3d achtergronden

Transcription

3d achtergronden

Theoretische achtergronden
en selectiecriteria voor
niveaumeting op vaste stoffen
Alain ENGELS
Slide 1
Ultrasoon
(voor vaste stoffen toepassingen)
Theoretische achtergronden en selectiecriteria voor
ultrasoon
Alain ENGELS
Slide 2
VIK : Radar,Ultrasoon en Guided Wave niveaumeting
Ultrasonic - continuous improvement
1977- 84
First Nivosonic lines
1969
1985/86
Nivosonic 19‚ goes
microprocessor
Birthyear of Ultrasonic
1993
Prosonic
Fieldhousing +new sensor
generation
1996
Prosonic T
compact version
2 wire
2002
2005
Alain ENGELS
Slide 3
Time of flight measurement
Alain ENGELS
Slide 4
Ultrasonic measurement
The bat has the most ideal
ultrasonic system. With different
frequencies they can distinguish
between small and bigger
reflection targets and they can
great in there brain a picture
out of the reflections. So they
can find with this system during
night something to eat and they
can fly safe through obstacles.
Alain ENGELS
Slide 5
Alain ENGELS
Slide 6
Alain ENGELS
Slide 7
How far away is the
thunder storm?
Alain ENGELS
Slide 8
Distance
Distance == 344
1720m/s
m x t
53421
Ultrasonic measuring principle
B
t
D
L=E-D
E
D=
t
• vs
2
L
t
= run time of sound
vs = velocity of sound
B = blocking distance
Reflection on liquids
or solids
Alain ENGELS
Slide 9
Propagation velocity of ultrasound waves in gases
C
=
Rm =
T
=
M
=
X =
sound velocity
Universal gas Constant
Temperature
Molar mass
Adiabatic Index
Ex : Velocity (C) in the air at 20°C
Alain ENGELS
Slide 10
C =
1,4 x 8314,3 x (273 + 20)
28,8
(m/s)
(8314, 3 J/Kmol.K)
(°C)
( g / mole)
(= Cp/Cv)
Rm = 8314, 3 J/Kmol.K
T
=
20 ° C
M =
28,8 g / mole
X
= Cp/Cv = 1,4
= 344 m/s
Examples of Velocity of Propagation for Ultrasound
Gas
Speed [m/s]
CI
206
CO2
258
Ar
308
O2
0°C
O2 -183°C
178
NO
324
Air
Alain ENGELS
Slide 11
315
0°C
331
Air +20°C
334
Air +40°C
355
CO
N2
337
Coal gas
441
Helium
971
Helium
1261
377
Effects on velocity of sound
Air moisture
0.3 % with
change in
relative moisture
from 0 to 100 %
Temperature
0.17 % / °C
insignificant
measured/
compensated
Velocity of sound
co = 331.6 m/s
c=
x • Rm (273 + T)
M
c: velocity of sound [m/s]
Rm: universal gas constant
(8314.3 J/kmol k)
Pressure change
30 bar
change in run time
approx. 0.3 %
pmin = 700 mbar
T: temperature [°C]
x: adiabatic index
cair at 20°C =
1.4 • 8314.3 • (273+20)
=
irrelevant
Vapour pressure
< 50 mbar ?
no problem
Alain ENGELS
Slide 12
= 344 m /s
28.8
Ultrasonic
Measurement principle - piezoelectric effect
~
++++
----
+ ++ + +
++++
----
- -
1 Individual piezos have
a fixed orientation
and are polarised
-
+
~
- -
2 Voltage with
same polarity
- piezo compressed -
AC voltage causes the piezo to oscillate with AC frequency
Alain ENGELS
Slide 13
- -- - ++++
----
++
-
~
+ ++
3 Voltage with
different polarity
- piezo expanded -
Composition
Piston oscillator
D
A
E
C
C
C
E
B
Alain ENGELS
Slide 14
A
Piezo crystal
B
Impedance matching layer
C
Sensor pot
D
Damping layer
E
Temperature sensor
D
E
D
A
A
B
B
Basics Reflection
 Ultrasound waves are mechanical
waves
Air:
d 0,00129
 Reflection of ultrasound waves
depends on a change of the
wave impedance
--> Change of density
Change
of impedance
Medium: water
Alain ENGELS
Slide 15
d 1
Influence of Grain Size
= C / f
grain size >>
Alain ENGELS
Slide 16
propagation speed c
[m/s]
frequency f [1/s]
wavelenght
[mm]
300
300
30k
1k
10
30
grain size ≈
Reflection on solides
Diffuse -Reflection
Diffuse Reflection
grain size >
/4
f/kHz grain size
30
29
21
17
12
10
Alain ENGELS
Slide 17
...
...
...
...
...
...
2.8 mm
2.9 mm
4.0 mm
4.9 mm
6.9 mm
8.3 mm
Mirror -Reflection
Multiple Echoes in Solids – Grain Size
 Mirror reflections
 Main part of the microwave
energy gets reflected to the
side
 Multiple path propagation over
the tank wall
 Huge amount of microwave
energy gets reflected directly
back to the transmitter
 Less energy gets reflected to
the tank wall
Alain ENGELS
Slide 18
 Almost no multi path
propagation
Multiple Echoes in Solids – Angle of Repose
 Angle of repose
 Mirror reflections
 Multi path
propagation
 Conical outlet in case
of emptying
 Creation of crown
echoes
 Increasing inaccuracy
Alain ENGELS
Slide 19
 Angle of repose changes with
height
of filling
Reflection on solides
TTP
(FAU40)
?
Mirror-Reflection
(grain size <
Alain ENGELS
Slide 20
/4
)
The attunation of Ultrasonic Waves
related to different frequencies
Alain ENGELS
Slide 21
Performance
Product portfolio ultrasonic
Prosonic S
FMU9x/
FDU9x
Prosonic M
FMU4x
Prosonic T
FMU30
Alain ENGELS
Slide 22
Value
Product family – overview
Prosonic T
Prosonic M
 Compact instrument
 Compact instrument
 Measuring range
up to 8 m
 Measuring range
up to 15 m
 Output 4…20 mA
 Output 4…20 mA
with HART, optional
PROFIBUS PA or FF
 Simple applications
 utilities
Alain ENGELS
Slide 23
 Demanding applications
e.g. agitated tanks
Prosonic S
 Sensor and switching unit separately
instrumented
 DIN rail housing or field housing
alternatively
 Measuring range up to 70 m
 Multichannel, optional up to
6 relays
 Output 4…20 mA HART, optional
PROFIBUS
 Programmed functions for Primaries /
Solid industry
FMU90 and FDU9x
 Easy menu-guided commissioning with backlit on
site display
 Fast inspection of the measurement by envelope
curve on the display or ToF-Tool
FMU90
Top hat rail housing
FMU90
Field housing
