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PrincipleSpecial anti-friction bearings and the fact that the
machine features one movable and one
stationary roll permit the two rolls to adjust
themselves obliquely to each other during
material feeding. This means that varying gap
widths are established at the two roll ends (being
the maximum and minimum distance between
the roll shell surfaces) and different hydraulic
pressures in the two cylinders of the movable
roll. Consequently, two sensors each have to be
installed for measuring gap width and pressure.
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Roller Press on SCADA
.
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+ Bearing dist. = 0 mm
RP - Frame
Gap sensor Limit switch
Press cylinder
Fixed Bearing
Roller dist. = 10 mm fix
Gap = 10 mm
Movable Bearing
Retraction cylinder
measured by
Distance block
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Roller Press
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Pressure acting on the rolls
The pressure inside the gap witch has vital importance for the quality of theproduct is set via the hydraulic cylinders relative to the material properties
The gap width adjusts itself as a function of the resistance to compactionoriginating from the material.
The pressure in the cylinders is measured and controlled with the controlsystem - by way of automatic re-adjustment - warranting that the pressure willneither fall below the minimum level required for the operating point nor
exceed the maximum pressure permitted for the system.
A pressure loss will occur if the gap width - being a function of materialhardness and granulometry- is reduced.
The bearing distance is measured continuously on both sides of the movableroll with two sensors. The program, stored in the controller, permanentlycalculates the difference between the two values with correct sign indication
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Components Roller Press 1 hydraulic set consists of hydraulic pump and;
2 proportional valves for pressure control, a number of solenoid valves forpressure decrease, bypass valves, valves for the retraction cylinder and valvefor pressure release in case of an emergency shut-down, 1 resistance
thermometer PT100 for monitoring of the hydraulic oil temperature in thereservoir accumulator, 1 temperature limiting switch for the hydraulic oilreservoir
2 pressure sensors for the pressure acting on the rolls
2 position sensors for the bearing distance
4 resistance thermometers PT100 for monitoring the bearing temperatures at
the rolls 2 resistance thermometers PT100 for monitoring the temperature of the gear
box bearings and 2 resistance thermometers PT100 for monitoring thetemperature of the oil gear box bearings.
2 limit switches for monitoring the permitted operating range of the roll
1 Solenoid valve for the shut-off gate and 2 Sensors for monitoring shut-offgate position
1 pump for grease lubrication of the roller bearings and
1 heating unit for the grease barrel including temperature
controller
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2 Sensors for monitoring shut-off gate position Grease lubrication system consisting of 1 Pump for of the roller
bearings, 1 heating unit for the grease barrel including temperaturecontroller, 1 heating unit for the grease pipes including temperaturecontroller and resistance thermometer PT100, 1 signalling contact for
monitoring the minimum grease flow rate behind the grease pump, 2signalling contacts (one each at the two progressive distributors) of thegrease lubrication unit for the roller bearings.
2 differential pressure monitoring of the gear oil filter
2 speed sensors for under speed monitoring of the rolls
1 Lubrication oil system with circulation pump, 1 feed pump, 1 Heaterfor oil in the reservoir ( oil tank ), 1 Stirrer within the oil reservoir ( oiltank ), 3 Solenoid valves, 4 Resistance thermometers PT100 formonitoring oil temperatures, 10 Oil flow sensors for monitoring the oilflow and 3 heating units for the oil pipes including temperature
controller and resistance thermometer PT100 1 Servo drive for feed regulating gate
1 ROLCOX control panel with control system, power supply andterminals for all external cable connections
local junction boxes for the collection of all signals at the Roller Press
1 local operating panel for the operation of the hydraulic valves inlocal mode
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The control unit isdesigned as closed
system for the Roller
Press based on thehardware platform S7-
300. The interface to
the client control
system is performedvia discrete I/O`s and a
Profibus DP - standard
interface.
