A prominent manufacturer specializing in wastewater disposal pipe systems encountered a significant obstacle: the server responsible for managing silo level data was no longer supported. Consequently, any system failure would render the material monitoring system inoperable. VEGA level transmitters, leveraging sophisticated radar technology and comprehensive digitalization, provided an effective solution.
Image Credit: VEGA Controls Ltd.
VEGA Level Transmitters: Delivering Tangible Benefits to Plant Operators
Accurate level data is crucial for preventing silo overfill and ensuring efficient material throughput. Discharge mechanisms and conveyor systems require continuous oversight and recalibration to avert blockages and process inefficiencies.
At Poloplast in Leonding, Austria, silo level measurement relied on an outdated system until late 2019. This legacy system was increasingly unreliable and unmaintainable, creating an unacceptable situation that demanded a robust, future-proof solution.
This scenario highlighted the need for VEGA level transmitters and marked the beginning of a project that effectively showcases the added value for plant operators derived from the integration of advanced measurement technology and cloud-based digital evaluation solutions.
From Basic Inventory Tracking to a Bespoke Solution
Following an in-depth assessment and analysis of the existing infrastructure in late 2019, VEGA level transmitters were installed at critical points within the silos. These transmitters are designed for measuring ranges up to 20 meters, operating at process temperatures between -20 and +50 °C.
A significant hurdle in silo-level measurement is the substantial dust generation, which can compromise measurement accuracy. VEGA transmitters, however, consistently deliver dependable measurement results even under these challenging conditions.
Various models were deployed, including 55 VEGAPULS 6X units for level measurement, several VEGAWAVE 62 and VEGAVIB S61 level switches, and the intrinsically safe VEGATRENN 141 separator.
The transmitters were installed at strategic points in the silos. In this application, the expert knowledge of the VEGA employees really paid off. After all, precise level measurement in bulk solids handling systems is a core competence of the instrument manufacturer. Image Credit: VEGA Controls Ltd.
Transitioning Level Data Visualization to the Cloud
In 2021, the approach to data visualization also underwent a transformation. Signal processing and data transmission are now managed by the VEGAMET 625 controller, alongside the VEGASCAN 693 controller, which is capable of aggregating signals from up to 15 HART transmitters.
This data is then relayed via an Ethernet switch and a router to the VEGA Inventory System, a cloud-based solution. Here, the data is processed and made accessible to operators through a website that displays all measurement data.
This web-based software was specifically engineered for the collection and visualization of level data in applications such as storage tanks and silos. It functions as an ideal service for monitoring material levels and for vendor-managed inventory (VMI) initiatives.
Automated monitoring, coupled with limit-level alarm notifications, enables the early identification and resolution of potential issues before they impact production.
The VEGAMET and VEGASCAN controllers collect the signals from the level transmitters and send them pre-processed via a router to VEGA Inventory System in the cloud. From there, the measurement data is made available for visualization on a dedicated website. Image Credit: VEGA Controls Ltd.
Tailored Adaptations for Precise Level Measurement
The comprehensive solution implemented at Poloplast made use of the full spectrum of adjustment capabilities offered by VEGA instruments. This allowed for precise level alignment, ensuring individual adaptation to the specific requirements of the plastic processor.
The VEGAMET 625 controller features an integrated web server, facilitating straightforward integration into the company’s intranet/extranet. Three scalable current outputs enable the control of displays and downstream systems, such as a PLC.
Poloplast also employs an additional current output on the controller to directly use measurement data for controlling the conveyor system. The controller is further equipped with interfaces for straightforward long-distance data transmission, which are used for inventory monitoring in storage silos located at remote sites and equipped with VEGA level transmitters.
Conclusion
The experience at Poloplast demonstrates how early adoption of cutting-edge technologies not only enhances operational processes but also confers a distinct competitive advantage. The future of material monitoring is undeniably digital.
This information has been sourced, reviewed and adapted from materials provided by VEGA Controls Ltd.
For more information on this source, please visit VEGA Controls Ltd.