Products Solutions Services

Process Instrumentation Training

Level Measurement of Endress+Hauser

Time of Flight Measurement
Products Solutions Services

Introduction

Product Center
Producing – Guided-radar, Radar, Ultrasonic Level and Pressure
Process Instrumentation Training

Strong presence worldwide

 Holding company in Reinach, Switzerland

 Production facilities in 11 countries
 Endress+Hauser sales centers in more than 100 countries
 Four regional sales support centers
We are worldwide close to our customers!
 Process Instrumentation Training

Endress+Hauser Maulburg in Germany

Metal processing

Level Production

R&D Level

Industrial Engineering

Ceramic Sensor Production Main Office

Electronic Production
Logistics + Dispatch

R&D Pressure

Test Centre
Pressure Production
Process Instrumentation Training

Production sites

Maulburg Kassel Stahnsdorf, near Berlin

Greenwood (USA) Suzhou (China) Aurangabad (India)

Yamanashi (Japan) Richmond (England) Itatiba (Brazil)

Process Instrumentation Training

Level
Limit Detection Continuous Measurement

HART®
S PA / FF

HART®
M PA / FF

T Analogue
Process Instrumentation Training

Tank Gauging
Endress+Hauser offers the most extensive
product range in instrumentation and system
solutions for tank farms and terminals in the
oil and gas industry.

 Selection of technology

 Open systems

 Certifications and approvals

 Overspill protection

 Remote monitoring
Process Instrumentation Training

Areas of Production
• The most modern production facilities
and the latest manufacturing
technologies safeguard the quality of
our instruments

• A world-wide installed base of more

than 6,500,000 measuring points

• 5,400,000 level measuring points

• 4,300,000 in level limit detection

• 1,100,000 in continuous level

measurement

• 1,100,000 pressure and differential

pressure transmitters
Process Instrumentation Training

Electronically Production
• 2,100,000 assembled and tested
printed circuit boards per annum
• 129,000,000 electronic components
• 113,000,000 SMD components
(Surface Mounted Devices)
• 16,000,000 conventional components
• Development of Backside Reflow and
unleaded soldering
Process Instrumentation Training

Mechanical Production

• Production facilities and tools for

machining of 1,250,000 mechanical
parts – predominantly of stainless
steel

• Processing methods
• Drilling
• Milling (conventional and CNC)
• Filing
• Bending
• Welding
• Cutting
• Polishing
Process Instrumentation Training

Final Assembly
 537,000 measuring points
manufactured, tested and supplied
 250,000 level limit switches
 70,000 continuous level measurement
instruments
 35,000 level transmitters
 182,000 pressure and differential
pressure instruments

 Key data
 16 product lines with approx.
1 million variants each
 Standard delivery period
Ø 2 to 5 working days
Process Instrumentation Training

Test Center – operational testing for extreme

• Application and environmental conditions

• Extreme temperature fluctuations
• Wind and weather
• Mechanical strain
• Electro smog
• Corrosive, abrasive, aggressive and
explosive media

• Test scenarios
• Splashing
• Temperature
• Abrasion
• EMC
Process Instrumentation Training

Segmentation Level Measurement

According to physical
measuring principles

Vibration Radar
Liquids Capacitance Guided radar
Capacitance
Conductive
Ultrasonic
Electromechanical
Hydrostatic
Ultrasonics
Radiometric
Radiometrics Differential pressure
Vibration Radar
Solids Capacitance Guided radar
Electromechanical Ultrasonic
Radar Electromechanical
Ultrasonic Radiometric
Radiometric
Process Instrumentation Training

Level measurement

• 10 different physical measuring principles

• Continuous level measurement and
level limit detection
• Level measurement in liquids and solids
 Process Instrumentation Training

Increasing amount of variations – ToF Family

1995
1993

Micropilot I
2002
Prosonic M
2004
1998 2007
Levelflex
2002
1998 Levelflex M 2004
2007
2001
Hygienic
Micropilot II
2004 HT/HP
version
Micropilot M
2008
Micropilot S
Life Sciences
Process Instrumentation Training

ToF Family – system overview

Plastic Alu 316L 316L-Pharma

Level radar Guided level radar Ultrasonic

basic … high performance

basic … high performance basic … high performance

Flexibility in technology Maybe also flow products

Process Instrumentation Training

What is so new about New Micropilot M?

Self Proof Test
Uniform commissoninig IEC 61508 (SIL2)
according to HMI standard

Multi Echo Tracking Quick Setup menu

Optical display HistoROM

Data Management

Up to 17 languages Two Chamber housing

As Standard
Process Instrumentation Training

Innovative display modules

Displays SD02 SD03 (Feb. 2013)

Picture

• Mechanical push buttons • Touch control (IR)

• HistoROM concept: Backup • HistoROM concept: Backup and
and copy of transmitter data copy of transmitter data

Feature • IP20/NEMA1 mounted in • Backlight of display included

the housing (without cover)
• Backlight with
• White color

• Red color for alarm

Process Instrumentation Training

Remote display FHX50

• Two housing types:

• Plastic (PBT)
• Stainless steel (316L) (in prep.)
• Suitable for both displays:
• Push button operation (SD02)
• Touch control operation from outside (SD03)
• Device FMP/FMR5x must be ordered with option prepared for display FHX50:
• Two options:
• With M12 plug at the device (max length: 30m)
• Customer standard cable for own installation (up to 60m installation length)
Products Solutions Services

Basic Principle

Radar Level
Principle of Time of Flight

• What is Time of Flight?

• Transmission of ultrasonic or
microwave impulses
• Reflection on the product surface
• Receiving of the reflected impulses
• Calculation of the distance between
sensor and reflector
• (= product surface) via:

00.40

d=c
2
Process Instrumentation Training

Basics Reflection

Difference between electromagnetic and mechanical waves

 Ultrasound waves are mechanical waves

 Reflection of ultrasound waves

Air: depends on a change of the wave
r  1 impedance
-> Change of density

Change  Microwaves are electromagnetic

of
impedance waves

 Reflection of microwaves depends

on a change of the wave impedance
Medium:
r > 1
-> Change of dielectric constant
(DK, r)
Process Instrumentation Training

Microwaves – independent on:

gas layers

vacuum

strong air
Density turbulence
changes

high
pressure
temperature
changes
changes
Process Instrumentation Training

Mechanical / Electromagnetical waves

Frequency Wave length 
Telephone
1 Hz
AC current kilometre
10 Hz
100 Hz Ultrasonic:
Radio
1 kHz approx. 40 ... 70 kHz
10 kHz
Ultrasonic (at 0°C)
100 kHz
metre (mechanical waves)
1 MHz
TV Television
10 MHz
100
1 GHz
z
MHz - (108 Hz )
decimetre
Microwaves 10 GHz
centimetre Levelflex
millimetre
100 GHz approx. 200 MHz ... 1,5 GHz
1 THz - (1012 Hz) (electromagnetic waves)
Heat micrometer
10 THz
100 THz
visible 1 - (1015 Hz)
10
Light nanometer
100 Micropilot:
1 - (10 Hz)
18
FMR 53x: approx. 6 GHz
ultra violet
10
100 FMR 23x: approx. 6 GHz
picometer
X-rays 1 - (1021 Hz) FMR 24x: approx. 26 GHz
10 (electromagnetic waves)
100
femtometer
1 - (1024 Hz)
Gammawaves
10
cosmic radiation
100
Process Instrumentation Training

Micropilot - Basics
Density power - effects on humans ?

