Flowline EchoPod Field Product Evaluation

Flowline EchoPod, Field Product Evaluation  

Field Product Evaluation

In our continuing effort to “Do Your Level Best,” Flowline has put EchoPod through a rigorous field evaluation program. Flowline validated our internal findings and gained critical customer feedback that made EchoPod an even better sensor. Field testing resulted in a 98% success rate. Where EchoPod didn’t perform as desired, Flowline’s engineers identified corrective action and issued engineering change requests for quick resolution.

Throughout this program, Flowline validated the market applications where EchoPod will be installed. This process has enhanced the final released product, and we thank everyone for their contribution. Below are brief desscriptions of some of the EchoPod field evaluation sites.

Flowline EchoPod, Field Product Evaluation
Zinc waste sump
Flowline EchoPod, Field Product Evaluation Flowline EchoPod, Field Product Evaluation
Underground waste sump
Plating Line

Function Legend

Each icon displays what functions of EchoPod's multifunction capabilities were used.

Plating Line: EchoPod was installed in multiple rinse tanks for a leading manufacturer of the aircraft industry. Each sensor was quickly retrofitted into the existing PLC system to provide alarm and refill control of the tanks. Due to the limited space and the corrosiveness of the environment, EchoPod was a perfect fit.

Waste Sump: EchoPod was installed on a wastewater tank catching a mixture of zinc and wastewater. The sensor monitored 4 levels including a high alarm. Due to heavy turbulence in the tank, a standpipe was used to dampen the wave motion allowing for a tight tolerance between activation points. Due to the coating nature of the liquid, the customer preferred a non-contact solution to reduce maintenance time required to rinse/clean contact devices. EchoPod provided the solution.

Diesel Fuel Tanks: EchoPod was installed on diesel fuel tanks for a yacht. The 4-20 mA output provided the level of the fuel in each of the 4 tanks and were all run to a local display in the wheelhouse to track the usage of fuel (in gallons) as the ship cruised. Due to the limited space for installation, EchoPod was the perfect choice.

Chemical Feed Tanks: EchoPod was installed in a chemical feed system to indicate re-order levels for the chemical. The relays outputs provided a local high-level alarm to prevent overflow as well as a low level alarm to indicate a re-order level. The unit was directly wired into a controller that enabled the supplier to record an overflow as well as send an email notification when it was time to reorder. The small size and non-contact controlling made EchoPod the best solution.

Water Chillers:
EchoPod was installed in a Water Chiller used for the semi-conductor industry. The level of coolant is very critical for the effectiveness of a chiller. The sensor was wired directly to a local controller to provide three relay output to indicate the coolant storage tank was empty, full and too full. Because of the nature of chillers, temperature swings are always present. EchoPod provided a solution that met the environment of the chiller, the limited space available and direct connection to the existing controller.

Electroplating Final Rinse Tank:
EchoPod was installed in the final rinse tank of a machine that electroplates copper wire at high speeds. Previous installations of reed switches and magnetic floats had proven to be unreliable which resulted in unscheduled shut down. EchoPod was selected because of the compact size, programmable range and resistance to the effects of the acidic environment. The 4-20ma output of the sensor is fed to the PLC, which in turn controls the level in the tank as well as machine shut down in the event of loss of the rinse water. Installation of the EchoPod was virtually Plug and Play. The sensor directly replaced the original equipment with no hardware or software changes required.

Process Water Cooling System: EchoPod was installed in tandem with an EchoSonic sensor. The sensor is used as the backup for level indication with the 4-20 mA output as well as a low level alarm, which will shut off the main pump and activate an alarm. What makes this application critical is that the cooling tower has such a capacity for a volume of water that the pump would drain the tank in less than 1 minute. EchoPod was wired directly to an existing PLC that does all of the controlling for this system.

Steel Tube Processing: EchoPod was installed in a shallow, but large capacity sump that contains the waste from harsh acid bath washes. The sensor was mounted on the top of the sump through a stilling well that extends 4 feet down to the bottom. EchoPod provided level indication back to a local display as well as control of two pumps to maintain the process.

Bulk Transfer Pump: EchoPod was installed in 200 liter day tank and was used to control a bulk transfer pump as well as a high and low alarm for a local municipality. The sensor was connected to a local controller that activated the pumps and/or alarms based upon the switch inputs from EchoPod. The tank contained sodium hypochlorite, which was used for chemical feed. The compact size and flexibility of control features made EchoPod the right solution.