2010/2

3

In terms of quality and reliability: 3-year full warranty ..........4NIVELCO making its debut on the IFAT ..............................5The TQM (Total Quality Management) ...........................6–7NIVELCO on film shooting ............................................8–9

NIVELCO Romania’s 5th anniversary...........................10–12NIVELCO Czech Republic ...............................................13NIVELCO Russia.......................................................14–15

New solution for instrumentation of sewage shafts .......16–17NIVOPRESS N – Hydrostatic pressure transmitters........18–19

Iterative development in the instrumentation industry....20–23

Instrumentation of a sewage works – Romania ..................24Instruments of a concrete plant – Czech Republic ..............25NIVELCO instruments in the oil industry – Hungary......26–27Level measurement in a bread factory – Hungary ..............28Screening plant of limestone – Poland..............................29NIVELCO instruments in the steel industry – Hungary ...30–31Controlling of rotary drum screens – Hungary .............32–33

CIP cleaning ..................................................................34

Introduction 3

NIVELCO News

Applications

NIVELCO Instrument News

Process Instrumentation

Professional Forum

NIVELCO subsidiaries

Esteemed Partner!

I do welcome you again and by commendingour latest NIVELCO magazine aimed at high-lighting the most significant achievements ofour company in the year of 2010.

I proudly announce NIVELCO introducing3-year full warranty for all products, startingwith the 1st Sept 2010. I am confident that thisannouncement shall improve our standingamong the manufacturers of industrial equip-ment and will reinforce NIVELCO's image as a world class producer.

This year we celebrate the 5th anniversary ofour Romanian subsidiary, NIVELCO TehnicaMasurarii, a company dynamically expandingand increasing its market share over the years.Today Tehnica Masurarii is well known all overthe country, their acceptance level and prestigegrowing along with sales.

For the first time in its history, NIVELCO exhibitson the IFAT ENTSORGA 2010 Trade Fare inMunich. Expecting a most positive outcome bybeing able to address a different clientele inthe prestigious IFAT Trade Show, we also hopeto witness the recovery of the global economyalong with the same of our process control industries.

A new promotional video was shot recently onlocation mostly to illustrate the applicationpossibilities of NIVELCO instruments.

We are counting on your visiting our exhibi-tions and numerous presentations of NIVELCO.In the hope the articles on the next pages willbe helpful in your professional life, I commendagain the 2nd edition of our magazine.

Tamás SzőllősPresident (CEO)

IntroductionContents

NIVELCO Magazine 2010/2

Published by: NIVELCO Process Control Co.H-1043 Budapest, Dugonics u. 11.

Tel.: (36-1) 889-0100 Fax: (36-1) 889-0200 email: info@nivelco.com web: www.nivelco.com

4

NIVELCO offers 3-year full warranty forall NIVELCO instruments from 2010September 1.

A thoroughful analysis of breakdowns occurring duringand after the warranty period is a regular process we atNIVELCO exercise over the last many years.

As observed, among the reasons of breakdowns most fre-quent are component failures or production related ones,a good share of them however can be attributed to theuser, as improper installation or the neglect of our speci-fication limits. A special attention is given to regularly oc-curring or returning faults of a particular model in orderto provide a useful feedback to our R&D and Productiondivisions. The reward of a good feedback is improvedquality.

Studying and analyzing sporadic and non-returning faultsmay also be beneficial for the R&D for their perfection offuture designs. Finding out about breakdowns attributedto customer mishandling may help to perfect our User'smanuals to the effect of what is to be highlighted as criti-cal when installing our equipment.Failure analysis may serve as a link between producer andcustomer, to the benefit of both. NIVELCO's productionoutput is over 30.000 units of level measuring equipmentannually, sold in 65 countries. To increase our marketshare is possible only by meeting customer expectationsand turning out state of the art, highly reliable products,since reliability and technical level of its products are jo-intly representing the status and ranking of a manufactu-rer.

The following diagram illustrates thequality indicators of NIVELCO products,based on the failure analysis of the last few years:

In terms of quality and reliability, the above can be ratedas a superior result.

By introducing a 3 years warranty, we at NIVELCO wishedto send the message to the world concerning our beingconfident about the quality of our products and about ourdetermination of improving our standing among the ma-nufacturers of industrial instrumentation.

In terms of quality and reliability: 3-year full warranty

András KálmánTechnical ConsultantNIVELCO Co.akalman@nivelco.com

Warranty repairs as a function of manufactured instruments.

Failures per 2 years

Failures per 3 years

Failure percentage

5

NIVELCO making its debut on the IFAT

For the first time in its history, NIVELCO exhibits on the IFAT ENTSORGA 2010 in Munich. IFAT poses an adventure for NIVELCO, a regular exhibitorof the Interkama show since 1989. Expecting a most pos-itive outcome by being able to address a different clien-tele, we hope for a good exposure such as every exhibitorof a prestigious Trade Show as IFAT does. Established in the year of 1982 and exhibiting for the firsttime in 1989 on an international show, the Interkama hasprovided NIVELCO with the international exposure theyoung company was wishing for. The totally level orientedcompany having a narrow range of level products waspropelled to the international world of business by the In-terkama back in 1989. Now, fully grown and having a ripe and wide portfolio ofproducts sold in 65 countries with success we expectsomething similar to happen after our debut on the IFAT. Why do we expect this to happen in 2010 regarded notto be best of the years for the process control industriesand why on the occasion of our participating a TradeShow different than Interkama? The answer is easy for the insider. NIVELCO in 2010 isnot the Level Only company any more it used to be forthe decades gone by. Having launched a range of instru-ments in 2009 to cover applications in connection withliquid analysis and intending to expand this range in theyears to come, we are determined to make an impact onthe market. A healthy synergy is expected with our levelmeters already established in the water-wastewater marketand in various industries where the need of liquid analysisexists by our addition of the new analytic transmitters. IFATENTSORGA 2010, an environmentally focused exhibitionprovides for an excellent forum for the re-introduction ofNIVELCO as a company standing on both legs repre-sented by Level and Liquid Analysis. Liquid analysis is a new field for us, getting established isgoing to be a hard process taking some time but we areoptimistic since the acceptance of our level transmittersshall greatly contribute to achieving our goals. The rangeof analytical instruments we have already introduced tothe market include pH, ORP, Dissolved Oxygen and Con-ductivity transmitters with others to come in the near future. The AnaCONT range of transmitters aimed at being usedfor various liquid analysis oriented applications are bear-ing the character lines common with the existing range ofour level oriented transmitters.

The Compact Architecture we have opted for back in1988 when introducing the World's First compact Ultrasonic Level Transmitter has although gone through afew transformations and revampings nevertheless it hasremained NIVELCO's trademark for the last 22 years. No wonder, the AnaCONT line will go compact. Beside the entirely new AnaCONT range of analytic trans-mitters, NIVELCO shall introduce its total portfolio of leveltransmitters to the visitors of the IFAT. The latest of the levelproducts are the Microwave Level Transmitters repre-sented by the MicroTREK TDR and the PiloTREK non-con-tact radar transmitters. NIVELCO's best selling Ultrasonicrange, the widest in the market now comes with ProfibusPA as an option. The NIVOTRACK magnetostrictive level transmitters al-though not novelty with NIVELCO, deserve attention sincethe range went through a major revamping lately. Featur-ing an enhanced accuracy of 1 mm, extremely low deadband and an increased measuring range of 15 m thisproduct will appeal mostly for accuracy conscious clients. 65 countries are a great many places to export to. IFATwill provide an opportunity for expansion and we at NIVELCO are thrilled to find new export markets or newdistributors in markets where our existing ones are not inthe position to sell our AnaCONT line.

