Manual Filtros Vpa 1540-50.En

Operation & Maintenance Manual

Pressure FilterVPA 1540-50

Supplier / YearMetso Minerals (Sala) AB / 2009

Customer

Compaia Minera Doa Ins de Collahuasi S.C.M., Chile

Edition 1 HHD / 281703 09-W8 Index 0 1/1

GENERAL 1

DESCRIPTION 2

HEALTH AND SAFETY 3

FUNCTIONAL DESCRIPTION 4

CONTROL SYSTEM 5

INSTALLATION 6

COMMISSIONING 7

OPERATING INSTRUCTIONS 8

CARE AND MAINTENANCE 9

SPARE PARTS 10

DRAWINGS See separate binder 2/4 11

ASSOCIATED PUBLICATIONS See separate binder 3/4 12

Operation & Maintenance Manual 1/4

Operation & Maintenance Manual 2/4 Drawings

Operation & Maintenance Manual 3/4 Associated Publications

Hydraulic Manual 4/4

Pressure Filter VPA 1540-50

Edition 1 HHD / 281703 09-W8 General 1 1/7

1. GENERAL

1.1 About this manual

1.2 Delivery data

1.3 Service and repair information

1.4 Storage instruction at site

1.4.1 Long time storing before installation

1.4.2 Long time storing after installation

1.5 EC declaration not applicable

1.6 Brochure



1.1 About this manual This manual contains information on equipment bearing the article number SA 253370-M1. It is written for the use of installers, operators and maintainers.

Manual provided by Metso Minerals should be regarded as a part of the equipment to which it relates. It should be kept for the life of the equipment and passed on to any

subsequent purchaser of the equipment. Any amendments issued by Metso Minerals should be promptly inserted into this manual.

HEALTH AND SAFETY STATEMENT

TAKE TIME TO ENSURE THAT YOUR SAFETY AND THAT OF OTHERS IS NOT PUT AT RISK. FAILURE TO OBSERVE PRECAUTIONS, BOTH ELEMENTARY AND THOSE EXPLICIT IN THIS MANUAL, MAY RESULT IN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT. SEE ALSO MANUAL SECTION 3 - HEALTH AND SAFETY.



1.2 Delivery data End customer : Compaia Minera Doa Ins de Collahuasi S.C.M.

Customer : Metso Minerals (Chile) S.A. Machine type : VPA 1540-50 Hydraulic unit, see separate manual, binder 4/4 Number of machines : 1 off Country : Chile Year of manufacture : 2009

1.3 Service and repair information For any enquiry regarding the servicing and repair of equipment supplied by Metso Minerals, please contact Metso Minerals (Sala) AB Norrngsgatan 2 PO Box 302 SE-733 25 Sala Sweden Telephone: +46 224 570 00 Telefax: +46 224 169 50 Please provide the following information: 1 model and size of equipment 2 article number 3 approximate date of purchase



1.4 Storage instruction at site

1.4.1 Long time storing before installation

General If the VPA unit must be stored a long time before installation or shut down for a longer period after installation some precautions must take place. In general, the following instructions given below should be followed. Also see the instructions given in the sub suppliers manuals. Storage for more than 6 months is considered extended storage. Place the machine on a level area and protect from rain, dust and dirt. The storage area must be free from vibrations, as vibrations can cause damage to the bearings. In order to avoid damage from freezing and corrosion damages, drain the machine from rainwater and other foreign liquids. After a machine has been transported on ship, rail or road, it is always necessary to perform a general maintenance, refill all grease nipples, rotate all shafts for several revolutions, check oil levels, and replenish all rust protection on unprotected surfaces.

Bearings Rotate shafts for several revolutions, every six months, so that all bearings Will be coated with a fresh film of grease. Grease all bearings every twelve months.

Rubber parts Protect all rubber parts from exposure to sunlight, ozone and temperatures higher than

+25 C. Nitrile rubber parts may be protected by a film of silicone grease.

Hydraulic cylinders Before transport, all cylinders have to be filled with oil. The quality of hydraulic oil stated by Metso Minerals must be used. Cover plate for inlet ports have to be sealed with O-rings. Following not painted cylinder parts must be rust protected. Use Metso MP 30, or equivalent protection from other supplier:

the part of the piston rod outside the cylinder

rod end, rear and front ear

surfaces around the cover cap and inlet ports must be protected

shafts at centre yoke



Hydraulic unit Rotate the hydraulic pumps minimum twice a year. Can be done by rotating the fan on the

electrical motor, clockwise. The pump shafts have to be rotated minimum two turnes. Visual control that rust not exists around valves and on the bolt heads (bolt kits for valves). Before delivery the following has been done to prevent rusting:

The hydraulic unit(s) have been tested with a hydraulic oil with good rust protection.

Shafts on electric motors and pumps are prepared with rust protection, Metso MP 30

Core tubes on hydraulic valves have been prepared with oil.

Before installation has taken place: Protect the VPA unit parts from rain, dust, dirt and freezing temperature, in order to avoid freezing and corrosion damages. The filter plates must be protected from sun and rain with a tarpaulin.

The vibrators must be stored indoors at a temperature not below 0 C.



1.4.2 Long time storing after installation

Separate the filter plates as far as possible. Take out the filter cloths. Wash the cloths at high pressure with water and let them dry. When the cloths have dried they must be stored lying on top of each other and on a flat base. There must be no weight on the cloths during storage since this would cause an obvious risk of permanent deformation at the point where the weight is concentrated. Empty and flush all pipes with the exception of hydraulic pipes (water, air, slurry) and drain all liquid from system. Flush the machine clean with water. It is especially important that all plates and their ducts are thoroughly cleaned.

Drive the plates together using the hydraulic low pressure system. Disconnect the electrical power supply (vibrator). Touch-up all areas of damaged paint work. Apply rust protection to all machine surfaces which are exposed to the surrounding air. Wedge up the moveable press head so that the wheels are lifted from the rails. Turn the wheels several times every month. Cover the filter with a tarpaulin or equivalent.



1.5 EC declaration Not applicable.

1.6 Brochure

See enclosed brochure.

Vertical Plate Pressure Filter

Filtration

Equ

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w.m

etsom

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Simple mechanical constructionThe Svedala Pressure Filter is a heavy duty machine, developed for ltration of metallic minerals, industrial minerals, coal and tailings.

The lter has simple mechanical construction and design, with few moving parts.

By using a pulling hydraulic cylinder system for closing and sealing the lter plate pack,we can provide a compact layout and a light weight support frame design.

Polypropylene lter plates are used for good chemical resistance and the light weight.

Smart fully automatic control system The Svedala Pressure lter is controlled by a system consisting of a PLC connected to a PC screen, built in a well sealed and well insulated cabinet.

All control logics are implemented in the PLC. On the PC monitor the lter operator can follow and control the lter operation and information such as settings, statistics and alarms.

High unit capacityBy installing the Svedala Pressure Filter on load cells connected to the PLC a multitude of data become available.

The weighing system provides accurate production information, and can be used to optimise the ltration- and drying steps in

the lter cycle.

Low dewatering cost with the membrane technology

The Svedala Pressure Filters use a rubber membrane in each lter chamber. The membrane technology eliminates cracks in the cakes and also compensates for the shrinking in the cake during the compressed air drying. The result means lower com-pressed air consumption and lower total dewatering cost.

Low maintenance costBecause of the simple mechanical design with few moving parts as well as the lter cloth sign and system, with extremely short downtime for cloth changing, the Svedala Pressure Filters have very low maintenance costs.

