Tailor-made solutions for the textile industry – UWT solution in acetone

 

Tailor-made solutions for the textile industry – UWT solution in acetone

Single-rod probes using the capacitive measuring method are in many cases a clever solution when it comes to level detection. They can be found in overfill protection and as demand or empty detectors in process or storage containers. These limit switches are suitable for almost all bulk materials from different industries, due to high sensitivity, high mechanical load and a variety of probe extensions. But these qualities also make them a suitable solution in the fascinating world of varied liquid applications, be they in food, wood, rubber, plastics, environmental and power plants, building materials, and chemical industries.

Tailor-made solutions - UWT solution in acetone

Capacitive sensor RFnivo® RF8100 for point level measurement

The use of the RFnivo® capacitive rod within the textile production process featuring the aggressive substance of acetone.

Satisfied by a classic solution – The Rotary Paddle Level Switch

A synthetic fibre company producing a wide range of polyester textile yarns, geotextiles and carbon, and heat resistant polypropylene materials, for products such as special protective clothing or packaging solutions in agriculture and construction have successfully installed Rotonivo® devices for different powders and granules in several process vessels. Depending on the requirements, they function as full, demand or empty detectors and, thanks to their simple electromechanical measuring principle, can also be adapted to extreme process conditions, such as high temperatures up to +1,100°C. The RN rotary paddle is mainly used for storage and drying of plastic particles as a full detector as well as in dosing tanks and extruders for demand reporting. During conveying processes, it works as an overfill detector. For protection against temperatures of below -20°C, a heating function was integrated in the electronics.

Level measurement in clean and contaminated acetone within the textile industry: Capacitance solution in acetone tanks for overfill protection and empty detection

As the synthetic fibre manufacturer was satisfied with the rotary paddle detectors, they also required a measuring solution from UWT for their acetone containers.  Preliminary tests in the solvent tanks were conducted.  During synthetic fibre manufacturing, acetone is used to impregnate the fabric. Each fabric to be produced is passed through a bath of clean, pure acetone, where amongst others excess epoxy resin, which is used for bonding the fibres, is washed off. Most of the resin is usually cured after the heat treatment, non-hardened epoxy resin can be removed during this process step. Thereafter, the acetone is considered polluted and enters a separate tank, where it is cleaned in a special mechanical process. Subsequently, the purified solvent is filled in the tank container with so-called regenerated acetone.

Acetone is an extremely aggressive substance that secretes corrosive vapors and quickly corrodes ordinary materials. For the individual tanks with clean, contaminated as well as regenerated acetone the synthetic fibre manufacturer needed a reliable, and at the same time robust, level monitoring system. Tests carried out with a variety of sensors made it clear that the robust RFnivo® probe was the most favorable solution. The RF series consists of single-rod probes that require, due to their design, no temperature-limiting components for media detection and can, therefore, be used in processes of up to 500°C.

They work with the capacitive measuring principle, whereby the capacitance is detected independently of the length of the sensor of the medium between the probe and the container wall.

 

The customer has different tanks measuring from 1.2 to 1.6 meters in diameter. Apart from a reliable measurement, even with frequently occurring pressure fluctuations, it was also essential that the sensor carried a corresponding certificate according to gas explosion protection (Zone1). Firstly, each tank was equipped with an RF probe (standard version) for full signal, that ensured reliable protection against the overfilling of the acetone containers. Secondly, an empty detection system was installed in each container, that switches on time to prevent dry running. As it is common that the sensor probe is exposed to the acetone and the aggressive molecules of the acetone vapour for longer periods of time, especially during the empty detection process – it was realized that an extra robust version of the device was required. The capacitive single rod was thus refined – 1.4404 (316L) stainless steel and PPS isolators were used with a FFKM seal in the product-contacting probe.