Do not hesitate to visit our Stand no. 618 in Hall A4.

Tibor Winkler Board MemberNIVELCO Co.twinkler@nivelco.com

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The TQM (Total Quality Management)

Need of introduction and implementation of TQM

Companies’ most essential purpose is to supply the needsof their clients. Strict technical regulations (meeting theISO-standards) referring to the quality of the product,warrant only partly the corresponding to the intensifyingand rising customer demands.

The sharpening race make the companies to use moreand more developed quality managing methods to focuswhole company’s quality, not just the products’ quality. So in this area also has involved a sharprace between the companies per-suading their partners that fun-damental of their activity isquality. They attempt toget external, third-partydeclarations for exam-ple by winning differentquality awards.

Noticeable trend is thatleaders of the companyrequire wider way of thinkingand more and more difficultleader-guider tool set to provide thecompetitiveness on the market. In order to achieve this, companies continuously developextant and applied methods.

Goal of all quality management disposals are the en-hancement of business performance, effectiveness, ef-ficiency, productiveness, profitability, satisfaction,confidence and the competitiveness. Proper purposesof quality strengthening program should define the wayof development of the company.

Benefits are for example improvement of the cost sav-ing, reduction of the internal conflicts and better internalcooperation, growth of the productiveness, improvedteam-work, more satisfied internal and external partners, decrease of the wastage, development ofcompetitive and innovative products etc..

TQM (Total Quality Management) is one of the tools forknowing and satisfying the varying customer needs.

TQM is a kind of leading and controlling conception ofthe enterprise focusing on the customer driven approach,authorizing and involving the workers, continuous self-rating and improvement of the business processesand the systems based on prevention. Lately a significantstretch of TQM methods is noticeable, and the method-ology of the TQM usually is considered as the first stepafter introducing ISO 9001, not just a simple improve-ment of the ISO. The advantage and disadvantage of the TQM method isthe same by regarding many ways. TQM is less attached,so there isn’t any determined compliance and external

certifier. The evaluation is made by themanagement of the organisation,

they are responsible for self-rating, starting up and

developing processes atthe same time.

Nowadays basicallytwo methods are avail-able for the examina-

tion of quality systems:audition for the systems

build-up by ISO 9001 stan-dard, and self-rating for the or-

ganizations operating by TQMdisciplines.

Spreading of the TQM system is aimed to promote byquality awards, like the best known: Baldridge Award,EQA (European Quality Award), Hungarian IIASA-Shiba(International Institute for Applied Systems Analysis) Awardand the National Quality Award. These awards mean thebusiness excellence under quality, not just the product-quality. Presently the most widely used company qualitycontrol systems are ISO standard series and the TQM,but there are significant differences between them:

ISO 9001 is a suitable tool for the documentation andunderstanding of the planning and manufacturingprocesses, and for consistent realisation of theseprocesses. TQM is an excellent method for the under-standing of the whole management system and for deter-mination of the possibilities, in order to improve theefficiency of the whole business and work out the devel-opment plans.

7

Company subsystem of the ISO 9001 guarantees stabilequality by synchronizing the work of the organizationaldepartments and TQM is a leading method, philosophyfor supporting and helping the continuous development.

Agreement among the experts says that quality controland quality assurance could work optimally according tothe ISO standards, if they are integrated into the systemof TQM and forms the systematic basis of it.

The leadership of NIVELCO has decided to improve thepresent quality management system – based on the ISO9001 standard – and has charged me to make TQM ap-proach known and to support the introduction of it insidethe company.

ISO 9004 standard is an essential literature usable forachieving TQM and also a guidance for improving quality.

Achieved culture of quality brings results meeting the customer demands. If we want to take known our systemsand products beyond the current customer base, we canpossibly participate in a quality award competition.

European Foundation for Quality Management (EFQM)is used in regional, national and European quality awardcontests for revealing the strong and weak points of thecompany in order to determine the duties of the qualitydevelopment.

Applying this model the results are measurable, compa-rable and could be improved, and we could become morecompetitive. If we apply this model, we should not forgetabout the objectivity as a tool of quality development.

Goals:Short term: All employees of NIVELCO get to knowthe TQM approachMid-term: Integration of TQM is completedLong term: NIVELCO participates on the National Quality Award contest

I wish a lot of energy, toughness and success to this seri-ous challenge for all employees of NIVELCO.

Best regards: Gábor Lonkai

The TQM (Total Quality Management)

Gábor LonkaiCEOLONIBOR Ltd.lonibor@gmail.com

8

NIVELCO on film shooting

NIVELCO Co. decided to make a newpromotional video replacing the five-year old NIVELCO movie on www.nivelco.com.

Hungarian representative of industrial measurement tech-nologies, especially level measurement, NIVELCO Co. always has been manufactured instruments to provide so-lutions for automatized and efficient production manage-ment based on reliable measurement of raw materialsand end products. Here at NIVELCO we are very proudof our instruments used in wide range of areas with greatsatisfaction by even domestic and foreign industrial app-lications. In order to present the operating conditions andvariety of application possibilities of NIVELCO instru-ments, marketing team of NIVELCO decided to step upwith a new film.

During the film-shooting, we have visited lots of our part-ners, and NIVELCO instrumented sites like beverage factory, quarry, steel, plaster and aluminium factory, cannery, sewage plant, waterworks and even a drilling-mud factory had taken into pictures with NIVELCO inst-ruments from old to brand-new ones.We filmed and shot pictures on top of very tall silos, pla-ces covered with white or black dust, in shoe-melting heator high humidity, deafening noise, between gigantic lots-of-tons machines, in huge production halls or dark cor-ners of little factories, among strange smells and othercircumstances, where complete safety clothing (helmet,safety-glass, ear-plug, acid-proof overall, safety work-shoe) was necessary at all times. Of course NIVELCOinstruments work reliable in such extreme conditions andmeasure anything from water, wastewater, through plasterpowder to green-peas.

The unpredictable weather and long distances betweenthe plants made a lot of difficulties during the film-making, not to mention the strict EHS (Environmental Health and Safety) standards and regulations. The filmingcrue also had to shoot in hostile environment like in thesteel or aluminium factory.

Among the recorded NIVELCO instrumentations in the best-known beverage brand’s factory, the wastewater recyclingas cooling water is controlled by NIVOSWITCH vibratingfork level switches and the huge outdoor bottle-cleaner al-kali tank is level transmitted by an EchoTREK ultrasonic instrument.

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NIVELCO on film shooting

In a west-Hungarian quarry a compact ultrasonic leveltransmitter is operating in the grinder bunker in extremelydusty environment. A converter department of a steel factory in the region of middle-Hungary, NIVELCO inst-ruments measures the flux (burnt lime) which is fed intothe vessel to form slag, absorbing impurities of the steel-making process. In the capital city, a major waterworksuse NIVOPRESS hydrostatic level transmitters to controlthe level of drinking water. In a south-east Hungarian can-nery MicroTREK guided microwave instruments measurethe level of processed green-peas waiting to be canned.