Control cabinet with
ROLCOX software
The application software is stored in the micromemory card of the CPU. The micro memory
card is plugged-in in the CPU unit and shall
not be removed.
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Local operation box
Local operation box for the operationof the Roller Press hydraulic system inLOCAL mode during trouble-shooting and maintenance activities,
consisting of: 4 push buttons for manual control of
the hydraulic pressures at the movableroll
1 push button with signal lamp foralarm acknowledgement. The signallamp is energized at specific,unacknowledged alarms.
1 mushroom push button foremergency stop
4 digital indicators for indication thehydraulic pressures and the bearingdistances at the left and the right sideof the roller press.
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Control unit The control unit is designed to control the following drives of the
Roller Press:
2 Roller drives 2 Gear oil pumps
1 Grease barrel pump
1 Hydraulic pump
2 Proportional valves for pressure control of the hydraulic system 1 Solenoid valve for emergency shut-down
2 Solenoid valves for pressure decrease
2 Solenoid valves ( bypass valves for pressure release )
1 Solenoid valve for moving the two rolls apart by the help of theretraction cylinder
1 Servo drive for the feed regulating gate
1 magnetic valve for the pre-bin shut-off gate
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5312HD1.V 3/4 Prop. valve right
5312HD1. V 1/2 Prop. valve left
5312HD1 V 08 Emergency valve
5312HD1.V 05 Pressure decrease valve left
5312HD1.V 06 Pressure decrease valve right
5312HD1.V 07 Retraction cylinder valve
5312HD1.M01 Hydraulic pump
5312HD1.V 10 Bypass valve right
5312HD1.V 09 Bypass valve left
Left Right
Retraction cylinder
Fixed Roller
Retract. cylinder
Hydraulic oil tank
Movable Roller
Press cylinder
V 08
V 07
Pump 5312.HD1
V 10V 09
V 05 V 06
V 1/2 V 3/4V 10
V 09
V 08
M01
V 07
V 06
V 05
V 1/2
V 3/4
Hydraulic system of the
roller press
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HYDRAULIC SYSTEM13
Hydraulic set consists of :
1 hydraulic pump, 2 proportionalvalves for pressure control, anumber of solenoid valves for
pressure decrease, bypassvalves, valves for the retractioncylinder and valve for pressurerelease in case of an emergency
shut-down, 1 resistancethermometer PT100 formonitoring of the hydraulic oiltemperature in the reservoiraccumulator, 1 temperature
limiting switch for the hydraulicoil reservoir
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Hydraulic control equipment of the roller press
5312HD1.V 3/4 Prop. valve right
5312HD1. V 1/2 Prop. valve left 5312HD1.V 05 Pressure decrease valve left
5312HD1.V 06 Pressure decrease valve right
5312HD1.H01 Tank heater
5312HD1.T02
Temperature measurement
T > 70 C RP STOP with ALARM
T > 50 C Alarm
T < 20 C Heating OFF
T < 15 C Heating ON
5312HD1.T01 Tank temperature > 40C
5312HD1.V07 For valve retraction cylinder5312HD1.L01 Tank level
5312HD1.M01 Hydraulic pump
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Hydraulic layout:15
Fixed value: 50 C for Hydraulic oil temperature (warning) Fixed value: 70 C for Hydraulic oil temperature (fault, group Roller
Press STOP)
If the temperature exceeds the above fixed value, the roller press is
stopped with an alarm.
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Oil circulating lubrication ( Woerner)
The pump station includes the oil tank divided in twosections with a heating device and an external mountedoil circulation pump
The heating device, temperature safety switch, PT100temperature detectors,
and oil filling level meters, a duplex filter is installed on the pressure side of the
circulation pump,
oil-to-water heat exchanger,
the delivery pipe is routed over two distributingbranches leading to the rollers,
bypass valves controlled by PT100 resistors.
