BaseCal: The diaphragm seal performance calculation tool

BaseCal is the web-based performance calculation tool for diaphragm seal applications, powered by Badotherm.
The tool is intended for instrumentation engineers or anyone wishing to understand the effect of all variables and conditions on a diaphragm seal application.
The tool calculates the total installed performance of the diaphragm seal application, including the transmitter.
BaseCal allows you to easily change different variables and conditions, so you can simulate and analyse the effects of these different variables.

Apply for a Basecal account

BaseCal is intended to be used by instrument engineers at end users and transmitter manufacturers that are actively working with Badotherm Diaphragm Seals systems. The outcomes and results are only applicable to Badotherm manufactured diaphragm seal system. To make use of the BaseCal software, you may apply for an account through the link below. Your application will then be processed and evaluated by our Sales Team. Should you have any further questions, please do let us know.

In case of incidental use, it is easier and more convenient for you that a Badotherm sales engineer takes you through your specific request. Interested and need a hand, please schedule your meeting by contacting our sales team.

 

Go to Basecal.com

How can BaseCal help you

BaseCal is a tool that considers all process and ambient conditions such as pressure to be measured, the ambient and process temperatures, and the actual mounting position of the complete diaphragm seal system. Resulting in an easy one-page report with a clear TPE outcome. See below in more detail the factors that BaseCal takes into account.

Process temperature effect

Showing the error of a combined effect of the fill fluid characteristics and its related expansion or contraction error of the seal volume. This is based on the volumetric displacement of the diaphragm, which is dependent on thickness, diameter and material of construction. All based on the maximum process temperature.

Process temperature effect

Showing the error of a combined effect of the fill fluid characteristics and its related expansion or contraction error of the seal volume. This is based on the volumetric displacement of the diaphragm, which is dependent on thickness, diameter and material of construction. All based on the maximum process temperature.

Ambient temperature effect

Showing the error of a combined effect of the fill fluid characteristics and its related expansion or contraction error of the system volume (capillary + transmitter) showing the effect based on the maximum ambient temperature deviation.

Ambient temperature effect

Showing the error of a combined effect of the fill fluid characteristics and its related expansion or contraction error of the system volume (capillary + transmitter) showing the effect based on the maximum ambient temperature deviation.

Mounting effect

Showing the error based on the (vertical) mounting of the transmitter and the diaphragm seals, taking also into account the change in density of the fill fluid based on the maximum ambient temperature deviation, and thus the pressure of the liquid column of the fill fluid.

Mounting effect

Showing the error based on the (vertical) mounting of the transmitter and the diaphragm seals, taking also into account the change in density of the fill fluid based on the maximum ambient temperature deviation, and thus the pressure of the liquid column of the fill fluid.

Accuracy effect

Showing the combined error based on the accuracy of the selected transmitter and the error of the selected diaphragm, taking into account the span effects related to the temperature effects.

Accuracy effect

Showing the combined error based on the accuracy of the selected transmitter and the error of the selected diaphragm, taking into account the span effects related to the temperature effects.

Static pressure effect

Showing the error based on the static pressure effect of the selected transmitter and selected diaphragm seal application (only applicable for dP measurements).

Static pressure effect

Showing the error based on the static pressure effect of the selected transmitter and selected diaphragm seal application (only applicable for dP measurements).

Total Probable Error (TPE)

It is difficult to make a general statement on the performance of any diaphragm seal application based on only one single effect or factor. It is the combination of the set of factors that determines the total performance. Statistical mathematics shows that the most realistic way to combine the effects of independent factors is by using the root-sum-square (RSS) method instead of just summing or averaging them. The result of the RSS method is what we refer to as the Total Probable Error of the diaphragm seal application. BaseCal’s TPE is based on the following effects :

  • Process temperature effect
  • Ambient temperature effect
  • Mounting effect
  • Accuracy at process temperature
  • Static pressure effect
Total Probable Error (TPE)

It is difficult to make a general statement on the performance of any diaphragm seal application based on only one single effect or factor. It is the combination of the set of factors that determines the total performance. Statistical mathematics shows that the most realistic way to combine the effects of independent factors is by using the root-sum-square (RSS) method instead of just summing or averaging them. The result of the RSS method is what we refer to as the Total Probable Error of the diaphragm seal application. BaseCal’s TPE is based on the following effects :

  • Process temperature effect
  • Ambient temperature effect
  • Mounting effect
  • Accuracy at process temperature
  • Static pressure effect
Response time

The response time is defined as the time lag between the pressure response in the pressure measuring instrument (e.g., moment when reaching 63.2 % or 90 % of the total pressure change) and the step-change moment of the process-medium pressure.

Response time

The response time is defined as the time lag between the pressure response in the pressure measuring instrument (e.g., moment when reaching 63.2 % or 90 % of the total pressure change) and the step-change moment of the process-medium pressure.

Example calculation

With BaseCal it is possible to show the difference between a well-engineered diaphragm seal application and a poor designed application. See below calculation example, based on a level measurement.

Mounting position: Style 2| H1: 50 cm | H2: 850cm
Process data: Distance between 0-100% level: 600cm | Density process fluid: 1.02 g/cm2 | Maximum process temperature: 125 °C | Ambient temperature from 10°C to 55°C | Process pressure from 1050 to 15000 mbara
Diaphragm seal: size: 2” | type: BC | diaphragm material: AISI 316L
Capillary: length: 17mtr | diameter: 1mm
Filling Fluid: type: silicon| name: BSO-21

Based on these characteristics the following errors are calculated in BaseCal. The TPE is 23.53 mbar which is equal to 3.92% of the span. The Response Time at 90% of the span at -10°C is 59.27 seconds.

Example calculation - improvement

In practically all situations it is impossible to change the process conditions, as these are required to produce a certain product. However, changes in the selection of the diaphragm seal application variables are possible. In this example the following changes are made to improve the performance of the measurement:

Reduce capillary length to minimum required length of 9.0 meter
Increase diaphragm size by selecting USL type seal
Increase capillary diameter to 2mm
Change filling fluid to BSO-22, a silicone based fill fluid
Apply tracing on capillary and transmitter limiting the ambient temperature variation between 18°C to 22°C

The diaphragm seal performance improves enormously. The TPE reduces to 2.07 mbar which is equal to 0.34% error on the span. The Response time at 90% of the span and -10°C reduces to only 0.05 seconds. Of course, you don’t have to apply all changes. You cancheck the effect of each of the steps. There can be a great advantage in using BaseCal to find the best solution for your application.

Background to BaseCal

BaseCal is designed to support the user in selecting the correct diaphragm seal configuration to measure level, pressure, or differential pressure. It is not only the selection of the type of diaphragm seal that is important, but mostly the combination of all critical values that determine the performance of the application. BaseCal uses exclusionary logic to align Badotherm diaphragm seals with a variety of well-known industrial transmitters.

  • BaseCal ensures configured combinations that would result in reliable measurements, especially during the design for dP level applications
  • BaseCal will not generate a result when the configuration made is in conflict with diaphragm seal technology
  • BaseCal is based on the laws of physics and provides possibilities and limitations for diaphragm seal technology

BaseCal provides a total probable error (TPE) and response time based on the process conditions. It is important to know that BaseCal is independent and will not favour any particular solution or transmitter manufacturer. The outcome of a correct selected configuration and the diaphragm seal performance are warranted by Badotherm. This warranty is only valid when the diaphragm seal application is assembled and tested by Badotherm.

For more information on BaseCal get in touch with our Sales team or download the brochure for more details.