NIVELCO also represents temperature transmitters, disp-lay and controller units in most of the visited places nextto the level instruments and in more and more places thenewest of NIVELCO products, the AnaCONT analyticaltransmitters have appeared. Among the recorded instru-ments there are still reliable operating models older than20 years and they surely will get placed in the museum ofNIVELCO instruments after replacing.

In NIVELCO we hope we can present to all our partnersand customers the wide application range and workingconditions of NIVELCO instruments with the help of thisnew NIVELCO film.

Please enjoy our new film on www.nivelco.com!

Csaba NádasdiMarketing EngineerNIVELCO Co.csnadasdi@nivelco.com

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Romanian subsidiary of NIVELCO, NIVELCO TehnicaMasurarii started to work inde-pendently in 2005 with head-quarters in Marosvásárhely. This year is the 5th anniversary ofthe subsidiary, which is a greatopportunity for making a reviewand evaluating this 5-year period behind us.

Main activities of the companyare process instrumentation, au-tomation, measurement techno-logies and installation. Major goals are still unchanged since the foundation:distribution of NIVELCO products, providing high-levelengineering consultancy and services in connection withprocess automation and instrumentation technologies.

NIVELCO Tehnica Masurarii started building the marketwith three local employees and a Hungarian sales engi-neer. Since than company has been developed signifi-cantly, the headcount increased to eight: consists of fourregional representatives, one technician, a two-memberadministration group and the company leader. Presentlywe have achieved full market coverage in whole Romaniathanks to this staff. Besides the headquarters, we havecompany representation in Banat region in Lugoj, inMoldva in Iaşi and in the capital, Bucharest.

Our highly qualified engineers participate successively notjust in selling, but in development and testing of new pro-ducts by the help of experiences and new ideas getting du-ring installation of the instruments.During the recent five years of pioneering work we areproud of some great successes like:

NIVISON process visualisation software has installedfirst in Intersnack chipset manufacturer in Brasso, whichwas followed by 10 another successful projects.We have participated in the development of the screw-in type and the built-in temperature sensor type bore-hole level transmitter, and also the multipointtemperature transmitter, used first in Botoşan ElsacoElectronics and in a local waterworks company.First EchoTREK level transmitter with ModBus outputsignal has put into operation in the sewage treatmentstation in Marosvásárhely.Testing of the new NIVOTRACK magnetostrictive trans-mitters and first application with more than 10 metersof measuring range.

We constantly pay close attention to attending on majortrade shows. Thus, we have been represented from thevery beginning in the most important Romanian exhibiti-ons of measurement and automation technologies. Wecan declare that 40% of our customers were reached dueto the involvement of the following events:

IEAS (International Electric and Automation Show) – Bucharest 2005, 2006, 2008, 2009, 2010ROMCONTROLA (Exhibition of Process Automation) –Bucharest 2006, 2007, 2008, 2009TIB (International Trade Show of Bucharest) – Bucharest2005,2006TIT (International Technical Exhibition) – Cluj 2006,2007, 2008, 2009EXPOAPA (Water and wastewater Trade Show) – Bucharest 2007, 2008, 2009, 2010

NIVELCO Romania’s 5th anniversary

11

Since 2007 NIVELCO DEMOBUS has appeared on ourexhibitions and has became very popular, because wecould present NIVELCO instruments during operation withthe help of it. We organized demonstration tours to different Romanian regions (Transylvania, Banat, Moldva,and South-Romania) directly to our partners’ own headquarters.

We have built a close relationship with technical univer-sities providing new-generation of professionals. We usually hold professional presentations for students inSapientia Technical University and Petru Maior TechnicalUniversity in Marosvásárhely and in the Engineering Faculty of Iaşi Technical University. As a support we provide discounts for the schools to purchase laboratoryinstruments. We worked together with Cluj Technical University in the instrumentation of the catchment-damsin Mezőtelegd.

Presence in the press has been taken seriously into consi-deration. The most prestigious professional journals, suchas Masurari şi automatizari, or the Automatizari şi instru-mente regularly publish articles about NIVELCO newsand application successes.

With the help of the parent-company from the beginningof the year, Navision ERP system was introduced in thesubsidiaries of NIVELCO. Navision has been used first inNIVELCO Tehnica Masurarii since 2009, by which thecompany's processes have become more simple andtransparent; customer services have become faster andmore flexible.

We plan to maintain market share, and exploring newmarkets as long-term strategic goals despite of the factthat the economic crisis in Romania is still very much affecting.Since mid-2010 market potential of the Republic of Moldova has been exploited.

NIVELCO Tehnica Masurarii is facing the competitors ofthe market with favourable pricing policies. NIVELCO hasbecome a well-known brand name in the Romanian mar-ket known as the symbol of affordable high-quality.

NIVELCO Romania’s 5th anniversary

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As a milestone of our market and customer-oriented stra-tegy – to ensure high quality and full service to our clients –from June 2010 NIVELCO Romania moved to a new of-fice. We remain at our customers’ disposal in the futurewith a new office, which is conveniently located in thecentral part of Marosvásárhely in a modern building withnice and friendly environment and above all with goodparking conditions.

We would like to invite you to the company's fifth anniver-sary party between 6th and 8th of October in 2010. Wealso count on your presence on IEAS 2010 (InternationalElectric and Automation Show) exhibition between 14thand 17th of September in Bucharest, Parliament head-quarters.

NIVELCO Romania’s 5th anniversary

András Péter OlteánManaging DirectorNIVELCO T.M.aoltean@nivelco.com

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NIVELCO Czech Republic (NIVELCO Bohemia)

NIVELCO Bohemia - Czech subsidiary of NIVELCO - wasfounded in 2004 December with headquarters in Brno todistribute directly the product range of NIVELCO instru-ments in one of the most developed country of Middle-East Europe.

The Company became a dominant player in the processinstrumentation over the years in the Czech market following the guidelines laid down by the founders. The company now has seven employees, three of themare Sales Engineers with regional representative tasks.

In addition to selling NIVELCO products, NIVELCO Bohemia also offers complete technical solutions, support, installation and repair service.

Now the Company has more than 1200 satisfied customers across the country, thanks to the impressivemarket-building activity since 2004.

We always strive to serve our customers at the highestlevel by providing simple but suitable solutions for anymeasurement tasks with the most fitting level switches andtransmitters.

We pay conscious attention to keep the friendly, family at-mosphere, in the company as well towards our customerswe have had since the foundation. Like in other countriesin the region, the recession of 2009 had a deep impacton the Czech economy. NIVELCO Bohemia has felt, thatcustomers' investments were restrained, tenders and projects have been postponed, funding was inadequate.

Our philosophy is that weak companies will bleed todeath in the crisis, but companies with conscious, long-term marketing and financial policies could strengthentheir position. Even though our income decreased, butthe crisis provided the chance to re-design our businessprocesses. With the help of our parent-company during

the year, Navision ERP system was intro-duced, resulting in the company's proces-ses to become simpler and moretransparent.

Goals:

According to our short term goals, wewant to increase the number of the salesteam with 1-2 people in the capital and itssurroundings. We have reorganized ourquoting work in terms of efficiency, responsibility and team-spirit. Although wehave smaller team compared to the majorcompetitors, we hope we have set up a

more efficient team than our rivals.

Our advantages and competitiveness are based on:

flexibility, providing fast solutions, customer-driven approach, direct, close contact, precise knowledge of customer-demands, surveyingprofessional, reliable sales team.

