Instrumentation in flour millsSolutions matching the requirements from the receiving to the flour silo

Operational challenges in grain millingExplosion protection: Who takes care of safety?Implementation of your country-specific directives • Endress+Hauser offers support to select the right measuring

devices to ensure safe operation

Inventory Control: How much is in which storage bin?• Endress+Hauser offers customized solutions for storage and logistics

Traceability of material flows: Where from, where to? • Endress+Hauser provides solutions for silos based on level measurement which support the traceability through each step of the production from grain to flour

Services: Who has time for maintenance? • Endress+Hauser offers professional support for startup and

maintenance for safety and quality relevant measuring points

One-stop-shopping: Optimization of process automation • Endress+Hauser offers the complete measurement instrumentation

and additional system components for every area of a mill

Flammable Material Present Continuously

Flammable Material Present Intermittently

Flammable Material Present Abnormally

IEC/EU Zone 0 Zone 1 Zone 2

US NEC® 505 NEC® 500

Zone 0 Zone 1 Zone 2

Division 1 Division 2

CA CEC Section 18 CEC Annex J

Zone 0 Zone 1 Zone 2

Division 1 Division 2

Duty for operator of facility• Hazard evaluation• Safety of working environment and equipment• Classification of areas • Explosion protection document• Inspection and maintenance• Training of employees

Duty for manufacture of measuring devices • Safety of measuring devices• Categorisation of measuring devices• Declaration of conformity

Challenge #1: Explosion protection: Who takes care of safety?During processing grain and flour, dust is an inevitable by-product. It is generated from particles adhering to the grain kernel, by abrasion of the grain and by the end product flour itself. Dust is able to generate an explosive atmosphere that can result in devastating losses if not addressed.

Endress+Hauser provides measuring devices according to ATEX, FM and CSA directives and supports in selecting the right instrumentation according to your area classifi- cation. Duties of facility operators and manufacturers of measuring devices are split according to the following overview:

Explosive areas are divided into zones. The following table shows the Area Classification in different countries.

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Manually, on foot and on paper… Who doesn’t have this experience: was the storage bin no. 2�� empty or not? To insure yourself you take the lift to the top floor of your storage elevator and have a look in this bin. And how can you get this information if the silos are remotely located?

...this has to be a thing of the pastInventory Control by Endress+Hauser provides solutions to opti-mize your warehousing and supply chain.

Around the clock, around the world: be informedThe signal output of the transmitter e.g. Levelflex M is connected via Fieldgate FXA520 like a PC to the Intranet of your company or to the Internet. This offers a cost-effective possibility to get local or remote informations about the actual levels and limits of your storage elevator.

The right solution for visualisation is our system P View. Alarm limits can automatically be sent by mail or SMS to avoid produc-tion downtimes or to initiate a new material order.

Multiply your cost savings potentials together with your supplier or customerAllow your supplier access to your stock data or get access to the stock data of your customer by Fieldgate FXA520 and Internet. This opens up cost saving potentials by scheduling the delivery in adaptation to the actual consumption.

Additional parameters like temperature can easily be integrated and by the software TOF-Tool you are able to do a quick and com-fortable remote maintenance of your measuring devices.

Warehouse with storage binsIdeal field of application for inventory Control Solutions

Picture:Intranet drawing

Checking every storage bin visually is a thing of the past

Inventory Control just by weighing and writing requires time consuming accounting

Challenge #2:How much is in which storage bin?Inventory Control Solutions for storage and logistics

6x Levelflex:4-20 mA/HART

HART

RS-485Ethernet

hubWireless LAN Access Point

Wireless LAN Access Point

PCI cardRemote monitoring via Internet

HART multiplexer

FieldgateFXA520

Soliswitch FTE30Limit paddle switch

7Silopilot M FMM50Electromechanical system

6Levelflex M FMP40 Guided radar level measurement

5

Micropilot FMR250Radar level measurement

4Soliphant T FTM20Single-rod vibronic sensor

3Nivector FTC968Capacitance limit switch

2Omnigrad M TR10Temperature sensor

1

Instrumentation in the grain receiving and grain elevator

5

DryingMonitoring of grain temperature with temperature sensor Omnigrad M TR10. The modular sensor concept allows the adaption to any measuring application.