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5312LQ5. M01 Feed Pump 5312LQ55 M01Oil Circulation
pump Pump
5312LQ4.P02Filter with
pressure switch
Oil level indication
Tank T1
L > Max 3
L > Max 2 (Early morning)
L < Min Pump LQ4.M01 OFF
5312LQ5.T03Oil return
temperature
Oil level indication
Tank T 2L < Min Pump LQ5.M01 OFF
5312LQ4.P02 Filter
5312MX1.M01 Mixer
Terminal box Oil re/filling pipe
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OIL LUBRICATION SYSTEM
Site view of the oil reservoir
5312LQ5.T02 Tank oil temperature
5312LQ5.T01Heating with oil
temperature controller
5312LQ5.T03
Oil return line with
temperature
measurement
Roller press bearing lubrication
Bypass-Valve
5312LQ5.V01
Oil circulation pump
5312LQ4.M01
5312MX1.M01 Stirrer motor
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Longitudinal / radial oil lubrication of
Roller Press bearings Behind the heat exchanger, the delivery oil
pipe is routed over two distributing branchesto the bearing lubrication points of themovable and the fixed roll. The bypassvalves 3212LQ5.V02 and V03 located at theends of the distributing branches are openedduring the heating up phase. As soon as theoil temperature in the pipeline reaches a limitvalue (approx. 40C) - measured with thePT100 resistor directly in front of thedistributing branches at the roller press. Both
bypass valves 3212LQ5.V02 and V03 areclosed thereby clearing the way for the oil tothe different bearing lubrication points.
As soon as the oil temperature in front of thebearing decrease below 10C, both bypass
valves will open and after approx. 15 min.the roller press group will be stopped.
All pipelines branched to these locationshave been equipped with flow governors;their flow switches are used for monitoring.
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Oil Lubrication governors for Longitudinal bearingAdjusted for 3,75 l/minMeasuring range 0 10 l/min
Oil Lubrication governor for radial bearingAdjusted for 1,5 l/minMeasuring range 0 5 l/min
1 Flow NOK max 3 ours, 2 Flows NOK max 15 min, then stop Roller Press
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Longitudinal / radial oil lubrication of
Roller Press bearings20
Bearing- Oil-
Flow- Meters
Oil Lubrication governors for LongitudinalbearingsAdjusted for 3,75 l/minMeasuring range 0 10 l/min
Oil Lubrication governor for radial bearingsAdjusted for 1,5 l/minMeasuring range 0 5 l/min
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Longitudinal / radial oil lubrication of
Roller Press bearings21
Bypass valve LQ5.V02
Oil return line
PT100 in one ofthe oil lubrication
lines for bearinglubrication
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Grease lubrication for roller bearings
The grease lubrication consists of a grease tankwith grease pump and two progressivedistributors each mounted on the left- andright-hand side of the roller press. Greaseconveying of the pump is monitored by apressure switch. In case of a failure an alarm iscreated. In addition, each progressivedistributor has been provided with a switchwhich is operated at each stroke of the pistonof the progressive distributor at the cycle ofgrease distribution.
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Grease lubrication barrel with pump
In order to guarantee a sufficient greasesupply to the roller bearings, the signalsfrom the pressure switch and the
progressive distributors are analyzed.
Level switch at grease barrel
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Monitoring of the bearing lubrication
The required amount of grease is determined by the amount of pulses sentfrom the progressive distributors. A preset difference (40 pulses) of both
pulse rates shall not be exceeded.
If the pulses are not reached within one hour, the pulse difference (8)
exceeds the permissible limit or no pressure signal is monitored within 180sec after pump start, an alarm is generated
The remaining operating time for the Roller Press is now reduced to 2hours.
Occurred another grease lubrication fault after the next hour of operation,
the remaining operating time is now reduced to 1 hour. After 3 hours of continuous alarms the Roller Press will be shut-down
(normal stop). The indication of the remaining operating time will betemporarily set to "0".
