Page 1 PartschW 29 Sep 2006 I:\Daten\PartschW\POLYCOM Minerals\Anlagen\CERROWAL\Training\Presentation\5 Polycom interlocking.

ppt

POLYCOM Process

Dipl. Ing.
Wolfgang Partsch
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POLYCOM Process

Content:

• General start stop procedure and interlocking

• Control loops

• Data acquisition and sample taking

• Safety instructions
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POLYCOM interlocking

• General start / stop procedure and interlocking

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POLYCOM interlocking
A. Start POLYCOM

When the unit is shut down, the floating roll is moved into its back end position, i.e. the roll gap is opened;
the hydraulic system on the oil side is de-pressurized; the main motors are started in this roll position.

Machine Function Switch-on conditions

component
Hydraulic pump ON Oil temperature > 10 °C
Oil temperature < 70 °C
Oil level > min.
Oil filter o.k.
Grease lubrication ON Grease level o.k.
Pressure switch for air > 4 bar
Motor ON Oil temperature t > +5 °C (in the case of mineral oil)
gear lubrication
floating roll + fixed Oil temperature t > -5 °C (in the case of synthetic oil)
roll
(only in the case of
forced-feed
circulatory
lubrication)
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POLYCOM interlocking
A. Start POLYCOM

Interlocking Polycom lubrication system

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POLYCOM interlocking
A. Start POLYCOM

Interlocking Polycom lubrication system

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POLYCOM interlocking
A. Start POLYCOM

Main motors ON The floating roll is in the back end position

The ground material outward conveying equipment is running

Bearing temperature bearings 1 to 4: t < 80 °C

Grease lubrication o.k.
Position measuring device: skewing Ds < 8 mm
Proximity switch of gear unit guard: o.k.
Forced-feed circulatory lubrication of gear unit:
oil pump motors running;
(Pressure switch: p oil > p min , if installed)
Oil temperature of gear unit floating roll + fixed roll t < 75 °C

Bearing temperature of gear unit floating roll + fixed roll t < 90 °C

Oil pressure (hydraulic system) p oil < p oil min

Cooling water of bearing cooling system off (solenoid valve energized)*

Limit switch for roll position floating roll + fixed roll covered
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POLYCOM interlocking
A. Start POLYCOM

Interlocking Polycom drive Flender

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POLYCOM interlocking
A. Start POLYCOM

Pressure build-up ON Hydraulic system o.k.

(see machine manual
Hydraulic system for Main motors running
POLYCOM)

If the POLYCOM reached an operating time of more than 24 hours before this startup, a hydraulic cylinder
flushing process now takes place
(see machine manual Hydraulic system for POLYCOM, point Flushing the plunger cylinder).

Material feed ON The floating roll is in basic gap position s = s 0

The start-up pressure is o.k. p oil =p0

The roll speed is ok

The metal detector is ok

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POLYCOM interlocking
B. Start after EMERGENCY OFF or interlocking shutdown

After EMERGENCY OFF or interlocking shutdown of the plant, there is usually still some mill feed material in the
feed bin that has to be conveyed away before the plant can be started again.

Machine Function Switch-on conditions

component
Hydraulic pump ON Oil temperature > 10 °C
Oil temperature < 70 °C
Oil level > min.
Oil filter o.k.
Backward travel ON The discharge conveying equipment is running
of floating roll

Grease lubrication ON Grease level o.k.

Pressure switch for air > 4 bar
Motor ON Oil temperature t > +5 °C (in the case of mineral oil)
gear lubrication
floating roll + fixed roll Oil temperature t > -5 °C (in the case of synthetic oil)
(only in the case of
forced-feed circulatory
lubrication)
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POLYCOM interlocking
Main motors ON Bin filling level h < h min

The floating roll is in the back end position

Main motors ON The ground material outward conveying equipment is running

Bearing temperature bearings 1 to 4: t < 80 °C

Grease lubrication o.k.
Position measuring device: skewing s diff < 8 mm
Proximity switch of gear unit guard: o.k.
Forced-feed circulatory lubrication of gear unit:
oil pump motors running; (Pressure switch: p oil > p min , if installed)