Control cabinet, inside view

PC screen picture

Product Presentation

The clean and simple construction of the Svedala pressure lter type VPA

Process schematic VPA pressure lter installation

SLURRYTANK

HYDRAULICUNIT

FILTRATERECEIVER

FEEDPUMP

FEED

V4

V1V3

V5 V7

V2

V10

HIGHPRESSAURE

HIGHFLOW

DRIP PAN CLOSED OPEN

PRESSCLOSED PRESS OPEN

CLOTHVIBRATOR

V6

V8

V9

COMPRESSEDAIR

WATER

Fixed Head

Filter Cloth Support Upper RailsCloth Wash Spray Bars

Parallel Hydraulic Cylinders

Filter Cake Discharge Chute

Moving Head Load Cells

Technical Specifications

Svedala Tube Press

Subject to alteration without prior notice. Brochure No: 0000-00-00-MP/Sala - English Metso Minerals

Our range:

Metso MineralsSE-733 25 SalaSwedenPhone: +46 224 570 00Fax: +46 224 169 50

Metso MineralsP.O. Box 340Colorado Springs, CO 80901USAPhone: +1 719 471 3443Fax: +1 719 471 4469

Metso Minerals4050 B Sladeview CrescentMississauga, Ontario L5L 5Y5CanadaPhone: +1 905 607 3330Fax: +1 905 607 3339

Metso MineralsStocks HouseNorth StreetLeatherhead, Surrey KT22 7AXUnited KingdomPhone: +44 1372 81 43 00Fax: +44 1372 81 43 05

Metso MineralsPrivate Bag X2006Isando, Johannesburg,1600South AfricaPhone: +27 11 397 5090Fax: +27 11 397 5826

Metso MineralsP.O. Box 6306Silwerwater, NSW 1811Lidcombe, NSW 2141AustraliaPhone: +61 2 9748 1777Fax: +61 2 9748 1939

www.metsominerals.comE-mail:[email protected]

Flotation Machines Magnetic Separators Sedimentation Equipment Filtration Equipment Thermal EquipmentReactor Cell Systems Low Intensity Magnetic Inclined Plate Settlers Vertical Plate Pressure Holo-Flite ProcessorsDR Flotation Machines Separators Thickeners & Clarifiers FiltersClassifiers High Gradient Magnetic Spiral Dewaterers Tube PressesSpiral Classifiers SeparatorsAgitatorsMixers


Edition 1 HHD / 281703 09-W8 Description 2 1/15

2. DESCRIPTION

2.1 General description

2.2 Technical specification

2.3 Machinery identification and warning signs

2.3.1 Machine sign

2.3.2 Sign lift point

2.3.3 Electrical cubicle signs

2.4 Certificates and test results not applicable



2.1 General description

Nomenclature

VPA stands for Vertical Press Airblow, and refers to compressed- air filtration with compressed-air drying.

Design VPA The basic design of the pressure filter consists of a rectangular frame formed by a fixed press head with fittings for hydraulic cylinders, an end support with longitudinal side rails between this and the press head. A moving press head runs on the side rails, controlled by four hydraulic cylinders working in parallel. Moving filter chambers are placed between the fixed and moving press heads. The filter chambers contain double filter cloths which allow filtration on both sides of the chamber. The filter cloths are suspended from tubular supports which run on two upper slide rails. These tubes also act as spray bars for flushing the clothes. Water for flushing the clothes is supplied through flexible hoses from a fixed supply-pipe at the side of the pressure filter.

The cloth supports run on a sprung frame fitted with four motorised vibrators. These operate while the filter cloths are being rinsed to maximise the effectiveness of the flushing. The moving press head and the filter chambers are connected together to ensure that the movement is smooth and uniform and to maintain a precise distance between the filter chambers in the open position. Similarly, the cloth support tubes are linked together so that the filter cloths always move in the centre of the chambers and with the same speed as the chambers.

Filter chambers The filter chambers consists of two closely spaced plates of machined polypropylene. The feed ports in the upper sections of the chambers are fitted with rubber seals which seal against the feed ports on the filter cloths. The filter chamber has a compression membrane manufactured from natural rubber, which is activated by compressed air to a maximum of 9 bar. Compressed-air enters and the filter water drains through four ports in the corner of the filter chamber.



Chute with doors Through the floor under the filter there is a chute, with launders for wash water on each side of the chute. The chute is there to guide the concentrate to the conveyor belt. When the filter opens to empty the chambers the doors are also open. When washing the cloths, the doors are closed, and the washing water is led away through the launders.

Slurry system The pressure filter must be fed with the thickest possible slurry. It is essential that the concentration stage before pressure filtration functions at maximum efficiency at all times. A mixer tank for the filter holds the slurry in suspension. During the filtration cycle a centrifugal pump transfers the slurry to all the chambers and maintains the correct filtration pressure.

Cloth washing system The system contains a flush water tank, valves and feed pumps. The tank is equipped with level-indicators (provided by the customer).

Cloth damage detector The VP type pressure filter is fitted with an indicator which triggers an alarm if any of the filter cloths are damaged. A detector is placed in the filter outlet port on the fixed press head and another detector on the filter outlet port on the moving press head. The detector consists of a photocell which shines through a side current of the filter water. If a cloth is damaged the filter water becomes muddy and this is registered by the photocell which warns the control system.

Alignment monitor for movement 4 inductive sensors are fitted to the moving press head which trigger alarm and stop the pressure filter if the moving press head for any reason begins to go off square with a risk of derailment.

Limit position switch At each extreme position of the movement inductive sensors are installed to establish that the moving press head is in the correct position before the following sequence is allowed to begin.



Hydraulic system The VPA filter chambers are opened and closed by four parallel operated hydraulic cylinders. The oil to the cylinders is supplied by a hydraulic unit which is designed as follows: A foundation frame of U-beams is the base for an oil tank which is equipped with a screwed cover plate, oil-spill trough and drip edge around the tank. Each cylinder is supplied with oil from its own high-flow pump. The four high-flow pumps are parallel connected to the same electric motor and are factory tested to provide exactly the same amount of oil to each cylinder. The oil to each cylinder is filtered through an oil filter. Each cylinder circuit has an integrated pilot oil controlled valve system including pressure switches and check valves. After the piston rods have reached the closed filter chamber position, a high pressure pump (piston pump) supplies oil at a high pressure ( 250 Bar), to each cylinder, in order to seal the chambers against air and filtrate leakage during the dewatering process. A filter consists of four hydraulic steps:

transport closing

high pressure closing

high pressure relief

transport opening All these steps are controlled and regulated by the filter control (computer) system and the electrically operated solenoid valves. The high pressure pump on the hydraulic unit is also providing oil to hydraulic cylinders, through solenoid valves, to the two hatches in the chute below the filter. The hydraulic unit is normally placed on the platform around the top of the filter. Two hydraulic hoses are connected between the unit and each hydraulic cylinder.

Control system The pressure filter is controlled by a system consisting of a PLC connected to a PC. All control logics are implemented in the PLC. The operator uses the PC monitor and a mouse to operate the filter press either Manually or Automatically. The operator can also do Settings, Statistics and Alarm handling from the monitor.



2.2 Technical specification

PROCESS DATA Application Copper conc. Capacity (dry metric ton/h) 70 t/h Pulp density (feed) 1,85 t/m

3

Cake moisture 9 % w/w Cake density (dry) 2,6 kg/l

OPERATING CYCLE/FILTER Filtration 2 min Compression 0,5 min Washing 0 min Air-through blow 1 min Service time 3,75 min Total cycle time 7,25 min

COMPRESSED AIR Through blow pressure 6,5 bar Through blow, air flow/filter 0,85 Nm/m

2,min

Through blow, area/filter 85 m Recommended air flow/filter 72 Nm/min free air (at end of air blow) Membrane pressure 8 bar Filtration pressure 5,5 bar



TECHNICAL DATA

General

Dimension dwg SA253376

General arrangement drawing SA253377 side view

Danger zones, drawing SA253383

Foundations and loads, drawing SA253380

P & I diagram, drawing 52248 X 025

Total weight, empty 48600 kg (incl. hydraulic unit and chute with doors) Chambers, number 50 Chamber depth 42 mm Chamber volume/filter 50x68=3400 litres Filtration area, total/filter 170 m Control unit Hydraulic cylinders Drive medium Oil Painting program S444 SV/200 RAL 5009



PRESSURE FILTER

Frame Material Steel EU No. 1.0038

Press head (fixed and moving) Material Steel EU No. 1.0038

Hydraulic cylinders Number 4 Manufacturer Hllaryds Hydraulik AB, Sweden Model HDC 250 x 4020 Cylinder diameter 250 mm Piston rod diameter 125 mm Stroke length 4020 mm Surface coating of piston rod Chromium alloy