Inside: app. 1 W/cm²

Leakage at closed door:
app. 5 mW/cm²

At transmitting power of 2 W:
app. 0,1 mW/cm²

Pulse during measurement:

app. 0,00021 mW/cm²
Process Instrumentation Training

Reflection
Difference between electromagnetic and mechanical waves

Microwaves are electromagnetic waves

Ultrasonics are mechanical waves
Reflexion depends
on the change of the wave impedance

Reflexion of ultrasonics
depends on the
--> change of the density

Reflexion of microwave and microimpulse

depends on the
-- > change of the dielectric constant
Process Instrumentation Training

ToF Definitions - from Distance to Level

Calculation of level:
L=E-D
t
D = •c
2

L = level
D D = measured distance
E = Empty distance
F = Full calibration
(measuring range)
E
t = run time of impuls
c = velocity of impuls
F L
BD = Blocking distance
SD = Safety distance
Process Instrumentation Training

Envelope curve Microwave

Amplitude

„ringing ramp“

Envelope curve

noise

level signal
Products Solutions Services

Operation

Radar Level
Process Instrumentation Training

The S/N -ratio of Electromagnetic Wave

1. Influence of different media
Process Instrumentation Training

The S/N -ratio of Electromagnetic Wave

2. Influence of the surface
Process Instrumentation Training

The S/N -ratio of Electromagnetic Wave

3. Influence of different antenna sizes
Process Instrumentation Training

Reflection of Electromagnetic Waves

Influence of foam in liquids

 Ideal  “something in-between“  Dense foam,

 "light" foam,
conditions small bubbles,
big bubbles,
--> signal absorption conductive
non conductive
???
Process Instrumentation Training

Operating Frequency

narrow beam angle

± 3 mm accuracy
small horns are ideal for
small vessels
use of full vessel capacity

less effected by boiling surface

less effected by foam
less effected by condensation and build up
rod antenna for aggressive media
Process Instrumentation Training

Advantage of 2 Frequencies

~ 26 GHz
+
3

Sensitivity against Build-up, foam

 Increased accuracy
 Small beam angle

and turbulent surface

 Ideal in small vessels
mm- accuracy

~ 6 GHz
 Less effected by turbulent
10 surface and foam
 Less effected by condensate
and build-up –
– Size of antenna / beam angle +
Slide 36

Reflection of Electromagnetic Waves

Influence of different antenna types resp. size
(Example: 6 GHz)
Slide 37

Comparison of Beam Angles

6 GHz 26 GHz

DN150 Horn DN40 Horn DN100 Horn

23° 23° 8°
 Process Instrumentation Training

Mounting / Installation
> 1/6 , min. 30 cm  No center mounting!
In case of build-up:  horn antenna appr. 5 cm
distance to
antenna
tip, because of
• weldings build-up and
• single limit switches, corrosion
sensors, ...
• pipes
 Out of the beam in the • vacuum rings
first meter. • heating pipes
• baffles

max. range  tank drawing

•For antennas with

strong directivity and
high measuring ranges:

 Vertical alignment is
important!
Process Instrumentation Training

Multiple Echoes with Central Installation

FEF
First Echo Factor
Process Instrumentation Training

Installation in Plastic Tank (Liquid & Solid Application)

 If the outer wall is made of non-conductive wall, microwave can

also be reflected off interfering installation outside the signal
beam.
1)metallic pipe
2)ladder
3)grates
Process Instrumentation Training

Mounting in Nozzle
Standard installation

When mounting in a tank, please observe

the following points:
For optimum measurement, the horn antenna
should extend below the nozzle. Nozzle
Heights (H) up to 500mm can be accepted if this
should not be possible due to mechanical reasons.

Note!
Please contact Endress+Hauser for application with higher nozzle.

The horn antenna must be aligned vertically.

Caution!
At not vertically aligned horn antenna can be reduced the maximum range.
Process Instrumentation Training

Optimization by Orientation of the Antenna

Free Space Installation

 Marker MUST be aligned toward the tank wall.
 The marker is exactly in the middle between 2 bolt-hole in the flange.
Process Instrumentation Training

Setup (Level, liquid FMR50/51/52/53/54)

1. • Distance unit

2. • Tank type

3. • Medium group
…

4. • Empty calibration
…

5. • Full calibration
Device tag

• Easy setup • Level/Dist./Signal quality

• Only 6 steps to
enter + mapping
6. • Mapping (Sequence)
sequence!
Process Instrumentation Training

Setup FieldCare DTM

Same user oriented menu structure like on-site display

User role is per default: Maintenance FieldCare Device
Setup delivered with device

Measuring
Linearization point
table
Envelope curve analysis
documentation
with tank calculation tool
Products Solutions Services

Advantages, Features & Benefits

Radar Level
Process Instrumentation Training

The Next Level Instrumentation – overview

FMR244 FMR240 FMR245 FMR231 FMR230 FMR244 FMR250

* *
Today

FMR50 FMR51 FMR52 FMR53 FMR54 FMR56 FMR57

Tomorrow

* *

Liquid Solid
* advanced dynamics
 ToF / Levelflex
Process Instrumentation Family – Product Strategy
Training

Next Level Instrumentation

Efficient
Precise

Safe
Process Instrumentation Training

Micropilot FMR5x SAFE – PRECISE – EFFICIENT

Safe due to: Devices which are

developed in accordance
to SIL up to SIL 3
Process Instrumentation Training

SIL safety orientated instrumentation

Process Instrumentation Training

Developed according IEC61508

Continuous automatic internal check in the device Check

• Logic program run control
• Reference pulse HF

• Quartz synchronization

• Measuring cycle time

• Supply voltage

• Temperature

• Check sum RAM

• Cable breakage

• Continuous self-monitoring to check the correct functionality of the device

• More than 80 diagnostic measures and techniques permanently running in the
background
Process Instrumentation Training

Proof test from control room

Proof procedure via manual started self check (proof test)

Check

Send
Developed acc. to IEC61508, also the data communication between
Device-DTM and device is secured (send – check).
 The proof test can easily done out of the control room

Save time and costs with worlds easiest proof test for SIL/WHG
1. Start the “Self check” (device checks internal communication
path)
2. Check the signal output by simply starting the simulation

Proof test is done without interruption of the process!

