Electricity + Control March 2019

INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

Monitoring the level of molten polyethylene for car parts

A good portion of our cars today are made from plastics and plastic composites. According to the American Chemistry Council, plas- tics account for about 50 % of the volume of a typical vehicle. The use of plastic in cars helps achieve better fuel efficiencies and improves vehicle safety. Often, these plastic parts are made of polyethylene and recently, Vega Americas helped an auto parts manufacturer achieve accurate tracking on the levels of molten pol- yethylene in its tanks. The auto parts manufacturer, which is responsible for making vehicle interiors, steering wheels, exterior mouldings and trim pieces for large automobile manufacturers, had not been getting level measurements in any of its 30 polyethylene tanks. Poly- ethylene is a product with poor reflective properties and not easy to measure. In a particular plant, the tanks are very small – about 1,5 m tall and just more than 0,5 m in diameter. On top of the tanks, there’s only a single 1” process connection, and it’s pushed to the sidewall because of a bulky mixer mounted on top. In ad- dition, there’s little to no headspace above the vessel to install a guided wave radar measurement instrument. Because of the low Dk product and the tanks’ proximity to the sidewall, Vega representatives suggested testing a Vegapuls 64 on three of the vessels. In order to bypass the large mixer flange on top of the tank, installers had to reduce the 1” threaded process connection to a ¾” thread and mount an 8” extension. This was only possible because of the Vegapuls 64’s versatile process con-

nections. The ¾” connection wasn’t a problem. After constructing a more elaborate process connection and commissioning the ra- dars, the installers were able to get a reliable signal. The previous instrumentation on these vessels had not func- tioned for years, so operators had been working blind. The new solution involving a small, unique process connection and the Veg- apuls 64, has enabled the plant to run at an optimal production rate,

and the auto parts man- ufacturer has reduced its risk of overflowing the tanks. It is now planning to implement the same solution in most of its existing tanks. Enquiries: Vega Controls SA. Tel. +27 (0)11 795 3249 or visit www.vega.com

The purpose-designed process connection for the Vegapuls 64 allows for ef- fective level measurement even in such tight spaces.

Electricity + Control

MARCH 2019

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