Filter and membrane plates Material Polypropylene (PP)

Filter cloths Number 100 Size Width 1620 mm. Length 2415 mm Material Polypropylene Hydraulic cylinders for wash water doors operating system, number 2 per filter

CLOTH WASHING SYSTEM Water pressure required (minimum) 2 bar Pump capacity max 7200 l/min Water consumption 1800 l/cycle at 15 sec washing time

Cloth water spray nozzles Number/Filter 50 x 3 per filter Manufacturer Spraying systems Co. Type H U 316 SS 95150



Cloth vibrator Number 4 Type Electrical motor vibrators Model Dynapac AB type ER 303 S Speed 1500 rpm El. data 400 V, 50 Hz Protection/Insulation IP 55 / Class F

VALVE SYSTEM

Valves V1 (Slurry) type Pinch valve, DN 150 V3 (Filtrate) type Butterfly valve, DN 150 V4 (Slurry-return Top blow) type Pinch valve, DN 150 V5 (Compressed air) type Butterfly valve, DN 150 V6 (Air Top blow) type Butterfly valve, DN 50 V7 (Air) type Butterfly valve, DN 50 V8 (Water/Top blow) type Butterfly valve, DN 50 V9 (Water/Washing) type Butterfly valve, DN 200 V10 (Air Membrane Evacuating) type Butterfly valve, DN 50 V41 (Top blow) Butterfly valve DN 50

HYDRAULIC UNIT See separate Hydraulic Manual, binder 4/4

Manufacturer INAB Ingenirsbyr, Sweden



CONTROL SYSTEM Type Process controller The VPA control system mainly consists of following units: Main cabinet, +K.1, with PLC, PC and MCC functions (preferable mounted on the filter platform).

Pneumatic valve control, +PV.1 and +PV.2, for control of the pneumatic valves (for installation on the filter).

Hydraulic valve control, +HV.1, for control of the hydraulic valves (pre-mounted on the hydraulic unit).

Weighing system with 4 load cells connected

The main control cabinet +K.1 consists of:

Siemens S7 314 PLC

PC with Citect HMI

Motor starters for Start/Stop of hydraulic pump- and vibrators-motors

Emergency stop, with safety relay

Transformers for control voltage, 24 VDC

Automatic fuses for the control circuits

The pneumatic valve control +PV.1 and PV.2 consists of:

Electrical solenoids

Pressure regulator

Pneumatic manifold

Pneumatic valve

Terminals

The hydraulic valve control +HV.1 consists of

HAND operation switches

Terminals Description, see manual section 4, Functional description



General electrical data Power supply 400 VAC, 50 Hz Maneuver voltage 230 VAC Control voltage 24 VDC Protection IP 54 or better

Dimensions w* h* d* : +K.1 1400*2000*600 mm +PV.1 800*800*250 mm +PV.2 600*600*200 mm +HV.1 500*500*200 mm

I/O Chassis Manufacturer Siemens Model S7 314

Pneumatic valves

Manufacturer Camozzi Pneumatics



CONTROL COMPONENTS

Cloth damage detector Manufacturer IFM Electronics Type Fibre-optic amplifier + Fibre optics Model OI 0013 + E 20160

Limit switches for: Pressure head movement, model II 5492 Misalignment, model IG 5597 Chute doors IG 5597 Manufacturer IFM Electronics Type Proximity switches

Emergency stop Manufacturer Schmersal Model ZS 71 2 WVDA

PRODUCT WEIGHING SYSTEM

Load cells Manufacturer Vishay Nobel, Sweden Model KIM 1/200 kN

Junction box Manufacturer Vishay Nobel, Sweden Model SL-4SS

Weighing central Manufacturer Vishay Nobel, Sweden

Model AST 3P



2.3 Machinery identification and warning signs

2.3.1 Machine sign





2.3.1 Machine sign The VPA 1540-50 is provided with machine signs with following information:

Metso Minerals (Sala) ABSE-733 25 Sala, Sweden

metso

The sign plates are located as per assembly drawing SA253370.


Article No.: SA253370-M1

Manufacture No.: L-281703

Delivery year: 2009

Net weight: 48600 kg




Above sign indicates correct lifting points. Do not attach lifting devices elsewhere.


The sign plates are located on the front doors of the cubicles and boxes.



2.4 Certificate and test results

Not applicable.


Edition 1 HHD / 281703 09-W8 Health and Safety 3 1/6

3. HEALTH AND SAFETY

3.1 Safety regulations



3.1 Safety regulations The operator must be familiar with the contents of the machine's manual(s) before the equipment is put into operation and must observe all applicable safety regulations.

Concrete and steel structures to support the equipment must be inspected and approved by an authorised inspector in accordance with the provisions in force before the assembly and installation of the equipment.

During operation all safety devices must be in working order and functioning. As a protection against the unintentional restarting of the machine during repair or other work the local MCC must be shut off and/or emergency stop switch activated.

If the machine is remote controlled this must be shown on a clearly visible sign with the following text:

DANGER! This machine is remote controlled and can start

without warning.



During operation it is not permitted to remain within the danger zone of the machine. Danger zones: Within the designated area shown on the service areas and danger zone

drawings SA253383, see section 11.1, separate binder 2/4.

Lifting Always handle the equipment with care during lifting. Use the lifting eyes provided and/or follow special handling instructions where these are given. In addition to general practice and local safety regulations the following should be stressed:

The equipment must be lifted using suitable, approved lifting equipment.

Detached or loose parts must be properly secured before lifting.

It is absolutely forbidden to enter into or to remain in the risk zone under a suspended load.

Acceleration and retardation during lifting must be kept within safe limits.

Access

NB Before any access to the machine or its area of risk the electrical supply must be shut off and the local circuit breaker locked in the off position. In situations involving pressurised pipe systems or pressure vessels, it is essential to ascertain what has been transported in the pipes and that they are depressurised and empty before any operations are carried out. During maintenance and repair work only personnel completely familiar with the machine shall be allowed access to the machine and its area of risk.



Recommissioning after maintenance or repair Before the equipment is started the work carried out shall be checked by an authorised person to ensure that:

the work was correctly carried out

safety equipment functions properly

all safety devices have been completely assembled

tools, working equipment and other extraneous articles have been completely removed

Welding In general the welding of mechanical and electrical equipment should be avoided. If welding nevertheless must be carried out, the following must be observed:

weld only after all electric current to the equipment has been switched off

earth the welding area

the welding current must not pass through bearings, load cells or similar sensitive components

protect the equipment from damage and/or burning by weld splash

Responsibility

Metso Minerals take no responsibility for damage resulting from failure to observe these safety regulations, or if ordinary care has not been exercised in handling, operation, maintenance or repair, even if such is not specifically mentioned in these regulations. Changes, such as rebuilding or modifying the machine without our permission, relieves us of all responsibility.

Definitions 1. Danger zone, every area within and/or around a machine which involves a risk to

thehealth or safety of an exposed person. 2. Exposed person, a person who find himself completely or partially within an area of

risk.

Operator, a person or persons whose job it is to install, use, adjust, maintain, clean, repair or transport machines.



Electrical safety rules

Main breaker The main breaker in the main control cabinet disconnects incoming main power.

NOTE! When the main switch is in off position there is still power in the main feed cable.

Electrical installation work All electrical installation work should be made by qualified and skilled personnel using only suitable materials.

Service work Simple operations inside the cabinets, when safety guards not need to be dismounted, e.g. resetting of circuit breakers, can be made with power-on.

In all other cases electrical work on the equipment or inside the cabinet must be made

with disconnected power.

When servicing electric motors the safety switch must be used. During such work this

safety switch must be padlocked in off position, in order to prevent any possible starting of

the motor by mistake.

Danger board(s) should be put up, warning for the prevailing electrical work. Service on electric equipment must only be made by qualified and skilled personnel.

Plant operators All operators of the pressure filter must be informed of the instructions stated here.

Touch guards In the control cabinets are mounted touch guards in order to prevent any unintentional

contact with live surfaces. Such guards must be reinstalled after any service work necessitating their removal.