Precleaning / batch-weighingSupply and overrun hopper are equipped with a high level alarm by capacitive limit switch Nivector FTC968.

Bucket elevatorAccumulation indication of grain in the elevator boot:vibronic sensor Soliphant FMT2x. Functional principle of sensor has no moving parts and guarantees maintenance free operation.

Grain elevator – level indicationElevators up to 70m/2�0ft: Non-contact radar level measurement with Micropilot M FMR250. Air purge allows long time operation without additional cleaning.

Elevators up to �5m/115ft: Guided Radar Levelflex M FMP40, factory adjusted for easy start-up, insensitive against build-up on rope-antenna.

Alternatively:Electromechanical system Silopilot M or T. Quick and easy startup procedure requires no adaptation to geometry of silo and no special technical know-how. Silopilot T FMM20 measures up to �2m/105ft and Silopilot M FMM50 measures up to 70m/2�0ft.

1

2

3

4

5

6

Grain elevator/limit detectionHigh level alarm:paddle switch Siloswitch FTE30, simple operation by proven principle.

Low-level alarm:vibronic sensor Soliphant T FTM2x. The single-rod sensor allows reliable operation.

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3

Silopilot T FMM20Electromechanical system

6

Flow rate weigher with Nivector FTC968 as high alarm

Instrumentation technology in purification and conditioning

Conveying / machine feedingDetecting overflows and blockage, the capacitive limit switch Nivector FTC968 ensures a cost effective monitoring of your products. A protective cap is available for abrasive materials.

ConditioningControlling the quantity of water by magnetic-inductive flow measuring system Promag 50. Available from DN 2 up to DN 100, software options for batching and pulsating flow.

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9

Tempering bin – level indicationTwo ultrasonic sensors FDU9x connected at one transmitter, Prosonic FMU90, allow the configuration of two different ranges, e.g. 0% to 100% for level indication and 50% to 70% for control of screw conveyor with corresponding relay configuration.

Tampering bin – limit detectionHigh-level alarm: low-price solution with the paddle switch Siloswitch FTE30, sensor length from 70 up to 2000 mm.

Low-level alarm: vibronic single-rod sensor Soliphant T FTM2x allows failure-free operation.

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7

3

Nivector FTC968With replaceable protector

Receiving Precleaning

Grain Storage

Legend

LA

LI

FI

TI

PI

PDI

Limit detection, alarm

Level indication

Flow indication

Temperature indication

Pressure indication

Differential pressure indication

TI

TI

TI

LA

LA

LA

LA

LA LA

LA

LA

LA

LA

LI

Furnace

Bucket Elevator

Dryer

Dust collector

Fan

Precleaning separator

Dumping pit

Chain conveyor

Flow-rate weigher

Grain storage elevator

Chain conveyor

Silo elevator Elevator

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1

1

2

2

2

3 3

3

8

74 od. 5 od. 6

2Prosonic FMU90With FDU91 sensor

Promag 50WElectromagnetic flow measuring system

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2 9 10

Nivector FTC968Capacitance limit switch

2

Instrumentation technology for milling, sifting and flour storage

Purification Conditioning

Purification Conditioning

Flour Storage Loadout+Package

LA

LA

LA

LA

LAFI

LA

LALI

LA

LALA

PIPDI

PI

LA

LA

LA

LA

LA

PDI

LA

LA

Elevator

Metal separator

Separator with

aspiration channel

Dry stoner

Indented surface

separator

Dampener

Tempering bin

Pneumatic pressure conveying system

Dust col-lector

Scourer

Aspirator

Roller stand

Planswifter

Bran cen-trifugal

Pneumatic pressure conveying system

Loadout

Pneumatic mill stock conveying system

Bag-packing station

LA

LALA

LA

LA

LALI

Batch-weighing

Flour storage

Dust collector

Airjet filter

Blending/Homogenization

Fan2

2

2

2

2

9

2

710

3

2

313

12

8

2

12

2 + 11

2

2

13

14

2

22

3

85

2

2

Nivector and Multicap – Roller mills

Multicap DC16Capacitance probe

Levelflex FMP40Guided radar device

Milling processSecuring a consistent feed to the roller mill:

Overfill protection at the filling spout with capacitance limit switch Nivector FTC968.

