Mechanical document DRW 4.1

OPERATING INSTRUCTIONS Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-BD-a-GB ROTOR WEIGHFEEDER DRW 4.10/4.12/4.14 PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 1/103 Page / OPERATING INSTRUCTIONS Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-BD-a-GB The persons responsible for transport, assembly, commissioning, operation, maintenance and repairs must read and apply the operating instructions This is a prerequisite for faultfree operation and serves to prevent damage and hazards, particularly with regard to explosion protection The operating instructions must always be kept near to the unit, because they contain important information about maintenance and repairs Before starting work, consult our customer service department if you not understand information related to safety They will also be please to answer any other questions We can accept no liability for damage or breakdown caused by failure to observe these operating instructions! These operating instructions are compiled in accordance with the valid regulations for machines, electrical systems and explosion protection and are made up of the following sections: Contents Document no Pg.: Unit description 550.096.60.04-GB-a-GB Safety sheet 550.096.60.04-SI-a-GB 11 Transport instructions 550.096.60.04-TA-a-GB 15 Mounting instructions 550.096.60.04-MA-a-GB 21 Commissioning instructions .550.096.60.04-IN-a-GB 33 Operator’s manual 550.096.60.04-BA-a-GB 57 Maintenance instructions 550.096.60.04-WA-a-GB 61 Repair instructions .550.096.60.04-IS-a-GB 79 We reserve the right to make changes due to technical advancements which may cause deviations from the illustrations and information contained in these operating instructions PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 2/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB ROTOR WEIGHFEEDER DRW 4.10/4.12/4.14 Contents Page General description 2 Operating method of the rotor weighfeeder Construction .3 Proportioning system 5 Correct application 6 5.1 Explosion protection 5.2 Bulk materials 5.3 Temperatures 5.4 Operating pressures Index History PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 3/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB General description The rotor weighfeeder is employed for the continuous, gravimetric proportioning of coal dust and coke dust in the cement burn process This architecturally simple, enclosed proportioning device integrates the bulk material outlet, the weighing, the regulation of the proportioning flow, and the bulk material delivery in the pneumatic delivery piping Operating method of the rotor weighfeeder The rotor weighfeeder uses the operating principle of a gravimetric functioning, horizontally lying sluice (Fig 1) Through the rotor (cellular wheel), the bulk material is extracted directly out of the silo or prehopper, led over the weighing section, proportioned in the pneumatic delivery piping and with the ventilator generated carrier air delivered directly in the operation Load cell Joint Foundation frame Bulk material inlet Rotor chamber Blow-out pipe Air supply Bulk material outlet Bulk material inlet A-A Weighing axis B Weighing point Fig 1: Operating principle of the rotor weighfeeder The weighing axis runs through the connection compensators between the bulk material delivery, the pneumatic delivery piping and the rotor, whereby secondary power reactions resulting from pressure fluctuations are completely compensated and thereby have no effect on the proportioning outcome The bulk material content found at the moment in the rotor weighing section is gathered in weighing section B The bulk material content with the attending position is registered in the weighing electronics; that is to say, the local load of the rotor is already known before the discharge The angular velocity required for discharge is computed in advance and aligned through the rotor propulsion according to the designated conveyor strength set value and the registered bulk material content The rotor weighfeeder is able through this principle of long range regulation to realize a disturbance variable compensation resulting in the highest short-time precision PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 4/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB Construction A-A B C D Swiveling axis Load cell Inlet field Blow-out head Rotor housing Foundation frame Weighing joint Weighing device Clean gas compensator Outlet compensator Inlet compensator Rotor Drive Fig.2: Construction of the rotor weighfeeder PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 5/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB The elliptical rotor housing (1) with rotor, drive and transport air distribution is situated on the foundation frame (2) in the weighing joints (3) and hanged in the weighing device (4) (Fig 2) The swivelling axis A-A, structured through the pendulum bearing, is hereby so situated that it runs through the blow pipe compensators (5) and (6) and compensator (7) of the bulk material inlet Because of the required pressure shock resistance, the horizontal rotor (8) is enclosed by stabile sealing plates supported over the elliptical rotor housing The bulk material flows under the gravity effect out of the silo into rotor chamber C Through the rotation of the rotor, the bulk material reaches the ejection position in blow-out head D The ventilator generated transport air is equally distributed on all three rotor chamber rows Reliable discharge of the bulk material is guaranteed by flow velocities between 18 and 35 m/s The large number of rotor chamber webs between the bulk material inlet and the blowout head, as well as the axial adjustability of the seal opening guaranty the maximum airtightness between the bulk material outlet and blow pipe Through the large number of rotor chambers in connection with a regulating range of 1:10, the rotor weighfeeder can also proportion very low dose rates of bulk material virtually pulsation free PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 6/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB Proportioning system Figure 3: Proportioning system for coal dust The coal dust deposited in the silo (1) is drawn off with the aid of ventilation (2) and bulk material activator (4) and is carried to the prehopper (11) by the frequency-controlled rotary valve (6) Extraction from the prehopper is supported by the prehopper ventilation A prehopper stirring device (10) can be used here to make the material constant and to prevent it baking onto the vessel wall If there is a risk of the condensation point being fallen below, the walls of the silo and of the prehopper are insulated and, if necessary, heated PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 7/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB The rotor weighfeeder (17) transports, weighs and meters the coal dust, and feeds it into the pneumatic transport line to the burner Automatic control measurements are carried out cyclically in the prehopper mounted on load cells (18) The rotary valve (6) is stopped and the shut-off gate (5) is closed A defined quantity of material is taken out of the prehopper, compared with the rotor weighfeeder’s counter and the zero point of the rotor weighfeeder is readjusted if there is any deviation After the control measurement ends, the shut-off gate (5) is opened again, the rotor weighfeeder starts and the prehopper is brought back to its normal filling level The filling level limit switch (8) prevents overfilling of the vessel To prevent pressure fluctuations in the system influencing the control measurement, pressure compensation in the prehopper is carried out by a pressure measurement (9) Force changes resulting from pressure changes in the transport line are compensated for by the compensators arranged opposite each other in the blow-in pipe (14) and the blow-out pipe (15) Please refer to the descriptions for the supplied system for more detailed functional descriptions and switching sequences Correct application The use of the appliance over and above the correct application is prohibited The manufacturer is not responsible for any damage resulting out of this The operator bears the sole responsibility for risk The rotor weighfeeder is built in keeping with the latest technological developments and recognised technical safety regulations It complies with the relevant EC directives, in particular with · 98/37/EG (Machine directive) · 73/23/EG (Low-voltage directive) · 89/336/EG (Electromagnetic compatibility) · 94/9/EG (Equipment intended for use in potentially explosive atmospheres) 5.1 Explosion protection The Rotor Weighfeeder is suitable for use in explosive atmospheres The appliance can be supplied with category Ex II 1/3 D or EX II 1/2 D The applicable category and the temperature class can be obtained from the name plate or from the certificate of conformity Use is only permitted in the zone stipulated for the category, in compliance with operating instructions, and safety instructions for explosion protection contained therein PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 8/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB 1/3 D 140°C 0158 1/2 D 140°C 0123 0123 0158 Ex-marking and CE-marking The Rotor Weighfeeder DRW 4.10 is, in addition, tested by a designated authority for safety against ignitable disruptive discharges in case of dust explosions The appliance is designed to be pressure shock-resistant During operation and servicing of the Rotor Weighfeeder the local safety regulations, in particular the regulations for potentially explosive areas, are to be observed 5.2 Bulk materials Permitted bulk materials are combustible dusts such as brown-coal dust, hard-coal dust, powdered charcoal and breeze, above all petroleum coke dusts These products can also be a combination of one with another, or even a combination with other substances, such as fly ashes, filter dusts, animal meal, etc The explosive overpressure of the bulk materials used is permitted to amount to a maximum of 10 bar The Rotor Weighfeeder must only be used for the bulk materials stated in the order confirmation and in the data sheet, including specified grain size and humidity 5.3 Temperatures The maximum permitted material temperature is 80°C The maximum permitted ambient temperature is 40°C Higher temperatures are only possible with special designs with additional certification by the manufacturer Air should always be used for pneumatic feeding Should the conveyor air exceed 80°C, it must be cooled 5.4 Operating pressures The maximum permitted operating overpressure in respect of pressure shock resistance amounts to 0.7 bar The permitted operating overpressure is stated in the respective data sheet PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 9/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10/4.12/4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB Index History Index Author Date of issue Modifications Ripp 02.07.2003 Documentation release a Ripp 24.09.2003 Supplementation: chapter Correct application Introduction: chapter Index history Subject to change without notice The technical data and specifications are valid at the time of publication of this documentation The information provided in this publication is, however, checked on a regular basis and any necessary corrections made in subsequent editions Pfister GmbH reserves the right to alter these versions at any time We are always grateful for suggestions for improvement PFISTER GmbH, D-86068 Augsburg 550.096.60.04-BD-a-GB-(kpl) 10/103 Page / ... 550.096.60.04-BD-a-GB-(kpl) 2/103 Page / UNIT DESCRIPTION Rotor Weighfeeder DRW 4.10 /4.12 /4.14 TRM / 24.09.2003 550.096.60.04-GB-a-GB ROTOR WEIGHFEEDER DRW 4.10 /4.12 /4.14 Contents Page General description... 550.096.60.04-BD-a-GB-(kpl) 10/103 Page / SAFETY SHEET Rotor Weighfeeder DRW 4.10 /4.12 /4.14 TRM / 24.09.2003 550.096.60.04-SI-a-GB ROTOR WEIGHFEEDER DRW 4.10 /4.12 /4.14 Contents Page Symbols and instructions... 14/103 Page / TRANSPORT INSTRUCTIONS Rotor Weighfeeder DRW 4.10 /4.12 /4.14 TRM / 24.09.2003 550.096.60.04-TA-a-GB ROTOR WEIGHFEEDER DRW 4.10 /4.12 /4.14 Contents Page Packing