Emergency shutdowns There are emergency switches placed at various positions in the equipment. For emergencies endangering operators or the entire equipment, these switches should be used to stop moving parts and to cut out the electric power. The pressure filter is then completely stopped.

NOTE! There is still main power in the control cabinets. Before resetting an emergency switch it must be made sure that no person is within the danger area of moving parts. After that the switch can be reset. The pressure filter can, however, not be restarted without resetting the emergency shutdown relay. This is done by acknowledge of the alarm on the Citect alarm page.

Operation Before start-up of the pressure filter always make sure that:

touch guards are in place

control cabinet doors are locked

locks on connecting boxes are bolted on

external electrical devices are connected so that intended IP class is maintained

no person is on top of the pressure filter or within its danger area

no tools or other material are left on the machine.


Edition 1 HHD / 281703 09-W8 Functional description 4 1/30

4. FUNCTIONAL DESCRIPTION

4.1 General operational description

4.1.1 What is compressed-air dewatering? 4.1.2. Why compressed-air dewatering? 4.1.3. How does a pressure filter work? 4.1.4. Arguments for compressed-air dewatering 4.1.5. How is a VPA filter designed? 4.1.6. The VPA product system 4.1.7. Service life of VPA filter components 4.1.8. Electric external vibrators



4.1 General operational description 4.1.1 What is compressed-air dewatering? The technique of replacing the water in a particle slurry with air, ie removing the water through a pore system using air at a specified pressure, has been in use for a very long time.

Air penetration in a pore system



Dewatering curve A simple way of showing the process of dewatering using this principle is to draw a "Dewatering curve", which is unique to each filter cake.

Dewatering curve

The dewatering curve shows the 3 stages of dewatering with air under pressure.

Stage 1 The pores in the filter cake are at first completely filled with liquid, and the air pushes the water out of the way with a very high degree of efficiency. The curve falls steeply for a short time.

Stage 2 At the break-through point the air breaks through the filter cake in places, and the degree of efficiency falls. The air loses its hold on the water, which drains more slowly.

Stage 3 During the last dewatering phase the air has broken through almost completely, and the transport of water is reduced still further. During this stage a certain amount of the water evaporates in the rush of air, but efficiency is very low.



Summary When water is being removed from hard (non-compressible) particles, each sequence in the dewatering process can be described using a dewatering curve, which varies from material to material. This dewatering curve constitutes a "filter cake fingerprint" and it is always drawing up during the rating of Metso Minerals dewatering machines in the laboratory.



4.1.2 Why compressed-air dewatering? Dewatering curves at different pressures Since it is now often possible to carry out air-dewatering with a vacuum filter, why use compressed-air dewatering?

The effect of pressure on the dewatering curve

If we increase the concentration of energy in the air by increasing the pressure, we can see that the dewatering curve changes. "When we increase the air pressure, the residual moisture in the dewatered product decreases, at the same time as the dewatering rate increases." Using air at high pressure allows dewatering to be carried out for longer and more efficiently in the same machine = compressed-air dewatering.

Is there an upper limit for pressure? In theory there is no upper limit. In tubular presses air at over 100 bar pressure is used. In practice nowadays we work in the region of 7-8 bar, and this is the working range for most of the compressor plant on the market. In the future considerably higher pressures will be used.



4.1.3 How does a pressure filter work? In order to withstand the high working pressure, these filters are assembled from a number of pressure-proof chambers which can be opened and closed.

S lu rry

Rubber

membrane

Filter

cloths

Filtrate

Membrane air

Drying air

These chambers have the additional essential function of shaping the filter cake, which always has the same dimensions irrespective of the density of the slurry, pulp, etc.



Dewatering cycles The process of dewatering in a pressure filter, which is not continuous, is divided in to the following dewatering sequences.

Filtration, in which the slurry is pumped in and the filtrate led away.

S lu rry

Filtrate water

Compression, in which the rubber membranes in the chambers are activated and the filter cake is compressed, (close-packed).

Filtrate water

Membrane air

Note This close-packing prevents unnecessary leakage of air during the subsequent drying stage.



Air drying, in which compressed air is forced through the filter cake squeezing out water.

Filtrate water

Membrane air

Drying air

Note During the whole of the drying sequence the rubber membrane is activated to counteract cracking as the filter cake shrinks as its water content decreases. Service sequences In addition to the dewatering procedure described above, there are also a number of service routines: Open flushing door under filter Open filter Close flushing door under filter Flush filter cloths Close filter

Discharging: When the filter is opened the dried filter cake drops out of the filter.



Washing the filters. The filter cloths are flushed completely clean before the filter is closed.



4.1.4 Arguments for compressed-air dewatering To summarise the advantages of compressed-air filtration: In a compressed-air filter the formation of cake is controlled, ie it does not vary,

whereas with vacuum and hyperbar filtration it can vary.

With a compressed-air filter it is possible to change the drying time and drying pressure to compensate for variations in the ingoing material.

Capital investment and running costs are lower than with vacuum filters and

thermal drying.

The method is environmentally-friendly and space-saving.

The method is suitable for a highly-automated system. Conveyor belt compensation A slow moving pick-up belt under the filter continuously feeds a high-speed belt. The speed of the slow belt is synchronised with the cycle time. What does VPA 1540-50 stand for?

V = Vertical [filter chamber]

P = Pressure [compressed-air filter]

A = Airblow [compressed-air drying]

1540-50

15 = chamber size

approx. 15 x 15 decimetres [1 dm = 10 cm]

40 = chamber depth

mm

-50 = number of chambers



4.1.5 How is a VPA filter designed? Basic construction To enable it to cope with high pressure (> 6 bar), the compressed-air filter is built up from a number of pressure-proof chambers (1) which can be opened and closed hydraulically.

VPA compressed-air filter

Remark: Picture shows the VPA 15 model These chambers are suspended from a frame (2) and are moved laterally by four traction hydraulic cylinders (3). Filter cloths hang through the chambers, attached to a cloth bridge which sits on top of the frame.



The cloths can be serviced, changed and flushed as required from the bridge. To filter chute is fitted with two doors to prevent water running down into the dewatered product.

Arguments for the basic construction Simple assembly makes it possible to select any production site. Bolt-together design makes assembly and dismantling easy. Traction cylinders allow a compact layout and a lightweight frame. The system uses permanent suspended cloths and so has few moving parts, ie

running costs are low.



The dewatering chamber - a key part In the dewatering chamber the whole dewatering process takes place, and Svedala has put a great deal of effort into ensuring that it is correctly designed.

2

1

Filter plate (picture shows size VPA 15)

Arguments for Metso Minerals chamber design

The material is machined (not moulded) polypropylene, to give maximum strength and flexibility. Minor damage can be repaired using melted or thermosetting resin.

The weight of the chambers is extremely low in comparison to cast-iron and steel, which lightens the basic construction and makes for a low overall weight. It also facilitates servicing and maintenance.

The rubber membrane is protected by the filter cloth and is not exposed to mechanical damage (no wearing parts).

The chamber is top-fed to maximise filling.

The ducts for the inputs (pulp, water and air) are generously sized to ensure the lowest possible loss.



1

2, 3

Membrane plate (picture shows size VPA 15)

Membrane air

During filtration the pulp is fed in through the feed-ports (1) and the filtrate drained away through the filtrate ducts (2 and 3).

During drying compressed-air is fed through the membrane plate ducts (3) and the filtrate water drained away through the filter plate ducts (2). Chamber area

Chamber area: the area of the working part of the filter cloth, enclosed in the filter chamber.

Chamber area VPA 15 = 1,70 m/chamber Filtration area

The filtration area for the VPA = 2 x the chamber area. (The chambers have double cloths and filtration takes place at both sides). Drying area

The drying area for the VPA = chamber area. (Blowing takes place from one side only). Chamber volume

The volume of the VPA 1540 = 68 l/chamber



Inlet collar To ensure problem-free feeding to each chamber and to expose the filter cloths during discharge, Metso has developed a special rubber collar in a steel holder.

The inlet collar consists of two identical halves each attached to the respective filter cloth.

