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Capacitance point level detection in liquid naphthalene

Capacitance point level detection in liquid naphthalene – A point level measurement to avoid overfilling or emptying is required in almost all process containers today. In the chemical industry, sensors are usually exposed to aggressive, adhesive, or caustic materials. The measurement technology must deal with high temperatures, varying DK values, and viscosity fast and efficiently. To meet these conditions in practice, system planners are increasingly using the capacitive rod probes.

Precision & process compatibility through adaptable point level detection

A leading chemical manufacturer, mainly processing naphthalene derivatives in addition to carbon, coal tar, pitch, and special oils required reliable and robust level monitoring, which could be flexibly adapted to fluctuating ambient conditions.

As a combustion product of organic materials, naphthalene occurs in low concentrations almost everywhere in the environment and can be used as a contaminant, e.g. in carbon blacks, which are used for blackening, and in mineral oils, which are used as plasticizers. Another application is in the production of solvents, plastics, fuel additives, and insecticides.

Capacitance point level detection in liquid naphthalene
Capacitive RFnivo® for overfill protection in liquid naphthalene. Process conditions: changing temperature, caking and inconsistent DK values.

In the liquid state, naphthalene is an aggressive substance that quickly corrodes common materials. If it becomes firmer as it cools down, it tends to become heavily attached.  Tests concluded that tanks can be constantly monitored using the capacitance measuring principle of UWT’s robust RFnivo® probe. The RF series are adaptable rod probes, which due to their design do not require any temperature-restricting components for media detection and can, therefore, be used smoothly in processes up to 500°C. They work with the capacitive measuring principle, whereby the capacitance is measured regardless of the length of the sensor of the medium between the probe tip and the container wall.

Active Shield Technology
Through the integrated “Active Shield” technology the RF limit switch delivers precise measurement results despite strong buildup of the naphthalene

The chemical manufacturer has several storage tanks that are electrically heated to maintain the melting point of the naphthalene. There is a process pressure of approx. 0.8 bar (11.6 psi). The DK value fluctuates between 1.6 and 2.0. Each tank was equipped with a RFnivo® installed on the overflow line for full notification to ensure reliable protection against the overfilling of the containers. When the material is removed, the temperature drops rapidly causing caking on the sensor boom. Overflow line being there at a height of 1700mm, the installed RF probes work within this overflow line under constantly changing process temperatures (max. up to 80°C (176°F). The “Active Shield” technology integrated as standard in the RF probe ensures that the measurement result is not influenced in the long term by the buildup on the probe. The storage tanks could thus be provided with a reliable content monitoring system, which, due to the design, can optimally adapt to the changing environmental conditions, which meant the optimal support of a smooth and maintenance-free manufacturing process for the plant operator. Special attention was also paid to the aspect of process safety in chemical plants. A certified design in accordance with international approvals according to ATEX, IEC-Ex, FM, FMc, etc. qualifies the RFnivo® for the safety standards of this demanding industry.

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 its application. If an 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 now.

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.

More solutions with the capacitance series for level measurement in liquids, pastes and foams

After gaining valuable experience within liquids applications, UWT has expanded its portfolio to include compatible solutions for all liquids, pastes and foams. The RFnivo® 8000 series was included in the RFnivo® level switch series, which is especially suitable for the detection of pasty, adhesive and corrosive liquids as well as for foam detection. It can also be used for interface measurement of different liquids or sludges and is with WHG and according to Lloyd’s Register certified. The compressive strength of this RF version is up to 35bar. The optionally available PFA coating also provides improved chemical resistance. The devices are equipped with encapsulated electronics and work with the innovative Inverse Frequency Shift Technology, which allows a very precise sensitivity adjustment to the medium. Due to the variation of versions with rod and tube extensions, the sensors can be easily adjusted to the respective container conditions and installation situations.

Reliable empty alarm in cosmetics tank

Reliable empty alarm in cosmetics tank

Economy and ecology in harmony through automatic monitoring of the filling line – Reliable empty alarm in cosmetics tank with NCS-L-12/18   

For over 60 years, the French brand Yves Rocher has been synonymous with high-quality cosmetics based on vegetable raw materials. The company is strongly committed to ecological issues and biodiversity. Even small factors such as the optimal use of raw materials play a role.

  1. The application

The filling systems for cosmetic creams were previously controlled manually. The filling level in the buffer tank had to be monitored by an employee and the filling process had to be stopped manually at the appropriate moment.

In order to prevent the filling pump from running dry, the process was stopped for safety reasons at an early stage, leaving important quantities of cream in the tank. This residual product was then disposed of, resulting in a significant loss of value.

Application advantages

  • Significantly lower product losses due to optimal emptying of the tank during filling
  • Precise measurement results despite high viscosity of the cream and corresponding adherences to the sensor probe
  • No manual control and monitoring required
  • Fast amortization through reduction of product losses and time savings for employees
  1. The solution

With the NCS-L level sensor, the filling process is automated. Due to its special sensor shape with 18 mm length and its measuring method with an extended measuring range, the NCS-L-12/18 is particularly suitable for low-water, viscous media such as oils, syrups or even cosmetic creams. Due to its inline integration in the outlet pipe of the filling system, the sensor signals safely and reliably as soon as the cream is depleted, thus stopping the filling process automatically.

