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Page 1

KN.:0.21098
13.11.2007

FUNCTION AND PLANT DESCRIPTION


CUSTOMER :

PLANT :

IBAU HAMBURG KN :

PLANT SYSTEM : NEW RAW MEAL BLENDING SILO


6.000 T

ZEICHNUNGSNUMMER :
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CONTENT

1 General Data ........................................................................................................................ 3


1.1 Plant Data ........................................................................................................................ 3
1.2 Material Data .................................................................................................................... 3
2 Raw meal silo feeding .......................................................................................................... 4
2.1 Technical Data ................................................................................................................. 4
2.2 Plant Description .............................................................................................................. 4
2.3 Equipment Data During Process ..................................................................................... 4
2.4 Start-up Procedure ........................................................................................................... 5
2.5 Shut-down Procedure ...................................................................................................... 6
2.6 Interlocking ....................................................................................................................... 6
3 Raw Meal Silo Discharge ..................................................................................................... 7
3.1 Technical Data ................................................................................................................. 7
3.2 Plant Description .............................................................................................................. 8
3.3 Equipment Data During Process ................................................................................... 10
3.4 Start-up Procedure ......................................................................................................... 11
3.4.1 Shifting register: Normal Silo Discharge ............................................................... 11
3.4.2 Shifting register: Silo Discharge with one Blower ................................................. 14
3.5 Shut-down Procedure .................................................................................................... 17
3.6 Interlocking ..................................................................................................................... 17
4 Weighing Feeding Station .................................................................................................. 18
4.1 Technical Data ............................................................................................................... 18
4.2 Plant Description ............................................................................................................ 19
4.3 Equipment Data During Process ................................................................................... 19
4.4 Start-up Procedure ......................................................................................................... 20
4.5 Shut-down Procedure .................................................................................................... 21
4.6 Interlocking ..................................................................................................................... 21
5 Silo Cone Aeration ............................................................................................................. 22
5.1 Plant Description ............................................................................................................ 22
5.2 Equipment Data During Process ................................................................................... 22
5.3 Start-up Procedure ......................................................................................................... 22
5.4 Interlocking ..................................................................................................................... 22
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1 General Data

1.1 Plant Data

Operating time : 24 hours per day


7 Days per week

Voltage : 400 V
Frequency 50 Hz
Control voltage : 240 V

Site elevation above sea level : <500 m


Ambient temperature : +40 C max.
-10 C min.

1.2 Material Data

Raw Meal

Bulk density : 0,8 kg/dm (fluidized)

Fineness : 10-12 % R 0,09

Temperature : 100 C max.

Moisture : 0,5 % H2O max.

Air volumes and air pressure at : 1 bar


20 C

Pressure data refer to differential pressures


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13.11.2007

2 Raw meal silo feeding

2.1 Technical Data

Conveying capacity : 200 t/h

Fluidslide slope : 6

Fluidslide size : 300

2.2 Plant Description

The finished raw meal is transported from raw meal mill (by customer) via bucket elevator (by
customer), fluidslides (by customer) and one distributor box into the raw meal blending silo.
The required conveying air for fluidslides is generated by high pressure fans (by customer).
In order to attain an even material distribution in the silo, there is a parallel distributor system
with eight airslides legs which finally discharge the material into the silo.
The parallel distributor with connected airslides is aerated by a high pressure fan.
The actual feeding of raw meal blending silo has to be carried out in accordance with the
requirement of the correct material layer built-up
The raw meal silo is equipped with an air balance valve to compensate for extreme pressure
fluctuations in the delivery air. The air balance valve does not provide overfilling protection.
The filter plant for the silo to be charged ensures that the delivery air is dedusted and
discharged (by customer).
The silo filling level is continuously monitored by a silo radar.
A max. level indicator is used for sequential switch-off of the feeding process

2.3 Equipment Data During Process

During the silo feeding operation, the following plant components are activated:
Filter plant on silo roof
Further transfer components
The high pressure fan(s) for Fluidslide
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13.11.2007