 Automatic sensor recognition (FDU9x).
 Alternatively top hat rail housing or field housing
(IP66/NEMA4x); optional display for
switchboard installation
FDU95
FDU92
FDU96
 4-wire technology (10-32 V DC /
90-253 V AC)
 1 or 2 sensors connectable
FDU91
FDU91F
Alain ENGELS
Slide 24
FDU93
Standard
DP
FMU90 – transmitter
Transmitter
NEW
FMU90
Protection class
Material
Number of sensors FDU
Power supply
Output signal
Relay
Temperature
Operating / Display
Functions
Alain ENGELS
Slide 25
Certificates
Top-hat rail housing
IP20
(Option: sep. displ. front IP65)
PBT (Polybutyl)
Field housing
IP66 / NEMA 4x
PC (Polycarbonat)
Up to 2 ultrasonic sensors FDU (automatic sensor recognition for FDU9x)
90...253V AC, 10.5...32V DC
Up to 2 x 4...20mA incl. HART® / PROFIBUS DP
1 Relay standard, optional: 3 or 6 relays (free programmable)
-40 … +60 °C
Operating tool: ToF Tool or
3 push buttons with LCD 6 line graphic display
menu guidance, envelope curve on site
Level-, open channel flow measurement
Pre-programmed open channel flow curves with totalizer /daily counter
Pump control or Rake control
ATEX II 3D
FDU9x – sensors
Sensors
NEW
91
91F
92
93
95
96
Bulk solids (m)
5
5
10
15
45
70
Liquids (m)
10
10
20
25
–
–
Blocking distance (cm)
30
30
40
60
70*/90**
+95
+95
+80*/
+150**
+150
4
3
1,5
3
FDU
Measuring range max.
Temperature (°C)
-40 …
Pressure (bar abs.)
Materials
+105 /
+135 (30 min)
+80
4
completely welded (without sealing)
PVDF
Process connections
Degree of protection
Certificates
Alain ENGELS
Slide 26
4
G1‛, 1‛NPT
SS 316L
PVDF
UP, Al/PTFEcoated
membrane
G1‛, 1‛NPT,
Triclamp,
Slip on flange
UP
PE-foam*/
SS membrane**
G1‛, 1‛NPT
IP68 / NEMA6P
ATEX II 2G, 1/2D, FM, CSA
Automatic sensor recognition
Specific sensor data is recognized by the FMU90 automatically.
160
UP, Al/PTFEcoated
membrane
Level Measurement in Rotary Crusher
Requirement:
Level monitoring under rough
conditions
- Vibration, dirt
Solution:
Non-invasive measurement
with Prosonic
Robust sensors with
self-cleaning effect
Alain ENGELS
Slide 27
Level Measurement in Plastic Powder Storage Silos
Requirement:
Level measurement in a storage silo
Product: PE powder
Height of silo: 28 m
Diameter of silo: 3.5 m
Filling: 14 - 20 t/h (pneumatically)
Solution:
by Prosonic
Robust sensors with
self-cleaning effect
Alain ENGELS
Slide 28
Stockpile control with Prosonic
Applications in primaries
Alain ENGELS
Slide 29
Ultrasonic with extreme built up in wood chips
Alain ENGELS
Slide 30
Iron and steelworks
Alain ENGELS
Slide 31
Level Measurement in Limestones
Requirement:
Level measurement under
dusty,
build-up conditions
Solution:
by Prosonic.
Sensor – self-cleaning effect
Alain ENGELS
Slide 32
Level Measurement in a Coaling Plant
Requirement:
Continuous monitoring of coal stock in a power plant Measurement past baffles
Solution: Level measurement with ultrasonic instrumentation
Alain ENGELS
Slide 33
Prosonic S FMU90 + FDU 95 - Cement
Prosonic under extreme conditions
System was powered all the time while being
installed.
No build-up at the sensor surface.
Self-cleaning effect due to flat membrane.
Alain ENGELS
Slide 34
Cement : on the crusher
Prosonic for crusher control - reliable under heavy vibration
System is installed to prevent the
crusher from running empty. Otherwise
rocks will destroy the crusher rolls.
Prosonic FMU 90 and sensor FDU 91
/ 92 because of non-contact and no
maintenance.
Cement plant, Germany
Alain ENGELS
Slide 35
Solid Continuous – Rough Segmentation
Radar
Alain ENGELS
Slide 36
Guided Radar
Ultrasonics
Electromechan
+ non-contact
+ max. 70m
+ independent of dust and
filling noise
+ easy installation in
filled silos
+ price
+ independent of angle of
repose
+ low DK (EoP)
+ independent of dust and
filling noise
++
+
+
+
+
price (scanner)
non-contact
self cleaning effect
independent of DK
easy installation in
filled silos
+ separate instrumentation
+ easy understanding of
measurement principle
+ fast commissioning
+ independent of almost all
product properties
- dep. on angle of repose
- low DK (<1.6)
- contact
> pulling force
> abrasion
> bulid-up
- dust, noise during filling
- dep. on angle of repose
- contact
> buried during filling
- wear out, maintenance
Target Application:
- Cement
- Grain
Target Application:
Plastic Pellets
Target Application:
- Silo farms (price)
- Conveyor, crusher, …
Target Application:
Contractors, export
Micropilot M
Alain ENGELS
Slide 37
Micropilot – History
1993
FMR130
1995
FMR131
- antistatic
rod antenna
1998
Micropilot II
- 2 wire – loop powered
- antistatic rod antenna
- inactive rod antenna
- gas-tight feed through
1999
- Profibus PA
- Fieldbus FF
- HT-antenna
- Enamel antenna
2001
Micropilot M
Micropilot S
Alain ENGELS
Slide 38
2002
- flush mounted, PTFE
- SIL2
2004
- Solid Radar
E+H Strategy 2008 Radar Continuous Improvement
SW adds for Solids
2004
SW adds for Liquids
2005
FMR250
New SW 2006
2008
FMR24x
new antenna
designs (May 2008)
2011
ES version
Continuous Improvement:
From Advanced Dynamics
 new antennas
Alain ENGELS
Slide 39
Reasons for RADAR Technology
RAdio Detecting And Ranging
 Non contact with the process
 Measurement unaffected by:
 vacuum
 temperature
 process pressure
 changing density
 air turbulence
 Easy calibration and commissioning
Alain ENGELS
Slide 40
Measurement Principle
time
Principle of Time of Flight (ToF):

