In- House Training

On
LOSS-IN-WEIGHT SYSTEM
(Make- Schenck Process) By
Mohiuddin Islam
 Program Content
1 Introduction

2 Principle of Operation

3 System Design and Selection

4 Parameter List and Details

5 Calibration of system

6 Factors affecting Accuracy.

7 Troubleshooting

6 Question & Answers

2
 INTRODUCTION

LOSS IN WEIGHT/ SIMPLEX feeder is

a gravimetric metering device that
receives material from an upstream
supply and accurately doses the
material into a process at a
predetermined set feedrate, typically
through a helix screw, twin screw or
vibratory tray.

True to its “LOSS IN WEIGHT” name, this feeder operation is regulated by the amount
of live load that is lost as product is discharged. In order to do this effectively, the loss
in weight feeder receives constant feedback from a sensitive weighing device(Loadcells),
which ensures that the precise amount of material is delivered either continuously or in
each batch.

3
PRINCIPLE OF OPERATION

Loss-in- Weight feeder model “PSS” is used

to feed pulverized material. Depending upon
material to be fed, explosion shock proof or
stainless steel design is decided.

A hopper along with extraction screw and

adjoining bag filter is placed on Loadcells.
Same is being weighed, extraction screw
delivers material into the process and feed
being controlled through controller
“Intecont Plus” by varying the speed of
screw(AC Drive) according to weight loss.

To maintain continuity of feed, refilling of

hopper takes place during brief periods.
During filling system operates
“Volumetrically” i.e. control
magnitude(Screw speed) being stored as per
preceding “Gravimetric mode”.

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PRINCIPLE OF OPERATION
 Filling to weigh hopper from storage
bin is aided by flow pad placed at the
lower conical portion of bin. This flow
pad being given pulsating output of
air or inert gas.

 To further aid the flow promotion, bin

outlet area is lined with SS Liner.

 Expected filling time should be

between 8-12 seconds.

 Inlet cone is cleaned by air or inert

gas ( “IBO-Inlet Blow Out” ) after
every filling to ensure no material will
fall into the weigh hopper during
“Gravimetric mode”.

 Inert gas connection is provided in bin

and weigh hopper, if explosion type
material is handled.

5
PRINCIPLE OF OPERATION
 Filling system of weigh hopper from
storage bin consists of:-
a. Fill Gate (6)
b. Inlet cone (4)
c. Inlet Blow Out (14)
d. Flexible connection (7)
e. Deflector Plate
f. Bag filter (9)
g. Agitator

 During “Volumetric mode” fill

gate opens and material is
discharged from bin to weigh
hopper as per the fill amount.
During this time bag filter purging
and IBO and Surge Bin
Aeration(SBA) is ON till the fill
amount is discharged to weigh
hopper. After this the fill gate
closes resulting in “OFF” of SBA
and bag filter purging, but IBO is
“ON” as per set parameter time so
that inlet cone is fully cleared out.

 Deflector Plate is fitted inside weigh

hopper reverse to the screw so that
direct impact of fill amount weight
is not on the buffer material.

 Agitator is provided for proper

packing of screw flight and no
lumps is formed.
6
PRINCIPLE OF OPERATION

 As soon as weigh hopper is filled with

pre defined amount of fill amount
system waits for set parameter of
volumetric time so that material
settles down and changes back to
“Gravimetric mode” and speed of
screw is varied according to the set
feedrate.

 Material is being conveyed to the

process by Fuller Kinyon (FK) pump.

 This cycle of “Gravimetric mode”

and “ Volumetric mode” continues
and system feed and accuracy is
being maintained.

7
SYSTEM DESIGN AND SELECTION
TDS POINTS CLARIFICATION
 Type Of Equipment
 Equipment No
 Revision Number. etc

 Material type, temperature, grain size, Bulk Density required for feeding.
 General Arrangement drawing Number.

 Type of Loadcells, Number of Loadcells.

