Title: On/off level switch

Objective: TO control the level in the process vessel using an on/off level switch with a normally
closed solenoid valve (SOL 1) controlling inflow to the vessel.

Theory:

There are two level control switches used in this experiment and these are:

1. Float switch

A float switch is a type of level sensor, a device used to detect the level of liquid within a tank.
The switch may be used to control a pump, as an indicator, an alarm, or to control other devices.

One type of float switch uses a mercury switch inside a hinged float. Another common type is a
float that raises a rod to actuate a micro switch. One pattern uses a reed switch mounted in a
tube; a float, containing a magnet, surrounds the tube and is guided by it. When the float raises
the magnet to the reed switch, it closes. Several reeds can be mounted in the tube for different
level indications by one assembly.

A very common application is in sump pumps and condensate pumps where the switch detects
the rising level of liquid in the sump or tank and energizes an electrical pump which then pumps
liquid out until the level of the liquid has been substantially reduced, at which point the pump is
switched off again. Float switches are often adjustable and can include substantial hysteresis.
That is, the switch's "turn on" point may be much higher than the "shut off" point. This minimizes
the on-off cycling of the associated pump.

Some float switches contain a two-stage switch. As liquid rises to the trigger point of the first
stage, the associated pump is activated. If the liquid continues to rise (perhaps because the pump
has failed or its discharge is blocked), the second stage will be triggered. This stage may switch
off the source of the liquid being pumped, trigger an alarm, or both.

Where level must be sensed inside a pressurized vessel, often a magnet is used to couple the
motion of the float to a switch located outside the pressurized volume. In some cases, a rod
through a stuffing box can be used to operate a switch, but this creates high drag and has a
potential for leakage. Successful float switch installations minimize the opportunity for
accumulation of dirt on the float that would impede its motion. Float switch materials are
selected to resists the deleterious effects of corrosive process liquids. In some systems, a properly
selected and sized float can be used to sense the interface level between two liquids of different
density.
 2. Differential switch

This level control switch has two rods: blue and red. And the red rod positioned higher than the
blue rod. And one of the rods control the level by avoiding the level from dropping very low and
the other rod control the level from going above the set point value. Compared to the float switch
this switch is a lot more effective.

The differential level switch used in this exercise consists of a sensor designed to simultaneously
accept two independent pressure sources. The output is proportional to the pressure difference
between the two sources and it is used to control an on/off switch.

Apparatus and Chemicals

Apparatus:

 Floating ball switch

 Differential switch

Chemicals:

 Water

Procedures:

1. The equipment was setup as:

The inlet connector for the apparatus (on the right of the plinth behind the pressure regulator)
was connected to a suitable mains water power supply. The central cylinder was put securely in
position inside large process vessel. The self-sealing connection socket on the base of the large
process vessel was connected the quick release connection on the valve SOL1 (at the front right
of the plinth) using a suitable length of tubing. The drain valve at the end of the plinth was
directed to a drain and left open. Solenoid valves 2 and 3 was also connected to a suitable drain
using the tubing supplied. The drain valve in the base of large process vessel was also connected
directly to drain using flexible tubing.

2. The mains power to the console was switched on.

3. In case of the vessel volume reaching the overflow pipe or the drainage channel in the
plinth, manual operation of the inlet pressure regulator and drain valves is necessary to
control the fluid level.
4. The locking nuts at the top of the differential level switches were loosened and the height
of the rods were also adjusted to a suitable starting values of 20mm for the blue-topped
rod and 50mm for the red-topped rod. (the red rod was positioned higher than the blue
rod)
 5. The drain valve at the base of the large process vessel was partially closed.
6. The data logging (in the software) was set to automatic at an interval of 10 seconds.
7. The pressure reading PI was found to be varying with the rising water levels.
8. The differential level switch was primed.
9. The level switch (float switch) was adjusted until the float was higher than the lower of
the two electrodes on the differential level switch.
10. (In the software) the radio button for control was selected using the level switch and the
water level was allowed to reach the lower electrode on the differential level switch and
the water level in the vessel was dropped by lowering the level switch.
11. When the level was at least 50mm below the lower of the two electrodes on the
differential level switch, the radio button for the differential level switch control in the
software was selected.
12. The GO icon was selected to begin logging the data.
13. The data was logged on until the oscillations in the fluid level reached stable values for
magnitude (height) and duration. And the STOP icon was selected to finish the data
logging.

