Nexisense Double Flange Level Gauge: Precision “Zero-Contact” Measurement Expert for Extreme Conditions

Double Flange Level Gauge: “Zero-Contact” Precision Measurement Expert for Extreme Working Conditions

Full isolation remote transmission technology: Remote transmission flange combined with capillary oil-filled system completely solves the physical damage to the instrument caused by high temperature and strong corrosive media.

High-stability differential pressure core: Implements industrial-grade ±0.1% and above high-precision standards, with stable readings even under severe pressure fluctuations.

Digital industrial integration: Natively supports RS485 Modbus and HART communication, adapts to mainstream DCS systems, and realizes remote diagnosis of equipment status.

Product Overview

In the level measurement of sealed containers or vacuum containers, the medium is often accompanied by high temperature, high viscosity or extremely strong corrosiveness. Traditional plug-in or direct-connected instruments are extremely easy to damage or block. The Nexisense 3051 series double flange level gauge adopts the differential pressure measurement principle and accurately captures the differential pressure signal generated by the liquid level height through two remote transmission flanges installed at different heights of the container. As a flagship pressure/level product under the Nexisense brand, it not only pursues the ultimate in hardware materials — such as 316L, Hastelloy electrodes, etc. — but also performs deep optimization in digital algorithms. For system integrators, Nexisense means a simpler debugging process and a more reliable data chain, helping industrial sites achieve true “unattended” operation.

Core Technical Advantages

1. Fully Welded Sealed Remote Transmission System
              Nexisense adopts high-quality full welding process to connect the remote transmission flange and the transmitter. Through precise filling of silicone oil or high-temperature fluorocarbon oil, process pressure is transmitted without loss. This “isolated measurement” logic ensures that the measured medium does not enter the interior of the instrument, effectively preventing blockage of the pressure guiding tube caused by crystallization, coking and particulate matter, and greatly extending the mean time between failures (MTBF) of the instrument in coking, papermaking and other industries.

2. Excellent Sensor Core and Dynamic Balance Algorithm
              Built-in single crystal silicon pressure sensing element with extremely high sensitivity and linearity. Nexisense has developed a dynamic static pressure compensation algorithm for the common “temperature drift” phenomenon of flange-type instruments (micro change in capillary oil-filled volume caused by ambient temperature). Even in outdoor environments with large day-night temperature differences, the temperature drift effect can be offset through software algorithms to maintain the accuracy of liquid level measurement.

3. Multiple Material Support and Protection Design
              In order to adapt to various harsh chemical environments, Nexisense provides a variety of isolation diaphragm material options (316L, tantalum, titanium, Hastelloy, Monel alloy, etc.). The outer shell adopts thickened die-cast aluminum or stainless steel material, with a protection rating of IP67, which is not only waterproof and dustproof, but also can keep the circuit board dry and safe for a long time in chemical workshops surrounded by acid mist.

4. Easy Integration and Digital Diagnosis
              The product comes standard with RS485 Modbus-RTU interface, supporting long-distance, multi-station bus-type installation. In addition, the transmitter has built-in intelligent diagnosis function, which can report status such as “diaphragm damage risk” and “over-range warning” in real time through the communication protocol, helping engineers complete preventive maintenance before failures occur and avoid production accidents caused by out-of-control liquid level.

Technical Parameter Specifications

Application Scenarios

Chemical reaction kettle level monitoring: Measure chemical liquids with stirring, easy to produce foam or strong corrosiveness. Flange installation can avoid physical impact of stirring paddle on the sensor.

High temperature steam boiler drum: In power plant drum level monitoring, the transmitter is moved to the normal temperature area through remote transmission to ensure that the core components are not damaged by high temperature.

Vacuum container and rectification tower: For vacuum negative pressure conditions, Nexisense can customize a special oil filling system to prevent the diaphragm from bulging and deforming outward under vacuum.

Hygienic food processing: Select polished stainless steel remote transmission flange to meet CIP/SIP cleaning requirements, and apply to aseptic measurement of milk, juice, and pharmaceutical liquids.

Wiring and Installation Tips

High and low pressure side matching: During installation, please strictly check the high pressure side (bottom end) and low pressure side (top end) flanges on the container. Do not reverse them, otherwise the output signal will be reversed.

Capillary protection: Remote transmission capillaries must not be folded, excessively bent or subjected to external mechanical extrusion. It is recommended to use protective sleeves. The two capillaries should be fixed side by side as much as possible to ensure that they are affected by ambient temperature consistently.

Zero point migration: Since the double flange level gauge has static pressure accumulation (generated by the self-weight of the filling liquid in the capillary), negative migration or positive migration must be performed in the empty tank state after installation.

Wiring safety: Use shielded cables to connect RS485 signals, and connect the transmitter shell to the process pipeline with equipotential grounding to eliminate static electricity and electromagnetic interference in industrial sites.

Frequently Asked Questions (FAQ)

Q1: Can Nexisense double flange level gauge measure vacuum containers?

A: Yes. However, special attention is required. When ordering, “vacuum condition” must be specified. We will use vacuum-resistant filling liquid and strengthen the diaphragm prestress to prevent the filling liquid from vaporizing or the diaphragm from losing accuracy in vacuum environment.

Q2: How to choose diaphragm material according to the medium?

A: Generally, 316L is used for fresh water/oil; Hastelloy alloy is recommended for media containing chloride ions; tantalum diaphragm is required for strong acids (such as aqua regia). Nexisense engineers can provide you with a specific material compatibility comparison table.

Q3: Can the unit displayed on the transmitter display screen be changed?

A: Yes. Through the meter head buttons or Modbus commands, the unit can be switched between Pa, kPa, MPa, mH2O, mmHg and other units.

Q4: Why is the reading not zero when the tank is empty after installation?

A: This is a normal phenomenon. Because the filling liquid in the remote transmission flange has its own weight, it will generate an initial differential pressure on the core. You only need to perform one-key zeroing (migration) through the “zero point calibration” button on the instrument.

Q5: Does Nexisense transmitter have requirements for installation height?

A: The transmitter body is recommended to be installed at the horizontal position of the center line of the high and low pressure flanges to reduce the static pressure deviation caused by the height difference of the two capillaries. If there are special restrictions on installation height, it can be compensated by the migration function.

Q6: What is the maximum communication distance of RS485?

A: Under standard shielded twisted pair and baud rate 9600, the reliable transmission distance can reach 1200 meters. It is recommended to connect a 120 ohm terminating resistor at the end of the bus.

Summary

The Nexisense 3051 double flange remote level transmitter is not only a measuring tool, but also an important guarantee of stability in industrial processes. Through precise mechanical physical isolation and advanced digital compensation technology, it simplifies the originally complex measurement environment into accurate and reliable data flow. In today’s pursuit of ultimate precision and long-term maintenance-free operation, Nexisense is your ideal partner to solve the difficult problem of heavy industrial level measurement.

Does your site working condition have serious high temperature crystallization or vacuum negative pressure challenges? You can provide us with the height of the container, medium density and temperature range. Nexisense’s senior application experts will calculate the most accurate range migration data and selection suggestions for you.