Differential Pressure Transmitter

Differential Pressure Transmitter

Key Features

High Accuracy
• Typical accuracy: ±0.25% to ±0.5% of span
• Suitable for critical industrial measurements
Wide Measurement Range
• Measures very low to very high differential pressures
• Applicable for flow, level, and pressure applications
Multi-Variable Capability
• Measures differential pressure, static pressure, and temperature (advanced models)
Digital Communication Protocols
• Supports HART, Modbus, Profibus, Foundation Fieldbus
• Enables remote configuration and diagnostics
High Stability & Reliability
• Long-term drift ≤ ±0.1% per year
• Ensures consistent long-term performance
Rugged Industrial Design
• Robust construction (SS316, aluminum housing)
• IP65 / IP67 or higher protection for harsh environments
Temperature Compensation
• Built-in compensation reduces temperature-related errors
Flexible Output Signal
• Standard 4–20 mA analog output
• Digital output available in smart transmitters
Explosion-Proof Options
• Suitable for hazardous areas
• ATEX and IECEx certified models available
Easy Calibration & Maintenance
• Zero and span adjustment available
• Supports local display and handheld communicator
Low Power Consumption
• Suitable for remote and field installations
• Energy-efficient operation
Versatile Mounting Options
• Pipe, wall, or manifold mounting options
• Flexible installation in different systems

Working Principle

The transmitter has two pressure ports:
o High Pressure (HP) side
o Low Pressure (LP) side

  • The measured differential pressure is:
    ΔP=Phigh−Plow\Delta P = P_{high} – P_{low}ΔP=Phigh−Plow
    Step-by-Step Working
    1. Pressure Application
  • Process pressure is applied to both sides:
    o HP side → higher pressure
    o LP side → lower pressure
    2. Sensing Element (Diaphragm)
  • Inside the transmitter, a flexible diaphragm (usually stainless steel) separates the two pressures
  • The diaphragm deflects based on the pressure difference
    More pressure difference = more diaphragm movement
    3. Conversion to Electrical Signal
    Different sensing technologies convert this movement into an electrical signal:
    a) Capacitive Type
  • Diaphragm movement changes capacitance
  • Capacitance change ∝ pressure difference
    b) Piezoresistive (Strain Gauge)
  • Strain changes resistance of sensor elements
  • Resistance change converted into voltage
    c) Resonant / Silicon Sensor
  • Frequency change in sensor due to pressure
    4. Signal Processing
  • The raw signal is very small
  • Internal electronics:
    o Amplify signal
    o Apply temperature compensation
    o Linearize output
    5. Output Signal
  • Final output is:
    o 4 mA → Minimum DP
    o 20 mA → Maximum DP
  • Can also provide digital output (HART, Modbus, etc.)
    Flow Measurement Principle (Important Use Case)
    When used with flow elements (like orifice plate):
    Q∝ΔPQ \propto \sqrt{\Delta P}Q∝ΔP
  • Flow rate (Q) is proportional to the square root of differential pressure
  • Higher flow → higher pressure difference
    Example Applications
    Flow Measurement
  • Across orifice plate / venturi / flow nozzle
    Level Measurement
  • In closed tanks:
    o Bottom pressure = liquid head
    o Top pressure = vapor pressure
    o DP gives actual level
    Filter Monitoring
  • Measures pressure drop across filters
  • High DP = clogged filter

Industrial Applications

Flow Measurement
• Uses primary elements: Orifice plate, Venturi tube, Flow nozzle
• Measures pressure drop to calculate flow rate
• Common in oil & gas pipelines, steam systems, and water distribution
Level Measurement (Closed Tanks)
• Measures level in pressurized vessels
• Uses pressure difference between tank bottom and vapor space
• Applied in boilers, chemical storage tanks, and fuel tanks
Filter Monitoring
• Measures pressure drop across filters
• High differential pressure indicates clogging
• Used in water treatment, HVAC, and oil filtration systems
Pressure Drop Monitoring
• Monitors pressure difference across equipment
• Detects blockages, leakages, and efficiency loss
• Used in heat exchangers, pumps, and pipelines
Boiler Drum Level Measurement
• Critical application in power plants
• Maintains safe boiler water level
• Prevents dry run and overfilling
HVAC Systems
• Air flow measurement and duct pressure monitoring
• Cleanroom pressure control
• Ensures proper ventilation and air balance
Leak Detection
• Detects abnormal pressure differences in pipelines
• Used in oil & gas and chemical plants
• Helps prevent system losses
Pump & Compressor Monitoring
• Measures suction and discharge pressure
• Helps in performance analysis and fault detection
Density & Interface Measurement
• Measures difference between two fluids
• Used in oil-water separation and chemical reactors

Technical Specifications

Category Parameter / Specification
General
Measured VariableDifferential Pressure (DP)
ApplicationsFlow, Level, Pressure, Density
Output Signal4–20 mA (2-wire), Digital (HART / Modbus / Fieldbus)
Power & Display
Power Supply12 V DC
DisplayLCD / Digital Display (optional)
Response Time≤ 1 second (adjustable)
Damping0–60 seconds selectable
Measurement Range
DP Range0–100 Pa to 0–10 MPa (model dependent)
Static Pressure RangeUp to 40 MPa
Overpressure Limit1.5 to 2 times maximum pressure
Turndown RatioUp to 100:1
Performance
Accuracy±0.075% to ±0.25% of span
Stability±0.1% of URL per year
Repeatability±0.05% of span
Hysteresis±0.05% of span
Temperature
Operating Temperature-40°C to +85°C
Process Temperature-40°C to +120°C (higher with remote seal)
Compensation Temperature-10°C to +70°C
Mechanical
Wetted Parts MaterialSS316 / Hastelloy C
Housing MaterialAluminum / SS
Process Connection1/4" NPT, 1/2" NPT, Flanged
MountingPipe / Wall / Manifold Mount
Protection
Ingress Protection (IP)IP65 / IP67 / IP68
Explosion ProtectionATEX / IECEx / Flameproof / Intrinsically Safe
Electrical
Signal Output4–20 mA / 0–5 V / RS485
Communication ProtocolHART, Modbus, Profibus, Foundation Fieldbus
Load Resistance0–600 Ω (typical)
Calibration & Installation
Zero AdjustmentYes
Span AdjustmentYes
Calibration MethodDigital / Manual
Orientation EffectMinimal / Compensated
Vibration ResistanceAs per IEC standards
Optional Features
Remote SealAvailable
Smart DiagnosticsYes
Data LoggingAvailable in advanced models