The highest fault memory will be reset in case the fist hour of operation
ends without fault. The indication of the remaining operating time will beincreased by 1 hour. With undisturbed grease distribution system aremaining operating time of 3 hours will be indicated
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Bearing distance measurement
The bearing distance is measured at theleft- and right-hand side of themovable roll. Since the distance
between the roll surfaces insidethe gap cannot be measureddirectly, the distance between thehousings of fixed and movable
bearing is used as a measure.
The sensors are inductive positionsensors with integratedtransducers.
The transducer is of a four-wiretype. The measuring range is
0 -100mm.
The output signal is 4 ... 20 mA.
In case of wire breakage, a fault signalis generated and the roller press
group will be stopped.
Bearing distance MAX switch
Bearing distance measurement
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Pressure measuring The pressure is measured with
one pressure sensor each on theleft- and right-hand side of the
movable roll. The correspondingtransducer is of a two-wire type.
The measuring range is 0 ... 400bar, the output signal 4 ... 20 mA.
Sensor and transducer areaccommodated in one housing.
In case of wire breakage a faultsignal is generated and the roller
press group will be stopped.
Pressure transmitter
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Temperature measuring The roller bearing temperatures
and the gear box bearingtemperatures are measured at
every test point with oneresistance thermometer PT100each. These thermometers have
been connected in three-wiretechnique to the temperature
transducer. The transducer is of atwo-wire type. The measuringrange is 20 +100 degC, theoutput signal is 4 ... 20 mA.
In case of wire breakage a faultsignal is generated and the rollerpress group will be stoppedimmediately.
Temperature PT100 sensorof one bearing measurement
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Pre-bin level measurement and Shut-Off Gate control
The Roller Press requires alwayssufficient material between andabove the rolls. This is achieved byswitching-on the pre-bin shut-offgate control.
This function can be switched on oroff via switching template atSCADA
During operation and de-activatedpre-bin shut-off gate control theshut-off gate will open when the
bin level exceeds the set maximumlimit, e.g. 50% and stays open evenwhen the bin level drops below theset minimum limit. The gate closesonly at stop of the Roller Press.
During operation and activated pre-bin shut-off gate control will openthe shut-off gate when the bin levelexceeds the set maximum limit,e.g. 50% and closes when the pre-
bin level drops below the set
minimum limit, e.g. 5%
Pre- bin level transmitter
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Pre-bin shut-off gate
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Pre-Bin - Shut-Off - Gate control
During operation and activated pre-bin shut-off gate control theshut-off gate will open when the bin level exceeds the setmaximum limit, e.g. 50% and closes when the pre-bin level drops
below the set minimum limit, e.g. 5%. Exceeds the pre-bin levelagain the maximum limit the gate will be opened again.
The pressure control function is not active and the movable rollwill be positioned to limit L2 at closed shut-off gate. This willlimit the amount of uncrushed material passing the Roller Presswhen the gate opens. The pressure control is activated again when
the gate is open. When the shut-off gate closes the pressure reducing valves are
energized and the gap increases. This procedure continues until themovable roll reaches the limit L3 at any side or the delay time (10sec) is elapsed.
Then, the movable roll is moved back to the start position L2. Themovable roll is now parallel the stationary roll and ready for thenext start.
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Control of the feed
regulating gate
The purpose of the feed regulating
gate is the adjustment of thematerial flow to the Roller Press.
The positioning is done in
AUTOMATIC MODE by setting a
position set point at SCADA and
in LOCAL MODE with thecontrol switch
At shut-down of the Roller Press
the feed regulating gate is moved
to a start set point pre-defined in
ROLCOX (e.g. 20%). The feedregulating gate opens to the
position set at SCADA after start
of the material feeding.
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min. Pos.
open
close
Dosing
Gate in
Movable
Roller
Fixed
Roller
33
RP - Bin
Slide Gate.
max. Pos.
