Process’ Diagnostic Handbook Update: Nov-04

Chapter VI: General

services and auxiliary Code DP-002 Page 1
equipment

Contents

1 Objective ..................................................................................................................................... 2
2. Auxiliary equipment. ................................................................................................................... 3
2.1 Transportation elements ........................................................................................................ 3
2.1.1 Conveyor Belts. ............................................................................................................... 3
2.1.2 Air sliders. ....................................................................................................................... 4
2.1.3 Helical transportation (Worm screws, screws). .................................................................. 5
2.1.4 Elevators......................................................................................................................... 6
2.1.5 Bucket and tray conveyors ............................................................................................... 7
2.1.6 Plate and dragging chains conveyors ................................................................................ 8
2.1.7 Pneumatic conveyors. ...................................................................................................... 9
2.2 Filters ................................................................................................................................. 10
2.3 Stocks, storage capacities. ................................................................................................... 11
3 General Services ........................................................................................................................ 12
3.1 Compressed air ................................................................................................................... 12
3.2 Water and pumping systems ................................................................................................ 12
3.3 Electric power ..................................................................................................................... 12
3.3.1 General services’ electric consumption: ........................................................................... 13
3.3.2 Electric substation ......................................................................................................... 13
3.3.3 Control architecture ....................................................................................................... 18
Annex .......................................................................................................................................... 21
ANNEX A. ELECTROTECHNICAL CONCEPTS ................................................................................ 21
ANNEX B. CLASSIFICATION OF MOTORS ................................................................................... 24
ANNEX C. FUZZY LOGIC ............................................................................................................ 26
ANEXX D. NEURONAL NETWORKS.............................................................................................. 28
ANEXO E. PID LOOP CONTROL. ................................................................................................. 29
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 2
equipment

1 Objective

After analyzing the main machinery for each step of the process on the previous chapters, the
information is completed in this chapter by presenting the diagnosis, design and control of peripheral
equipment (transportation elements and filters) as well as by commenting on the dimensioning of
General Services (air, water, electric power). Such information even helps on the design estimations of
a possible new cement plant.
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 3
equipment

2. Auxiliary equipment.
In this section we will study both transportation elements and filters. Separators have already been
studied in other chapters. This information serves not only for design purposes but also as a tool for
detecting problems or areas with improving potential in our plants.

2.1 Transportation elements

2.1.1 Conveyor Belts.

Equations
Tons per hour (Q) = 0.3 * A * (1- 0.24 * 0.5) *  * V * (1- 0.0004 * I2)

Power (kW) =  0.13* A *1.8 *V * 0.55 * L  35.06    Q * H    0.04 * Q * 0.55 * L  35.06 

 6273   367   373 
Where:
A = Width of the conveyor given in mm
H = Height between extremes of the conveyor given in m
I = Steepness/slope of the conveyor given in degrees
L = Horizontal Length of the conveyor given in m
V = Conveyor’s speed given in m/s
 = Concavity of the conveyor given in degrees
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 4
equipment

 = Density of the material being transported given in Ton/m 3

2.1.2 Air sliders.

Equations
Necessary air (Va) = 60 * 0.0508 * R * a1 / 1000
Tons per hour (Q) = 0.014 * (A / 100)1.43 * 
Power (kW) = (Va/60) * 21.4 * 0.2489 / 0.65 * 0.746 * 0.91

Where
A = Area of the slider given in mm2
a1 = Width of the slider given in mm
R = Linear length of the sliders given in m
Va = Necessary air in m3/min
 = Density of the material being transported given in Ton/m 3
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 5
equipment

2.1.3 Helical transportation (Worm screws, screws).

Equations
Tons per hour (Q) = 1.16 * 10-5 * D * V * ( / 45) *  * (1- 2* I / 100)
Power (kW) = 3.2 * ((0.0014 * L * V) + (0.003 * Q * L) + (Q * H / 367))

Where
D = Diameter of the vanes given in cm.
H = Height to the discharge point given in m
I = Steepness/Slope of the screw given in degrees
L = Horizontal Length of the screw given in m
V = Rotating speed in RPM.
 = Filling degree given as a %.
 = Density of the material being transported given in Ton/m 3
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 6
equipment