Observation:

We have observed that the parameter (that was set into the software) can used to see how
effective the level switches are by controlling the valves (SOL 1, 2 and 3).

Result and Discussion:

The data for this level control experiment is given on the next page.

The set point for this experiment is 300mm.

 Level Flowrate Solenoid Solenoid Solenoid
Sample Elapsed Level Differential
1 2 3
Number Time Switch Level
L1 F1
Switch
[mm] [ml/min] [On/Off] [On/Off] [On/Off]
1 00:00 42 1211 1 1 On Off Off
2 00:10 56 1206 1 1 On Off Off
3 00:20 70 1207 1 1 On Off Off
4 00:30 83 1203 1 1 On Off On
5 00:40 90 1199 1 1 On Off On
6 00:50 97 1206 1 1 On Off On
7 01:00 103 1204 1 1 On Off On
8 01:10 110 1206 1 1 On Off On
9 01:20 117 1204 1 1 On Off On
10 01:30 124 1202 1 1 On Off On
11 01:40 131 1198 1 1 On Off On
12 01:50 138 1198 1 1 On Off On
13 02:00 144 1195 1 1 On Off On
14 02:10 152 1199 1 1 On Off On
15 02:20 159 1195 1 1 On Off On
16 02:30 166 1197 1 1 On Off On
17 02:40 174 1189 1 1 On Off On
18 02:50 181 1189 1 1 On Off On
19 03:00 189 1174 1 1 On Off On
20 03:10 196 1180 1 1 On Off On
21 03:20 204 1174 1 1 On Off On
22 03:30 211 1176 1 1 On Off On
23 03:40 218 1171 0 1 On Off On
24 03:50 225 1168 0 1 On Off On
25 04:00 233 1167 0 1 On Off On
26 04:10 232 3 0 1 Off Off On
27 04:20 226 3 0 1 Off Off On
28 04:30 227 1168 1 1 On Off On
29 04:40 232 1165 1 1 On Off On
30 04:50 235 1162 1 1 On Off On
31 05:00 238 1169 0 1 Off Off On
32 05:10 238 4 0 1 Off Off On
33 05:20 241 3 0 1 Off Off On
34 05:30 243 4 0 1 Off Off On
35 05:40 245 3 0 1 Off Off On
36 05:50 247 1148 1 1 On Off On
37 06:00 249 1167 1 1 On Off On
38 06:10 252 1164 1 1 On Off On
39 06:20 254 4 0 1 Off Off On
40 06:30 257 1156 1 1 On Off On
41 06:40 259 19 0 1 Off Off On
42 06:50 261 1165 1 1 On Off On
43 07:00 262 1172 1 1 On Off On
44 07:10 265 1164 1 1 On Off On
45 07:20 267 1167 1 1 On Off On
46 07:30 267 1166 1 1 On Off On
47 07:40 271 1167 0 1 Off Off On
48 07:50 271 4 0 1 Off Off On
49 08:00 275 20 0 1 Off Off On
50 08:10 275 3 0 1 Off Off On
51 08:20 275 4 0 1 Off Off On
52 08:30 276 4 0 1 Off Off On
53 08:40 277 3 1 1 On Off On
54 08:50 278 4 1 1 On Off On
55 09:00 279 1156 1 1 On Off On
56 09:10 280 1156 1 1 On Off On
57 09:20 280 1161 1 1 On Off On
58 09:30 283 1162 1 1 On Off On
59 09:40 284 1175 1 1 On Off On
60 09:50 285 1167 1 1 On Off On
61 10:00 286 1170 0 1 Off Off On
62 10:10 285 3 0 1 Off Off On
63 10:20 286 1160 1 1 On Off On
64 10:30 285 1163 1 1 On Off On
65 10:40 285 3 0 1 Off Off On
66 10:50 285 1178 1 1 On Off On
67 11:00 289 3 0 1 Off Off On
68 11:10 289 1167 1 1 On Off On
69 11:20 290 1170 1 1 On Off On
70 11:30 291 1172 1 1 On Off On
71 11:40 292 1179 1 1 On Off On
72 11:50 293 1181 1 1 On Off On
73 12:00 293 4 0 1 Off Off On
74 12:10 292 3 0 1 Off Off On
75 12:20 294 3 0 1 Off Off On
76 12:30 293 2 1 1 On Off On
77 12:40 294 1175 1 1 On Off On
78 12:50 295 1176 1 1 On Off On
79 13:00 297 1185 0 1 Off Off On
80 13:10 296 3 0 1 Off Off On
81 13:20 295 2 1 1 On Off On
82 13:30 298 1176 1 1 On Off On
83 13:40 299 20 0 1 Off Off On
84 13:50 298 3 0 1 Off Off On
85 14:00 298 3 1 1 On Off On
86 14:10 300 1195 1 1 On Off On
87 14:20 300 1190 0 1 Off Off On
88 14:30 300 21 0 1 Off Off On
89 14:40 300 4 0 1 Off Off On
90 14:50 299 3 0 1 Off Off On
91 15:00 300 1176 1 1 On Off On
92 15:10 300 1187 1 1 On Off On
93 15:20 300 21 0 1 Off Off On
94 15:30 300 4 0 1 Off Off On
95 15:40 300 3 1 1 On Off On
96 15:50 300 1179 1 1 On Off On
97 16:00 300 1184 1 1 On Off On
98 16:10 300 21 0 1 Off Off On
99 16:20 300 4 0 1 Off Off On
100 16:30 300 1170 1 1 On Off On
101 16:40 300 1181 1 1 On Off On
102 16:50 300 4 0 1 Off Off On
103 17:00 300 3 1 1 On Off On
104 17:10 300 1181 1 1 On Off On
105 17:20 300 4 0 1 Off Off On
106 17:30 300 20 0 1 Off Off On
107 17:40 300 1166 1 1 On Off On
108 17:50 300 1181 0 1 Off Off On
109 18:00 300 4 1 1 On Off On
110 18:10 300 1183 1 1 On Off On
111 18:20 300 1187 0 1 Off Off On
112 18:30 300 20 0 1 Off Off On

