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BaseCal is the web-based performance calculation BaseCal provides a total probable error (TPE) and respon-
tool for diaphragm seal applications, powered by se time based on the process conditions. It is important to
Badotherm. The tool is intended for instrumentation know that BaseCal is independent and will not favour any
engineers or anyone wishing to understand the effect particular solution or transmitter manufacturer. The outco-
of all variables and conditions on a diaphragm seal me of a correct selected configuration and the diaphragm
application. The tool calculates the total installed per- seal performance are warranted by Badotherm. This war-
formance of the diaphragm seal application, inclu- ranty is only valid when the diaphragm seal application is
ding the transmitter. BaseCal allows you to easily assembled and tested by Badotherm.
change different variables and conditions, so you can
simulate and analyse the effects of these different Diaphragm seal applications
variables. A diaphragm seal application consists of a measuring
instrument, typically a pressure transmitter, with one or
Mounting a diaphragm seal to a pressure transmitter two diaphragm seals and either a direct mount con-
changes the performance of the transmitter. The dia- struction or with capillary lines, filled with a fill fluid. A
phragm seal application will have additional tempera- correctly prepared and filled diaphragm seal application
ture and pressure effects and changes the response will accurately transfer process pressure on the dia-
time depending on the transmitter diaphragm seal con- phragm to the sensing element of the measuring instru-
figuration. The performance of the entire system needs ment. This is based on Pascal’s principle which states
to be evaluated when specifying a diaphragm seal sys- that a pressure exerted on a fluid is transmitted undimi-
tem for a new application to ensure satisfactory perfor- nished through that fluid in every direction. The process
mance once installed. pressure exerts a force on the outside face of the seal,
the flexible diaphragm. As the diaphragm flexes under
BaseCal will help you select the best diaphragm seal this force it pushes inwards and attempts to compress
application. The tool can also be used to evaluate and the transmission or fill fluid behind the diaphragm. The
analyse existing measurement problems in your pro- transmission fluid is designed to withstand compression
cess. Our objective is to help you acquire more under- so the force is channeled proportionally and directly in
standing and knowledge regarding diaphragm seals to the measuring instrument to produce a resultant rea-
mounted on pressure instruments and overall, engineer ding on the connected instrument.
better applications.
The importance of proper engineered diaphragm
BaseCal is designed to support the user in selecting seal applications
the correct diaphragm seal configuration to measure Diaphragm seals are often used in the most hazardous
level, pressure, or differential pressure. It is not only the and extreme environments. The process media can be
selection of the type of diaphragm seal that is impor- very aggressive, corrosive, toxic, and/or highly viscous.
tant, but mostly the combination of all critical values The process conditions can be with very high or low
that determine the performance of the application. temperatures, or it can crystalize or polymerize. A proper
BaseCal uses exclusionary logic to align Badotherm diaphragm seal selection is important, because dia-
diaphragm seals with a variety of well-known industrial phragm seals are used in those conditions where proces-
transmitters. ses are difficult to measure and accurate measurements
are required. Accurate measurements and reliable pres-
• BaseCal ensures configured combinations that would sure measurements enables better and more efficient
result in reliable measurements, especially during the plant management. A well-tuned diaphragm seal appli-
design for dP level applications. cation engineered to your process conditions increases
• BaseCal will not generate a result when the configurati- the durability and lifetime of the applications. This
on made is in conflict with diaphragm seal technology. increases the general uptime of the instrument and redu-
• BaseCal is based on the laws of physics and provi- ces the total cost of the application. Using diaphragm
des possibilities and limitations for diaphragm seal seals gives the opportunity for easier and better main-
technology. tenance, hence keeping costs under control.
