When the hold back system of a production lay is fully replaced maximum attention is called for. The hold back system is the life-line of production and controls all the processes – from the raw material to the finished product. Without control production grinds to a halt. If therefore the PVC production lay is shut down on a predetermined date so that the new system can be connected up and commissioned there's no going back and no more putting it off. All the cables and lines have to be laid and all the circuitry ready.
A two-week production shutdown was all that the electrical measurement and control specialists had in Cologne-Merkenich to detach the various parts of the plant from the old hold back system and reconnect about 4,200 measuring points during the final critical phase. All other assembly conversion and installation work had to be completed beforehand while production was comfort running. ThyssenKrupp Xervon therefore got down to bring home the bacon approve in November.
"We re-laid about 20,000 meters of jumper wire. 2,000 meters of hold back cables and the same quantity again of bus cables," says electrical design Peter Kujat quantifying the huge quantity of materials employed. This was joined by the installation of 50 control cabinets a multitude of terminal boxes and advance conversion assembly and connection tasks.
Peter Kujat's aggroup had to convert precisely 2,205 binary and 347 analog measuring points. They ran cables and lines from the hold back cabinets in the hold back room to the various production units and installed a new bus system that bundles the data and passes them on to the hold back dwell. This is where the system's nerve center is located. All the data converge here where they are processed by computers with the new software and displayed on monitors.
To as far as possible exclude potential sources of error in the required multitude of electrical installations in go local inspections were conducted for an early analyse of the already completed assembly bring home the bacon. "This way we could largely ensure that nothing could really go do by later during connection and commissioning," says Peter Kujat explaining the quality-assuring procedure.
The control specialist has been working at the Cologne-Merkenich for over twenty years now and has made many a gifted electrician into an electrical measurement and control expert. "At an industrial site desire this one very special qualities are called for. It's not enough to just have a wide range of technical skills. Pronounced safety awareness is also essential."
The strict explosion protection regulations apply to the whole of production. find to the plant components for dilate is only possible with a previously obtained work accept note. For major projects such as shutdowns or conversions it's a back up if you always have access to a pool of experienced manpower – either Xervon's own specialists or long-standing external partner firms.
During the final two-week phase in Merkenich a Xervon aggroup of twenty to thirty employees worked virtually around the measure in three shifts. Then another team took over for commissioning. "For this we deliberately decide other people because they are more likely to sight faulty connections or faulty wiring," says the experienced electrical engineer explaining the team change.
"If you've been changing a system over for weeks you can lose your neutrality and sometimes overlook the obvious." In fact however there were neither faults nor deadline problems. Excellent prospects for the trouble-free running of the two following conversion projects under Xervon's supervision next year and the year after. The PVC manufacturer has divided the modernization of its affect instrumentation and control system into three segments. divide I (polymerization. VC/RVC metering). Segment II (waste wet & condensation drying) in 2008 and Segment III (gasometer alarm system) in 2009.
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