 Nominal load on load cell as per design.
 Tare weight of load cell and total load on load cell at max bulk density.
 Loadcells sensitivity, resistance and input voltage to load cell from
controller.

 Tare weight( empty weight) of bin.

 Fill amount and buffer amount of material.
 Gross weight of bin.
 Number of bin support.
 Rpm of screw motor @ 60 Hz (nominal feed rate speed)of VFD drive.

 Motor description.
 Screw description.
 Agitator description.
 Bag filter description

9
 SYSTEM DESIGN AND SELECTION
 Screw Specification- PSS 100 BDS 315 - =68.5 m3 /Hr at 100 RPM of screw

 Screw motor specification = 7.5 kW, 1500 RPM @ 50 Hz, 415 V

Gear Box ratio = 44.32:1

So, output RPM of Screw at 50 Hz =(1500/44.32)RPM

=33.845 RPM

So, at 1990.79 nominal RPM at 20TPH

output RPM of Screw =(1990.79/44.32)
= 44.918 RPM

So, at 44.918 RPM = (68.5*0.44918) m3 /Hr

= 30.769 m3 /Hr

Bulk Density of pulverized coal = 0.65 ton/ m3

Total TPH = (0.65 x 30.769)ton/ hr

≈20 TPH

 Fill amount calculation.

Filling time should be within 15-20 seconds and settling time to be 10 sec and considering 20 cycles/ Hr.

Fill amount in each cycle = (20/20)

= 1 Ton
 Buffer amount calculation.

Four times of fill amount is the buffer amount

So, buffer amount =(1x4) Ton
=4 Ton
10
 SYSTEM OTHER PARAMETERS

 Surge Bin Aeration (SBA) air pressure- 1.2 to 2 Bar

 Inlet Blow Out (IBO) air pressure - 1.2 to 2 Bar

 Operation of fill gate (Pneumatic) air pressure - 5 to 7 Bar

 Suction at screw outlet - 10 to 20 mmWC

 Gap between screw and barrel - 5 to 8 mm

 Material Temperature - 800C

 Moisture of pulverized coal - 1 to 2 %

 Grain Size - 12 to 15% over 90 micron.

 Bag filter fan status while system running - ON

 Weigh hopper free from any obstruction as it may affect weighing of system.

11
SQUENCE OF OPERATION

12
SQUENCE OF OPERATION
 SQUENCE OF OPERATION

In “Volumetric mode” fill gate opens and material is discharged from bin to weigh hopper as per the fill amount.
During this time bag filter purging and IBO and Surge Bin Aeration(SBA) is ON till the fill amount is
discharged to weigh hopper. After this the fill gate closes resulting in “OFF” of SBA and bag filter purging,
but IBO is “ON” as per set parameter time so that inlet cone is fully cleared out.
14
PARAMETER LIST AND DETAILS
No Description
B01 Feed rate unit selection.
B02 Nominal feed rate.
B06 Start Command selection source
B07 Feed reference selection (Analog)
B09 Fill weight unit selection
B10-13 Pulse output parameters
C01 Load cell sensitivity
C02 Total of 3 load cell capacity
C04 Known check weight for calibration
D01 Span correction in bin weight reading
D02 Empty weight of Bin
E01-03 Analog output-1 selection, min and max range values.
E04-06 Analog output-2 selection, min and max range values.
F01-04 Min/Max values for feedrate parameters and alarm annunciation
F05-08 Min/Max values for Fill weight parameters and alarm annunciation
F09-12 Min/Max values for Speed parameters and alarm annunciation
Drive (DO Feeder ON) with set points below F 13. Conrol magnitude is reduced to the
F13 value of Parameter R04 “Contr. Magn. Elev”. Change over to Stand-By mode is
delayed by 3s; switchback takes place immediately
F14 Event class for stand-by limit
G01 Feed rate display refresh time
G02 Feed rate analog output refresh time
G03 Fill weight display refresh time
G06 Loadcell sensing filter time.
PARAMETER LIST AND DETAILS
No Description
H01 Measurement and Control upon hopper discharge (Discharge Weighing)
H02 Controller control the discharge weighing
H03 Control filling using limit values in H10 and H11( F_Control Min/Max).
H04 Filter time of differentiator computing feed rate from weight values.
Between value AMOUNTmin and Nominal AMOUNT (Fo) control takes place
H05
gravimetrically ; outside these values, volumetrically.
H06 Below this value, “Start Filling” function must be used for filling.
H07 Event class for AMOUNT min
H08-09 Indicates the maximum possible material amount in hopper and its event class
When fill weight falls below limit value H10, filling starts. With values below 0 or
H10
AMOUNTmin, control intervention is suppressed.
H11 End of filling with automatic changeover functions. H11>H10 and H10>H06.
Filling aborts automatically after elapse of max. filling time and system goes to
H12
gravimetric mode, without checking that fill amount is being discharged.

