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So let’s get down to the facts about non-contact technologies, both new and older in the market place today. The technology known as ultrasonic has been around for many years, and it is as the name implies, sub sound technology in the kilohertz frequency band. The designers of ultrasonic technology have made valiant attempts to solve the difficult solids applications with frequencies down to as low as 8 to 12 kHz and various transducer designs in size and shape, but the overall measurement success has been inconsistent at best. Then along comes non-contact microwave technology with the claims that it is the new “sexy” technology to measure the long range, dusty solids measurements. Great claims for something that performs well in dry materials, but induce moisture into the solids materials along with heavy dust, water sprayers for dust abatement, and that’s a formula for disaster. This new technology is not the panacea for all level applications as many companies tout, and it definitely does not have carte blanche performance in the industries like coal, metal mining, minerals, and other solids industries.

With the less than desirable results on solids using “ultrasonic” and the through air radar not capitalizing in the mining industries, what technology is out there to solve these applications? Well the overlooked technology, which is a variation on a technology theme of ultrasonic, but designed in a way to offer significant application benefits, is acoustic wave technology. The magic behind this technology is the fact that it utilizes audible frequencies (5 to 30 KHz) in a transducer design that is harnessed as a balanced resonant mass. The combination of low frequency, high applied power, and variable adaptive gain control makes this acoustic wave technology a real solids solution that can’t be beat and is really underestimated. On the transducer, the low frequency with high applied pulsing power to the face creates a pressure wave that literally offers consistent and proven self-cleaning properties. Effectively, there are no materials that will adhere to this transducer face regardless of their moisture or sticky properties.

So in mining applications, where there are wet screens from sprayers, or ROM bins with dust abatement controls causing heavy build-up on anything in the area, the acoustic wave technology can reliably provide level measurement under those conditions. Microwave radar CAN Not function under these moist solids conditions as it would be disastrous with material build-up adhering to the emitter on the inside of the horn antenna. Or worse yet, adherence of moist, powdered ore fines on the face of a “dust” cover that is designed to keep material from entering the horn antenna, but does not prevent adherence on the dust cover face. Many suppliers of non-contact radar designs today will recommend the use of antenna purging with either water or air within the plant site. This purging option sounds great in design, but in reality, the air purge causes more problems than it’s worth because most instrument air supplies have moisture, and this moist air will increase the chances of dust build-up on the emitter within the horn. Additionally, the instrument air is not inexpensive to supply on a regular basis.

The key to measuring solids materials in conditions where moist, wet, powders, ores, aggregate exist, then there needs to be a technology used where there are self-cleaning properties available. With acoustic wave technology, the power to the transducer with low frequency is one key design criteria, however, it takes a lot more than just that, and that’s where an Australian company has led the solids measurement charge within the level industry. The long wavelength of the low frequency designs also makes them appropriate for the tough stuff. Guaranteed for high performance without fail in the worst conditions known to man, the acoustic wave technology will absolutely amaze the doubting customer, until they see in action, and “how it take a beating, yet keeps on repeating” in the measurement.

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So, when one looks at level applications, the split is either liquids or solids. With liquids, many technologies can be applied depending upon the conditions in the application (temperature, pressure, air space conditions above the liquid surface, mounting, mechanical obstructions, and more. Liquids though are not nearly as difficult to solve with level technologies as the solids materials, which can range from fine powders to chunked aggregate materials, to the worst conditions of wet, moist fine powdery material that adheres to almost anything. When it comes to the technologies of through air radar, guided wave radar, or ultrasonic or acoustic, the choice of the technology is relatively straight forward with a few exceptions. If the liquid material is water based, with virtually conditions of a non-vaporous atmosphere, and temperatures/pressures in the ambient/atmospheric range, then ultrasonic or acoustic is suitable. With microwave radar applied, the liquids are probably going to be of a chemical or hydrocarbon formulation, probably have some excessive temperatures or pressures, and have heavy vapor conditions in the airspace. Guided wave radar can be applied as well in the aforementioned conditions, with the exception maybe of the range being too lengthy for a rod or flexible cable antenna or if there is an agitator in the vessel.

But, make no mistake about the fact that when dealing with solids materials in an industrial environment like a metal or coal mine, or fly ash in a load out silo at a power generation facility, the conditions for measurement are usually much more difficult. It requires a technology that can endure the atmosphere conditions like heavy dust, undulated material surfaces, wet or moist conditions from process sprayers, and sometimes hot conditions with build-up problems on any equipment installed in the application. If the height of the material containment for level measurement is more than 30 to 40 feet, then it is more appropriate and practical to choose a non-contact level measurement technology like ultrasonic, acoustic, or microwave radar. TDR or guided wave radar can provide continuous level measurements up to 80 feet; however, in solids materials, the tensile forces and loading on the cable become extreme, and thus will potentially cause breakage and shearing. It is just not practical to outfit any solids measurement application with something of a contacting design like guided wave radar when there is any sort of build-up potential, or lengths beyond 30 feet (10 meters). Also, as material shifts from one point to another in the solids, the cable follows that line of movement. Cost also becomes a factor too for guided wave radar in long measurements as cable lengths increase, so does pricing. With level measurement in solids beyond 30 to 40 feet, it is a wiser choice to go with a non-contact technology.

