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1 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l Power Hydraulic Engineers Operation and Maintenance Manual Bubble Level Transmitter 51-E, Saraswati Vihar, Adhoiwala, Dehradun-248001, Uttarakhand, India. +91-9758119801, +91-6395649473 powerhydraulicengineers@gmail.com

2 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l Introduction Bubbler Level Measurement System Working Principle The Bubbler Level Measurement System determines liquid level by measuring the hydrostatic back pressure developed at the outlet of a continuously purged dip tube. Regulated instrument air or nitrogen is introduced into the dip tube at a low, constant flow rate, producing continuous bubbling at the tube outlet. The resulting back pressure, corresponding to the hydrostatic head of liquid above the dip-tube outlet, is applied to the HP side of the Digital DP Transmitter, with the LP side connected to the applicable reference pressure. The measured differential pressure is proportional to liquid level in accordance with ΔP = ρgH, assuming constant liquid density. The DP transmitter converts the measured pressure into a 4–20 mA output for level indication. Industrial Applications The Bubbler Level Measurement System is ideally suited for storage and process tanks, waste water and effluent systems, slurries, corrosive or viscous liquids and high-temperature fluids services, where direct-contact level instruments may be unsuitable. Since the transmitter remains isolated from the process medium, the system offers reliable measurement in demanding process environments. Key limitations Measurement accuracy depends on liquid density and requires a stable specific gravity. The dip tube must remain free from blockage or deposits, while purge flow must be maintained at a low and constant rate. Reliable instrument air or nitrogen supply is required, and pressurized vessels require proper pressure reference compensation. Calibration Procedure Calibration is performed using a certified pressure/DP calibrator and precision current measurement device. With the transmitter isolated and at zero DP, verify 4.00 mA at 0% level and apply calibrated pressures corresponding to the operating range. Verify the output at 25%, 50%, 75%, and 100% span, corresponding to 8, 12, 16, and 20 mA respectively. Adjust zero/span as required and verify that all readings are within the specified accuracy. After calibration, restore the process connections, establish the specified purge flow, confirm stable bubbling, and verify the level indication at the PLC/DCS/SCADA.

3 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l Bubble Level Transmitter Major components: 1. Air Filter and Regulator -12 bar,14micron Filteration 2. Rotamter 0-20 lpm 3. Pressure Gauge 0-500mb 4. DP Type Smart Transmitter 5. Ball Valve ½ ” BSP 6. Needle Valve ¼” BSP 7. Control Panel 600mmx 600mmx 250mm

4 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l Description and control of the components Air Filter and Regulator Part No. MS6-LFR-1/2-D7-E-R-M-AS. Technical Specifications :  Connection: G 1/2  Filtration: 40 μm  Drain: Manual rotating drain  Bowl: Polycarbonate with plastic bowl guard  Maximum condensate volume: 38 ml  Operating pressure: 0.8–20 bar  Pressure regulation range: 0.5–12 bar  Nominal flow: approximately 4,500 L/min  Medium: compressed air / inert gas  Temperature: approximately −10 to +60 °C  Regulator characteristic: constant outlet pressure with secondary venting  Pressure hysteresis: maximum approximately 0.25 bar. Rotamter 0-20 lpm  Type: Panel mount Acrylic Rotameter with control valve at bottom  Make: From URL japsin.co.in - Japsin Instrumentation  Scale: LPM AIR - Liters Per Minute for Air Range: 0 to 20 LPM  Tube: Clear Acrylic body with SS float inside Connection: Threaded top + bottom  Bottom has control knob for flow adjustment  Use: Measuring and controlling air flow  How it works: The float rises to the flow rate  Read at the center of the float. Right now it's at 0 LPM Pressure Gauge 0-500mb  Brand:"Ji" Japsin Instrumentation  Product Type:Capsule Pressure Gauge  Dial Size:4" (100 mm)  Pressure Range:0 to 5000 mmWC  Secondary Scale:0 to 500 mBar  Mounting Type: Direct Mounting  Entry Type: Bottom Entry  Connection Size:3/8" BSP (M)  Case Material: Stainless Steel  Wetted Parts Material:Stainless Steel  Pointer Type: Micro Adjustable Pointer  Measuring Element: Capsule Element

5 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l DP Type Smart Transmitter  Make: Instrument &Systems  Type: DP Transmitter - 2 wire, 4-20mA + HART  Supply Volt : 24V DC (2 wire)  Output : 4-20 mA (HART)  Display: Digital LCD on top with blue protective cover  Medium: Air / Nitrogen  Range: 0to0.6bar  Accuracy : ±0.075%of calibrated span  Diaphragm: SS316L Ball Valve ½ ” BSP  Type: Ball valve.  Lever handle = on/off  Body: SS316, square block body, panel mount with bracket  Connections: Double ferrule compression fitting on top and bottom  Handle: Flat SS lever.  Parallel to pipe = OPEN,  Perpendicular = CLOSED Needle Valve ¼” BSP  Type: 2-way, Straight pattern Needle Valve  Body: SS316  Handle: T-bar / lever handle for fine throttling  Connections: Double ferrule compression fitting 1/4" x 12mm OD tube  Use: Isolating pressure gauges, transmitters, fine flow control and tight shut-off