Emission of a wave (mechanical or electromagnetic)

Wave spreads with the propagation speed ‚c‛

Wave gets reflected by the surface
Alain ENGELS
Slide 41

Measurement of the running time ‚t‛

Calculation of the distance ‚d‛ between the transceiver and the
reflective surface:
2 d c
d
distance
Receiving the reflected wave
d
transceiver

t
t
t c
2
reflective surface
Electromagnetic Waves
 EM Wave travels in vacuum with the speed of light:
c
0
1
(µ
0
0
)
c
propagation velocity of electromagnetic wave in vacuum
(meter/second)
µ0
permeability of free space (4 x ∏ x 10-7H/m)
ε0
permittivity of free space (8.854 x 10-12F/m)
c
propagation velocity of electromagnetic wave
(meter/second)
λ
wavelenght (meter)
f
frequency (Hertz)
 Characterization of waves:
Alain ENGELS
Slide 42
c
f
Electromagnetic Waves
 Propagation speed in medium is slower than in vacuum
 Speed depends on the material properties:
c' c'
Alain ENGELS
Slide 43
c
c’
propagation velocity of electromagnetic wave in medium
(meter/second)
µr
relative permeability
εr
relative permittivity / dielectric constant
0
(
r
µ)
r
r
Medium
εr
µr
c‘
Air
CO2
O2
N2
SO2
1.000594
1.000985
1.000486
1.000528
1.009900
1.000000
1.000000
1.000002
1.000000
0.999991
299792458
299644919
299719335
299713344
298320756
µr ≈ 1
for non - magnetic media the
influence of µr is negligible
εr is the most important factor for
RADAR measurement
Influence on the Dielectric Constant
εr
bar
Temperature
Measured error in %
as a function of temperature
(air at 1 barabs)
Alain ENGELS
Slide 44
Pressure
Measured error in %
as a function of static pressure
(air at 20°C)
DC examples for Solids and Fluids
 Reference value is air with εr ≈ 1
 εr > 1 for all fluids and liquids
 Summary of εr values in the ‚DC Handbook‛
Media
group
Solid
Fluid
DC (εr )
Examples [DC]
DC (εr )
Examples [DC]
A
1,4 … 1,9
plastic granulate [1.8],
sugar [1.8], white cement
[1.43]
1,4 … 1,9
non – conductive liquids
(e.g. liquefied gas like
butane [1.2], chlorine [1.8])
B
1,9 … 2,5
portland cement [3.8],
plaster [1.9]
1,9 … 4
non – conductive liquids
(e.g. oil [3], toluene [2.5])
C
2,5 … 4
quartz sand [2.6], rice
[3.5]
4 … 10
e.g. hydrochloric acid [4.6],
chloroform [5.5]
D
4…7
copper ore [6],
phosphorus salt [4],
coffee [4.6]
> 10
conductive liquids e.g.
petroleum [17.8], water [81]
E
>7
ferrite [9.3], active coal
pellets [14]
Alain ENGELS
Slide 45
Microwaves – Effects on Humans
Device
microwave oven
mobile
RADAR level measurement
device
Measuring Conditions
inside:
Slide 46
approx. 1W/cm2
leakage at closed door:
approx. 0.005W/cm2
at transmitting power
of 2W:
approx. 0.0001W/cm2
pulse:
average:
Alain ENGELS
Intensity
approx. 0.00015W/cm2
approx. 0.000000021W/cm2
Structure of a Microwave Transmitter
HF module
Alain ENGELS
Slide 47
Antenna
(amplifier)
A/D converter,
microcontroller
Output
Principle of Pulse Time Of Flight
transmission
reception
reception
transmission
Antenna
envelope curve
HF module
P
A
D
signal processing
Alain ENGELS
Slide 48
measured
value
Time Of Flight (TOF) principle
transmission
reception
envelope curve
sending pulse with
reverberation time
amplitude y
interference echo
caused by installations
interference echo
caused by agitator
interference echoes
caused by installations
level echo
x time-of-flight
Alain ENGELS
Slide 49
techn. representation
of the envelope curve
HF-Coupling
(pin-coupler)
& Antenna
Hf Module
Alain ENGELS
Slide 50
Antenna
(amplifier)
A\D converter &
Microcontroler
Output
Components of a Antenna
 Coaxial Cable
 connection to the HF - module
50Ω
 Gas tight coupling
 Waveguide (PTFE cone and horn)
 PTFE cone
 adaptation of wave impedance
 impedance converter to provide
adaptation to antenna horn
245Ω
ideal
 O – Ring
 sealing to the process
Alain ENGELS
Slide 51
 Horn
 adaptation of wave impedance
 amplifier
374Ω
377Ω
Horn Antenna – Transmission
Task of the antenna:

Adaptation of the wave impedance for optimized energy transfer
Benefits of larger antennas:

Alain ENGELS
Slide 52
Better adaptation of wave impedance  changing impedances are causing errors
Reflection – Influence of different Antenna
Influence of different antenna types resp. size….
FMR240
DN100- horn antenna
FMR240 DN40 - horn antenna
antenna
characteristics
Alain ENGELS
Slide 53
…. The bigger the best
Horn Antenna - Transmission

Directivity of the emitted microwave energy

Less diffraction  Smaller beam angle and therefore better focusing
40°
15°
Alain ENGELS
Slide 54
Horn Antenna - Receiving

Collecting the reflected microwave energy

Alain ENGELS
Slide 55
Larger horn = bigger aperture diameter (surface of the antenna opening)
 more energy can be received
Basics Reflection
 Microwaves are electromagnetic
waves (energy wave)
Air:
r
1
 Reflection of microwaves depends
on a change of the wave impedance
--> Change of dielectric constant
Change
of impedance
Medium:
r > 1
Alain ENGELS
Slide 56
(DK,
r)
Reflection
Wave impedance of air:
0
0
377
Z
Z
r
Degree of reflection ‘r’:
Z
Z
0
0
Z
Z
0
P
0
r
ECHO
Z
Wave impedance of media:
r
P
r
1
1
r = 0
no reflection
Slide 57
Z2
ε2 > 1
r = 1
full reflection
Example:
Alain ENGELS
ε1 ≈ 1
Interpretation of ‘r’:
P
Air:
Z1
ε1 ≈ 1
r
2 1
0.2
2 1
20%
reflected
Oil: ε1 = 2
80%
transmitted
Construction of Silo, Installation
 Be careful if silo wall is not smooth, especially with small diameters
Silo wall of
corrugated metal
Silo wall of
welded metal plates
 solution: installation more in the center
 Obstacles, internal construction within the beam can cause big reflection
 Be careful with ‚reflectors‛ outside of plastic silos
 The TI statements to the construction of the nozzle have been confirmed
Alain ENGELS
Slide 58
Silo with Conical Outlet
 Generally dependent on mounting position and
diameter of silo
 Dependent on DK value of medium
 Experience showed that it is difficult to
measure in the outlet for diameters smaller
than 3…4 m
Alain ENGELS
Slide 59
Grain Size and Angle of Repose (1)
Same physics than
Ultrasound:
= C / f
= 300 m/sec / 17kHz
= 17.6mm
Radar:
= 300.000.000 m/sec /26.000.000 KHz
= 11.5mm
Mirror-Reflection
(grain size <
/4
)
Grain size < 3 mm
 mirror effect
Alain ENGELS
Slide 60
Alain ENGELS
Slide 61
 higher inaccuracy
Alain ENGELS
Slide 62
 angle of repose changes with
height of filling
 ideal echo curve is influenced
Micropilot M in Solids
2-wire-technology / Frequency 26 GHz
FMR244
 Measuring range up to 15m
FMR244
FMR250
 Temperatures up to 80°C / 3bar
 Cost effective alternative for bulk solids
FMR250
 Alignment device
 Air purge connection as standard
 Temperatures up to +200°C / 16bar
 Optimal for:
Alain ENGELS
Slide 63

small nozzle diameters

small vessels, stock piles, …
Micropilot M in Solids
FMR250
2-wire-technology
Frequency 26 GHz
 200mm (DN200) & 250mm (DN250) parabolic reflector
 Small beam angle 4° (200mm), 3.5° (250mm)
 Enhanced signals 5…10dB to horn