2.1.4 Bucket Elevators.

Equations
Tons per hour (Q) = n * ( /100) * (0.45*A* b* c) *  * V * 3600
Power (kW) = (Q * 9.81 * H /3600) + PL + PS

Where
A = Width of the bucket, given in m
b = Bottom of the bucket, given in m
c = Depth of the bucket, given in m
H = Distance between pulleys, given in m
n = Number of buckets per meter
PL = Power of peripherals kW
PS = Power per bucketing kW
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 7
equipment

V = Speed of the elevator, given in m/s

 = Filling degree as a %.
 = Density of the material being transported given in Ton/m 3

2.1.5 Bucket and tray conveyors

Equations

Tons per hour (Q) = n* ( / 100) * 0.75 * (A * b * c) * V * H * 3600

Power (kW) = (Q * H / 367) + 2.7 * 10-5 * A * Tm0.24 + 0.17 * A0.5

Where
A = Width of tray, given in mm
b = Bottom of tray, given in mm
c = Depth of tray, given in mm
H = Height to the discharge point, given in m
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 8
equipment

Tm = Maximum size of the material, given in mm

V = Speed of the conveyor, given in m/s
 = Filling degree, given in m/s %.

2.1.6 Plate and dragging chains conveyors

Equations

Tons per hour (Q) = 3.54 * 10-4 * V * A * h *  * (1 – I * a)

Power (kW) = (Q * H / 367) + 1.4 * (A /1000) 1.4 * 

Where
A = Width of the plates, given in mm
a = Adimensional constant that depends on the kind of equipment
H = Height up to the discharge, given in m
h = Height of the plates (or their bucket), given in mm
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 9
equipment

I = Steepness/Slope of the conveyor, given in degrees

V = Speed of the conveyor, given in m/s
 = Density of the material being transported given in Ton/m 3

2.1.7 Pneumatic conveyors.

 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 10
equipment

2.2 Filters

The filtering surface (SF) given in m2 is estimated using the following expression:

 
SF m 2  0.26  F  c0.18  350   0.5
Where:
F = gas flow at 25 °C given in m3/min
c = concentration of dust given in g/m3
φ = average diameter of the particle, in μm
For example, con F=700 m3/min , c = 40 g/m3, φ = 50 μm :

     
SF m2  0.26  700  (40) 0.18  350  (50) 0.5  403m 2
Volume occupied by the filter (m3) = 0.33 · SF; 133 m3 for the example
Consumption of compressed air (Nm3/h) = 0.215 · SF; 87 Nm3/h for the example
Surface occupied by the filter (m2) = 0.047 · SF; 19 m2 for the example
In case the values of “c” and “φ” are unkown, an appropriate expression is:

 
SF m 2  0.014  Q, Q must be given in Nm 3 / h
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 11
equipment

2.3 Stocks, storage capacities.

The storage capacity must be able to absorb a “serious” shutdown of the facilities that feeds it. It is
understood that a serious shutdown is the one that stops the machinery for a few days (usually 7
days). The storage capacity depends on the number of machines that feed it. A larger number of
equipments lets us assume that a serious shutdown of any of them won’t imply an increase of the
stock needs. The criterion used is the following:
Silo capacity = (Tons that exit in 1 day + Ton lost during 1 week of a mill’s shutdown) * 1.1

6) CEMENT MILL HM/S 168 6) CEMENT MILL HM/S 168

Days /Week Sales 7 Days /Week Sales 7
Exits /day 7361 Tons Exits /day 7361 Tons
N° of Mills 2 T/H 176 N° of Mills 4 T/H 88
Balls Roller Mill Refine. Balls R. Press mill refine
%proportion press 100 %proporti 100
Length (m) 14.85 on
Length(m) 12.28
Diameter (m) 4.95 Diameter(m) 4.09
Speed(rpm) 14.33 Speed(rpm) 15.82
Tons of balls 348 Tons of Balls 192
%filling 29.34 %filling 29.34
Kw consumed 5481 Kw consumption 2740
Kw installed 5755 Kw installed 2877
Kw aux 1261 Installed1450 SILOS CEMENT Kw aux 630 Installed 725 SILOS CEMENT
Kw tot consumption 6741 type1 3,644 Kw tot consumed 3371 type1 2,227
Kw tot Installed 7204 type2 21,863 Kw tot Installed 3602 type2 13,360
Kwh/Tons (w /shutdown) 42.07 type3 3,644 Kwh/Tons(w7shutdown) 42.07 type3 2,227
Need.Iny.Water(L/h) 143 Need.Iny.Water(L/h) 62 type4 2,227
type4 3,644
Nm3/h Mill 24176 Nm3/h Mill 16270
type5 3,644 type5 2,227
Nm3/h Separator 153934 Nm3/h Separator 76967
% suspension 6 V(m/s) 0.8 Total 36,438 % suspension 6 V(m/s) 0.8 Total 22,267

