Level Measurement Blog Feed

Multiple Options for In-line Solids Flow Monitoring

 

Monitor Technologies’ offers a variety of solids flow sensors used to automate and enhance process performance.
The QuantiMass(TM) solids flow sensor measures the flow of quantities in pneumatic conveying & free-falling processes. The sensor is based on the latest microwave technology to provide fast, accurate and reproducible in-line measuring without the use of weight scales. The sturdy, non-intrusive design of the sensor minimizes maintenance. In addition, the compact size of the sensor makes for easy installation into existing processes. Totalizer feature can provide a sum of the mass flow for a period of time. Suitable for powders, dust, sand, grain, dry ingredients, pellets, dry chemicals, granular up to 0.75 inch (2cm) and more. Available with a DIN-rail transmitter to connect with an existing control panel or a controller to provide local operator interface.

The Model SFD-2 and SFI solids flow detectors from Monitor Technologies, LLC provide analog or relay outputs to indicate the flow / no-flow condition of powder and bulk solids materials in chutes, feeders and pneumatic conveying lines. These units use microwave Doppler radar technology that makes them extremely reliable. Their rugged design withstands the rigors of the installation and process extremes. From automated systems with pneumatic lines to gravity chutes, solids flow monitors can help to improve process performance. They can assist in detecting flow problems, as well as, enhance the level of automation at a facility like turning a conveyor on or off.

For more information visit www.monitortech.com or contact Monitor's Technical/Application Support Team at Tel.: 1-630-365-9403.

Level Measurement e-Newsletter / Tech Tip Archive

 

Welcome... Below is a list of current and past issues of Monitor Technologies' e-Newsletters / Tech Tips. These issues cover a variety of application and product topics regarding level measurement, solid flows monitoring, moisture measurement, bin aeration, particle emission (dust) detection and more. In addition, please visit Monitor's Web site for more product and application information. Web site: www.monitortech.com

Join our E-newsletter / Tech Tip List!

• Tech Tip - September/October 2021
  
  Ensure Proper Moisture Content and Product Quality; Versatile RF Capacitance Level Sensor; Optimize Dust Monitoring
  
  
• Tech Tip - June/July 2021
  
  Wireless Communication for Continuous Level Sensors; Dust Monitors with Hazardous Location Approvals; Vibratory-Style Bin Level Indicators MarComm2013
  
  
• Tech Tip - March/April 2021
  
  Minimize Costs & Ensure Process Efficiency with Moisture Measurement System; Reliable & Affordable Level Indicator and Plugged Chute Detector; Remote Inventory Management https://conta.cc/3kEdW3q
  
  
• Tech Tip - January/February 2021
  The Many Uses of the Level Indicator; Easily Check Silo Inventory Levels from Anywhere; Material Fluidization Devices
  
  
• Tech Tip - October/November 2020
• Know Your Material Inventory Levels Anytime from Anywhere; Dust Monitors with Hazardous Location Approvals
  
  
• Tech Tip - July/August 2020
• Getting the Most out of a SiloPatrol Level Sensor; RF Capacitance Level Sensors With Ultimate Haz Loc Protection
  
  

• Tech Tip - April/May 2020
• Low Voltage Level Indicators; Level Sensors With Ultimate Haz Loc Protection; COVID-19 Update
• 
  Tech Tip - February/March 2020
• Simplify Installation of Bin Level Sensor with Insertable Paddles; In-Line Moisture Measurement Sensor
  
  Tech Tip - November/December 2019
• Reliable & Flexible Solution for Level Measurement and Inventory Management; In-Line Solids Flow Measurement Sensor
  
  Tech Tip - July/August 2019
• Flexible Bin Level Solutions; Flow Detection
  
  Tech Tip - March/April 2019
  • The "Dynamic Duo" for Continuous Level and Silo Inventory Management; Dust Emission Trend Monitor
  • 
    Tech Tip - Jan/Feb 2019
    
  • Protecting Against Silo Overfills; Aiding Material Flow; New Full Line Brochure
    
    Tech Tip - Oct/Nov 2018
  • Are Inspections Needed on Level Sensors? ; Fluidization Solution; Monitor Celebrating 60 Years
    
