MULTICOR-K....

Feed System
Safety concept
Safety Instructions
BV-H2021GB
Copyright:

All rights reserved. No part of this documentation may be reprodu-

ced by any means without the prior permission of SCHENCK
PROCESS GmbH, given in writing.
Subject to change without prior notice.

Copyright © 1997
SCHENCK PROCESS GmbH, D-64273 Darmstadt

Sales: Tel.: +49 (0)6151 32-1028,

Email: sales2.process@csd.de

Service: 24 h Tel. +49 (0)172 650 1700

Fax: +49 (0)6151 32-1370
Email: service3.process@csd.de

SCHENCK PROCESS GmbH -

a Corporate Division of CARL SCHENCK AG
CONTENTS
1. Safety concept of the feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. Notes on design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. MULTICOR-K with MULTICELL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3. MULTICOR-K160 with MULTICELL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4. MULTICOR-K with silo discharge agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1. Qualification of skilled personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2. Qualification of the operating personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3. System check after a pulverized coal explosion or fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Use as originally intended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1. General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2. Silo discharge pulse ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3. Smooth-start control of MULTICOR-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4. Schematic drawing of a MULTICOR-K feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5. COMMISSIONING - NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6. Disturbed operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7. Terminating the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SAFETY INSTRUCTIONS for MULTICOR-K BV-H2021GB/749 I1

 Schenck Process GmbH, Darmstadt
1. Feed System Safety Concept 1.1. Notes on design

1. Feed System Safety Concept

As a general rule, the feeding system is installed under pulverized
coal bins equipped with devices to reduce the explosion pressure
to 3 bars or having a 10 bars explosion-pressure-proof design.
On the following pages, the safety concept of the MULTICOR®-K
feed system for pulverized coal is described with examples.

1.1. Notes on design

The electrical equipment of the units are designed for use in
the dust explosion zone 11 in accordance with the VDE 0165.
– Under normal operating conditions, the drive motors of the
units maintain the specified temperature difference to the
glow and inflammation temperature of the pulverized coal
since there are sufficient power reserves.
– In case of fault, they are switched off by a thermal excess-
current circuit-breaker or the frequency converter.
– The motor protection rating is at least IP 54.
The unit has a 10 bars explosion-pressure-proof design in ac-
cordance with VDI guideline VDI 2263 sheet 3.
The MULTICELL horizontal starfeeder has been subjected to a
test by DMT (German association for coal and steel technolo-
gy), which proved its resistance to spark penetration and to an
explosion pressure of 10 bars.
Since the dust concentrations are always high in the interior of
the units (dust explosion zone 10), the unit volumes are inten-
tionally small in order not to support explosions.
Under nominal operating conditions, the unit components do
not generate sparks nor lead to raised temperatures. Derivati-
on of electrostatic charges is effected by protective earthing in
accordance with the corresponding regulations.
The unit configurations described in the following subsections
1.2 to 1.4 are example solutions. For individual orders, please
refer to the pertaining dimensioned drawings and planning
documentation.

SAFETY INSTRUCTIONS for MULTICOR-K BV-H2021GB/749 1

 Schenck Process GmbH, Darmstadt
1.2. MULTICOR-K with MULTICELL 1. Feed System Safety Concept

1.2. MULTICOR-K with MULTICELL

This design is used in areas
which are under the pressure
of the pneumatic pulverized
coal conveyor to the burner.
In the basic design, the forces
resulting from the conveying
pressure, its pressure variati-
ons and the silo displacement
≤5mm, (displacement caused
by difference between empty
and full weight of silo) are ab-
sorbed by a compensator.
A pressure compensation as
shown in the figure may be
supplied as an option. In this
case, the forces will not affect
the measuring accuracy of the
silo weight measuring device.