Case 1: 2 mills with a silo capacity of 36,438 Tons Case 2: 4 mills with a silo capacity of 22,267 Tons

Finally, in the case of silos there should be an oversize of 10% because of the “dead bed” that is not
usable (compare and equal to the tool’s criteria).
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 12
equipment

3 General Services
3.1 Compressed air
a) For production
High pressure air (7 Kg/cm2) Filters, Big blasters, etc. m3/hr = 1.88 * TPDClinker
KwInstalled compressors ≈ 0.015 * KwMilling + 0.13 * TPDClinker
Low pressure air (2 Kg/cm2) Silos fluidization m3/hr = 0.02 * TPDClinker
KwInstalled compressors ≈ 0.035 * TPDClinker
b) For packing
High pressure air (7 Kg/cm2) Packagers, Valves, etc. m3/hr = 0.06 * TPDClinker
KwInstalled compressors ≈ 0.025 * TPDCement
Low pressure air (2 Kg/cm2) Silos fluidization m3/hr = 0.49 * TPDClinker
KwInstalled compressors ≈ 0.055 * TPDCement
Note: For consumed Kwh use 0.65

3.2 Water and pumping systems

a) Water that needs to be transported for cooling equipments, injection in mills and for cooling
gases:

QT (m3/hr) ≈ 2.2 TPD C link er

KwInstall ≈ 0.04 * TPDClinker
(For a closed circuit)
b) Water that need to be introduced because of the 20% that is lost by evaporation and
leakages
QR (m3/hr) ≈ 0.2 QT
KwInstall ≈ 0.04 * TPDClinker
(From the well to the plant)
Note: For consumed Kwh use 0.65

3.3 Electric power

In this section we will study general services’ electric consumption, load concepts and substation
design, as well as control architecture.
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 13
equipment

3.3.1 General services’ electric consumption:

Section Power (kW)

Offices, shop, warehouse, COP control room, 0.06 * TPDClinker
laboratory
Plant lighting, heating y Air Conditioning 0.06 * TPDClinker
Water pumps and compressors Section 3.1 y 3.2
Electric substation (own consumption) 0.015 * TPDClinker

3.3.2 Electric substation

Some concepts concerning electric distribution (substations and transformers) and power billing are
explained in this General Services section. In the annex there are some electro-technical and motor
concepts.
a) Distribution of electric energy
a.1 – Total power needed in the power lines (Total Kva)
a.1.1- Plant during operation
Knowing the power demanded by each equipment
Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 14
equipment
Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 15
equipment
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 16
equipment

The power installed in the transformers should be at least 30% (normally a 40% is used)
above this value in order to absorb the start-up peaks.

a.1.2- Case of a new plant

There will be as many transformers as the number of necessary voltage step-downs to provide
the various tensions at which different motors will work, besides the tension needed for
lighting and services.
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 17
equipment

