sugar, grain and milling measurement and inventory control solutions
DESCRIPTION
Overview of best practices for instrumentation and measurement of grain, sugar and flour.TRANSCRIPT
Instrumentation in flour millsSolutions matching the requirements from the receiving to the flour silo
Operational challenges in grain millingExplosion protection: Who takes care of safety?Implementation of your country-specific directives • Endress+Hauser offers support to select the right measuring
devices to ensure safe operation
Inventory Control: How much is in which storage bin?• Endress+Hauser offers customized solutions for storage and logistics
Traceability of material flows: Where from, where to? • Endress+Hauser provides solutions for silos based on level measurement which support the traceability through each step of the production from grain to flour
Services: Who has time for maintenance? • Endress+Hauser offers professional support for startup and
maintenance for safety and quality relevant measuring points
One-stop-shopping: Optimization of process automation • Endress+Hauser offers the complete measurement instrumentation
and additional system components for every area of a mill
Flammable Material Present Continuously
Flammable Material Present Intermittently
Flammable Material Present Abnormally
IEC/EU Zone 0 Zone 1 Zone 2
US NEC® 505 NEC® 500
Zone 0 Zone 1 Zone 2
Division 1 Division 2
CA CEC Section 18 CEC Annex J
Zone 0 Zone 1 Zone 2
Division 1 Division 2
Duty for operator of facility• Hazard evaluation• Safety of working environment and equipment• Classification of areas • Explosion protection document• Inspection and maintenance• Training of employees
Duty for manufacture of measuring devices • Safety of measuring devices• Categorisation of measuring devices• Declaration of conformity
Challenge #1: Explosion protection: Who takes care of safety?During processing grain and flour, dust is an inevitable by-product. It is generated from particles adhering to the grain kernel, by abrasion of the grain and by the end product flour itself. Dust is able to generate an explosive atmosphere that can result in devastating losses if not addressed.
Endress+Hauser provides measuring devices according to ATEX, FM and CSA directives and supports in selecting the right instrumentation according to your area classifi- cation. Duties of facility operators and manufacturers of measuring devices are split according to the following overview:
Explosive areas are divided into zones. The following table shows the Area Classification in different countries.
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Manually, on foot and on paper… Who doesn’t have this experience: was the storage bin no. 2�� empty or not? To insure yourself you take the lift to the top floor of your storage elevator and have a look in this bin. And how can you get this information if the silos are remotely located?
...this has to be a thing of the pastInventory Control by Endress+Hauser provides solutions to opti-mize your warehousing and supply chain.
Around the clock, around the world: be informedThe signal output of the transmitter e.g. Levelflex M is connected via Fieldgate FXA520 like a PC to the Intranet of your company or to the Internet. This offers a cost-effective possibility to get local or remote informations about the actual levels and limits of your storage elevator.
The right solution for visualisation is our system P View. Alarm limits can automatically be sent by mail or SMS to avoid produc-tion downtimes or to initiate a new material order.
Multiply your cost savings potentials together with your supplier or customerAllow your supplier access to your stock data or get access to the stock data of your customer by Fieldgate FXA520 and Internet. This opens up cost saving potentials by scheduling the delivery in adaptation to the actual consumption.
Additional parameters like temperature can easily be integrated and by the software TOF-Tool you are able to do a quick and com-fortable remote maintenance of your measuring devices.
Warehouse with storage binsIdeal field of application for inventory Control Solutions
Picture:Intranet drawing
Checking every storage bin visually is a thing of the past
Inventory Control just by weighing and writing requires time consuming accounting
Challenge #2:How much is in which storage bin?Inventory Control Solutions for storage and logistics
6x Levelflex:4-20 mA/HART
HART
RS-485Ethernet
hubWireless LAN Access Point
Wireless LAN Access Point
PCI cardRemote monitoring via Internet
HART multiplexer
FieldgateFXA520
Soliswitch FTE30Limit paddle switch
7Silopilot M FMM50Electromechanical system
6Levelflex M FMP40 Guided radar level measurement
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Micropilot FMR250Radar level measurement
4Soliphant T FTM20Single-rod vibronic sensor
3Nivector FTC968Capacitance limit switch
2Omnigrad M TR10Temperature sensor
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Instrumentation in the grain receiving and grain elevator
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DryingMonitoring of grain temperature with temperature sensor Omnigrad M TR10. The modular sensor concept allows the adaption to any measuring application.