Better beam focus

Large antenna aperture
 Optimal for:

large measuring ranges

tall, slim silos

Silos with lots of obstacles
 Measuring range 70 m
 Temperature up to 200°C
 Pressure up to 16 bar
Alain ENGELS
Slide 64
 Option: top target positioner
FMR250 – Integrated Air-Purge Connection
 Prepared for horn- and parabolic
antenna as standard
 Easy installation of the air purge
above the process connection
 In combination with top target
positioner as well
 Independent of process connection
an antenna extension
Alain ENGELS
Slide 65
FMR250 – Integrated Air-Purge Connection
Example with gypsum. 6 bar air pressure.
Alain ENGELS
Slide 66
FMR250 types of antennas (26GHz)
Horn antenna
Parabolic antenna
0mm
250mm
450mm
0mm
250mm
450mm
+/- 15°
+/- 15°
 Material: 316L, Peek + Viton (Horn) / 316L, PTFE + Viton (Parabolic)
 Antenna extension: 0mm, 250mm, 450mm
 Optional top target positioner: +/- 15°
 Accuracy: +/- 15mm (or 0.04% of range)
Alain ENGELS
Slide 67
 Horn: DN80, DN100
 Process connection:
 G 1½‚, 1½‚ NPT
 DN80, DN100, UNI flange
 ANSI 3‚, 4‚, JIS
 Vacuum … 16bar
 - 40°C … 200°C
 Reflector: DN200 / DN250
 Process connection:
 DN80, DN100
 DN100, DN200, DN250 UNI flange
 ANSI 3‚, 4‚, JIS
 Vacuum … 16bar
 - 40°C … 200°C
Solid - Radar FMR250: Application Advantages





independent of dust
independent of filling noise
no mechanical moving parts
independent of temperature (up to 200°C)
one device for all measuring ranges
 non-contact
 no abrasion
 no regard of pulling forces
 less sensitive to build-up and dirt
Alain ENGELS
Slide 68
 Typical applications are:
 Dusty media, e.g. cement, raw meal, animal feed
 Applications with high temperatures up to 200°C,
e.g. clinker, fly ash
 Abrasive solids, e.g. ferrite, clinker, …
Micropilot M FMR250 – Cement
 Product: Cement
 Application: buffer silo with fluidization
 Silo: 38 m high, 12 m diameter
 3 Segments
 Device: FMR250 (DN200 parabolic antenna,
450 mm antenna extension)
 air purge
 FMR250 – reliable measurement even in very dusty
applications
Alain ENGELS
Slide 69
Micropilot M FMR250 – Clinker
 Product: Clinker (DC ~1.9)
 Temperature: max. 120°C
 Mounting position 80 cm beside filling nozzle
 Non-contact Solid-Radar FMR250
- no problem at high temperatures and
abrasive products.
Alain ENGELS
Slide 70
Micropilot M FMR250 – Animal Feed
 Product: wheat, corn, oat, barley, …
 Storage silos
 9 Silos: 65 m high, 6 m diameter
4 „star silo‚: 65 m high
 Device: FMR250 (DN100 horn antenna,
 FMR250 – reliable measurement in grain
up to 65 m with DN100 horn antenna
Silo 311
Silo 306
Silo
309
Silo 312
Silo
304
Silo 307
Silo
310
Silo 313
Alain ENGELS
Slide 71
Silo 301
Silo 302
Silo
305
Silo 308
Silo 303
40 m – 20dB
Micropilot M FMR250 – Plastic Pellets
 Product: PE Granulate (small DC)
 Aluminium silo
 Silo: 15 m high, 3.5 m diameter
 Nozzle: man hole
 Device: FMR250 (DN200 parabolic
antenna, 450 mm antenna extension)
 Large echo amplitudes even at
low DC products.
Alain ENGELS
Slide 72
Different Ways to Display the Envelope Curve
FieldCare via Service Tool
(e.g. Commubox FXA291)
Alain ENGELS
Slide 73
Micropilot device display
Micropilot M – Advanced Dynamics
0
-10
-20
Number of all applications (solids & liquids)
Amplitude / dB
-30
+18dB
-40
-50
PulseMaster®
Customer Set Up
PulseMaster® eXact
Customer Set Up
-60
-70
-80
0%
-90
Customer Set Up
25%
50%
Service Know-how
-100
-2
-1
0
1
2
3
4
5
6
Distance / m
Advanced Dynamics
PulseMaster® eXact
Alain ENGELS
Slide 74
Power is nothing without control
75%
100%
Application Limits
Micropilot – Advanced Dynamics
0
-10
-20
Number of all applications (solids & liquids)
Amplitude / dB
-30
+18dB
-40
-50
PulseMaster®
Customer Set Up
PulseMaster® eXact
Customer Set Up
-60
-70
-80
0%
-90
Customer Set Up
25%
50%
Service Know-how
-100
-2
-1
0
1
2
3
4
5
6
Distance / m
Advanced Dynamics
Alain ENGELS
Slide 75
PulseMaster® eXact
Power is nothing without control
75%
100%
Application Limits
How to do the right choice ?
Frequency, antenna, ….
Alain ENGELS
Slide 76
Which Antenna ?
refer to the selection and engineering guide (CP023F)
… and
Alain ENGELS
Slide 77
Function and system design
Alain ENGELS
Slide 78
Product caracteristic
Alain ENGELS
Slide 79
Antenna dimensions : FMR250
Alain ENGELS
Slide 80
Mounting recommendations
Alain ENGELS
Slide 81
Measuring conditions
Alain ENGELS
Slide 82
Measurement in plastic Tanks
Alain ENGELS
Slide 83
Antenna FMR244 and FRM25x
Alain ENGELS
Slide 84
Electronic insert
Hf Module
Alain ENGELS
Slide 85
Antenna
(amplifier)
A\D converter &
Microcontroler
Output
Power supply
Profibus-PA
4-20mA/ HART
Alain ENGELS
Slide 86
Foundation Fieldbus
FMR25x : Mounting recommendations
Alain ENGELS
Slide 87
FMR250 : Mounting recommendations
…in a Nozzle
Alain ENGELS
Slide 88
Accessories
Protective Cover
(code : 543 199-0001)
Remote Display
FXA40
Alain ENGELS
Slide 89
The right (sensor) choice….
Alain ENGELS
Slide 90
Micropilot M
Applications
Alain ENGELS
Slide 91
Solid - Radar FMR250: Application Advantages