Oil temperature of gear unit floating roll + fixed roll t < 75 °C

Bearing temperature of gear unit floating roll + fixed roll t < 90 °C

Oil pressure (hydraulic system) p oil < p oil min

Cooling water of bearing cooling system off (solenoid valve energized)*

Limit switch for roll position floating roll + fixed roll covered
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POLYCOM interlocking
Pressure build-up ON Hydraulic system o.k.
(see machine manual
Hydraulic system for Main motors running
POLYCOM)

If the POLYCOM reached an operating time of more than 24 hours before this startup, a hydraulic cylinder
flushing process now takes place
(see machine manual Hydraulic system for POLYCOM, point Flushing the plunger cylinder).

Material feed ON The floating roll is in basic gap position s = s 0

The start-up pressure is o.k. P oil =p0

The roll speed is ok

The metal detector is ok

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POLYCOM interlocking
Normal operation

During operation, all measured variables relevant to safe operation are recorded and monitored in order to detect
possible malfunction at an early stage. Two types of malfunctions are distinguished, one that only triggers an alarm
(warning) and one that immediately causes shutdown (emergency off).

Alarm

The following malfunctions are triggering an alarm:

Hydraulic system: - Oil level in tank h < min.

- Oil temperature t < 10 °C
- Oil temperature t > 70 °C
- Oil filter clogged up n p > n p max

Grease lubrication: - Grease level in grease barrel < min.

- Pressure switch for compressed air p > 4 bar
- Number of pulses of distributor monitor 1 too low
- Number of pulses of distributor monitor 2 too low
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POLYCOM interlocking
Alarm

The following malfunctions are triggering an alarm:

Drive: - Oil temperature of gear unit t > t max = 75 °C

- Oil filter is clogged up n p > n p max (the plant is shut down after 8 hours
unless the cause is eliminated)

High-pressure grinding roll:

- Bearing temperature of fixed roll fixed bearing t > t max = 80 °C

- Bearing temperature of fixed roll floating bearing t > t max = 80 °C
- Bearing temperature of floating roll fixed bearing t > t max = 80 °C
- Bearing temperature of floating roll floating bearing t > t max = 80 °C
- Skewing ns > 8 mm
- Vibration monitor: vibration velocity u > 3 mm/s
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POLYCOM interlocking
EMERGENCY OFF

This machine protection device is either manually tripped by intervention via emergency switch near the machine,
or is tripped by power cut ore interlocking to downstream equipment.

In the case of emergency off, the high-pressure grinding roll is immediately stopped and the feed material
conveying system, the drives and the central lubrication system are shut down.

Machine Function Consequences

component

Emergency switch ON The main motors are stopped

or interlocking
emergency
The bearing lubrication is stopped
shutdown

The hydraulic system is stopped

The material feed is stopped

The outward conveying of ground material is

stopped
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POLYCOM interlocking
Interlocking shutdown of the POLYCOM, when one measured variable is exceeded:

Cause of tripping Consequences:

Impermissible pressure build-up on right-hand cylinder end
p > 210 bar
• The main motors are stopped
Impermissible pressure build-up on left-hand cylinder end
p > 210 bar • The bearing lubrication is stopped
Minimum pressure on right-hand cylinder end p < 30 bar
• The hydraulic system is stopped
Minimum pressure on left-hand cylinder end p < 30 bar
• The material feed is stopped
Oil level in tank h < min min
• The downstream transports are stopped
Oil temperature in tank t > 75 °C

Bearing temperature: bearing (1) > 90 °C

Bearing temperature: bearing (2) > 90 °C

Bearing temperature: bearing (3) > 90 °C

Bearing temperature: bearing (4) > 90 °C

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POLYCOM interlocking

Skewing of the floating roll n s > 10 mm

Roll gap too wide s > smax
Vibration monitor: Consequences:
vibration velocity is u > 5 mm/s
Grease lubrication:
Distributor monitor 1; after second working cycle without pulse • The main motors are stopped
or too few pulses
Distributor monitor 2; after second working cycle without pulse • The bearing lubrication is stopped
or too few pulses
• The hydraulic system is stopped
Excessive winding temperature at main motor of fixed roll
• The material feed is stopped
Excessive winding temperature at main motor of floating roll
• The downstream transports are stopped

