The Misery of Malfunctioning Measurements
Level measurement is a critical function of most manufacturing operations, and asphalt shingles are no exception. When stakeholders and plant personnel have a clear picture of their inventory, they are able to keep their processes running as efficiently as possible without the fear of detrimental events like overfills. Needless to say, level sensor malfunctions can be inconvenient at best, and in some cases can even be disastrous.
In the case of this shingles manufacturer, plant personnel had to take on the task of level measurement themselves when their sensors malfunctioned. This meant climbing up on the asphalt tanks to manually check the product level. Not only are manual measurements generally less precise than those obtained through purpose-built level sensors, they also can be risky. In this case, climbing the tanks required more safety precautions, especially during winter months when snow would cover the ground and steps leading up to the tops of the tanks. These risky climbs came to be too frequent when the company failed to receive service or support for their malfunctioning sensors, and so the search for a new sensor supplier began. That’s when the company got in touch with VEGA.
Reliability + Safety = 6X
Experts at VEGA assessed the shingles manufacturer’s heated asphalt tanks to determine what level measurement solution would best fit their needs. A good sensor would need to stand up to the high temperatures of the asphalt vapors and be resistant to the buildup caused by these vapors. Additionally, the tanks required a maximum measurement range of at least 60 feet from the mounting location that was already in place above the tank.
The solution came in the form of VEGA’s latest non-contact radar sensor, VEGAPULS 6X. THE 6X® is designed to meet the needs of any level measurement application; each sensor is built according to the needs of the application. VEGAPULS 6X can withstand process temperatures as high as 450°C (842°F), easily above the temperature output by the asphalt vapors. As for the measurement range, VEGAPULS 6X would have no problem reaching 60 feet down, as it tops out at maximum distance of 393 feet (120 meters). When presented with the benefits of VEGA’s sensor, the company agreed to place one on each of their four asphalt tanks.
The VEGA Difference
While the company’s old malfunctioning sensors certainly caused major issues, some of these challenges could have been avoided if they had been able to obtain service and support for the ailing equipment. To ensure they found a level measurement partner that would be able to offer better service and expertise, they entrusted the commissioning and setup of the new sensors to VEGA service personnel. This task would be a good testing ground for VEGA’s service: the company was badly in need of new sensors, so commissioning and setup would need to be done as quickly as possible. Fortunately, VEGA was more than up to the task.
VEGAPULS 6X is designed to be simple and intuitive, from the point of purchase to usage in the field. And with PLICSCOM, VEGA’s display and adjustment module, setting up multiple sensors is a breeze. One VEGA representative set up the first VEGAPULS 6X and then copied its settings using a PLICSCOM module. From there, all that needed to be done was to paste the settings to the other three VEGAPULS 6X units in the tank farm. Thanks to the intuitive setup features provided by VEGAPULS 6X and the PLICSCOM module, all four sensors were up and running within an hour.
Reliable instrumentation and expert service all under one roof
Equipped with VEGAPULS 6X sensors and backed by the support of VEGA’s expert service team, the company now enjoys a clearer view of their asphalt inventory, allowing them to run their plant and produce shingles more efficiently than ever before. The high precision of VEGA’s sensors is matched by their high reliability, meaning plant personnel don’t have to worry about trudging up slippery steps in the cold of winter to make level measurements. VEGA’s easy-to-use instrumentation gives users the confidence to operate and configure their level measurement sensors to best fit their needs. And with VEGA’s robust support options backing them, the company doesn’t have to worry about being stuck with malfunctioning equipment. That’s what makes VEGA the partner of choice for so many companies in the building materials industry looking to optimize their processes.