independent of dust
independent of filling noise
no mechanical moving parts
independent of temperature (up to 200°C)
one device for all measuring ranges
 non-contact
 no abrasion
 no regard of pulling forces
 less sensitive to build-up and dirt
Alain ENGELS
Slide 92
 Typical applications are:
 Dusty media, e.g. cement, raw meal, animal feed
 Applications with high temperatures up to 200°C,
e.g. clinker, fly ash
 Abrasive solids, e.g. ferrite, clinker, …
Micropilot M FMR250 – Cement
 Product: Cement
 Application: buffer silo with fluidization
 3 Segments
 air purge
 FMR250 – reliable measurement even in very dusty
applications
Alain ENGELS
Slide 93
Micropilot M FMR250 – Clinker
 Product: Clinker (DC ~1.9)
 Temperature: max. 120°C
 Mounting position 80 cm beside filling nozzle
 Non-contact Solid-Radar FMR250
- no problem at high temperatures and
abrasive products.
Alain ENGELS
Slide 94
Micropilot M FMR250 – Animal Feed
 Product: wheat, corn, oat, barley, …
 Storage silos
 9 Silos: 65 m high, 6 m diameter
4 „star silo‚: 65 m high
 Device: FMR250 (DN100 horn antenna,
 FMR250 – reliable measurement in grain
up to 65 m with DN100 horn antenna
Silo 311
Silo 306
Silo
309
Silo 312
Silo
304
Silo 307
Silo
310
Silo 313
Alain ENGELS
Slide 95
Silo 301
Silo 302
Silo
305
Silo 308
Silo 303
40 m – 20dB
Radar
Micropilot M FMR250 – Plastic Pellets
 Product: PE Granulate (small DC)
 Aluminium silo
 Silo: 15 m high, 3.5 m diameter
 Nozzle: man hole
 Device: FMR250 (DN200 parabolic
antenna, 450 mm antenna extension)
 Large echo amplitudes even at
low DC products.
Dieter Markanic
Slide 96
Micropilot M - FMR244
Application: CHARGING HOPPER
Device:
Height:
Medium:
Mounting:
2 x FMR244-A4SXMEAA2F
6m
Lime stone with different grain sizes (< 3m)
Two FMR244 were mounted on each side
of the charging hopper for level detection.
Reference device:
FMU90 with FDU93
Alain ENGELS
Slide 97
Micropilot M - FMR244 - MATO SILO
Application: MATO SILO
Device:
Silo:
Diameter:
Height:
Medium:
Filling:
Mounting:
FMR244-A4SXXGAC2F
Cylindrical upright metallic buffer silo with conical outlet
6m
11m
Lime stone (DC > 1.8), grain size (1cm to 5cm)
Filling with conveyer belt
Manhole 800mm x 800mm without any alignment
of the device. The tank wall distance was appr. 1.5m
Reference Device:
FMR250-A5E1XEJAA2K
Alain ENGELS
Slide 98
Micropilot M - FMR244
Application: Train Buffer Silo
Device:
Silo:
Diameter:
Height:
Medium:
Mounting:
Reference:
Alain ENGELS
Slide 99
FMR244-A4SXXG4A2F
Cylindrical upright buffer silo with conical outlet.
Dusty atmosphere and very strong angle of repose
is present!
6m
11m
lime stone (DC > 1.8) grain size (<10mm)
Manhole with 775mm x 775mm. The device was
mounted without any alignment of the device!
Prosonic S FMU90
Micropilot M - FMR244 – Stone Crusher
Application: Stone Crusher
Device:
Height:
Medium:
Mounting:
Problem:
FMR244-A4SXMEAC2F
4m
Lime stones with different grain sizes
(up to 3m possible)
On steel girder beside the filling position.
Very strong vibrations are present!

