Weighfeeders

Learning objectives
• Participants will learn the basics of weighfeeders
• Importance of maintenance

2
P19 Weighfeeders
Agenda
• Safety in weighfeeders maintenance
• Principle of operation
• Failure modes
• Maintenance program for weighfeeders
• Conclusion

3
P19 Weighfeeders
Safety First
When working with weighfeeders ..
• Weighfeeders are operating under dangerous voltage
levels both in the field and in the panel!
• Weighfeeders may start anytime, observe proper
lock out-tag out procedure before doing any
maintenance

4
P19 Weighfeeders
 Weighfeeder maintenance
• Maintaining the accuracy but avoiding too frequent
calibration, correction and adjustment of the dosing
equipment

Feeder Error Calibrate

Calibrate
% Calibrate

Calibrate
Calibrate
Calibrate

1 Month

5
P19 Weighfeeders
Principle of operation: Evolution
Oldest Type: Belt weighfeeder
• Principle has remained the same since 40 years
 Weight of material on the belt is measured
 Speed of belt is measured
 Speed of belt is controlled according to set point

6
P19 Weighfeeders
 Principle of Operation: Evolution
1960’s and 1970’s 1980’s 1990’s –
earlier

Speed Analog Tachogenerator

tachogenerator Proximity sensor
Proximity Speed encoder
Measurement Tachogenerator sensorcounter
/Pulse /Pulse
Potentiometer counter
Weight Potentiometer (or
(or Variable
Variable Load Cell / Strain
Measurement Potentiometer
nothing)
nothing) (or Variable
Inductance
Inductance Load Cell / Strain Gauge
Gauge
nothing) Inductance
Motor Control Thyratron vacuum Solid
Solid State
State SCR
SCR // SCR – DC Motor
Thyratron vacuum
tube Solid State
magnetic
magnetic SCR /
clutch
clutch SCR – DC Motor Freq Converter –
tube magnetic clutch AC Motor
Signal Analog, Discrete Analog,
Analog, Integrated
Integrated Digital, Integrated
Processing Analog, Discrete
Transistors Analog,
Circuits Integrated
Circuits Digital, Integrated
Circuits Digital,
Transistors Circuits Circuits Programmable
Controllers
Mechanical Belt
Belt Conveyor
BeltPrinciple
Conveyor Conveyor Principle (roller,pulley,belt)
(roller,pulley,belt)
Principle Belt Conveyor Principle (roller,pulley,belt)
System (roller,pulley,belt)

7
P19 Weighfeeders
 Other types of dosing equipment

• Rotor scale feeder • Impact flow feeder • Coriolis feeder

8
P19 Weighfeeders
 Principle of operation: Components

• Mechanical components: gearbox, pulley, roller, skirt, belt, etc

• Electrical (Power) components: Motor, speed controller, breaker
• Instruments / Sensors: Load cell, speed sensor, drift switch
• Control (computer) components: Controller, interface, indicator

90.0 T/H 1 2 3
ESC

Ent
4 5 6
De
l
7 8 9
Span Zero
>
* 0 #
On Of
f

9
P19 Weighfeeders
 Common failures and consequence
• Materials getting stuck: inaccuracy, belt damage
• Belt misalignment, incorrect tension, roller failure: inaccuracy, stoppage
• Instrument failure: inaccuracy, stoppage
• Motor (grease, carbon brush) and VSD failures: stoppage

90.0 T/H 1 2 3
ESC

Ent
4 5 6
De
l
7 8 9
Span Zero
>
* 0 #
On Of
f

10
P19 Weighfeeders
 Maintenance: Who‘s doing it?

• Mechanics?
• Electrician?

• Instrument technician?
• Automation personnel?
• Production personnel?

11
P19 Weighfeeders
 Condition-based maintenance
Calibration: How do you know it’s time to calibrate?

• Laboratory result: Accurate but takes at least 1 shift and large error
in order to be noticeable

• Process parameters: A good operator can immediately determine if

the feeders are inaccurate

• Alarms, Trends, and diagnostics messages

• Material balance at the end of the month

Unnecessary frequent calibration should be avoided!

12
P19 Weighfeeders
Maintenance: Calibration

Calibration: Who decides when to perform an

unscheduled calibration?

• Operator ?

• Laboratory supervisor?

• Production supervisor?

• Maintenance supervisor

13
P19 Weighfeeders
 Maintenance: Calibration
What is the limit of error before a calibration or correction
check is done ?
Up to 3% Normal, actual value will depend on the technology and
brand
between 3-10 % Process (Operator) should be informed to make necessary
process offset, maintenance should investigate probable
cause of error, (TIS can distribute or backsolve the
correction at the end of the month)
More than 10 % Error already unacceptable, should be corrected
immediately

Dosing equipment calibration that drifts more than once in 3 months

means something else is causing the problem, should be corrected
before doing another calibration !