In 2010 we face bravely to the challenges of the yearthanks to the support of the financially strong parent-company and the devoted and motivated colleagues. We are sure, we will be able to get more satisfied custo-mers and close the year with more successful businesses.

Aleš ČekalManaging DirectorNIVELCO Bohemiacekal@nivelco.com

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NIVELCO Russia

NIVELCO has already attempted to break into the Sovietmarket in the 80’s. Conditions for long term cooperationwere not appropriate at that time.

The story continued in the 90’s one of our local partnersdelivered automation systems for the oil industry. The pro-ject needed mainly industrial thermo- and level metersmanufactured by NIVELCO. This was the beginning of thereal break into this market, during those times more than3000 instruments were sold and installed.

Obtaining Russian certificates of the instruments have be-come essential for further sales. The Company’s mana-gement decided to strengthen market presence. As firststep NIVELCO took part independently in Russian processinstrumentation exhibitions and subsequently NIVELCOdecided to establish a subsidiary in the capital, Moscow.

This new brand office started to work by involving anexternal professional contractor and then sales started toincrease. Due to the size of the country, the main task ofthe subsidiary besides boosting sales is to build a distri-bution network. According to this, setting up a logisticssystem for providing door-to-door delivery had to be thefirst step. NIVELCO Rus. involved a Russian professionalfirm (Notex) to handle the specific bureaucratic procedu-res of the country. This decision has proven to be successful, the cooperation is still fruitful.

The other key element of the market conquest was the expansion of the distribution network. Involving partnercompanies provided to cover the huge Russian market tosell and distribute NIVELCO products.

Distributors operate currently in the following areas:Kaliningrad, Moscow, Moscow region, Tatarstan, Ryazan, Krasnodar, Chelyabinsk, Rostov-na-Donu

In progress:Krasnoyarsk, Tomsk, St-Petersburg, Yekaterinburg, Volgograd, Novosibirsk, Irkutsk

Long-term plans:Expansion of the distribution network in the area of theformer Soviet Republics

NIVELCO Rus. was established in Moscow in 2007 toprovide higher-level solutions for distribution tasks. Laterengineering and service tasks are also going to be solvedby the subsidiary. Competitive prices, flexible and fast ser-vice together make possible to serve small and large projects as well at high-level. These are the majorstrengths of NIVELCO Rus.

Now we are present in almost every sector of the industries as a result of our work:

water / wastewater treatmentchemical industrymetallurgymining (marble)food (cooking oil, milk factories)oil mining and processingconstruction industryenergetics

We plan to participate in instrumentation of nuclearpower plants.

Installation of NIVOPRESS (hydrostatic transmitter)instruments were performed in cooperation with Rosp-ribor, our distributor in Moscow in a water treatmentfacility of the Water and Sewerage Works of Moscow.

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NIVELCO Russia

During ourmarketing work, wetake part inregional andMoscow exhibitionsindependently ortogether with ourdistributors.

On the demand ofour distributors, weorganize trainingsfor them:(Chelyabinsk,Moscow).

We usuallyparticipate forexample in Russian-Hungarianinternationalexperts meetings.

We facilitate increasing our market presence with conti-nuous qualification of our products and compliance withRussian certificates. More and more brochures and documentations have been translated into Russian, providing for second level in marketing.

NIVELCO’s webpage is also available in Russian langu-age with Cyrillic letters, drawing more and more attentionindicating serious interest in the market.

The economic crisis has reached its turning point in early2010 and since then business is picking up. Developmentof human resources and infrastructure are expected to becarried out in 2011.

Attila KovácsManaging DirectorNIVELCO Rus.akovacs@nivelco.com

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New solution for instrumentation of sewage shafts

UNICONT PKW-101, new product from NIVELCO

NIVELCO keeps close relationships with public water utility and wastewater treatment companies, many of theminformed us about a problem about controlling of pumpsin small (1-2 m3) “domestic sewage shafts” used in non-canalised areas.

Most important aspect in realizations is cost-saving, reliability and low operational costs are unfortunately leastimportant for the contractors. Costs of the more powerfulultrasonic and hydrostatic level transmitters with suitablecontrolling units are beyond the economic price-level incase of “normal” sized sewage shafts.

Float switches are applied in most cases as lowest-costsolutions, but least reliable, they may require frequent maintenance, because switching could be unreliable due to unwanted deposits.

Thinking along the demands for a reliable, maintenance-free pump controller combined with ultrasonic level trans-mitter, we have designed UNICONT PKW-101 for thisspecific task, as a relatively low-cost unit affordable incontrast to the total cost of the sewage shaft.

Our bestsel-ler productEasyTREKSPA-340 ultrasonictransmitter –the bench-mark instru-ment ofordinary se-wage shafts –

gave the idea to construct the PWK-101.

17

New solution for instrumentation of sewage shafts

Our goal was to develop a level controlling system to sim-plify pump control tasks with some advantageous properties of the more expensive level transmitters resulted ahigh-level instrumented, cheaply automated sewage shaftsolution for the users and the suppliers.

This new product is the UNICONT PKW-101, the com-plete pump control unit for small „domestic” sewageshafts, with the following properties:

ultrasonic level measurement – no contact with the sewageapplication in sewage shafts up to 2 meters depth,does not require any programmingdaily starts the sewage pump independently from theusage, so the sewage won’t be rotten in case of rareor paused usage (for example in a summer house,etc..)sensor with IP68 protection, submersible design

control box with IP65protection, wall-mountable, sealabledesignpower supply: 230VAC, grounded, sen-sor in the shaft oper-ates with 24V DCvoltage, instrumenthas short-circuit protectiondoes not requireroutine maintenancein case of appropri-ate installation, fullycomplies with the re-lating standards

The PKW-101 ultrasonic domestic sewage shaft controller unit is going to be launched soon in the Hungarian market.

Low maintenance costs and an expected minimum num-ber of breakdowns will make the UNICONT PWK-101 anattractive buy in the future.

Sándor ÚjfaludySales EngineerNIVELCO Co.sujfaludy@nivelco.com

18

Level transmitting in clear and pollutedliquids

The NIVOPRESS N400/500 type hydrostatic level transmitters are the new generation of the borehole leveltransmitters manufactured successfully for years. Level transmitters have HART communication ability andhave optional temperature sensor.

ApplicationsLevel and temperature measurement of drinking waterwells, tanks, poolsSubmersible pump controlScrew-in submersible type with IP68 protection for applications with risk of floodingClean or slightly polluted liquidsFor contaminated wastewater, sewageDraw-down protectionSewage lift station control

FeaturesMeasuring range up to 200mIP68 protectionSubmersible or screw-in typesØ 22 mm tubeHART communication2- or 3-wire versionsEx versions2 x 4…20mA output (level + temperature)Built-in Pt100 temperature sensorOvervoltage and inverse polarity protectionWide range of accessories

General descriptionThe NIVOPRESS N hydrostatic level transmitters are desig-ned to measure the level of clean or contaminated liquids.The pressure sensor at the bottom of the probe measuresthe sum of the hydrostatic pressure (Phydro) of the liquidcolumn above it and the atmospheric pressure (Patm).The atmospheric pressure is led to the sensor through abreathing capillary which is equipped with a moisture filterthat prevents the moisture reaching and damaging theelectronics. This enables the atmospheric pressure to besubtracted from the measured pressure to get the hydros-tatic pressure which is proportional to the height of the liquid column (h). The electronics converts the sensor'ssignal into an output signal. If temperature measurement(of the liquid) is needed beside the level measurement acombined (level + temperature) transmitter should beused. The installation and wiring of the transmitter is hel-ped by the wide variety of accessories. A sewage adapterworking on the principle of the diving bell can be snappedinto the place of the protecting cap to avoid the directcontact between the sensor and the measured contami-nated liquid. An extra mechanical protection is built in theNZ type transmitters in the form of a mechanical filter.The N-500 types can be used in hazardous environments.The NZ screw-in types are recommended for applicationswhere there is a risk of flooding.