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Plant personnel like reliability engineers, operations managers, facilities engineers, maintenance, and more are always looking for ways to increase throughput, reduce downtime, and improve process efficiencies. With technology on the constant cutting edge, companies are designing process instrumentation that offers many different types of techniques for providing reliable level and point level detection solutions for tough applications. In order to be successful in this instrumentation market, a company must be offering solutions that are value added to customers, and offer user friendly configuration with high accuracy and reliability in mind. With technology like it is today, upgrading of level instrumentation at a plant location from older measurement techniques to newer designs will definitely lower maintenance costs, improve process efficiency and provide higher accuracy devices, which will provide many benefits. With safety being most industrial company’s number one goal, any basic level measurement must be reliable, robust and accurate and there must also be robust systems to guard against spillages from overfilling vessels.

Unfortunately, even with today’s advancement in process instrumentation, there is not one technology that will provide undaunted measurement results in every application. Although, it is the technology of microwave radar that has been promoted over the last several years as the panacea for all liquid or solid level materials. Is this really the case? What has happened in this instrumentation market to the idea of providing the right engineered solution for the customer’s application? Let’s really look at the technologies out there for liquids and solids level measurement like through air radar, guided wave radar, ultrasonic, and what’s being referred to by Hawk as acoustic wave. In applications, there are mechanical installation constraints, the conditions within the containment, and the capabilities of the level device will all affect the choice of measuring device. In the level instrumentation spectrum, there are many different technologies, but the major technology contenders are ultrasonic or acoustic wave, TDR (guided wave radar), and non-contact microwave radar. It is interesting to note too that the technology of ultrasonic or sometimes promoted as acoustic wave technology has flat lined or hit a road block in growth. The technology of microwave radar has been growing at the “speed of light” and being regarded, or at least touted as the end all beat all technology for measuring level in liquids and solids. Well, choosing the proper technology from one of these three can be a challenge, but if you’re looking for high reliability, low maintenance, and repeatable performance, then look below for some guidelines on each technology.

Myth or Reality: The Facts about Radar, and the Right Choice for Level in Solids Applications

With so many level technologies on the market today, the choice of technology is much more difficult and can be confusing. Process measurement and controls are an essential component for any industrial plant attempting to conform and abide by the strict safety and environmental regulations set forth by state agencies. Not only is it important to know what is contained within any silo or vessel, but it is vital to know whether a silo or flow area has material blocked. Whether that material is too high or low in the containment is also critical as it can cause enormous safety hazards to plant personnel as well as clean-up costs and agency fines. Additionally, installing point detection devices in transfer chutes for blockage detection is also important as it is an inexpensive way of preempting a nasty chute blockage. These transfer chutes are all over the place throughout a mining site, and one plugged chute can stop production, which incurs hundreds of thousands of dollars in downtime production costs. So with that stated, reliable continuous level measurement and redundant point level detection are an important part of any process plant, particularly at a time when improving energy efficiency and reducing operating and maintenance costs are important considerations. Plant safety and meeting stricter environmental regulations become a challenge in this tough competitive marketplace.

Many level applications pose special problems for process level equipment and technologies. Whether the industrial site is a mine, power generation facility, or cement plant, these sites all require technologies that will withstand the tough environmental conditions as well as the harsh nature of the solids applications. These include heavy dust in the airspace, steep angles of repose, high temperatures, changing process conditions, corrosive media, abrasive solids materials, and more. In addition, so many different sizes and shapes of containment mean that many installations have to deal with obstructions like mechanical bracing for structural support.

Importance of backup systems for small and medium size businesses (SMBs) is in no way less, as compared to big companies. SMBs also depend heavily on the computers for the data management. There are several examples of SMBs that lost all their valuable data because of computer failure and never returned to the scene again.

Every business generates critical data while conducting day to day activities.

This data can be in the form of:

• Business Application Data e.g. Accounting Software, Inventory, Tally, ERP, CRM etc.
• Documents, Spreadsheets, Presentations e.g. Quotation, Communication with Clients, etc.
• Emails, Communications, Contacts, Notes, To-Do List, Appointments etc.
• Pictures of products, Digital Catalogues

How data loss occurs:

• a physical failure of Hard Disk
• power failure which can corrupt your data
• virus attacks
• accidental deletion
• overwriting a new file with an old one
• someone deleting necessary files deliberately to harm the organization

Lack of Systematic Backup Policy:

SMBs do not have any backup policies in place because of which the following issues exists even if they are taking backups:

• Backups are done at random and irregular intervals
• Backups are done manually so there are chances of missing important files
• Usually taken by a Copy Paste command so there is no verification of backup
• None or rarely backups are taken from the Laptops of the Executives
• Backups are not tested for integration by restoring it at regular intervals
• Usually backups are non-encrypted and anyone who has the access to it can read or take away all of it
• Backups are kept on-site and no off-site copies are kept
• No multiple copies Daily, Weekly and Monthly are available

Best policies to follow:

• must be taken at regular intervals
• must be verified after the backup completes
• Laptops also must be backed up at regular intervals
• must be restored at regular intervals to check its integrity
• must be encrypted so that no unauthorized person can get access to the data
• There should be daily, weekly and monthly copies of the backup
• must have at least one off-site copy of the backup
• must be taken on an external Hard Disk or a Tape Drive media and not on one of the computers in the office