Application Installation

Smar Guided Wave Level Transmitter .
Application in the Sadia S.A – Uberlândia - MG.
Application
USA
Smar International Corporation
6001 Stonington Street, Suite 100
Houston, TX 77040
Phone: +1 713 849-2021
Fax: +1 713 849-2022
[email protected]
Smar Research Corporation
2110 5th Ave
Ronkonkoma, New York 11779
Phone: +1 631 737 3111
Fax: +1 631 737 3892
[email protected]
Smar Laboratories Corporation
6001 Stonington Street, Suite 100
Houston, TX 77040
Phone: +1 713 849-2021
Fax: +1 713 849-2022
[email protected]
BRAZIL
Smar Equipamentos Ind. Ltda.
Rua Dr. Antonio Furlan Jr., 1028
Sertãozinho SP 14170-480
Phone: +55 16 3946-3510
Fax: +55 16 3946-3554
[email protected]
GERMANY
Smar GmbH
Rheingaustrasse 9
55545 Bad Kreuznach
Phone: + 49 671-794680
Fax: + 49 671-7946829
[email protected]
MEXICO
Smar Mexico
Cerro del Cubilete #140
Fracc. Lomas de Mazatlán
C.P. 82110 Mazatlán, Sinaloa,
Phone / Fax: 52 + (669) 984 47 34
Phone / Fax: 52 + (669) 913 32 96
[email protected]
FRANCE
Smar France S. A. R. L.
42, rue du Pavé des Gardes
F-92370 Chaville
Phone: +33 1 41 15-0220
Fax: +33 1 41 15-0219
[email protected]
CHINA
Smar China Corp.
C-209, Ye Qing Plaza
No. 9 Wangjing Beilu
Chaoyang District
Beijing 100102, P.R. China
Tel.: +86 10 6439-8693
Fax: +86 10 6439-0781
[email protected]
www.smar.com.cn
UNITED KINGDOM
Smar UK Ltd.
Bluebell Farm,
Sandy Lane
Romsey,
Hampshire
SO51 0PD
Phone: +44 (0)797 0094138
Fax: +44 (0)797 4747502
[email protected]
SINGAPORE
Smar Singapore Pte. Ltd.
315 Outram Road
#06-07, Tan Boon Liat Building
Singapore 169074
Phone: +65 6324-0182
Fax: +65 6324-0183
[email protected]
NETHERLANDS
Smar Netherlands
A. van Leeuwenhoekweg 19b
2408 AL Alphen aan den Rijn
Phone: +31 172 494 922
Fax: +31 172 479 888
[email protected]
Plus a network of
representatives in 58 countries.
For your nearest representative
please contact:
[email protected]
w w w. s m a r. c o m
Specifications and information are subject to change without notice. For the latest updates, please visit the Smar website above.
© Copyright 2008 - Smar International - all rights reserved. - May/2008
Practically in all the plants, the tanks of industrial and
biological effluents need some cares, environmental or
referring to the very industrial process.
Many times, due to overflow, those effluents may return to
certain plant points where the risk of process contamination
cannot exist. Therefore, constant monitoring of the tanks
level is necessary.
Installation
Sadia company has in Uberlândia-MG two plants,
one directed to poultry production and other for swine
slaughtering and the industrial production of steaks,
sausages, salamis, among other delicatessen.
The RD400 was installed in an underground tank of
industrial effluents with biological content.
After the slaughterhouse, many residues are used
for animal rations production. What is not used it
is conducted, together with animal grease, for the
effluents tank. All product is processed to separate
the water and the fat in subsequent phases, mechanic
and biologically.
Besides a very low level situation and consequent
cavitation of the pumps, what should be mainly
avoided in that tank is process overflow and the
fat in the surface entering the biological treatment
ponds – a situation that can generate a high cost
plant repair.
Plant effluents tank. In the detail, the process surface is
shown with great fat accumulation and other mixed residues.
As shown in the previous image, level keys were
previously used - five in total - to monitor the tank overflow,
but the results were beyond expectations.
The proposed solution was the installation of a RD400
with single cable. In spite of the equipment not having a
metallic vessel around it, as a guarantee for capturing the
emitted and reflected waves, the support in which RD400
was coupled fitted that purpose. A stainless steel plate
approximately 1.5m x 1.0m was used to provide a good
“mirror” to the reflected waves that the pulse generator/
receiver will receive.
