PLCS, HMIS & INDUSTRIAL PCS FEATURE Improving productivity with batch


control A


s the creator of diamond polishing compounds, slurries and machinery


for a wide range of industrial processes, Kemet International wanted to create a more efficient fluid control system that would make the entire manufacturing process more productive. However, although the company


initially contacted Bürkert for a replacement flowmeter, discussions soon turned to the application itself and additional improvements that could be made. The final concept therefore included the addition of batch controllers, fluid control valves and level sensors, all of which would improve productivity and reduce waste.


A NEW CONTROL SYSTEM The company wanted to reduce the time taken to fill a storage tank and to add a control circuit that would automatically stop the pump when the tank was full. Here, a larger capacity pump and new pipework were installed, which reduced the filling time by 75%. The addition of a Type 8110 tuning fork level switch gave the necessary signal to the pump to prevent overfilling. In conjunction with this, a new batch


control system was designed and manufactured by Bürkert that would allow several pre-set batch sizes from 450ml to 25 litres to be produced automatically. The system used a paddlewheel flowmeter and an angle seat control valve directly connected to the electronic control module to provide a simple, inline batch control installation. A second batch control system


of a similar design was also installed, but this time the batch sizes were much smaller so the pump and associated pipework were sized accordingly. Both systems incorporated the Type 8025 batch controller, which can accommodate seven batch sizes and has a built-in automated calibration process. In each case the pumps were


connected to the batch control panel to allow them to be directly controlled by the batch process. In this way, the pumps only operate when necessary, reducing energy consumption and prolonging their service life. The final part of the project was installed


for the production of de-ionised water. Here, a new 1200 litre tank was supplied, along with a pump and the installation of all the pipework to allow several batching


A RELIABLE SOLUTION FOR BEER AND WHISKY PRODUCTION


At Bairds Malt’s facility in Witham, Essex, where barley is turned into malt for use in beer and whisky production, a new germination machine has been installed to increase productivity and improve safety. An ACS880 variable speed drive (VSD) from ABB is used on the


machine to control four gear motors located on the corners of a 15-tonne trolley (known as a turner) that is used to agitate the barley during the germination process. The turner plays a crucial role in the


malting process. Once barley has been steeped, it is fed into an open-topped box of around 45m – known as a street – to enable germination to occur. It is necessary to constantly agitate the barley in order to stop the roots from knitting together. The turner performs this function as it moves along the box at exactly 0.42rpm, driven by the gear motors on each corner. As the trolley progresses, 12 motor-powered screws turn the barley to break it apart. With the new system, the VSD takes


its signal from a programmable logic controller (PLC) which is mounted, together with the VSD, in a stainless steel box on the turner. The PLC monitors the load drawn by the gear


ABB


Needing a more efficient fluid control system, Kemet International turned to Bürkert for a solution


points to be supplied at once via a manual ball valve. The new pump has an improved


delivery capacity and throughput has increased by 70%. It is designed to provide a pressurised supply to four outlets. When demand is low the water is recirculated back to the storage tank via a bypass valve. The installation includes a digital flowmeter, located downstream of the pump, that also acts as a totalizer to record the amount of de-ionised water produced each day. Richard Bolton, operations


manager at Kemet International, commented: “This project has been developed using Bürkert’s expertise


Bairds The company wanted to reduce the time taken to fill a storage tank and to add a control circuit that would automatically stop the pump when the tank was full


with the aim of improving productivity and efficiency. The final installation has achieved this and also helped us with our company goals of reducing waste and minimising energy usage.”


Bürkert Fluid Control Systems www.burkert.co.uk


motors to detect spikes in current of 20% or more that signal a blockage. Should this occur, the drive reduces the speed of the motors to 50%, giving the turner time to work through the obstruction. It repeats this process three times. If the blockage has still not cleared, an alarm is triggered to notify the operator. The system also uses ABB switchgear, including a door interlocked


isolator, miniature circuit breakers, contactors with thermal overloads and signal transducers. Following the installation of the system,


stoppages at the site have been reduced from once a fortnight, on average, to practically zero. Furthermore, as the turner no longer has to attempt to drive through blockages, the ABB drive is also expected to cut energy use by reducing the amount of work the gear motors have to do. Savings are also likely as a result of reduced maintenance costs. For the project, Bairds designed the new system


itself and ABB authorised value provider, Gibbons Engineering Group, designed and supplied the control package. Gibbons has recently completed a similar installation at Bairds Malt’s facility in Pencaitland, Scotland.


www.abb.com


/ DESIGNSOLUTIONS


DESIGN SOLUTIONS | SEPTEMBER 2018


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