During the closing sequence the halves of the inlet collar are pressed together to seal off the inlet to the filter chamber



Flushing the filter cloths - not washing A look at a vacuum filter, which normally operates without the cloths being washed, makes it easy to see why a compressed-air filter functions in the same way, ie the cloth does not require washing. But since there is a risk of some residue from the filter cake being left on the filter cloth in the chamber, we flush the cloth after each discharge. This takes place at low pressure during a short period of the dewatering cycle. The water consumption is much less than with high-pressure washing compressed-air filters. Cloths The advantages of using a system with permanent cloths simply attached to the flushing tubes are:

Few moving parts = low maintenance costs.

Simple and time-saving cloth-changes = greater availability.



Traction cylinders - keeping things parallel! The four cylinders must move in parallel - this is an absolute requirement. To achieve this four accurately-matched pumps - one for each cylinder - have been fitted on a common engine shaft. A system of four inductive sensors monitors the moving press head to ensure that it does not get out of alignment with a risk of derailment. If any oblique movement is sensed the pressure filter is shut down. Summary of the main arguments for the VPA The main arguments for the design of the VPA filter are:

Compactness

Low weight

Few moving parts

Simple to maintain and repair



4.1.6 The VPA product system The compressed-air filter is only one part of the complete dewatering installation, which we call the VPA product system.

The VPA product system consists of the following equipment:

Concentrating equipment, which deliver pulp of the right density to the filter.

Intermediate blender for removing air and controlling density before pumping in.

Material pump for pumping pulp in during the filter cycle.

Input valves for pulp, water and air.

Flushing water system for filter cloths.

Weighing system to optimise the operating parameters for filtration, compressed-air drying etc.

Compressor for compressed-air supply.

Computer-based control system for controlling and regulating the filtering process.

Let's have a closer look at the various parts of the system.



Effective concentrating - an undiluted advantage! Concentrating is the cheapest of all dewatering methods. The further the concentration process is taken, the cheaper the filtration - this is important with all dewatering, but particularly for compressed-air dewatering in chambers.

Effective concentration leads to:

rapid filtration = high capacity

high pulp-density which reduces the chances of segregation and uneven cake-formation in the chambers.

totally-filled filter chambers

General dewatering curve

weight %

solids

Feed time sec.

The material pump - runs the filter The choice of the right material pump is vital for compressed-air filtration. The material pump does the hard work during filtration when large quantities of pulp have to be forced into the filter chambers in a short time under high pressure. The pump pressure should not fall below 5 bar.



Valve control - the nervous system of the VPA The VPA pressure filter is a mechanical robot, with all its movements and input-changes regulated by a number of valves. The accurate control of these valves is a basic precondition for the product system to function properly.

1 V1 Pinch valve Regulates the input of slurry into the filter

3 V3 Butterfly valve Regulates the discharge of filtrate

4 V4 Pinch valve Regulates the clearing of material from feedspace (top-blow)

5 V5 Butterfly valve Regulates the compressed air during the drying cycle

6 V6 Butterfly valve Regulates the compressed air during the clearing of material from the inlet duct (top-blow)

7 V7 Butterfly valve Regulates compressed air to the membrane

8 V8 Butterfly valve Regulates the water during washing of the inlet duct

9 V9 Butterfly valve Regulates the water during cloth-flushing

10 V10 Butterfly valve Regulates evacuation of compressed air from the membrane

11 V11* Butterfly valve Regulates booster compressed air to the membrane

12 V12 Butterfly valve VPA20 Regulates the discharge of filtrate (MPH) // V3

13 V13 Butterfly valve VPA20 Regulates the discharge of filtrate (MPH) // V3

41 V41 Butterfly valve Regulates the clearing of material from feedspace (top-blow) // V4

* Only if a special booster-compresor for the membrane has been included in the installation



Valve control The VPA filter valves are controlled as follows:

The valve actuators are electrical-pneumatic*, i e an electrical signal is sent from the control computer system to the electrical / pneumatic solenoid valve, which regulates the compressed-air for operation of the function-valves.

*) V1 and V4 are electrical-hydraulic on VPA 20



Wave language Continuous accurate weighing of the filter generates a weight curve for each dewatering job. This weight curve is also called "wave language", since it makes it possible to communicate with the machine.

Filtration Compression-Drying Discharge Cloth washing

Time

VPA wave language

By utilising the appearance of the weight curve during filtration, compression and drying, the dewatering process can be optimised for maximum economy of operation. The machine itself can also carry out certain control functions, such as cake-discharge.



Load cell control The VPA system offers the option of load cell control. The principle is based on the filter being weighed on a continuous basis with high precision using load cells fitted under each of the 4 support legs of the filter frame.

1. Load cells (4 off) 2. Collection of load signals 3. Balancing unit which sends the final load signal to the PC. The measurement accuracy of this system is very high, 25 kg.



Cloth-flushing system The cloths in the VPA filter are flushed once per filtration cycle. Governing principle for cloth-flushing: "Ample water-flow at low pressure for a short time". Flushing water The flushing pipes, which also provide attachment for the permanent filter cloths, are fitted with three flushing nozzles with a high rate of flow and an effective flow pattern. The water for the flushing pipes is supplied through flexible hoses which connect each flushing pipe to a supply pipe alongside the pressure filter.

VPA 15 3 nozzles

The flow of water for each spray bar is 68 litres per minute at a pressure of 4 bar, 48 litres per minute at a pressure of 2 bars. Normal flushing approx. 15-20 sec per cycle.



The compressor - the energy-source for the VPA filter As is clear thus far, compressed-air is the active energy-supplying input in the VPA filter. Compressed-air drives all the dewatering processes after filtration (pumping in).

activating the rubber membrane

drying the filter cake

clearing the feeder of slurry and material deposits

operating the pneumatic regulating valves The compressed air must satisfy the following criteria:

Completely oil-free (otherwise the rubber membrane swells).

The capacity must be sufficient for the whole process of dewatering, even after the air break-through, when the consumption of air increases.

The pressure must remain constant throughout the whole drying cycle.

The membrane pressure must be approximately 1 bar higher than the air-blow.

A separate compressed-air system for activating the membrane.

Working-pressure range 6-8 bar (in future 8-10).



The control system

General The pressure filter is controlled by a local control system connected to the overriding system. All control logics are implemented in the local control system.

Description The VPA local control system consists of below major electrical cubicles: - Main cabinet, +K.1, with PLC, PC and motor control circuits. - Pneumatic valve controls, +PV.1 and +PV.2, for control of the pneumatic valves, (for installation on the filter). - Hydraulic valve control, +HV.1, for control of the hydraulic valves, (pre-mounted on the hydraulic unit). The VPA-filter press can be operated from the overriding system, located in the control room. The filter can be operated either Automatically or Manually. In AUTO the filter press operates by the programmed sequences. In MAN it is operated step by step. The main power supply from Customer is connected to the main cabinet, all other supply and control voltages are created internally by the use of a transformer. A weighing system consisting of 4 load cells, (one in each corner), junction boxes and weigh-centrals deliver the actual weight of the pressed material to the control system for process control and statistics.



4.1.7 Service life of VPA filter components Even where a machine is simple and robustly built, certain elements of the machine are permanently exposed to various degrees of wear. The following is a summary of the parts of the VPA filter which are subject to wear, and their normal service lives.

Wearing part Approx. service life

Filter cloth 4,000 - 8,000 cycles Inlet collar 1 year Slide blocks 1 year Pump wearing parts 1 - 2 years Rubber membrane > 5 years Filter chamber > 5 years As is clear from the above table, the filter cloths are by far the most susceptible to wear of all, and we shall have a closer look at them.

The filter cloth - the pressure filter's weakest link

How to recognise a clogged cloth The filtration time lengthens The air blow time becomes longer The cloth becomes stiff and looses its flexibility The amount of residual moisture in the filter cake increases Production falls off



What causes cloth clogging? Microscope studies show that all filter cloths gradually clog up through close packing and chemical build-up in the weave of the filter cloth. Continued washing with high-pressure nozzles only combats this to a limited extent. Why does the clogging time vary? Precise knowledge of the mechanism which causes this is lacking but the chief causes are:

The distribution of particle size

The pulp chemistry

The structure and weave of the filter cloth

NEVER LET USED CLOTHS GET DRY!