NIVOPRESS N – hydrostatic pressure transmitters

Hydrostatic transmitters for clean water

Hydrostatic transmitters for contaminated water

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NC ty

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Subm

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(NZ)

Moisture filter

19

AccessoriesA wide range of accessories make aneasier installation and usage of the NIVOPRESS N hydrostatic level trans-mitters

NAA-101: Cable terminal box withmoisture filter and termi-nals for wiring the unit

NAA-102: Cable terminal box withmoisture filter and termi-nals and OVP-12/33 forwiring the unit

OVP-12/33: Outdoor overvoltageprotection unit with IP54protection for use in 4..20 mA loop

OVP-32/33: Indoor overvoltage pro-tection unit with IP20protection for use in4..20 mA loop

NAA-209: Cable mounting wedgeclamp

NAW-104: Stainless steel 1.4571 se-wage adapter for NP types

NAA-105: Cable holding assy; material: stainless steel1.4571

Measuring circuitsDifferent measuring circuits can be created by using thesuitable accessories with NIVOPRESS N hydrostatic leveltransmitters.

NIVOPRESS N in system with MultiCONTThe MultiCONT process controller unit can handle amax. of 15 normal or max 4 Ex-proof HART capabletransmitters. The digital (HART) information is processed,displayed and if needed it can be transmitted via RS485communication line to a PC. Remote programming of thetransmitters is also possible. Visualisation on PC can beaccomplished with NIVISION process visualization software.

NIVOPRESS N in system with a PCThe instrument with HART output can be connected to aPC using a SAT-304 HART-USB modem. Max. 15 normal(non Ex) instruments can be connected to a HART line.Measured values can be visualised and/or the instrumentscan be programmed via digital HART communication.Applicable software: NPCal configuration software or NIVISION process visualization software.

NIVOPRESS N – hydrostatic pressure transmitters

András KálmánTechnical ConsultantNIVELCO Co.akalman@nivelco.com

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Iterative development in the instrumentation industry

„Agile” and „Scrum” techniques

Modern instrumentation technology uses the results ofthree different aged and specialized technical disciplines:mechanics, electronics and software-technologies. Whilemechanics designs tangible things using mostly spectac-ular operating principle, then electronics has a quite unseen operating principle with no obvious troubleshoot-ing methods. Writing a software results an abstract, virtualsystem, where the finished product is also invisible! Moreover software-development has only 30 years of history, in contrast to the 100 years of history of electronics and centuries of history of the mechanics. Applied mechanics has not changed essentially (expectthe quantum mechanics and relativity theory) in the lasthundred years, so designing techniques in this topic arereally clear-out. Similarly, it is also true for its methodologyof project-management. Nevertheless these coordinatingand leading techniques are usually not – or just limitedly –applicable in the instrumentation technology, because ofthe mentioned diversity between the three disciplines. The most important difference is the youngest and leasttangible element, the software.

Classic project management techniques and their limitations in themodern instrument-development

Regardless of the industry segment or the size, goal of theproject-leadership is to achieve project targets in most op-timal way keeping given boundary conditions by planningand organizing with the available resources. Success isthe simplest measurement number of the project-leader-ship, consists of five following phases:

In the ancient times there were also good “project lead-ers”, but the methodology above is used consciously sincethe middle of last century besides industrial scales. Thereare countless implementation methods (waterfall-model,“V”-model), having differences in some sub-processes (forexample the role of testing), but the point of all methodsis the succession of the events: parallel running events areonly in the “Implementation” phase. Project-leader is continuously following the progress ofthe specific tasks, but intervening possibility is negligible:could only expand the available resources (professionals,equipments). This would cause unwanted increase in costand in most cases do not bring desired result, becausethe enlargement also requires time (coaching, equipmentpurchase).

Only determined pieces of information - specified at thestart of the project - are available during the planning, sothe product specification should be comprehensive, oth-erwise any changes of the boundary conditions can even-tuate the failure (cost or time delay) of the project. Duringthe project direct, real tangible result will achieve only inthe “Finish” phase, so the progress cannot be followed bythe aspect of the customer or the leadership.

1. Start: Declaring tasks, goals and boundary conditions.2. Project-designing: Dividing tasks into subtasks, deter-

mining the team and the non-human resources, record-ing deadlines and milestones.

3. Implementation: Carrying out the activities describedin each specific tasks. Probably this is the classic senseof the development work.

4. Observation and intervention: Rearrangements or anyother intervention in case of the implementation is notin accordance with the design.

5. Finish: Introducing the product, evaluation of the project.

Iterative development in the instrumentation industry

Final success depends on the appropriate informationand experience available to estimate the weight, time andresource requirement of the specific subtasks. That is why mechanical projects are more fluent than elec-tronics and even more than software projects. If classicalproject leading technique is applied in case of developingmicrocontroller controlled electromechanical systems, wehave to count with delaying deadlines or a requirementfor larger number of staff occurs than the initial estimated.

In resource-rich industries, typically with a mechanical his-tory (mechanical engineering, automotive industry), thisis acceptable, but impassable way for developments ofmodern instrument industry!

How could a development be successful in the instrumentation industry?

First of all it has to be accepted that the least sized (however the most complex) component determines theproject development. In case of embedded systems elec-tronics and software are the scaled and mechanics is onlyat the third place! It seems to be a simple consequence,but it is hard to be accepted that in case of mass-manufactured products the minimal-cost electronics andeffective without-cost software are the “lead-dogs”.

Change is needed in the way of thinking!

We have to start to examine the specialities of the softwaredevelopment. Instead of very detailed product flows wehave to determine the next step by empirical methods:observation and adaptation.

We should not think we can determine everything precisely at the beginning of the project, we have to beopen-minded for changes of requirements and expecta-tions. Instead of the corded-hand developers by themethodologies and the administration, we have to buildin personal interviews, professional and technical excellence and simplicity.

The stress should be on the operation-ready product. Rateof progress shall be the more and more valuable functionality of the software!

2001. February 13: Manifesto for theagile software development

In a common occasion for wintervacation in the Rocky Mountains,next to one of the most famousdownhill course Snowbird, AgileManifesto was designed by 17leading software developers, sys-tem designers and project man-agers as the basic statements of the modern softwaredevelopment and IT project management. Like any manifesto, it is also an extreme brevity and revolutionary,and also calls for a change in thinking.