    
  • Tech Tip - Aug/Sept 2018
  • SiloTrack Cloud Web App; Selecting the Proper Paddle for an Application
    
    
  • Tech Tip - June/July 2018
  • Level Sensors with Haz Loc Approvals For Dust; Continuous Level Measurement of Lightweight Material with Low Dielectric Constant
    
    
  • Tech Tip - April/May 2018
  • Solutions for Low Cost, Low Maintenance Level Sensing; Options for Material Fluidization; In-Line Moisture Measurement
    
    
  • Tech Tip - Feb/March 2018
  • TrueCap...Overcoming Material Build-up on Level Indicators; The Latest Products From Monitor Technologies; Continuous Level Suggestion for Granulated Carbon
  •  
  • Tech Tip - Sept/Oct 2017
  • New Generation of Dust Monitor; RadarRight Level Monitoring for Dynamic Storage Situations; Cost-Effective Level or Backed-Up Conveyor Chute Indication
    

     
  • Tech Tip - July/August 2017
  • NEW DuraVibe Vibratory Level Sensors; In-Line Moisture Measurement to Ensure Product Quality; Simple Insertable Paddle
    
    
  • Tech Tip - May/June 2017
  • Solutions for Material Fluidization; Non-Contact Continuous Level Sensor; Plugged Chute Detection
    
    
  • Tech Tip - Feb/March 2017
  • NEW Non-Contact Continuous Level Sensor; Flexibility with RF Capacitance Level Sensors

 Join our E-newsletter / Tech Tip List!

Mass flow measurement for dust, powders and bulk solids

The QuantiMass^TM mass flow sensor measures the flow of quantities in pneumatic conveying & free-falling processes. It is well suited for powders, dust, pellets, and granular up to 0.75 inch (2cm).

The QuantiMass^TM system is ideal for applications such as monitoring material flow rates to verify blending mixture ratios; Monitoring for variable flow quantities due to disturbance like different densities; Measuring flow when filling trucks to avoid over-filling or under-filling; Monitoring when an entire batch has passed a certain point in a system; or Inventorying how much material is in a storage bin / silo.

The sensor is based on the latest Microwave doppler effect technology and provides fast, in-line (on-line) measuring without the use of weight scales.

The sturdy, non-intrusive design of the QuantiMass^TM sensor minimizes maintenance. In addition, the compact size of the sensor makes for easy installation into existing processes.

Data output can be provided through a controller for local operator interface or through a DIN-Rail transmitter for communication with an existing control system.

For more product details please visit:
http://www.monitortech.com/mass-flow-meter.shtml

Diaphram Switches as Over Flow Indicators

A simple and economic solution to plugged chute detection or material over flow indication is the use of a diaphragm switch.  This type of configuration has been used in feed, grain and seed processing for years.

How does it work?  A housing that contains a microswitch is activated by the depression of a flexible diaphragm.  The standard material of construction for the diaphragm is a thin rubber sheet, however, other materials such as very thin stainless steel, fiberglass, and other flexible materials are available per application.  When the material contacts the diaphragm, it depresses the microswitch.  The microswitch is a dry type contact that can be tied to a light, horn or some other process indicator/control.  A spring or counterweight returns the switch to the open position when the material moves away or cleared from the diaphragm.

The unit should be placed where falling material cannot hit it but material that would back up can activate it.  Typical applications could be the following:

1. On the top of a screw conveyor housing at above the discharge spout.
2. In the upper portion of the discharge housing of a belt conveyor, away from the regular flow of material.
3. On the top side of a declined chute.
4. In a vertical pipe, located in an offset "Y" with a short stub to mount the diaphragm switch.  Be sure to allow enough decline in the stub of the "Y" so that material can clear or fall out of the stub.  This is best used for very free flowing material.

The material being detected should be very free flowing, not allowing build up to occur on the face of the diaphragm switch.  The diaphragm switch can only be used in atmospheric conditions.  No air pressure or pneumatic conveying applications.

When looking for a simple and economical over flow indicator or plugged chute detector, please consider a diaphragm switch.

Ross M. Jamison

Technorati Tags: level sensor level measurement bin level indicator level control solids level indicator diaphragm switch plugged chute detector

Plug chute detector - Is there really such a thing?

