Download - Nivelco Process Control Co., Inc.

ITEM # _______________________________________________Pasta SolutionsPasta Station 4-BasketAutomatic Pasta CookerMODEL # _____________________________________________PROJECT NAME # ______________________________________SIS # _________________________________________________AIA # _________________________________________________Pasta SolutionsPasta Station 4-BasketAutomatic Pasta Cooker168747 (7PCSE2AU) 4-Basket AutomaticPasta Cooker208 V/3p/60z - 27.5AShort Form SpecificationItem No. ___________________________________Unit to be Electrolux 4-Basket Automatic Pasta Cooker 168747. Theunit is a free-standing, 4-basket and automatic Pasta Cooker. Eachbasket is to be independently programmable and cooking times aremicroprocessor controlled. The water temperature is to be thermostatcontrolled and programmable. The unit shall feature constantwater level and starch removal during cooking process. IPX4 (NEMA4 equivalent) splash water protection. Two stainless steel basketsincluded. The 10.5 gallon tank is pressed in AISI 316 stainless steeland features only rounded corners. The unit to be completely inAISI 304 Stainless steel.Covered by Electrolux Platinum Star® Service Program two-yearparts and one-year labor warranty, installation start-up andperformance check-up after one year from installation.Approval: ___________________________________________Main features• 4-baskets: independently controlled by push-buttons.• Microprocessor controlled programmable coking time for each basket.• 10.5 gallon tank.• Thermostat controlled programmable water temperature: for cooking, rethermingand sous-vides applications.• 9 position energy regulator.• Constant water level.• Automatic starch removal function during cooking: improved water qualityover time.• Automatic low-water level shut-off: no accidental over-heating.• Electrolux Platinum Star® Service package included:• 2-year parts, 1-year labor warranty, 5-year compressor warranty.• Start-up install check.• Equipment check-up after 12 month from installation.Construction• Pressed 10.5 gal capacity tank: only rounded corners for improvedcleanability.• AISI 316 stainless steel tank: maximum corrosion resistance.• All stainless steel construction.• IPX 4 splash water protection (NEMA 4 equivalent).• 5″, height adjustable legs.Included Accessories• 4 of AISI 304 stainless steel baskets.Optional Accessories• Bulk cooking basket.• 2 of 1/2 size bulk cooking baskets.• 3 of 1/3 size bulk cooking baskets.• 3 of round individual-portion baskets.• False bottom for round individual-portion baskets.• Castors.Electrolux Professional, Inc.www.electroluxusa.com/professional3225 SW 42nd Street, Fort Lauderdale, Florida, 33312 • Telephone Number: 866-449-4200 • Fax Number: 954-327-6789Pasta SolutionsPasta Station 4-Basket Automatic Pasta Cooker

NIVELCO’s Road Tour of IndiaAn important element of NIVELCO’s support for the salesnetwork is the help offered with marketing. Of the manyways NIVELCO may provide marketing support, we do tryto treat those companies located far away equally to thosegeographically close to headquarters, choosing an approachthat suits the market best. Our popular DemonstrationVehicle, NIVELCO’s “Level On The Road” is well suited foruse by our Central European companies, but for our Indiansubsidiary, NIVELCO INSTRUMENTS INDIA PVT. LTD.the use of such a vehicle would be totally uneconomic forlogical reasons.Having its stages in Bangalore, Hyderabad and Mumbai,the series of events were organised by the staff of NIVELCOIndia – a subsidiary of NIVELCO Process Control Co. –supported by its local distributors, Fluitec Instruments andBartem Instruments. The presentations were done by invitedexecutives from Budapest as well as by staff members ofNIVELCO India.Over the years we have developed a similar marketing tool,optimised for the Indian marketplace, and that is our socalled “Road Tour” organized in larger cities. Invited for thefull evening events are engineers and executives of existingor prospective clients of the city involved and its vicinity.The presentations we seek to do on such an event aremeant to portray the Mother Company, its achievements aswell as the same of its Indian subsidiary. Included aretechnical and application oriented presentations as well.These informative sessions are followed by a dinner givento honour the participants.Such road tours arenormally organisedbi-annually involvingthree of four Indiancities. A recent ThreeCity Road Touraimed at providinguseful informationabout the company,its products and theirapplications tookplace successfully inearly May.Drawing an average ofabout 100 visitors anight, the tour was a successwith benefits forboth sides to come.Tibor WinklerBoard MemberNIVELCO Co.twinkler@nivelco.com4

Marketing strategiesA long planned intention of ours, to create a completeproduct catalogue has come true at the end of March.This book, of almost 160 pages, is currently only availablein Hungarian language, but it will be launched soonin English as well. The catalogue contains technical dataof the instruments with all available order codes.We hold Demo-bus aided presentations at approximately100 locations annually, and have visited all major citiesin our homeland and the neighbouring countries –meeting with our partners, companies and corporationson a regular basis. Besides the “Exhibition on Wheels”we organize regular trainings to educate technicallycompetent sales and service engineers to be able toperform optimally on the front line of today’s tough marketof Process Control.Having a retrospective view on the nearly 30 years goneby since NIVELCO was founded, we are proud of themore than 10000 trade relationships we have workedto establish. The number of our satisfied customers is steadilyrising year to year thanks to the attention paidto them. In the spirit of this attention we continue our“Level on the Road” exhibition with a renewed vehicleto demonstrate our newest developments in operation.Only those sales engineers equipped with top rate expertisecan measure up with their counterparts in ourcompetitors and can take up the fight with a good chanceto win. NIVELCO identified the necessity for technicaltrainings early on and started to run international trainingprograms at an average of two courses a year.Taking not more than 10 people for optimal efficiency ata time, we have trained approximately two hundred staffmembers from our distributors over the last 12 years.We wish to continue along this line in the future by offeringsimilar further technical training courses.Péter SzőllősMarketing DirectorNIVELCO Co.pszollos@nivelco.com7

Representing FISCHER in HungaryExclusive distribution of FISCHERMeasurement Technology in NIVELCONIVELCO established a partner relationship withSindelfingen based Helmut Fischer GmbH in 1985. ThisGerman company has developed innovative measuringtechnology for coating thickness measurement, materialanalysis, micro hardness measurement and material testingfor almost 60 years.The closer the magnet is to the steel surface, the strongeris the induced magnetic field. The thickness of the coatingdetermines how close the pole of the magnet canapproach the substrate, therefore layer thickness determinesthe strength of the magnetic field around themagnet placed on the test sample.The Fischer Company was founded by Helmut Fischer,a physicist, in 1953. At that time the rapidly developingautomotive industry needed thickness measurement ofcoatings and pore-exemption inspection. These measurementsare essential in monitoring the quality ofthe layers and the applied coating technologies (paintand galvanic coatings). The old testing method for thesemeasurements was to make a cut. The layer thicknesscan be examined on the cut by a microscope.The first non-destructive thickness measurement methodused the magnetic principle. The main point of thismethod is: the strength of the electromagnetic fieldaround the magnet is dependant on the pole of themagnet and the distance of the tested steel surface.8