Process Instrumentation Training
“Tell me what to do” diagnostics
symbols recommended by NAMUR NE107
 Diagnostics:  Clear text information
icons + text maintenance instructions

Events storage
 Measurement view
clear failure signals
 on DAT (SD) card
Process Instrumentation Training

SAFE – PRECISE – EFFICIENT

Precise due to: Intelligent self-

learning software
evaluation:
Multi-Echo-Tracking
Process Instrumentation Training

Multi-Echo-Tracking: Situation FMR2xx

Level =
A

distance
Process Instrumentation Training

Multi-Echo Tracking
Process Instrumentation Training

ToF family

Safe Precise Efficient

• Hardware and software • Dynamic algorithms • Intuitive operating concept
developed according to IEC • Multi-Echo Tracking • HistoROM – data management
61508, SIL2 for single device and
SIL3 in homogenous redundancy • Accuracy ±2mm • Seamless system integration

• High temperature and • Exact instrument and process

high pressure versions diagnosis
• Gastight feedthrough as second
line of defense
Process Instrumentation Training

SAFE – PRECISE – EFFICIENT

Efficient due to: HistoROM data

management
concept
Process Instrumentation Training

HistoROM

Example HistoROM functionality

Electronic change during night shift

The HistoROM is
fixed in the housing
(can not be lost or
“forgotten”)
Process Instrumentation Training

HistoROM

Backup functionality: BACKUP / RESTORE / DUPLICATE

In combination with on-site display
Backup

Restore
Duplicate

Duplicate
Tank 1, Device 1 Tank 2, Device 2
Process Instrumentation Training

SAFE – PRECISE – EFFICIENT

Efficient due to: Simple and easy

device setup
Process Instrumentation Training

Example: Basic Setup of an Oil Tank 2/2

Basic
Mapping = Distance
What else?
(f) Tank empty Setup m = meter
Unit?

Full
Full Storage
Tank Type?
Calibration?
F = 4,25m vessel

Empty
Empty Others
Medium
Calibration?
E = 5m (DC > 1.9)
Group?
Process Instrumentation Training

Micropilot FMR50

FMR50 – For common applications

FMR50 • Optimum price-performance ratio
• Temperature -40…+130°C/-40…+266°F
• Pressure -1…+3bar/-14.5…+43.5psi
• Process connection: 1½" thread, assembly
bracket or slip-on flange
• Max. measuring range: up to 40m/131ft
• Accuracy up to ±2mm/0.078inch
• K-Band 26GHz

WHG
Process Instrumentation Training

Micropilot FMR51

FMR51 – The Allrounder

• Highest safety due to second line of defense with
gastight feedthrough
• Temperature -196…+450°C/-321…+842°F
• Pressure -1…+160bar/-14.5…+2,320psi
• Max. measuring range: up to 70m/230ft
FMR51

• Accuracy up to ±2mm/0.078inch
• K-Band 26GHz

WHG
Process Instrumentation Training

Micropilot FMR52
FMR52 – For aggressive media
FMR52 • Complete PTFE filled horn antenna, flush mounted
• Temperature -40…+200°C/-40…+392°F
• Pressure -1…+16bar/-14.5…+232psi
• Max. measuring range: up to 60m/197ft
• Gastight feedthrough (option)
• Accuracy up to ±2mm/0.078inch
• K-Band 26GHz

FMR52 – For highest hygienic requirements

• Flush mounted and gap-free design
according to ASME BPE (CoC)
• Parts in contact with the medium are FDA-listed
according to USP Class VI
• Hygiene process connections
• Proven biological compatibility
WHG
Process Instrumentation Training

Micropilot FMR53

FMR53 – For common applications in liquids

• Optimum price-performance ratio
• PTFE coating of the rod antenna including flange
plating
• Process temperature
-40…+150°C/-40…+302°F
• Process pressure
FMR53 -1…+40bar/-14.5…+580psi
• Process connection: 1½" thread or flange
• Max. measuring range: 20m/66ft
• Accuracy up to ±6mm/0.23inch
• C-Band 6GHz

WHG
Process Instrumentation Training

Micropilot FMR54

FMR54 – For special applications in liquids

FMR54 • Available with horn or stilling well (planar)
antenna
• Process temperature
-196…+400°C/-321…+752°F
• Process pressure
-1…+160bar/-14.5…+2,320psi
• Process connection: flange
• Max. measuring range: 20m/66ft
• Accuracy up to ±6mm/0.23inch
• C-Band 6GHz

WHG
Process Instrumentation Training

Micropilot FMR51/54 for high temperature applications

FMR51 – For sophisticated measuring tasks

• Highest safety due second line of defense with
gastight feedthrough
FMR51 • Up to SIL3 (homogeneous redundancy)
• Process connection: 1½" thread, tri-clamp or flange
• Temperature -196…+450°C/-321…+842°F
• Pressure -1…+160bar/-14.5…+2,320psi
• Max. measuring range: 70m/66ft
• Accuracy up to ±2mm/0.078inch
• K-Band 26GHz

FMR54 FMR54 – For special applications in liquids

• Available with horn or planar antenna
• Temperature -196…+400°C/-321…+752°F
• Pressure -1…+160bar/-14.5…+2,320psi
• Process connection: flange
• Max. measuring range: 20m/66ft
• Accuracy up to ±6mm/0.23inch
WHG
• C-Band 6GHz
Process Instrumentation Training

Micropilot FMR56

FMR56 – For common solid applications

• Optimum price-performance ratio
• Process connection: Assembly bracket or
slip-on flange
• Temperature -40…+80°C/-40…+176°F
• Pressure -1…+3bar/-14.5…+43.5psi
FMR56 • Max. measuring range: 30m/98ft
• K-Band 26GHz
Process Instrumentation Training

Micropilot FMR57
FMR57 – The standard in bulk solids
• Optimum adaption to the surface of the
bulk solid with alignment device
• Air purge connection
FMR57 • Process connection: 1½" or flange
• Temperature -40…+400°C/-40…+752°F
• Pressure -1…+16bar/-14.5…+232psi
• Max. measuring range: 70m/230ft
• K-Band 26GHz
Products Solutions Services

Applications

Radar Level
Process Instrumentation Training

Sulfur tank still pipe FMR245

• Customized still pipe design to avoid built up in FMR245 antenna

Products Solutions Services

Basic Principle

Guided Radar Level

Process Instrumentation Training

Levelflex - the guided radar

+ =
Process Instrumentation Training

Time of Flight / ToF

 Time of Flight (ToF)