The FFKM seal (perfluoroelastomer / perfluoro rubber) has a particularly high chemical resistance against aggressive materials. Perfluoro rubber is considered as the new generation plastic. It is a true high-tech elastomer, which is always used when special demands are placed on resistance to chemicals, temperature, and form. The equipping of the probe seals of the capacitance level indicator with the highly robust polymer made them resistant to the acetone. Clean and regenerated as well as contaminated acetone tanks can be similarly monitored using the capacitive measuring principle.

The Active Shield Technology, which is integrated into the RF probe as standard, also ensures that the measurement result will not be affected by any build-up on the sensor probe. A total of 16 acetone tanks could be fitted with a reliable content monitoring, which meant the optimal support of a smooth and maintenance-free manufacturing process for the synthetic fibre producer.

What is important to the operator?

The RFnivo® calibrated itself after mounting and wiring in the box after power was applied. The operator had to do nothing further but set the signal output in the Quickstart menu after application. If a RFnivo® is used in an application to which the supply voltage has already been applied, only the calibration button needs to be pressed after installation in the container. The probe automatically adjusts to the new application. Thus, the calibration of the RFnivo® is easily performed. For “diehard” RF probe operators, there is also a powerful manual and menu-driven calibration. This ultimately leads to the same result as the automatic calibration. The universal voltage electronics are clearly equipped with a display and 3 control buttons and provide a DPDT signal output for signal evaluation. During operation, the display will always show the capacity measured at that moment. Parameters such as FSH (fail save high) and FSL (fail save low) as well as reaction time of the signal output can be clearly arranged in a quick start menu. A test button allows the manual start of a self-diagnosis of the sensor. If required, an automatic self-diagnosis can be set, which then regularly checks the correct function of the RFnivo® and activates the failsafe in case of error. This self-diagnostic runs in the background without affecting the function of the probe in the application. A simple operating system was integrated into the capacitance limit switch, which can be easily operated.

 

UWT’s Rotary Paddle switch for point level measurement

UWT’s Rotary Paddle switch Rotonivo® RN 3002 with rope extension for point level measurement

Limit detection is required in most silos and containers to avoid overfilling or unnecessary downtime. The sensor needs to deal with an assortment of process conditions within a wide range of industries.

Contingent upon the necessities, the Rotonivo® rotary paddle switch is utilized as a full, demand or empty detector in storage silos or process vessels and is suitable for use in almost all solids. With its simple electromechanical measuring principle, it can also be adjusted for extraordinary process conditions.

A motor-driven shaft causes the vane to rotate. Once the material level reaches the vane, thereby preventing further rotation, this creates a torque, which is converted via a switch to an electric signal. Once the vane is free again of the material, the output signal is reset, and the motor-driven shaft rotates again.

This dependable and maintenance-free limit switch for safe level detection in bulk solids has international approvals for use in gas and dust hazardous areas and is also certified to SIL

The RotoNivo offers a universal voltage power supply, 24VDC to 220VAC. It can be connected to the same unit without any alterations being made and with the absence of additional power supply to the unit, for example in very old plants, is completely nullified. This makes it easy for a processing plant to keep one version in stock that can be used in various applications on different parts of the plant.

UWT suits the unit to your application, to ensure complete reliability and effectiveness.

Features:  Suitable for most bulk solids

  • Reliable, easy to operate and maintenance-free measurement principle.
  • Unaffected by dust, electrostatic charging and caking.
  • Compact, rotatable electronics housing for easy installation.
  • Mechanically stable shaft bearing design with ball bearings.
  • Process seal with radial shaft seal.
  • Robust aluminium die-cast housing.
  • International approvals for use in potentially explosive atmospheres (dust)
  • Varying shaft lengths available.
  • Enclosure IP66 as standard.
  • Wide range of process connections and supply voltages available.
  • RoHS compliant.