Representing FISCHER in HungaryThese instruments, using the magnetic inductionprinciple, are available in small handheld typesand there are also desktop versions. Today’smodern instruments provide a data-loggingcapability to even make statistical calculationson the measured values in a single handheldinstrument.Similarly to the above measurement method,the Eddy current method provides measurementof non conductive (varnish, plastic, oxide)coatings on ferric materials. There are compactinstruments operating with both (magneticinduction, and eddy current) methods usinginterchangeable probes. The instruments consistof a measurement probe and a signalprocessing/displayunit.The probe can be incorporated in theenclosure, or can be connected with a cable tothe enclosure. There are numerous probe typesand instrument versions in order to provide theproper solution for any measurement task.Unfortunately the above measuring methods are not suitablefor the measurement of multilayer coatings, magneticcoatings on steel, metal coatings on plastics, not tomention the material analysis of the coatings.The X-ray method was developed to satisfy this purpose.The main point of this method is to radiate X-rays into thetest sample.The energy of the reflected X-ray depends on the quality ofthe irradiated material, while the intensity of the reflectedX-ray depends on the thickness of the irradiated material.Therefore many types X-ray spectrometers were developedto create suitable instruments for high-precision thicknessmeasurement and material analysis. The X-ray method allowsexamination of very small structures (PCBs, connectors),or the trace analysis required by the RoHS directive.NIVELCO Process Control Co. - as the exclusive Hungariandistributor of the Fischer Company - has been importingand selling fair amount of Fischer instruments and widerange of probes on the domestic market over the years. Moreoverthe sales we provide include repair and maintenanceservices, assistance to our customers in choosing the appropriateinstrument type, as well teaching the proper useand handling of the instruments to the end-users.Dr. Ferenc HaskóFISCHER Product ManagerNIVELCO Co.fhasko@nivelco.com9

Exhibition-series of NIVELCO RussiaNIVELCO exhibitions in RussiaAccording to the forecast of leading economists, 2010 isgoing to be the year of expansion in Russia. The statisticsof the first quarter confirms the above since all sectors ofthe economy have shown a powerful recovery, manifestingin industry especially. Using the marketing conceptof the NIVELCO group as a basis NIVELCO Russia carriesout its conscientious and dynamic marketing campaignin order to ride the upward trend of the Russianmarket. Joint participation in trade shows along with jointlyheld presentations and seminars with our distributorsare well proven and efficient vehicles of marketing. Themarketing activities are targeted to inform our businesspartners throughout Russia. Tracking the changes of theRussian market and observing the development of the differentsegments of the economy are extremely importantfor us. Our attention extends to the Belarusian, Kazakhand Ukrainian markets as being strategic partners of Russiathese countries present business opportunities for us.In this sense, we have participated on the "Automationand Electronics 2011" Fair in Minsk jointly withBelpromtehnologii, our distributor in Belorussia.One of our Russian distributors, Energopromavtomatikaexhibited on the „Metrol-Expo’2011” Fair inMoscow last May representing NIVELCO on thisprestigious show.The 20th of May is the World Metrology Day all over theworld celebrating the signature by representatives of seventeennations – including Russia – of The MetreConvention on 20 May 1875. The Convention set theframework for global collaboration in the science ofmeasurement and in its industrial, commercial and socialapplication. Metrology is the science of measurement includingall theoretical and practical aspects.Likewise life is not imaginable without mathematics andtheoretical calculations, so metrology can not be avoidedduring the realization of any calculations. This was noticedand precisely formulated by the famous Russian scientist,Dmitri Ivanovich Mendeleev: “Science of accuracyis meaningless without measurement.”10

Exhibition-series of NIVELCO RussiaIn June 2011 Metrology Conference willbe held in Voskresensk near to Moscow.We are taking part with one of our localdistributors, Rizur and we will stage apresentation entitled “NIVELCO instrumentsfor the chemical industry”.In the autumn we are planning to organisemany regional company and productintroductions in the Moscow region.In the headquarters of Energopromavtomatikawe will hold NIVELCOProfessional Days to present ourcompany and its total portfolio, highlightingmodern technology leveltransmitters, analytics, pressure andtemperature transmitters. We will organisefurther Company introductions in theheadquarters of Elmetro in Chelyabinsktogether with our Moscow distributor,Rospribor.The main goal of this event is to transferour experience and knowledge for thedeveloping heavy-industrial companiesof the Ural region. We are also supportingour distributors with technical adviceand information about selling andmarketing NIVELCO products. In thelast quarter we are planning to holdRoad-shows in the southern areas suchas Krasnodar. This region has remarkableagricultural and related processing industry.We are aiming to find new partners there by powerfulmarketing activity together with our local distributor,PO Interface. In addition to the above plans we arelooking forward to further cooperation opportunities in SaintPetersburg, Tatarstan, Siberian and the Far-Eastern areas.Attila KovácsManaging DirectorNIVELCO Rus.russia@nivelco.com11

3 rd anniversary of NIVELCO USA LLCNIVELCO subsidiaryin the United StatesNIVELCO USA is a limited liability company establishedin the US in late 2008 as a part of NIVELCO zRt.Our office is located in Los Angeles, California in the Westcoast.Therefore moving forward into 2011, our primary goal isto more aggressively market and promote the sales ofNIVELCO’s range of products under their own name inthe North American market.The two NIVELCO Companies are nine hours away fromeach other. NIVELCO zRt, a global manufacturer andexporter, entered the North American market in 1995, byappointing a General Distribution on the eastern part ofthe country. Apart from selling NIVELCO branded equipmentthrough its own distribution channels, similar or thesame equipment was also sold in the market by majorAmerican level instrumentation manufacturers on thebasis of private labelling agreements. We are continuing,broadening, and creating new partnerships for privatelabel products. In addition, we feel the time is right tomarket the NIVELCO brand of products to take advantageof NIVELCO’s growing worldwide name recognitionfor quality level measurement products in their field.The key in developing the NIVELCO brand has been inboth having a good product at a good price to sell aswell as communicating with our customers on a dailybasis in providing them with fast and thorough information.We are learning how best to serve and service ourclientele, enabling them to fill their customer’s orders.NIVELCO USA is working hard to become the pre-eminentbrand that our distributors can rely upon in buildinga relationship of service and trust.The NIVELCO USA team is dedicated and hard working.We understand that in uncertain economic times, companiestend to be more cautious in what they are purchasing,and whom they are purchasing it from. Our team iscommitted to giving our customers the very best productsand service at the most competitive prices in our industry.We would like to say thanks for the help and support ofour distributors for what we have achieved. Our goal isto find new distributors in order to expand our distributionnetwork and reach nation-wide coverage.Paul DennisManaging DirectorNIVELCO USA LLCusa@nivelco.com12

TradeCenterNIVELCO TRADE CENTER was established after areconstruction in 1993. Equipped with the newesttechnology and communication appliance NIVELCOTRADE CENTER became an office building with uniqueworking conditions.High quality offices, shops and stores are to let.From 5 minutes walk from the "Újpest Városkapu" metrostation. NIVELCO TRADE CENTER can be easilyreached from the city centre in 15 minutes with any publicconveyance.As owners of NIVELCO TRADE CENTER we conceivethat long-term collaboration is the most rewarding andthe key of success is the affordable comfort and reach.Flexible offices satisfying any demands150 interior place for carsRestaurant, canteen24h reception and security serviceCamera surveillance systemNIVELCO TRADE CENTER offers offices of highstandard, warehouses and parlours to let in 3 officebuildings in cca. 10000 square meters. The serviceincludes fully comprehensive office and internet servicesand 24h gate-keeper service.13