Reflection peak.
Threshold represented
by the yellow line
Which difficulties you previously had on level
measuring?
Measuring was made through a Capacitive Level Key,
where the fluid to be measured generated a residual
layer in the Level Key rod, and consequently, a false level
indication, which caused the pumps to switch off or the
pumps without tank fluid to switch on automatically.
tank from 0% to 100% and created an interlocking with
a single measuring instrument, with efficiency confirmed
on Smar tests.
Do you recommend the Smar RD400?
Yes, the RD400 is very efficient in processes with fluids with
solids in suspension, vapor, etc. But it is very important a
technician’s presence for the accompaniment of the whole
RD400 installation, because it is common in industries the
product to be inefficient in the process because its electric
or mechanical installation is incorrect. That did not happen
when Smar visited us.
Which benefits the RD400 brought to your process?
Five Capacitive Level Keys were removed, because they
presented little efficiency to the process application.
With the Installation of the RD400, we monitored the
Features
RD400 installation, level keys removed and metal plate to
ensure good reflection
Reflection at a 5.3 m level. The following peaks refer to the same reflection
surface, and were repeated due to the scale chosen for the graphic
The so-called “mirrors” characterize a type of “shield”
that will receive the returned waves adequately.
The tank is 7m deep approximately. The single cable
was 6 m long and was installed as shown below.
The equipment measured the level at the interface point
between the emulsion (fat and other surface residues)
and the liquid itself, which characterizes the upper layer
(approximately 10 cm height) as a low dielectric constant
material. The client’s objective: to measure the liquidfoam interface level accurately, as the foam thickness
varies in several points of the tank.
The RD400 uses the Time Domain
Reflectometry (TDR) technology, a principle
used in civil construction, telecommunication,
agriculture, among other areas, and recently in
industrial processes level measuring.
This principle is based on the concept that
electromagnetic waves, guided in a certain
ambient (in the case of RD400, its probes),
suffer reflection when meeting other ambient
with different dielectric constant, due to
impedance change.
The RD400 depends originally of the ambient
dielectric constant whose level is measured. For
humid ambients, the wave reflection improves
significantly due to the high dielectric constant
of the water.
Elements as dust, internal obstacles to the
tank (level keys, filters, etc.), bubbles on the
surface, among others, are most times ignored
by the equipment, since the waves are guided
by probes, without loss of power.
For each type of process, there will be the
need for a different probe, which can be a single
or dual rod, a single or dual cable or even a
coaxial terminal. What will determine which will
be the probe type are parameters as the tank
height, the installation or not of RD400 in the
communicating vessels, the dielectric constant
of the process, among others. Consult our
representatives for more information.
Conclusion
Installation in the Effluents Tank
Where:
01 and 02 - RD400 (electronics, generator/receiver and
coupling to the single probe);
03 – Metallic plate in 316 stainless steel, with of 1 ½”NPT
sleeve adapted;
04 - Single cable;
05 and 06 – 5 kg counter-weight.
The reflection signal, shown in the following figure, indicates
a satisfactory reflection, characterizing a transmitter
accurate and constant operation
Djalma Corrêa dos Santos.
Testimonial by Djalma Corrêa dos Santos, Instrumentation
Sector supervisor for the Uberlândia unit, concerning
the RD400.
02
03
Reflection peak.
Threshold represented
by the yellow line
Which difficulties you previously had on level
measuring?
Measuring was made through a Capacitive Level Key,
where the fluid to be measured generated a residual
layer in the Level Key rod, and consequently, a false level
indication, which caused the pumps to switch off or the
pumps without tank fluid to switch on automatically.
tank from 0% to 100% and created an interlocking with
a single measuring instrument, with efficiency confirmed
on Smar tests.
Do you recommend the Smar RD400?
Yes, the RD400 is very efficient in processes with fluids with
solids in suspension, vapor, etc. But it is very important a
technician’s presence for the accompaniment of the whole
RD400 installation, because it is common in industries the
product to be inefficient in the process because its electric
or mechanical installation is incorrect. That did not happen
when Smar visited us.
Which benefits the RD400 brought to your process?
Five Capacitive Level Keys were removed, because they
presented little efficiency to the process application.