2.4 Start-up Procedure

(In sequence with time delays)

Preconditions:
Pressure switch indicates a control air pressure of min. 6 bar.
All field and plant components are in functioning.
Start signal for silo feeding is given
Silo level device indicates "free capacity", material can be accepted
All respective electrical components (i.e., fuses, breaker) are functioning
Further transfer components and filter plants from mill are ready for operation

Start up-procedure:

Start feeding to Raw Meal silo: Silo


initiated by operator at the Central Control Room
Sequence Sequence

Respective Dedusting equipment 6.0/1 and 6.0/3
ON
-by customer
Parallel Distributor bevel drive 4.0/1 ON
High pressure fan 4.0/5 ON
High pressure fan 3.0/3
ON
-by customer
Bucket elevator 2.0/1
ON
-by customer
High pressure fan 1.0/3
ON
-by customer
Start and Release Signal for preceding transfer components ON
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2.5 Shut-down Procedure

Normal shut-down (Sequence switch-off with time delay)

The shut-down process takes place in the reverse sequence to start up (included delay time
between the sequences).

Normal shut-down of the process takes place, if the lagging time for emptying out the relevant
activated conveying systems is over. The filtering system switches off after an adjustable
slowing down time.

The respective process will be normal-shut down in case of:


e.g. Control room interrupted the discharge process
control air decrease 6bar
fault of respective filter control unit occurs
preceding transfer component has a fault
maximum level into the silo (only if the free room into the silo allows the quantity of resting
material / signal given from max. level indicator, executed with damping switching output)

Interrupted shut-down (preceding equipment will switch-off immediately / following


equipment will switch-off in sequence with time delay)

The interrupted shut-down takes place if any part has a fault, that means the preceding
equipment will stop immediately (feeder flow route) and the following equipment will take
place in the reverse sequence to start up (included delay time between the sequences the
delay time will be set during the commissioning period).

The feeding process will be shut-down interrupted in case of:


electrical or mechanical fault of any component which is integrated in the respective
process, e.g. circuit breaker of any motor
max.-max. level into the silo (signal given from max.-max. level indicator)

Emergency shut-down (power supply switch-off)

Emergency shut down will be initiated in case of:


heavy electrical fault (e.g. circuit breaker)
one of the emergency push button has been pressed

2.6 Interlocking

There is always a locking device for the compressed air switch / control air compressor, for the
filtering system, or within sequential switching.
The material supply must be automatically interrupted during power failure.
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3 Raw Meal Silo Discharge

3.1 Technical Data

Feeding capacity : 200 t/h

Discharging capacity : 180 t/h

Silo diameter : 16,0 m

Silo height : 48,0 m

Useful silo volume : 6.000 m

Useful silo content : 6.000 t

Number of silos : 1 unit


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13.11.2007

3.2 Plant Description

The raw meal silo is designed as a central cone silo. The blending effect is attained during the
discharge process which means that raw meal from different material layers (built-up during silo
feeding) flow together.
During the discharging process, raw meal from different material layers (built-up when feeding
the silo) will flow together and create the blending effect.
The silo is provided with a total of six outlets, each equipped with one manually operated cut-off
gate, one electro-pneumatic regulated flow control gate and a fluidslide conveyor systems.
The silo bottom aeration area is divided into six sections, with each section subdivided into two
(left hand and right hand from respective flow control gate).
Each silo section and sub-section is independently controlled through pneumatically operated
butterfly valves, supplied by two dedicated rotary piston blowers.
For silo discharge, each aeration section is supplied with compressed air from the silo blowers
via a pneumatically actuated butterfly valve belonging to the respective silo bottom section.
Required air for the discharge process is delivered by rotary piston blowers.
The airslides between the silo and the weighing bin are aerated by a high pressure fan.
The discharge process into the weighing bin is controlled by a shifting register via e.g. PLC. The
respective shifting register (e.g. via PLC) ensures an even silo discharge by switching from two
discharge (sub-) sections to the next discharge (sub-) sections (timer based).
During the discharge two of the subsections in the silo are supplied with aerating air at the
same time.
After elapsing a set time period (about 10-20min), the next discharge (sub-) sections will be
activated, by means of closing and opening the concerned pneumatic butterfly valves and
electro-pneumatic regulated flow control gates.
This change-over is carried out with an overlap time of approx. 5 seconds (adjustable period of
time), i.e. before the last selected pneumatic butterfly valves and flow control gates close, the
next pneumatic butterfly valves and flow control gates are opened.
After a stop or completion of a discharge procedure, for the next start (restart) the butterfly
valves and the flow control gates selected last will be activated again (for the remaining period
of time).
If a rotary piston blower has a fault, the required air for the discharge process is delivered by
only one rotary piston blower. In this case only one discharge subsection is supplied with
aerating air at the same time.
If the discharge process takes place with only one rotary piston blower the blending effect is
inferior as the blending effect by the normal discharge process.
The material level in the weighing bin is kept constant in accordance with the set value by
opening and closing the electro-pneumatic regulated flow control gates (silo outlets) and
pneumatic butterfly valves. The angle of opening for the flow control gates (silo outlets) is
controlled via a Max-Max level indicator and via load cells (weigh bin).
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Max.-max.-level indicator

