Single Flange Level Transmitter: A Stable Solution for Level Measurement in Complex Operating Conditions

In industrial fields such as chemical processing, energy, power generation, and metallurgy, level parameters not only affect production continuity but are also directly related to equipment safety and process stability. When facing complex operating conditions such as high temperature, high pressure, and strong corrosion, traditional level gauges often suffer from short service life, frequent maintenance, or insufficient reliability.

The single flange level transmitter is an industrial level measurement solution that has been widely adopted under such conditions.

The Nexisense single flange level transmitter uses an isolation diaphragm and remote transmission structure to stably transmit process pressure to the sensing unit, significantly improving system safety and adaptability while ensuring measurement accuracy.

Working Principle of the Single Flange Level Transmitter

The single flange level transmitter is essentially a level measurement device based on the principle of hydrostatic pressure. Its core concept is:

The static pressure generated by a liquid in a vessel is proportional to the liquid level height.

In actual operation, the process medium applies pressure to the flange-mounted isolation diaphragm installed on the side wall or bottom of the vessel. This pressure is transmitted through a filled inert transmission fluid to the internal pressure sensing element of the transmitter. The sensing element converts the pressure signal into an electrical signal, which is then conditioned and output as a standard 4–20 mA DC analog signal for acquisition and control by PLC, DCS, or supervisory systems.

For smart models, digital communication can be superimposed on the 4–20 mA signal, enabling parameter configuration and remote diagnostics.

Structural Composition Analysis

Structurally, the Nexisense single flange level transmitter consists of the following key components:

Flange Isolation Diaphragm Assembly
Directly contacts the measured medium and provides pressure isolation. Through appropriate material selection (such as stainless steel or Hastelloy), it can withstand strongly corrosive, high-temperature, or high-pressure media.

Inert Transmission Fluid System
Located between the diaphragm and the sensing unit, it stably transmits pressure while preventing the process medium from entering the measurement chamber, thereby improving long-term reliability.

Pressure Sensing and Signal Processing Module
Uses mature pressure measurement technology to convert minute pressure changes into stable electrical signals, with temperature compensation and linear correction.

Amplification and Output Circuit
Supports analog or digital/smart amplifiers and outputs standard industrial signals for easy system integration.

Core Features of the Single Flange Level Transmitter

Based on engineering application practice, the single flange level transmitter has the following notable features:

Simple Structure and Long-Term Stability
With no moving or elastic mechanical parts inside, the highly integrated structure reduces failure risks caused by mechanical fatigue or wear.

Flexible Installation
The flush-mounted structural design makes installation simple and efficient, often requiring no additional tools and suitable for rapid on-site deployment.

Convenient Adjustment and Calibration
Zero point and span are adjusted via independent potentiometers, allowing zero shift and range adjustment within the effective measurement range without mutual interference, greatly simplifying on-site commissioning.

Strong Media Compatibility
Suitable for measuring liquid levels of high-temperature, high-pressure, strongly corrosive, or high-viscosity media, making it a reliable alternative to traditional float or glass tube level gauges.

Technical Parameters of the Nexisense Single Flange Level Transmitter

In engineering selection, parameters are critical for evaluating device suitability. Common technical specifications include:

Output Signal:
4–20 mA DC two-wire (analog type)
4–20 mA DC with superimposed digital signal (smart type, optional linear or square-root output)

Power Supply:
12–45 V DC

Rangeability:
10:1 or 100:1

Measurement Accuracy:
Standard ±1.2% FS (other accuracy grades available upon order)

Power Supply Effect:
<0.005% of output span per volt

Load Effect:
No significant effect under stable power supply conditions

Damping Time:
Adjustable from 0.1 to 16 seconds (response time increases accordingly when filled with inert fluid or using remote seals)

Startup Time:
<2 seconds, no warm-up required

Operating Ambient Temperature:
-29 to 93°C (analog amplifier)
-29 to 75°C (digital/smart amplifier)
-29 to 65°C (with display)

Ambient Humidity:
0–95%

Ingress Protection:
IP65

Explosion Protection:
Flameproof: Exd II BT4 to BT6
Intrinsic safety: Exia II CT5

Typical Application Scenarios

The single flange level transmitter is widely and maturely applied in multiple industrial fields:

Chemical storage tanks and reactor level monitoring
Oil, natural gas, and energy industry process vessels
Power plant boilers and condensate system level measurement
Metallurgy, papermaking, and high-temperature process liquid monitoring
Storage and transfer systems for strongly corrosive media

In these scenarios, the Nexisense single flange level transmitter maintains stable output under harsh environments, reduces maintenance frequency, and improves overall system reliability.

Installation and Usage Recommendations

To ensure optimal measurement performance, the following points are recommended in engineering applications:

Ensure the flange mounting surface is clean and flat to avoid stress concentration
Select appropriate diaphragm materials and transmission fluids for high-temperature conditions
Perform zero calibration first during commissioning, followed by span setting
Regularly inspect sealing conditions to prevent leakage risks after long-term operation

Frequently Asked Questions (FAQ)

What is the difference between a single flange level transmitter and a submersible level transmitter?
A submersible level transmitter is directly immersed in the medium, whereas a single flange level transmitter measures pressure through an isolation diaphragm, making it more suitable for high-temperature, high-pressure, or strongly corrosive environments.

Does it support smart communication?
Yes. Smart models support superimposed digital signals on the 4–20 mA output, enabling remote parameter setting and diagnostics.

Conclusion

With its simple structure, strong adaptability, and low maintenance requirements, the single flange level transmitter has become an important choice for level measurement in complex operating conditions.

Building on mature measurement principles, the Nexisense single flange level transmitter provides industrial users with a level monitoring solution that balances safety, stability, and engineering practicality through reliable structural design and stable signal output.

For application scenarios with high requirements for measurement reliability and long-term operational stability, the single flange level transmitter is undoubtedly a level measurement device well worth serious consideration.