Inner limit switch at cardan shaft guard, fixed roll

Outer limit switch at cardan shaft guard, fixed roll
Inner limit switch at cardan shaft guard, floating roll
Outer limit switch at cardan shaft guard, floating roll
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POLYCOM interlocking
Oil temperature of fixed roll gear unit t > 85 °C

Oil pressure monitoring system of fixed roll gear unit

p < pmin (if installed)

Oil temperature of floating roll gear unit t > 85 °C

Consequences:
Oil pressure monitoring system of floating roll gear unit
p < pmin (if installed)

Bearing temperature of fixed roll gear unit t > 90 °C • The main motors are stopped
(if installed)
• The bearing lubrication is stopped
Bearing temperature of floating roll gear unit t > 90 °C
(if installed)
• The hydraulic system is stopped
Limit switch for roll position of fixed roll covered
• The material feed is stopped
Limit switch for roll position of floating roll covered
• The downstream transports are stopped
Speed monitor of fixed roll n < 90 % of rated speed

Speed monitor of floating roll n < 90 % of rated speed

Excessive difference in power draw of main motors Pdiff > 50 %

POLYCOM discharge equipment failed

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POLYCOM interlocking
EMERGENCY OFF:

In the case of an EMERGENCY OFF, the high-pressure grinding roll is immediately shut down

Emergency off Function Consequences

Emergency switch ON The main motors are stopped

or automatic
emergency The lubrication system is stopped
shutdown

The hydraulic system is stopped

The material feed is stopped

The downstream transports are stopped

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POLYCOM interlocking
Shutdown sequence of POLYCOM

Machine Function
component
Feed material OFF Timer
Hopper filling level = 0
Floating roll to basic gap
Main motors OFF Oil cooling for gear unit: OFF by temperature control
Solenoid valve for cooling water: De-energized
Push back of floating ON Opening of roller until proximity switch is reached
roll
Hydraulic system OFF Pressure relieve
Lubrication system OFF

Discharge conveyor OFF

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POLYCOM control loops

• Control loops
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POLYCOM interlocking
Throughput Control of POLYCOM with Variable Speed Drives

In complex treatment plants, the POLYCOM has to handle the amount of material which is fed into the POLYCOM section.
The feed rate is determined either by requirements of the up-stream (material in) or down-stream (material out) process.
Alternatively, it could also be pre-set by the operator as a set point on the weigh belt feeder (2).

Material in POLYCOM Section

3

FL FL Filling level measurement

FL Mass flow measurement

1 MF
2
M Motor
5
4

FL
MF
M 6
M
M
1 Feed bin 2 Weigh belt feeder
3 Feed belt conveyor 4 POLYCOM
5 Discharge belt conveyor 6 Product bin Material out
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POLYCOM interlocking
• In case that speed variable POLYCOM drives are installed, the throughput of the unit
is adjustable by the roll speed.
• The required roll speed mainly depends on the throughput to be handled and has to be fine tuned
according to

1. variations of the feed material properties or

2. machine settings

• The throughput may vary + x % between min and max at a certain roll speed.
• This range varies for different materials and different applications.

Throughput versus Motor Speed

1500

1250 Max
Throughput [tph]

1000 Min

750

500
design
250 max
min
0
0 250 500 750 1.000 1.250 1.500 1.750 2.000

Motor speed [rpm]

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POLYCOM interlocking
Two strategies for throughput control are possible:

1. Isolated throughput control

Material in 3 POLYCOM Section

FL FL Filling level measurement

FL Mass flow measurement

1 MF
2
M Motor
5
4

FL
MF
M 6
M
M
1 Feed bin 2 Weigh belt feeder
3 Feed belt conveyor 4 POLYCOM
5 Discharge belt conveyor 6 Product bin Material out
The isolated throughput control does not involve the up-stream or down-stream plant sections. The throughput to be handled
is determined by a set point on the weigh belt feeder (2). The speed of the rolls is adjusted according to the filling level in the
POLYCOM feed chute (4). The roll speed may need to be changed quite frequently if the feed material properties vary.
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POLYCOM interlocking
2. Integrated throughput control