CareerSales Engineer – RomaniaNIVELCO Technica Măsurării SRLis seeking a professional for the Sales Engineer positionSales Engineer – PolandNIVELCO POLAND Sp. z o.o.is seeking a professional for the Sales Engineer positionTasks:Build & maintain strong customer relationshipsNew client acquisition in the territory,regular visits to customersTechnical support for Marketing team relatedto NIVELCO productsProposing adequate solutions for the customersFollowing up on quotations and projectswithin the territoryDistribution development and managementRequirements:Diploma (Academic degree in a technical discipline,preferably Electrical Engineering)Strong communication skillsFluent Romanian and English knowledgeHungarian knowledge is preferableThe ideal candidate is an energetic,self-starter person with team-player attitudePreferred Skills:Experience in Sales or acquisitionExperience in Process Control IndustryOur offer:Integration in a very dynamic working teamCompetitive salaryAttractive professional careerLocation of the job: Bucharest, in home office systemIf you are interested in the position, please send yourresume and motivation letter to: romania@nivelco.comTasks:Build & maintain strong customer relationshipsNew client acquisition in the territory,regular visits to customersTechnical support for Marketing team relatedto NIVELCO productsProposing adequate solutions for the customersFollowing up on quotations and projectswithin the territoryDistribution development and managementRequirements:Diploma (Academic degree in a technical discipline,preferably Electrical Engineering)Strong communication skillsFluent Polish and English knowledgeThe ideal candidate is an energetic,self-starter person with team-player attitudePreferred Skills:Experience in Sales or acquisitionExperience in Process Control IndustryOur offer:Integration in a very dynamic working teamCompetitive salaryAttractive professional careerLocation of the job: Gdańsk, in home office systemIf you are interested in the position, please send yourresume and motivation letter to: poland@nivelco.com14

NIVOFLIP bypass level indicatorNew category on the productrange of NIVELCOThe NIVOFLIP - NIVELCO’s bypass liquid level indicatorfeaturing an optical bi-coloured magnetic flap display -opening a new category in NIVELCO’s product portfolio,had its debut in March 2010. Although enjoying popularityin quite a few industries, bypass level indicators werenot represented in NIVELCO’s rich product offering.This gap has been closed by the product launch last year.NIVOFLIP consists of a welded bypass chamber that isthe body of the indicator, connection flanges, an opticaldisplay, and contains a magnetic float. The chamber andthe tank form one pressurized system, mounted onsuitable connection flanges located on the side of the tankthe liquid level in the bypass tube and the tank is equal.The float in the bypass tube incorporating a polarizedmagnet tracks the level of the liquid. Bi-coloured magneticflaps mounted on the tube composing a bar are servingas visual indicators by changing their colour as the floatpasses. The bottom section of the indicating barrepresents the true level. The lower 100 mm of the bottomsection of the indicating bar has different colouringproviding for an optical error signal in case the liquidlevel drops below the lower connection point of theinstrument.The NIVOFLIP level indicator can be equipped with levelswitches and a level transmitter if level switching andtransmitting are needed. Both switch and transmitter areavailable in an intrinsicallysafe version.The highly accurateNIVOTRACK magnetostrictivelevel transmittercan be clampedexternally on the sideof the bypass tube.The level transmitterwhich is suitable forcustody transfermeasurement isoperated by the magneticfloat ofNIVOFLIP via magneticcoupling.The MAK-100 level switches incorporating a microswitchcan also be clamped externally on the side of the bypasstube and operated by the magnetic float of NIVOFLIPvia magnetic coupling. In case of using MAK-100 levelswitches the minimal medium density decreases by0.1 kg/dm 3 .Most important news about NIVOFLIP isthe PED (Pressure Equipment Directive)approval, which certifies NIVOFLIP asan applicable part of pressurized systemsup to 40 bars. Besides the standard version,from now NIVOFLIP isavailable toorder in a versionwith alarger tube diameterwhich issuitable forviscous materials.There are alsoavailable thetitan float versionsfor lowerdensity liquidmaterials, and aspecial versionoperating at upto 100 bars.15

THERMOPOINT multipoint temperature transmitterMultipoint temperature transmittersfor liquids and solidsIn an expansion to the THERMOCONT model range wellknownin our home-market, NIVELCO introduced theTHERMOPOINT multipoint temperature transmitter in Aprilof 2010. The first model, the plastic coated flexible probetype, is called a silo-thermometer. Monitoring of the totalvolume of the silo containing grains of various kinds isneeded to provide information on accidental quality loss orthe appearance of germs or fungus. Eventual temperatureincreases will alert the operator to perform further operationsor recycling the medium. Temperature measurement isdone by electronic temperature sensors placed at equaldistances in a coated stainless steel flexible tube.Each sensor sends the actual measured temperature of itsenvironment to the transmitter head. The transmitter headcommunicates with control room devices using the HARTprotocol. The output is 2-wire, the communication is digital.The measured values are transmitted for further processingthrough HART.A maximum of 15 transmitters can beconnected to one HART loop (only 4 incase of Ex transmitters) allowing themonitoring of up to 225 temperaturesensors incorporated into 15 probes.If a system needs more sensors than225 sensing points, furtherMultiCONT units (max. 30) can be organisedin chain using the RS485 interface,therefore even 6750temperature sensors can handled ina single measurement system.Up to 15 digitally addressable semi-conductor temperaturesensors can be placed into a single probe. Measurementvalues of the 15-point sensor can be displayed in aSAP-300 plug-in display unit located on the probe head,or in a MultiCONT process controller screen, in tabularform. The MultiCONT units are also able to display a temperaturechart to indicate the time-trend of the measuredvalues. The greatest advantage of a measurement systemusing THERMOPOINT temperature transmitters is thatother transmitters from NIVELCO (for example: MicroTREKor EchoTREK) can be connected to the same HART loop,expanding the system with level measurement.The HART capable transmitters can beconnected with a UNICOMMSAK-305 communication module or aMultiCONT multichannel processcontroller to transmit the measurementdata from the sensors to a PLC or a PC.The THERMOPOINT product familyhas recently been further expandedwith rod and cable probe versions forthe average-temperature measurementof liquids. The instruments are availablein intrinsically safe and Dust-Exversions.16

UNICONT PMM-500 universal controllersThe newest member of the successfulUNICONT controller familyNIVELCO has produced a wide range of indicating andcontrolling instruments for temperature sensors. Thenewest members of the UNICONT universal controllerfamily are the PMM-500, featuring easy programmingas well as ease of use. Since June 2011, new anddifferent versions of PMM-500 have been available,replacing most members of the PMM-300 family ina 1/16 DIN (48x48 mm) size - such as our PMG-400,also offered at a better price.The greatest improvement with the UNICONT PMM-500controllers is the wider variation of the outputs comparedto the former series. The controllers are expandable withup to 4 output modules providing a wide variation ofoutputs thanks to the modular structure of the device.An excellent quality, 2-line, 7-segment, 4-digit LEDdisplay indicates the measured and process values, programmingsteps or other settings. Flashing status LEDsindicate the modes of operation and alarms.Among the output modules there are a maximum of threerelays, 24V DC power supply for transmitters, SSR drivers,an analogue output, plus RS485 (Modbus) communication.The RS485 Modbus RTU serial line provides digitalcommunication with a PC as well as remote programming.The four-key front panel provides easy programming.EEPROM memory ensures data and program protectionagainst power-cuts.The universal input accepts a wide range of temperaturesensors (Pt-100 RTDs and most types of thermocouple),standard analogue current or voltage signals (mA, mV, V).Using the Auto-Tune mode, the instrument provides optimalsettings of control parameters without entering anyPID parameters.17