Assuming
Supóngasethat
quetension is received
la tensión se recibeata 45,000
45000vVy and
se tiene
6000v 3000v 500v
2 ball
2 millsdeforbolas
molinos raw para
meal:crudo:
mill’smotor
motormolino
is 6000v
de .......5724
6000v .......5724
Kw ,total 11448 0 0
The restresto,
of themotores
motorsare
de 500v..........2069
500v.........2069Kw , total 0 0 4138
1 vertical mill for paracoke::
molino vertical mill’s molino
: motor motor isde 3000v
3000v..........664
.......664 Kw , total 0 664 0
The restresto,
of themotores
motorsare
de 500v............616
500v..........616 Kw , total 0 0 616
1 kiln
Hornoof de
7200Tpd:
7200Tpd: VTI’s
VTI’s
of 3000v
de 3000v
...............
...............
.......3168
....3168 Kw , total 0 3168 0
The restresto,
of themotores
motorsare
de 500v..........5532
500v.........5532Kw , total 0 0 5532
3 ball
molinos paraCto::
millsdeforbolas Cement motor motor
mill’s molinoisde
6000v
6000v.......3835
.......3835Kw ,total 11505 0 0
The restresto,
of themotores
motorsare
de 500v...........968
500v.... .....968Kw , total 0 0 2904
2 crushers:
trituradoras:
motors
motores
of 500v
de 500v
...altogether.................
...en conjunto.................
.....1428 Kw , total 0 0 1428
1 packing
Envase: station: motoresmotors
de 500vof...en
500vconjunto................
...total: ........600 Kw , total 0 0 600
conjunto................
1 General
ServiciosServices
Generales : consumes
: consumos 500vde ...altogether
500v ...en conjunto....120
...120 0 Kw , total 0 0 1200
TOTAL = 43203 = 22953 3832 16418
Así con
With 3 tranformers
3 trafos 45000/6000 de 14400Kva
45000/6000 se cubrirían
of 14400Kva would los 22953
cover Kw + la mayoría de
22953 los 16418
+ most of 16418
Kw
With
Y con
2 2transformers 45000/3000
trafos 45000/3000 of 5000Kva
de 5000Kva wouldlos
se cubrirían cover 3832+ el resto de
3832Kw Kw + the rest of 16418,
los 16418,
dando
For a total
un total
of 3*14400+2*5000=
de 3*14400+2*5000=53000 which
53000Kva un 23%isde
23%
sobredimensionamiento sobre elcapacity
more than the installed instalado
As forReferente
transformers of 6000/500 de Kva , thereunos
would be (16418*1.23/1500)
a losTrafos 6000/500
andy 3000/500
3000/500 of
de1000
1000and
y 2000
2000
Kva , saldrían (16418*1.23/1500) 13. 13.
As De
for los
low-tension
Trafos detransformers
baja tensión 500/220
500/220deof500Kva
500Kva, ,para
forserv.generales
.General serianwe
Services unos (1200/500)
would 3.
have (1200/500) 3.
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 18
equipment

b – Power billing and equipment run time planning x

It is fundamental to know thoroughly the billing conditions applicable to the plant in order to
know the different considerations and possible bonuses. This will help us to identify
opportunity areas for a better power management and contracting.
When we are already bound to a specific power contract, it is very important to have an
excellent planning and scheduling of the running time of the machinery. Fulfilling this schedule
is equally important. This is why it is essential to have a tool for planning the running time for
machinery and another one for the facilities (as it was shown before), so that the demanded
power meets the contracted one.

3.3.3 Control architecture

CONTROL ARCHITECTURE PROCESS SCADA VISUALISATION FOR OTHERS

ENGINEERING
LABORATORY

DRX, FRX, G.LASER...

ENGINEERING EXPERT PROCESS

STATION SYSTEM LABORATORY
STATION: STATION
STATION
SCADA

ETHERNET

PLC PROGRAMMING

FIELD

REDUNDANT PLCs
REGULATORY I/O I/O
INSTRUMENTATION
(PID’s) REDUNDANT
RACKS

MANOEUVRE
I/O I/O
SEQUENTIAL CONTROL
REDUNDANT
START-UP C
SHUTDOWNS/PROTECTIONS RACKS C
M
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 19
equipment

Centralized Control Scheme

MOTOR CONTROL
CENTER REMOTO I/O
REMOTE E/S
PLC
REMOTO I/O
REMOTE E/S
(FIELD)

LOGIC
PROGRAMMABLE
CONTROLLER
(PLC)

CONTROL
ROOM MONITORS
INSTRUMENTATION

PRINTERS
POWER MANOUVRE
KEYBOARDS
R S T Fuses
Manouvre
Fuses Emergency Stop
POWER
Thermal
rele
Local contactor Aux.
CONVERTER control contact of
contactor
A
Running
AMPERÍMETER Rele
PROCESS CPUDE
ORDENADOR
PROCESOS
Contactor Rele
EXPERT Control of
(SOFT. DE
SYSTEM Rotation Motor ready
Contactor Rele (running
SOFTWARE
SISTEMAS Rele
500 V Grid confirmation)
EXPERTOS) Thermal
MAQUINA
MACHINE MOTOR Rele 24 V Grid