How to get the most from your Feed Plant

How to get the most from your Feed Plant

UWT in partnership with Morton Controls have the solutions for the Animal Feed Industry

The process and storage environments within the feed industry sector often have factors such as moisture, vapor and fat to consider which cause the materials to have caking tendencies.  In order to withstand and remain fully operational, UWT devices have special coatings which in turn provides the customer with economically viable solutions.  With years of experience within the feed industry and the continual research and development of measurement technology, UWT sensors offer wide and innovative versatility.

Reliable measurement technology for versatile solutions within the animal feed industry

The production of high-quality animal feed and pet food is an important economic growth sector. As well as livestock feed, this sector also includes pet and sports animal nutrition.

The requirements of animals in terms of nutrition are diverse and so a variety of mixed feed formulations is manufactured. Accordingly, the focus of the measuring technology equipment in the manufacturing plant is on the ability to easily and quickly adapt to the varying processing conditions. The formulation of a compound feed is based on the particular use for which the product is intended. Similarly, the use of appropriate measuring sensors is in accordance with the relevant requirements of the application.

The level sensor is an indispensable element of the technical equipment within a modern feed production plant for the detection and monitoring of levels and limit levels within the different process stages. All UWT devices are designed to allow easy integration into the various processes and are characterized by being completely maintenance free in accordance with the principle of “install and forget “.

  1. UWT Portfolio

UWT provides sensors for the measurement of level and limit level in bulk solids and liquids. Depending on the medium and application, different measurement techniques are used as well as a range of complete systems for level monitoring and visualization. The product lines include not only an economic standard but also particularly high grade, premium versions. UWT devices are completely maintenance-free and, importantly, carry international certificates.  All limit switches are available with universal voltage electronics as standard or as an option.

1.1 Sensors for Level Detection:

Rotary Paddle Level Switch – Rotonivo® Series 3/6

  • Variable extension lengths – either rope or tube
  • Extension and process connection available in stainless steel
  • Adjustable sensitivity
  • EHEDG compliant
  • Suitable for use in high temperatures of up to 1,100°C
  • Modular design
  • Rotonivo® 6000 SIL 2 compliant
  • All-rounder suitable for all applications
  • Wide variety of configuration options

Rotary Paddle Level Switch – Rotonivo® Series 4000

  • Variable extension lengths – either with pendulum shaft or rope extension
  • Version with plastic housing and process connection
  • Various process connections
  • Adjustable sensitivity
  • Modular design
  • The plastic design offers increased corrosion resistance

Vibrating Fork Level Switch – Vibranivo® Series 1/2/5/6

  • Variable extension lengths – either rope or cable extension
  • Extension and process connection available in stainless steel
  • Sensitive to the lightest bulk materials (< 5g/l)
  • EHEDG compliant
  • Version with separate housing available
  • NAMUR-electronics
  • Suitable for interface measurement within sediment tanks/containers

Vibrating Fork Level Switch – Vibranivo® Series 4000

  • Variable extension lengths – either rope or cable extension
  • Extension and process connection available in stainless steel
  • Extension, process connection, and oscillators cast from one mold
  • Sensitivity from 30g/l

 

Vibrating Single Rod Level Switch – Mononivo® Series 4000

  • Variable extension lengths – either rope or cable extension
  • Heavy mechanical loading
  • High-quality material in the process (SS 316L)
  • High surface quality
  • Sensitivity adjustable in 4 settings
  • Temperature range from -40°C to +150°C
  • Robust version
  • Suitable for overpressure up to 16bar
  • Compact Limit switch with threads from 1″

Capacitive Level Switch – RFnivo® Series 3000

  • Variable extension lengths – either rope or cable extension
  • Extension and process connection available in stainless steel (Stainless steel probe material with FDA conformity)

  • Version with plastic coated extension available
  • Can be used in low dielectric values from 1.5 DK
  • EHEDG compliant
  • Suitable for use in high temperatures of up to 500°C
  • Suitable for use in process pressures of up to 25bar
  • “Active Shield Technology” for anti-caking functionality
  • Available as remote version
  • User-friendly parameter setting via display and function buttons with measurement results given also via display
  • Simple automatic calibration at startup