MultiCONT P-200 multichannel process controllerThe sum of relays in UNICONT PJK-100 extensionmodules and MultiCONT must not exceed 64, the sum ofanalogue outputs (4…20mA) must not exceed 16. Thereis a universal module with both relay and current output inthe variety of the UNICONT PJK series. The maximumnumber of these modules is 32. Programming of themodules is done by MultiCONT.Monitoring the average, minimum andmaximum value or highest values of theflow can be used only for NIVELCOmanufactured transmitters used in theflow-metering mode. Content of the internalmemory is retrievable through the USBport, within the capacity of 65000 entries.Maximal capacity of the applicable SDcard is 2GB. The devices have receivedATEX approval, so they are suitable foruse with intrinsically safe transmitters.RS 485 capable versions of MultiCONTare able to communicate withNIVELCO’s NIVISION process visualizationsoftware to indicate parameters ofa process control system graphically on aprocess controller PC.The process, the measured values or any further processedvalues can be visualized also in tabular form withNIVISION. The NIVISION performs data logging, trendmonitoring, database handling and various other tasks inaddition to a basic visualization.Another important new feature of the P-200 series is theonboard logging capability version which has an SDmemory card extension slot and an USB connector on itsfront panel. MultiCONT are able to store measurementvalues and three additional parameters of the connectedtransmitters in a measurement system into the internalFLASH memory or an SD memory card. The two modes,time-controlled and event-controlled logging modes, canbe used simultaneously.Csaba NádasdiMarketing EngineerNIVELCO Co.csnadasdi@nivelco.com19

Approvals and certifications of the Instrument IndustryWhat is approved by an approvaland what is certified by a certification?Nowadays all significant manufacturers - for example medical,telecommunication, technical equipment producersor even food supplier companies - have longer lists ontheir websites of the received certifications, than exist fortheir application studies or successful references. Althoughthese documents are validating only the measurementresults of a certification institute, and justifying theirown statements, in many cases they can be more important:more important even than a perfectly operationalproduction-line equipped with hundreds of instruments.How is it possible?The simplest answer for this question is that the currentlaws and regulations require many certification proceduresrelated to a given industrial segment. So these documentsare regarded as an entry into each specific sector.This simple answer raises another question, why are thelaws so strict? First of all it is essential to protect humanlife, health and material resources. Of course the lawdoes not protect directly against anything, it provides onlya reduction of the risks of possible unexpected situationsand its consequences. Secondly during the evaluation ofa product the ‘conformity’ is a really important aspect forthe end-users. It would be very problematic if users shouldperform product-examinations, therefore the manufacturersare obliged by the law to label a conformance markon their products. This conformance mark is known as theCE mark in the European Union.The letters of "CE" stand for the "Conformité Européenne",a French expression which means European Conformity.If a manufacturer or an importer uses the CE mark on aproduct, it indicates that the product complies with alladministrative and safety standards of the relevantdirectives. The most commonly used administrative requirementis the “Declaration of Conformity”.This document stresses that the conformance is not finishedonly by marking the product with CE. According tothe standard manufacturers are obliged to appendDeclaration of Conformity of the product which provesthat the manufacturer admits that its product is in compliancewith applicable regulations.How many different directives are there and how manyare concerned with the electronic products for industrialusage from these? If the directives of automotive,transportation, telecommunication and medical industryare regarded as not important, then a dozen directivesremain relevant.The most important ones from these:ATEX Directive (94/9/EC)Pressure Equipment Directive (97/23/EC)Simple Pressure Vessels Directive(2009/105/EC, former 87/404/EEC)Low Voltage Directive (2006/95/EC)Electromagnetic Compatibility Directive(2004/108/EC)The CE mark is a mandatory conformance mark in theEU required by the 93/68/EEC Directive. Its goal is to ensurereliable product quality and the needed safety for theusers in case of any products manufactured or sold withinthe EU. It relates to all kinds of products, from toys to theautomotive industry, from medical equipment to mechanicalproduction and of course covers the process instrumentationindustry.Measuring Instruments Directive (2004/22/EC)Restriction of Hazardous Substances Directive(2002/95/EC)Waste Electrical and Electronic Equipment Directive(2002/96/EC)20

Approvals and certifications of the Instrument IndustryIn Hungary there are nearly 30 Notified Bodies, in caseof many directives we can choose between three Institutes,but there are some special areas when we have to turn toforeign Certification Institutes. The European Committeeappoints the Notified Body as the administration body inmost of the cases of any Directives.With all directives, it is also true that these contain only“guidelines”, which are considered mandatory. The detailedprocedures are described in the local (national) laws.It is possible that the law is a straight translation of theoriginal directive, but for example the “9/2001. (IV. 5.)GM” regulation for pressure equipped devices is a combinedregulation consisting of the elements of two(different directives 87/404/EEC and 97/23/EC).What does an evaluation of the conformity look like,and what does the type-approval mean? The differentdirectives usually provide 8 optional procedures (examinationmodules) to test the product conformance.These modules cover different methods and combinationsfrom unique product examination to manufacturing ordocumentation of quality-control tests. In case of higher riskcategory products only certain modules can be chosen.The obvious choice for mass-produced types is the multistageexamination. At the first stage is a so-called NotifiedBody, (chosen by the European Committee) which performsa careful design-test according to the manufacturer'sdesign documentation, then examines one (or more)finished products. If the examination results in the documentsand the product (mostly a destructive test methodis used for product tests) both meeting the requirementsof the current standards, then the production related qualitycontrol system gets under verification. During this procedurethe manufacturer has to show his systems are ableto provide the required quality independently from the volumeof the manufactured products.Considering thatconformity of a productis fully guaranteedby themanufacturers accordingto the abovementioned Declarationof Conformity,the accredited notified bodies only take a role as an accessoryplayer and the responsibility remains with the manufacturer.It is clearly visible now, that clever solutionsare not enough to obtain a type-approval.Manufacturers have to implement the requirements of thecurrent standards and regulations and these proceduresshould be approved by a third-party Notified Body.This is a riskier process than the realisation of a successfulproject, consuming more time, money and energy –therefore it represents undoubtedly greater marketingpower.The oldest and still the most commonly used safety requirementis the safety of equipment in hazardous explosiveatmospheres. The history of this requirement is as old asmining itself. At first it contained technical solutions almostexclusively in order to avoid firedamp explosions.Unfortunately, as with all safety standards: catastropheshappen first, then safety regulations come seeking toprevent these catastrophes as a next step. Exactly the samehappened in the city of Minneapolis, Minnesota, USA, in1878 when the biggest corn mill in the world exploded.The explosion at the Washburn Company’s mill killed 18workers and destroyed the neighbouring houses, razingthem to the ground. The reason was a simple spark, ignitingthe dust in the air (full of electrostatically chargedpowder), which was enough to blow apart the enormousconcrete-monster. However nobody was surprised at thispreviously unknown phenomenon, and suitable safety regulations(related mostly to airing) came into effect onlyin 1880 at similar factories.21