H13 “DI” is selected, gate position is acquired via sensor input. Internally, gate
feedback is effected after time H14.
H14,H16 Monitoring time for gate feedback upon opening and closing. It’s event class.
H15,H17 System’s volumetric time. If filling exceeds time H15 + H18, event B8 is output.
After filling (gate feedback), control continues in Volumetric mode for time H17
H18
and prevents mechanical vibrations, if any, from taking effect.
H19,H20 If in parameter H03 pulse is activated.
I01-I09 Required only if batch mode is being activated.
J01-03 Required only if parallel printer being connected to the Intecont plus.
On time of controller, Runninig hrs etc being monitored by system and its event if
K01-06
required can be activated by these parameters.
PARAMETER LIST AND DETAILS
No Description
L01-21 Communication protocol, timeout, node address, baud rate etc parameters.
Hopper blow-out starts 1s before opening of material gate and ends after set
gate closing timeout (N01). By this we are ensuring that the inlet cone is
N01
being completely cleaned out and no material will fall into weigh hopper
during gravimetric phase.
Agitator starts in all operating intervals if set point exceeds limit value set in
N02 N02 and feeder is ON. This will ensure smooth feed property on higher TPH ,
and uniform packing of feed screw.
Parameters relating to Disturbance Auto Eliminator (DAE). It is designed to
eliminate disturbances in feed rate acquisition and control arising from
O01-11 mechanical influences, e.g. vibrations, accidental touching of weigh hopper.
The system operates in turned-on state of feeder, in Gravimetric and
Volumetric modes, but not in the filling phase.
Q01-02 Event class for power failure and memory error.
Q03-05 Event class for tacho input, namur tacho(DI7) and namur sensor (DI6).
Q06 Event class for loss in loadcell input.
Q07 Event class for loss of release DI bit(T01 parameter).
Q08-09 Event class for loadcell value min and max.
Q10 Event class for Simulation from calibration functions being activated.
Q11 Event class for Setpoint is more that nominal TPH.
Q12 Event class for external event bit loss.
S01-10 Parameters relating to activation of linearization function of controller.
T01 DI assigned for release bit, without this bit system will not operate.
T02-03 DI assigned for batch stop and fault acknowledge.
T04,05 DI assigned to activate Volumetric mode or volumetric sync mode from DI
T06 DI assigned for fill gate ON/OFF feedback.
T07,08 DI assigned Discharge of screw and external event is being activated.
PARAMETER LIST AND DETAILS
No Description
R01 Proportional component for feed rate controller
R02 Setback time (integral component) for feed rate controller.
Control magnitude is additively superimposed by a value proportional to preset
R03
setpoint. Parameter indicates bypass value for nominal setpoint.
R04 Elevates control magnitude by a constant value.
R05,06 Control magnitude lower limit and upper limit
R07 In Stop state of feeder, set control magnitude either to 0 or to lower limit R05.
R08 Stores last value of control magnitude in memory as per R09 for next start.
In the measuring phase, the controller output is meaned and used as control
R09
magnitude for filling(measuring direction DOWN).
Automatically adjusts control magnitude during filling. Material flow
R10 compensation is active only if the feeder’s discharge time is 4 times higher than
the value of R09.
R11,12 Second-order filter in setpoint and correction if required.
Evaluates proportional controller component as a function of setpoint, e.g.
R13
KP control = 2: KP proportionally increases with setpoint
R14-17 Speed transducer yes then its P and I components and its normalization.
R18-25 Controller adaptation, time, filter factor of deviation etc.
Volumetric start-up cycle after start of feeder. If set time has elapsed, system
R26 goes to Gravimetric (controlled) mode. Speed controller is also active in Start-up
mode. “V” flashes on display.
R27-29 Setpoint range and offset.
U01 DO for fault output.
U02 DO for gate feedback output.
U03-04 DO for feeder ON output.
U05,06 DO for Bag filter fan blower ON and agitator ON feedback output.
V01-04 Easyserve communication parameters.
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 CALIBRATION OF SYSTEM
1. Checking of Weigh Hopper
This ensures that the loadcell reading of weigh hopper is accurate.
 Taring of empty weigh hopper by using “TW Tare” setting program in “Calib functions”.
 Applying known check weight on weigh hopper in steps and recording the reading and subsequent correction in
parameter “D01” for accuracy of weigh hopper reading.