• Accuracy effect: this shows the way to combine the effects of inde-
combined error based on the pendent factors is by using the
accuracy of the selected trans- root-sum-square (RSS) method
PERFORMANCE mitter and the error of the selected instead of just summing or aver-
EFFECTS ON diaphragm, taking into account aging them. The result of the RSS
the span effects related to the method is what we refer to as the
DIAPHRAGM SEAL temperature effects. Total Probable Error of the dia-
APPLICATIONS • Static pressure effect: this shows phragm seal application. BaseCal’s
the error based on the static pres- TPE is based on the following
sure effect of the selected trans- effects :
mitter and selected diaphragm • Process temperature effect
seal application (only applicable • Ambient temperature effect
for dP measurements). • Mounting effect
The diaphragm seal application • Accuracy at process temperature
will be exposed to various factors • Static pressure effect
and conditions influencing the
performance, such as varying pro- Total probable error (TPE) The total probable error is the most
cess and ambient temperatures, It is difficult to make a general likely error that will appear on the
location of the transmitter, fluctua- statement on the performance of measurement outcome of the dia-
ting static and process pressures, any diaphragm seal application phragm seal application. It is based
choice of instrument, etc. All these based on only one single effect or on the statistical mathematic com-
factors have an effect on the per- factor. It is the combination of the bination of the worst case tolerances
formance of the diaphragm seal set of factors that determines the of the independent factors that
application. These are also the fac- total performance. Statistical mathe- influence the diaphragm seal appli-
tors which have a performance matics shows that the most realistic cation.
specification written around them
on product datasheets (e.g. accu-
racy). This specification describes With BaseCal it is possible to show the difference between a well-enginee-
the worst case tolerance for the red diaphragm seal application and a poor designed application. See
independent factor. BaseCal takes below calculation example, based on a level measurement (see drawing).
into account the worst case tole-
rance or error for each of the follo-
wing factors:
• Process temperature effect: sho-
wing the error of a combined EXAMPLE CALCULATION
effect of the fill fluid characteristics
and its related expansion or con-
traction error of the seal volume. Mounting position Diaphragm seal
This is based on the volumetric Style 2 size: 2”
displacement of the diaphragm, H1: 50cm type: BC
which is dependent on thickness, H2: 850cm diaphragm material: AISI 316L
diameter and material of construction. Process data Capillary
All based on the maximum process Distance between 0-100% level: 600cm length: 17mtr
temperature. Density process fluid: 1.02 g/cm2 diameter: 1mm
• Ambient temperature effect: sho- Maximum process temperature: 125 °C Filling Fluid
wing the error of a combined Ambient temperature from 10°C to 55°C type: silicon
effect of the fill fluid characteristics Process pressure from 1050 to 15000 mbara name: BSO-21
and its related expansion or con-
traction error of the system volume
(capillary + transmitter) showing
the effect based on the maximum
ambient temperature deviation.
• Mounting effect: this shows the
error based on the (vertical)
mounting of the transmitter and Based on these characteristics the
the diaphragm seals, taking also following errors are calculated in
into account the change in density BaseCal. The TPE is 23.37 mbar
which equals 3.89% of the span.
of the fill fluid based on the maxi- The Response time at 90% of the
mum ambient temperature devia- span at 25°C is 453 sec (almost 8
tion, and thus the pressure of the minutes).
liquid column of the fill fluid.
• Increase diaphragm size by • Apply tracing on capillary and
selecting USL type seal transmitter limiting the ambient
Resulting in a smaller process temperature variation between
IMPROVING THE temperature effect due to a 18°C to 22°C
larger diaphragm. Large dia- Eliminating the ambient tempe-
DIAPHRAGM SEAL phragms are more sensitive rature effect by keeping the tem-
PERFORMANCE resulting in more accurate mea- perature conditions constant.
surements. They are less sensitive Tracing of +/- 2°C can be simula-
to ambient and process tempe- ted by entering 18°C as minimum
rature changes. Larger dia- and 22°C as maximum ambient
phragms are capable of larger temperatures.
volumetric displacements. This
also allows them to accommodate
In practically all situations it is not the volume changes of the fill
possible to change the process liquid in the instrument and long
conditions as these are required to capillaries due to ambient tem-
produce a certain product. How- perature changes.
ever, changes in the selection of • Increase capillary diameter to
the diaphragm seal application 2mm
variables are possible. In this Increasing your response time
example the following changes due to larger flow. This change
are made to improve the perfor- slightly increases the ambient
mance of the measurement: temperature effect.
• Reduce capillary length to mini- • Change filling fluid to BSO-22, a
mum required length of 9.0 meter silicone based fill fluid Support
Resulting in a smaller ambient BSO-22 has a lower viscosity than Should you require any technical
temperature effect due to smaller BSO-21 and lesser expansion support in using BaseCal, or do
volume in the application. coefficient. Hence the response you have any other questions rela-
Accessiblilty of instrument should time improves, and the tempera- ting to diaphragm seal technology,
not be guiding, but performance ture effect reduces. Badotherm is always there to help.
of the measurement.
www.badotherm.com