Nord Lock Dish Washers
Customer is using a contact measurement
system as level switch for overfill protection!
FMR244 as switch
Cap. level
switch
Alain ENGELS
Slide 100
Guided Level-Radar
Levelflex M & ES
Alain ENGELS
Slide 101
Time of Flight / ToF
 Time of Flight (ToF)
 Speed of light:
300.000.000 m/s
E: empty
 Level:
L = E - (0,5 x refl. Time x 3.108 ) L
= ….. m
L
Alain ENGELS
Slide 102
Measuring principle
typical envelope curve:
amplitude
Reflection from
process connection
Level
Sand
Powdered clay
Fly ash
Talcum
Lime
Alain ENGELS
Slide 103
End of probe
Envelope Curve
 Envelope curve: graphic representation of received energy with respect to its run time
(„Time of Flight‚)
Alain ENGELS
Slide 104
Reliable measurement even with echo loss
End of probe algorithm allows
level measurement even if the
echo is lost
Typical envelope curve:
amplitude
 If the probe-end signal and the echo from the
product surface are available, the electric
product property is automatically calculated.
 If the echo from the product surface cannot be
measured any more, the level is calculated
from the shift in the probe-end signal.
L = (
L
Alain ENGELS
Slide 105
EOP Shift
1) L
(EOP Shift)
End of probe algorithm permits to measure
level, even if the echo is lost from time to
time
= (1 + (EOP Shift / L))²
Envelopp curve
6 quadrant management
Reference peak
control
1
Level Direct signal
2
3
5
4
6
Lost weight
HF connection
control
Alain ENGELS
Slide 106
EOP Signal
Weight to the earth
EOP Signal
Weight Free
Advantages of the measuring principle
Measures precisely and independent of
temperature, pressure and gas layers:
Solids:
 Particle size
 Dust, measuring
while filling
 Turbulent
surfaces or foam
 Humidity
 Wall material of
the vessel
 Obstacles
Slide 107
 Product density
and variation of
density
 Filling noise
 Shape of silo
Alain ENGELS
Liquids:
 Shape of vessel
 Obstacles
Operation conditions : measuring limits
Alain ENGELS
Slide 108
Operation conditions : installation
OK
Alain ENGELS
Slide 109
Electromagnetic field distribution
twin rod is much more sensitive to build up than single rod
Alain ENGELS
Slide 110
nozzle ringing
small nozzle (DN 100 x 200), no lateral resonance
Alain ENGELS
Slide 111
nozzle ringing
large nozzle (DN 300 x 400), excitation with lateral resonance
Alain ENGELS
Slide 112
Mounting variants and the influences
Advantage: To avoid strong forces at the cable or extension!
Standard (normal)
Adapter flange FAU 70
Adapter flange FAU 20
Alain ENGELS
Slide 113
Extension rod &
Centering disc FAU 30
advantage: Less ringing + stronger signals
By high nozzle  bigger Upper BD
Alain ENGELS
Slide 114
Mounting on ...
… a plastic vessel
… a concrete vessel
Alain ENGELS
Slide 115
Signal damping in case of mounting in plastic silos
Envelope Curve
Coupling
End Of Probe signal
(EOP)
Alain ENGELS
Slide 116
Signal damping in case of mounting in plastic silos
Envelope Curve
Coupling
Steel plate to get
A bigger signal (amplitude)
End Of Probe signal
(EOP)
!!!!!
Alain ENGELS
Slide 117
Levelflex M - Liquid
PPE, Schopfheim
Application:
- acid and bases with different concentrations,
-
foam and conductive built up
FMP 40 outside the tank
plastic tank (PP), Ø 2.5m, wall thickness 2.0cm
ambient temperature
rod- probe Ø16mm, probe-length 2100mm
Result:
Measurement from outside the tank works without any problems
since commissioning.
A contact prevention for reliable measurement was realized with a
plastic raceway.
Alain ENGELS
Slide 118
Special installations situations
Fixing rope probe
Alain ENGELS
Slide 119
From side
Product & Technology
Levelflex ES
Alain ENGELS
Slide 120
HistoROM (basic, standard)
 Event Recorder
 For max 20 events according to Endress+Hauser standard
Basic
 Failure / Maintenance / Check /
Alain ENGELS
Slide 121
Out of
Spec / Information
 Backup / Copy / Restore functionality
 Easy electronics (main board) replacement
HistoROM (extended, option to order)
Storage of
 40 events, 10 envelope curves, max. 1000 measurement values
 Event recorder according to Endress+Hauser standard
 Failure / Maintenance / Check /
Out of
Spec / Information
EXTENDED
 Recording of trends
 Up to 4 independent parameters, time interval: 0.15s…3600s
 Max. 1000 values / 1 parameter => max 1000h for 1 parameter
 Or 500 values (with 2 parameters), 333 values (3), 250 values (4)
 Envelope curve diagnostics -> storage of max. 10 envelope curves
 Can be triggered automatically to
 Echo loss, S/N to small, Distance greater / smaller than…,
Filling speed greater than…
 Storage of reference envelope curve
Alain ENGELS
Slide 122
 Comparison to start up / commissioning conditions for maintenance
Technical innovation
Levelflex FMP55
Alain ENGELS
Slide 123
FMP55 – Multiparameter sensor system
What is the Total Level ?
What is the Height of Lower Product ?
What is the thickness of the upper Layer ?
d1
h1
3 variables :
h2
d2
= 1.4…10
h1 , h2 ,
2 measured parameters TDR :
d1 h1
d2
h2
1 measured parameter capacitance :
C
Alain ENGELS
Slide 124
f (h1 , h2 , )
FMP55 SensorFusion – Multiparameter
Alain ENGELS
Slide 125
