High Static Pressure DP Transmitter for Flow and Level Measurement

What SCADA Didn’t Tell Us About Our Hydraulic Press

During a routine inspection of our plant’s hydraulic press system, we noticed an unusual pattern in the flow measurements. The press was cycling slower than expected, and the gauge indicated normal pressure levels. However, critical components were not meeting specifications during certain operations. This discrepancy hinted at a deeper issue within the differential pressure (DP) measurement system. Specifically, the lack of real-time data made it impossible to correlate the slow cycling with any process variable. As a result, we initially suspected mechanical wear, but further analysis pointed to a measurement error.

Calendar Days vs Pressure Drop: The $25,000 Difference

Flow through an orifice is proportional to the square root of the differential pressure. This means that any inaccuracies in measuring this pressure can lead to significant errors in flow calculations. The problem was further compounded by the lack of real-time data, making it difficult to pinpoint the exact cause of the discrepancy. Our investigation revealed that the traditional DP transmitters were not equipped with the necessary square root extraction functionality required for accurate flow measurement and level calculation. This oversight led to miscalculations in our DCS system, affecting not only the hydraulic press but also other dependent processes. In fact, the square root extraction is critical because without it, the DCS assumes a linear relationship, causing flow errors that compound over time.

How DR3421 Solved Our Inefficiency

We installed the DR3421 Differential Pressure Transmitter, which includes square root extraction for flow measurement and level calculation. The DR3421’s wide turndown ratio ensures precise measurements across various operating conditions, while its two-wire 4-20mA output provides reliable data transmission even in challenging environments. Additionally, the high static pressure capability allows it to handle the demanding conditions of our hydraulic system. The installation was straightforward, and the transmitter immediately began providing accurate, real-time differential pressure readings.

$30,000 in Energy Waste: How We Found the Hidden Problem

The installation of the DR3421 immediately addressed the issues we were facing. Our hydraulic press began cycling more efficiently, and downstream processes showed improved performance. The quantifiable results included a 25% reduction in cycle times, leading to an estimated savings of $30,000 per year in operational costs. Moreover, the real-time data allowed us to optimize the entire system, reducing energy consumption and extending equipment life.

Key Specifications

• Differential pressure measurement
• High static pressure capability
• Square root extraction for flow
• Wide turndown ratio
• Two-wire 4-20mA output

Closing Question

Could your plant be losing thousands of dollars due to inaccurate DP measurements? Consider upgrading to a transmitter with square root extraction to ensure your flow calculations are correct and your processes are optimized.

Tags: #differentialpressuretransmitter #flowmeasurementDP #squarerootextraction #DR3421