In order to understand how effective the floating ball level switch is we have drawn the level
value against time and the graph is shown below:

Level Switch
350

300

250
Level (mm)

200

150

100

50

0
00:00 02:53 05:46 08:38 11:31 14:24 17:17 20:10
Elapsed time

We can see from the above graph that the floating ball switch has taken 14.24 minutes to
maintain the process fluid at level of 300mm.

This kind of control switch isn’t much used in industries it can’t take action for the disturbances
as soon as it detects it and this will be dangerous for some processes that small change in level
can cause a disaster. But it can be used in the feedback control configuration as long as the
disturbance didn’t upset the process until this level switch controls the level.

Conclusion

 In this experiment, the machine has recorded the level data for the differential data so
we can’t be able to compare the float and the differential switch and suggest the best
one. But from the theory we can understand that the differential level switch better
controls the level without wasting much time.
 The level switch in this experiment can be used in the feedback control system where
correction of disturbances instantly isn’t necessary.
 The on/off level switch are used and more effective in lower level control.
  Because of it is easiness to us and simple to control, the following industries use level
switch: process water and drinking water treatment, food and beverage industry.
 The differential switch are used in a variety of industrial processes to provide reliable,
instantaneous and continuous information about system conditions. For instance they are used
in low pressure pump tank (in pump re-circulation systems), pump tanks in gas pump systems,
intermediate coolers in two stages refrigeration plant and condensers.

Recommendation

We, as a group, recommend that the software on the level control switch to be fixed so that we
could get data for the differential level switch as the float switch.