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Flexar
- 1. GUIDED WAVE RADAR CONTINUOUS LEVEL MEASUREMENT SYSTEM Presented by
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Editor's Notes
- Monitor Technologies uniquely brings together the things needed to provide a continuous level measurement system for bulk solids that works in most applications up to 30m (100ft) in total vessel height. We make the pieces fit together just right by combining proven TDR technology with five decades or expertise and focus in powder and bulk solids applications, along with our SiloTrack inventory management software interface. The Flexar continuous level measurement system is a smart guided wave radar level sensor that is proven accurate and reliable for the monitoring of powder, granular and other bulk solids. It is also suitable for use with a multiplicity of liquids. Flexar uses TDR technology that has been used for level sensing since the early 1990’s. TDR, or Time Domain Reflectometry, is ideal for powders and pneumatically conveyed bulk solids because it is unaffected by airborne dust, bulk density, temperature and most other properties. This level sensor is used in a wide assortment of vessels and industries and is easy to install and setup. TDR principles were first developed in the middle part of the 20 th century for use in the geological field where it was used to define the relationship between the different dielectric constants of soil, rocks and other materials and their moisture content. Subsequent to World War II TDR was developed and used in telecommunications to look for breaks in cable and in the early 1990’s it found its way into the process level measurement arena. Monitor’s five decades of expertise and focus in powder and bulk solids applications has been second to none and is priceless in the application of TDR guided wave radar technology to measuring the level of a wide variety of materials in a broad range of bulk solids industries. Monitor’s experience, proven TDR technology along with our SiloTrack inventory management software that allows interfacing with up to 128 sensors in local and remote locations, allows Monitor to uniquely delivery the best solutions in level measurement and inventory management of powders and bulk solids.
- In the application of TDR for process level measurement micro-pulses are continuously transmitted along a probe or “wave guide” at the speed of light. As soon as the pulses reach the material surface they are reflected back to the sensor electronics. The time-of-flight of the pulses is calculated and directly related to the distance from where the sensor is mounted on top of the vessel to the material surface. Subtracting the distance measured from the height of the vessel from discharge to sensor mounting point yields the level of the material. The output from the electronics is continuously updated as the level of the material changes. Flexar sensors are equipped with two measuring modes to handle virtually any application. These are the Direct measuring mode and TBF measuring mode. The vast majority of applications use the Direct mode where the pulses directly reflect off the material surface and the distance measurement is calculated based on the time-of-flight of this direct reflection. Almost all applications where the dielectric constant of the material is 1.8 and above use the Direct mode. This also is dependent upon the measuring range in addition to dielectric constant. For materials where the dielectric constant is too low for the Direct mode, the TBF mode is used. TBF stands for Tank Bottom Following. This mode will be effective down to a dielectric constant of 1.4 and, as with the Direct mode, this is also dependent on measuring range. The use of TBF mode is required because the amount of reflection in the Direct mode is too small when measuring materials with very low dielectric constants. Most of the radar energy in Direct and TBF is absorbed by the material. A rule-of-thumb is that if the dielectric constant of the material is 2.0, then about 2% of the energy is reflected. The lower the dielectric, the more challenging the measuring application. In the TBF mode the sensor has a “short circuit” at the bottom of the probe at a precisely known distance from the sensor mounting point. Now consider that radar pulses travel through air at the speed of light, but pass through the material at a slower speed that is dependent on the dielectric constant of the material. Once the radar pulses travel through the material and reach the end of the probes’ counterweight, another reflection of the radar energy occurs. Because the return time of a pulse through air for the entire probe length is known, it can be compared to the travel time through material when the material. The difference in these times is directly related to the material level for a given dielectric constant.
- Standard features in the Flexar guided wave radar continuous level sensor makes it the best choice in most any application requiring true continuous measurement. Flexar requires no continual maintenance like some other sensors such as the yo-yo weight & cable unit and older weight & cable technologies. Even through-air solid-state devices like ultrasonic is very problematic in powder applications and many granular applications as well. Flexar works in a very wide range of applications. These include virtually any where the dielectric constant of the material is equal to or greater than 1.4. The only real limiting factor is the interdependency between dielectric constant and measuring range as we have already discussed. Flexar is ideal for applications involving the measurement of the level of powders that are pneumatically filled because the TDR technology is not affected by the internal dust in the vessel, even during the pneumatic filling of a powder. This is where guided wave technology and Flexar surpasses all other technologies including weight & cable, through-air radar, laser and ultrasonic. All of these others may be problematic when it comes to providing uninterrupted reliable measurements during filling. The probe selection that Flexar offers allows our experienced application engineers to select the most appropriate to meet almost any application in bulk solids measurement. The most common probe type is the single-cable probe. This probe can be either 4mm or 8mm diameter, 316SS cable and counterweight and is cut to length at the factory to fit the specific application. Our heavy-duty cable probes can be used with heavy materials at long ranges without fear because the maximum traction load handling capability is 3.5 metric tons or 7,700 lbs. The single cable probes are used primarily for bulk solids applications while the twin-cable and single rod are used mainly for liquid applications.