These goals have cleared out over nearly a decade, andrevolution has been calmed down, but the changes -started by the points of the manifesto - were successfullyapplied by several software giants (IBM, SAP, Google) andmanufacturer and development companies of embeddedsystems (Nokia, Siemens, HP…)

agileactive, alert,nimble, brisk, lively,efficient

source: collectionof foreign words

We are uncovering better ways of developing software by doingit and helping others do it. Through this work we have come tovalue:

Individuals and interactions over processes and toolsWorking software over comprehensive documentationCustomer collaboration over contract negotiationResponding to change over following a plan

That is, while there is value in the items on the right, we valuethe items on the left more

source: www.agilemanifesto.org

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Iterative development in the instrumentation industry

Project leader is responsible for continuous controllingwhether the steps are in sake of the cause of the project,because iterative development techniques are based onthe expertise of the developers, not on the detailedprocess plans. We have to take serious actions against“professional terrorists” and “code-generating cowboys”This technique is called “Scrum”, creating order from thevisible chaos. The project leader and the developers ofthe project hold daily or weekly evaluations of the pro-gression and specify the open tasks.

Basic elements of this technique:

Daily or at least weekly discussions of the developers andthe project-management to evaluate the solved andopen tasks. To-do list is determined by the availabletime and actual priority. So-called “burn-down” tablecontains the list of still open tasks and the remainingtime to finish.2-4 weeks frequent sprint planning meetings betweenproject management and the customer (marketing /sales) for specification of the following tasks to do inthe next iteration. Sprint backlog contains the short sub-tasks with some description and priority available to ac-cess for everybody in the project.On the inner evaluation after finishing the sprint,developers and the project management evaluate thefinished and the tested tasks and finalize the softwareor device for a presentation.2-4 weeks frequent evaluation or presentation for thecustomers as closing the sprint, mostly concurrent tothe sprint planningEvaluation and product presentation for closing the development

Project leader has to protect the whole project from ex-ternal influences, organize the work and guarantee thequality besides the huge demands on changing:

filtering communication between developers and thecustomer (marketing / management) if necessary,changes can be made in the project only with author-ization of the project leader,untested faulty software or device is worthless for thecustomer (marketing / sales), management also unableto utilizeduring the development only the technical parameterscan be changed, quality, deadlines and budgets arenot subject to compromise

Frequent changes are the main characteristics of the iter-ative development, regarded to sign of chaos between thesupporters of the classical project leading techniques. We should not confuse the agile technique with chaos, thisrevolutionary manifesto does not want to create anarchy!

Agile techniquesin the development projects

Agile techniques are based on the so-called “iterative”development techniques in contrast to the classical (linear)developments. Points of these techniques:

daily personal communication among developers and project management,frequently (2-4 weekly) held agreements among the customer (in case of serial-products marketing /sales) and the development,frequently (2-4 weekly) held inner evaluations, prefer-ably on the basis of operation-ready software or device,re-design the project periodically (2-4 weekly) regarding the results of the inner evaluation,quick handling of the changing requirements,immediate reaction if necessary

scrum [scrummage]: struggle of two teams to get themiddle placed ball in the rugby field

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Iterative development in the instrumentation industry

Theory in practise: Actual development projects in NIVELCO

All theoretical results are as valuable as much we can utilize from it. Usefulness of project leading, controllingmodel is characterized by the successful closed projects.Numerous instruments of NIVELCO Process Co. has beenimproved recently, and many are in progress. Some examples without the need for completeness:

NIVOPRESS -400: Revised HART interface, high-preci-sion measurement, digital communication and calibra-tion. Protection against overvoltage and transientinterferes.PILOTREK–400: Newly developed non-contact high-frequency microwave radar for liquids and solidsNIVOCONT–500: Mechanically enhanced version,universal power supply (20-255V AC/DC)NIVOTRACK–500: Extreme accuracy (within 1 mm –OMH certification as per OIML R85), expanded meas-uring range up to 18 m, graphic displayMULTICONT–PRD: Logger version, high-brightnessdisplay, USB communication with PCUSB/RS485 – HART modem: Isolating circuit for „Exia” environment, rail mounted versionTHERMOPOINT–500: Multipoint rope temperaturetransmitter for silos and liquids with graphic displayANACONT–100: Water analytics instrument family formeasuring pH, redox-potential, dissolved oxygen, andconductivity. Available with wide selection of probesand optional accessories.NIVOFLIP–100: Bypass optical liquid level indicator(certified by Pressure Equipment Directive (PED)) withoptional NIVOTRACK magnetostrictive level transmitterand magnetic level switches

Visibly the iterative development is not some kind of revolutionary change, just an adaptation of former techniques following the changes resulted by appearanceof software. While subtasks are short in time, the dead-lines are fixed and progression is under a daily control,then delays can be minimized, customers (marketing /sales and leadership) get continuous feedbacks about thework in progress. Operation-ready device can be pro-duced quickly if necessary.

Developing team consider the device as their own child,because creativity is not limited by pre-defined sub-processes, therefore motivation can be significantlyincreased. It is essential in a market-oriented developmentto react with flexibility to the changes!

dr. Gábor KunDirector of R&D DepartmentNIVELCO Co.gkun@nivelco.com

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Instrumentation of a sewage works – Romania

Aquaserv in Marosvásárhely

Aquaserv, the regional public drinking water supplier andsewerage treatment provider of Marosvásárhely has cho-sen NIVELCO to provide solution for instrumentation inthe renewal of the sewage treatment plant.Within the confines of this renewal the following sewagemeasuring instruments were applied:

NIVOPRESS NCK-200 hydrostatic level transmitters(10 units)NIVOFLOAT NWP-100 sewage level switches (30 units)EchoTREK SBP-380-6 ultrasonic level transmitters(9 units)

I would like to emphasize the EchoTREK level transmitterfamily, which works with ModBus protocol. The commu-nication module was the result of the cooperation withProbit, SVT Electronics and NIVELCO T.M., adjusting theinstruments together to the system. EchoTREK transmittersare connected to a Schneider PLC in SLAVE mode. Because of the averaging measurement method of ultra-sonic level transmitters, the PLC could loose the measuredvalues in normal mode, so the PLC was programmed toa special mode, when only 1 measured value is allowedto be valid from every 10 measured values. With the helpof this special mode the dropouts of the measured valueswere avoided and the process has become as slow as itdoes not have any affect on the evaluation.

Eight EchoTREK transmitters are tracking the levels of thegrids and control the sludge-lifting pulley-system. One EchoTREK is installed to a P9 Parshall flume to measure flow.

The EchoTREK transmitters communicate with the indus-trial computer via RS485/ModBus protocol.

The ultrasonic transmitters were built into pipes to coverthem from water, when the room is under washing-up.

The measured val-ues can be also dis-played by thebuilt-in SAP-100local graphic dis-play.

András Péter OlteánManaging DirectorNIVELCO T.M.aoltean@nivelco.com

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CS Beton in Velke Zernoseky

Concrete producing technologies in CS Beton site in VelkeZernoseky require storing, gauging and material management of raw materials, for example cement, sand,gravel or chemical admixtures. The process of the manufacturing has a great need in knowing the accurateamounts of materials in the storage silos. The need foraccurate measurement and the hostile environment require deliberate selection of instruments.

