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Ceramic measuring cells – corrosion-resistant, robust, precise

One of the most important parameters to be monitored in chemical industry processes is pressure. That’s because pressure and differential pressure values can be used to determine things like; levels, volume, flow or filter performance, among many others. However, especially in the chemical industry, pressure sensors also have to meet special requirements,. VEGA instruments are built to meet these requirements – with metallic and more importantly ceramic measuring cells.

Metallic measuring cell: Reliable solution

Metallic-based pressure sensors, just like the VEGABAR 83, have been ensuring safety and reliability in chemical plants for decades. They are usually made of high-quality stainless steel such as 316L or other specialist alloys. This makes them ideal for use under harsh conditions. With the correct materials in there design, they can withstand high-pressure applications and extreme temperatures. 

Ceramic measuring cell: an optimal alternative

This is how the ceramic measuring cell is constructed

For chemical processes in which aggressive substances are used, ceramic pressure sensors are often an ideal alternative to metallic sensors – and not only because of their outstanding corrosion resistance. But how does a ceramic pressure sensor actually work? It is comparable to a capacitor: Together with air as a dielectric, the measuring electrodes embedded in the diaphragm and base body create an electric field. When pressure is applied to the ceramic membrane, it is slightly deflected and the capacitance changes. The pressure can then be calculated from the capacitance via the formula programmed by the factory calibration.

In-house development and production

VEGA is one of the few manufacturers in the world that develop and produce their own ceramic measuring cells like CERTEC®. It is the key element of a ceramic pressure sensor. In an extremely complex manufacturing process, the diaphragm and the base body of aluminium oxide ceramic are printed with gold paste under clean-room conditions and joined together with glass solder at high temperature to form the measuring cell.

The many advantages of ceramic

Besides high corrosion resistance, the ceramic measuring cell also offers the following advantages:

  • First-class long-term stability
  • High reliability
  • Outstanding overload resistance

It enables precise measurement over a long period of time. The ceramic measuring cell is often met with initial skepticism, as the material is assumed to be susceptible to breakage. “This is an unjustified concern,” explains Robin Müller, product manager at VEGA. “Ceramic measuring cells have a significantly higher overload resistance than metallic cells. Metallic diaphragms can deform irreversibly when exposed to very high pressures or shocks, a ceramic diaphragm simply deflects until it touches the base body and then returns to its original position.”

Dry and robust

VEGA manufactures the ceramic measuring cells in a clean room.

Another argument in favour of the ceramic measuring cell: it is a dry cell, i.e. free of oil. In the event of a diaphragm rupture, no substance can escape to contaminate – unlike with a metallic measuring cell, where oil often needs to be used as the transmission medium.
Planners and operators also take advantage of this when it comes to measuring aggressive and toxic gases, as safety plays a particularly important role in such cases. But even in applications with the VEGABAR 82 and 83 in acids and alkalis, VEGA can offer highly resistant materials for process fittings and measuring cell – and with a “Second line of Defense” as well. This means the measuring cell is separated from the electronics by a gas-tight, glass feed-through.

Temperature shocks? No problem!

The sensitivity of ceramic sensors to moisture and temperature shocks – once a great disadvantage compared to metallic measuring cells – is no longer a problem. For one thing, the process temperature is measured, and the value is calculated to compensate for the influence of temperature on the measured pressure value. At the same time, a second temperature sensor in the glass seam behind the ceramic diaphragm detects even the smallest temperature changes. An algorithm built into the sensor electronics ensures that temperature shocks are compensated for. “This quite sensitive temperature measurement value can be utilised for process temperature monitoring and also transmitted as a separate signal,” says Robin Müller, describing another useful function.

Suitable for hydrogen

Applications involving vacuum or hydrogen present special challenges for measurement technology. The boiling point of liquids drops in a vacuum. As a result, the oil in the metallic measuring system may begin to boil at temperatures below the atmospheric boiling point, causing significant errors. Also, hydrogen presents another, but no less significant, hurdle: Hydrogen molecules can penetrate metal – even the thin diaphragm of a metallic pressure measuring cell. “If hydrogen diffuses into and through the diaphragm, it contaminates the transmission oil behind it,” explains Robin Müller. The resulting hydrogen deposits can lead to a permanent change in measurement performance.

Besides diffusion, a metallic diaphragm material can also become brittle with hydrogen. But it is not an issue if diffusion-tight fittings and resistant materials, such as gold/gold-rhodium coatings are used, as VEGA provides with sensors in hydrogen applications. The dry ceramic measuring cells play an important role here: “Even if hydrogen were to get into the measuring cell, it will not cause any damage,” says Robin Müller. “Ceramic pressure sensors are a good solution for use in hydrogen production via electrolysis, which works at low pressures.” 

Differential pressure measurement made easy

In chemical applications, differential pressure measurement delivers important data on flow, level and tank pressure. It can be used, for example, to

  • measure the level in a pressurised vessel
  • determine the flow rate at orifice plates and other flow elements
  • monitor a filter or heat exchanger

Differential pressure measurement without using impulse lines: Two electronically connected sensors make it possible.

It is common practice to install a differential pressure sensor linked to the process areas to be measured via an impulse line . However, it is these installations that can “repeatedly cause problems in practice,” says Robin Müller – for example, measurement innacuracies from liquids or condensate getting trapped, blocked or freezing in impulse lines, or gas bubbles in oil filled capilliary systems. VEGA’s solution:: Two independently operating sensors are used, which are communicating electronically to each other. The result is a reliable and precise differential pressure measurement – without any temperature influence or error-prone impulse lines.

In this episode of VEGA Talk, Stefan and Tom show what makes the ceramic measuring cell from VEGA so stable:

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