Dosing
Gate
Start Roller Press
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Start Group Roller Press Following conditions must be considered in the client control system:
No failures causing a pre-alarm or a stop.
The signal MATERIAL DISCHARGE ON must be present.
Pressure control functions must be switched ON in order to allow a
complete start of the Roller Press with its start-up procedure. Upon every start of the group Roller Press, a startprogram BCON is
started.
At first, the solenoid valve for emergency off(V08) will be energized(the valve is fail open) and the hydraulic system closed. The pressurereducing valves (V05 and V06) will be energized (opened) and theRoller drives started. The pressure reducing valves will be closed timedelayed or when any bearing distance has reached the limit L3.
If the bearing distances are >L2 after the start-up time, the pressureincrease valves and the hydraulic pump will be energized and the
movable roll will be positioned to the limit L2. In case the pressure exceeds the limit 40barthe group start will be
terminated with an alarm message.
After some delay time the feed belt will be started, the material feed isreleased and the pressure control function is activated.
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Start Group Roller Press33
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RP Trouble, trip,
Group off, automatic
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SCADA35RP Trouble, trip, Fast stop automatic
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36RP Trouble, trip, Loop alarm
Start RP group
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MovbleRoller
V 09
V 07
Hydraulic oil tank
Pump 5312.HD1
Press cylinder
Af ter reaching of L2 + 10 mm, the main dr ives wi ll be
started one by one.
Start RP group
At every start the emergency
valve V08 is energizedto close the hydraulic circuit.
The movable roller will be moved
by the retraction cylindersto L2 + 10 mm = 45 mm
To release the oil of the maincylinders the bypass valves(V09 and V10) and the
pressure decrease valves areenergized (opened).
This will occur with standingrollers.
V 06V 06 V 07V 07V 08
Movable
Roller
Left
Fixed
Roller Right
Gap = 45 mm
L min
L2
+ 10 mm
V 11
V 3/4
V 10
V 1/2
V 05
V 06V 06 V 07V 07
V 3/4V 1/2
V 07V 07V 07V 10V 06V 06V 06V 09
V 06
Valve closed
Valve open
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Bearing distance Lmin, (L2, L3)
Lmin= 1.0 ... 12.0 mm
minimum limit for a gapreduction at activatedpressure control function.
The control system stopsany pressure increase
when the bearing distancedrops below this limit.
A limit violation is notshown as fault alarm. Theinput has to be madecarefully to avoidincorrect function of the
pressure control system.
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Bearing distance L2, L3 L2= 5.0 ... 30.0 mm
At the start of both rollerdrives start of the roller pressgroup, the start programBCON is activated. Herebythe movable roll as opposed to
the fixed roll is moved to L2with running roller drives.
After stopping the feed beltthe movable roll will be
positioned again to this value.
A limit violation is notsignalized as fault alarm.
L3= 5.0 ... 20.0 mm
With activated pressurecontrol system, the sum fromBEARING DISTANCE L2 +BEARING DISTANCEL2increase = L3 serves as
maximum limit for a bearingdistance increase duringoperation.
Any pressure relief measureswill be stopped when the
bearing distance reaches this
limit.
The sum of L3= (L2 + L2incr.) must never exceed the maximum travel
range of the hydraulic pistons.
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V 08
Start RP group
Retraction cylinders are drawn back by springs.
After L2 will be reached - the shut off Gate will be openedto release material flow to the rollers.
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L2 Gap = 35 mm
In case if during moving back the movable roller an oil pressureis measured of more than 40 bar ( normal < 40 bar ), the start willbe interrupted by an alarm signal.Fault has to be acknowledged at the roller press after checking.
Possible causes:Material between the rollers.
Disturbance in the hydraulic circuit.Roller can not move free.
After bearing distance is on both sides L2 the roller press group willbe released and feeding of the pre bin can be started.