 Speed of light:
300.000.000 m/s

 Level:
L=E-D

empty
E:
L
Process Instrumentation Training

Typical Envelope Curve

amplitude
Reflection from
process connection

Level

Sand
Powdered clay
Fly ash
Talcum
Lime

End of probe
Process Instrumentation Training

Functional Principle
t
d=c
2
signal of total level
d = distance
c = propagation speed
DC1
t = time

receiving
emitting
signal of interface level
DC2 (delayed)

• High-frequency pulses are injected to a probe and reflected by the product surface

• Whenever DC1 is small, one part of the pulse will penetrate through the upper medium

• A second reflection will take place at the interface between the lower medium with a higher DC2.
Process Instrumentation Training

Basic Principle of Guided Radar

Products Solutions Services

Operation

Guided Radar Level

Process Instrumentation Training

Effects on the signal

Signalamplitude: Disturbing signals:

Probetype: - big nozzles

+ stilling well
+ Coax probe - near constructions

Application: - irregular build-up

+ metal wall
+ small nozzles
- plastic tanks
- damping due to concrete
wall

Media:
+ high DC-values
+ flat, vertical surface
- build-up
Products Solutions Services

Advantages, Features & Benefits

Guided Radar Level

Process Instrumentation Training

Benefits of the Levelflex (guided wave radar)

• No upper blocking
distance.
• Independent of product
density changes.
• Less influence by buildup.
• Independent of foam.
• Less influence by
corrosion.
• No moving parts.
• Independent of vibration.
 Process Instrumentation Training

The Next Level Instrumentation – overview

FMP40 FMP41C FMP43 FMP45 FMP40
Today
Tomorrow

FMP50 FMP51 FMP52 FMP53 FMP54 FMP55 FMP56 FMP57

LIQUID INTERFACE SOLID
Process Instrumentation Training

FMP50 at a glance

 Basic device for simple applications

 Measuring range up to 12m (39ft)
 For products with
dielectric constant  1.4
 Temperature: -20…+80°C
(-4…+176°F)
 Pressure: -1…+6bar
(-14.5…+90psi)
 Process connections: ¾" G or NPT
Process Instrumentation Training

FMP51 at a glance
 The all-rounder in liquid applications
 Measuring range up to 45m (148ft)
 For products with
dielectric constant  1.4
 Temperature: -40…+200°C
(-40…+392°F)
 Pressure: -1…+40bar
(-14.5…+580psi)
 Process connections: ¾", 1½" and flanges
 Optional with gastight feedthrough
Process Instrumentation Training

FMP52 – high resistance to corrosion

 For aggressive media
 PFA coated rod or rope versions
 Flange or hygienic process connection:
PTFE clad (TFM 1600)
 All wetted parts are FDA listed materials
 Measuring range up to 45m (148ft)
*
 Temperature: -50…+200°C
(-58…+392°F)
*
 Pressure: -1…+40bar (-14.5…+580psi)
 Process connections: flange from
DN40, Tri-Clamp, 11851
 Optional gastight feedthrough

* certificate in preparation
Process Instrumentation Training

FMP53 – for hygienic application

 The specialist for the life science industry
 All wetted parts are FDA listed materials
 ASME BPE and USP Class VI for hygienic
requirement.
 Measuring range up to 6m (20ft)
* *  Temperature: -20…+150°C (-4…+302°F)
 Pressure: -1…+16bar (-14.5…+232psi)
 Process connections: flange from DN40,
Triclamp from 1½", NEUMO BioControl,
11864, 11851, Ingold

* in preparation
Process Instrumentation Training

FMP54 – for highest pressures and temperatures

 For high-temperature and high-pressure
applications
 Gastight feedthrough as standard
 High diffusion resistance due to ceramic
incoupling and graphite sealing
 hot steam resistance
 Suitable for steam boiler according to
EN12952/12953*
 Ideal as a replacement for displacer
and floating systems
 Measuring range up to 45m (148ft)
 Temperature:
– XT version: -196…+280°C (-320…+536°F)
– HT version: -196…+450 C (-320…+842°F)
 Pressure: -1…+400bar (-14.5…+5.800psi)

* in preparation
Process Instrumentation Training

FMP55 – the Multiparameter for interface measurement

The innovation in interface measurement – SensorFusion
 Combination of guided radar and
capacitance probe for interface
measurement even in emulsion layers
 Up to 3 measurements (level, interface,
upper phase thickness) with one device
NEW
 PTFE coated probe
 Measuring range up to 10m (33ft)
 Temperature: -50…+200°C
(-58…+392°F)
 Pressure: -1...+40bar
(-14.5…+580psi)
Process Instrumentation Training

FMP56 – for fine grained solids

 The basic model for fine grained / powdery

solids
 Rope material: stainless steel or PA coated
 Measuring range up to 12m (39ft)
 Temperature: -40…+150°C
(-40…+302°F)
 Pressure: -1…+16bar (-14.5…+232psi)
 Tensile load: 12kN
 Process connections: ¾" G or NPT
Process Instrumentation Training

FMP57 – for standard solid applications

 The standard probe for solids
 Rope material: stainless steel or PA coated
 Measuring range up to 45m (148ft)
 Temperature: -40…+150°C (-40…+302°F)
 Pressure: -1…+16bar (-14.5…+232psi)
 Tensile load: 30kN
 Process connections: 1½" G/NPT or flange
 Process Instrumentation Training

Reliable measurement even with echo loss

Typical envelope
amplitude curve:
End of probe algorithm allows
level measurement even if the
echo is lost

 If the probe-end signal and

the echo from the product
surface are available, the
electric product property is
automatically calculated.

If the echo from the

product surface cannot be
measured any more, the
level is calculated from the
shift in the probe-end
EOPlow level signal.
EOPhigh level
Process Instrumentation Training

Advantages of the measuring principle

Measures precisely and independent of
temperature, pressure and gas layers:

• Solids: Liquids:

• Particle size  Product density

and variation of
• Dust, measuring
density
while filling
• Filling noise  Turbulent
surfaces or foam
• Humidity
• Shape of silo  Wall material of
the vessel
• Obstacles
 Shape of vessel
 Obstacles
Products Solutions Services

Applications

Guided Radar Level

Process Instrumentation Training

Displacer Replacement

Replace with

Displacer are extremely affected by vibration due to the big displacement body
over the whole measurement range and due to the small mechanical
movement of the torque tube
Process Instrumentation Training

Levelflex  Trouble free operation

Reliable level measurement
• down to DC  1,4
• Independent of nozzles
• independent of foam
• independent of bubbles
• independent of boiling surface