2. Checking of Check Control System

 The Simulation mode lets us to easily check gate control, limits values and drive control. No material is required.

3. Accuracy check by bin level drop w.r.t. time during gravimetric mode.

 Start the system with any setpoint.

 As soon as bin filling is stopped and system goes to gravimetric mode.

 After some time record the weigh hopper weight and the time.
 Before the filling start level comes record the bin level and time

 So by measuring the weight loss w.r.t time the feed accuracy of the system can be established.
 FACTOR AFFECTING ACCURACY
Performance of a Loss-in-Weight feeder is judged mainly by feed consistency. Following
factors can affect:-

 Leakage from fill gate due to damaged seal of the gate. Material entered into the weigh hopper in gravimetric
phase will falsify loss-in-weight rate measurement.
 Packing of material at the inlet flexible joint will make weigh hopper stiff with non weighing part.
 Material drop from filter unit or vent port in gravimetric phase will cause wrong measurement and fluctuation.
 Stiff connections of inert gas line on weigh hopper top or stiff connection to the motor cables, earth connection
etc.
 Any physical arrest on the weigh hopper or screw wall.
 Stiff Load Cell assembly, particularly compression piece sitting over load button or thick dust settlement
surrounding the load cell assembly.
 Venting problem below metering screw will lead jamming in the flexible connection. This may arise due to fault
development in the delivery pump / route or inappropriate venting line configuration.
 Flow property deterioration due to moisture or low temperature will cause feed fluctuation.
 Long filling time due to incorrect operation of filling aid or material flow property deterioration.
 External factors which are not eliminated by DAE system will cause measurement problem.
 Partial flushing out of material due to pressurization or insufficient buffer material will cause performance
problem.
 Electrical interference , like EMI pick-up in the load cell cable or load cell signal cable’s insulation leakage.
 TROUBLESHOOTING
1. Inaccurate TPH of system-
 Cross check weigh hopper reading with known weight.
 Flexibility of weigh hopper and any stiffness to be eliminated.

2. Feed fluctation of system-

 Elimination of material drop in gravimetric mode.
 Proper venting below feed screw otherwise it will lead to jamming in flexible connection.
 Flow property deterioration due to moisture or low temperature.
 Long filling time due to incorrect operation of filling aid or material flow property deterioration.
 Maintain system other parameter as per Slide No-11.
 Partial flushing out of material due to pressurization or insufficient buffer material.
 Inappropriate positioning of Dosing star which will either lead to flushing or overload of screw motor.
QUESTION & ANSWERS

22