Material in
3 POLYCOM Section
FL FL Filling level measurement

FL Mass flow measurement

1 MF
2
5

FL
MF
M 6
M
M
OPTIONALLY
M Motor

Material out
Integrated throughput control could be applied if the feed or discharge material is collected in intermediate feed and/or discharge
bins. In this mode, the weigh belt feeder controls the level in the feed chute of the POLYCOM within the desired level range.
The speed of the POLYCOM rolls is only adjusted in order to keep the filling level in the feed or discharge bin constant.

The roll speed of the POLYCOM does not have to be corrected as frequently as in the isolated mode since the “fine tuning” is done
by the weigh belt feeder. Operation of the POLYCOM is more stable and not disturbed by frequent speed changes.
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POLYCOM interlocking
Level control in feed chute

• The filling level in the feed chute shall be maintained

between the minimum and maximum operating level.

• The filling level can be either controlled by the roll speed

or the feed rate of the weigh belt feeder.

max, max
operating max

operating min
min, min

“Hopper type” feed arrangements, which angular side plates could be equipped with load cells.
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POLYCOM interlocking

Start-up of POLYCOM

• It is recommended to start-up the POLYCOM at lowest motor speed in order to achieve

a material level in the chute (choke feed conditions) as soon as possible.

• After reaching the “min, min” - level the motor speed should be increased according to a
function to be determined during commissioning.

• After reaching the minimum operating level, automatic throughput control should be activated.
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POLYCOM interlocking

Lack of feed material

• Feed material may not be available for limited periods of time since tramp material
is automatically removed either by bypass flaps or by reversing the feeding belt.

• A signal should indicate this situation and the motor speed could be reduced to
for instance to 50 % of the motor speed at that time.

• The motor speed should be reduced to its minimum if the material level falls below
the “min operating” level.
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POLYCOM interlocking

Overfeeding of POLYCOM

• The feed belt has to be stopped if the “max, max level” is exceeded and the
roll speed cannot be further increased.

• It should be started again after the filling level falls below the maximum operating level.
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POLYCOM interlocking
Pressure Control of POLYCOM

• The product fineness of a POLYCOM is controlled by the applied grinding force.

• A typical correlation between grinding force and product fineness is shown in

the diagram below.

Product fineness vs specific grinding force

100
Product fineness[ % passing]

80

60

40

% < 1 mm
20
% < 8 mm
0
0 1 2 3 4 5
Specific grinding force [N/mm²]
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POLYCOM interlocking
“Pressure Control” of POLYCOM

The operating pressure of POLYCOM is adjustable during operation. In general, two modes can be applied:

1. Pressure adjustment by operator

The hydraulic pressure adjusts itself according to the actual working gap and the characteristic of the
hydrodynamic spring. If desired, the pressure is manually increased or reduced during operation by the
operator. These pressure changes may become necessary due to changes in feed material characteristic
or if the product fineness shall be optimised.

2. Automatic pressure control within a “dead band”

The operating pressure shall be automatically maintained within a certain band, for instance 90 + 10 bar.
In this case the operating pressure shall be independent from the working gap. If the pressure leaves this
band it is automatically increased or reduced to the set-point, 90 bar in this case.

Note: Only one of the two modes can be applied at the same time!
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POLYCOM interlocking
“Roll parallel control” of POLYCOM

• The working gap between the rolls may differ at both roll edges (skewing) due to segregation
of the feed material or any other reasons.

• In case of skewing, the pressure at the side with the smaller gap is reduced until the difference
of the working gap becomes lower than a certain value.

• A limit of the maximum pressure difference at both sides of the rolls is given.

• Compensation of the skew has to be achieved within this maximum acceptable pressure difference.
Otherwise, other measures have to be taken to compensate the skew.