Ideale reflection signal

Threshold

And before ?
...... Previous displacer got frequently stuck Gasoline tower
in sump ! Courtesy of Shell/DEA refinery
Heide, Germany
Process Instrumentation Training

Interface level measurement in condensate and mix water

• Medium info = Condensate and water mixture

• Knock Out Drum on a offshore cellar deck on a platform
• FMP55 with coaxial probe (with Fischer process connection)
Process Instrumentation Training

Functional Principle

t
d=c
2
signal of total level
d = distance
DC1
c = propagation speed

receiving
emitting
t = time
signal of interface level
DC2 (delayed)

• High-frequency pulses are injected to a probe and reflected by the product surface
• Whenever DC1 is small, one part of the pulse will penetrate through the upper
medium
• A second reflection will take place at the interface between the lower medium with a
higher DC2.
Process Instrumentation Training

Interface measurement

Air:
c = c0 = 300 000 km / s

 oil = 1,8 Velocity through medium:

c = 300 000 km / s / √Epsilon
c = 223 000 km / s

 water = 80
Process Instrumentation Training

Interface measurement

 oil = 1,8

?
 water = 80
 Interface measurement
• No echo from the interface when there is a only emulsion!
• After separation both signals can be detected again.

Emulsion characteristic

120

100
emulsion
80
Amplitude (mV)

Direct after blew up air

w ait 30 minute
60
w ait 45 minute
2 emulsion appear

40

20

separated
0
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
Distance (m )
 Process Instrumentation Training

FMP55 – Multiparameter sensor system

3 variables :
h1 , h2 , 

2 measured parameters TDR :

h1 d1 d1  h1
d 2  h2  

h2 d2 1 measured parameter capacitance :

 = 1.4…10 C  f (h1 , h2 ,  )

TDR Capacitance TDR +

Capacitance
Clean  has to be C1 << C2 measurement
interface constant with variable 
and known possible

Emulsion signal loss worst case: worst case:

possible slightly slightly
enhanced error enhanced error
Process Instrumentation Training

FMP55 – benefits

 Determination of interface and/or level if one echo is lost

(e.g. due to emulsion, damping, bypass fully flooded)

 Determination of the interface if multiple layers may occur

 Check if TDR echoes are plausible

 Determination of the medium if only one medium is filled

Products Solutions Services

Summary

Level Measurement
Process Instrumentation Training

Comparison Free Space Radar vs. Guided Wave Radar

Free Space Radar Guided Wave Radar

Non-contact measurement Contact measurement

Possible with: Possible with:

• Bypass
• Agitator
• Obstacles inside tanks
• Ball valve • Turbulent surfaces
• Sticky media (build up) • Foam
• Interface measurement
Evaluation affected by/limits:
• Foam Evaluation affected by/limits:
• Strong lateral forces
• Turbulent, boiling surfaces (agitators)
• Conductive build up on antenna • Extreme build-up
Products Solutions Services

Basic Principle

Ultrasonic Level
Process Instrumentation Training

Measuring principle

t
L=E-D D=  vs
2
 t = run time of sound
 vs = velocity of sound
B  B = blocking distance
t
Reflection on liquids and solids

D
The Prosonic family works with
ultrasonic pulses which are reflected
from the medium surface by the
E
density change between air and the
medium.
L The time between transmission and
reception of the pulse is measured
and analyzed by the instrument and
provides a direct value for the
distance between the sensor
diaphragm and the medium surface.
Process Instrumentation Training
Process Instrumentation Training

Envelope curve of a tank

Attenuation in
120 50 0 dB

2 Interference

Level echo
5

6
Distance in
meters
Products Solutions Services

Operation

Ultrasonic Level
Process Instrumentation Training

Effects on velocity of sound

Air moisture
0.3 % with
change in Temperature
relative moisture 0.17 % / °C
from 0 to 100 %
measured/
insignificant Velocity of sound compensated
co = 331.6 m/s
(1088 ft/s)
x  Rm (273 + T)
c= M
c: velocity of sound [m/s]
Pressure change Rm: universal gas constant
(8314,3 J/kmol k)
30 bar / 435 psi
T: temperature [°C]
change in run time
x: adiabatic index
approx 0.3 %
M: molecular weight
pmin = 700 mbar / 10 psi
cair at 20°C =
irrelevant Vapor pressure
1.4  8314.3  (273+20)
< 50 mbar ? = 28.8
no problem
= 344 m /s
Process Instrumentation Training

Reflection in liquids and foam

 ideal  light foam  thick, light foam  compact, thick

conditions  large bubbles foam
 thin foam layer  small bubbles
 high density
Process Instrumentation Training

Reflection in solids
Diffuse
Reflection
Mirror reflection
f/kHz grain size
30 ... 2.8 mm
29 ... 2.9 mm
21 ... 4.0 mm
17 ... 4.9 mm
12 ... 6.9 mm
10 ... 8.3 mm
Process Instrumentation Training

Installation for Level Measurement

Process Instrumentation Training

Tank Installation (Liquid Application)

1. Make sure the distance from sensor to wall

is 1/6 of tank diameter.

2. Recommended the install the protection cover

to avoid the transmitter expose direct to rain or
sunlight.

3. No centre installation.

4. Do not install above the filling stream.

5. Avoid any installation such as temperature

sensor,limit switches,etc.,inside the signal
beam.
Process Instrumentation Training

Sensor Blocking Distance

Process Instrumentation Training

Nozzle Installation

■ Install the sensor at the nozzle (Highest place) to avoid blocking distance
undershot.
■ Use pipe nozzle if unable to maintain blocking distance in any other way.
■ The interior of nozzle must be smooth and cannot contain any edges or
welded joints.
■ Note the specified limit for nozzle diameter and length to minimize
disturbing factor.
Process Instrumentation Training

Nozzle Mounting
Process Instrumentation Training

Prosonic S (FMU9x) – Menu-guided operation

Products Solutions Services

Advantages, Features & Benefits

Ultrasonic Level
Process Instrumentation Training

Continuous improvement
1977- 84
First Nivosonic family

1985/86
Nivosonic 19“ receives
1969 a microprocessor
Birth of
Ultrasonic
1993
Prosonic
Field housing with new
sensor generation

1996
Prosonic T
Compact design
loop powered
2002
2006
Process Instrumentation Training

Prosonic M – Performance

 Easy menu-guided commissioning

 Fast inspection of the measurement
by envelope curve on the display or

FMU43
ToF tool
FMU40

 IP68/NEMA 6P –
submergible 24 h/1.83 m (6 Ft)
 Blocking distance from 0.25 m
 2-wire or 4-wire version
FMU41

