By Tapan Bhavsar May 9, 2020

DP Level Transmitter Dry Leg & Wet Overview, Basic

Calculations and Design Considerations

In any process industry, level measurement is very important for Process safety and control
applications.

A differential pressure transmitter is a common and well-understood technology for liquid

level measurement. If the tank/vessel is closed or pressurized, a DP measurement must be
made to compensate for the vapor pressure of the tank/vessel.

DP Transmitter Level Measurement for Closed Tank

In closed tank DP level measurement, LP leg is connected to the top of tank. There are two
methods in closed tank DP Level Measurement.

Dry leg method:

Dry leg method is used in normal closed tank when process vapors are not corrosive and
condensations at ambient temperature are not expected.

Wet leg method:

The wet-leg installations are used when the process vapors would otherwise condense into
the compensating leg, thereby exposing the low-pressure side of the d/p cell to
unpredictable hydraulic heads, or when the transmitter must be sealed from corrosive
vapors.

Wet-leg application in which the compensating leg (LP side) is prefilled with a chemically
inert liquid that will not freeze or vaporize under operating temperature conditions.

Diaphragm seals with capillary filled in shall be used in highly Toxic, highly corrosive, and
Hazardous liquid level measurement.

Special Cases:

For Boiling Application like in steam drum, the DP range shall be reversed considering
steam will be always condensed at the ambient temperature. Additional measures to be
taken care of for the compensation in the Control System for proper control of the drum
level. Installation and performance characteristics shall be followed as per ASME Boiler and
Pressure Code.

For Cryogenic Application, special consideration for installation must be taken care of
considering Liquid will be evaporated at the ambient temperature conditions while using DP
type level.

Input Documents from engineering aspect:

- P&Id
- Equipment Mechanical Datasheet
- Process Datasheet

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By Tapan Bhavsar May 9, 2020

DP Transmitter Level Measurement for Closed Tank – Dry Leg Method:

When LP side of the DP transmitter is filled with any gas/air/, then we call it as Dry
Leg & we apply Dry Leg Method for calculations.

At 0 % Level (LRV) = Pressure acting on HP leg – Pressure acting on LP leg

= H2 x specific gravity – (H1+H2) x 0 (In absence of liquid)

= 200 x 0.9 – 0

= 180 mmH2O

At 100 % Level (URV) = Pressure acting on HP leg – Pressure acting on LP leg

= (H2+H1) x specific gravity – (H1+H2) x 0 (In absence of liquid)

= (200 + 1000) x 0.9 – 0

= 1080 mmH2O

Calibration Range of DP Transmitter = URV to LRV = 180 to 1080 mmH2O

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By Tapan Bhavsar May 9, 2020

DP Transmitter Level Measurement for Closed Tank – Wet Leg Method:

When LP side of the DP transmitter is filled with liquid then we call it as Wet Leg & we apply
Wet Leg Method for calculations.

At 0 % Level (LRV) = Pressure acting on HP leg – Pressure acting on LP leg

= H2 x SG1 – (H1+H2) x SG2

= 200 x 0.9 – 1200 x 1.0

= 180 – 1200

= – 1020 mmH2O

At 100 % Level (URV) = Pressure acting on HP leg – Pressure acting on LP leg

= (H2+H1) x SG1 – (H1+H2) x SG2

= 1200 x 0.9 – 1200 x 1.0

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By Tapan Bhavsar May 9, 2020

= 1080 – 1200

= -120 mmH2O

Calibration Range of DP Transmitter = LRV to URV = -1020 to -120 mmH2O.

Suitable method based on application, we need to select and calibrate Lower Range Value
(LRV) and Upper Range Value (URV).we need to find out correct calibration range before
ordering the Transmitter as long as possible. That is quite important during engineering
phase.

DP Level Transmitter installed elevation effect:

The DP Level Transmitter calibration parameters will vary depending on installation & seal
system also. Generally we can see three possibilities of installation of a transmitter in the
field as per following.

1. Transmitter installed Exactly at HP tapping point (Ideal & preferred way of

installation).

2. Transmitter installed above HP tapping point (Not preferable, Chance of bubble

formation in the impulse line). Only acceptable for Diaphragm sealed Level
Transmitter.

3. Transmitter installed below HP tapping point (Error can be compensated effectively).

During engineering phase, Elevation of transmitter shall be verified in the 3D model and
must be taken into consideration during Level calculations.

Note: Selection of DP type level transmitter over other technologies for level
measurement is not part or an intension of this document.

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