- Installation can be quick and easy by following the guidelines in our Installation & Operation manual. We provide a variety of process connections. The simplest is the 1-1/2” BSP or NPT. In addition, we offer carbon steel flange accessories and a DN50PN40 or 2” ANSI stainless steel flange option. Setup of Flexar level sensors is quick and easy. All units are factory calibrated and therefore do not required field calibration. User configuration parameters are easily accessible via the built-in LCD display with keypad. In addition, parameter adjustments can be made through SiloTrack PC-based inventory management software. Flexar offers a universal power supply for high voltage ranging from 100-240VAC. A low voltage option is available for 24V AC/DC.
- Flexar can be a standalone level sensor and transmitter or part of a complete inventory management system. The Flexar sensor can be provided with one of three possible types of output. These are the “Smart” RS-485 communications output, the analog 4-20mA output or the RS-485+Passive 4-20mA analog output. The RS485 output is used to connect a sensor network of up to 16 Flexar sensors to SiloTrack PC-based inventory management software. The analog 4-20mA output makes Flexar a standalone level transmitter. This analog output is an active output and does not require any external power source to drive it. Maximum loop impedance is 350ohms. The analog output selection also includes HART communication protocol. A third output selection is also available. This is a combination of the RS-485 communications output and a passive 4-20mA output. This 4-20mA output requires the use of an external transmitter power supply and does not include HART. With this output option the sensor can interface with SiloTrack and also transmit a 4-20mA signal to a remote readout device, PLC or control system. Flexar can be an integral part of a complete inventory management system. In these applications the “smart” sensor with RS-485 digital communications output is chosen and connected with the SiloTrack PC-based inventory management software. SiloTrack is a PC-based software application that allows the operator to gather measured data for up to 128 “smart” sensors. SiloTrack can calculate volume and weight based on the measured distance along with the vessel and material data you provide. SiloTrack software provides a graphical interface and many more useful features including remote managed inventory and vendor managed inventory applications.
- Flexar guided wave radar are used to measure the amount of material contained within a vessel by indicating the material level based on a measure of empty distance between the sensor mounting and the material surface and the vessel height from discharge to sensor mounting. Flexar applications can include the level measurement of powders, granular materials and liquids. The primary limiting factor is the material dielectric constant, which must be 1.4 or greater, and the measuring range as previously discussed. Typical maximum ranges are 30m (100ft) for solids applications and 60m (200ft) for liquids. Ranges are dependent on dielectric constant of the material. A common application involves inventory monitoring of granular, powder and liquids. Monitoring and managing the inventory of a material within a storage vessel is usually accomplished using the Flexar sensor with the “smart” RS-485 output connected with SiloTrack PC-based software. However, the analog 4-20mA output may also be used and connected to an external inventory or control system or PLC. The RS-485+Passive Analog output choice allows the sensor to communicate with SiloTrack via RS485 and also connect with a remote control system or panel meter readout device. Flexar is utilized in virtually every industry that processes, stores and handles bulk solids and liquids. These industries include plastic processors, feed & grain, aggregates processing such as concrete production, cement and other mineral processors, food, bulk chemicals and many others. Flexar may be used to monitor inventory levels of virtually any powder and granular material.
- Whether its at a cement plant or at a concrete batch plant, a coal fired power generating plant or the processing plant that handles the flyash from the power plant, Flexar has been successful in measuring the inventory levels of cement powder and flyash. In addition, ground-blast-furnace slag is no problem either. Slag and flyash are used somewhat interchangeably as additives to concrete mix. The nature of all of these powder materials are such that heavy dust clouds are created in their storage vessels, especially during the filling process. In the case of concrete batch applications material levels change relatively quickly too so a reliable and accurate measuring system is necessary for operators to manage both cement powder and flyash or slag inventory levels. The picture on the left is a Flexar installed in a concrete batch plant silo measuring cement powder for a large regional batch plant company in the greater Chicago, IL USA area. Coal fired power generating stations produce tons of flyash. This has become a valuable commodity and it is not unusual for flyash to be stored at the facility for transport to processing plants or direct to end users like concrete batch plants. The facility in the center picture is a flyash processing facility in Joppa, IL USA that is located near a coal fired power plant. Flexar is a great choice for powders, especially when reliable readings during pneumatic filling are required.