Material is covered the Max.-max.-level


indicator:
Action = stop conveyor system immediately

Material level is over set value :


Action = flow control gate drives slightly close

Material level is below set value :

Action = flow control gate drives slightly open

The degree of opening for the electro-pneumatic flow control gates (silo outlets) is inversely
proportional to the material level in the weighing bin (load cells indication).
The correct opening position as a function of the material level in the weighing bin must be
determined during commissioning!
When the material level in the weighing bin reached the set value the activated flow control gate
will close towards to 0%. Furthermore the concerned butterfly valve will be close and the active
rotary piston blower will be switched off!
When the material level in the weighing bin reached the Max-Max level (e.g. 95% indication via
level indicator) the conveyor system would be stop immediately.
The electro pneumatic regulated flow control gates are equipped with a microprocessor
controller unit.
The power supply to the controller is 15...30V DC
The angle of rotation of the drive is set by supply of specified set point signal via 4...20mA.
This signal is accordance with 0...100% opening position of the gate. The position feedback
signal would be done via 4 ...20mA.

Note:
During switch over to the next aeration sections, the next pneumatic butterfly valves will
open first before the preceding pneumatic butterfly valves will close
The same procedure applies to flow-control gates
After a stop and than followed by a new start, the shifting register will start with the last
sequence and the remaining time period.

Silo discharge process can only start when the control air pressure switch indicates air pressure
of min. 6 bar.
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3.3 Equipment Data During Process

The following plant components for silo discharge are activated:


Respective flow control gates and butterfly valves (for discharge section)
The respective Blowers
The respective high pressure fan
The filter plant on weighing bin roof

Two discharge sections from the silo are in operation at the same time for best blending effects
which means two blowers are activated.
After the preset time period, the air supply and material discharge is switched over to the next
discharge sections.
The respective shifting register (e.g. via PLC) ensures an even silo discharge by switching from
two discharge sections to the next discharge sections (timer based).
If a rotary piston blower has a fault, the required air for the discharge process is delivered by
only one rotary piston blower. In this case only one discharge subsection is supplied with
aerating air at the same time.
If the discharge process takes place with only one rotary piston blower the blending effect is
inferior as the blending effect by the normal discharge process.
The respective shifting register (e.g. via PLC) ensures an even silo discharge by switching from
one discharge section to the next discharge section (timer based).
The degree of opening for the flow control gates (silo outlets) are automatically controlled and
regulated on the basis of the actual weight of the weighing bin (via load cells) The flow control
gates are equipped with transducers to indicating the current position. The information on the
current roller position is transmitted to the control panel.
The correct opening position as a function of the material level in the weighing bin must be
determined during commissioning!
Silo discharge is carried out via the currently selected open type fluidslides on the silo bottom,
the hand cut-off gates and the electro-pneumatic regulated flow control gates followed to the
weighing bin.
Silo discharge should always be started at a reduced capacity for a time period of approx. 10
sec. in order to avoid an initial gush of material.
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3.4 Start-up Procedure