The MULTICELL unit feeds the

pulverized coal speed-control-
led into the MULTICOR unit.
The mass flow of the pulveri-
zed coal is supported by a
stainless steel lining and ventila-
tion nozzles in the silo outlet
area. The stainless steel coa-
ting must reach to half the cone
height, at least to a ∅ of 3 m at
a wall inclination of ≤20°
against the vertical. The requi-
red number of ventilation
nozzles is determined for each
individual order in accordance with the flow properties of the pulve-
rized coal.
Important operating notes!!
The air bearing of the MULTICOR-K unit must permanently
be supplied with air, even during a system standstill. The com-
pressed air supply may only be switched off before a system
standstill, if
– the silo shut-off gate has been closed,
– MULTICELL and MULTICOR-K have been emptied; i. e.
there is no pulverized coal left within them,
– the conveyor route of the feeding system is unpressurized,
i.e. it is under atmospheric pressure (no furnace return air).
To protect the measuring gear, MULTICOR-K may only be swit-
ched on with the smooth-start control system properly adjusted.

2 BV-H2021GB/749 SAFETY INSTRUCTIONS for MULTICOR-K

 Schenck Process GmbH, Darmstadt
1. Feed System Safety Concept 1.2. MULTICOR-K with MULTICELL

If MULTICOR-K is in no-motion state, ensure that feed line re-

turn pressure is totally locked off to protect air bearing from
being damaged by return flow.
With MULTICOR-K, this can be done by a shut-off gate moun-
ted right before the kiln.
With multiple MULTICOR-K systems, lock-off is to be provided
directly below MULTICOR-K (e.g. by using a ball cock).

SAFETY INSTRUCTIONS for MULTICOR-K BV-H2021GB/749 3

 Schenck Process GmbH, Darmstadt
1.3. MULTICOR-K160 with MULTICELL 1. Feed System Safety Concept

1.3. MULTICOR-K160 with MULTICELL

The design MULTICOR-K160 is used

for pulverized coal feeding in unpres-
surized areas, i. e. in areas under at-
mospheric pressure, e. g. ahead of
pulverized coal pumps.

The return air of the pulverized coal

pump is lead into the atmosphere as
pure air via a pressure filter on the
pump extension hopper.
For this reason, the air pressure varia-
tion at the MULTICOR-K outlet may
not exceed the filter pressure diffe-
rence specified in the drawing.
Thus, air pressure variations cannot
affect the measuring accuracy of MUL-
TICOR-K160 nor that of the silo
weight measuring device.

An admissible silo displacement

fy=5mm, which may be caused by the
difference between the full silo weight
and the empty silo weight, is compen-
sated by a compensator. The compen-
sator can also compensate silo
displacements up to 30mm, in this
case, however, measuring errors by
the silo weight measuring device may
arise.

The starfeeder - in the drawing type

MULTICELL - feeds the pulverized
coal speed-controlled to the MULTI-
COR unit.

The mass flow of the pulverized coal is supported by a stainless

steel lining and ventilation nozzles in the silo outlet area. The stain-
less steel coating must reach to half the cone height, at least to a
∅ of 3 m at a wall inclination of ≤20° against the vertical. The requi-
red number of ventilation nozzles is determined for each individual
order in accordance with the flow properties of the pulverized coal.

Instead of the MULTICELL unit, it is also possible to use an appro-

priate feed screw with explosion-pressure-proof design.

4 BV-H2021GB/749 SAFETY INSTRUCTIONS for MULTICOR-K

 Schenck Process GmbH, Darmstadt
1. Feed System Safety Concept 1.4. MULTICOR-K with silo discharge agitator

1.4. MULTICOR-K with silo discharge agitator

This design is used for pulverized
coal feeding in areas which are un-
der the pressure of the pneumatic
pulverized coal conveyor to the bur-
ner.
In the basic version, the forces re-
sulting from the conveying pressu-
re, its pressure variations and the
silo displacement fy≤5mm, (caused
by the difference between full and
empty silo weight) are absorbed by
a compensator.
A pressure compensator as shown
in the drawing may be supplied as
an option. In this case, the forces
will not affect the measuring accu-
racy of the silo weight measuring
device.

The silo discharge agitator trans-

ports the pulverized coal into the
pipeline to the MULTICELL unit.
This unit feeds the pulverized coal
speed-controlled into the MULTI-
COR unit.