ALWAYS PARK THE VPA IN CLOSED POSITION WITH WET CLOTHS! What is a cloth damage detector? If any of the filter cloths tear, hard particles pour out in all the ducts. During the drying cycle the compressed air draws these particles with it and blast damage can result. To enable damage to a cloth to be detected quickly the VPA filter is fitted with a cloth damage detector.

The filtrate is drained through a duct which is lit with fibre optics. A photo cell measures the light shining through the filtrate. If a cloth is damaged the filtrate darkens and the photocell triggers an alarm. The damaged cloth can easily be located by checking the filtrate ports. "Downstream" of the damaged cloth, left-over particles can be seen while the ports upstream are clean. The cloth is changed and production can continue.



What to do if cloths are damaged

Rule 1 Try if possible to change the full set of filter cloths at the same time. This ensures that the filter resistance and pressure gradient remains the same across all the chambers at all times.

Exception If a single cloth is damaged at a sensitive operating time (night shift, full production etc.) it is possible to change only the damaged cloth.

On the next day shift, however, the whole set should be changed.

Rule 2 Do not carry on too long with the cloths in the press since the resulting constant alarms may eventually upset the operation and cause blow damage.

Summary of cloth changes Every filter installation requires its own system of change

intervals. Don't carry on for too long between washing and checking. Always change a full set together.

NEVER LET THE FILTER WORK WITH DAMAGED CLOTHS!



4.1.8 Electric external vibrators

The direction of rotation is optional, but the opposite vibrator shall always rotate with the

opposite direction of rotation.

All vibrators shall start simultaneously.

To prevent damages to the vibrators they should be fail-safe connected so that they all

stop in case of a breakdown.

fig. 1

Electric external vibrators

Direction of rotation

The excentric counterweights of the vibrators can be adjusted into 5 positions to give the

best function. At delivery, if nothing else is said, the excenters are placed in position 3.

Position 3 should be the startposition at first start.

For more information about the electric external vibrators see the manufacturers information under section 12.


Edition 1 HHD / 281703 09-W8 Control System 5 1/1

5. CONTROL SYSTEM

Operators Instruction 52248 X 040

Electrical drawings see section 11.2, separate binder.

Filtro de presin VPA

Tipo 1540-50

Instrucciones para el

operador

Prep.. JSR INSTRUCCIONES PARA EL OPERADOR Doc.des Item des. Appr. MTH 2009-02-24 Resp.dept. ME Rev. 0 Lang. en Project name VPA-1540-50

281703

Collahuasi, Chile

Document number

52248X040

Sheet

No of sh.

1

52

Del. Doc. OPinstr.DOC

Instrucciones para el operador

1 Visin perspectiva ....................................................................... 2 1.1 Puesta en marcha del sistema ................................................................... 3

1.2 Bloques funcionales ................................................................................... 3

1.3 Reinicializacin general del PLC y rearranque del PC ............................ 5

1.4 El Coordinador ............................................................................................ 5

2. Armario del ordenador y pantalla de control ............................. 7 2.1 Pantalla de control ...................................................................................... 8

2.2 Botones de control de activacin .............................................................. 9

2.3 El ratn ....................................................................................................... 14

3. EN FUNCIONAMIENTO / PARADO / ARRANCADO .............................. 15 3.1 Arranque .................................................................................................... 15

3.2 Funcionamiento ......................................................................................... 15

3.3 Comprobaciones ....................................................................................... 16

3.4 Parada ........................................................................................................ 16

3.5 Puesta en marcha despus de una parada de emergencia ................... 17

3.6 Apagado ..................................................................................................... 17

4. Ajustes ........................................................................................ 18 4.1 Para valores de tiempos ........................................................................... 20

5. Arranque desde la posicin de aparcado ................................ 21

6. Auto ON ...................................................................................... 25 6.1a Cierre baja presin .................................................................................... 26

6.1b Cierre alta presin ..................................................................................... 27

6.2 Filtrado de alimentacin ........................................................................... 28

6.3 Compresin de la membrana ................................................................... 31

6.4 Secado por aire ......................................................................................... 32

6.5 Soplado superior (aire-agua-aire) ............................................................ 33

6.6 Drenaje ....................................................................................................... 36

6.7 Apertura de portillos ................................................................................. 37

6.8 Descarga y vibracin de la masa ............................................................. 38

6.9 Cierre del portillo....................................................................................... 39

6.10 Lavado del tejido y vibracin del tejido ............................................... 40

6.11 En espera ............................................................................................... 41

7. Estadsticas ................................................................................ 43

11. Alarma ......................................................................................... 45 11.1 Lista de alarmas .................................................................................... 47

11.1 Pgina sumario ...................................................................................... 49

11.2 Gestin de alarma y eventos ................................................................ 50

11.3 Textos de la Alarmas ............................................................................. 51


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1. Visin perspectiva

Sistema del operador del filtro VPA

Este documento explica brevemente las funciones del sistema de control del filtro VPA y sus componentes.

Descripcin funcional

Control por ordenador con jerarqua de capas

Cada filtro VPA est equipado con un control por ordenador con jerarqua de dos capas. Se usa un ordenador tipo PC para la interfaz del usuario y un ordenador PLC se hace cargo del control real. Las principales ventajas de esta organizacin son una interfaz de usuario ms sencilla de utilizar combinada con la seguridad de un PLC separado controlando la mquina.

Sistema de operador basado en Windows

El PC ejecuta un sistema operativo basado en Windows XP denominado Citect. El PC se comunica con el PLC a travs de un enlace serie.

El control del filtro se hace con software de control en un PLC.

El software del PLC es responsable de todas las acciones de control en el filtro. Todas las ordenes son pasadas al PLC a travs del sistema PC. el PLC conoce el estado actual de del filtro y permite o excluye las acciones del operador. El PLC solamente remite las acciones del usuario y muestra el estado del PLC (y por lo tanto tambin el estado del filtro). Cada PLC de filtro se comunica tambin con el PLC Coordinador, si ello es aplicable.

El PLC de filtro

Cada filtro VPA est equipado con un PLC que ejecuta su propio software de control (programa del PLC). Este software de PLC controla el filtro. Una vez ha recibido del PC la orden de correr en modo automtico continua funcionando hasta que se produce un error o se recibe una orden diferente.


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1.1 Puesta en marcha del sistema

El procedimiento de puesta en marcha del sistema PC est completamente automatizado. Cuando se enciende, el ordenador arranca el programa del operador despus de que ha finalizado la carga de Windows NT 4.0

Procedimientos operacionales

Este captulo trata solamente temas relacionados con el software de control. Para una lectura en ms profundidad vase el manual de SVEDALA relativo a los consejos sobre cmo hacer funcionar el filtro.

El sistema del operador del PC est basado en Windows NT. La principal implicacin de esto es que si, por cualquier razn, se desea apagar el PC hay que apagarlo DESPUS de salir del programa del operador (y en consecuencia salir tambin de Windows). No se puede apagar simplemente el ordenador. La razn d de esto es que, de lo contrario, se podra acabar perdiendo datos o incluso corrompiendo el sistema de archivos en el disco causando graves daos al software.

El software del PC necesita poder comunicarse con xito con un programa de PLC completamente operacional. El PLC debe estar en modo RUN (Ejecutando) incluso antes de intentar arrancar el PC.

1.2 Bloques funcionales

El software del PC tiene los siguientes bloques funcionales principales: Presentacin del estado del filtro incluyendo animaciones, Ordenes, Ajustes, Gestin de Alarmas y Eventos, Diagnsticos de error, Estadsticas y comunicaciones PC-PLC.

Ordenes

Las ordenes inician acciones del operador. Las ordenes se envan al PLC para su ejecucin (si es posible). Entre otras muchas posibles acciones estn: Auto ON, Manual ON. Filtro abierto y otras.

Ajustes

Los ajustes constan principalmente de ajustes de tiempos para el filtro. Los ajustes de tiempo surten efecto cuando se aprieta el botn [OK]. Este botn enva los ajustes al PLC y surtirn efecto inmediatamente.