(Delayed switch-on - setting during initial start-up)

Preconditions per silo:


Pressure switch indicates a control air pressure of min. 6 bar.
All respective electrical components (i.e., fuses, breaker) are functioning
All field and plant components are in functioning
Extraction from raw meal silo has been selected
No Max level signal from the weighing bin

Function of shifting register for silo bottom aeration:


Open the butterfly valves on opposite arrangement and switching clockwise (waiting time in
section approx. 10-20 min.) to the next sections.
During switch over to the next sequence, the butterfly valves will open first before the preceding
butterfly valves will close. The same applies to the flow control gates.
Switch over will be carried out with approx. 5 sec. overlapping time.

Start up-procedure:

Start Raw meal silo discharge


initiated by operator at the Central Control Room
Material level set value selected by operator
Sequence Sequence

Respective dedusting equipment weighing bin and fluidslide
ON
-by others-
High pressure fan 7.1/5 ON
Start shifting register: Normal Silo discharge (refer to chapter 3.4.1)
If one of the blowers has a fault then:
Start shifting register: Silo discharge with one Blower (refer to chapter 3.4.2)

3.4.1 Shifting register: Normal Silo Discharge

Normal Silo Discharge: Action


Sequence Sequence

Shifting register (Normal Silo Discharge) / Cycle control by i.e. PLC-system
ON
(One of the following sequence will be in operation)
1. Sequence:
IN POSITION
1. section flow control gate 7.1/2.1
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
IN POSITION
4. section flow control gate 7.1/2.4
and 4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
and 1.section left butterfly valve 5.0/4.01 OPEN
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-feedback via limit switch


4.section left butterfly valve 5.0/4.07
and OPEN
-feedback via limit switch
3. section flow control gate 7.1/2.3
and CLOSE
-feedback via actual value
6. section flow control gate 7.1/2.6
and CLOSE
-feedback via actual value
3. section right butterfly valve 5.0/4.06
and CLOSE
-feedback via limit switch
6. section right butterfly valve 5.0/4.12
and CLOSE
-feedback via limit switch
2. Sequence
IN POSITION
2. section flow control gate 7.1/2.2
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
IN POSITION
5. section flow control gate 7.1/2.5
and 4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
2.section left butterfly valve 5.0/4.03
and OPEN
-feedback via limit switch
5.section left butterfly valve 5.0/4.09
and OPEN
-feedback via limit switch
1. section flow control gate 7.1/2.1
and CLOSE
-feedback via actual value
4. section flow control gate 7.1/2.4
and CLOSE
-feedback via actual value
1.section left butterfly valve 5.0/4.01
and CLOSE
-feedback via limit switch
4.section left butterfly valve 5.0/4.07
and CLOSE
-feedback via limit switch
3. Sequence
IN POSITION
3. section flow control gate 7.1/2.3
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
IN POSITION
6. section flow control gate 7.1/2.6
and 4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
3.section left butterfly valve 5.0/4.05
and OPEN
-feedback via limit switch
6.section left butterfly valve 5.0/4.11
and OPEN
-feedback via limit switch
2. section flow control gate 7.1/2.2
and CLOSE
-feedback via actual value
5. section flow control gate 7.1/2.5
and CLOSE
-feedback via actual value
2.section left butterfly valve 5.0/4.03
and CLOSE
-feedback via limit switch
5.section left butterfly valve 5.0/4.09
and CLOSE
-feedback via limit switch
4. Sequence
IN POSITION
1. section flow control gate 7.1/2.1
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
IN POSITION
4. section flow control gate 7.1/2.4
and 4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
1.section right butterfly valve 5.0/4.02
and OPEN
-feedback via limit switch
4.section right butterfly valve 5.0/4.08
and OPEN
-feedback via limit switch
3. section flow control gate 7.1/2.3
and CLOSE
-feedback via actual value
and 6. section flow control gate 7.1/2.6 CLOSE
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-feedback via actual value


