SOLIDS FLOW SENSOR SOLIDS FLOW SENSOR: MWS-DP-2

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Kerry Blankenship
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1 SOLIDS FLOW SENSOR AN INTRODUCTION TO: SOLIDS FLOW SENSOR: MWS-DP-2 Vr. 4.01

1. GENERAL 1.1 About WADECO s Microwave Flow Switch With over 25 years experience, WADECO is the world leader in the design and manufacture of high quality, reliable Microwave Flow Switches.

2 1. GENERAL 1.1 About WADECO s Microwave Flow Switch With over 25 years experience, WADECO is the world leader in the design and manufacture of high quality, reliable Microwave Flow Switches. WADECO's MWS-DP-2 is a microwave based noncontact solids flow sensor. It utilizes the Doppler effect to detect the movement of solid materials such as powders and granules in pipelines. This low cost, reliable sensor is an ideal for monitoring solids flow in vacuum pipelines, ducts, air slides, and at transfer points in vibrating chutes, conveyer belts and bucket elevators. MWS-DP-2 Solids Flow Switch The sensor has wide application across all areas of industry where highly reliable, non-contact flow detection is required.

3 1. GENERAL 1.2 Generic Features of Microwave Flow Switches Non contact detection, results in: Reduced wear and tear, Zero maintenance. Non invasive detection through refractory, glass, plastic windows / walls: No disruption to material flow, Keeps the process closed. Unaffected by build-up on the antenna head, thanks to the high penetrability of microwaves. No moving parts for solid state reliability. Benefits include: Increased reliability, Reduced downtime, Less wastage of raw materials, Reduction in unusable end product, Less wear on machinery, Energy savings.

1. GENERAL 1.3 Detection Principal WADECO's MWS-DP-2 utilizes the Doppler effect to detect the frequency shift between the transmitted and reflected microwaves.

4 1. GENERAL 1.3 Detection Principal WADECO's MWS-DP-2 utilizes the Doppler effect to detect the frequency shift between the transmitted and reflected microwaves. The sensor emits a low power microwave signal towards the target material. A portion of these microwaves are then reflected back to the sensing head and analyzed as to whether they are from a moving or stationary target. If the return signal has a Doppler frequency shift, then motion is detected and an output relay is actuated. Microwaves are able to penetrate non-metallic material, thus nominal material buildup on the sensor head does not affect flow detection.

5 2. APPLICATIONS & INDUSTRIES 2.1 Application Examples VOLUMETRIC DOSING Detection of major operational malfunctions: - blockages, - empty hoppers etc. This avoids unexplainable output variations due to improper or missing batching components. The MWS-DP-2 verifies that a volumetric dosing system is operating as expected. Blockages and empty hoppers can be detected early enough to prevent major damage to the process. Monitoring volumetric dosing operation

6 2. APPLICATIONS & INDUSTRIES 2.1 Application Examples VOLUMETRIC DOSING Detection of major operational malfunctions: - blockages, - empty hoppers etc. This avoids unexplainable output variations due to improper or missing batching components. The MWS-DP-2 verifies that a volumetric dosing system is operating as expected. Blockages and empty hoppers can be detected early enough to prevent major damage to the process. Monitoring volumetric dosing operation

7 2. APPLICATIONS & INDUSTRIES 2.1 Application Examples SILO DISCHARGE Detection of operational malfunctions at the silo discharge: - Bridging, - No flow, - Rat holing / loose gates. Subsequent diverters valves can be easily monitored as well. It can be used to supply a signal to the bin activators or operators. Monitoring the correct operation of gates and valves is an additional benefit for this application. Avoids loss of material, accidental discharge or materials going though wrong paths. Monitoring silo discharge

8 2. APPLICATIONS & INDUSTRIES 2.1 Application Examples MECHANICAL CONVEYING Detection of mechanical damage in conveyers as well as conveyers running empty. Ensures early indication of problems in the conveying system, avoiding accumulative damage. Allows activation of mechanical conveyers only when needed which reduces maintenance, energy costs and equipment wear. Installing a sensor before or after mechanical conveyers provides valuable information about the mechanical function of upstream and downstream equipment. Monitoring flow at transfer point on conveyer system

9 2. APPLICATIONS & INDUSTRIES 2.1 Application Examples DRYER, SCREENER, CLASSIFIER, MILLS ETC. Detection of proper material flow to and from the process. Failure of material supply to the process will be detected early enough to avoid inefficient operation of the equipment. Blockage or damage in the screens, mills, etc., are detected when they occur. Monitoring various phases of a process Preventive actions can be taken before production or quality losses occur. Functions as a safety measure to avoid in-plant hazards or damage to expensive equipment.