We recommended guided microwave level transmitters formeasuring dusty materials, and non-contract ultrasoniclevel transmitters for the strongly sticking materials. Thereare 14 open tanks containing various grain-sized materialsbetween 0.4 and 16 mm, like cement, sand, and otherchemical admixtures, which have to be measured withhigh accuracy despite the dusty industrial environment. ecause of the strong dust we offered MicroTREK HTN-413guided microwave radar transmitters in the seven 13 mtall cement storage silos. The transmitters transfer 4..20mAcurrent signals proportional to the level in the silos, whichwere sent directly to the process control system. Anotherfour 10 m tall sand storage silos were instrumented withnon-contact ultrasonic transmitters in order to provide reliable and accurate measuring of strongly sticking sand.The output signals of the EasyTREK SCD-34J-4 ultrasoniclevel transmitters are also processed directly by the processcontrol computer.Fulfilling the demands of our customer NIVELCO has notonly delivered the instruments but also installed the whole system, which still has been working flawlessly.

Instruments of a concrete plant – Czech Republic

Aleš ČekalManaging DirectorNIVELCO Bohemiacekal@nivelco.com

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Rotary Drilling Co.drilling fluid plant inAlgyő

Today’s modern drilling tech-nologies use special technologicliquid – for drilling of hydrocar-bon wells – so-called drilling-mud. This is usually a mixture ofmilled bentonite and water providing hydrostatic pressure tomaintain the wellbore stabilityand help the drilling assembly tobe brought in and out of thehole, or help the removing of excavated soil by making circula-tion. In the drilling fluid plant dif-ferent quality, aged for average24 hours drilling mud are produced with suitable thixotropic properties for differentcomposition of soil structures. These materials were produced at the place of the drilling and after the usagethey were transported to slurry deposits or let into an infiltration trench.

Rotary Drilling Co. decided to phase in new Germanmodel technologies, where producing and processing ofdrilling mud are not performed at the place of the drilling,but in a site for this special purpose to provide higher efficiency for this technology, including regeneration – re-adjusting the properties – of drilling fluid.In addition to these advantages, the used drilling muddoes not contain explosive components, when got backto the site, so Ex-technology or application of Ex-instruments is not necessary.

On the site of the industrial park in Algyő has been established:

2000 m3 containers,20 m3/h saltwater filtering,4 m3/h capacity chemical separation technology drilling fluid plant17 pieces of 120 m3 temporary tanks,20 m3, shared 20+10 m3 mixing tanks.

The outside tank-park contains different quality, density,or diverse doped mud. Level transmitters and switchescontrol the pumps through the process automation systemand provide information for the operators, who can interrupt the processes.

NIVELCO instruments in the oil industry – Hungary

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NIVELCO’s EchoTREK SEP-325 ultrasonic level transmit-ters were installed for level metering of the tanks. Theseunits are 2 wire, loop powered versions with HART com-munication, working from 24V DC. Measurement of thetanks of 15 m height with a relatively small diameter isvery difficult, so accurate installation of the ultrasonic sen-sor and specialized programming was necessary.

4–20 mA signals of the transmitters are processed by aPLC system. The data are recorded and used for makingtrends following the production and the procession ofdrilling mud. The system generates maximum and mini-mum signals from the output data to control the motoredcut-off valve in the top of the tank and the pumps.NIVELCO’s EchoTREK SEP-380-2 ultrasonic level trans-mitters were installed in the centrifugal and the mixertanks. Taking into consideration the heavier foaming occurred by the stronger mixing, one mixer tank wasequipped with MicroTREK HTR-425 microwave leveltransmitter.

NIVELCO’s double chambered NIVOFLOAT NWP-110float level switches sense the minimum and the maximumlevel in the top and the bottom of all the 17 tanks. Theyare applied for fail-safe indication. As they indicate thepossible failure of the measurement or the control in caseof switching all further technological operations areblocked for the time of the troubleshooting.

In the site of the tank park rainwater is collected to underground tanks. Rainwater tanks are instrumented withNIVELCO NIVOSWITCH RCM-400-3 vibration fork levelswitches. Emptying of the rainwater tanks are performedby hand-intervention based on the signals of the levelswitches.The whole tank park system is controlled by VISIONprocess visualizing system.

NIVELCO instruments in the oil industry – Hungary

Ákos NollSales EngineerNIVELCO Co.anoll@nivelco.com

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Level measurement in a bread factory – Hungary

Bakeries in Hajdúság

Bread factories and bakeries consider significant impor-tance for proper storing, handling, transporting and processing of flour and also demand accurate levelmeasurement of flour, the most important material ofbread-making. In the bakery - shown on the pictures - theflour silos and the flour-conveying system have been renovated and renewed. Fulfilling the request of the investor, seven flour storage silos were installed with continuous level transmission and display of the measuredvalues and empty silo indication to the controlling system.

Technical data of the silos:Height: 18 mDiameter: 3 mInner height of the flour storage silo: 14.3 mMaximal filling level: 13.5 mMaximal weight of stored flour: 55000 kg

The measurement is seriously hindered by 3 cross bracesangled of 120° inside the silos. The filling of the silos isdone by pneumatic conveying, which cause so muchdusting, so it is also a great challenge for our instruments.Taking into consideration these circumstances, the obvi-ous choice for this task was MicroTREK HTN-414-6guided microwave radar level transmitter, which providesreliable measurement accuracy despite the dusting. The applied instrumentshave “Dust Ex” certification.Probe cables of the leveltransmitters were fixed atthe bottom, not to get incontact with the crossbraces inside the silos.

Signals of the level transmitters aresent on an approximately 120 mlong shielded cable to the display-ing and processing unit, the MultiCONT PRC-18A-1 multi-channel process controller. The empty silo indication is doneby a UNICONT PJK- 102-4 relayinterface module connected to the MultiCONT. Remoteprogramming and parameterizing of the transmitters isdone by a PC in the control room via HART communica-tion with SAT-304 USB HART modem.

Fulfilling the demands of the customer, the flour-amountsin the silos are displayed in kilograms and levels aredisplayed in percentage by bar graphs on the graphic

display of MultiCONT installed in the control room.

Sándor ÚjfaludySales EngineerNIVELCO Co.sujfaludy@nivelco.com

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Nordalk in Miedzianka

NIVELCO’s Polish distributor has supplied EchoTREKSTD-33J-1 – our flagship ultrasonic level transmitter forsolids – to Nordalk, one of our customers inMiedzianka, for solving measurement tasks in a lime-stones screening plant in Poland.After positive trials NIVELCO has delivered six pieces ofsuch instruments which allow full automation ofprocesses in the screening plant.All signals from the level measuring EchoTREK-s go directly to central control and visualization room andhelp to optimize efficiency of screening without presenceof employees in this highly dangerous and dusty environment. Mechanical and electrical installation wasdone by a contractor and NIVELCO-Poland’s specialistsoptimized and adjusted settings of the instruments.

Application:Limestone of different sizes are loaded directly from conveyor belts into 10-15 meters high bins and bunkers,in very dusty environment, among high acoustic noises andextremely strong vibrations from the screens and conveyors.

All delivered instruments work reliable and are crediblesource of information about level in bins. This allows thepersonnel to minimize time and number of operationsrequired to control filling and emptying processes and

what is very important, also helps to enhance work conditions and safety which ultimately means improvedoverall health of employees.

As a proof of perfectly satisfied customer, they have chosenNIVELCO EchoTREK instruments once again to handlelevel measurement in their raw lime-stone buffer tanks.

Screening plant of limestone – Poland

Darius PiszerCEONIVELCO Polanddpiszer@nivelco.com

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Test of reliability and quality

Steel-works in Dunaújváros. A fac-tory-city inside the city. Those whohave been there, know, those whohave not been there need strongimagination to be able to imaginethe milieu of this factory, the onlyone steel and coke productionplant of Hungary, which is also fa-mous throughout Europe and allover the world.Fifty years of technology, knowl-edge and experience are combinedwith one of today's most advancedtechnologies in the citadel of Hun-garian heavy industry.