Capacitive Level Switch – Capanivo® Series 4000

  • Variable extension lengths – either rope or cable extension
  • The version available with plastic housing, process connection, and extension
  • Extension FDA compliant
  • Can be used in low dielectric values from 1.6 DK
  • Suitable for use in high temperatures of up to 180°C
  • “Active Shield Technology” for anti-caking functionality
  • Integrated earthing in-process connection
  • No calibration required

1.2 Sensors for Level Control:

Electro-mechanical Plumb Bob Sensors – Nivobob® Series 3000

  • Measuring range up to 50m (silo height)
  • Easy commissioning
  • Rope and tape version
  • Integrated tape cleaner
  • Threaded or flanged process connection
  • Modbus and Profibus interface
  • Reliable measurement results independent of material
  • Suitable for interface measurement within sediment tanks/Containers

Electro-mechanical Plumb Bob Sensors – Nivobob® Series 4000

  • Measuring range up to 30m (silo height)
  • Easy commissioning
  • Rope and tape version
  • Integrated tape cleaner
  • Threaded or flanged process connection
  • Aiming flange for angled installation

Radar sensor – NivoRadar® 3000

  • Measuring range up to 100m (silo height)
  • Aiming flange model
  • Robust stainless-steel housing IP68
  • High sensitivity (DK ≥ 1.6)
  • Temperature solution up to +200°C
  • 78 GHz technology
  • 4° beam angle
  • Lens antenna and mounting flange are flush
  • Integrated lens cleaner
  • Simple, six-step commissioning

Visualization – Nivotec® Series 2/3/4

  • Web-based visualization solution
  • Level monitoring and analysis via ethernet
  • Remote access via internet option
  • Complete system for plug and play
  • Sensor interface for 4-20mA or Modbus RTU
  • Expandable to monitor up to 15 or 30 silos within a plant
  • Full, empty, demand, fault alarm via email option
  • Signal output for silo full alarm
  • Effective silo management

Complete system for:

  • Level indication
  • Trend display
  • Data storage
  • Remote fill level analysis

The main processes involved in the production of feed are storage, weighing and mixing with conditioning, pelletizing, followed by cooling and crushing. There are also other processes such as extrusion, conveying and dosing applications. UWT level technology is used in almost all sectors, for level indication or to control limit levels for all bulk solids.

 

Efficient silo management for smooth process flow

Efficient silo management for smooth process flow

The electromechanical Lot system Nivobob® 4000 is equipped with a Modbus function which allows easy connection to visualization systems, thus providing an economic silo management solution.

 

Multifunctional unit for discontinuous level monitoring in bulk goods

 

The electromechanical measurement device is an invaluable instrument in the field of inventory management due to its advanced electronics technology. The reliable electromechanical lot system Nivobob® with its robust mechanical design has for that reason become the choice of many plant operators across the globe faced with demanding conditions. The Nivobob® series of plumb bob sensors is used for continuous level measurement within bulk storage silos and for interface measurement. The simple electromechanical measurement principle is a truly reliable all-rounder in most bulk materials.

 

Nivobob® 4000 with Modbus function

The electromechanical Lot system Nivobob® 4000 is equipped with a Modbus function which allows easy connection to visualization systems, providing an economical silo management solution.

UWT GmbH has developed an economical and practical solution in terms of centralized content level monitoring; especially suited for the storage processes within industrial plants. The maintenance-free electromechanical lot system Nivobob® is mounted on each silo within the plant for continuous level monitoring. The plumb bob systems of the economical Nivobob® 4000 series come standard with a Modbus interface which allows for quick and easy connection of the units to the visualization system.

Parameters such as content level, operating time, pending replacement intervals, sensor status are available to the operator. For level control, diagnostics etc. the license-free visualization software Nivotec® is used: The information is sent from the electromechanical lot sensors to the visualization system via Modbus. The operator can access the required information from any PC 24h a day. The software with its data storage and trend analysis function enables the operator to perfectly plan material disposition and any logistics required. The outcome is efficient silo management resulting in cost saving due to planning security. With this new development UWT has responded to the demands for an affordable solution which combines reliable level monitoring with live-data visualization for effective silo management.