 Measuring range up to 15 m/0.8 ft

FMU42

 Chemical resistant sensors made of

PVDF
 Optional separate display FHX40
Process Instrumentation Training

Prosonic M – Technical data

FMU40 FMU41 FMU42 FMU43

Measuring range
Bulk solids (m/ft) 2 /6.6 3.5 / 11 5 / 16 7 / 23
Liquids (m/ft) 5 / 16 8 / 26 10 / 32 15 / 49

Block. distance (m/”) 0.25 / 10 0.35 / 14 0.4 / 16 0.6 / 24

Temperature (°C/°F) -40 … +80 / -40 … +176

Pressure (bar/psi abs.) 0.7 … 3 / 10 … 43 0.7 … 2.5 / 10 … 37

Process connections 1½“ (G, NPT) 2“ (G, NPT) 3“ / DN80 4“ / DN100

Output 4…20 mA/HART®, PROFIBUS PA, FOUNDATION Fieldbus

Certificates ATEX II 3G, ATEX II 1/2G, ATEX II 1/2D, FM, CSA

Process Instrumentation Training

Prosonic M – Features and benefits

Robust aluminum Resistant against UV and mechanical
housing forces
 long lifetime

32 Linearization points Higher accuracy

resolution 1 mm
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

accuracy from ± 2 mm

PROFIBUS PA, All important digital communications

FOUNDATION Fieldbus, with one instrument line, unique
HART® operation and setup

EEx ia and EEx d All important approvals with one

FM/CSA IS/XP instrument line

Q/h Excel sheet and Low cost open channel measurement

ToF tool
Process Instrumentation Training

Prosonic S – Performance
 Easy, menu-guided commissioning
 Fast inspection of the measurement by
envelope curve on the display or on
ToF tool
FMU90  Automatic sensor recognition (FDU9x),
FMU90 Top-hat rail
Field housing previous sensors suitable (FDU8x)
housing
 Alternatively top-hat rail housing or
field housing (IP66/NEMA4x); optional
display for switchboard installation
 4-wire technology (10-36 V DC /
90-253 V AC)
FDU91 FDU95
FDU96  Pre-programmed curves for the flow
FDU92 measurement in open channels and
weirs
FDU93  Functions for pump and screen control
FDU91F
with up to 6 relays
 1 or 2 sensors connectable
Process Instrumentation Training

Prosonic S – Technical data of transmitter

optional display

FMU90 Top-hat rail housing Field housng

Ingress protection IP20 (IP65 at optional display/operation IP66 / NEMA 4x

unit for switchboard installation)
Material PBT (Polybutyl) PC (Polycarbonate)

Input signal up to 2 ultrasonic sensors FDU9x (automatic sensor recognition)

Power supply 90...253V AC, 10.5...32V DC

Output signal up to 2 x 4...20mA incl. HART® / PROFIBUS DP

Relay 1 relay standard, optional: 3 or 6 relays (freely programmable)
Temperature -40 … +60 °C / -40 … +140°F
Operation / Display ToF tool or
3 keys with 6-line and backlit plain text display,
menu-guidance, on site envelope curve
Functions Level measurement, open channel measurement,
pre-programmed flow curves with totalizer /daily counters,
pump and screen control
Certificates ATEX II 3D
Process Instrumentation Training

Prosonic S – Sensors

FDU 91 91F 92 93 95 96
Measuring range
bulk solids (m/ft) 5 / 16 10 / 32 15 / 49 45 / 147 70 / 230
Liquids (m/ft) 10 / 32 20 / 65 25 / 82 – –
0.7/2.3*;
Block. distance (m/ft) 0.3 / 0.98 0.4 / 1.3 0.6 /2.0 1,6 / 3.2
0.9/2.9**
Temperature +80/+176 +105/+220; +95/+203 +95/+203 +80/+176*; +150/+302
from -40… (°C/°F) +135/+275 +150/302**
(30 min)
Pressure (bar/psi abs.) 0.7…4/10…58 0.7…3/10…43.5 0.7…1,5/10…22 0.7…3/10…43.5
Materials Completely welded UP, Al/PTFE- UP UP, Al/PTFE-
(without sealing) coated PE foam*/ coated
PVDF 316L PVDF diaphragm SS diaphragm** diaphragm
Ingress protection IP68 / NEMA6P

Certificates ATEX II 2G, ATEX II 1/2D, FM, CSA

Automatic sensor recognition
Specific sensor data are recognized by the FMU90 automatically.
Process Instrumentation Training

Prosonic S – Engineering, mounting, connection

Fast mounting and connection
 Plug in cable connectors and
identification
 Connections easy to reach
(frontside view)
 Easy mounting of field housing
 Suitable accessories (stainless steel)
 Saves time and costs

Easy and fast engineering

 Price attractive basic unit and options
 Field housing or top-hat rail housing
M
 ½-channel, relay, PROFIBUS DP, display
 Basic functionality, optional flow
Hebewerk
 Sensors – adapted to every application
 Explosion proof certificated sensors
 Wide range of accessories (stainless steel)
 Compatible to Prosonic sensors FDU8x
 Saves time and costs
 Process Instrumentation Training

Prosonic S – Commissioning, operation, service

Fast diagnosis, service

 Plain text error messages
 Envelope curve on display
Products
Safe and reliable operation
 Fully welded sensors IP68/NEMA6P
 High self-cleaning effect
 High media resistance (PVDF, SS)
 Up to 3 measurements/sec
 Formula calculation

Easy and fast commissioning

 Automatic sensor recognition
 Menu-guided plain text operation
 Backlit LCD display
 Device comprehensive operation (M line)
 Free ToF tool
 Pre-programmed functions for waste water
applications
 Saves time and costs
Process Instrumentation Training

Prosonic S – Sensor for liquids

Welded seam  Hermetically sealed, welded between
sensor and process connection. Only one
material in the process
 PVDF for FDU91/FDU92
 316L for FDU91F
 highest chemical resistance
 Self-cleaning effect (condensate)
 increased process safety
Fully functional even with
corrosion or dirt
Process Instrumentation Training
Products Solutions Services

Applications

Ultrasonic Level
Process Instrumentation Training

Prosonic S – Instrumentation
Process Instrumentation Training

Prosonic S – Application example (Level)

Level and limit detection Average, difference, sum
e.g. 1 sensor, 3 relays, 2 sensors, 2 outputs
1 output

Volume
 32 point table
 Pre-defined tank forms
 horizontal cylindrical
 spherical
 angled bottom, pyramid bottom, conical bottom
Process Instrumentation Training

Prosonic S – Application example (Differential Level)

Pump control (up to 6 relays) Screen control / difference
1 sensor, 3 relays 2 sensors, 1 relays, 2 outputs