Approvals and certifications of the Instrument IndustryAnother sad fact: only a few years ago Washburn mill wascompletely burned down for the second time in 1991.The reason was very simple again, which did not lead toany new physical theories. Around the machines inside thebuilding, flammable plastic and wooden materials wereused in the hazardous area. Now the ATEX Directive prohibitsthe usage of all flammable materials in Dust-Exzones.At NIVELCO we achieveincreased safety - in orderto avoid catastrophes - byapplying active and passivecircuit protectioncomponents. In manycases these methodsmake the system toocomplex, eventually theycould be the obstacles to reliable functionality.This is almost the same situation as in the case of thehousehold electrical miniature circuit breakers or fuses:if they shut down the power frequently, the power supplywill be unstable, if we disable the protection, we are endangeringour personal and material safety.The Washburn millon 2nd of May in 1878 (source: wikipedia.org)Learning from the experiences of similar accidents, safetyregulations for hazardous explosive atmospheres arechanging every year and getting stricter and stricter in orderto prevent future disasters. At NIVELCO we are using therevised versions (MSZ EN 60079-0:2010, MSZ EN60079-25:2011, MSZ EN 60079-31:2010) of the 60079numbered multi-volume standard-collection, done by theIEC. This standard has been revised recently in 2010 and2011 by CEN/CENELEC (European Committee forElectrotechnical Standardization).Another conformance mark, similar to CE is the so-calledUL sign used in the USA. In contrast to CE, this does notmark hundreds of notified bodies, but only one certificationinstitute. This institute is the Underwriters Laboratories establishedin 1894. UL has developed remarkable amountof safety and measurement standards in many specificareas during the past 120years. Most of these standardsare required by thelaws, one of these is UL94which is binding all overthe world. The UL94 standardis about the classificationand determinationof plastics flammability.The IEC (International Electrotechnical Commission)created a multi-volume standard-library numbered61508 in order to define the categories of operationalsafety as well as summarise the measures for achievingadequate safety. The related application-technologydescription can be found in the 61511 numbered standard.These standards provide detailed definition of relatedconcepts including hazard, risk, hazardous and safefailure, probability of failure, allowable frequency offailure, statistical life expectancy. Usually there are complexprobability-calculating algorithms likewise testing andmeasuring techniques for the determination of theseconcepts. The question of operational safety is mainlyapproached by mathematical and statistical methods inthe standard. In a huge system it is not enough to determinethe “weakest link” or fix it, because all instrumentscarry the probability of failure.The devices are divided into 4 categories according totheir probability of failure. These categories are the socalled„SIL” (Safety Integrity Level) classes. In case of thelowest (SIL1) class the statistical expected failure-less periodis approximately 100 years, the highest (SIL4) classequipments are able to operate flawlessly up to 100000years! Of course if we want to use 5000 pieces of independentSIL4 rated instruments the statistical time periodof flawless operation is only 20 years. It is easy to justifywith the help of mathematics that using “redundant” devices- two devices for one application - the probabilityof failure can be halved.22

Approvals and certifications of the Instrument IndustryShips are the oldest and perhaps still the most expensivetransportation vehicles. Since loss of a ship always involvesconsiderable material costs (cargo, environmentaleffects), all ships are individually insured from the timeof the shipbuilding. There are only a few insurance companieshaving enough capital to insure these kindsof ships. The main classification companies in Europe areLloyd’s Register, Germanischer Lloyd, Det Norske Veritasand Bureau Veritas. Since they conclude high value insurances,they make their own regulations in order tominimize risks that all parts and components of the shipshould come from the approved range of suppliers andshould have the appropriate certifications.Receiving these kinds of certifications (in contrast to theabove described for the CE mark) we could not turn toany independent accredited institution, or we cannot referto a different type of shipping approval we have. Everytime the whole certification procedure has to be performedagain, if we wish to work with another classification society.Accuracy is a special aspect in the instrumentationindustry. In case of examining the accuracy we are curiousabout the ability of providing suitable measurement, whilethe possibility of causing catastrophic situations has onlysecondary importance. Certain countries (for exampleRussia) have uniquely strict measurement regulationscovering all application areas.All instruments (from the simplest float switches to thecomplex radar level transmitters) should undergo deeptype-approval procedures independently for its applicationarea. Regulations within the European Union andseveral other countries are more permissive. They requireonly application-dependent approval procedures.A typical example for the application-dependentmeasurement regulation is the OIML. In the OIML R85,the requirement for accurate measurement is standardizedconcerning tank measurement of custody transferproducts (for example gasoline, diesel). Obviously thesekinds of products generate a high level of state-interest,through the imposed taxes, therefore all the politicalpowers are seeking precise control. An essential way forthis purpose is the binding of the accuracy of applicablemeasuring instruments by the law. The OIML R85standard is compulsory in all countries of the EuropeanUnion, which allows only 1mm measurement error on thetotal measurement rangepractically independentlyfrom the size of themeasured tank. This isonly 0.01% of toleratederror in the case of a10 m tank height!It would be too much to list all the approvals and certificationsavailable within the NIVELCO’s total portfolio.Every NIVELCO designed and manufactured device haswhichever of the above mentioned documents is relevantand they are downloadable from our website. Furthermorethe manufacturing of NIVELCO is in compliancewith the ATEX (94/9/EC), RoHS (2002/95/EC) and thePED (97/23/EC) Directives. Almost all of our products areavailable to order in explosion-proof versions (in accordanceto ATEX and/or IEC Ex), while products sold inRussia have received the regional metrology certifications.The most frequently used NIVELCO level switches for theshipbuilding industry have BV, GL and DNV approvals.NIVOMAG magnetic coupling level switches have receivedSIL1 certification, and NIVOTRACK magnetostrictivetransmitters meet the requirements of the OIML R85standard.dr. Gábor KunHead of Research & DevelopmentNIVELCO Co.gkun@nivelco.com23

Level measurement of a tank farm in beverage productionCoca-Cola HBC HungaryThe Coca-Cola Company is the world’s leading beverageretailer, distributing nearly 2400 products in more than200 countries all over the world. The Hungarian site ofCoca Cola Company in Dunaharaszti operates 2 bottlingand 10 regional distribution centres, employing morethan 1400 workers to meet its annual production capacityof one billion litres. Thanks to the previous successfulinstrumentation projects of NIVELCO – presented in the2010/1 issue of our Magazine – we received a newrequest in this year for providing further instrumentationsolutions for other tasks.Accuracy of this “measurement” was much less than therequired 0.5%, which is a general requirement insidethe factory for all measurement tasks. Therefore improvementof the instrumentation was necessary andsignificant in order to provide a safer environment in theaspect of OSH (Occupational health and safety) likewiseto increase the level of measurement technology.Tanks of the carbonated soft-drink production line inDunaharaszti were equipped with a low and high levelswitch and also an out-of-age visual level indicator.This solution was quite dangerous because the staff hadto use a 4–5 m tall ladder for reading the actual level.Regarding the customer demands and the neededmeasurement accuracy, we made an offer for acontinuous level measurement solution, for 17 standingstainless steel tanks, after a careful site-survey. We offeredfor this task our guided microwave MicroTREK radartransmitters. Further demands were the local displayof the measured values and centralised parameterisationpossibility of the transmitters. The obvious choice for thispurpose is the MultiCONT multichannel process controller.Summarisation and displaying of the measurement datais performed by a PC running the NIVISION processvisualisation software.24

