................................................................................................... 7
Calculations .............................................................................................................................. 8
Liquid Level Calculations (Figure 2) ..................................................................................... 8
Interface Calculations (Figure 3 and Figure 4) ...................................................................... 9
With Constant Tank Level (One Bubble Tube) .............................................................. 9
With Varying Tank Level (Two Bubble Tubes) ............................................................... 9
Density Calculations (Figure 5 and Figure 6) ..................................................................... 10
With Constant Tank Level (One Bubble Tube) ............................................................ 10
With Varying Tank Level (Two Bubble Tubes) ............................................................. 11
Installation .............................................................................................................................. 12
Typical Piping Arrangements ............................................................................................. 12
Determination of Length Difference (Dimension “H”) With a Pair of Tubes .................... 12
Piping Parts List ................................................................................................................. 12
Installation Notes ............................................................................................................... 13
Typical Bubble Tube Installations (Figure 8 and Figure 9) ................................................. 14
Tank With One Bubble Tube ....................................................................................... 14
Tank With Two Bubble Tubes ...................................................................................... 15
Typical Side-Connection Installations ................................................................................ 15
Tank With One Bubble Connection At Side Of Tank .................................................. 15
Tank With Two Bubble Connections At Side Of Tank ................................................. 16
Use of a Differential Pressure Regulator ............................................................................. 16
B0107XY Differential Pressure Regulator (Figure 12) ................................................... 17
B0107XX Differential Pressure Regulator (Figure 13) ................................................... 18
Pressure Drop in Air Lines ................................................................................................. 18
Operation ............................................................................................................................... 19
Operating Notes ................................................................................................................. 19
Putting into Operation ....................................................................................................... 19
Formulas to Calculate Output and Pressure Loss .................................................................... 20
Calculating Output for Any Input ...................................................................................... 20
Liquid Level Formula .................................................................................................... 20
Density Formula ............................................................................................................ 21
Interface Level Formula (Figure 14) ............................................................................... 21
Calculating Pressure Loss in Air Line .................................................................................. 22
Calibration .............................................................................................................................. 23
Maintenance ........................................................................................................................... 23
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MI 020-328 – September 2013 Contents
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Figures
1 Bubble Tube Functional Diagram ........................................................................................6
2 Liquid Level Calculation ......................................................................................................8
3 Interface Calculation - One Tube .......................................................................................10
4 Interface Calculation - Two Tubes .....................................................................................10
5 Density Calculation - One Tube ........................................................................................11
6 Density Calculation - Two Tubes ......................................................................................12
7 Bubble Tube Notch Details ...............................................................................................13
8 Bubble Tube Installation - One Tube ................................................................................14
9 Bubble Tube Installation - One Tube at Side of Tank .......................................................15
10 Bubble Tube Installation - One Tube at Side of Tank .......................................................15
11 Bubble Tube Installation - Two Tubes at Side of Tank ......................................................16
12 B0107XY Differential Pressure Regulator and Bubble Tube Piping ...................................17
13 B0107XX Differential Pressure Regulator and Bubble Tube Piping ...................................18
14 Interface Level Calculation Calculating Output for any Input ............................................22
15 Bubble Tube Maintenance .................................................................................................24
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Introduction
The bubble tube principle of hydrostatic measurement is a convenient, low-cost method of
measuring liquid level, density, or interface level in an open tank. It is particularly applicable for
those installations where:
Process liquid could crystallize in transmitter lines.
Process temperature exceeds temperature limit of flange-mounted transmitter.
Process tank does not have side connections for flange-mounted transmitter.
Process liquid is corrosive and cannot have direct contact with transmitter.
Abbreviations
The abbreviations below are used in this instruction.
Abbreviation Meaning
LRV Lower-range value (measurement that produces a 4 mA output).
URV Upper-range value (measurement that produces a 20 mA output).
Sp.G. Specific gravity (relative density) of a liquid. Specific gravity of water in
both customary and SI systems is 1.00.
Principle of Operation
Air is passed through a restrictor to a tube partly immersed in a liquid. The lower end of the tube
is at a fixed distance above the bottom of the tank (see Figure 1).