The mass flow of the pulverized

coal is supported by a stainless
steel lining and ventilation nozzles
in the silo outlet area. The stainless
steel coating must reach to half the
cone height, at least to a ∅ of 3 m
at a wall inclination of ≤20° against
the vertical. The required number of ventilation nozzles is deter-
mined for each individual order in accordance with the flow proper-
ties of the pulverized coal.
Important operating notes!!
The air bearing of the MULTICOR-K unit must permanently
be supplied with air, even during a system standstill. The com-
pressed air supply may only be switched off before a system
standstill, if
– the silo shut-off gate has been closed,
– MULTICELL and MULTICOR-K have been emptied, i. e. there
is no pulverized coal left within them,
– the conveyor route of the feeding system is unpressurized, i.e.
it is under atmospheric pressure (no furnace return air).
To protect the measuring gear, MULTICOR-K may only be swit-
ched on with the smooth-start control system properly adjusted.

SAFETY INSTRUCTIONS for MULTICOR-K BV-H2021GB/749 5

 Schenck Process GmbH, Darmstadt
2.3. System check after a pulverized coal explosion or fire 2. Safety instructions

2. Safety instructions
2.1. Qualification of skilled personnel

Only qualified, trained personnel which has been instructed corre-

spondingly may carry out the maintenance work described in the
operating manuals.
The qualified personnel must be familiar with locksmith’s work
and safety-conscious handling of parts with the crane.
CAUTION IN CASE OF WELDING WORK!!
– Installation welding on explosion-pressure-proof components
may only be carried out by qualified welders,
– the quality of the weld seams is to be assured in accordance
with
DIN EN 25 817/09.92, group C (mean),
– To protect the load cell, connect the negative pole directly to
the welding point.
Measurement work may only be performed by qualified meas-
urement and control engineers.
The qualified personnel must be familiar with the local safety
and accident prevention rules and observe them.

2.2. Qualification of the operating personnel

Only trained and instructed personnel may operate the feed sy-
stem in accordance with the following instructions.
@BLICKFANG_1 = Since the feed system forms part of an over-
all system (plant), the operator is obliged to add such instructions
to these operating instructions which are valid for the entire sy-
stem, and to make them available to the operating personnel.
The operating personnel must be familiar with the in-house
safety and accident prevention rules of the company and obser-
ve them.

2.3. System check after a pulverized coal explosion or fire

After a pulverized coal explosion or after a fire in the area of
the feed system or after smoulder spots have been passed
through the feed system, all units of the feed system must be
subjected to a checking procedure in accordance with the cor-
responding notes and instructions in their manuals.
As a general rule, flexible connection pieces and compensa-
tors are to be replaced.

6 BV-H2021GB/749 SAFETY INSTRUCTIONS for MULTICOR-K

 Schenck Process GmbH, Darmstadt
3. Use as originally intended 3.1. General instructions

3. Use as originally intended

3.1. General instructions
Your MULTICOR-K.... feed system is designed for measuring
the feed rate of pulverized coal in accordance with the Coriolis
measuring principle.
The feed system must be operated in keeping with the order-
specific TECHNICAL DATA, which form part of the operating
instructions.
During commissioning, the feed system with the electronic eva-
luation system must be calibrated for the order-specific materi-
al in accordance with the TECHNICAL DATA of the system.
For safety reasons, the feed system must not go into operation
until it has been installed into an enclosed conveyor route in
keeping with the order-specific INSTALLATION MANUAL.
If the customer’s process and pulverized coal data deviate
from the order-specific TECHNICAL DATA, we would strongly
recommend to consult SCHENCK Process in order to avoid da-
mage.
The feed system is not appropriate for passing
– foreign substances with an edge measure ≥40mm and
– threads such as hemp fibres.
The feed system operates hermetically sealed.
To avoid pulverized coal leakage and the loss of explosion-
pressure resistance , the screws, in particular at the flanged
connections, must never be loose. The screws must be tighte-
ned with the specified tightening torque.
Any pulverized coal leakage at the shaft leadthroughs of the
silo discharge agitator , MULTICELL , feed screw and / or verti-
cal starfeeder must be remedied without delay to prevent spon-
taneous ignition.
Maintenance work must always be carried out during standstill
of the unit in accordance with the operating and revision manu-
als of the units.