Many instrument manufactures claim they have just such an instrument. Unfortunately it has been my experience this is simply not the case. Often these claims will promote instruments that will report only a symptom of a plug condition.

There are two general categories of sensors often touted as plug chute detectors; field disturbance and point level.

Field disturbance instruments detect motion – material flowing is motion and no material flowing is no motion. Sensor 'A' depicts microwave solids flow field disturbance detector. Unfortunately field disturbance sensors cannot differentiate between a plugged no-flow condition and an empty no-flow condition. A logic function must be employed to compare the material flow state against the operating state of the process. If no-flow is detected and the process is operating with sufficient material feed/supply then a problem can be concluded. If no-flow is detected and the process is shut down or material feed/supply is exhausted it can be concluded there is no problem. Not exactly straight-forward.

Point level sensors detect the absence or presence of a material at the exact point at which they are installed. Unfortunately, these devices may not reliably differentiate between a saturated dynamic condition (e.g. flow stream) and a highly saturated static condition (e.g. line plugged). And don’t even mention the physical punishment imparted on a sensing element!

So how does one detect a flow blockage in a timely fashion?
Like many other situations it comes down to choosing the best of the options available. My experiences have proven that clever installation of a point level sensor can prove the most fool-proof method.
The big secret: install the point level sensor in an area that the material will occupy only in a plug condition. It is often necessary to make some modification to the process so as to isolate the point level sensor from the material flow stream. Sensors 'B' depict rotary paddle type and RF capacitance type point level sensors in just such an application. With this method it is very important to ensure the point level sensor is in an area that will clear of material when the plug condition passes.

With all the details presented up front it will be much less stressful for an engineer to properly instrument a process to achieve the desired results.

Andy Bowman

Technorati Tags: plugged chute detector plugged conveying line solids flow detector

Are you all plugged up?

Trying to detect when a pneumatic conveying line plugs can be challenging.  A line can plug at any moment, usually without notice and typically at the worst time for it to happen.  Then begins the expensive and time consuming process of taking the line apart to find and clear the plug. 

Some systems use a pressure transducer to detect when the line is starting to plug.  When a plug starts, there will be resistance and an increase in line pressure.  The blower has to work harder to try and blow the plug free.  A rise in convey line pressure occurs and the pressure switch gives an indication.  This may be fine for shorter conveying distances but when the distance is great and/or the diameter of the pipe becomes large, the pressure transducer may not react quickly enough.  Sometimes pressure oscillations from material feeding into the line can cause erroneous errors.   The signal may not offer a stable enough signal to monitor.

The use of a microwave flow/no flow detector can aid with the plugged convey line scenario.  Using the Doppler effect, the detector can tell if the normal flow of material is beginning to slow.  The best place to locate this device is near or at the end of the convey line.  If the line begins to plug, it can detect a lessening flow and go into alarm mode.  The flow/no flow detector can be used in conjunction with a pressure transducer to confirm a plugged situation.  The flow detector can be tuned to the particular application for sensitivity and alarm delay.  In this manner, the operator can use the pressure readings to further determine if a plug condition is starting.  Consider the use of a flow/no flow detector as an “umbrella” policy for your conveying lines. 


Ross Jamison

Technorati Tags: plugged chute detector plugged conveying line solids flow detector

Avoiding explosive situations in coal power plants

According to the DOE coal is "the workhorse of the nation’s electric power industry, supplying more than half the electricity consumed by Americans".  Given that 1/4 of the world's coal reserves are located in the USA it's not a wonder that we as a country are investing in developments that will make coal-fired power plants more efficient and more emission-free.  The US government in 2003 funded an initiative with $1 billion to study and develop the worlds first zero-emission coal-fired power plant in conjunction with hydrogen technology.  This is called FutureGen.  For more information on FutureGen take a look at this link.

While FutureGen and initiatives like it are designed to strengthen the USA's position in the future, we have to deal with making coal-fired plants of today work efficiently and safely.  With that regard I have noticed that coal fired power plants tend to use solids flow detection as a means of providing critical process flow feedback and protecting the feeding system from material backup that might become a dangerous situation.  Here is a good example of how a solids flow detector can be used in this situation.