3.section left butterfly valve 5.0/4.05
and CLOSE
-feedback via limit switch
6.section left butterfly valve 5.0/4.11
and CLOSE
-feedback via limit switch
5. Sequence
IN POSITION
2. section flow control gate 7.1/2.2
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
IN POSITION
5. section flow control gate 7.1/2.5
and 4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
2.section right butterfly valve 5.0/4.04
and OPEN
-feedback via limit switch
5.section right butterfly valve 5.0/4.10
and OPEN
-feedback via limit switch
1. section flow control gate 7.1/2.1
and CLOSE
-feedback via actual value
4. section flow control gate 7.1/2.4
and CLOSE
-feedback via actual value
1.section right butterfly valve 5.0/4.02
and CLOSE
-feedback via limit switch
4.section right butterfly valve 5.0/4.08
and CLOSE
-feedback via limit switch
6. Sequence
IN POSITION
3. section flow control gate 7.1/2.3
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
IN POSITION
6. section flow control gate 7.1/2.6
and 4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
3.section right butterfly valve 5.0/4.06
and OPEN
-feedback via limit switch
6.section right butterfly valve 5.0/4.12
and OPEN
-feedback via limit switch
2. section flow control gate 7.1/2.2
and CLOSE
-feedback via actual value
5. section flow control gate 7.1/2.5
and CLOSE
-feedback via actual value
2.section right butterfly valve 5.0/4.04
and CLOSE
-feedback via limit switch
5.section right butterfly valve 5.0/4.10
and CLOSE
-feedback via limit switch
Return to Sequence 1
Note: Only ONE Sequence is activated for the time period of approx. 20 min.
During switch over to the next sequence, the butterfly valves will open first before the
preceding butterfly valves will close. The same applies to the flow control gates.
Switch over will be carried out with approx. 5 sec. overlapping time.
The angle of opening for the pneumatic flow control gates (silo outlets) is controlled via
Max-Max level indicator and via load cells (weighing bin).
IF one of the butterfly valves 5.0/4.01 - 5.0/4.06 OPEN then:
- Blower 5.0/3.1 ON
- Butterfly valves 5.0/4.14 AND 5.0/4.15 OPEN
- Butterfly valve 5.0/4.13 CLOSE
IF one of the butterfly valves 5.0/4.07 - 5.0/4.12 OPEN then:
- Blower 5.0/3.2 ON
- Butterfly valves 5.0/4.16 AND 5.0/4.17 OPEN
- Butterfly valve 5.0/4.13 CLOSE
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3.4.2 Shifting register: Silo Discharge with one Blower

Silo Discharge with one Blower: Action


Sequence Sequence

Shifting register (Silo Discharge with one Blower) / Cycle control by i.e. PLC-system
ON
(One of the following sequence will be in operation)
1. Sequence:
IN POSITION
1. section flow control gate 7.1/2.1
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
1.section left butterfly valve 5.0/4.01
and OPEN
-feedback via limit switch
6. section flow control gate 7.1/2.6
and CLOSE
-feedback via actual value
6. section right butterfly valve 5.0/4.12
and CLOSE
-feedback via limit switch
2. Sequence
IN POSITION
4. section flow control gate 7.1/2.4
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
4.section left butterfly valve 5.0/4.07
and OPEN
-feedback via limit switch
1. section flow control gate 7.1/2.1
and CLOSE
-feedback via actual value
1.section left butterfly valve 5.0/4.01
and CLOSE
-feedback via limit switch
3. Sequence
IN POSITION
2. section flow control gate 7.1/2.2
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
2.section left butterfly valve 5.0/4.03
and OPEN
-feedback via limit switch
4. section flow control gate 7.1/2.4
and CLOSE
-feedback via actual value
4.section left butterfly valve 5.0/4.07
and CLOSE
-feedback via limit switch
4. Sequence
IN POSITION
5. section flow control gate 7.1/2.5
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
5.section left butterfly valve 5.0/4.09
and OPEN
-feedback via limit switch
2. section flow control gate 7.1/2.2
and CLOSE
-feedback via actual value
2.section left butterfly valve 5.0/4.03
and CLOSE
-feedback via limit switch
5. Sequence
IN POSITION
3. section flow control gate 7.1/2.3
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
3.section left butterfly valve 5.0/4.05
and OPEN
-feedback via limit switch
5. section flow control gate 7.1/2.5
and CLOSE
-feedback via actual value
5.section left butterfly valve 5.0/4.09
and CLOSE
-feedback via limit switch
6. Sequence
IN POSITION
6. section flow control gate 7.1/2.6
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
6.section left butterfly valve 5.0/4.11
and OPEN
-feedback via limit switch
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3. section flow control gate 7.1/2.3