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Estadsticas

El mdulo de estadsticas recoge datos de produccin. Se almacena el peso de los siete ltimos prensados y tambin se suma en rgimen diario. La recogida de estadsticas se activa desde el PLC. El PLC ordena al mdulo de estadsticas tomar datos de produccin (pesos y tiempos) cuando se finaliza el ciclo y se conocen todos los valores del prensado.

Comunicaciones PC - PLC

Los bloques de datos del PLC almacenan diversos elementos . El PLC y el PC se comunican mediante estos bloques de datos. Se usan cuatro bloques de datos comunes para este paso de mensajes. Un bloque de datos se usa solamente para transmitir informacin en una direccin.

El PC enva al PLC:

1. Ordenes (Manual ON, Auto ON, Cerrar filtro y otras.)

2. Ajustes (Tiempo de lavado, Tiempo de espera, Tiempo de vibracin etc.)

El PLC enva al PC:

1. informacin de estado (Actividad, Tiempo para el prximo paso, E/S de datos en bruto, Paso actual, Peso, Punto de activacin de estadsticas)

2. Condiciones de alarma

Solucin de problemas

Las siguientes reglas son aplicables si se experimentan problemas con el software:

1. Comprobar primero todas las alarmas, segundo comprobar todos los eventos. Si ninguno de ellos apunta a ninguna condicin anormal, proseguir.

2. Si el PC funciona pero el PLC no parece responder a las acciones del usuario

Entrar en modo manual

1. Pulsar [Manual ON] en el sistema del operador del PC. Despus proseguir con [Abrir Filtro] o [Cerrar Filtro], dependiendo de lo que sea apropiado para el estado actual del filtro. Esto pondr algunos datos internos del PLC en sus valores iniciales y permitir volver a poner en marcha. NOTA: Podra ser necesario lavar y vibrar manualmente antes de volver al modo automtico despus de esta operacin.

2. Si las acciones del punto 3. no ayudan o si el [Manual ON] no est todava disponible en la pantalla del PC, intentar lo siguiente:

3. En el PLC, mover el conmutador run/stop/mres a STOP y despus volver a RUN de nuevo. Despus volver a intentar los pasos del punto 3.


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4. Si esto no es suficiente, podra se necesario hacer la reinicializacin general del PLC, as como volver a arrancar el PC.

1.3 Reinicializacin general del PLC y rearranque del PC

Es muy importante que la siguiente secuencia de pasos se siga estrictamente. No hacerlo as podra dar como resultado daos en el software instalado en el PC. El uso inadecuado de los controles del PLC podra producir como resultado la prdida del contenido del mdulo EEPROM.

1. Apagar el PC

En el PC pulsar [Shutdown] pulsar [OK] cuando pulsar [START] seleccionar [Shutdown] pulsar [OK]

apagar el PC cuando en la pantalla se lea [Now its safe to switch of your device] (Ahora es seguro apagar su dispositivo) en el fusible F10 en la fila de en medio del armario.

La regla principal es: No apagar nunca el PC mientras se est ejecutando

el software.

2. Reinicializacin general del PLC

Poner el conmutador de alimentacin a 0 en la Poner el conmutador de alimentacin a 1 en la esto debe encender de nuevo el LED verde RUN.

3. Encender el PC

Encender el PC con el fusible F10 en la fila de en medio del armario. Esperar mientras el ordenador se pone en marcha. Hacer el procedimiento ajustes, porque cuando se vuelve a poner el PLC, todos los valores de tiempos del PLC se pondrn en sus valores iniciales estndar. Si es necesario, proceder al modo manual como se explica arriba.

1.4 El Coordinador

Cuando una planta usa dos o ms filtros, uno de los PLC tiene una funcin coordinadora

El PLC coordinador es responsable del acceso a los recursos de medios (en la actualidad mortero, agua de lavado y aire comprimido). Cada PLC de filtro est conectado directamente al PLC coordinador.


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Cuando, por ejemplo, un filtro necesita agua, sucede lo siguiente: El filtro pide al Coordinador agua de lavado indicando al Coordinador su necesidad. Si ello es posible, el Coordinador a su vez acusa recibo de la peticin al PLC de filtro, indicando con ello que est permitido proceder con su ciclo. Despus de finalizar el uso de medios, el PLC de filtro normaliza de nuevo la lnea de peticin. El medio est de nuevo libre para ser usado por los dems filtros.

El Coordinador gestiona poniendo en cola el uso de los diferentes medios a fin de evitar las contiendas (varios filtros usando un recurso escaso simultneamente).

El funcin coordinadora no tiene ninguna interfaz de usuario ni ningn otro control operacional.

El PLC Coordinador puede intercambiarse con los otros PLC si coordinador original se apaga por cualquier razn. Esto es un proceso automtico. Despus de que el PLC Coordinador se apaga el siguiente PLC en lnea se hace cargo de su funcin.


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2. Armario del ordenador y pantalla de control

Parada emergencia

Luz alarma parpadeante

Monitor

botones clic

ratn

enfriador


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No of sh.

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2.1 Pantalla de control

Pantalla de control

Descripcin

1. Tipo de operacin: manual on, auto on, parada en punto muerto, etc.

2. Actividad en curso = secuencia actual

3. Peso real del filtro. Un filtro vaco debe pesar 0-100 kg., el peso de un filtro antes de la descarga debe ser de 700-1200 kg.

4. Tiempo real de ciclo time en el presente ciclo.

Para ms informacin sobre pantalla a pantalla, vanse las instrucciones para cada estado de operacin manual on, auto on, a aparcamiento, a punto muerto, alarmas etc.

Hora actual

Vlvula abierta. Verde

1

2

4

3

Fecha actual Fila alarma

Botones de control de

activacin

Estado filtro

incluyendo

animaciones

4

3

2

1

Vlvula cerrada. Rojo

Ent./Sal.

Sistema


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Collahuasi, Chile

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2.2 Botones de control de activacin

A Aparcamiento (P)

A Punto muerto (N) (2) A Aparcamiento (P)

(Durante la secuencia de operacin ningn botn de control de activacin)

Parado (Encamino a N/P) (3)

Auto ON (4) Principal

Parado (5) (Punto muerto (N))

Parado (6) (Principal en marcha)

Parada (7) (Bajo peso alimentacin)

Manual ON (8)


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No of sh.

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En la pantalla de control de operacin del PC, dependiendo de en qu secuencia de operacin est activado o parado el filtro, la posibilidad de operar/activar el filtro viene dada por los botones de control de activacin en la pantalla de control. Los botones de control de activacin son los siguientes (excepto los botones de control en la lista de alarmas, ajustes, estadsticas etc.)

A Aparcamiento

Cuando se activa, se ponen en marcha las bombas hidrulicas de alto y bajo caudal, el filtro se empieza a abrir hasta la posicin de totalmente abierto, donde se detiene; en esta posicin comienzan un lavado y una vibracin automticos del tejido. Cuando ha transcurrido el tiempo de lavado y vibracin del tejido se detiene la secuencia y el filtro est listo para el funcionamiento.

Cuando se activa, aparece la pantalla manual (vanse las instrucciones para funcionamiento Manual On)

A Punto muerto (N) (2) A Aparcamiento (P)

(Durante la secuencia de operacin ningn botn de control de activacin)

Parada (3) (En camino a N/P)

Cuando el filtro est parado y ha estado parado durante el movimiento de apertura-cierre, aparecen en la pantalla los siguientes botones de control activacin:

Cuando se activa, se activa la secuencia programada para A Punto muerto ( Vanse las instrucciones para A Punto muerto)

Cuando se activa, se activa la secuencia programada para A Aparcamiento y en este caso el filtro comienza el movimiento de cierre hasta la posicin de cerrado de baja presin hidrulica = aparcado.(Vanse las instrucciones para A Aparcamiento)

Cuando se activa, aparece la pantalla manual (vanse las instrucciones para funcionamiento Manual On)


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Auto ON (4) Principal

Cuando se pone en marcha el filtro y se est trabajando en operacin automtica = auto on, aparecen en la pantalla los siguientes botones de control:

Cuando se activa, se activa la secuencia programada para A Aparcamiento y en este caso el filtro entra automticamente en la secuencia "A Aparcamiento" despus de un ciclo completo real (Vanse las instrucciones para A Aparcamiento)

Cuando se activa, el filtro se para despus haber terminado el paso

actual (i.e. despus de haber transcurrido el secado de aire el filtro se para). El filtro permanece en esta PARADA hasta que se da una nueva orden.

