In the production and circulation process of chemical plants, weighing with Truck Scales is a crucial node for raw material procurement and finished product delivery.
It involves special scenarios such as flammable, explosive, and corrosive materials, and has extremely high requirements for safety and explosion-proof as well as measurement accuracy.
The intelligent explosion-proof Truck scale unmanned weighing system developed precisely meets the operational requirements of chemical plants. It integrates explosion-proof design with intelligent weighing functions, solving the pain points such as large measurement errors and difficult traceability.
It realizes the integrated management of purchasing, measurement and settlement, becoming the core support for the safe and efficient operation of chemical plants.
Case background: The pain points in security and measurement are prominent, and the demand for integration is urgent
The subject of this case is a large petrochemical enterprise, mainly engaged in the production of organic chemical raw materials, synthetic resins and other products. It processes over 800,000 tons of raw materials annually and needs to handle a large number of flammable and explosive raw material transport vehicles (such as methanol and ethylene tankers) and finished product transport vehicles on a daily basis. On average, more than 180 weighing vehicles pass through each day. The traditional weighing mode of floor scales is difficult to meet the special operation requirements of chemical plants, exposing many core pain points: First, the safety risk is high. Traditional floor scales lack professional explosion-proof design, and electrical components are prone to sparks, which can easily cause safety accidents in the weighing scenarios of loading and unloading flammable and explosive materials. Second, there is a large measurement error.
The manual weighing reading is affected by environmental interference (such as chemical dust and odors), and the measurement error rate of raw materials/finished products exceeds 3%, resulting in raw material waste and cost loss. Thirdly, the traceability system is lacking. Manual recording of weighing data is prone to errors and omissions, and the scattered retention of data makes it difficult to trace, which cannot meet the compliance regulatory requirements of the chemical industry. Fourth, the process is disconnected and inefficient. The processes of incoming goods weighing, measurement accounting, and financial settlement are independent of each other. Data needs to be manually transferred. The entire process for a single vehicle takes more than 25 minutes. During peak hours, vehicle congestion is severe, and the settlement cycle lasts for up to three days, affecting capital turnover. The fifth issue is the high labor cost. Eight heavy duty personnel and five data accountants need to be on duty in shifts, with an average annual labor cost of over 550,000 yuan.
Based on the above pain points, the chemical plant has clearly defined its core demand: a set of equipment that complies with explosion-proof standards (Ex d IIC T6) is required
The intelligent unmanned weighbridge system ensures the safety of operations in flammable and explosive scenarios. Achieve precise measurement of raw materials and finished products, with an error rate controlled within 1%. It has the functions of unattended automatic recording and cloud storage, and builds a full-chain data traceability system. Realize the integrated linkage of purchasing, measurement and settlement, connect with production and financial systems, improve process efficiency and compliance, and reduce.
Solution: Prioritize explosion-proof for precise selection, and ensure core functions are suitable for specific scenarios
Combining the explosion-proof safety requirements of the chemical plant, the demand for precise measurement and the demand for integrated management, the intelligent explosion-proof floor scale unmanned weighing system of Vitworth was finally selected. The core reason for the selection is that this system has passed the Ex d IIC T6 explosion-proof certification, has reliable explosion-proof performance, and at the same time integrates intelligent weighing, automatic recording, cloud storage and multi-system linkage functions. It can be perfectly adapted to the special operation scenarios in chemical plants. The core functions of the system are precisely adapted to the requirements, as follows:
1.Explosion-proof design + unattended automatic recording + cloud storage: The core components of the system (sensors, control cabinets, cameras) all adopt explosion-proof sealed design, which can operate safely in flammable and explosive hazardous environments. Equipped with an AI intelligent license plate recognition module (with a recognition accuracy rate of 99.9%), it automatically recognizes the license plate when the vehicle enters the site and associates it with the purchase order information. The weighing process automatically completes data collection and recording, and the entire process does not require manual intervention. Integrated cloud-based encrypted storage module
It automatically uploads weighing data (including vehicle information, weighing time, weight data, and material type), with a data retention period of over 5 years. It supports one-click traceability query and meets compliance regulatory requirements.
active members
years experience
events & challenges
expert instructors
2.Unattended sealed explosion-proof control cabinet + automatic cleaning linkage: Equipped with a customized sealed explosion-proof control cabinet, made of anti-corrosion and anti-static materials, it has excellent heat dissipation performance, can resist the erosion of chemical dust and corrosive gases, and ensure the stable operation of the system for 24 hours. The linked explosion-proof high-pressure automatic cleaning device automatically cleans and disinfects the scale platform after the vehicle weighing is completed, removing material residues (such as corrosive raw material droplets), avoiding the impact on weighing accuracy, and reducing the safety risks brought by manual cleaning at the same time.