PROBLEM:
A coal-fired power plant in India, Hindalco Industries specifically, wanted to detect the presence of coal flow from their feeders to the furnaces. A plugged chute or equipment failure would possibly go unnoticed until a more serious problem occurred. Knowing whether the coal was positively feeding into the furnaces was of paramount importance to the efficient operation of the power plant.
SOLUTION:
Most all coal-fired power plants have this problem. If coal flow is interrupted this quickly effects the efficient operation of the plant. The solution to Hindalco’s problem came with the use of a microwave solids flow detector.  These devices are a non-invasive microwave device that uses Doppler-radar technology to monitor the flow of powders and other bulk solids, like coal from the feeder. The sensors are rated for hazardous areas, like Class II, Div. I locations.

Doppler-radar is used in weather system detection and analysis and the technology is ideally suited for solids flow detection.  It is non-invasive and potentially non-contact.  It will detect the flow of a wide variety of powders and other bulk solids in chutes and pipes.  It is relatively low-cost as a flow sensor and is very reliable.

Joe Lewis

Technorati Tags: solids flow detection solids flow monitoring flow monitor coal flow solids flow detector

What's useful to you?

So what industry websites and tools do you use?  I'd really like to know how useful our visitors feel that industry sites like Powder and Bulk Dot Com are to them.  There appears to be some great content at this website.  I personally think the discussion forums, the News Center summaries and the Case Histories are valuable.  But to be useful the user and readers need to be in charge.  While I have nothing to do with the creation or content on the particular site mentioned previously, I am interested in what you think.  And, if you are really in the powder and bulk solids processing industry or in the need for instruments or PBS equipment and take the time to comment on this blog post I will make sure we send you a "thank you" gift in return (we can get your mailing data by email after you post a comment).  The gift will include one of the popular industry white papers on continuous level measurement along with a marketing premium (small token or gift) from Monitor Technologies for you to use.  All comments are screened.

In addition to the website mentioned above, do you actively review magazine websites and their forums and product news information?  Take a look at some of the better ones in our industry, such as Processing magazine, chemengonline - Chemical Engineering, Powder Bulk Solids magazine, Powder Bulk Engineering magazine and Canadian Process and Equipment Control News.  Are any of these sites useful to you?  If yes, why?  If no, why not?  What can these sites and this blog do to be of service to you?

Let's start a conversation!

Joe Lewis

Technorati Tags: level sensor level measurement bin level indicator level control solids level indicator

Get fed automatically

Want to read the Level Measurement weblog whenever their is a new posting?  Want to read it without coming back to the blog to check to see if anything is new?  You can make that happen.  Ever hear about RSS feeds and newsreaders?  A newsreader is a free web tool you can use to read any blog you subscribe to.  It's simple and there are lots of blogs out their, close to 80 million as we speak.  I use bloglines and I recommend it, though there are many others.

It's quick and easy to begin using a newsreader.  Go to Bloglines and register if you don't already have a newsreader you use.  The registration process is quick and easy and you can use it for subscribing to as many blogs or RSS feeds as you want.  After you register with a user name and password, just subscribe to the Level Measurement blog by copying the blog URL into the subscribe page at Bloglines.  If you want to learn more about using RSS feeds and newsreaders I recommend Seth Godin's blog post on this subject as he is very knowledgeable and can be entertaining too.

Once you are setup using Bloglines or some other newsreader you can also subscribe to this and other blogs by clicking on the subscribe link usually present in any blog.  Ours is in the upper right hand area of the main blog page just about the category listings.

If you need assistance, give us a call or email me.

Joe Lewis
Vice President
Monitor Technologies LLC

(note: comments and recommendations contained in this blog posting are personal opinion of the author and does not represent any view, position or strategy of Monitor Technologies LLC)

Welcome!

Monitor Technologies LLC offers superior solutions in level monitoring, solids flow detection, particle emission monitoring and bin aeration.

In the Technical Tips section, you will find information pertaining to specific application problems/solutionsr. Feel free to comment, question, and add to some of these tech tip blogs.

Let us put our creative solutions to work for you!