Precleaning / batch-weighingSupply and overrun hopper are equipped with a high level alarm by capacitive limit switch Nivector FTC968.
Bucket elevatorAccumulation indication of grain in the elevator boot:vibronic sensor Soliphant FMT2x. Functional principle of sensor has no moving parts and guarantees maintenance free operation.
Grain elevator – level indicationElevators up to 70m/2�0ft: Non-contact radar level measurement with Micropilot M FMR250. Air purge allows long time operation without additional cleaning.
Elevators up to �5m/115ft: Guided Radar Levelflex M FMP40, factory adjusted for easy start-up, insensitive against build-up on rope-antenna.
Alternatively:Electromechanical system Silopilot M or T. Quick and easy startup procedure requires no adaptation to geometry of silo and no special technical know-how. Silopilot T FMM20 measures up to �2m/105ft and Silopilot M FMM50 measures up to 70m/2�0ft.
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Grain elevator/limit detectionHigh level alarm:paddle switch Siloswitch FTE30, simple operation by proven principle.
Low-level alarm:vibronic sensor Soliphant T FTM2x. The single-rod sensor allows reliable operation.
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Silopilot T FMM20Electromechanical system
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Flow rate weigher with Nivector FTC968 as high alarm
Instrumentation technology in purification and conditioning
Conveying / machine feedingDetecting overflows and blockage, the capacitive limit switch Nivector FTC968 ensures a cost effective monitoring of your products. A protective cap is available for abrasive materials.
ConditioningControlling the quantity of water by magnetic-inductive flow measuring system Promag 50. Available from DN 2 up to DN 100, software options for batching and pulsating flow.
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Tempering bin – level indicationTwo ultrasonic sensors FDU9x connected at one transmitter, Prosonic FMU90, allow the configuration of two different ranges, e.g. 0% to 100% for level indication and 50% to 70% for control of screw conveyor with corresponding relay configuration.
Tampering bin – limit detectionHigh-level alarm: low-price solution with the paddle switch Siloswitch FTE30, sensor length from 70 up to 2000 mm.
Low-level alarm: vibronic single-rod sensor Soliphant T FTM2x allows failure-free operation.
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Nivector FTC968With replaceable protector
Receiving Precleaning
Grain Storage
Legend
LA
LI
FI
TI
PI
PDI
Limit detection, alarm
Level indication
Flow indication
Temperature indication
Pressure indication
Differential pressure indication
TI
TI
TI
LA
LA
LA
LA
LA LA
LA
LA
LA
LA
LI
Furnace
Bucket Elevator
Dryer
Dust collector
Fan
Precleaning separator
Dumping pit
Chain conveyor
Flow-rate weigher
Grain storage elevator
Chain conveyor
Silo elevator Elevator
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1
1
2
2
2
3 3
3
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74 od. 5 od. 6
2Prosonic FMU90With FDU91 sensor
Promag 50WElectromagnetic flow measuring system
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Nivector FTC968Capacitance limit switch
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Instrumentation technology for milling, sifting and flour storage
Purification Conditioning
Purification Conditioning
Flour Storage Loadout+Package
LA
LA
LA
LA
LAFI
LA
LALI
LA
LALA
PIPDI
PI
LA
LA
LA
LA
LA
PDI
LA
LA
Elevator
Metal separator
Separator with
aspiration channel
Dry stoner
Indented surface
separator
Dampener
Tempering bin
Pneumatic pressure conveying system
Dust col-lector
Scourer
Aspirator
Roller stand
Planswifter
Bran cen-trifugal
Pneumatic pressure conveying system
Loadout
Pneumatic mill stock conveying system
Bag-packing station
LA
LALA
LA
LA
LALI
Batch-weighing
Flour storage
Dust collector
Airjet filter
Blending/Homogenization
Fan2
2
2
2
2
9
2
710
3
2
313
12
8
2
12
2 + 11
2
2
13
14
2
22
3
85
2
2
Nivector and Multicap – Roller mills
Multicap DC16Capacitance probe
Levelflex FMP40Guided radar device
Milling processSecuring a consistent feed to the roller mill:
Overfill protection at the filling spout with capacitance limit switch Nivector FTC968.