NEW
6 instead
of 5 relays

2 independent pump groups

 Alternating or non alternating Control with
 Limit control (FMU86x)  Difference
 Pump rate control (1 ON/OFF point)  Ratio
 For each pump programmable:
 Switch on delay
 Backlash interval / time
 Crust reduction (switch point band)
 Error handling
Process Instrumentation Training

Prosonic S – Application examples (Flow)

Flow measurement Counting pulse for flow volume
1/2 sensors, 1 relay, 2 outputs 1 sensor, 3 relays, 1 output

NEW
Calculation NEW
with online 3 Totalizer
formula 3 Daily counters

 Creep suppression  3 non resetable counters (totalizer)

 Backwater detection (2 sensors)  Calculation of flow volumes
 Backwater alarm relay (e.g. difference flow1 – flow2)
 Linear flow reduction  3 resetable daily counters
 Dirt detection (2 sensors)
 Dirt water relay
Products Solutions Services

Demonstration

Guided Wave Radar vs Capacitance Method

Process Instrumentation Training

Comparison between GWR Capacitive measuring method

Products Solutions Services

Pressure Product 2013

Process Instrumentation Training

Application Area

Process Level
Pressure

Application
Area

Flow Differential
Pressure
Process Instrumentation Training

Pressure
F
Overpressure Hygiene series Process series
u Absolute pressure
n Differential pressure Food, pharmaceuticals, Chemicals, pulp and paper,
Hydrostatic pressure biotechnology, etc. petrochemicals, refineries,
c
Sensor technology power plants, oil and gas, etc.
t
i
o
n
S
a Deltapilot S Cerabar S
Cerabar S Deltabar S
Deltatop
l
i
t M
y
Cerabar M Cerabar M

T
Cerabar T Waterpilot
Cerabar T
Ceraphant T Ceraphant T

Pric
e
Process Instrumentation Training

Pressure Measuring Technology

Products Solutions Services

Basic Principle

Pressure
Process Instrumentation Training

Metal Sensor for Pressure Transmitter

Working Principle : Wheatstone Bridge

monosilicone
strain gauge

channel with fill fluid

metallic
process connection process diaphragm

process pressure
Process Instrumentation Training

Metal Sensors

- Suited for high pressures - additional error due to

- Suited for high temperatures temperature influence
- Fully welded (no seal) - oil filled sensor necessary
- Hygienic - thin and sensitive membrane
- hydrogen diffusion
- abrasion
- expensive coating (e.g. Au-Rh)
- Not well suited for vacuum
(oil filling)
Process Instrumentation Training

Ceramic Sensor for Pressure Transmitter

CERAPHIRE ®

CERAmic SapPHIRE
Process Instrumentation Training

CERAPHIRE®

o Membrane
Up to 100 times
overload resistance
o electrode (tantalum)

o active solder ring

Resistant to
alternating loads
o electrode (tantalum)

o reference electrode
(tantalum)
Abrasion / corrosion
resistant
o body

Long-term stability
0.1 % per year
Process Instrumentation Training

Ceramic Sensor for Pressure Transmitter

Atmospheric pressure
Substrate

Gauge pressure cell

max. deflecting
Diaphragm Pressure of the membrane =
25μm

Absolute pressure cell

Pressure
Process Instrumentation Training

Ceramic Sensors

- high overload protection - Max. pressure 600 psi (40 bar)

(alternating) - Max. continuous temperature
- no filling fluids at the face 150 °C (260 °F)

(Gauge sensors) - Always seal between sensor

- long-term stability 0.1 %/ year and housing

- highly corrosion resistant

- high abrasion resistant
- best for vacuum
Process Instrumentation Training

dP Transmitter with Metal Cell

Process Instrumentation Training

dP Transmitter with Metal Cell

Process
membrane Process membrane

Sensor chip

Process pressure Process pressure

Substrate layer Oilfilled channels

Overpressure
Welded Welded damping
membrane
Process Instrumentation Training

dP Transmitter with Ceramic Cell

Process Instrumentation Training

dP Transmitter with Ceramic Cell

Working Principle : Capacitive effect

dP Ceramic Cell

Ceramic Membrane

Ceramic Body

Process
Pressure

Capacitor Plates
(C1 / C2)

Additional Temperature
Fill Fluid Sensor for permanent
self monitioring
Process Instrumentation Training

Physical basics - Metal and ceramic behavior

Length
Length

(Creeping)
("Memory")

ta
l
(Rupture)
M e Ceramic

0 1 3
Force (Pressure)

Ceramic extension force = 3 x metal extension force

Process Instrumentation Training

Flow Measurement with Primary Devices

ISO 5167: Orifice plate with corner,
flange or D and D/2 pressure tapping

p+ p = p+ - p-
p- pressure tapping via
carrier ring and qm(v) = K()  2  p  
annular slot
p+
p- individual
tapping
D d

diameter ratio of d
= D
orifice plate:
Products Solutions Services

Operation

Pressure
Process Instrumentation Training

Installation – Pressure & dP Level

Opened Vessel Closed Vessel

Process Instrumentation Training

Installation – dP Flow & Diaphragm Seal

dP Flow Diaphragm Seal

Process Instrumentation Training

Level Measurement with dP Transmitter

With impulse piping in an open vessel

pamb

phead
Impulse pipe
g
h


dP-transmitter
hb

Condensate trap
if required
Drain valve
Process Instrumentation Training

Level Measurement with dP Transmitter

With impulse piping on closed vessel

Primary shut-off valve

Impulse pipe
phead

g

 h
dP-transmitter

hb

sump

Condensate trap
if required Drain valve
Evolution Cerabar /Deltabar S - Operation
Application oriented modes of operation
4 3 modes
pressure, level and flow

Process Instrumentation Training

Evolution Cerabar S / Deltabar S - Operation
Modes of operation - Pressure

Process Instrumentation Training

Evolution Cerabar S / Deltabar S - Operation
Tooling

• Full functionality
• ToF DD available
• Service Pack V 1.04.00
12/2003
• New release V 3.00.00
15.07.2005
-> Japanese & Chinese

• All Parameters
• Local Operation

Process Instrumentation Training

Products Solutions Services

Advantages, Features & Benefits

Pressure
Evolution Cerabar/Deltabar S - Quick Setup Menu

Allows an easy, safe and quick commissioning.