Interface applications – segmentation
Alain ENGELS
Slide 126
Product & Technology
Levelflex ES
Alain ENGELS
Slide 133
The Next Level Instrumentation – overview
INTERFACE
LIQUID
FMP50
Alain ENGELS
Slide 134
FMP51
FMP52
FMP53
FMP54
FMP55
SOLID
FMP56
FMP57
FMP56 – for fine grained solids
 The basic model for fine grained / powdery solids
 Rope material: SS 316L or Steel PA coated
 Temperature: -40… +120°C
 Pressure: -1…+16bar
 Tensile load: 12kN
 Process connections: ¾" G or NPT
Alain ENGELS
Slide 135
FMP57 – for standard solid applications
 The standard probe for solids
 Rope material: SS 316L or Steel PA coated
 Temperature: -40… +150°C
 Pressure: -1…+16bar
 Tensile load:
4mm 12kN (Rope probe)
6mm 30kN
 Side strength:
30Nm (Rod probe)
 Process connections: 1½" G/NPT or flange
Alain ENGELS
Slide 136
New offerings with ToF Family
 Uniform commissioning in accordance to HMI standard
 Developed in accordance to IEC 61508 (SIL2)
 Compliance with all important NAMUR guidelines:
E.g. for diagnosis NE107
 Quick setup menu for fast and easy setup
 HistoROM simplifies commissioning and enables diagnostic functions
 Two chamber housing as standard for comfortable
and secure installation
 Up to 17 languages, for easy local commissioning
 Optical display for operation from the outside, for secure onside commissioning without
opening the device
Adaptive
Algorithms
Alain ENGELS CAA
inside
Slide 137
 Highest reliability due to innovative continuous adapting algorithms
for tracking of various tank echo's
Applications
Levelflex M & ES
Alain ENGELS
Slide 138
FMP57 – BARLEY APPLICATION
APPLICATION:
TITLE
APPLICATION
PRODUCT 1
DK VALUE 1
HEIGHT
DIAMETER
PRESSURE
TEMPERATURE
DEVICE
PROBE LENGTH
Alain ENGELS
Slide 139
FMP57- BARLEY APPLICATION - CUSTOMER: NAMYSŁÓW
QUADRATIC STORAGE SILO WITH PYRAMIDE BOTTOM
BARLEY
3.13
15237MM
QUADRATIC 4M X 4M
MIN: AMBIENT NORM: AMBIENT MAX: AMBIENT
MIN: AMBIENT NORM: AMBIENT MAX: AMBIENT
FMP57- AA A C C A NB A4 GGE
13800MM
FMP57 – BARLEY APPLICATION
Installation:
Cabinet
Metallic silo with obstructions
Rope FMP57
Alain ENGELS
Slide 140
Pyramid
silo
outlet
Manhole with FMP57
FMP57 – DUST FURNACE
APPLICATION:
TITLE
FMP57 - DUST OF FURNACE (CEMENT)
CUSTOMER: CBR
APPLICATION
CYLINDRICAL UPRIGHT CONCRETE SILO WITH CONE-SHAPED
OUTLET.
PRODUCT 1
DK VALUE 1
HEIGHT
DIAMETER
DUST OF FURNACE
UNKNOWN
20M
6.5M
PRESSURE
MIN: LOW UNDER PRESSURE NORM: LOW UNDER PRESSURE
MAX: LOW UNDER PRESSURE
TEMPERATURE
DEVICE
PROBE LENGTH
Alain ENGELS
Slide 141
MIN: 15°C NORM: 15°C MAX: 80°C
FMP57- AA A C C NB A4 GGE
20000MM
FMP57 – DUST FURNACE
With optimized application parameter for solids implemented
 the current output followed the level continuously (not stepwise)
During emptying the
product from the side
walls
slipped into the middle
of the tank 
increased the level
value
Alain ENGELS
Slide 142
The FMP57 followed the real level in the silo!
40596: FMP57 – ZINC OXIDE POWDER
APPLICATION:
TITLE
APPLICATION
PRODUCT 1
DK VALUE 1
PRODUCT 2
DK VALUE 2
HEIGHT
DIAMETER
PRESSURE
TEMPERATURE
FMP57 - ZINC OXIDE POWDER CUSTOMER: PRAYON - SILOX
RECTANGULAR UPRIGHT STEEL SILO WITH PYRAMID OUTLET
ZINC OXIDE POWDER
2.1 - 2.2
6.2M
4.01M X 3.4M
MIN: - NORM: - MAX: MIN: 20°C NORM: - MAX: 120°C
DEVICE
FMP57- AA A C C A LC A4 GGE
PROBE LENGTH
Alain ENGELS
Slide 143
6M
FMP57 – ZINC OXIDE POWDER
Installation:
Alain ENGELS
Slide 144
Level measurement in sugar industry
 Requirements:
–
Measurement in narrow silo cells containing
sugar of different grain sizes
–
Adjacent max. limit switch causes
interference
–
Sugar surface is partially even and shiny thus
deflecting ultrasonic waves laterally
 Solution:
Levelflex M, FMP 40 with
6 mm rope
Suppression of max. limit
switch in top 2 m of the
measuring range
Alain ENGELS
Slide 145
Measurement in maize
 Requirements:
- Different kind of grain
- Changing filling
- Only low ceiling load allowed
- Measuring range: 30 m
 Levelflex M, FMP40
- Reduction of the ceiling load by 4 mm rope
- Envelope curve with maize:
Alain ENGELS
Slide 146
Measurement in soot (carbon black)
 Requirements:
- Steel silo, 10 m high
- Installation in manhole,
diameter 350 mm
and 250 mm high
 Solution:
- Levelflex M, FMP40
- 6 mm rope probe
- Upper blocking distance
adjusted to 500 mm
Alain ENGELS
Slide 147
Level measurement in PE and PP granules
 Requirements:
– Measuring range 18 m
– Aluminum silo Ø approx. 3 m,
ceiling with relatively low
loading capacity
– Cost-effective replacement for
the old FMM 460
– Strong electrostatic charging
of product
 Solution:
Levelflex M, FMP 40 with
4 mm rope
A 4 mm rope was selected to
reduce ceiling load.
The 4 mm rope provides ample
stability (12 kN).
Integrated protection against
electrostatic charging.
Alain ENGELS
Slide 148
Fixing probe
Fixed outside :
 Envelope curve : Good EOP-signal of the tank wall.
 Commissioning : ‚End of Probe tie down gnd‛ ( grounded)! positive EOP-signal
Alain ENGELS
Slide 149
 Diameter of execution should correspond to the rope diameter? positive eop signal

3d achtergronden

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