Posts

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.

 

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!

 

cip system

The CIP System – Within the F&B Industry

In food manufacturing, cleaning-in-place or the CIP system is a standard component for ensuring reliable and efficient adherence to quality standards. The requirements placed on sensors, used for process control, are particularly high in the food and beverage industry.  They are tailored solutions for optimizing the CIP process, using turbidity and conductivity sensors.

What is involved?

The CIP system consists of numerous interlinked steps. Plant operators need to take into account more than just the downtime of the system. Costs also arise from the consumption of water, chemicals and energy, as well as product loss.

The sequence of the individual cleaning cycles is often still time-controlled. These fixed cleaning intervals will guarantee that the system is always cleaned properly.  However, more water, and cleaning solution and time, may be consumed than would actually be necessary for the medium being processed.

What is the solution?

The solution is to automate control of the CIP system using turbidity and conductivity sensors. The average water consumption, depending on the product, is 1.5 to 3 liters per processed liter of product.  Half of this water is used for cleaning the system.

Are there disadvantages?

A disadvantage of cleaning processes with fixed time intervals is that the maximum required cleaning duration must be used for each cleaning cycle. For example, the removal time for pasty media is considerably longer than for less viscous products. Therefore, when performing CIP cleaning after producing media with less viscosity, more water is used than is necessary.

This, however, can be remedied through automated process control using the turbidity and conductivity sensors. Water consumption at large F&B manufacturing plants can be lowered from an average of 6,500 to 2,500 liters per cleaning cycle simply by deploying an intelligent phase detection system. This will result in savings of water and wastewater costs.

In addition, shorter cleaning cycles lead to a lower consumption of acids and bases.  The use of chemicals can be precisely controlled by measuring their concentrations using the conductivity sensor, allowing their consumption to be further optimized.

What are the production-related stats?

Experience has shown that production-related losses reach 0.5% in large operations and 2.5% in small operations. It is particularly the plants with low levels of automation that experience significant losses in product.

The precise and rapid detection of water-to-product phases using the turbidity sensor lead to reductions in product losses of 5–10% in customer field projects. A CIP system usually takes 60–90 minutes. A hygienic design of the entire system is therefore an important contributor to shortening the cleaning cycles and increasing the efficiency and productivity of the process.

How can Morton Controls help?

As a specialist for sensor systems in hygienic processes, we, at Morton Controls, have sensors and process connections that are optimally designed for the demanding requirements of the F&B industry and that ensure reliable and efficient cleaning of the system.

 

 

 

 


 

History Around Coal Mining

We love a little bit of history, and coal mining has an interesting tale to be told.

One of the largest mining industries, mining for coal started out in the 18th century and boomed all the way to the 1950’s.  Although maybe not as huge as some other mined commodities, coal is still a valuable form of energy for open-pit extraction.

Interestingly, tunnelling into the earth to pull the coal was the initial method, but had to be stopped due to the perilous vapours that were emitted (carbon monoxide, carbon dioxide, and hydrogen sulphite) deadly to say the least.

The sensors now used in the coal mining process have helped with detecting these harmful vapours and have progressed from the mining’s canary method.

What is the Miners Canary?

If you know mining, you would have heard of this amazing story.  Very simply, miners would take a canary in a cage down with them as they descended. Canaries were known to be very sensitive to odourless vapours, such as carbon monoxide, and they would show effects of distress, rocking from side to side, before falling off their perches.

While not a very animal safe procedure, it was known to have saved many human lives.  After a time, the canary method of detection was stopped as it proved not to be as effective as they assumed it was.

In steps the Pellistor

The Pellistor was introduced as a catalytic sensor and was able to detect a very wide range of toxic vapours and flammable gases.

Due to limitations, such as malfunction when exposed to chemicals with chlorine, sulphur, halogen, and any metals containing silicon or lead; as well as high costs to maintain the pellistor, this method was withdrawn.

Infrared LED-based Gas Sensor

The more modern and more effective method is the infrared LED – based Gas Sensor.

The advantages of this method are:

  • A wider measurement range
  • A rapid response rate
  • Background gases do not affect the gas sensor, as it did with the Pellistor
  • Each gas can be detected and measured separately

UWT Level Control’s Measuring principles for level detection / level measurement

The measurement methods that UWT distinguish between are, Level Detection and Continuous Level Measurement.

Level detection is used to measure a predefined fill level, and continuous level measurement is the continuous checking of the level of the medium in a silo or a hopper.

The different measuring principles which are used in the field of level measurement technology are explained here in detail.

UWT’s Level Detection Measurement Method

Level detection is used to avoid overfilling or downtime in silos and containers.  Level limit switches are also used as spillage detectors in pipes or for the measurement of levels in interface applications.  The switching point depends on the installation position of the sensor and its configuration.  The information is analysed and transmitted via a digital signal to the control unit directly or via a fieldbus.  Other operations and alarms such as a filling stop and start, or demand signal can thus be triggered.  Level switches are used in solids, liquids or sticky media.

 

UWT’s Measurement method – continuous level measurement

Continuous level measurement,  the constant determining of the fill level, is already built into many silos, containers or process vessels, in order to implement optimum material logistics. For these measuring applications various factors such as silo and vessel geometry, sensor mounting position, the properties of the medium such as flowability, bulk density, conductivity, moisture, dust and adhesion all play a role and must be considered when selecting the right measuring principle.

 

MORTON CONTROLS FOR MORE INFO:

TELEPHONE: 0861 000 393

EMAIL:  sales@mortoncontrols.co.za / ian@mortcon.co.za

 

WHO AND WHERE? A brief look into the brands and industries that Morton Controls supports

One of the core values that Morton Controls has lived by, over the past 21 years, is treating our clients and suppliers as we would like to be treated. We integrate honesty, integrity, and innovation in all our business dealings. And, this can be seen by our track record with clients, as well as the top-drawer list of suppliers we deal with.

