Pressure measurement becomes difficult when reactor media are viscous, crystallizing, or likely to solidify.
Traditional pressure connections may become blocked by material buildup. This can cause slow response, unstable readings, or complete measurement failure.
Choosing the right pressure connection and diaphragm seal is essential.
1. Why Do Pressure Connections Become Blocked?
Several process conditions can cause blockage:
High-viscosity liquids
Crystallization near the process connection
Material solidification during cooling
Suspended particles
Polymerization or material buildup
When the pressure connection is blocked, the transmitter may no longer accurately reflect the actual reactor pressure.
2. Direct Pressure Connection
A conventional threaded or flanged pressure connection is suitable for many clean, low-viscosity media.
However, it may be unsuitable when the process medium can accumulate or solidify inside a narrow connection.
The process connection should be evaluated based on the medium’s physical properties and cleaning requirements.
3. Flush Diaphragm Seal
A flush diaphragm seal can reduce the risk of material accumulating in a narrow pressure passage.
Its diaphragm is exposed to the process medium, allowing pressure to be transferred through a sealed filling system to the transmitter.
This design may be suitable for:
Viscous liquids
Crystallizing media
Slurries
Certain corrosive process fluids
The diaphragm material and seal design must be compatible with the actual medium.
4. Remote Diaphragm Seal
A remote diaphragm seal can be connected to the transmitter through a capillary.
It is useful when direct installation is difficult or when the transmitter needs to be installed away from the process connection.
However, capillary length, filling fluid, ambient temperature, and installation height can affect measurement performance.
5. What Should Engineers Confirm?
Before choosing a solution, check:
Medium viscosity
Crystallization and solidification temperature
Process temperature and pressure
Cleaning and flushing requirements
Diaphragm material compatibility
Required response time
Installation space
Conclusion
For viscous and crystallizing reactor media, the problem may not be the pressure transmitter itself but the pressure connection.
A suitable flush diaphragm or remote seal can help reduce blockage risks, provided the complete seal system is correctly selected for the process.
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