As for maneuvers, relays and contactors help in getting a motor to full tension. Contactors and
relays operate in the same way, but have different functions, as it is seen in the chart (motor-
ready relays, thermal relays, running relays, contactor relay and contactor). Both relays and
contactors have solenoids or electromagnets that, when energized, generate a magnetic field
that causes the cores to come together. This movement opens or closes contacts that allow or
avoid the flow of electric current to a specific location. The function of the contactor is to allow
the flow of electric current to the three motor phases.
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 20
equipment

Aux. contacts for making

sure that the motor is
CONTACTOR ready to run

Núcleo
Core

Bobina
Coil
relay
Power
Núcleo contacts

Note: same for

MOTOR
other fases

As for regulating processes, the next image illustrates different kinds of control (loops or expert
systems).

CONTROL DE
OFPROCESOS:
PROCESSES:
REGULACIÓN
REGULATION

LAZOS DE CONTROL
CONTROL LOOPS SISTEMASYSTEM
EXPERT EXPERTO
SIMPLE REGULATION
REGULACIÓN SENCILLA
:PREDICTION
:PREDICCIÓN
COMPLEX REGULATION :PREDICTION
REGULACIÓNCOMPLEJA :PREDICCIÓNOF
DEL
OF
DELRESPONSE DUE TOAAUNA
EFECTO DEBIDA SINGLE
SOLA
EFECTO DUE
EFFECT DEBIDA
TO SEVERAL
A VARIASCAUSES
CAUSASOR
O DE
TO
CAUSA,
UNA
CAUSE,
SOLA
USING:
MEDIANTE:
DINÁMICA OR
COMPLEX COMPLEJA
UNKNOWNO DESCONOCIDA
DYNAMICS.

PID’s

PREDICTIVO-ADAPTIVE
PREDICTIVE ADAPTATIVO 1.-DISCRETE
LOGICA DISCRETA
LOGIC
USED WHEN
CUANDO SE CONOCEN
MODELS ARE
LOSAVAILABLE
MODELOS
DE COMPORTAMIENTO

THE
EL USO
USEDE
OFUNO
ONEUOVER
OTROTHE 2.-ARTIFICIAL
INTELIGENCIA
INTELLIGENCE
ARTIFICIAL
ESTÁ CONDICIONADO
OTHER DEPENDS ON THE
A USED WHEN
CUANDO NO MODELS ARE NOT
SE CONOCEN LOS
AVAILABLE
MODELOS DE COMPORTAMIENTO
LAS CONDICIONES
CONDITIONS OF CONTROL,
DEL
CONTROL
NOT ON TRENDS.
Y NO A MODAS.
LÓGICALOGIC
FUZZY BORROSA RED NEURONAL
NEURONAL NET
O FUZZY

Complementary information on artificial intelligence can be found in the Annex section.

 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 21
equipment

Annex
ANNEX A. ELECTROTECHNICAL CONCEPTS
Contrary to what occurs with direct current, in alternating current both potential (voltage) and
intensity (current) vary through time. Both variables are waves that own a certain frequency and
amplitude. In order to apply the same laws of direct current to alternating current it is necessary to
use the modulus of vectors (phasors).

Phase =  + wt
Angular frequency
t
Maximum
w = 2 f
Amplitude
Ilm t =0
Wave length  t

Frequency f = 1/ 

i(t)  Im  cos (wt   )  j  Im  sen (wt   )  Im  e jwt  e j

    
Real Part Imaginary Part Intensity factor FI

To emulate direct current, we use the magnitude (modulus) of the intensity factor
I = | FI |
We do the same for voltage:
V = | FV |
With this simplification it is possible to use direct current laws, for example:

Resistance V
V = I * R, R = resistance is given in (Ω)
XL

Coil V
V = I * XL, XL = inductive resistance (Ω)
Xc

Capacitor V
V = I * XC, XC = capacitive resistance (Ω)
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 22
equipment

