Tank level measurement solution at Ford Motors

The new tank farm built for oil management at Ford in Dagenham uses Mobrey 9700 series level transmitters in a system recommended and implemented by the company's application experts

The new tank farm built for oil management in the stamping operations at Ford in Dagenham uses Mobrey 9700 series level transmitters in a system recommended and implemented by the company's application experts.

Emerson consulted with Ford to develop its application for reliable, accurate measurement of oil levels across the new Ford tank farm, built to increase the company's stamping operational performance while meeting environmental standards.

The Emerson solution includes continuous collection and presentation of oil level information to support early detection of any operational issues, enabling efficient press operations, management of oil use, and facility maintenance cost savings.

Emerson used the Mobrey 9700 series hydrostatic transmitters for the level measurement sensors.

The Ford Motor Dagenham Stamping Operations produce the body parts and wheels for Ford brands such as Ka, Fiesta, Focus and Transit as well as other manufacturers including Land Rover and Jaguar.

The site uses 87 presses each weighing 1,600 tons that require thousands of litres of hydraulic and lubricating oil each year.

As part of the company's on-going commitment to running safe, environmentally friendly and cost-effective facilities, Ford decided to review the supply, delivery, storage and use of oil at the site.

In order to meet environmental standards regarding the handling of bulk liquids (ISO 14001) and the Pollution Prevention Guidelines set down by the Environment Agency, it was decided that an oil tank farm should be designed and built at the site.

To do this a team of oil, electrical and instrumentation specialists were brought together, led by the site maintenance co-ordinator John Cooper.

The aim was to streamline deliveries, reduce stock and minimise oil spillage and waste.

An essential element was reliable and consistent measurement at each stage - from tanker delivery at the storage tanks to the intermediate bulk containers (IBCs) that take the oil to the production floor.

Following an initial meeting at the site, the use of the Emerson Mobrey 9700 series hydrostatic electronic level transmitters were recommended to measure the oil in the storage tanks and IBCs.

"Our job," comments Ron Perks, UK Sales Manager for the Mobrey Measurement division of Emerson Process Management, "was to identify the technology that met the needs of the site without incurring unnecessary cost.

Hydrostatic level transmitters are a proven reliable technology with a choice of mounting options that made them ideal for the Ford site".

There are five storage tanks and ten IBCs at the site, all of which have a Mobrey 9700 installed.

The transmitters use a ceramic capacitive pressure sensor that measures the head of the liquid with an accuracy of +/-0.1%.

The sensor is ceramic, providing good corrosion resistance, and the transmitter is factory sealed and tested to IP68 for submersible duty and long-term stability.

The 9700 transmitters are suspended by cable in the 3-5000 litre capacity storage tanks.

In the IBCs they are pole mounted for extra durability because of the constant movement of the IBCs between storage tank and production floor.

Output from all the 9700s is monitored by a programmable logic controller (PLC) designed for Ford by Emerson and its partner B and G Controls.

In addition to showing level readings, the PLC provides data logging and time stamps all events.

This information provides an essential insight into the running of the presses.

For example, if one IBC is using more oil than the others it could signify a leak or problem with machinery.

By analysing this data, Ford can identify and investigate problems early, minimising maintenance costs in the short term and helping to optimise processes in the long term.

Since its completion, the tank farm at Ford Dagenham has also had a significant impact on the plant environmental performance.

The Emerson level solution contributed to process improvement and cost savings, while supporting increasingly stringent safety and environmental legislation.

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