Reducing commissioning costs and safes time.
Process Instrumentation Training
Process Instrumentation Training

Cerabar S / Deltabar S Evolution

Operation Safety Ceramics + HT
Easy – Fast Adjustment – Convenient - Safe -
• No opening to the compartments user friendly
• Commissioning without any tool on side
• 3 button concept for all functions save your time/save your money
• Local configuration buttons -/+/E
Easy, safe and quick commissioning

• Application oriented modes of

• reduce risk of faulty configuration
operation pressure - flow - level

• The quickest and easiest way to setup your

• Quick setup menu device
• extremely user-friendly system

• Easy and safe duplicate of adjustments

• Easy replacement
with HistoROM® • Duplication of measuring points

• 380° revolving of the housing • Best view to the display and operation points

380°

• 4-line graphic display - choose the • easy to read

language • easy to understand

•Operation via HART/PA/FF • safe operation in any case

ToF Tool - Fieldcare
Process Instrumentation Training

Cerabar S / Deltabar S Evolution

Operation Safety Ceramics + HT
Reliable and Safe – transparence in process
• Record of events and modifications in the
configuration
• HistoROM® • Backup of measured values
• Saving configuration data on the HistoROM®
• All data can be visualized in the ToF Tool
• 25-hour protocol at your fingertips!

• Diagnostic functions • Safe working conditions in the field with

an additional possibility to control the
Simulation - Analysis-Service application.
• Fast reactions save possible repair costs
Parameter
20 years of experience
• Safety Integrated Level - SIL 2 • Avoiding systematic failures during
development

Overload resistance up to 40 times

• High abrasion resistance
• CERAPHIRE® -The ceramic cell ! • Dry sensor, no filling fluids
best for vacuum
99,9% purity ceramic - best in class no additional temperature effect
• Corrosion resistant to most chemicals, acids
and alka

A second barrier to the process prevents the

• Secondary containment media to enter the housing and may continue
to leak out of the cable entries. The secondary
containment gives an enhanced mechanical
integrity which enables the end user to
operate his process even safer.
Evolution Cerabar S / Deltabar S
Safety

HistoROM
Functional Safety

Diagnostic Functions
Secondary Containment

Process Instrumentation Training

 Process Instrumentation Training

Technology Details
Push buttons

• push button lid - protection against

ambient conditions
• Push buttons + / - / E
B- Field
• Hall sensor principle (magnetic)
• No „hole“ in the housing
• EMC compatibility
– Safe operation mode
• Safe operation w/o tooling
Process Instrumentation Training

HistoROM
Process Instrumentation Training

Electronic box

Detailed description of the new PCB:

•Push buttons + / - / E operation w/o display
• Signal LED (confirmation for configuration)
• Display and sensor connector
• New ASIC- chip set (Larousse, PSP LIPS)
– High resolution interface for C/P sensors
– High speed signal processing
– HART- Modem
• HistoROM functionality
- Process recorder for pressure / temperature
- Configuration backup
• DIP switch for damping and write protection
Evolution Cerabar S / Deltabar S - Safety
HistoROM / M-DAT

Configuration
Data

• Easy Replacement • Duplicate measuring points

• Backup every 20sec.

Backup of • 15min. Average stored to
measured HistoROM
values • 25h FiFo memory

• Parameters / device conditions

Record of (max. / min. pointer, alarms &
events and warnings) stored with time
configuration stamp
changes • Graphic analysis of the process
in ToF
Process Instrumentation Training
Evolution Cerabar S / Deltabar S - Safety
HistoROM - ToF Tool

Add info Pressure

reading
Date / Time Event: Plain Text message
Operating hours [s] Temperature
reading
Event code

Event table

Process Instrumentation Training

Evolution Cerabar S / Deltabar S - Safety
HistoROM - ToF Tool
Cursor Zoom window
Pmax / Tmax
Sensor

User limit
max.
Pressure Temperature
(Process
window)

User limit
max.
Temperature Pressure
(Process
window)

min limits
(see above)

Single event
Bundle of events -> zoom in
Process Instrumentation Training
(Sensor or electronic change, Power up)
Process Instrumentation Training

Pressure and temperature range for Pressure sensor

Process Instrumentation Training

Pressure and temperature range for DP sensor

Process Instrumentation Training

Diaphragm Seal Systems

Process Instrumentation Training

Agenda

 What is a Diaphragm Seal System ?

 When to use Diaphragm Seal Systems ?
 Membrane behaviour
 Applicator
 Applicator Sizing Diaphragm Seal
 Examples/Exercises
Process Instrumentation Training

What is a diaphragm seal system?

A diaphragm seal system consists of a pressure transmitter, a diaphragm
seal, a fill fluid and a capillary!
Process Instrumentation Training

What is a diaphragm seal system?

"Standard"
transmitter

coupling

Diaphragm seal
Process Instrumentation Training

When to use?
Process Instrumentation Training

When use diaphragm seals?

 The process temperature is higher than the temperature specs of

the standard transmitter
Process Instrumentation Training

Impulse Pipe systems (wet leg)

Purpose: Reduce the process temperature to suit the sensor limits

and protect it from overheating
Rule of thumb:
Reduction of 1°C /1 cm (gas)
Reduction of 10°C /1 cm (liquid)

Max. 125°C
measuring cell

membrane Impulse pipe filled with process medium

Process Instrumentation Training

Why Diaphragm Seal Systems

Why ? => to transmit the pressure

=> to protect the transmitter
max 85 °C
(sensor electronics)

measuring cell

1st membrane
2nd membrane Oil filled channel or capillary

Process medium

400 °C
Process Instrumentation Training

Process Temperature

PMD 75 PMP 71 PMC 71 PMD 70

85°C 125°C 150°C 85°C

Process Instrumentation Training

Temperature
Solution: Diaphragm seals

Up to 400°C
Process Instrumentation Training

When use diaphragm seals?

 The process contains suspended solids or is viscous and may plug

impulse pipes or Transmitter via freezing or solidifying
Process Instrumentation Training

Impulse Pipe Installation

in closed vessels

p = g (h + hb) + phead - phead

impulse pipe

phead
g

 h
Deltabar S
PMD 70
PMD 75
hb

sump

Condensate trap
if required Drain valve
Process Instrumentation Training

When use diaphragm seals?

 The process medium is corrosive and would require frequent

transmitter replacement or unusual materials of construction
Process Instrumentation Training

Corrosion
Process Instrumentation Training

When use diaphragm seals?

 The application requires an unique process connection (e.g. pipe

diaphragm, special flange…)
Process Instrumentation Training

Unique process connection

Process Instrumentation Training

When use diaphragm seals?

 Temp shocks in the process

Process Instrumentation Training

Temperature Shock

Temperature shocks in the process =>

Damping of the system
Process Instrumentation Training

When use diaphragm seals?

 There is a need of easier cleaning of the process from the
connections to avoid contamination between batches
(pharmaceutical)
Process Instrumentation
DiaphragmTraining
Seal Systems

Easier cleaning
Process Instrumentation Training

Transmitters with diaphragm seal

Process Instrumentation Training

What affects the performance

Air bubbles inside the

system causes a big
temperature effect

Oil volume and expansion

factor will influence the
temperature effect

Stiffness of the membrane

will influence the
temperature effect
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