DP Transmitter Dry Leg & Wet Leg Calculations

In any process industry, level measurement is very important for safety and process purpose.

The level can be measured by two methods.

1. Direct method
2. Indirect method

Here we discuss the indirect method and which is using DP transmitter for level measurement.

A Differential pressure transmitter is a common and well-understood technology for liquid level
measurement. If the tank is closed or pressurized, a DP measurement must be made to compensate
for the vessel pressure.

DP Transmitter Level Measurement for Closed Tank

In closed tank DP level measurement, LP leg is connected to the top of tank.

There are two methods in closed tank DP Level Measurement.

Dry leg method:

Dry leg method is used in normal close tank where vapor is not condensate and temperature of
process is equal to atmospheric.

Wet leg method:

Wet leg method is used where vapor has a tendency to make the condensate and temperature of
process is high or low from the atmospheric .

For DP Transmitter Configuration, we have to find out Zero Level & Span Level. Accordingly we have
to configure Lower Range Value (LRV) and Upper Range Value (URV) using HART communicator.

DP Transmitter Level Measurement for Closed Tank – Dry Leg

Method
Simply when LP side of the DP transmitter is filled with any gas/air then we call it as Dry Leg & we
apply Dry Leg Method for calculations.
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At zero level (LRV) = pressure acting on HP leg – Pressure acting on LP leg

=H2 x specific gravity – 0

= 200 x 0.9 – 0

= 180 mmwc

At 100 % level (URV) = pressure acting on HP leg – Pressure acting on LP leg

= (H2+H1) x specific gravity – 0

= (200 + 500) x 0.9 – 0

= 630 mmwc

Range = URV – LRV = 630 – 180 mmwc = 450 mmwc

So, we have to set Lower Range Value (LRV) = 180 mmwc and Upper Range Value (URV) = 630
mmwc in the DP Transmitter using HART communicator.

DP Transmitter Level Measurement for Closed Tank – Wet Leg

Method
Simply when LP side of the DP transmitter is filled with liquid then we call it as Wet Leg & we apply
Wet Leg Method for calculations.

Y = H1 +H2 = 500 + 200 = 700 mm

At zero level (LRV) = pressure acting on HP leg – Pressure acting on LP leg

= H2 x SG1 – Y x SG2

= 200 x 0.9 – 700 x 1.0

= 180 – 700

= – 520 mmwc
At 100 % level (URV) = pressure acting on HP leg – Pressure acting on LP leg

= (H2+H1) x SG1 – Y x SG2

= (200 + 500) x 0.9 – 700 x 1.0

= 630 – 700

= -70 mmwc

Range = URV – LRV = -70 – (-520) = 450 mmwc

So, we have to set Lower Range Value (LRV) = -520 mmwc and Upper Range Value (URV) = -70
mmwc in the DP Transmitter using HART communicator

Open Tank DP Level Transmitter Calculations

In any process industry, level measurement is very important for safety and process purpose.

Level can be measured by two methods.

1. Direct method
2. Indirect method

Here we discuss about indirect method and which is using DP transmitter for level measurement.

A Differential pressure transmitter is a common and well understood technology for liquid level
measurement. If the tank is closed or pressurized, a DP measurement must be made to compensate
for the vessel pressure.

DP Transmitter Level Measurement for Open Tank

Suppose there is a open tank in which a DP transmitter installed for the measurement of level then
HP leg of the DP transmitter is connected with bottom of tank and LP leg is open in atmosphere.
Assume process fluid specific gravity in the tank is 1.0

Definition of specific gravity: Specific gravity is a measure of density relative to the density of a
reference substance. Reference substance is taken water.

For DP Transmitter Configuration, we have to find out Zero Level & Span Level. Accordingly we have
to configure Lower Range Value (LRV) and Upper Range Value (URV) using HART communicator.
DP Transmitter installed at the exact HP tapping point

At Zero level = 0 mmwc

At Span level = H x Specific gravity

= 500 x 1.0

= 500 mmwc

Then Range = 500 – 0 = 500 mmwc

So, we have to set Lower Range Value (LRV) = 0 mmwc and Upper Range Value (URV) = 500 mmwc
in the DP Transmitter using HART communicator.

DP Transmitter Installed Below Tapping Point for Open Tank

If transmitter is installed below the tank then it’s called zero suppression then calculation is below:
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When zero suppression is used then H1 height always filled with process fluid.

At zero level (LRV) = H1 x specific gravity

= 100 x 1.0

= 100 mmwc

At 100% level (URV) = (H1 + H2) x specific gravity

= (100 + 500) x 1.0

= 600 mmwc

Range = URV – LRV = 600 – 100 = 500 mmwc

Open and Closed Tank Level Calculations
Open Vessel Level Calculation
Open tank : Level Transmitter installed at HP Tapping Point

In above example, transmitter installed exactly at HP tapping point i.e. at 0 % Level

Calibration Range

LRV or 4mA point = 1.1 * 0 = 0 inH2O

URV or 20mA Point = Head = 1.1*50” = 55 inH2O

Cal. Range = 0 to 55 inH2O

Open Tank : Level Transmitter Zero Scale above HP Tapping

Point
In above example, transmitter installed point and Tank Zero Percentage level are different.
Calibration Range

LRV or 4mA point = Head1 = 1.1*10” = 11 inH2O

URV or 20mA Point = Head2 = 1.1*50” = 55 inH2O

Cal. Range = 11 to 55 inH2O

Open Tank : Level Transmitter Installed below HP Tapping

Point
Calibration Range

LRV or 4mA point = Head1 = 1.1*10” = 11 inH2O

URV or 20mA Point = Head1 + Head2 = (1.1*10”) + (1.1*50”) = 66 inH2O

Cal. Range = 11 to 66 inH2O

Closed Tank Level Calculation (Wet Leg)
Closed Tank : Level Transmitter installed at HP Tapping Point

In above example, transmitter installed exactly at HP tapping point i.e. at 0 % Level

Calibration Range

LRV or 4mA point = Phigh – Plow = 0 – Head1 = 0 – (1.2*70”) = -84”H2O

URV or 20mA Point = Phigh – Plow = Head2 – Head1 = (1.1*50”)] – (1.2*70”) = -29”H2O

Cal. Range = -84 to -29 inH2O

Closed Tank : Level Transmitter Zero Scale above HP Tapping

Point
In above example, transmitter installed point and Tank Zero Percentage level are different.
Calibration Range

LRV or 4mA point = Phigh – Plow = Head2 – Head1 = (1.1*10”) – (1.2*70”) = -73”H2O

URV or 20mA Point = Phigh – Plow = (Head2 + Head3) – Head1

= [(1.1*10”) + (1.1*40”)] – (1.2*70”) = -29”H2O

Cal. Range = -73 to -29 inH2O

Closed Tank : Level Transmitter Installed below HP Tapping

Point
Calibration Range

LRV or 4mA point = Phigh – Plow = Head2 – Head1 = (1.1*10”) – (1.2*80”) = -85”H2O

URV or 20mA Point = Phigh – Plow = (Head2 + Head3) – Head1

= [(1.1*10”) + (1.1*50”)] – (1.2*80”) = -30”H2O

Cal. Range = -85 to -30 inH2O