- The growing Ethanol production industry in the USA has application and need for reliable continuous level measurement of both solids and liquids. Monitors’ experience in measuring grains and other bulk solids makes Flexar ideal for corn storage measurements and also the level measurement of corn during the multiple steps of processing for Ethanol. The example shown here is at an Ethanol plant in Wisconsin, IL USA with a proprietary process, where seventeen Flexar units are installed measuring corn in various stages and areas of the process. In addition, the use of Flexar in the corn surge hopper has been a repetitive application at Ethanol production facilities. The United States and Brazil are the top Ethanol producing countries in the world. Flexar can be a part of the ethanol production process as a reliable and accurate level sensor in this global market.
- A common application for Flexar sensors is as a part of an inventory monitoring system for plastics processors, including pellets and powders like PVC compounding at pipe manufacturers. Most plastic processors make specialty items so there is no single industry. The commonality between all of these processors is that they consume tons of plastic materials. However, most plastic materials have very low dielectric constants of 1.8 and below. Even in these applications Flexar has been proven reliable using the TBF mode. The two pictures shown here are different plastic processors and Flexar is measuring the level of different materials. The picture on the left is one of eight Flexar level sensors being used by a manufacturer of mirror products for the automotive industry located in Michigan, USA. They use Flexar and SiloTrack to measure inventory levels of ABS and polyester materials. The picture on the left is showing one of eight total Flexar sensors that are being used by a manufacturer of specialty plastic tubing located in Wisconsin, USA. Flexar is used to measure the inventory levels of polypropylene and polyethylene pellets. Monitor’s SiloTrack Server and Client software is being used to provide inventory management functions.
- Monitors’ presence in the Grain Processing industries is very large. Flexar is reliably providing continuous level measurements for seed processors and other grain processing companies as well. The Flexar units shown in the left picture are being used by a leading seed producer to help manage their seed product through treating and storage applications. Accuracy and reliability are extremely important. These two units are part of a dozen installed at this facility.
- As previously mentioned a common application for Flexar sensors is as a part of a remote and vendor managed inventory application. These applications require the use of SiloTrack PC-based inventory management software. In remote managed inventory applications the user is managing material inventory at one or multiple locations from either a corporate or local point. For vendor managed inventory applications the supplier or distributor of the bulk material is performing the monitoring and inventory management function automatically replenishing material based on a pre-arranged agreement with the user of the material. There are two primary ways in which these applications can be implemented using SiloTrack software. The first uses only the capabilities of the SiloTrack Server software that is located at the site where the material storage exists. The Server software allows for up to two alarm alerts per vessel, including a reorder alarm. In such cases the alert method can be set to send an email to up to two email addresses. These emails can alert vendors or corporate locations of the need for replenishment of the material in the specific vessel in which the alarm exists. In addition, SiloTrack Server can be setup to automatically generate and transmit reports in Excel, Word and other formats to the email addresses of choice. These reports can provide historical usage information and can be used by vendors or a procurement function to determine when material replenishment may be required and how much. The second manner in which either remote or vendor managed inventory can be implemented is the use of the SiloTrack Server software at the site where the sensors and the material is located and the use of SiloTrack Client software at the location where the inventory replenishment or management function would take place. The SiloTrack Client software provides graphical display and the database of measurement information about the materials and silos subscribed to. System security access is provided and data transmitted is encrypted. The example shown here is a plastic processor tied to the automotive industry located in Michigan. This customer has eight Flexar sensors monitoring the level and inventory of a variety of plastics include forms of ABS. The sensors are connected to SiloTrack via the RS-485 sensor network. The customer says “the system works great!”.
- The alternative operator interface to the HMI for “smart” sensors is the SiloTrack PC-based inventory management software. This graphical interface will connect with up to 128 sensors using multiple RS-485 networks. The software provides the user with a graphical display of the silos that have the sensor units installed and will display the graphic based on either the material distance, level, volume or weight values. All calculated data can be seen in the silo details screen. The SiloTrack software is a network-ready software package consisting of Server type software that must be resident on the PC in which the sensor networks will be connected. The optional Client software can be used by remote users to view and display the same data as the Server software via LAN, WAN/Internet or dial-up connection. This allows for multiple user viewing and access. SiloTrack is easy to setup and operate. The software incorporates a Setup Wizard that guides the user through input of standard information needed to create a silo graphic and gather the appropriate measurement information. The Setup Wizard is included in both the Server and Client software. As discussed previously, SiloTrack software can be used to implement remote and vendor managed inventory applications quickly and easily. This can be done by using standard features of the Server software or by combining the Server and Client software. SiloTrack can be setup with up to four alarms per silo. These alarms can each be set with a variety of alert notifications, including sending email to two email addresses. In addition, history and data reports can be generated and transmitted to two email addresses automatically. These reports can be in a wide variety of formats including Excel and Word. The SiloTrack software also provides dual language including English as its standard language and the ability to change to Spanish with just a couple of mouse-clicks. The language database may also be customized somewhat by the user for other languages or dialects. More flexibility is provided. The software can interface with both SiloPatrol SE smart sensors as well as the smart Flexar guided wave radar continuous level sensors.