Note: It has to be ensured that “pressure control” has a higher

priority than “roll parallel control”!
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POLYCOM Data Acquisition

• Data acquisition and sample taking

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POLYCOM Data Acquisition

- Configuration- MCC-Room
Power supply
PC data
230V AC, 10A
acquisition
15 signals
system
(No. 1 to 15 )
Polysius
Power supply Modem
Switch box
230V AC, 10A 7 Process signals
for
4-20mA

Analog telephone line

Frequency inverter MR
data acquisition

Frequency inverter FR
(No. 9 to 15)
(installed near
POLYCOM)

DCS-System
Cerro Verde

POLYCOM PM01

7 Process signals
4-20mA
(No. 9 to 15)
2 new signals
20mA
(No. 7 to 8 )

6 new signals
20mA
(No. 1 to 6 )
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POLYCOM Data Acquisition

- Acquired process variables -

1 Torque movable roll Torque MR new (torsion rod, gearbox support)

2 Difference torque Torque Dif new (pendulum support, gearbox support)

3 Speed motor movable roll Speed MR new (output shaft main motor)

4 Speed motor fixed roll Speed FR new (output shaft main motor)

5 Vibration gearbox movable roll Vibration MR new (gearbox on top)

6 Vibration gearbox fixed roll Vibration FR new (gearbox on top)

7 Power motor movable roll Power MR new (ABB frequency inverter)

8 Power motor fixed roll Power FR new (ABB frequency inverter)

9 Pressure left side Pressure left existing

10 Pressure right side Pressure right existing

11 Gap left side Gap left existing

12 Gap right side Gap right existing

13 Vibration mill Vibration mill existing

14 Total feed mill Total feed existing

15 Level hopper Level hopper existing

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POLYCOM Data Acquisition

- Location new signals -

Vibration MR Vibration FR

Speed MR Speed FR

Torque MR Torque Diff.

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POLYCOM Data Acquisition

- Example for connecting existing signals to data acquisition -

Switch box
for
data acquisition

(installed near
POLYCOM)

Universal Isolator
Knick A 26000
4-20mA 4-20mA
PC data
20mA
acquisition
Input Output 50Ω system
Polysius
20mA

Pressure left 4-20mA

DCS-System
Cerro Verde
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POLYCOM sample taking

Sampling point 1, new feed material

Sampling point 3, Polycom feed

Sampling point 10, screen feed

Sampling point 4, Polycom discharge

Sampling point 2, ball mill screen oversize

Sampling point 5, screen undersize

Sampling point 8, primary cyclone overflow

Sampling point 9, ball mill feed

Sampling point 6, ball mill discharge Sampling point 7, primary cyclone feed
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POLYCOM sample taking

The new feed material is the COARSE ORE SCREEN UNDERSIZE in the secondary crusher circuit. The material is dry and
conveyed by means of a conveyor belt to the feed conveyor belt of the Polycom feed bin. The samples must be taken at
the discharge end.
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POLYCOM sample taking

The samples can be taken at the discharge end of belt C-3310-FE-101 or

belt C-3310-FE- 102.

The BALL MILL SCREEN OVERSIZE is moist and is conveyed by means

of a conveyor belt to the Polycom feed bin. The samples must be taken
at the screen discharge end.

The BALL MILL SCREEN UNDERSIZE is moist and is conveyed to the

sump of the pump for the hydro cyclone. A possible sampling point is
chute C-3310-ST-108 after the screen C-3310-SC-102.
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POLYCOM sample taking

The HPGR FEED consists of new feed material and ball mill screen
oversize. The samples can be taken at the discharge end of belt C-3220-
CV-008, at the discharge end of belt C-3220-CV-012 or C-3220-ST-066 .

Samples must be taken at chute C-3230-ST-081 after the Polycom.

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POLYCOM sample taking

The PRIMARY CYCLONE FEED is slurry. The feed consists of the An automatic sampler (C-3330-SA-101) is installed for the
streams of material 5 (screen undersize) and 6 (ball mill discharge). The PRIMARY CYCLONE OVERFLOW.
exact sampling point and the type of sampling have to be determined.

The BALL MILL DISCHARGE is moist and is conveyed to the sump (C-3310-BX-101)
of the pump for the hydro cyclone. The exact sampling point and the type of
sampling have to be determined.

