State-of-the-art measurement technology for safe chemical logistics: VEGA equips new chemical tank farm with instrumentation

With a storage capacity of 2 million litres, distributed across 40 tank chambers in 22 above-ground tanks, the new tank farm at Friedrich Scharr KG is a high-performance centrepiece of the company’s chemical logistics operations. A wide variety of water-polluting substances, such as solvents and fuels, are stored and processed there.

A fully automated filling system for all types of containers and a 15,000-litre mixing tank for customer-specific solvents round out the existing infrastructure. During construction of the new tank facility, special requirements like earthquake safety and the placement of storage containers on multiple floors of the building had to be taken into account. The aim of the project was to improve economic efficiency, maximise plant safety and minimise environmental impact.  These requirements are being met thanks to the use of advanced level measurement and pressure measurement technology from VEGA.

By eliminating the internal shuttle trips between the old tank farm and the truck scales on the company premises, the new tank farm could also be optimised in terms of emissions and energy consumption. The measurement technology integrated into the processes played a decisive role here. Precise pressure measurement technology and level monitoring with continuous data transmission ensure that no hazardous substances escape or become mixed. The VEGA instrument technology therefore not only ensures safety, but also helps to automate the filling and mixing processes. The use of renewable energy sources such as photovoltaics and district heating improves the ecological balance and rounds out the sustainable concept.

For precise level monitoring, overfill protection and early leak detection, the company relies on advanced measurement technology from VEGA. Among other instruments, around 170 vibrating level switches of type VEGASWING 63 and 40 continuously measuring radar level sensors from the VEGAPULS series have been deployed. These not only enable continuous level measurement, but also provide reliable overfill protection in accordance with WHG (German Water Resources Act).

The heart of the system: A VEGATOR controller installed in a switching cabinet, which allows the sensors to be tested centrally without having to access hazardous areas. The central VEGATOR controller transmits NAMUR signals (IEC 60947-5-6) and provides a relay output for the VEGASWING, VEGAVIB and VEGAWAVE vibrating level switches.

This effectively moves the test button for the function check from the level switch on the tank to the controller in the switching cabinet, where a simple WHG-compliant function check can be carried out at the touch of a button, allowing all sensors to be tested centrally. And all of this without having to apply time-consuming and costly methods, such as filling the container to the response level during operation or manually checking the individual probes by dismounting them, an action that can also be extremely dangerous. 

The use of VEGA instrumentation therefore not only saves time and money, but also increases occupational safety. This represents a huge advantage in plant operation, especially in the hazardous areas of chemical plants, where many sensors are installed. 

VEGA technology also impresses users with its safety features: Thanks to flexible locking screw fittings, VEGASWING vibrating level switches can be configured in standard lengths, which simplifies spare parts inventory and planning. Furthermore, the sensitivity of the level switches as leakage sensors on pumps can be individually adjusted so that even low levels in collecting trays can be reliably detected – a decisive advantage when storing volatile or low-viscosity chemicals like solvents.

The VEGAPULS radar sensors installed utilise 80-GHz technology, which offers numerous advantages: They require only small process fittings (e.g. 1.5-inch thread), which allows flexible integration. Thanks to their narrow beam focussing, they deliver exact readings even in tanks with agitators or internal fixtures. What is more, the free-air radar operates has no contact with the medium, which means that material resistance is less of an issue.

VEGA uses high-quality materials like 316L stainless steel and, for radar antennas, the super tough plastic PEEK, which guarantees a long service life and maximum chemical resistance, even in extremely aggressive media. These properties are indispensable in chemical logistics, where reliability is paramount.

The new chemical tank farm at Friedrich Scharr KG is a prime example of how intelligent measurement technology combined with well thought-out plant design can contribute to safety, sustainability and efficiency in chemical logistics. With its level and pressure measurement solutions, VEGA provides the technological backbone for safe and environmentally conscious operations. 

“VEGA measurement technology sets standards in operational safety and measurement accuracy for these processes,” explains René Kozica, project manager at Göhler.

The project impressively demonstrates how technological innovations solve big challenges in chemical logistics – while meeting legal requirements and high safety standards as well as offering economic benefits, especially in the form of operational efficiency. Measurement technology is thus far more than just a technical component – it is the key to sustainable storage of hazardous substances. By making use of diverse redundancy – i.e., combining different measuring principles – Scharr achieves the highest level of operational safety. Even though modern radar systems can already take over the task of overfill prevention in compliance with WHG (German Water Resources Act), Göhler relies on additional mechanical point level sensors to minimise risks.