Level measurement of a tank farm in beverage productionThe main advantage of microwave(radar) level measurement is the±5 mm accuracy along with themaximal operational safety. Moreoverthe measurement is independent ofdielectric constant, temperature,pressure and density changes andapplicable for mediums with turbulentsurface, and capable of ignoringdense dust, vapour or pressurized gaslayers above the product surface.It is a key feature that MicroTREKtransmitters are suitable for using inand with CIP (Clean-In-Place) procedures which involvesa 90 Celsius alkaline and acidic cleaning process.In the aspect of the demand for a local display, the17 tanks can be divided into 3 sections:Production line: 8 pieces of MicroTREK HTFtransmitter communicating with aMultiCONT PEW 18B 1 process controllerProduction line: 7 pieces of MicroTREK HTFtransmitter communicating with a secondMultiCONT PEW 18B 1 process controllerConcentrate tanks: 8 pieces of MicroTREK HTDtwin-probe transmitter connected to twoUNICONT PDF-501 loop indicators. The UNICONTunits provide local display of the measured data andtransfer the HART signals to a MultiCONT placed inthe control room.In order to be able to use the whole capacity of the tanks,a special mechanical solution was necessary to beconstructed on the top of the tanks. The special narrowstandpipe facilitates that dead-zones of the transmitters are‘shifted’ outside of the tanks so even the highest level ofthe filling does not reach the instrument dead-zone.The concentrate, diluted with water, comes from thedissolving-tanks, and in the production-tanks more sugarand further water is added, and circulation mixing starts.The parameters of the exact recipe were determined on thebasis of several measurement steps. Therefore it wasessential to increase the measurement accuracy becausethe contents data is indicated in litres via a linearizationtable. Along with the level measurement there are alsofrequent laboratory tests checking the compliance of theratio between each component. After the step-by-stepmeasurement and the blending, the finished carbonatedproducts pass into the bottling-line. The accuracy neededto keep to the required formula of the recipe is achievedby a 20-point linearization table. With the help of theMultiCONT multichannel process controller it is very easyto specify a linearization table, in this case we assigned themeasured value in millimetres to volume in litres.The MicroTREK transmitters transfer measurement signalsto the MultiCONT controllers by HART communication.The MultiCONT units collect the data of the three sectionsof the tank-farm per groups and communicate with thecentral control computer using an RS 485 communicationline. On the PC our NIVISION process visualizationsoftware performs reliable visual indication of the tank-farm.Tibor AsztalosRegional RepresentativeNIVELCO Co.tasztalos@nivelco.com25

Level measurement in the chemical and pharmaceutical industriesDemands on high-technologymeasurements in aNorth-Hungarian Chemical-worksIn the chemical and pharmaceutical industries the accuratemeasurement of materials in the stock-storage silosis regulated by ISO standards, so the applicable measurementinstruments have to satisfy increased requirementsin this industrial area.The primary demand is high accuracy, independently fromthe measurement range. The minimal accuracy neededis 5 mm, but in several cases measurement values haveto be provided within a measurement error of 1–2 mm.In parallel with high accuracy, the long-term operationalstability required is even more stringent. The applicableregulations define several calibration procedures to beundertaken on an annual basis, without the possibilityof transporting the instruments to the factory for anyreparation or adjustment. In most cases the specialmediums to be measured require explosion-proof instruments.Moreover the instruments have to be suitable forthe measurement of materials with a low dielectricconstant (ε r).There are two product families of level transmitter solutionsdeveloped and produced by NIVELCO ProcessControl Co. which satisfy these requirements:NIVOTRACK M-500/600 magnetostrictive leveltransmitters:Typically we offer rigid rod probe versionsof NIVOTRACK transmitters up to 3-meter probelength, and flexible probe versions are recommendedabove 3 meters because of easier packaging,transporting and handling. The wide range of theapplicable floats provide reliable solutions for lowdensity (below 0.85) mediums up to 0.4 g/cm 3 viscosity.Moreover this measurement method is independentfrom the relative dielectric constant (ε r) of the measuredmedium. Stainless steel probes are not applicable foruse in chemically aggressive mediums, in this case weoffer a PFA plastic coated probe version with aplastic (PP or PVDF) float.MicroTREK H-400/500 microwave level transmitters:MicroTREK guided microwave level transmittersare very popular, especially for high temperatureapplications. Flange temperature of the stainless steelprobe versions can reach 200 °C, moreover themeasurement is not affected by physical parameterchanges of the medium, such as temperature orpressure. Since the reflection of the microwave signalsis highly dependent on the relative dielectric constant(ε r) of the measured medium, it is essential for microwavemeasurement to have ε r >1.4. In the case ofhazardous substances it is necessary to use intrinsicallysafe devices. In the applications where transparentHART communication is needed to provide remoteparametering, NIVELCO offers its new development,the UNICONT PGK-301-B Ex isolated power supplymodules.26

Level measurement in the chemical and pharmaceutical industriesÉMV Incineration Plantin Sajóbábony, HungaryThe Incineration Plant of the North-Hungarian ChemicalWorks in Sajóbábony provides a very good example ofhigh-technology instrumentation. Thanks to intensivedevelopment and investment activities, the total tank-farmhas reached 4000 m 3 total storage capacity with17500 tons/year waste-to-energy capacity.This energy-content is sold in steam or hot-water form.The industrial and communal wastewater is treated bythe wastewater works which has a 6200 m 3 /day hydrauliccapacity and the Chemical Oxygen Demand (COD)capacity is 55000 kg/day.3 pieces of NIVOTRACK MTC-530-8 Ex magnetostrictivetransmitter with rigid probe, Measurementrange: 3 m. Accuracy: 1 mm, Output: HART4 pieces of MicroTREK HHR-428-8 Ex guided microwavetransmitter, Measurement range: 2.6m.Accuracy: 3 mm, Output: HART11 pieces of UNICONT PGK-301-B Ex 4…20 mA /4…20 mA analogue isolated power supply modulewith HART interface3 pieces of NIPOWER PPK-331 type 230V AC/24 V DC power supply module1 MH-02 type HART modem1 process controller PC with NIVISION softwareThe successful instrumentation project has involved:4 pieces of 6m tall standing xylol tanks3 pieces of 3m tall lying boric acid tanks4 pieces of xylol distillation tanks, with a temperaturerating of 130°C, and pressure of 3 barThe low relative dielectric constant (ε r) and hightemperature of the measured mediums made the measurementmore difficult. The average temperature xylol andboric acid tanks have been equipped with magnetostrictivetransmitters, and the high-temperature xylol distillationtanks use guided microwave transmitters.The applied instruments are the following:4 pieces of NIVOTRACK MTK-560-8 Ex magnetostrictivetransmitter with flexible probe, Measurementrange: 6 m. Accuracy: 2 mm, Output: HARTThe system component modules are placed in a commoninstrument rack. The three power supply modules supplythe level transmitters via the intrinsically safe isolatormodules. The HART signals of the transmitters are transferredto a process controller PC. The PC processes themeasurement data and visualizes the flowchart ofthe tank-park with the actual measurement results.Furthermore the processed data got archived. NIVISIONsoftware determines the low- and high level limit valuesfrom the measured levels and provides reliable datafor the filling and emptying processes.Sándor UjfaludiRegional RepresentativeNIVELCO Co.sujfaludi@nivelco.com27