The ball mill feed is the PRIMARY CYCLONE UNDERFLOW. The exact
sampling point and the type of sampling have to be determined.

The BALL MILL SCREEN UNDERSIZE is moist and is conveyed to the

sump of the pump for the hydro cyclone. A possible sampling point is
chute C-3310-ST-108 after the screen C-3310-SC-102.
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POLYCOM safety instructions

• Safety Instructions
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POLYCOM safety instructions

Safety instructions
NOTE:

Be sure to comply with the general safety requirements in the supplement of Machine Manual:
“Important notes on the documentation”.

Use:

• The machine is exclusively intended for the grinding of brittle minerals.

• The mill feed material must be free of tramp metal.

• Be sure to comply with the stipulations concerning the intended use in section Technical data.

• Any use other than the intended use is forbidden.

• POLYSIUS AG is not responsible for damage resulting from any use other than the
intended use. All other use is at the owner’s own risk.

• The intended use also includes the observance of the instructions in the machine manual and
the compliance with the maintenance instructions.
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POLYCOM safety instructions

Transport and assembly:

• All transportation instructions in this machine manual refer exclusively to transportation

of the machine at the plant site.

• Only use suitable hoisting and lifting equipment which is in serviceable order and has a sufficient
load bearing capacity.

• Take special care with the transportation of gear units already equipped with oil pumps and piping.
Before transporting the gear unit, remove the piping and close all pipe connections and openings with
weather and impact-proof sealing covers to prevent ingress of foreign bodies.

• Never work under a suspended load.

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POLYCOM safety instructions

Operation:

• Do not make any changes (software) to programmable control systems.

• Any safety checks before or during operation depend on the relevant national regulations.
The plant management is responsible for the performance and recording of such checks.

• If changes in the machine or its operating behavior relevant to safety occur, shut it down immediately.

• To protect the drives, the POLYCOM high-pressure grinding roll must not be started if there is mill
feed material in the roll gap and the floating roll is pressed against the fixed roll.

• Be sure to comply with the information about the special conditions when starting the POLYCOM
with hot feed material that is contained in the machine manual of the High-pressure grinding roll.
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POLYCOM safety instructions

Maintenance:

• Be sure to also comply with the safety instructions in the machine manuals for the individual subassemblies.

• Ensure that all machines and motors whose operation might endanger persons or equipment are switched
off and safeguarded against restarting for the entire duration of the maintenance work.

• Ensure that all rotating parts of the machine have come to a complete standstill before you remove any
protection devices or open any flaps.

• Before performing any work on the machine, make sure that there is no danger of suffering burns when
touching the machine and that no hot material is in the machine when inspection and service covers are opened.

• Keep the machine free of oily and combustible substances and materials. Never use gasoline or other easily
inflammable substances for cleaning the machine.

• Switch off the power supply to the electrical components before commencing any maintenance work.

• Make sure that the pneumatic piping is relieved of pressure before disconnecting it.
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POLYCOM safety instructions

• Before carrying out work on the central lubrication system with pneumatically operated grease pump,
you must disconnect the grease pump from the compressed air supply system.

• Make absolutely sure that the piping of the central lubrication system has been relieved of pressure.

• The hydraulic system is specially designed for the supplied machine and may, therefore, not be used for
any other machine without the express consent of POLYSIUS AG.

• Make sure that the hydraulic piping is relieved of pressure before disconnecting it.

• Never use the pumps of the hydraulic system for emptying or filling the oil tank.

• If you drain hydraulic oil at operating temperature, you risk scalding yourself.

• Only use pure nitrogen and never oxygen for filling the piston accumulators.

• After all maintenance work, check that there are no leaks in connecting points and connections.

• If you carry out electrical welding on any part of the machine, never conduct the welding current through
plain or antifriction bearings, other movable connections or measuring devices. Always directly connect
the welding current return lead to the part being welded.

• The plant management must ensure that all rotating parts are protected against accidental contact.

• Remount all protection devices when maintenance work has been finished. Make absolutely sure that
no persons are inside the plant component before you properly close the inspection and service covers.