With the Installation of the RD400, we monitored the
Features
RD400 installation, level keys removed and metal plate to
ensure good reflection
Reflection at a 5.3 m level. The following peaks refer to the same reflection
surface, and were repeated due to the scale chosen for the graphic
The so-called “mirrors” characterize a type of “shield”
that will receive the returned waves adequately.
The tank is 7m deep approximately. The single cable
was 6 m long and was installed as shown below.
The equipment measured the level at the interface point
between the emulsion (fat and other surface residues)
and the liquid itself, which characterizes the upper layer
(approximately 10 cm height) as a low dielectric constant
material. The client’s objective: to measure the liquidfoam interface level accurately, as the foam thickness
varies in several points of the tank.
The RD400 uses the Time Domain
Reflectometry (TDR) technology, a principle
used in civil construction, telecommunication,
agriculture, among other areas, and recently in
industrial processes level measuring.
This principle is based on the concept that
electromagnetic waves, guided in a certain
ambient (in the case of RD400, its probes),
suffer reflection when meeting other ambient
with different dielectric constant, due to
impedance change.
The RD400 depends originally of the ambient
dielectric constant whose level is measured. For
humid ambients, the wave reflection improves
significantly due to the high dielectric constant
of the water.
Elements as dust, internal obstacles to the
tank (level keys, filters, etc.), bubbles on the
surface, among others, are most times ignored
by the equipment, since the waves are guided
by probes, without loss of power.
For each type of process, there will be the
need for a different probe, which can be a single
or dual rod, a single or dual cable or even a
coaxial terminal. What will determine which will
be the probe type are parameters as the tank
height, the installation or not of RD400 in the
communicating vessels, the dielectric constant
of the process, among others. Consult our
representatives for more information.
Conclusion
Installation in the Effluents Tank
Where:
01 and 02 - RD400 (electronics, generator/receiver and
coupling to the single probe);
03 – Metallic plate in 316 stainless steel, with of 1 ½”NPT
sleeve adapted;
04 - Single cable;
05 and 06 – 5 kg counter-weight.
The reflection signal, shown in the following figure, indicates
a satisfactory reflection, characterizing a transmitter
accurate and constant operation
Djalma Corrêa dos Santos.
Testimonial by Djalma Corrêa dos Santos, Instrumentation
Sector supervisor for the Uberlândia unit, concerning
the RD400.
02
03
Conclusion
The RD400 guarantees reliability and accuracy in
level measuring in sugar and ethanol plants, as well as
in other segments.
Free from density and temperature variations, the
presence of bubbles, false echoes common in non-guided
waves (as in microwaves or ultrasound transmitters), and
the possibility of being installed on the lower part of the
tanks, the RD400 just needs that its probe is submerged
in the process to be measured, and that process needs
a minimum dielectric constant so that the guided waves
reflect back to the equipment. The presence of water, as
mentioned before, is a guarantee of high dielectrics.
Besides, the RD400 has the advantage of being
installed on top, which makes possible to easily access
its electronics, as well as its simplified maintenance.
Most industrial tanks already have on their top sockets,
inspection points or flanges for installing other equipments,
where the radar can be adapted.
RD400 provides a new measuring technology for the
industrial automation market, but one that is already
in use in civil construction, telecommunications,
agriculture, chemistry, among other areas. The Time
Domain Reflectometry (TDR) concept, based on the
reflection of electromagnetic waves in process surfaces
offers them impedance change. It is a world accepted
principle and one totally adapted to industries, to supply
what other level measuring types could not meet.
For each type of process there will be the need for
a different probe, which can be a single or dual rod, a
single or dual cable or a coaxial terminal. Parameters
as tank height, the installation or not of the RD400 in
a communicating vessel to a reservoir, the dielectric
constant of the process, etc. will determine which
type of probe it will be. Consult our representatives
for more information.
Smar Guided Wave Level Transmitter .
Application in Plants and Distilleries.