CAUTION!! Important operating note:

The service life of the air bearing for the measuring wheel shaft
in MULTICOR-K units largely depends on the permanent
availability of compressed air. Therefore, the compressed air
supply must always be ensured, even during a standstill in the
process, by appropriate measures.

SAFETY INSTRUCTIONS for MULTICOR-K BV-H2021GB/749 7

 Schenck Process GmbH, Darmstadt
3.3. Smooth-start control of MULTICOR-K 3. Use as originally intended

3.2. Silo discharge pulse ventilation

The silo discharge pulse ventilation implemented in accordance
with the planning documentation supports the necessary mass
flow of the pulverized coal in the area of the silo cone.
It is based on circular lines supplying compressed air to the ventila-
tion nozzles. The air supply is pulsed through solenoid valves. The
pulse to interpulse period ratio is to be entered in the electronic
evaluation system.
The nozzle-valve unit shown in the drawing below demonstrates
the function of the outcoming air (in direction of arrow) below the
rubber cap.

CAUTION!
Never set the compressed-air service unit to a pressure > 2
bars, since this could cause the rubber caps to fall from the
nozzles, and, as a consequence, the function of the solenoid
valve would be impeded by pulverized coal.
The customer must ensure that, in the event of a CO alarm,
the compressed air is automatically switched to silo inerting.

3.3. Smooth-start control of MULTICOR-K

As a general rule, before the MULTICOR-K is commissioned for
the first time by instructed measuring and control engineers, the
smooth-start control system in the control cabinet must be set to
the following values while the power supply is switched on :
Set start time tE to maximum value.
Set start voltage (phase - phase) via potentiometer “starting
torque” ME to 0.7 times the nominal motor voltage and measu-
re it with the moving coil instrument. Check whether the measu-
ring motor slowly starts accelerating at this voltage after
switch-on.
Disconnect motor and set start time to approx. 5 s. Check with
the help of light-emitting diodes.
Set deceleration torque MA and deceleration time tA to their re-
spective minimum values.

8 BV-H2021GB/749 SAFETY INSTRUCTIONS for MULTICOR-K

 Schenck Process GmbH, Darmstadt
3. Use as originally intended 3.4. Schematic drawing of a MULTICOR-K feed system

3.4. Schematic drawing of a MULTICOR-K feed system

The following drawing shows an example demonstrating how a
process control system works: Silo - MULTCELL - MULTICOR-K -
pneumatic pulverized coal transport to burner.

SAFETY INSTRUCTIONS for MULTICOR-K BV-H2021GB/749 9

 Schenck Process GmbH, Darmstadt
3.5. COMMISSIONING - NORMAL OPERATION 3. Use as originally intended

3.5. COMMISSIONING - NORMAL OPERATION

The following flow sheet shows the procedure for normal operation.

Min. silo level, see order-specific planning documentation

10 BV-H2021GB/749 SAFETY INSTRUCTIONS for MULTICOR-K

 Schenck Process GmbH, Darmstadt
3. Use as originally intended 3.6. Disturbed operation

3.6. Disturbed operation

This is a disturbance caused by CO alarm which requires the re-
moval of smouldering spots from the pulverized coal.
In case of a pulverized coal explosion in the silo, penetration into
the feed system is avoided by MULTICELL’s resistance to spark
penetration.

SAFETY INSTRUCTIONS for MULTICOR-K BV-H2021GB/749 11

 Schenck Process GmbH, Darmstadt
3.7. Terminating the operation 3. Use as originally intended

3.7. Terminating the operation

If the silo remains filled, automatic silo inerting in case of CO alarm
must be ensured.

12 BV-H2021GB/749 SAFETY INSTRUCTIONS for MULTICOR-K

 Schenck Process GmbH, Darmstadt