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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sourcesof information about level in the silos.One of our prospective customers asked for a quotationfor replacing an out-of-date level metering system(produced by one of our competitors) for controlling thelevel of sand, cement and different types of gravel in segmentedsilos.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
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