NIVELCO, as a prime contractorExpanding our profilewithin a local investmentCompanies in Hungary which have established commercialrelationships with NIVELCO in the past 30 years arepredominantly subsidiaries of some international (foreignbased)parent companies. According to the managementstrategy of these companies, they are trying to decreasetheir maintenance teams and operational personnel toa minimum.Consequently they are not able any more to implementmedium-size (compared to the size of the company)construction jobs within their own organization. Thereforethe implementation of these investment projects has beenperformed with the assistance of an outside contractor.In the case of new investments, the related organising jobis coordinated by the prime contractor - likewise there arealso many demands from the customer on completecommissioning of all smaller tasks. For the first time itshistory, NIVELCO acted as a prime contactor and madenew kinds of successes in this area. In the frameworkof the project detailed in the following, NIVELCO designedthe whole process controller system, of course usingmainly NIVELCO instruments.In the Industrial Park of Szentgotthárd, the Hungariansubsidiary of the American-based Allison TransmissionInc. (the world’s largest manufacturer of fully-automatictransmissions) established a new production hall.The key element of the production line is the oil containertank-farm with its complex instrumentation and electricalinstallation tasks.NIVELCO had to provide a complete solution, to includematerial specifications for the electrical system, andincluding wiring tasks, instrumentation and all accessoriesfor the process automation system. Finally the customerhas chosen NIVELCO thanks to the high technical levelof the offered solutions, especially the level instrumentation,the stainless steel control panels, and the galvanizedcable mounting structures. Moreover NIVELCO wasbeing proven as a reliable partner in the design of thecomplete technological implementation along with theprovided great price/value ratio. As a standard task, thecontinuous measurement of lubricant oil and emulsiontanks, and the control of filling-emptying pumps was alsodesigned and commissioned by NIVELCO. Since thefacility operates in a JIT (Just In Time) production strategy,any failure of the process control system hinders the productionseriously, so indication of alarm and warningsignals for the monitoring system was necessary.28

NIVELCO, as a prime contractorMeasurement solutionsMicroTREK HT-400 series guided radar transmittersmeasure the level in oil and oil-emulsion tanks.The control system continuously monitors the quantityof the homogeneous media, the level of each specifictank and the total quantity of the tank-farm, providinga reliable source of information for the filling andemptying processesMeasurement signals are processed by a MultiCONTmultichannel process controller in a HART multidroploop. HART communication facilitates centralizedsignal processing and provides easy access to changethe parameter-base of the product-specific technology.The local personnel decide which incoming materialshould be stored in which tank, based on the displayedvalues on the MultiCONT.Overfill protection on the tanks is achieved byNIVOMAG 210 4L magnetic level switches. To avoidthe possibility that any leakage may happen whenusing side-mounted equipment, the L-arm typeNIVOMAG was chosen for this reason. In additionto this, the required switching differential parameterswere easy to provide with this version.Leakage detection on the double-walled tanks is achievedby NIVOSWITCH RCM-400 vibrating forks.Thanks to the vibrating forks, the process controlsystem is able to indicate any negligible (comparedto the size of the tank) quantity (even a decilitre) ofleaking oil.Two UNICONT PJK-100 universal interface modulesare connected in the RS485 line, determining low andhigh fail safe level from the measured values, and thesemodules provide quick intervention if necessary.The filters and pumps used in the production plant arecontrolled by differential pressure switches. However althoughthese are not NIVELCO products, the measurementsignals from these instruments are also integratedinto the process controller system, therefore they are ableto indicate alarm signals. Also NIVELCO delivered the2 butterfly-valves which provide alternating filling for theemulsion-collecting tanks. Local electrical wiring and thestainless steel control panels were installed by a subcontractorpartner. The end users were fully satisfied with thequality of the finished project regarding as a great successfor NIVELCO’s local engineering team.Ákos NollRegional RepresentativeNIVELCO Co.anoll@nivelco.com29

NIVELCO in mechanical engineering automation (Hungary)Linamar Precision Part ManufacturingSite in Békéscsaba, HungaryLinamar Hungary is the Hungarian subsidiary of Canada'sleading automobile parts manufacturer. One of itsproduction halls is the PPM (Precision Part Manufacturing)in Békéscsaba, working in the place of the formeragricultural-machinery factory. Linamar produces steelautomotive parts in four main phases: casting, machining,purification by a high pressure cleaning system, thencoating on request. The high pressure cleaning systemwas instrumented with NIVELCO products.Instruments of the technologyEach workpiece comes under high pressure when it isinserted in the cleaner. Then the machine performs theneeded filtering-cleaning wash and finally rinses the workpiecebefore repeating the cycle.This washing procedure is under200 bar pressure, done with ahigh purity mineral oil.The filtering-cleaning CommonRail equipment removes anypossible small (0–3 μm) particlesor pollution remaining from themachining process. The washingliquidstorage tank of theCommon Rail equipment isinstrumented with two intrinsicallysafe mini compact typeNIVOTRACK MMA-504-6 Extransmitters. These models arethe same as the standard versionexcept for the 8 mm diameterprobe tube and the small 28 mmdiameter magnetic float. The 1” process connectionprovides a suitable solution for the small tanks used in thisapplication. The highly precise magnetostrictive transmittersare responsible for continuous level measurement ofthe washing liquid and perform level control of the tank,controlled by the 4–20mA output signals. A PLC receivesthe output signals and controls the filling-emptying pump.The accuracy of the NIVOTRACK transmitter is 1mmwhich fully meets the requirements of the measurement.Along with the level measurement instruments, someadditional NIVELCO devices have been installed as well.The local display of the measured levels is done byUNICONT PDF-501-6 Ex loop displays.The UNICONT PDF-s arein the local control room,quite far from the technologicalprocesses, so themeasurement results canbe read easily outside theproduction hall. Sensing,monitoring and displayingof the washing pressure isan essential parameter ofthe cleaning process.For this task, NIVOPRESSDBC-5H1-6 Ex hydrostatictransmitters with a SAP-200 display have been chosen asan excellent solution. Since the applied transmitters areexplosion-proof versions it wasnecessary to use 4 20 mA isolatedpower supply units for the transmitters.The newly developed UNICONTPGK-301-B Ex modules wereoffered for this purpose. NIPOWERPPK-331-1 power supply modulesgive supply voltage for theUNICONT PGK-s and thus for thetransmitters. Thanks to theseaccurate measurements, continuousoperation is ensured for the cleaningsystem and the efficiency ofthe whole production operationincreased significantly. In the frameworkof a future project, allmeasured data from the instruments will be integrated andprocessed by NIVELCO’s NIVISION process visualizationsoftware.Ferenc DékányRegional RepresentativeNIVELCO Co.fdekany@nivelco.com30