and CLOSE
-feedback via actual value
3.section left butterfly valve 5.0/4.05
and CLOSE
-feedback via limit switch
7. Sequence
IN POSITION
1. section flow control gate 7.1/2.1
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
1.section right butterfly valve 5.0/4.02
and OPEN
-feedback via limit switch
6. section flow control gate 7.1/2.6
and CLOSE
- feedback via actual value
6.section left butterfly valve 5.0/4.11
and CLOSE
-feedback via limit switch
8. Sequence
IN POSITION
4. section flow control gate 7.1/2.4
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
4.section right butterfly valve 5.0/4.08
and OPEN
-feedback via limit switch
1. section flow control gate 7.1/2.1
and CLOSE
- feedback via actual value
1.section right butterfly valve 5.0/4.02
and CLOSE
-feedback via limit switch
9. Sequence
IN POSITION
2. section flow control gate 7.1/2.2
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
2.section right butterfly valve 5.0/4.04
and OPEN
-feedback via limit switch
4. section flow control gate 7.1/2.4
and CLOSE
- feedback via actual value
4.section right butterfly valve 5.0/4.08
and CLOSE
-feedback via limit switch
10. Sequence
IN POSITION
5. section flow control gate 7.1/2.5
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
5.section right butterfly valve 5.0/4.10
and OPEN
-feedback via limit switch
2. section flow control gate 7.1/2.2
and CLOSE
- feedback via actual value
2.section right butterfly valve 5.0/4.04
and CLOSE
-feedback via limit switch
11. Sequence
IN POSITION
3. section flow control gate 7.1/2.3
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
3.section right butterfly valve 5.0/4.06
and OPEN
-feedback via limit switch
5. section flow control gate 7.1/2.5
and CLOSE
- feedback via actual value
5.section right butterfly valve 5.0/4.10
and CLOSE
-feedback via limit switch
12. Sequence
IN POSITION
6. section flow control gate 7.1/2.6
4-20mA Signal
-open position dependent from the material level in the weighing bin
(0 100%)
6.section right butterfly valve 5.0/4.12
and OPEN
-feedback via limit switch
3. section flow control gate 7.1/2.3
and CLOSE
- feedback via actual value
and 3.section right butterfly valve 5.0/4.06 CLOSE
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-feedback via limit switch


Return to Sequence 1
Note: Only ONE Sequence is activated for the time period of approx. 20 min.
During switch over to the next sequence, the butterfly valve will open first before the
preceding butterfly valve will close. The same applies to the flow control gates.
Switch over will be carried out with approx. 5 sec. overlapping time.
The angle of opening for the pneumatic flow control gate (silo outlets) is controlled via
Max-Max level indicator and via load cells (weighing bin).
IF Blower 5.0/3.1 has a fault:
Blower 5.0/3.2 ON
AND
IF one of the butterfly valves 5.0/4.01 - 5.0/4.06 OPEN then:
- Butterfly valves 5.0/4.13 AND 5.0/4.15 AND 5.0/4.16
OPEN
- Butterfly valves 5.0/4.14 AND 5.0/4.17
CLOSE
IF one of the butterfly valves 5.0/4.07 - 5.0/4.12 OPEN then
- Butterfly valves 5.0/4.16 AND 5.0/4.17 OPEN
- Butterfly valves 5.0/4.13 AND 5.0/4.14 AND 5.0/4.15 CLOSE
IF Blower 5.0/3.2 has a fault:
Blower 5.0/3.1 ON
AND
IF one of the butterfly valves 5.0/4.01 - 5.0/4.06 OPEN then:
- Butterfly valves 5.0/4.14 AND 5.0/4.15
OPEN
- Butterfly valves 5.0/4.13 AND 5.0/4.16 AND 5.0/4.17
CLOSE
IF one of the butterfly valves 5.0/4.07 - 5.0/4.12 OPEN then
- Butterfly valves 5.0/4.13 AND 5.0/4.14 AND 5.0/4.17 OPEN
- Butterfly valves 5.0/4.15 AND 5.0/4.16 CLOSE
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3.5 Shut-down Procedure