MovbleRoller
V 09
Press cylinder
V 06V 06 V 07V 07V 07
Movable
Roller
Left
Fixed
Roller Right
Gap = 45 mm
V 10
V 3/4V 1/2
V 07V 07V 07V 07V 06V 06V 06V 06
V 11
Af ter th is the movable roller wil l be pushed back to
L2 by the main cylinders from 45 mm to 35 mm.
This happens with running rollers.
V 07
V 06V 09 V 07V 10
V 06V 05
V 1/2 V 3/4V 1/2 V 3/4
Gap = 35 mm
Pump stops and valves will be closed.
Hydraulic oil tank
Pump 5312.HD1
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V 3/4V 1/2 V 3/4V 1/2
V 08
V 07
V 10V 09
Press cylinder
Left RightFixed Roller
The proportional valves will increasepressure to the main cylinders upuntil the set point. Hydraulic pump
start.
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Start Pressure control
After the start program is readythe pressure control will start
automatically.
After opening of the shut off gate therewill get material between the rollers.
Movable Roller
V 06V 05
Hydraulic oil tank
Pump 5312.HD1
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Pressure control
By the intake behaviour of therunning rollers combined with thepressure of the column ( gap )of material on the rollers the materialflow will tend to press the rollers
apart.
V 3/4V 1/2
V 07
V 08 V 10V 09
Left Right
Press cylinder
Movable Roller
Fixed Roller
When the hydraulic reaches thevalue set point-tolerancethe proportional valves will be
closed and the pump will stop.
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Pres.Set point
At this value the material counterpressure and the cylinder pressurewill be on balance.
- 10 bar
+ 10 bar
V 1/2 V 3/4
V 06V 05
Hydraulic oil tank
Pump 5312.HD1
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Accumulator
Gas ( N2 ) Pressure = 90 bar100 bar
135 bar
125 bar
115 bar
Set point 125 bar
Hydraulic oil tank
V 3/4V 1/2
V 07
Pump 3212HD1.M01
V 08 V 10V 09
Left RightFixed Roller
Press cylinder
Movable Roller
90
bar
Start up
< 90 bar
Pressure control
Pressure variations with intolerance will be compensatedby the N2 accumulators.
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V 1/2 V 3/4
100
bar
V 06V 05
P t l44
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Pressure control
When the hydraulic gets beneath the pressure (value)
set point tolerance the proportional valves will beopened and the pump will start.
V 3/4V 1/2
V 07
Hydraulic oil tank
Pump 28 HD 41 M 01
V 08 V 10V 09
Fixed Roller
Left Right
Press cylinder
Movable Roller
44
This will remain so until set point operation pressure tolerance
has been reached.After this the valves will close again and pump will stopped.
In this example on one side.
135 bar
125 bar
115 bar
Characteristics proportional valves.
100
%
100
%
12 m Amp
0 %
4 m Amp
Proportion valve
pressureincrease
20 m Amp
Proportion valve
pressuredecrease
80 %
80 %
18,4 m Amp
V 3/4
V 06V 05
Proportional valves
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Proportional valves
The proportional valves act in two flow directions
which are activated by two solenoids:a) Pressure increase: Analogue PLC output:
12 - 20mA corresponding to 0 - 100%opening
b) Pressure decrease: Analogue PLC output
12 - 4mA corresponding to 0 - 100% openingThe neutral position (both ways closed is
determined at I = 12mA ).The activation of the solenoids is organised via
valve amplifier installed on top of theproportional valve.
V 3/4V 1/2
V 07
Hydraulic oil tank
Pump 28 HD 41 M 01
45
Characteristics proportional valves.
100
%
100
%
12 m Amp
0 %
4 m Amp
Proportion valve
pressure
increase
20 m Amp
Proportion valve
pressuredecrease
80 %
80 %
18,4 m Amp
V 3/4
Set points
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This is the point where the bearing distance is 0.For the gap measuring this point is 4 m Amp.