Circuits

Series I = IR = I L = I C
R XL Voltage:
Xc
a) Dc
V = VR + VL + VC = I*R +I*XL + I*XC
I VL
VR VC
b) Ac

V V 2 = V R 2 + V L2 + V C 2

V IR 2  IX L 2  IX C 2

Parallel V = VR = VL = VC
Current:
a) Dc
I = IR + IL + IC = V/R +V/XL + V/XC
IR R IL XL IC Xc V
b) Ac
I = IR + |IC – IL|

Ic =V/Xc

IR =V/R
IL =V/XL

Power
DC: P = V * I (W)
AC: There are two kinds of power, each having a certain phase, Cos (), which should be
minimized for billing purposes. Active power (real power) is what is really consumed:
Pa = V * I * Cos () volt-ampere (Va) or Watt (W)
Reactive power is the one that is not consumed, it is only “received and sent back”, but it does
demand some energy from the power company. This energy is equal to the phase -Cos ()-
between the two powers. Power factor, or Cos (), becomes larger as more inductive loads are
present in our system:
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 23
equipment

Ps Ps = Power delivered = V * I
 Pa = Power consumed (active) = V * I * Cos ()
2 2
Reactive load qR = PS  Pa VAR (Volt-amperes reactive)
Pa

This reactive load is generated by the coils of motors and is essential for the development of
the magnetic field that makes the motor work.
To eliminate the negative effects of a reactive load (this is, to become closer to having Cos ()
= 1) capacitors are placed in the power line. They have an opposite effect, since coils
(inductors) and capacitors have a phase of 180 degrees between them.



Ps = Pa Cos 

In the case of three phase systems, voltage is “spread” between the three phases:

VLine = 3 * VPhase
Each one of them carries the same current,

Pa = 3 * V * I * Cos ()
For example, a three-phase motor at 6000 V, that uses a 300 amperes current and has a
power factor of Cos () = 0.8, will have the following power values:

Ps = 3 * 6000 * 300 /1000 = 3117 Kva

Pa = Ps * Cos () = 3117 * 0.8 = 2494 Kw (active Kw)
2 2
qR = PS  Pa = 1869 KVAR (reactive Kw)
Using Cos () = 0.98
Pa = 3055 Kw
qR = 618 KVAR
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 24
equipment

ANNEX B. CLASSIFICATION OF MOTORS

Asynchronous motors

stator Rpm = 3000/NP

NP = No. of poles
Wound
Rotor N N

Stator

Resistance

Alternating current 50– 60 cycles/s (Hz) S S

Three-phase alternating current reach the stator and creates a magnetic field that has a speed
of 3000/NP rpm. A magnetic field is created in the rotor as a result of this. Such field will try to
match the speed of the stator field but it will never reach it. If it did, the motor would stop.
This difference in speed (≈ 0.4 %) is known as slip. When the load is excessive to the motor
power, the slip increases so much that it stops the motor. Nevertheless, the fields are still
there and the motor can burn.
These motors have a starting torque problem, since they will present extremely large starting
currents to initiate movement (this is due to the approach of the field’s speeds). Taking three
wires from the coil in order to insert variable resistors solves this. The resistors will be short-
circuited until the desired speed is acquired (soft start).

Rhetoric Resistance

Another solution is the WYE-DELTA (triangular delta) starting that consists of connecting the
three phases of the rotor as a star.
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 25
equipment

TRIANGULAR (DELTA)

ILine = 3 * IPhase
VLine = VPhase

Convert it into a star (commuter), lowering the current.

WYE
ILine = IPhase

VLine = 3 * VPhase

Asynchronous motors: there are wound rotor (as the one previously studied) or short-circuited
rotors (known as squirrel cage motors, the coils are short-circuited in the rotor, they have no
brushes and the resistance is placed in the stator for WYE-TRIANGLE (DELTA-WYE) starters.

