Differential Pressure

Level Instruments
Mr. Aussanee K.

21-April-2010
 2

Fundamental Training

Differential Pressure
Level Measurement
Level Measurement
Differential Pressure : Theory 3

Differential pressure (DP) is a popular choice for clean liquids with a

constant specific gravity. DP transmitters do not measure level directly;
they instead infer level by the downward pressure (hydrostatic pressure)
of the liquid against a diaphragm. If the temperature or specific gravity
of the medium changes, significant error will occur. If the vessel is
pressurized, you need to add a second connection to the vessel above
the liquid to measure and allow for correction of this variable, hence
the term differential pressure, which measures the difference between
these two points.
Level Measurement
Hydrostatic Pressure : Theory 4

Hydrostatic Pressure (Pressure Head)

Considering a small cube of liquid at rest below a free surface, pressure caused by the
height of the liquid above must be balanced by a resisting pressure in this small cube.
For an infinitely small cube the stress is the same in all directions and liquid weight or
equivalent pressure can be expressed as

P = ρ*g*h
P = Hydrostatic Pressure (Pa)
ρ = Density (kg/m3)
g = Gravity (m/s2)
H = Height (mm)
h
ρ

P = SG * h
P = Hydrostatic Pressure (mmH2O)
SG = Specific gravity
H = Height (mm)
Differential Pressure Level Instruments
Open Tank Level Measurement

Impulse Line

d
Bubble t an
Tube o un eal
c t M te S
ire mo
D Re
 Operating conditions (Installation)
for Open Tank Level Measurement 7

Direct mount Impulse Line

Remote Seal Bubble Tube

DP Level Transmitters
Open Tank Level Measurement : Theory 8

Open Vessel Level Measurement (Direct mount)

Direct mount: The Differential pressure transmitter mounted near
the bottom of the tank by high side will measure the pressure
corresponding to the height of the fluid above it and low side will
measure the pressure at atmospheric.
100%
Example: Zero-Based Direct Mount
What is the Calibration Range ?
When has liquid at 0% we get
Phigh = 0 + Patm

Plow = Patm
Patm
Trans. Patm
ΔP at 0% = Phigh - Plow 0%
L H
= 0 + Patm - Patm

=0
 DP Level Transmitters
Open Tank Level Measurement : Theory 9

Open Vessel Level Measurement (Direct mount)

When has liquid at 100% we get
Phigh = Phead + Patm Patm
100%
Plow = Patm

ΔP at 100%= Phigh - Plow

= Phead + Patm - Patm

Phead
= Phead
Trans.
Patm 0%
Calibration Range = ΔP at 0% to ΔP at 100% L H
4 mA point = [ΔP at 0% ]
20 mA point = [ΔP at 100% ]
Exercise 1 (Open Tank Level Measurement ) 10

Find the Calibration Range ?

Appendix-1

Appendix-1.1
 DP Level Transmitters
Zero Suppression : Theory 11

• “Zero Suppression” is often applied to compress the range

of the liquid head in the pipe connecting the transmitter to a tank when
the transmitter is mounted below the vessel connection.

20mA Max. Level 20mA Max. Level

Range
Actual Zero

Range
Suppressed 4mA Min. Level

Actual Zero
Suppressed
4mA Min. Level
Trans. Trans.

L H L H
 DP Level Transmitters
Zero Elevation : Theory 12

• “Zero Elevation” is needed for transmitter mounted above the

high side tap, In this case transmitter reads a negative pressure when
the tank is empty due to the head effect of the capillary fill fluid

20mA Max. Level

Range
Trans.
L H

4mA Min. Level

Actual Zero
Elevation
Close Tank Level Measurement

Impulse Line

Bubble
a l
Tube Se
o te
m
Re
Operating conditions (Installation)
for Close Tank Level Measurement 14

Impulse Line
Remote Seal

Bubble Tube
DP Level Transmitters
Close Tank Level Measurement : Theory 15

Closed Tank Level Measurement (Dry Leg)

•Dry leg: no fluid in low side impulse piping, or leg
•If the gas above the fluid does not condense, the
piping for the low side of the transmitter will remain
empty.

