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 expansio...

Showing the error of a combined effect of the fill fluid characteristics ...

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Ambient temperature effect

Showing the error of a combined effect of the fill fluid characteristics and its related expansio...

Showing the error of a combined effect of the fill fluid characteristics ...

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Mounting effect

Showing the error based on the (vertical) mounting of the transmitter and the diaphragm seals, ta...

Showing the error based on the (vertical) mounting of the transmitter and...

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Accuracy effect

Showing the combined error based on the accuracy of the selected transmitter and the error of the...

Showing the combined error based on the accuracy of the selected transmit...

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Static pressure effect

Showing the error based on the static pressure effect of the selected transmitter and selected di...

Showing the error based on the static pressure effect of the selected tra...

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Total Probable Error (TPE)

It is difficult to make a general statement on the performance of any diaphragm seal application ...

It is difficult to make a general statement on the performance of any dia...

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Response time

The response time is defined as the time lag between the pressure response in the pressure measur...

The response time is defined as the time lag between the pressure respons...

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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

Mounting a diaphragm seal to a pressure transmitter changes the performance of the transmitter. The diaphragm seal application will have additional temperature and pressure effects and changes the response time depending on the transmitter diaphragm seal configuration. The performance of the entire system needs to be evaluated when specifying a diaphragm seal system for a new application to ensure satisfactory performance once installed. BaseCal will help you select the best diaphragm seal application. The tool can also be used to evaluate and analyse existing measurement problems in your process. Our objective is to help you acquire more understanding and knowledge regarding diaphragm seals mounted on pressure instruments and overall, engineer better applications.

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.

Download the brochure