This corner of Hungary puts both human, machine andtechnology to the test. Workers are giving testimony of tothe perseverance and commitment of their profession inDunaújváros. NIVELCO Process Co. is proud to have theopportunity to take part in the life of this high-value represented, leading producer both in social and eco-nomical aspects.

NIVELCO is present in almost every section of the plantwith instrumentation solutions. Within this in the coke worksNIVELCO provides unique measurement possibilities inmany areas contributing mutual success to each other.

Pyrolysis of coal means the heating of the coal in oxida-tion-free medium producing gases, liquids and solidresidues (coke or char). High-temperature pyrolysis ofcoal is called to carbonization.

Temperature of the flue gases is 1150-1350 °C heatingthe coal indirectly to 1000-1100 °C producing furnaceand foundry coke. In the furnace coke is the primary reducing material, cannot be fully replaced by other materials such as coal. Coke is an auxiliary materialwhich helps the gas to circulate in the process material.Coke dust is an important raw material in severalbranches such as chemical industry. Only certain coalscan be transformed into coke and numerous types canbe mixed into compound, for example coking or bitumi-nous coals having statuesque properties.

Processes of coke production can be divided into severalsubclasses, one of these is the coal treatment and the coalcharging between the block operations, classification ofthe finished product of the coking. Instrumentation of thecoke-works and controlling of the processes are theconnection points to NIVELCO.

NIVELCO instruments in the steel industry – Hungary

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Coal is placed into open tanks or closed coal bunkers.Closed coal bunkers mean a group of huge concrete siloswith 34 m height and 9 m diameter. Coal inside them isin divers forms, in blocks with diameter up to 30 cm, asa wet dollop, or very fine dusty particular material cavingor arching, regularly sticking up even to the vertical wallsof the silo.Filling level of the closed tanks is very important informa-tion for the technology. Measurement in this and in similarareas is one of the strengths of NIVELCO.

Excellent andsuitable instru-ment offered byour specialists isthe EchoTREKSBD-31J-8 Exultrasonic leveltransmitter. This instrument has a range up to 60 meters with a narrow beam angle. Well-chosen mounting place guar-antee measurement even during the filling of the tank.Efficient signal processing and noise suppression, temperature compensation in the whole range and ‘DustEx’ type makes our EchoTREK to the best choice. Uniqueconsole setting of the instrument complies with the arching resulted by the different grain-size pieces.

Presently 14 of these instruments are operating perfectlyin the coal bunkers.

During the classification of the finished product of thecoking process, vast amount of very fine dust is issued.Separation of this dust is made by the static dust cleaningsection with high-voltage. In this process, the collecteddust are stored in dust-tanks, filling and empting controlof these tanks is done by NIVOSWITCH RLH-304-EEx vibrating fork level switches in 4 tanks in each floor.These switches with non-parallel fork tines make possiblea reliable switching even in case of sticky dust.

THERMOCONT temperature transmitters and NIPRESSpressure transmitters are also applied in the coke-worksfor gauging temperature and pressure of the gases usedand produced during the coking process.

NIVELCO instruments in the steel industry – Hungary

József KaplonyiSales EngineerNIVELCO Co.jkaplonyi@nivelco.com

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Sewage Works of Budapest – South-PestWastewater TreatmentPlant

In the wastewater treatment plant ofSewage Works of Budapest, com-plex purification, sewage-process-ing and recovery technologies areused.

Daily wastewater treatment capacityof the plant is 80 thousand m3, and22 million m3 a year. The plant successively treats the wastewater ofapproximately 300 thousand inhab-itants of four district as well as businesses working in these districts.

Filtering of the incoming raw wastewater is performed withrotary drum screens. In the past screens were controlledby hydrostatic pressure transmitters, which had becameout-dated and operated unreliable. Unnecessary opera-tion of the drum screens resulted energy-loss. In severalinstances the drums did not start to operate on time.NIVELCO Co. was ready to provide solution for this prob-lem. The project had two phases. During the first phasetwo drum screens were equipped with instruments. Afterthe positive response four further drum screens were fittedwith NIVELCO made instruments.

NIVELCO has recommended ultrasonic transmitters forthis task. The control of the drum screens is based on thelevel difference between the waste water inflow and thewater effluent. The obvious choice was our EasyTREK SPA-380-4 type in-tegrated compact ultrasonic level transmitter with IP 68 pro-tection. The 4-20 mA output signals of the level transmittersare sent to the input of our UNICONT PMM 324-2 univer-sal controllers. The relay outputs of the controllers functiondepending on the difference of the water level measured bythe level transmitters before and after the drum screens.

Controlling of rotary drum screens – Hungary

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Power supply voltage for the transmitters is provided byour NIPOWER PKK-331-1 rail mounted power supplyunits.

This drum screen controlling system designed by NIVELCO starts the working cycles of the screen at therising edges of the controlling signals.

In case of large amount of sudden water flow (for exam-ple rain, snow-melt) controlling signals are generated byNITIME JEL-111 type rail mounted multifunction timersoperating in impulse generator mode.

Thanks to this solution, working of the screens had become reliable and energy-saving, drum screens operate only when it is needed. Moreover not just signif-icant energy-savings can be achieved, but reducing theoperation time of the screens results decreasing maintenance costs proportional to time.

Controlling of rotary drum screens – Hungary

Tibor AsztalosSales EngineerNIVELCO Co.tasztalos@nivelco.com

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Process instrumentation – CIP cleaning

Strict regulations of the food industry require that foodproduction plants regularly clean the tanks, pipes andpumps of a technological process.

Main stages of the cleaning process are:Washing with cold water and hot water (+ 82°C)Washing with a slightly acidic solution (concentration: 2…5 %)Disinfection with +130°C steam

This so called CIP program is controlled by a PLC. The needed cleaning solutions are prepared in a CIP washing centre. The washing solution that is used severaltimes gets contaminated and it is drained to the sewer.Cold water tank:For analogue level measurement EchoTREK SGA-3xxxtype 2-wire ultrasonic level transmitters are recommen-ded; for low / high level switching NIVOSWITCH vibratingfork level switches are the best choice. Dosing of thesupplementary water is controlled by a PLC and an ultra-sonic level transmitter.Hot water tank:Similar instruments are used for level measurement andlow / high level switching as for the cold water tanks. The temperature measurement and control system consists of a THERMOCONT TTJ-5xxx temperature trans-mitter and a UNICONT PMM-3xxx universal controller.

Acidic water tank:Instruments for level transmitting and level switching arethe same as in case of the cold water tank. Adjusting thepH value of the water can be done by using the followinginstruments, AnaCONT pH meter, UNICONT PMM-3xxxcontroller, JEL-111 dosing timer and a dosing valve.Steam cleaning phase:Measuring and controlling the pressure of the steam isdone by a NIPRESS DRC-3xxx pressure transmitter and aUNICONT PMM-3xxx controller.Detection of the dirty cleaning water:Water contamination is measured by an AnaCONT conductivity transmitter and the 4…20 mA output signalis led to a PLC which controls a 3-way valve.

Ferenc KusztosTechnical ConsultantNIVELCO Co.fkusztos@nivelco.com

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