NIVELCO measurement system in sponge production (Romania)Instrumentation of Spumotim’ssecond plant in Pitesti, RomaniaSpumotim is an automotivesupplier company manufacturingmultiple kinds ofsponge for car-seats.Moving the production plantcloser to the Romanian carmanufacturer Dacia (a subsidiaryof the French carmakerRenault), Spumotimestablished its second plantin Pitesti. The first plant inTemesvár, built in 2006, wasinstrumented with NIVELCOtransmitters, where they were very satisfied with theNIVELCO products - especially in terms of the productquality and the support service - so they again choseNIVELCO instruments. The shape and the durability ofa sponge are only two from the numerous aspects thatmanufacturers have to take into consideration during thedesign of car-seats. It is essential in terms of comfort andsafety to achieve the proper composition of the compoundingmaterials. That’s why continuous level measurementis needed in the tanks of the raw materials for theproduction process. The instrumentation tasks includelevel measurement, level switching and continuous stockmanagement on 4 polyol and 4 isocyanate tanks.The following instruments were installed:8 pcs. EasyTREK integrated ultrasonic transmitter8 pcs. NIVOSWITCH compact vibrating forklevel switch1 MultiCONT expandable multichannelprocess controller4 pcs. UNICONT PJK universal interface module1 unit of NIVISION process visualization software,with accessoriesThe complexity of theinstrumentation task wasincreased by the requirementto provide accessfor the centralizedstock management ofthe two plants from onecommon control centre.For the level measurementtask, the bestknownEasyTREKintegrated ultrasonictransmitters were chosen,following experience in the plant in Temesvár,because its accuracy and reliability fully meet the requirementsof this measurement task. Measurement signalsare processed by a MultiCONT PR-200 expandablemultichannel process controller. With the help of HARTcommunication the process values are transferred via anRS485/Modbus serial line to the process controller PC.The MultiCONT is also responsible for the high alarmindication which is realized with UNICONT PJK-100universal interface modules. The low-level switching isperformed by NIVOSWITCH RFM-400 compact vibratingfork level switches and the relay outputs of the switchesare connected to an indicator panel.The NIVISION process visualization software receives themeasurement data from the MultiCONT and visualizesthe actual level on the tank-farm. The controller PC inTemesvár and the central management PC are alsoconnected via a remote desktop connection to this PCrunning NIVISION. The complete installation, programmingand configuration tasks for the NIVISION weredone by NIVELCO Romania’s team.András Olteán-PéterFinancial DirectorNIVELCO Tehnica Masurarii SRLaoltean@nivelco.com31

Concrete manufacturing plant for Ekocem (Poland)EchoTREK transmitters help to optimizeoperations at a concrete manufacturingplantMeasurement of sand, cement and different sized gravelis performed in 10 m tall silos in extremely dusty environments.Stones are loaded directly into the silos, producingquite high acoustic noise and strong vibrations. All deliveredinstruments work reliably and provide credible sourcesof information about level in the silos.One of our prospective customers asked for a quotationfor replacing an out-of-date level metering system(produced by one of our competitors) for controlling thelevel of sand, cement and different types of gravel in segmentedsilos. In addition to this, the system has to ensuresafety with a fail-safe high level indication, even in thecase of a failure of the level measurement. Experts fromNIVELCO-Poland proposed the well known ultrasoniclevel meters for solids, the EasyTREK SCD-340-4 typewith HART communication. Additional elements of thesystem included a MultiCONT process controller unitexpanded with UNICONT PJK universal interface modulesfor control of filling and emptying the chambers of the siloas well as to generate a high level alarm.The operational processes became more fluent andthe control process for filling and emptying becamefail-safe with the overfill protection added by the additionalEasyTREK SCD. In a very important benefit for theworking environment, the system helps to improveworking conditions, the safety at work, and the health ofemployees, previously exposed to extreme dusty and unhealthyconditions.All instruments work in HART Multidrop loops, whichallows remarkable cost-savings on the installation. Duringthe mounting of the instruments the proper location hadto be considered carefully, especially for the high levelalarm sensor, because the mounting console is above thefilling apparatus. All of the control and alarm signals wereintegrated with the existing control system on the plant.Mechanical and electrical installation was done by theNIVELCO-Poland team, in addition to commissioning,configuration and optimization of the instrument settings.The whole system operates flawlessly, since it has beenbrought into use for the great satisfaction of the customer.Darius PiszerCEONIVELCO Polanddpiszer@nivelco.com32

Process Instrumentation – Concrete production plantThe demand for high quality concrete is growing rapidly,due to the changing requirements of the constructionindustry. Extreme construction conditions and tougherregulations are the main driving forces behind this change.To satisfy the demand, production of high quality concreterequires state of the art instrumentation and computerizedcontrol.The main production units of the plant are:Cement storage silosSand, gravel storage silosAuxiliary storage tanksWater tanksWeighing systemMixerMixed concrete storage tankTruck washer systemInstrumentation of the cement storage silos:The cement arrives at the plant by truck and it is transferredinto the silo by pneumatic filling.It is important to continuously monitor the level of thecement, the air pressure above the cement level andprovide an indication of high and low fail safe levels.MicroTREK HTN-4xxx guided microwave level transmittersare recommended for level measurement, NIVOROTAEKH-4xxx rotary paddle level switches for low/high fail safeswitching and NIVOPRESS DTF-5xxx pressure transmittersare recommended for pressure measurement, with theUNICONT PMG-411 type display and controller.Instrumentation of sand, gravel storage silos:The level measurement of these silos can be done withguided microwave radars or EasyTREK SCD-3xxx typeultrasonic level transmitters. For low/high level switchingvibrating rod or vibrating fork level switches are recommended.The low level switches always have to be mechanicallyprotected from damage by a plate mounted abovethem.Instrumentation of the water storage tanks and dirtywater tanks:For level measurement, ultrasonic level transmitters arerecommended (EchoTREK or EasyTREK) while level switchingcan be done by NIVOMAG MKA-2xxx type magneticcoupling level switches. The flow measurement of thewater used in concrete production is done by ISOMAGmagnetic flowmeters which have dosing/control functions.33

Process Instrumentation – Corn millThe production of culinary flour is made from grains: thesegrains are ground into flour.The main production units of the plant are:Stock storage silosSifter (separation and cleaning)Steep (with sprayed water)Rolling millsSeparation of flour and branGround flour or bran storage silosTransport with trucksThe stock storage and the finished product storage silosshould be considered in the aspect of the instruments.Instruments of stock storage silos:Continuous level transmitting with MicroTREKHTN-4xx-6 Ex guided microwave level transmittersAccessory instruments: NIPOWER PKK-331 powersupply, UNICOUNT PDF-401-6 Ex process indicatordisplay, UNICOUNT PMM-311 universal controllerIndication of full or empty status with high/low failsafe limit switchesSuitable level switches: NIVOROTA EKH-4xx -5 Exrotary paddle level switch, NIVOCONT RKH-5xx-5 Exvibration rod level switch, NIVOSWITCH RRH-3xx-B Exvibration fork level switchMultipoint temperature transmitting in silos:THERMOPOINT TMM-5xx-5 Ex with HART outputMeasured values can be displayed and stored in aPC. The PC could be connected to the THERMOPO-INT thermometer by using a MultiCONT PRW multichannelprocess controller or a SAT-304/SAK-305HART/USB/RS485 modem.Instruments of finished product silos:Continuous level measurement with MicroTREKHTN-4xx-6 Ex guided microwave level transmitters.Accuracy of the measurement allows the fillingcontrol of the trucks.Indication of full or empty status with high/low fail safelimit switches. Vibration fork level switches are notrecommended because of the cohesion of the flour.Ferenc KusztosTechnical ConsultantNIVELCO Co.fkusztos@nivelco.com34

nivma11a0603iNIVELCO – official sponsorof the Hungarian Paralympic Team