The bearing blocks are fixed in a way that therollers can never touch each other physically
Fixed Roller
Movable Roller
Left Right
Distance pieces
Movble
Roller
Fixed Roller
Left Right
Distance between the bearings used as lowerlimit for the pressure control.If distance is less pressure control will bedeactivated.
Roller distance 10 mm = Gap 10 mm
Roller distance 10 mm
+ Bearing dist. 15 mm
-----------------------------
= Gap 25 mm
Gap = 10 mm
Set points
0 mm ( Bearing distance )L 0mm
GAP > L min Pressure contro l ON
normal operation
L min 15 mm ( Bearing distance )
Movable Roller
GAP < L min Pressure contro l OFFGap = 25 mm
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LOCAL CONTROL PANEL:
One push button with signallamp is used foracknowledgement of alarms
which require a visualinspection at the Roller Pressfor the reason of followingalarms:
Pressure >40bar during start
programme (BCON) Pressure >180bar during
operation
Movable roll end limitposition has been reached
Under speed monitoring After local acknowledgement
these alarms have to beacknowledged at the SCADAtoo!
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Start program BCON (RP GROUP = START)
With the group Roller Pressstart command both pressuredecrease valves are energizedto allow the movable roll tomove backwards. This isimportant after a restartfollowing an emergency stopwith uncrushed material
above the rolls. Is the bearing distance left or
right
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Start program BCON Program Step 1 and 2
BCON Program Step 1
If the bearing distance left or right is
L3 or after a delay time the start ofthe roller drives in parallel mode orsequential mode is performed.
BCON Program Step 2
The movable roll will be movedtowards the fixed roll byenergizing both pressure increasevalves, when both roller drivesare in operation and the run-uptime is elapsed. Both pressureincrease valves are to becontrolled independently.
Exceeds any hydraulic pressurethe limit 40bar the group startsequence will be stopped withalarm.
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Start program BCON Program Step 3
BCON Program Step 3
The program BCON stops and theshut-off gate opens when the binlevel reaches the maximum limitset at SCADA, e.g. 50% and the
pressure control function isactivated in case the operationmode "AUTOMATIC" isselected.
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The delayed energising of pressure reducing valves takes place when the
shut-off gate is closed. This causes the movable roll to move apart from the
fixed roll. This action is terminated when the bearing distance has reachedthe limit L3 or latest after 5 sec.
Now, the movable roll will be positioned to the limit L2 (start position)
using the pressure increase valves.
Set points51
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L min
Movable
Roller
Fixed
RollerLeft Right
Gap = 35 mm
Movable
Roller
Fixed
RollerLeft Right
Gap = 45 mm
L2Parameter set in the PLC. Set only once.
Range from 5.0 to 30.0 mm
Actual set point 20 mm
( Set point for material feeding )
Roller distance 10 mm
p
L min
+ L2 + 10 Bearing dist. 30 mm
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= Gap 30 mm
+ L2 Bearing dist. 20 mm
L2+ 10 mmUntil this value the rollers are pushed back
by retraction cylinders
during start up the main motors.
= Gap 40 mm
Roller distance 10 mm
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Movable
Fixed
RollerLeft Right
Gap = 65 mm maximum
Roller distance 10 mm
+ Bearing dist. > 50 mm
= Gap > 60 mm
Limit switchMaximum distance allowed
between the bearings. ( 65 mm Gap )
Determined by a mechanical switch.Over 65 mm gap the roller press will
stop with max. gap alarm.
Set points52
Normal operation
Movable
Roller
L2
L min
+ 10 mm
Movable
RollerMovable
Roller
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Normal Stop of the group Roller Press
This command starts the shut-down procedure with:
- stopping of the feed belt, - the pressure reduction by opening of the pressure reducing valves
until the limit L3 has been reached or for max. 5sec,
- the run-off of the roller drives for 1min.