Level monitoring by capacitive probe Multicap DC16.Selectable sensor length from 100 up to 4000 mm allows easy adaption to feeding container.
Flour storage - level indicationLevel measurement by guided radar Levelflex M FMP40, factory adjusted for easy start-up
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Flour storage - limit detectionHigh-level alarm by Minicap FTC260 or by extended cable-version FTC262. Active build-up compensation guarantees failure-free operation
Low-level alarm: Vibronic sensor Soliphant T FTM2x. Installation in any direction possible. Time-saving startup without any adjust-ments. When sensor is covered with material, the vibration is stopped to avoid expulsion of material.
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Levelflex M - Dust occuring during filling process has no influence on the operation of the instrument
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Other applications in milling operations: aspiration, pneumatic conveying and loading
Cerabar M PMC41Pressure sensor
Deltabar S PMD70Pressure device
Soliphant M FTM50/52Point level switch (vibronic)
Pneumatic pressure conveying systemMonitoring of operating pressure by pressure sensor Cerabar M PMC41. Ceramic sensor membrane is stable against alternating loads and overload resistant.
Pneumatic mill stock conveying systemFilter monitoring by differential pressure sensor Deltabar S PMD70. Monitoring of functions from the measuring cell to the electronics ensures accurate and economical operation of your systems.
Exhaust systemOverrun alarm at the receiver or airjet filter by capacitive Minicap FTC260. Accurate switch point even with heavy build-up on the probe guarantee high operational safety.
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OutloadingOverfill protection at the filling spout by Soliphant M FTM5x. This vibronic sensor is available as a compact version with extension pipe up to 4m or with rope up to 20m, and therefore, can be installed in any position.
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Soliphant M - Outloading filling spout
Soliphant M - Filling spout
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Minicap FTC260/262Capacitance limit switch
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Reporting at a push of the buttonEndress+Hauser offers customized solutions. Start-ing with the connection by PROFIBUS, Foundation™ Fieldbus, HART® or Ethernet up to the visualization at your PC. The volume flow through each bin is calculated by the differences which occur during the
transfers between source and destination bin. All data relating to the batch and the bin levels are stored in a SQL (Structured Query Language) relational database system. Using these linked informations you receive a standard reporting.
Actual situationThe most important requirement regarding legislation is the consumer protection. Therefore, different laws, standards and guidelines are released to ensure the complete traceabi-lity of products along the food chain.
Example: European Directive (EG) 178/2002Starting the first of January 2005, every mill had to ensure that for every batch of flour being processed, it is possible at any time to trace back from which delivery of grain this product was made. The recipient of the batch has to be deter-mined as well.
Material flow traced back efficiently: we link your informationRegarding the chain of traceability, the mill itself can be considered as a closed system. It is not necessary to reveal steps of processing and blending. Endress+Hauser offers solutions based on level measuring technology which is an economical tool for documentation. At the push of a button you get any information which is required to trace back your material flows.
Weighment
Storage
Blending
Intermediate storage
Remote I/O
Purification / Milling
PROFIBUSPA
PROFIBUSPA
PROFIBUSPA
Delivery
4-20mA
Ethernet Ethernet
SQL-Database ReportingVolume flowTrackingWeights of deliveries
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Segment coupler
Segment coupler
PROFIBUS DP
Local PC Entry by operator:
Batch numberID of supplierType of productTime/dateDestination storage bin
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Fieldgate FXA 720
Printing of receipt
Network switch
Monitoring PC
Entry of BatchReceipt
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Visualization
Challenge #�: Traceability of material flows - Where from, where to?