Normal shut-down (Sequence switch-off with time delay)

The shut-down process for the silo discharge takes place in the reverse sequence to start up
(included delay time between the sequences).

Normal shut-down of the process takes place, if the lagging time for emptying out the relevant
activated conveying systems is over. The filtering system switches off after an adjustable
slowing down time.

The respective process will be normal-shut down in case of:


e.g. Control room interrupted the discharge process
control air decrease 6bar
fault of respective filter control unit occurs
maximum level into the weighing bin (signal given from load cell converter)

Interrupted shut-down (preceding equipment will switch-off immediately / following


equipment will switch-off in sequence with time delay)

The interrupted shut-down takes place if any part has a fault, that means the preceding
equipment will stop immediately (feeder flow route) and the following equipment will take
place in the reverse sequence to start up (included delay time between the sequences the
delay time will be set during the commissioning period).

The feeding process will be shut-down interrupted in case of:


electrical or mechanical fault of any component which is integrated in the respective
process, e.g. circuit breaker of any motor
max.-max. level into the weighing bin (signal given from max.-max. level indicator)

Emergency shut-down (power supply switch-off)

Emergency shut down will be initiated in case of:


heavy electrical fault (e.g. circuit breaker)
one of the emergency push button has been pressed

3.6 Interlocking

The filter unit and the chosen switching sequence are all interlocked.
In case of power failure the pneumatic butterfly valves and electro-pneumatic regulated flow
control gates will close automatically.
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4 Weighing Feeding Station

4.1 Technical Data

conveying capacity : 180 t/h

fluidslide slope : 6

fluidslide size : 300


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4.2 Plant Description

Discharge takes place via the aerated bin bottom, electro-pneumatic regulated flow-control
gates, weighing system, fluidslide and bucket elevator to the preheater.
The weighing bin bottom is equipped with aeration pads in order to promote material flow
towards the outlets.
During the discharge of the weighing bin the bottom area is supplied with aerating air via a
dedicated blower.
A weighing system is used to control the raw meal flow towards the preheater. The SCHENCK
system controls the electro-pneumatic regulated flow control gate at the weighing bin outlet.
See separate documentation from SCHENCK.
Is the weighing system faulty, it is possible to use the bypass electro-pneumatic regulated flow
control gate at the weighing bin outlet.
For calibration the filling level of the weighing bin will be checked by the SCHENCK - weighing
system. If the filling level is not sufficient, the SCHENCK - weighing system demands Request
for bin filling.

4.3 Equipment Data During Process

Following plant components are activated:


The filter plant on weighing bin roof (by customer)
The respective bucket elevator (by customer)
The respective Blower
The respective high pressure fan (by customer)
A high pressure fan generates the aeration air for the fluidslide (between weighing bin and
bucket elevator) (by customer).
Aeration air for the weighing bin is generated by one rotary piston blower.
Raw meal flows through the electro-pneumatic regulated flow-control gates in accordance with
the set value towards the preheater.
The actual flow-rate is measured by a weighing system.
The aperture angle of the electro-pneumatic regulated flow-control gate is automatically
controlled on the basis of the actual flow rate via the weighing system.
Calibration of the weighing system takes place by the weighing bin load cells signal.
During the calibration of the weighing system the material feeding to the weighing bin has to be
stopped.
If the weighing system faulty it is possible to use the by-pass electro-pneumatic regulated flow
control gate. In this case the same opening angle is to use as on the weigh feeder controlled
flow control gate.
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4.4 Start-up Procedure