Level monitoring by capacitive probe Multicap DC16.Selectable sensor length from 100 up to 4000 mm allows easy adaption to feeding container.

Flour storage - level indicationLevel measurement by guided radar Levelflex M FMP40, factory adjusted for easy start-up

2

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5

Flour storage - limit detectionHigh-level alarm by Minicap FTC260 or by extended cable-version FTC262. Active build-up compensation guarantees failure-free operation

Low-level alarm: Vibronic sensor Soliphant T FTM2x. Installation in any direction possible. Time-saving startup without any adjust-ments. When sensor is covered with material, the vibration is stopped to avoid expulsion of material.

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3

Levelflex M - Dust occuring during filling process has no influence on the operation of the instrument

7

5 11

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Other applications in milling operations: aspiration, pneumatic conveying and loading

Cerabar M PMC41Pressure sensor

Deltabar S PMD70Pressure device

Soliphant M FTM50/52Point level switch (vibronic)

Pneumatic pressure conveying systemMonitoring of operating pressure by pressure sensor Cerabar M PMC41. Ceramic sensor membrane is stable against alternating loads and overload resistant.

Pneumatic mill stock conveying systemFilter monitoring by differential pressure sensor Deltabar S PMD70. Monitoring of functions from the measuring cell to the electronics ensures accurate and economical operation of your systems.

Exhaust systemOverrun alarm at the receiver or airjet filter by capacitive Minicap FTC260. Accurate switch point even with heavy build-up on the probe guarantee high operational safety.

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12

8

OutloadingOverfill protection at the filling spout by Soliphant M FTM5x. This vibronic sensor is available as a compact version with extension pipe up to 4m or with rope up to 20m, and therefore, can be installed in any position.

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Soliphant M - Outloading filling spout

Soliphant M - Filling spout

13

12

14

Minicap FTC260/262Capacitance limit switch

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Reporting at a push of the buttonEndress+Hauser offers customized solutions. Start-ing with the connection by PROFIBUS, Foundation™ Fieldbus, HART® or Ethernet up to the visualization at your PC. The volume flow through each bin is calculated by the differences which occur during the

transfers between source and destination bin. All data relating to the batch and the bin levels are stored in a SQL (Structured Query Language) relational database system. Using these linked informations you receive a standard reporting.

Actual situationThe most important requirement regarding legislation is the consumer protection. Therefore, different laws, standards and guidelines are released to ensure the complete traceabi-lity of products along the food chain.

Example: European Directive (EG) 178/2002Starting the first of January 2005, every mill had to ensure that for every batch of flour being processed, it is possible at any time to trace back from which delivery of grain this product was made. The recipient of the batch has to be deter-mined as well.

Material flow traced back efficiently: we link your informationRegarding the chain of traceability, the mill itself can be considered as a closed system. It is not necessary to reveal steps of processing and blending. Endress+Hauser offers solutions based on level measuring technology which is an economical tool for documentation. At the push of a button you get any information which is required to trace back your material flows.

Weighment

Storage

Blending

Intermediate storage

Remote I/O

Purification / Milling

PROFIBUSPA

PROFIBUSPA

PROFIBUSPA

Delivery

4-20mA

Ethernet Ethernet

SQL-Database ReportingVolume flowTrackingWeights of deliveries

•••

Segment coupler

Segment coupler

PROFIBUS DP

Local PC Entry by operator:

Batch numberID of supplierType of productTime/dateDestination storage bin

•••••

Fieldgate FXA 720

Printing of receipt

Network switch

Monitoring PC

Entry of BatchReceipt

••

Visualization

Challenge #�: Traceability of material flows - Where from, where to?

Start-up in explosive areasEndress+Hauser provides a safe start-up in explosive areas, e.g. storage elevators, carried out by our special skilled service people. You receive a professional service report for your documentation.