The pressure of the air supply is high enough to overcome the hydrostatic head on the tube, and
the excess pressure appears as small bubbles coming out of the bottom of the tube. Thus, the back
pressure in the tube is a measure of the pressure on the bottom of the tube due to the level of
liquid. Since the position of the tube is fixed, any change in this back pressure is due to a change
in the level of the liquid.
The back pressure is connected to the high-pressure side of the transmitter, and the low- pressure
side is vented. Thus, the differential pressure measured by the transmitter is a measure of the level
of the liquid.
If the level of the liquid is constant (continuous overflow), any change in the transmitter
differential pressure must be due to a change in liquid density or interface level. Thus, density and
interface level can also be measured. If the tank level varies, these measurements can still be made
by using two different-length tubes connected to opposite sides of the transmitter; see Figure 4
and Figure 6.
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Reference Instructions
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Baume : 140 -
Sp.G. = -------------------------
Be + 130
API: 141.5 -
Sp.G. = --------------------------------
API + 131.5
Baume : 140 -
Sp.G. = -------------------------
145 – Be
Calibration
If measurement range was specified in the sales order, the transmitter was calibrated in the factory
to these values, and these same values are stamped on the transmitter data plate.
If measurement range was not specified, transmitter was calibrated in the factory to maximum
span for the particular sensor installed in the transmitter. In this case, the measurement range area
of the data plate is left blank so that the user can mark the desired calibrated range (in terms of
head of water) himself.
The transmitter must be calibrated to the desired range before putting it into operation. (If the
transmitter was calibrated in factory, the calibration should be checked.) Use the applicable
formula to determine the input pressures (in terms of head of water) corresponding to the desired
measurement limits. Mark these input pressure limits in the applicable area on the transmitter
data plate, and use these values as the calibrating input signals.
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Calculations
The sections that follow show typical calculations for liquid level measurement, interface
measurement, and density measurement. Interface and density measurements are shown with
both a constant tank level and a varying tank level.
Note that the upper-range and lower-range values (URV and LRV) refer to the desired maximum
and minimum measurements, respectively. The Calibrated Span = URV - LRV. The value of the
suppression is the output at LRV above 0%.
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Example: Liquid Sp.G. varies between 1.0 and 1.8; and A = 40 inches.
Span = (40)(1.8 - 1.0) = 32 inH2O
Hw at LRV = (40)(1.0) = 40 inH2O = Suppression
Hw at URV = (40)(1.8) = 72 inH2O
Calibrated Range = 40 to 72 inH2O
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Installation
Typical Piping Arrangements
With bubble tube installations, refer to either Figure 8 or Figure 9, as applicable. With side-
connection installations, refer to either Figure 10 or Figure 11, as applicable.
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Snubbers:
For installation in the process line to reduce or eliminate any unwanted pressure pulsations, 1/4
NPT at both ends.
For gases and thin liquids, see list below.
Installation Notes
1. Bubble tube and transmitter piping is supplied by user.
2. There should be a minimum of 75 mm (3 inches) of clear liquid (no sediment) below
the bottom of the tube. With two-tube installations, there should also be a minimum
of 75 mm (3 inches) of liquid above the upper tube.
3. Bubble tube assembly should be located in area of representative liquid, and where
liquid agitation is at a minimum.
4. Bubble tube assembly must be rigidly fixed in position.
5. Bottom of bubble tubes to be notched so that air comes out in a steady stream of small
bubbles (rather than an intermittent stream of large bubbles, which could introduce
errors). See Figure 7 for details of this notching. (Not applicable for side-connection
installations.)
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Figure 12. B0107XY Differential Pressure Regulator and Bubble Tube Piping
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Figure 13. B0107XX Differential Pressure Regulator and Bubble Tube Piping
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(With one-tube installations, a quick check for pressure loss is to momentarily turn off the air
supply and note if there is any change in transmitter output.)
If a significant pressure loss exists, reduce the air flow, and/or use a larger size line, and/or move
the transmitter nearer the bubble tube.
Operation
Operating Notes
1. Function of restrictor is to control flow of air. This is accomplished with needle valve
on bottom of rotameter (except if Type 62V differential pressure regulator [B0107XY]
is used). Use this needle valve to adjust air flow for optimum small bubble size.