 ADVANTAGES:

  • Communication between Nivotec® visualization software and Nivobob® 4000 lot systems can be    conveniently controlled directly from your PC
  • Modbus RTU interface reduces the installation time by using Daisy-Chain-Wiring
  • Silo full detector can be wired directly to the Modbus RTU interface of the Nivobob® 4000

For more information on UWT products contact Morton Controls today.

rn3004-rotonivo-rotary-paddle-switch-for-point-level-limit-measurement-horizontal-tube-extension

Product Focus – The Rotary Paddle switch Rotonivo® RN 3004

The Rotary Paddle switch Rotonivo® RN 3004

with horizontal tube extension for point level measurement

 

In the rubber industry the applications are very demanding and UWT can offer custom made level control solutions as per each client’s requirements.   For easy maintenance, durable ruggedness and reliable quality, the Rotary Paddle Switch Rotonivo® RN 3004 is perfect.

 

WHAT COULD THE CHALLENGE BE?

 

The environment could be extremely dusty, which is normal in the rubber factories, and an automated fill level measurement is required in a few carbon black storage silos.

What can UWT recommend?

 

WHAT IS THE SOLUTION?

 

The Rotary Paddle Switch Rotonivo® RN 3004 is perfect for such extreme environments and requirements.  The special bearing and sealing in the tube is suitable for dusty situations.

Let us take a closer look at this switch.

 

Here are the technical specs –

 rotovino specs

WHAT ARE THE FEATURES? 

  • The switch is perfect for most bulk solids
  • Easy maintenance
  • Easy to operate
  • Reliable
  • Not affected by caking, electrostatic charging and dust
  • A compact installation process
  • The die-cast aluminium housing is very robust
  • With a wide range of supply voltages and process connections, you are spoilt for choice
  • RoHS compliant
  • The boom is durable and rugged, including a protective tube
  • The switch has received international approval to be used in high explosive environments, such as where dust exists

 

Measuring Vanes Available

 rotovino vanes

Should you have similar needs in your rubber factory, contact Morton Controls today.

uwt rotovino

Solutions with the Rotating Paddle Switch Rotovino

The Rotovino from UWT is a real All-Rounder!

For point level measurement within different processes, UWT can supply an extensive range of high quality rotary paddle switches.

  • Weighing
  • Storing
  • Dosing
  • Mixing
  • Cooling
  • Crushing
  • Packing

Dependent on your need, the Rotovino from UWT can be used for either full, demand or empty detector in storage silos and process vessels and is suitable for most solids.

Where extreme conditions are the norm, the electromechanical measuring principal can be adapted to accommodate.

What does the Rotovino protect against?

  • Overfill safety-device
  • Dry-run protection

 

What are the situations the Rotovino can provide solutions for?

  • Extreme process temperatures of -40°C and up to +1,100°C
  • Aggressive and abrasive media
  • Very light materials such as Styrofoam
  • Material prone to caking
  • Dusty environments
  • Explosive environments
  • Heavy mechanical loading
  • Electrostatic charging

 

What are the special features of the Rotovino from UWT?

  • The Universal Voltage Electronic
  • A Fail-safe alarm
  • A wide variety of configuration options
  • The Modular design
  • A very robust design
  • Variable extension lengths
  • Adjustable sensitivity (>15g/l)
  • And, private label design is possible

 

Safety first with UWT’s Rotating Paddle Switch Rotovino

UWT has ensured that they have International approvals for use in gas and dust hazardous areas.  Their RN 6000 is the world‘s first rotating level limit switch compliant to SIL 2.  And, in addition, they have encased it with a flameproof housing.

For more on the Rotovino from UWT, please make contact with Morton Controls today!