Introduction
Coaxial
(1-3m)
Single Rod
(1-8m)
Dual Rod
(1-8m)
Tri-Clamp Connection
with Polished Rod
(1-4m)
05
Single Cable
(1-14m)
USA
Smar International Corporation
6001 Stonington Street, Suite 100
Houston, TX 77040
Phone: +1 713 849-2021
Fax: +1 713 849-2022
[email protected]
Smar Research Corporation
2110 5th Ave
Ronkonkoma, New York 11779
Phone: +1 631 737 3111
Fax: +1 631 737 3892
[email protected]
Smar Laboratories Corporation
6001 Stonington Street, Suite 100
Houston, TX 77040
Phone: +1 713 849-2021
Fax: +1 713 849-2022
[email protected]
BRAZIL
Smar Equipamentos Ind. Ltda.
Rua Dr. Antonio Furlan Jr., 1028
Sertãozinho SP 14170-480
Phone: +55 16 3946-3510
Fax: +55 16 3946-3554
[email protected]
GERMANY
Smar GmbH
Rheingaustrasse 9
55545 Bad Kreuznach
Phone: + 49 671-794680
Fax: + 49 671-7946829
[email protected]
MEXICO
Smar Mexico
Cerro del Cubilete #140
Fracc. Lomas de Mazatlán
C.P. 82110 Mazatlán, Sinaloa,
Phone / Fax: 52 + (669) 984 47 34
Phone / Fax: 52 + (669) 913 32 96
[email protected]
FRANCE
Smar France S. A. R. L.
42, rue du Pavé des Gardes
F-92370 Chaville
Phone: +33 1 41 15-0220
Fax: +33 1 41 15-0219
[email protected]
CHINA
Smar China Corp.
C-209, Ye Qing Plaza
No. 9 Wangjing Beilu
Chaoyang District
Beijing 100102, P.R. China
Tel.: +86 10 6439-8693
Fax: +86 10 6439-0781
[email protected]
www.smar.com.cn
UNITED KINGDOM
Smar UK Ltd.
Bluebell Farm,
Sandy Lane
Romsey,
Hampshire
SO51 0PD
Phone: +44 (0)797 0094138
Fax: +44 (0)797 4747502
[email protected]
SINGAPORE
Smar Singapore Pte. Ltd.
315 Outram Road
#06-07, Tan Boon Liat Building
Singapore 169074
Phone: +65 6324-0182
Fax: +65 6324-0183
[email protected]
NETHERLANDS
Smar Netherlands
A. van Leeuwenhoekweg 19b
2408 AL Alphen aan den Rijn
Phone: +31 172 494 922
Fax: +31 172 479 888
[email protected]
Plus a network of
representatives in 58 countries.
For your nearest representative
please contact:
[email protected]
Dual Cable
(1-14m)
w w w. s m a r. c o m
Specifications and information are subject to change without notice. For the latest updates, please visit the Smar website above.
© Copyright 2008 - Smar International - all rights reserved. - May/2008
Many industrial applications are run in the presence of
vapors, density and process temperature change, as well
as access difficulties and installation in the bottom part of
reservoirs.
The same applies for the sugar/ethanol sector. In many
cases, the job is measuring the process level as described
above, and solutions as load cells or free wave meters
require special installation cares, or simply are not fit for
some applications.
The level meter technology by the TDR (Time Domain
Reflectometry) principle, also known as Guided Wave
Radars, is one of the most modern existing in the industrial
automation market. This technology appeared as a solution
to fill gaps that other meters did not entirely do.
The new RD400, Smar’s Guided Wave Radar, has already
been installed at several sugar plants and distilleries, in
all over Brazil. These notes clarify some points that made
successful RD400 cases in this segment.
Effluents
Location: JPilon S/A Açúcar e Álcool Cerquilho-SP
Besides the vinaza, which is supplied
to farm areas as fertilizer, many industrial
effluents are deposited in plant tanks and
have the same use. Usually, they are
composed by such elements as:
• residual water from distillation (flegmaça);
• boiler discharge water;
• wash of the sugar production section.
At Usina J. Pilon S/A Açúcar e Álcool,
located in Cerquilho, São Paulo state, a
tank stores all those effluents. Next, the
effluents are pumped to cooling towers,
where a water spray cools them down and
they are sent for irrigation.
Both at the cooling tower and in the last tank,
the level control should be careful, because
it cannot overflow and cause the process
to stop. In the first tank, where the effluents
are received from the plant, a minimum level
must be kept at to avoid pump cavitation. The
RD400 is installed in the first effluent tank, as
shown in the following sketch.