3.Integrated classification weighing of sanitation vehicles + purchasing - measurement - settlement: The system can accurately distinguish raw material transport vehicles, finished product transport vehicles and factories.
Implementation process: Explosion-proof compliance deployment and debugging to ensure safe production connection
To ensure the safety and continuity of production at the chemical plant, the implementation team adopted a "priority for explosion-proof compliance and staggered deployment" plan. The entire installation and commissioning process was completed in just 18 days. The specific procedures are as follows: The first step is on-site investigation and customization of explosion-proof solutions. The technical team conducts on-site research on the hazard level and material characteristics of the weighing area in the chemical plant, optimizes the installation position of the floor scale and the explosion-proof layout of the lines, and ensures compliance with the Ex d IIC T6 explosion-proof standard.
The second step is to install the off-peak equipment. During the 4-day maintenance window of the chemical plant, complete the installation and wiring of the Vitworth intelligent explosion-proof floor scale, sealed explosion-proof control cabinet, explosion-proof camera, automatic cleaning device and other equipment, and simultaneously complete the explosion-proof performance test. The third step is system debugging and data connection.
The weighing accuracy, license plate recognition effect, explosion-proof performance, cloud storage stability, and integrated linkage function are debugged. Over 180 simulated weighing tests are completed, and the safety supervision department is invited to participate in the explosion-proof compliance verification. The fourth step is safety training and trial operation. Provide training to the operation and maintenance personnel on the operation of explosion-proof equipment, safety protection, and fault detection. Conduct a five-day trial operation to optimize the system response speed. The fifth step is to officially go online and operate. After the trial operation shows no abnormalities and passes the explosion-proof compliance acceptance, the system will be fully put into use.
Implementation effect: Both safety and intelligence meet the standards, and the results of cost reduction and efficiency improvement are remarkable
After the system was officially put into use, it precisely addressed the safety and efficiency pain points of weighing on the floor scale in chemical plants, with remarkable implementation effects and sufficient data support. Firstly, the safety risk was reduced to zero, and the explosion-proof design passed authoritative certification. No safety accidents have occurred since its operation, and the safety of the working environment has fully met the standards. Second, the weighing efficiency has increased by 68%. The full-process processing time for a single vehicle has been shortened from 25 minutes to 8 minutes, and the average daily number of weighing vehicles has risen from 180 to 320, completely solving the problem of vehicle congestion during peak hours. Third, the measurement accuracy meets the standards, and the error rate of raw material/finished product weighing remains stable within 0.5%, reducing raw material waste and cost loss caused by measurement deviations by over 450,000 yuan annually. Fourth, labor costs have been reduced by 64%. Under the unmanned operation mode, only three operation and maintenance personnel are needed, a reduction of ten staff members compared to before, saving over 350,000 yuan in labor costs annually. Fifth, the integrated efficiency has been enhanced by 90%. The entire process from purchasing to measurement and settlement is fully linked. The settlement cycle has been shortened from three days to one day, significantly improving the efficiency of capital turnover. Sixth, compliance has been fully met. The cloud-based traceability system complies with regulatory requirements and successfully passed the annual safety and compliance audit, with a data accuracy rate of 100%.
Summary: The value of explosion-proof intelligent adaptation contributes to the high-quality development of chemical plants
The successful implementation of the intelligent explosion-proof floor scale unmanned weighing system by Weightworth precisely meets the core demands of chemical plants for safety and explosion-proof, precise measurement, and integrated management. Through reliable explosion-proof design, it builds a solid safety defense line, solves the traceability problem with unmanned automatic recording and cloud storage, and improves operational efficiency through the integrated linkage of purchasing, measurement, and settlement. For industrial equipment operation and maintenance personnel, the stable explosion-proof performance of the system and the modular maintenance method have significantly reduced the difficulty and safety risks of operation and maintenance. For enterprise procurement, the explosion-proof compliance of the system and significant cost reduction and efficiency improvement.