(Delayed switch-on - setting during initial start-up)


Preconditions:
Pressure switch indicates a control air pressure of min. 6 bar.
All respective electrical components (i.e., fuses, breaker) are functioning
All field and plant components are in functioning
All manually operated cut-off gates (weighing bin outlets) are in open position
Further transfer components and filter plants are ready for operation
Preselection for preheater feeding or weigh feeder calibration is given (selected by
operator)

Start up-procedure:

Start preheater feeding: ACTION


The maximum capacity (180 t/h) of the bucket elevator must be observed!
initiated by operator at the Central Control Room
Controlled by the operator
Sequence Sequence

Further components (Preheater) ALREADY ON
Respective Dedusting equipment ON
-by others
Bucket elevator 9.0/1 ON
-by others
High pressure fan 8.0/3 ON
-by others
IF weigh feeder fault
Yes No
Flow control gate (by-pass) Flow feeder control unit
7.1/12.2 IN POSITION 7.1/18 ON
-the aperture angle as the last 4-20mA Signal AND
controlled position of Flow control (0 100%) Flow feeder drive unit
gate 7.1/12.1 7.1/17 ON
The controller maybe readjust the -Max. 200 t/h observed by
position of the gate controller
Blower 7.1/9 ON Flow control gate 7.1/12.1 IN POSITION
-controlled by weigher feeder 4-20mA Signal
system (0 100%)
Blower 7.1/9 ON
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4.5 Shut-down Procedure

Normal shut-down (Sequence switch-off with time delay)

The shut-down process for preheater feeding takes place in the reverse sequence to start up
(included delay time between the sequences).

The material flow will be stopped when the kiln operation resets the start signal or central
control room resets the start signal.

The filtering system switches off after an adjustable slowing down time.

The respective process will be normal-shut down in case of:


e.g. Control room interrupted the discharge process
control air decrease 6bar
fault of respective filter control unit occurs
preceding transfer component has a fault

Interrupted shut-down (preceding equipment will switch-off immediately / following


equipment will switch-off in sequence with time delay)

The interrupted shut-down takes place if any part has a fault, that means the preceding
equipment will stop immediately (feeder flow route) and the following equipment will take
place in the reverse sequence to start up (included delay time between the sequences the
delay time will be set during the commissioning period).

The feeding process will be shut-down interrupted in case of:


The Emergency Off switch is activated (if available)
Malfunction is signalled on a system part involved in the process

Emergency shut-down (power supply switch-off)

Emergency shut down will be initiated in case of:


heavy electrical fault (e.g. circuit breaker)
one of the emergency push button has been pressed

4.6 Interlocking

Dedusting filter, control air-pressure switch and chosen switching sequence are all interlocked.
In case of power failure the electro-pneumatic regulated flow control gates will close
automatically.
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5 Silo Cone Aeration

5.1 Plant Description

Under each central cone silo is an aeration pipe, which sucks off air under the area of the cone
with an axial fan and leads outside.
Fresh air will be taken in automatically through the openings (e. g. silo gate, bulk loading road
etc.).

5.2 Equipment Data During Process

Material can be loaded into the central cone silo with a temperature over 100 C. The heat will
be conveyed from the material to the silo body and through this arises retained heat, which
cannot be carried away under the central cone.
Through the using of the silo cone venting should be reached acceptable temperatures for the
staff and the equipment, which allows a staying resp. a trouble-free operation in this area.

5.3 Start-up Procedure

The axial fan will be switched on and off independent from all other plant parts via a
temperature switch (adjustable 0 - 40 C).

5.4 Interlocking

A locking to the other plant parts does not exist except for emergency shutdown.

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