Each brand has been carefully selected and we have always looked for certain values in each before signing up with them.

As our core business offering is instrumentation and process control, this is what most of our supplier’s supply. As the years have gone by, Morton Controls have branched out into more industries, as have our suppliers.

Here is a list of the industries Morton Controls can supply process measurement and control level systems for:

The brands that Morton Controls utilise, to provide instrumentation for these industries, are:

The actual process control instrumentation we can source from these brands, for those industries, are:

As we grow and engage, Morton Controls will increase these lists, but always with our mission in mind, “To build long-term relationships with our customers and clients, and provide exceptional customer service by pursuing business through integrity, innovation, and advanced technology.”

For more information, please contact us through one of the following mediums:
TELEPHONE: 0861 000 393
EMAIL:  sales@mortoncontrols.co.za / ian@mortcon.co.za

UWT LEVEL CONTROL – The Industry Award “Industriepries 2017″

At Morton Controls, we are always very proud when one of our suppliers achieves a milestone.

Just recently, UWT Level Control was awarded the “Industriepreis”, which is given to the most innovative and advanced company, in the industries of medical technology, automotive and their suppliers.

Companies with high values in technology, economic, social, and environmental areas were awarded the Huber Verlag für Neue Medien GmbH”, a very prestigious acknowledgement.

A panel of 30 professors and trade journalists, decided that UWT deserved the award of BEST OF 2017 for their RFnivo® 3100 with anti-corrosive PFA coating level limit switch.

A little background on the solution, that UWT developed, came from the need for a more accurate measurement instrument, particularly where dust from aggressive media occurs. Mediums such as acids, heavy metals, and sulphur oxides, can cause inaccuracy, as well as time delays, and a drop in revenue down the line.

The RFnivo® 3100 capacitive level limit switch works in conjunction with the process to extract the dust of flue gases. The material used in this switch is corrosion-resistant, and coated with PFA Teflon®. Certain sections of the process connection thread are made of PTFE, meaning that all component parts are completely corrosion-protected.

You are looking at a longer-life product, which in time will save you money.

For more info on the RFnivo® 3100 with anti-corrosive PFA coating level limit switch, reach out to us at Morton Controls, and we will be happy to assist.

TELEPHONE: 0861 000 393

EMAIL:  sales@mortoncontrols.co.za / ian@mortcon.co.za

UWT LEVEL CONTROL – Silo Management

Efficient silo management for

smooth process flow

UWT Level Control brings us a multifunctional unit, which is perfect for discontinuous level monitoring, especially in bulk goods. The Nivobob® 4000 has been revamped to include a Modbus function, allowing an easy connection to visualization systems.

For inventory management, and an economic management solution for silos, this controller has advanced electronic technology.

When running a plant operation, you need to know that your measurements will be accurate, and in particular, when there are demanding conditions.

 

Here are a few of the features:

  • Centralized content level monitoring is possible
  • Best suited for industrial plant with storage processes
  • The Nivobob® is mounted on each silo so that continuous level monitoring can take place
  • Each comes equipped with a Modbus interface, so that quick connection is possible to the visualization system
  • The Modbus register means that all aspects of the operation is transparent, recording the operating status and all diagnostic parameters
  • Areas that are measured are: pending replacement intervals, content level, sensor status, operating time, and other very pertinent aspects the operator will need
  • Nivotec® is the visualization software used, and is license-free
  • Data can be accessed remotely any time of the day, ensuring the processes are running smoothly at all times
  • Perfect planning is possible, which results in a cost savings
  • Installation time is also reduced using Daisy-Chain-Wiring

 

We at Morton Controls are very excited that UWT has responded to the requests and demands for a solution for silo management, that is both cost effective and time saving.

For full specs and to order this amazing controller, contact Morton Controls.

TELEPHONE: 0861 000 393

EMAIL:  sales@mortoncontrols.co.za / ian@mortcon.co.za

 

UWT LEVEL CONTROL – CELEBRATING 40 YEARS!

 

Quality – Reliability – Flexibility

 

That is what UWT is all about, and we, at Morton Controls, are very proud to be associated with UWT for those very reasons. In addition, they celebrate, this year, 40 years of supplying high quality sensors to the world.

For the bulk solids and liquid plants, UWT supplies content measurement and level limit sensors. They built themselves up from a small family run business to a company that is known the world over. UWT head office is in Germany and have very successful sales offices in a few other countries, namely UK, USA, India, China, and now in Russia.

UWT has always believed in producing and delivering high quality products utilising their technical expertise and particular way of building good relationships with all their suppliers, partners and customers alike.

Brand names like Nivobob®, Rotonivo®, and Vibranivo®, as this proves that they are focused on their methodology of flexibility, reliability and quality.

 

A few of their popular products

 

 

Rotonivo CSM-rn3000 Rotary Paddle Switch

 

Vibranivo CSM-vn1000 Vibration Fork Switch

 

Mononivo CSM-mn-4000 Vibration Rod Switch

 

UWT has strived to expand their portfolio by ensuring they have the right certifications in place, the most important one ISO 9001:2015 and others ATEX, EHEDGE, FM, CSA, and INMETRO.

The CEO, Uwe Niekrawietz, is very passionate about his employees, and believes that happy and healthy employees can achieve so much more than we know. That is also on par with how Morton Controls thinks and how we run our business.

Morton Controls has been one of UWT’s suppliers for a few years, and are always eager to see what innovative solutions UWT will develop, as well as what new industries they will include.