Start-up to get more value from your moneyTo reach the full performance range of ultrasonic and radar measuring devices for storage elevators it is necessary to select the right instrument, the optimal installation place and a start-up adjusted to the conditions of your process environment. We support you step by step.

Increase the availability of your facilityWhich effort of maintenance do you need and how often? We ascertain a maintenance concept which matches the requirements of your facility. With it you master your costs at a maximum availability of your facility. We offer 4 different maintenance levels.

Standard OptionsFunctional

checksStart-up* Travel & l

abor costs**Spare parts Wear

parts***Consumables Phone

supportCalibration

servicesOn-site

response time

Preventative service • • • • •

Extended service • • • • • • •

Total service • • • • • • • • •

Tailor-made service “It is your choice!” “It is your choice!”

*for new instruments added within the term of the contract **for on-site repairs ***annual exchange of wear parts for instruments like automatic pH measurment system...

Training: extend your know-howOrganized on your site or at one of our training centers: take the opportunity to increase the independence of your technicians handling your measuring devices by transfer of knowledge.

Helpdesk/W@M-CardQuestions related to technical problems can be addressed to our spe-cialists during our working hours. Owning the W@M-Card you are able to do this around the clock ��5 days a year.

Services for special measuring devicesStart-up in explosive areas

Concepts for maintenanceYou select between 4 maintenance levels

TrainingKnow-how-transfer for your service people

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Challenge #4: Services - Professional support for your security and quality relevant measuring points

System components Innovative and modern system components which link plant to control room are at the top of any forward thinking Process Engineer’s wish list. Whether he wants to visualize measured values, protect his sensors, or use signals directly for process control, Endress+Hauser will offer the simplest solution.

Limit switch and relaysIsolated switch amplifiersUniversal transmittersRecording devices and dataloggers

••••

RN221N active galvanic barrierThe RN221N provides galvanic isolation of 4-20mA signal cables. It is used for the intrinsically safe operation of two-wire transmitters and to eliminate earthing problems.

RIA452 process display The digital RIA452, with 7-digit bright multi-colored LC display and pump control functions, receives measurement signals from most field devices and can be installed in con-trol rooms or in panels throughout the plant.

RIA141 field displayThe RIA141 digital display in pressure sealed metal enclosure (explosionproof to EEx-d) is designed for installation in to a 4-20mA power circuit and to makeyour process more visible and plant much safer.

HAW562 spike or overvoltage protection The HAW5�2 protects 0/4-20mA, PROFIBUS-PA and PFM signal lines.

RMA422 process transmitter The RMA422 receives and processes measurement signals. Its modular concept makes it the perfect process measurement transmitter e.g. as tem-perature transmitter, contactor or signal converter. Using the two input process values, server values can be calculated.

System components - Completing your measuring point

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Instruments International

Endress+Hauser Instruments International AGKaegenstrasse 2415� ReinachSwitzerlandTel. +41 �1 715 �1 00Fax +41 �1 715 25 00http://www.endress.cominfo@ii.endress.com

12.0�/I.I.

SO 004B/24/ae/0�.077104�45�Straub/INDD CS2

Liquid Analysis

ConductivitypH/ORPChlorineDissolved oxygenTurbidityChemical analyzersNitrate/organic sensorsSludge level

••••••••

Recorders

Paperless recordersVisual data managersSafety data managers

•••

Components

DisplaysEnergy managersDensity calculationsSwitch over control

••••

Service

Start-upTrainingCalibrationMaintenance contractsInstrument Management Solutions

•••••

Level

Capacitance (RF)ConductiveMechanicalVibrationUltrasonicRadarGuided radar (TDR)Hydrostatic

••••••••

Pressure

Gauge/absoluteDifferential pressureHydrostatic

•••

Flow

ElectromagneticVortex sheddingCoriolis mass flowUltrasonicOpen channelD/P flowThermal mass flow

•••••••

Temperature

Temperature transmittersRTDs/thermocouplesSensors

•••

Endress+Hauser’s product portfolio