6 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l Standard Operating Procedure Pre-Start Checks  Visual Check: Ensure Ball valves (5.1 ,5.2 & 5.3 ), Needle valve (6.1 & 6.2 ) should be in CLOSED position.  Air Supply to panel : Confirm Instrument Air from Compressor is clean, dry, oil-free and at 0.4 bar to 0.5 bar. Connect T1 to the compressor through flexible pneumatic tubing or suitable SS Tubing’s.  Dip Tube: Confirm dip tube is installed in vessel to required depth. Tube end should be 50-100mm above vessel bottom.  DP Transmitter: Confirm DP transmitter is mounted and the pressure line is connected as shown in the lay out. Confirm the Transmitter is calibrated for 0-100% level of fluid level.  Drain Pot: Ensure drain pot’s vent line is connected to T3 through flexible pneumatic tubing or suitable SS Tubing’s.  Air Supply to drain Pot: The dip tube inlet port has to be connected to T2 of the panel through flexible pneumatic tubing or suitable SS Tubing’s. 5.1 5.2 5.3 6.1 6.2 T 1 T2 T3

7 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l Panel Start-Up  Open Air In: Slowly open the ball valves (5.1 & 5.3) and the needle valve 6.2.  Set FRL: Adjust Air Filter Regulator (1) to set pressure = 1.5 x Max expected level head in bar considering the maximum fluid level in the drain pot and its specific gravity.  Flow regulation: Adjust the Rotameter (4) to control the air flow to around 6-10 lpm just to create slow air bubble formation at the tip of the dip tube inside the drain pot. The goal is Just enough to maintain bubbles, not waste air.  Check Pressure Gauge (3): Open the needle valve 6.2 – the Gauge will show the back pressure which is the liquid head, note the reading.  Verify DP Transmitter: Check DP transmitter LCD reading. It should match actual vessel level. Normal Operation  Monitor: Keep Rotameter flow constant. If flow drops, check filter clogging.  DP Reading: DP transmitter converts back pressure to 4-20mA. 0% = 4mA, 100% = 20mA.  Drain Pot: Condensate will collect and vent out. Drain periodically if needed. Shut Down Procedure  Close the ball Valve (5.3) first to stop purge air.  Close Ball Valves (5.1) for AIR IN  Vent: Leave "AIR TO DRAIN POT" open to depressurize. Important Notes / Safety  Do NOT over-pressurize: FRL pressure should always be > max liquid head, but < tube burst pressure.  No Bubbles = Wrong Reading: If Rotameter = 0, DP will read wrong. Check for dip tube choking.  Too much flow: Wastes air and gives unstable reading. Keep bubbles slow and steady.  Calibration: Since DP is already calibrated, 0% = empty vessel, 100% = max level. Do not change FRL pressure after calibration. Troubleshooting  DP reads 0% but tank has liquid : Dip tube is choked or there is no air flow. Check the Rotameter if needed blow through the dip tube. Fot this close the ball valve 5.1&5.3 and both the needle valves 6.1 and 6.2 and let air to pass through the dip tube if needed the pressure may be increase directly prom the compressor control valve to clear the dip tube choking.  DP reads 100% always : The ball valve 5.3 is closed air is not coming to dip tube inlet. Open this ball valve and then check the bubble formation takes place slowly and smoothly.  Unstable reading : Too much air flow, Foaming inside the drain pot , reduce LPM on Rotameter and ensure bubble formation takes place slowly and smoothly.

8 | P a g e B L T o p e r a t i o n / M a i n t e n a n c e M a n u a l About Us Power Hydraulic Engineers (PHE) is a multidisciplinary engineering organization established in 2021 by Engineering professionals with experience in manufacturing and technical consultancy to many reputed industries in India as well as to few international firms. We are specialized in project engineering, industrial fabrication, hydraulic systems, instrumentation, automation, and customized machinery manufacturing all related to Mechanical Engineering. We provide complete engineering solutions from conceptual design through detailed engineering, manufacturing, inspection, installation, commissioning, and after-sales technical support. OUR CORE ENGINEERING SERVICES Project Cost Estimation Preparation of accurate and comprehensive project cost estimates includingMaterial cost, Fabrication cost, Procurement cost, Installation cost, Labor costing, Budgetary estimates, Tender costing, Commercial bid support. Project Planning & Scheduling Preparation of complete project execution schedules using Oracle Primavera P6, ensuring effective planning, monitoring, and timely project completion. Bill of Quantities (BOQ) Preparation Preparation of detailed BOQs from engineering drawings and project reports. Industrial Piping Engineering & Fabrication Complete engineering and fabrication of industrial piping systems based on Process Flow Diagrams (PFD), Piping & Instrumentation Diagrams (P&ID), General Arrangement Drawings, and Isometric Drawings. Design & Manufacturing Design, manufacture, assembly & testing of customized industrial equipment viz.Hydraulic Presses, Hydraulic Power Packs, Hydraulic Cylinders, Plate Rolling Machines, Overhead Travelling Cranes, Material Handling Equipment, Scissor Lift Platforms, Hydraulic Test Rigs, Custom Hydraulic Systems. Quality Commitment Power Hydraulic Engineers is committed to delivering engineering solutions that comply with applicable international codes, client specifications, and quality management practices. Industry we Serve Oil & Gas, Petrochemical, Chemical, Steel Cement, Power Generation and Heavy Engineering.