Example: Zero-Based Remote Mount

100%
What is the Calibration Range ?
When has liquid at 0% we get Ptop
Phigh = 0 + Ptop

Plow = Ptop
Trans.
ΔP at 0% = Phigh - Plow 0%
L H
= 0 + Ptop - Ptop

=0
 DP Level Transmitters
Close Tank Level Measurement : Theory 16

Closed Tank Level Measurement (Dry Leg)

When has liquid at 100% we get
Phigh = Phead + Ptop
Ptop
Plow = Ptop 100%

ΔP at 100%= Phigh - Plow

= Phead + Ptop - Ptop Phead

= Phead
Trans.
0%
Calibration Range = ΔP at 0% to ΔP at 100% L H
4 mA point = [ΔP at 0%
]
20 mA point = [ΔP at
100% ]
DP Level Transmitters
Close Tank Level Measurement : Theory 17

Closed Tank Level Measurement (Wet Leg)

•Wet leg pressure is additive to pressure on low side of the
transmitter.
•If the gas above the liquid condenses, the piping for the
low side of transmitter will slowly fill with liquid. To
eliminate this potential error, the pipe is filled with a
convenient reference liquid.

Example: Zero-Based Remote Mount 100%

What is the Calibration Range ?
Pwet Ptop
When has liquid at 0% we get
Phigh = 0 + Ptop

Plow = Pwet + Ptop

0%
ΔP at 0% = Phigh - Plow L H
Trans.
= 0 + Ptop – Pwet – Ptop

= - Pwet
 DP Level Transmitters
Close Tank Level Measurement : Theory 18

Closed Tank Level Measurement (Wet Leg)

When has liquid at 100% we get
Phigh = Phead + Ptop
Ptop
Plow = Pwet + Ptop
100%
ΔP at 100%= Phigh - Plow
Pwet
= Phead + Ptop – Pwet - Ptop Phead
= Phead – Pwet

Calibration Range = ΔP at 0% to ΔP at 100% 0%

L H
4 mA point = [ΔP at 0% Trans.
]
20 mA point = [ΔP at
100% ]
Exercise 2 (Close Tank Level Measurement ) 19

Find the Calibration Range ?

Appendix-2

Appendix-2.1
 DP Level Transmitters
Close Tank Level Measurement : Theory 20

Remote Seals
• Reliable, Simple, Easy to Use, Well
Understood, Flexible Uses:

Diaphragm Seals extend limitations

due to process conditions such as:

high temperatures
corrosion
Differential
viscous materials Pressure
suspended solids Transmitter
plugging
sanitary needs
Why Use Remote Seals ? 21

• High temperatures
• Corrosive processes
• Prevent clogging Debris
clogging up
• Sanitary applications the transmitter

Chemical Spray
(Clean in Place)
(CIP)

Effluent

Bacteria

Cracks and Crevices

 Why Use Remote Seals ? 22

• Reduce number of joints

Threaded Connection
TOXIC
• Wet or dry leg replacement
• Viscous Applications
Threaded Connection

Variable height

Changes head
pressure
How Remote Seal Works ? 23

PRESSURE
H

FILL
FLUID

PROCESS
ISOLATING
DIAPHRAGM PRESSURE
Classifications of Remote Seals 24

• Diaphragm seals fall into five groups:

 Flange Mount - Flushed
 Flange Mount - Extended
 Flange Mount - Internal
 Threaded
 Sanitary
 25
Exercise 3 (Close Tank Level Measurement (Remote Seal))

Find the Calibration Range ?

Appendix-3
Appendix-4
Appendix-5

Appendix-3.1
Appendix-4.1
Appendix-5.1
DP Level Transmitters
Bubble Tube : Theory 26

Application for bubble tube Trans.

Pin
- 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.

