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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
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