Parado (5) (Punto muerto)

Cuando se pone en marcha el filtro y despus se para en la posicin de punto muerto, aparecen en la pantalla los siguientes botones de control:

Cuando se activa, se activa la secuencia programada a aparcamiento. (Vanse las instrucciones para A Aparcamiento).

Cuando se activa, aparece la pantalla manual (Vanse las instrucciones para Manual On).

Cuando se activa, el filtro empieza a funcionar controlado por las secuencias programadas (Vanse las instrucciones para Auto On!).

Cuando se activa; el filtro va al modo de funcionamiento remoto. Todas las ordenes provienen de ordenador que se hace cargo del proceso.


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Collahuasi, Chile

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Parado (6) (Principal arrancado)

Cuando el filtro se pone en marcha y luego se para durante un funcionamiento auto on (i.e. se para por la activacin del botn de control parar o por una parada de emergencia, etc.) aparecen en la pantalla los siguientes botones de control:

Cuando se activa, se activa la secuencia programada a aparcamiento (Vanse las instrucciones para A Aparcamiento!). NOTA. El filtro arranca desde la posicin de parada

Cuando se activa, aparece la pantalla manual (Vanse las instrucciones para Manual On). NOTA. El filtro arranca desde la posicin de parada

Cuando se activa, el filtro empieza a funcionar controlado por las secuencias programadas (Vanse las instrucciones para Auto On!). NOTA. El filtro arranca desde la posicin de parada

Cuando se activa, se ponen en marcha el siguiente paso del ciclo programado y se para automticamente cuando ha terminado el paso de la secuencia programada. El botn de control de activacin debe ser activado despus de cada paso si se ha de tomar la operacin paso a paso..


Tipo 1540-50


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281703

Collahuasi, Chile

Document number

52248X040

Sheet

No of sh.

13

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Parado (7) (Bajo peso de alimentacin)

Cuando se pone en marcha el filtro y si, durante el ciclo de filtrado ha transcurrido el tiempo de alimentacin ajustado y el peso de filtrado de alimentacin es demasiado bajo, el filtro se para automticamente y aparecen en la pantalla los siguientes botones de control:

Cuando se activa, se activa la secuencia programada a aparcamiento (Vanse las instrucciones para A Aparcamiento).

Cuando se activa, aparece la pantalla manual (Vanse las instrucciones para Manual On!).

Cuando se activa, el filtro comienza a funcionar controlado por las secuencias programadas. En este caso el programa salta a siguiente paso = compresin de membrana y desde este paso se pone en marcha el ciclo para continuar (Vanse las instrucciones para Auto On).

Cuando se activa, el programa da una orden para hacer uno o ms filtrados de alimentacin con el mismo ajuste de tiempo, y si el peso alcanza el punto de ajuste mnimo (esto es, 4000 kg.) el filtro va al siguiente paso, si el programa se detiene y se produce una alarma en la fila de alarmas verdes.

Manual ON (8)

Cuando se pone en marcha el filtro y durante una posicin de parada, aparcamiento o espera (punto muerto), aparece en la pantalla el botn de control de activacin manual

. Si el botn de control ha sido activado aparece la pantalla manual. (Vanse las instrucciones para funcionamiento manual on).


Tipo 1540-50


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281703

Collahuasi, Chile

Document number

52248X040

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No of sh.

14

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2.3 El ratn

P. ej., mover el cursor usando el ratn al botn de control de activacin , hacer clic en el botn izquierdo o en el derecho para activar la funcin del botn.

Derecha

Botones clic

Izq.

ratn

cursor


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Collahuasi, Chile

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3. EN FUNCIONAMIENTO / PARADO / ARRANCADO

El VPA puede se puesto EN FUNCIONAMIENTO / PARADO / ARRANCADO:

Automticamente

Manualmente

Cuando se selecciona automtico, se activa el programa y el filtro empieza a funcionar siguiendo las secuencias programadas. Los siguientes secuencias programadas pueden ser activadas:

De aparcado a punto muerto Auto on A aparcamiento Siguiente paso Volver a efectuar alimentacin

Cuando se selecciona manual, se pueden seleccionar las siguientes funciones :

Abrir / cerrar prensa Abrir / cerrar portillo Lavado del tejido on ( off = ajustar tiempo en seg. ) Vibracin del tejido on (off = ajustar tiempo en seg.) Parada Manual off

3.1 Arranque

Antes de arrancar el filtro desde la pantalla de control local, comprobar los siguiente: Se han eliminado todos los objetos extraos El equipo de seguridad est en su sitio y operacional (esto es, rales y conmutadores de emergencia) El tejido del filtro est correctamente acoplado de acuerdo con las instrucciones oportunas. La presin del aire y del agua est correctamente ajustada Las vlvulas estn en la posicin correcta (abiertas/cerradas) El estado del mortero es correcto (densidad, nivel etc.) El filtro en la secuencia correcta No hay ninguna alarma activada

3.2 Funcionamiento

Durante el funcionamiento (operacin) es importante que el rea que rodea las plataformas y el filtro se mantenga limpia.


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281703

Collahuasi, Chile

Document number

52248X040

Sheet

No of sh.

16

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Se deben tomar notas diariamente en forma de diario de operaciones Se deben seguir las recomendaciones para las comprobaciones diarias Se debe mantener un registro estadstico (o sea, produccin, nmero de ciclos, humedad de la masa, etc.)

3.3 Comprobaciones

Durante las operaciones se deben efectuar diariamente las siguientes comprobaciones:

1. Calidad del agua filtrada. 2. Daos en el tejido: Si un tejido de filtro ha resultado daado, sustituirlo por uno nuevo. 3. Masa desprendida del tejido: Toda la masa se debe desprender del tejido y caer

directamente a la canaleta que hay debajo del filtro de presin. 4. Lavado del tejido (es suficiente el tiempo de lavado? Es correcta la presin del

agua?). El lavado del tejido continuar hasta que el agua que lo lava no contenga partculas ni residuos de masa.

5. Vibracin del tejido (Es suficiente el tiempo de vibracin? Es correcta la frecuencia de vibracin?).

6. Funcin de la vlvula. 7. Presin, agua/aire. 8. Concentracin de la pulpa en el tanque del mortero. 9. Presin de la bomba del mortero. 10. Consumo de aire. 11. Mximo peso de entrada. 12. Canaleta de cada. 13. Cinta transportadora. 14. Motores, temperaturas, sonidos no deseados, etc. 15. Consumible en prensa, zapatas de deslizamiento para tubera de tejido, zapatas de

deslizamiento para soportes de placa. 16. Prdidas, agua, aire, hidrulicas, mortero.

3.4 Parada

El filtro puede ser parado desde la pantalla de control local.

El filtro puede ser parado mediante una parada de emergencia (botn pulsador o cuerda de polea).

La parada desde la pantalla de control local est controlada por secuencias programadas.

Parada causada por la parada de emergencia, para el filtro inmediatamente = se detienen todas las funciones del sistema. La parada de emergencia dar una alarma en la pantalla de control.

NOTA. Una parada del filtro causada por un fallo elctrico o de programacin dar una alarma en la pantalla de control. El filtro solamente puede volver a ser puesto en


Tipo 1540-50


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281703

Collahuasi, Chile

Document number

52248X040

Sheet

No of sh.

17

52


marcha despus de haber confirmado la visualizacin de la alarma, se ha localizado el fallo y se han adoptado todas las medidas oportunas.

3.5 Puesta en marcha despus de una parada de emergencia

Despus de haberse activado una parada de emergencia, el filtro debe volver a ser puesto en marcha desde el panel local. Antes de arrancar, se debe comprobar la razn de la parada de emergencia y adoptar las medidas correctivas oportunas. La puesta en marcha desde el panel local debe hacerse en la secuencia en la que se par el filtro.

3.6 Apagado

Si hay que apagar el fi

Documents

Manual Filtros Vpa 1540-50.En