  1. The result
  • Cream losses are minimized.
  • The quantities of waste to be disposed of (cream remaining in the tank) is reduced.
  • Impurities (splashes due to dry running of the filling pump) are avoided.
  • Maximum process reliability for the personnel operating the filling system
  1. Sensors used in the application

NCS-L-12/18                   NCS-01, NCS-M, NCS-L-31P

       4.1 Point level NCS-L-12/18

 Advantages:

  • Limit level detection even with media with low water content such as syrup, fruit concentrates, alcohols and oils with εr (Dk) ≥ 2
  • Reliable indication even with strongly adhesive media due to capacitive measuring principle
  • Very short response time

4.2 NCS-01, NCS-M, NCS-L-31P

Advantages:

  • Insensitive to foam and adhesions
  • Different sensor lengths for adaptation to all installation situations in pipes and vessels

 

 

 

 

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.

Anderson-Negele provides application-specific hygienic Sensor solutions

Morton Controls in partnership with  Anderson-Negele provides application-specific hygienic sensor solutions and support for safe processing in the Food & Beverage and Pharmaceutical markets.

TFP-164

TFP-164 Flush Temperature Sensors – Temperature Measurement in vessels and pipes with flush Hygienic process fitting.

APPLICATIONS:

Applications include monitoring of temperature measurement in vessels with agitators and stirrers and in pipes where an inserted probe is not suitable.

FEATURES:

  • Product contacting materials compliant to FDA
  • Sensor completely made of stainless-steel resp. PEEK (front flush sensor)
  • Conforming to 3-A Sanitary Standard 74-06 for front flush sensors
  • Front flush mounting possible
  • Integrated transmitter optional
  • Different electrical connections available

P41


P41 Pressure Sensors – Pressure transmitter device for hygienic pressure monitoring for various applications in breweries, dairies and food & beverage industries.

APPLICATIONS:

Sanitary pressure measurement in pipes and tanks for process temperatures up to 250 °C for ranges from 0.2 to 40bar.

FEATURES:

  • Hygienic process connection with G1/2″ & G1” CLEANadapt
  • Rapid response time of < 10 ms
  • Vacuum-proof
  • Full stainless-steel body & easy installation
  • Electrical connection with M12 plug connection
  • Available with relative or absolute measurement cell
  • Built-in two-conductor measurement converter 4…20 mA

HM-E

HM-E Turbine Flow Sensors – Measurement of flow rate and volume in hygienic applications.

APPLICATIONS:

Designed for hygienic applications in food-, beverage- and pharmaceutical Industries e.g. Process water, demineralized water, aqueous media such as filtered fruit juice or beer, alcohols, light oils, saline solutions, cleaning agents, and acids.

FEATURES:

  • High quality and hygienic alternative to industrial, non-hygienic turbine, paddle wheel or variable area flowmeters
  • Economical alternative to mass flowmeters in non-conductive, low-viscosity media
  • Cost-effective and compact alternative to magnetic-inductive & Coriolis flowmeters
  • Hygienic design, confirmed by 3-A & FDA certification

NCS-M-12

NCS-M-12 Level Sensors – capacitive limit detection in metallic vessels and pipes with hygienic thread G1/2″ (CLEANadapt)

APPLICATIONS:

Limit detection of fluid also with low or no water content like syrup, fruit concentrates, alcohols and oils with a dielectric constant εr (Dk) ≥ 2

FEATURES:

  • Hygienic process connection with CLEANadapt
  • Conforming to 3-A Sanitary Standard
  • All wetted materials are FDA-conform
  • CIP- / SIP cleaning up to 143 °C / max. 120 minutes
  • Compact installation size
  • Capacitive measuring principle
  • Independent of the medium conductivity
  • Insensitive to foam and adherence
  • Very short response time (< 100 ms)

Anderson-Negele’s NCS-M Capacitive Level Sensor with the MPI-300 programming adapter

 

In combination with theMPI-300 USB programming adapter, the NCS-M sensor can be individually adapted to the application used by the customer. In addition to setting the device to the appropriate medium, switching threshold, hysteresis and time delay can also be individually configured.

 

Application examples of the capacitive level sensor:

  • Limit detection in vessels or pipes
  • Product monitoring in pipes
  • Pump/dry running protection
  • Detection of syrup and fruit concentrate

 

 

 

 MPI-300 USB programming adapter in combination with the NCS-M sensor

  1. NCS-M-12:
  • Version with enhanced measurement range for critical media (e.g. Oil, Fat)
  • No adjustment necessary
  • The switching threshold, hysteresis and time delay parameters can be set for the sensor for complex applications
  • Insensitive to foam and adherence
  • Very short response time (< 100 ms)
  • IP 69K

2. The MPI-300:

Adapter for the universal programming of the NCS-M capacitive level sensor family. Level detection even for media with a low or no water content such as syrup, fruit concentrate, alcohols and oils with a dielectric constant εr (Dk) ≥ 2.

The switching threshold, hysteresis and time delay parameters can be set for the sensor.