This procedure can be released by:
STOP command from SCADA
Drive fault
Instrument loop fault
Over temperature roller bearings
Over temperature gear box bearings Over temperature hydraulic oil
Disturbance BCON
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Fast stop of the group Roller Press
This command stops the group Roller Press immediately
- stopping the feed belt,
- Stop of the roller drives and all other drives of the Roller Press, - de-energising of the hydraulic valves.
This procedure can be released by:
EMERGENCY STOP command from the local control panel
Loss of control voltage
Activation of the movable roll end position
Hydraulic pressure >180bar
Under speed monitoring of any roll
Fault of any roller drive
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Group Aux. Heater = Start / Stop The commands Start/Stop and LOCAL are sent from SCADA to the
ROLCOX system. This signal starts the heating system for the
grease pipe and oil pipes. The heating units are self-controlling.
No temperature control is required in ROLCOX.
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3212LQ5.H01 3212LQ5.H02 3212LQ5.H03
Current control56
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By means of to much adjusting ofoperationpressure or due to changing materialproperties the electr ical load of the maindrives can become to high.If this load exceeds a preset maximum thepressure will be reduced.
V 07
Hydraulic oil tank
Pump 28 HD 41 M 01
V 08 V 10V 09
Left Right
Fixed Roller
After this the pressure control will be reactivated.
V 1/2V 1/2 V 3/4V 3/4
This will last until the movable roller reachesL2 + 10 mm = 45 mm gapor until the drives get below operation load.
Press cylinder
Movable Roller
V 11V 06V 10V 05
RP Group stop
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V 10V 11
The Pressure decrease valves will
open, the proportional valves willopen,and the emergency valve willopen.
Hydraulic oil tank
Pump 28 HD 41 M 01
Left RightFix Roller
Press cylinder
Movble
Roller
Fixed Roller
Movable Roller
V 07
V 09 V 10V 09
V 1/2V 1/2 V 3/4
V 08
The rollers will due to material pressure move apartuntil L2 is reached on both sides or after time limit.Roller press will stop after 60 sec.
At a stop of the roller press (desiredor undesired) the RP - slide gate willclose and stopped the material feedto the RP.
The Pressure decrease valves willclose, the proportional valves willclose, and the emergency valve willopen.
V 06
V 3/4
V 10V 05
ROLCOX Parameters58
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SCADA59
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SCADA59
OPERATION CURRENT
Adjusting range:
70 ... 90% of the nominal current In
EXCESS CURRENT
Adjusting range:
70 ... 90% of the nominal current In
This value corresponds to the upper
limit of the standard operating
current. As soon as that value isreached, the overload pressure
reliefing measure is terminated.
This value corresponds to the upper limit
of the standard operating current. As
soon as that value is reached, the
overload pressure reliefing measure isterminated.
CURRENT DIFFERENCE
Adjusting range:
5 ... 20% of the nominal current In
In case the current difference
between the drives exceeds the set
limit, an alarm will be generated
without further consequences for the
operation of the Roller press.
SCADA60
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SCADA60
With activated gap-dependent pressurecontrol, the SETPOINT PRESSURE islimited to the sum ofOPERATINGPRESSURE + PRESSUREINCREASE MAX. An internal pressure
limit (150 bar) cannot be exceeded!
OP.PRESSURE INCREASE MAX,
10-99bar
With activated gap-dependent pressurecontrol, the SETPOINT PRESSURE islimited to the sum ofOPERATING
PRESSURE + PRESSUREINCREASE MAX. An internal
pressure limit (150 bar) cannot beexceeded!
OP.PRESSURE INCREASE MAX,
10-99bar
With activated gap-dependent pressure
control, the SETPOINT PRESSURE islimited to the sum ofOPERATINGPRESSURE + PRESSUREINCREASE MAX. An internal
pressure limit (150 bar) cannot beexceeded!
OP.PRESSURE INCREASE MAX,
10-99bar
SCADA60
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SCADA
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