A comprehensive SCADA and automation infrastructure was commissioned at Koray Kimya’s chemical storage facility in Lüleburgaz to centralize tank level monitoring, simplify operator workflows, and enhance site safety. Within the scope of the project, three PTFE-coated NIVELCO radar level sensors were used to provide non-contact, high-precision measurement in tanks containing critical chemicals such as peroxide and acetic acid.
Automation and PLC Infrastructure
A new automation panel was designed according to the requirements of the site, with a Siemens S7-1200 PLC architecture integrated into the panel. Control sequences prepared in line with Koray Kimya’s operating scenarios were implemented in the PLC program, while tank levels, alarm thresholds, and process data were made available through the SCADA screens. This created an integrated structure that enables operators to monitor tank status in real time and make intervention decisions faster and with greater control.
Density-Based Weight Calculation
The system was designed to go beyond level indication by calculating the real-time weight of the chemical products in each tank in kilograms. Since product density values may vary over time, dedicated input fields were added to the SCADA interface so users can manually enter density values for each product. This allows level data to be evaluated together with density information and converted into more accurate, operationally meaningful mass data for different chemicals.
Operational Outcomes
The commissioned solution strengthened traceability across Koray Kimya’s storage operations, standardized alarm management, and supported safer working conditions. With user-friendly SCADA screens and a flexible automation architecture, the system meets the facility’s current needs while providing a scalable foundation for future capacity increases and new process integrations.
