differential temperature controller

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vinay asked explain about differential pressure transmitter and how it can be used in measuring drum level in boiler?

In boiler,how drum level can be measured by differential pressure transmitter.How can we give minimum and maximum value.Explain with example

And got the following answer:

Pressure gauges all measure pressure difference. There are three kinds in this sense: Absolute, where the pressure is measured against a reference vacuum. Gauge, where the pressure is measured against the atmosphere as a reference. Differential, where the pressure is measured as the difference between two pressures. To use in your system, one pressure port of the differential sensor is connected near the top, the other port near the bottom, and the difference is the pressure due to the height of the water (approx 10m of water/bar or atmosphere of pressure). Any pressure applied to the water does not matter, as it is common mode (the same on both ports, so cancels). There will be a common mode pressure rating for the sensor, as well as the differential pressure rating. Consider the two pressure ports on the sensor as one for plus pressure and one for minus pressure. If the tank is too full or too empty, I don't know what control happens, but there needs to be fail safe ideas in there. The analogue electrical signal output of the sensor will be so many mV per bar, or equivalents of that in other units. To detect minimum and maximum levels you should use an electronic controller, such as a PLC with a suitable analogue input (voltage or current). A simple circuit could be made with op-amps as comparators to detect the high and low signal limits, and operate appropriate relays etc. As this is a critical safety issue in the operation of a boiler it may need to be designed with fail safe techniques and may need certification. I expect there may be noise on the pressure signal due to the water movement, sudden changes in the common mode pressure and so on, so some filtering is probably needed to prevent "false alarms". Filtering is also required to protect electronics from radio transmitter interference, and consider the effect of power failures. I don't know if people do use differential sensors for this purpose. There may be hidden issues. Obviously the diaphragm and materials must withstand the medium, and pipes lead away to keep the temperature within the sensor ratings. The common mode pressure must be suitable for the maximum pressure in the drum plus the water level. The differential scale will be small, maybe one bar or less, so the sensor may be quite delicate, damaged if the pressure exceeds the rating, as in one port is disconnected. Boilers do explode. See the links. Edit: Added link for PDF file about boiler controls which mentions differential pressure gauges.

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