10 2. APPLICATIONS & INDUSTRIES 2.1 Application Examples PNEUMATIC CONVEYING & INJECTION Detection of any major malfunction in the operation of pneumatic conveying system which could result in changing of material characteristics, wear of gates or feeders, and moisture accumulation in the pipes etc. High pressure fluctuations in the transport line will not affect the operation of the MWS-DP-2. The sensor can successfully be applied to pipe diameters of 3/4 and larger. Monitoring pneumatic injection system Injection of solids via multiple injection points sometimes requires the control of each transport line, where the process cannot function with even a partial blockage in the material intake (e.g. coal injection in a blast furnace).

11 2. APPLICATIONS & INDUSTRIES 2.1 Application Examples BLAST FURNACE COAL LANCE INJECTION SYSTEMS NON INVASIVE DETECTION THROUGH CERAMIC PIPE Microwaves can penetrate the nonconductive inner pipe (ceramic), with negligible attenuation. External mounting allows the process to remain closed, and allows detection from the safe area outside the hazardous high pressure, high temperature system. This drastically reduces wear and tear on the sensor and also allows for easy access to the sensor without having to shut off the flow inside the pipe. Existing pipe Connection flange Outer pipe (SUS) Middle material Inner pipe (Ceramic)

12 2. APPLICATIONS & INDUSTRIES 2.2 Major Industries Primary Industry Sector: Natural Resources / Raw Materials Agriculture, Mining, Quarrying. Secondary Industry Sector: Refining / Manufacturing / Energy Aluminum, Cement, Energy / Electric Power Plants, Feed mills, Food Processing, Iron & Steel, Manufacturing, Waste Management.

13 3. HARDWARE OPTIONS 3.1 Standard Enclosure Standard enclosure is suitable for most applications that do not exceed the general specifications (temperature, pressure, vibration etc). Rubber packing SUS Lock nut

14 3. HARDWARE OPTIONS 3.2 Optional Flange Mounting Threaded flanges are available in most standards (JIS, DIN, ANSI etc). SUS Lock nut SUS Threaded flange

15 3. HARDWARE OPTIONS 3.3 Optional NP Type The NP type is useful for applications where the process material tends to buildup, impairing the microwaves; the polypropylene plug should be placed into the standoff portion preventing material from entering the standoff. It is also suitable for high pressure applications. Threaded flanges are available in most standards (JIS, DIN, ANSI etc). SUS Lock nut Polypropylene head SUS Threaded flange

16 3. HARDWARE OPTIONS 3.4 Optional NS Type The NS type is suited for applications where the higher penetrability is required and the sensing head comes into contact with corrosive/abrasive materials. The stainless steel antenna head provides increased resistance to physical wear and tear. Threaded flanges are available in most standards (JIS, DIN, ANSI etc). SUS Lock nut Stainless steel antenna with Teflon cover SUS Threaded flange

17 3. HARDWARE OPTIONS 3.5 Optional SH Type The SH type is suitable for applications where the sensing head comes into contact with corrosive/abrasive materials and for higher temperature applications up to 150ºC. The stainless steel antenna may be extended and cooling fins added to disperse heat energy conducted from the antenna. Thread size and head length are user selectable. Rubber packing SUS Lock nut Stainless steel threaded antenna head with Teflon antenna cover Aluminum cooling fins

18 3. HARDWARE OPTIONS 3.6 Optional EK Type The EK type super heavy duty extension kit is suitable for high temperature applications up to 600ºC. Flange, antenna size and waveguide length are user selectable. SUS Nut SUS Waveguide SUS Antenna with ceramic antenna cover Aluminum cooling fins SUS Threaded flange

19 4. USEFUL LINKS Catalogs: MWS-DP-2 North American Sales & Service Center HiTECH Technologies, Inc. 301 Oxford Valley Road,Yardley, PA Tel: Fax: Tech Support: Web: Copyright 2005 Wire Automatic Device Co., Ltd. All rights reserved.

Low-Cost, Non-Invasive, Microwave-Based Bulk Solids Flow Detector

Low-Cost, Non-Invasive, Microwave-Based Bulk Solids Flow Detector Granuflow Principle Sensor Features The Granuflow, a non-contact flow sensor, is ideal for monitoring solids flow in pipelines, ducts,