Franz Gysi turns to Baumer for training operation

27 April 2010

Franz Gysi Corporation has turned to Baumer for pressure and temperature measurement at its training centre for power and process engineering specialists. The centre, at the company’s headquarters in Switzerland, houses a replica of a real industrial plant with pipes and fittings made of glass.

Franz Gysi training centre and its planners
Franz Gysi training centre and its planners

Franz Gysi Corporation manufactures valves, industrial fittings and gaskets for the European market. The business operates two locations in Suhr and Rheinsulz with 38 employees.

Its training laboratory includes two technical subject areas: a steam plant demonstrating energy processes and a process plant, in which controlled standard processes can be run. The various standard characteristics are recorded by measuring devices; the following processes are then displayed in real-time via the process control system.

“We have been applying Baumer’s measuring instruments in our assembly shop before and they proved excellent”, explained Erich Ermel, head of process engineering at Franz Gysi. “Also, Baumer was very co-operative during the whole process of constructing our training centre.”

TE23 in the training laboratory
TE23 in the training laboratory

Temperature Measurement in Energy Management

In the energy management training department, steam and condensation processes are demonstrated and analysed. Condensate removal systems reproduced in glass show the numerous technical possibilities for pipe drainage. Systems like these are necessary in all industrial plants using steam. Several Baumer TE23 temperature sensors were installed in the temperature based condensate drains. Via the TE23’s analogue signal, steam and condensate temperature are visualised directly at an on-site digital temperature display.

Pressure Measurement in Process Engineering

For the pressure measurements, several MEX5 industrial pressure gauges of 100mm diameter were installed in the training centre. They measure the pressure of the main steam pipe, the water and pneumatic pipes as well as the pressure at the steam distribution towards several stations. Developed for the use with gaseous and liquid media, the series is suitable even for extreme conditions.

Department of process engineering with Erich Ermel
Department of process engineering with Erich Ermel

The MEX5 is used extensively in the training centre’s process engineering department where measurements are carried out visually, with additional directly transmission to the process control PLC (programmable logic controller) via ED701 pressure transmitters. Whereas a lot of circuits are switched manually in the energy management, numerous circuits in process engineering are carried out electronically, which results in more measuring points.

The control processes are demonstrated via various loops. “After pumping coloured water into the pipes, we switch on the processes”, explains Erich Ermel, director of Process Engineering. “In the different pipeline legs, the engineers can then see what happens in each case.”

One of these loops for instance displays the pressure peaks caused by closing fittings, which can happen in all industrial branches - especially if liquid media is processed. Since pressure hammers are measured in split seconds, the pressure measurement has to be carried out very fast both in front of the fitting and behind it. Manometers cannot deliver such quick results, but thanks to the ED701 pressure transmitter, those values can be displayed at the PLC via an oscilloscope.

MEX5, ED701 and ETTN in the training centre, department process engineering
MEX5, ED701 and ETTN in the training centre, department process engineering

Independent Emergency Circuit Controls Temperature in Food Production

In a different loop installed in the training centre, pure steam is first injected into the media and then heated. Here, the temperature is controlled by three measurements: two of them - the cold medium’s flow temperature and the return flow temperature the medium should reach - are both displayed visually and over the PLC. The third measurement takes place in an independent emergency circuit separated from the PLC. It provides a safety function and is measured with the digital thermostat ETTN. “If the temperature rises too much, one runs the risk of the devices getting broken and people getting hurt”, explains Ermel. “In case the permitted temperature is exceeded, the ETTN sends out a signal and closes the circuit.” This safety loop is mainly to be found in food industry processes, for example the manufacturing of ultra-heat treated milk, spinach or yoghurt.

Installation and Support

The Baumer devices’ installation ran smoothly and was supported by the manufacturer, who for example adjusted the ETTN calibration parameters. Also, the TE23 temperature sensors’ minimum and maximum temperature had to be recalibrated after the initial operation of the devices. “In both cases, we received generous support by Baumer”, says Ermel. “Altogether, we are most satisfied with the pressure and temperature measuring instruments which all work perfectly. A pleasant surprise was the very fast measurement in the pressure hammer sector.” In the end, the product design of the devices played an important role too, since the Franz Gysi Corporation set a high value on the visual appearance of its training centre. There, the Baumer devices have been operating since the opening of the laboratory at the beginning of 2009, when the training courses took place twice a month. By now, they are already run twice a week and fully booked for months ahead.

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