Start-up in explosive areasEndress+Hauser provides a safe start-up in explosive areas, e.g. storage elevators, carried out by our special skilled service people. You receive a professional service report for your documentation.
Start-up to get more value from your moneyTo reach the full performance range of ultrasonic and radar measuring devices for storage elevators it is necessary to select the right instrument, the optimal installation place and a start-up adjusted to the conditions of your process environment. We support you step by step.
Increase the availability of your facilityWhich effort of maintenance do you need and how often? We ascertain a maintenance concept which matches the requirements of your facility. With it you master your costs at a maximum availability of your facility. We offer 4 different maintenance levels.
Standard OptionsFunctional
checksStart-up* Travel & l
abor costs**Spare parts Wear
parts***Consumables Phone
supportCalibration
servicesOn-site
response time
Preventative service • • • • •
Extended service • • • • • • •
Total service • • • • • • • • •
Tailor-made service “It is your choice!” “It is your choice!”
*for new instruments added within the term of the contract **for on-site repairs ***annual exchange of wear parts for instruments like automatic pH measurment system...
Training: extend your know-howOrganized on your site or at one of our training centers: take the opportunity to increase the independence of your technicians handling your measuring devices by transfer of knowledge.
Helpdesk/W@M-CardQuestions related to technical problems can be addressed to our spe-cialists during our working hours. Owning the W@M-Card you are able to do this around the clock ��5 days a year.
Services for special measuring devicesStart-up in explosive areas
Concepts for maintenanceYou select between 4 maintenance levels
TrainingKnow-how-transfer for your service people
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Challenge #4: Services - Professional support for your security and quality relevant measuring points
System components Innovative and modern system components which link plant to control room are at the top of any forward thinking Process Engineer’s wish list. Whether he wants to visualize measured values, protect his sensors, or use signals directly for process control, Endress+Hauser will offer the simplest solution.
Limit switch and relaysIsolated switch amplifiersUniversal transmittersRecording devices and dataloggers
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RN221N active galvanic barrierThe RN221N provides galvanic isolation of 4-20mA signal cables. It is used for the intrinsically safe operation of two-wire transmitters and to eliminate earthing problems.
RIA452 process display The digital RIA452, with 7-digit bright multi-colored LC display and pump control functions, receives measurement signals from most field devices and can be installed in con-trol rooms or in panels throughout the plant.
RIA141 field displayThe RIA141 digital display in pressure sealed metal enclosure (explosionproof to EEx-d) is designed for installation in to a 4-20mA power circuit and to makeyour process more visible and plant much safer.
HAW562 spike or overvoltage protection The HAW5�2 protects 0/4-20mA, PROFIBUS-PA and PFM signal lines.
RMA422 process transmitter The RMA422 receives and processes measurement signals. Its modular concept makes it the perfect process measurement transmitter e.g. as tem-perature transmitter, contactor or signal converter. Using the two input process values, server values can be calculated.
System components - Completing your measuring point
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Instruments International
Endress+Hauser Instruments International AGKaegenstrasse 2415� ReinachSwitzerlandTel. +41 �1 715 �1 00Fax +41 �1 715 25 00http://[email protected]
12.0�/I.I.
SO 004B/24/ae/0�.077104�45�Straub/INDD CS2
Liquid Analysis
ConductivitypH/ORPChlorineDissolved oxygenTurbidityChemical analyzersNitrate/organic sensorsSludge level
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Recorders
Paperless recordersVisual data managersSafety data managers
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Components
DisplaysEnergy managersDensity calculationsSwitch over control
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Service
Start-upTrainingCalibrationMaintenance contractsInstrument Management Solutions
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Level
Capacitance (RF)ConductiveMechanicalVibrationUltrasonicRadarGuided radar (TDR)Hydrostatic
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Pressure
Gauge/absoluteDifferential pressureHydrostatic
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Flow
ElectromagneticVortex sheddingCoriolis mass flowUltrasonicOpen channelD/P flowThermal mass flow
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Temperature
Temperature transmittersRTDs/thermocouplesSensors
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Endress+Hauser’s product portfolio