Principle of Operation
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 H
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.
 DP Level Transmitters
Bubble Tube : Theory 27

Open Tank Level Measurement (Bubble Tube)

Pin
What is the Calibration Range ? Trans.
When has liquid at 0% we get
Phigh = 0 + Patm
Plow = Patm Patm
ΔP at 0% = Phigh - Plow 100%
= 0 + Patm - Patm
=0
When has liquid at 100% we get
Phigh = Phead + Patm H
Plow = Patm
ΔP at 100%= Phigh - Plow
= Phead + Patm - Patm
= Phead 0%
Calibration Range = ΔP at 0% to ΔP at 100%

4 mA point= [ΔP at 0% ]
20 mA point = [ΔP at
100% ]
 DP Level Transmitters
Bubble Tube : Theory 28

Close Tank Level Measurement (Bubble Tube)

Pin
What is the Calibration Range ? Trans.
When has liquid at 0% we get
Phigh = 0 + Ptop
Plow = Ptop Ptop
ΔP at 0% = Phigh - Plow 100%
= 0 + Ptop - Ptop
=0
When has liquid at 100% we get
Phigh = Phead + Ptop H
Plow = Ptop
ΔP at 100%= Phigh - Plow
= Phead + Ptop - Ptop
= Phead 0%
Calibration Range = ΔP at 0% to ΔP at 100%

4 mA point= [ΔP at 0% ]
20 mA point = [ΔP at
100% ]
DP Level Transmitters
Density and Interface Measurement : Theory 29

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
DP Level Transmitters
Density Measurement : Theory 30

Density Measurement (Constant Level)

Trans. Pin

What is the Calibration Range ?

When liquid has Constant Level overflow
Pmin = H * SGmin

Pmax = H * SGmax

Calibration Range = Pmin to Pmax

H
4 mA point = [ Pmin ]
20 mA point = [ Pmax ]
S.Gf
DP Level Transmitters
Density Measurement : Theory 31

Density Measurement (Vary Level)

Trans. Pin

What is the Calibration Range ?

When liquid has Vary Level
Pmin = H * SGmin

Pmax = H * SGmax

Calibration Range = Pmin to Pmax

4 mA point
20 mA point
= [ Pmin ]
= [ Pmax ]
H
S.Gf
 DP Level Transmitters
Density Measurement : Theory 32

Density Measurement (Vary Level)

Example: SG varies between 0.9 and 1.3; and Trans. Pin
H = 1000 mm
What is the Calibration Range ?
When liquid has Vary Level
Pmin = H * SGmin
Pmin = 1000 * 0.9

Pmin = 900 mmH2O

Pmax = H * SGmax
Pmax = 1000 * 1.3 H
Pmax = 1300 mmH2O
S.Gf
Calibration Range = 900 mmH2O to 1300 mmH2O
4 mA point = [ 900
mmH2O ]
20 mA point = [ 1300 mmH2O
DP Level Transmitters
Interface Measurement : Theory 33

Interface Measurement (Constant Level)

Trans. Pin

What is the Calibration Range ?

When liquid has Constant Level overflow
Maximum
Pmin = (H1 * SG1) + (H2 * SG2) interface level

Pmax = (H1 + H2) * SG2

H1 S.G1
Calibration Range = Pmin to Pmax
4 mA point = [ Pmin ] Minimum
interface level
20 mA point = [ Pmax ]
H2
S.G2
DP Level Transmitters
Interface Measurement : Theory 34

Interface Measurement (Vary Level)

Trans. Pin

What is the Calibration Range ?

When liquid has Vary Level
Pmin = H * SG1
S.G1
Pmax = H * SG2 Maximum
interface level

Calibration Range = Pmin to Pmax

4 mA point = [ Pmin ] H S.G2
20 mA point = [ Pmax ]
Minimum
interface level
 DP Level Transmitters
Interface Measurement : Theory 35

Interface Measurement (Vary Level)

Example: Interface liquid, SG varies between Trans. Pin
0.9 and 1.3; and H = 1000 mm
What is the Calibration Range ?
When liquid has Vary Level
Pmin = H * SG1
Pmin = 1000 * 0.9 S.G1
Maximum
Pmin = 900 mmH2O interface level

Pmax = H * SG2
Pmax = 1000 * 1.3 H S.G2

Pmax = 1300 mmH2O

Minimum
Calibration Range = 900 mmH2O to 1300 mmH2O interface level

4 mA point = [ 900
mmH2O ]
20 mA point = [ 1300 mmH2O