Synchronous Motor

Stator

Rotor

Direct current
(no cycles/s (Hz)

Alternating current 50– 60 cycles/s (Hz)

Thyristor circuit

Direct current creates a magnetic field in the rotor that has the same speed as the field found
in the stator (slip is 0). This motor must start-up from a total halt, since both fields are very
different (excessive slip). This is why there is a circuit of thyristors that regulates the stator’s
field frequency so that the rotor’s field matches the stator’s speed, starting up as an
asynchronous motor.
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 26
equipment

ANNEX C. FUZZY LOGIC

Human reasoning is based on “fuzzy” concepts, where the membership of an element to a given set is
not binary (yes/no), but gradual instead. We allow a certain tolerance in order to take a decision within
a certain degree of precision.
Set theory and Boolean algebra come together and result in a gradual scale between zero and one
(true and false): Fuzzy curves.

F(X) =1 – EXP {- [ a / ABS (X – c )] ^b }

Fuzzy Level curves

EXAMPLE

ACTUATION FUZZY CURVES

EXAMPLE

F(X) =1 – EXP {- [ a / ABS (X – c )] ^b }

Fuzzy term FL SET a b c
Abbreviation FCL

Large positive LPOS 0.25 2.5 1

Medium positive MPOS 0.25 2.5 0.7

Small positive SPOS 0.25 2.5 0.4

Zero positive ZPOS 0.10 6.0 0.1

Zero ZERO 0.25 6.0 0.0

Zero negative ZNEG 0.10 6.0 -0.1

Small negative SNEG 0.25 2.5 -0.4

Medium negative MNEG 0.25 2.5 -0.7

Large negative LNEG 0.25 2.5 -1.0

High HIGH 0.5 6.0 1.0

Ok OK 0.6 8.0 0.0

Low LOW 0.5 6.0 -1.0

 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 27
equipment

X has rationalized values between –1 and +1

Rationalized
Variable
X
X =1
+1
a  a3

a4  a3

a1 a2 X =0 a3 a4
0 a
Physical variable
a  a2
 (Process)
a 2  a1
-1
X =-1

Example:

If low(a) then LPOS (c)

If low(b) then SPOS (c)
If High(b) then LNEG (c)
If ok(a) then ZPOS (c)

In this way, we can see what

the outcome will be on (c).
 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 28
equipment

ANNEX D. NEURONAL NETWORKS

 Process’ Diagnostic Handbook Update: Nov-04
Chapter VI: General
services and auxiliary Code DP-002 Page 29
equipment

ANNEX E. PID LOOP CONTROL.

Example: Flow Control by adjusting the rpm of the I.D. fan.

SET-POINT Error (t) = Error (t)

Control Equation
+ Desired flow – Output signal(t) = G(t). Input Flow (t)
Desired flow Measured flow (t)
G(t)= (see the following table)

Output
- signal (t)

rpm

PROCESS

Measured flow (t)

Signal measurement

PID PROPORTIONAL INTEGRAL D ERIVATIVE

G(t ) = b + kc·Error(t) + Kc + Kc · T D · t · Error (t)

Relationship between It measures the actual
output and input when the error and only inferes the
error is zero. first strike that is close to
b=rpm/flow
the set-point.
Error
P pure
0 P pure
63%
time
t[s]
Pure proportional control
 never reaches a zero
error, it keeps a
=time constant (sec). It constant error (offset).
is the time that the
output takes for reaching
the 63.2% of the setpoint.
K monitors past error and
Kc   e   t
  t 1
where: K is the
proportional gain. It
Sec. For stabilization
r serves as an output
 amplifier that responds
4
to changes in the input.
Q =dead time (sec).
It is the time the process
takes for changing the
output when there’s a
An example is the change at the input.
temperature gauge Example: a control loop
with a signal located far
away from the actuator.
 Error (t )
Ti  t
It monitors past error. It is It foresees error (predicts
very aggressive since every it according to the slope
Ti (integral time) in of error-time)
seconds there will be
1,2,…n enhancements of
the magnitude of the
proportional error E(t)
offset (kError(t)). It is reset every
x “strikes”. E2
E1 T D = t - t2
I pure
0 t1 t2 t
Derivative time TD is the time
for prediction. Therefore,
proportional control monitors
the actual error, integral control
Integral error manages to
elliminate the offset of the
derivative control estimates the
error that will occur after a
proporcional control, by
certain amount of time.
building a a slope
TD.
0
PID
PI
P pure 0
Note: Fast loops...PI, slow
loops...PD. PID controllers
can’t have a large TI and TD
altogether.