If Type 62V regulator (B0107XY) is used, needle valve on regulator is used to adjust
flow of air.
2. To prevent measurement errors, open ends of the tubes should always be covered with
tank liquid.
3. With interface measurement, maximum level must be below open end of upper tube;
minimum level must be above open end of lower tube.
4. If range is to be changed, transmitter must be recalibrated to new range. Dimension
“H” may require changing for new range.
5. Needle valve on rotameter should not be used as a system air shutoff; instead use
upstream valve at air supply to system.
6. Do not allow level of liquid to fall below bottom of bubble tube (or tank connection).
7. Check all connections for leaks.
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3. If, in Step 2, the bubbles are not visible (because of tank location, type of liquid, etc.),
using the applicable air adjustments specified in Step 2, gradually increase flow of air
while noting output of transmitter. Keep increasing air flow as long as output
increases. At point where output stops increasing, increase air flow slightly.
4. With a one-tube installation, make the “pressure drop” test described in previous
section. If significant error exists, make necessary corrections.
If transmitter has been calibrated correctly, this completes the procedure; otherwise
proceed to Steps 5, 6, and 7 (reference adjustment). Note that the accuracy of the
measuring device in Step 5, will probably be less than that of the transmitter; this may
degrade the accuracy of the transmitter.
5. Using a suitable measuring device (such as a dipstick with level application or a
hydrometer with density application), determine actual measurement of liquid.
6. Using applicable formula listed in the section that follows, calculate transmitter
output corresponding to tank measurement.
7. Adjust transmitter zero to get correct output. If necessary, also adjust zero reading of
receiver.
In using these formulas, the transmitter must already be calibrated to the desired range. If the
transmitter has not been calibrated (or if the calibration is to be changed), complete the
calibration first. Use the applicable formula to determine the input pressures (in terms of head of
water) corresponding to the desired measurement limits. Mark these input pressure limits in the
applicable areas on the transmitter data plate.
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30 – 10
Output = 16 ------------------ + 4 = 8.0 mA
90 – 10
Density Formula
1.0 – 0.6
Output = 40 --------------------- + 10 = 30 mA
1.4 – 0.6
Output = X -------------------------------------------------------------- + Y
Actual Interface Level
Maximum Interface Level
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Figure 14. Interface Level Calculation Calculating Output for any Input
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If the ID of the actual pipe used is not listed in the table above, use the formula below to calculate
the approximate value of K.
K = 1/(62)(ID)4 [with line ID in inches]
If the measurements are in the SI system (line ID in mm, line length in meters, and flow in m3/h),
then use the following formula to calculate K.
KSI units = (65.9/ID)4
Example 1: Determine pressure loss in a 20 foot length of 1/8 pipe due to an air flow of 4 scfh.
K = 3.0 for 1/8 in pipe (from the table)
P = (K)(F)(L) = (3.0)(4)(20/1000)
P = 0.24 inH2O
Example 2: Determine pressure loss in a 10 meter length of 5 mm ID pipe due to an air flow of
0.1 m3/h.
KSI units = (65.9/ID)4 = (65.9/5)4 = 30176
P = (K)(F)(L) = (30176)(0.1)(10/1000)
P = 30 mmH2O
Calibration
In general, follow the calibrating procedures outlined in the appropriate transmitter instructions.
If desired, instead of using air pressures as calibrating signals, these signals can be generated by
varying the level (or density) of the tank liquid to values at or near each end of the range. Use the
calibrating values stamped on the data plate; or if the range is to be changed, calculate the new
values. In this way, the transmitter can be calibrated without removing it from the process.
Maintenance
Use applicable reference instructions listed on page 2 when servicing the transmitter, rotameter, or
differential pressure regulator.
If there is any tendency for solids to crystallize in the bubble tubes, or if dirt tends to collect there,
remove the cleanout plugs and push a rod down through the tubes and/or flush with a suitable
liquid. Perform as often as required.
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ISSUE DATES
SEP 1988
SEP 2013
Vertical lines to the right of text or illustrations indicate areas changed at last issue date.
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