14
P19 Weighfeeders
 Calibration Methods

Test weight method

  Volumetric measurement

Loss-in-weight  Drop test (Truck loading)

15
P19 Weighfeeders
Weighfeeders: What plant people think . . .

• The Mechanics think that weighfeeders are just belt

conveyors
• The Electrician/Instrument technician think that poorly
maintained weighfeeders can function properly by just
programming and calibration
• The Production people think that weighfeeders can still
be accurate no matter what kind of material they feed or
no matter how dirty the machines are
• Management would expect that the weighfeeders will be
100 % available and have 0% error in measurement

16
P19 Weighfeeders
Conclusion
• Weighfeeders maintenance is everybody’s business
• Weighfeeders maintenance is all about the right sense on
how and how often calibration is required

17
P19 Weighfeeders
Thanks

18
P19 Weighfeeders
Support Slides (Need not be printed)

19
P19 Weighfeeders
Calibration: Test Weight Method

20
P19 Weighfeeders
Calibration: Test Weight Method
• Zeroing or Taring
0.40 %
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
Span Zero >
* 0 #

Running empty
weighfeeder

21
P19 Weighfeeders
Calibration: Test Weight Method
• Zeroing or Taring
0.00 %
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
Span Zero >
* 0 #

Running empty
weighfeeder

22
P19 Weighfeeders
Calibration: Test Weight Method
• Span Adjustment
0.00 %
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
Span Zero >
* 0 #

Running empty
weighfeeder

23
P19 Weighfeeders
Calibration: Test Weight Method
• Span Adjustment
90.0 %
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
Span Zero >
* 0 #

Running empty
weighfeeder

Test
weight

24
P19 Weighfeeders
Calibration: Test Weight Method
• Span Adjustment
100.0 %
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
Span Zero >
* 0 #

Running empty
weighfeeder

Test
weight

25
P19 Weighfeeders
Calibration: Volumetric Method

26
P19 Weighfeeders
 Calibration: Volumetric Method
99.8 T/H
1 2 3
ESC

Ent
4 5 6
Del
7 8 9
Span Zero >
* 0 #

Step 1: Record the parameters as indicated in the controller

 Actual Feed rate, t/h

 Belt Speed or Drive Speed, m/s

 Weight measured on the platform, kg/ m

27
P19 Weighfeeders
 Calibration: Volumetric Method

Time for 1 belt circuit

Step 2: Measure the actual Belt Speed

 Two methods can be used:

- Measuring the time to complete 1 belt circuit, actual length of belt

should be known (appropriate for short belts)
- measuring the speed of the drive pulley, the diameter of the
pulley should be known ( for long belts)
- Result should be length per time, ie. meter / second
28
P19 Weighfeeders
 Calibration: Volumetric Method

length

Step 3: Weigh the material on the belt

 Measure the linear weight of the material
 The length has to be recorded

 Result should be weight per linear length, ie. kg. / m

29
P19 Weighfeeders
 Calibration: Volumetric Method

length

Step 4: Calculate and compare Feedrate

Feed Rate = Linear Weight x BeltSpeed

Compare the result with the indicated feed rate

30
P19 Weighfeeders
Calibration: Loss in Weight method

31
P19 Weighfeeders
Calibration: Loss in Weight method

099.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

005.5
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

32
P19 Weighfeeders
Calibration: Loss in Weight method
Feeding Stopped
_____- ____ =

099.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - _____ =

005.5
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

33
P19 Weighfeeders
Calibration: Loss in Weight method
Feeding Stopped
____ - ____ =

096.7
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - ____ =

008.9
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

34
P19 Weighfeeders
Calibration: Loss in Weight method

____ - ____ =

093.5
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - ____ =

011.6
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

35
P19 Weighfeeders
Calibration: Loss in Weight method

____ - ____ =

090.3
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - ____ =

014.1
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

36
P19 Weighfeeders
Calibration: Loss in Weight method

____ - ____ =

087.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - ____ =

017.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

37
P19 Weighfeeders
Calibration: Loss in Weight method
Feeding Empty
84.6 - ____ =
Record Initial Weight
084.6
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

Record Initial Reading

_____ - 20.7 =

020.7
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

38
P19 Weighfeeders
Calibration: Loss in Weight method
Feeding Empty
84.6 - ____ =
Record Initial Weight
081.8
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

Record Initial Reading

_____ - 20.7 =

023.5
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

39
P19 Weighfeeders
Calibration: Loss in Weight method
Bin Discharging
84.6 - ____ =

079.2
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - 20.7 =

026.1
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

40
P19 Weighfeeders
Calibration: Loss in Weight method
Bin Discharging
84.6 - ____ =

076.3
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - 20.7 =

029.3
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

41
P19 Weighfeeders
Calibration: Loss in Weight method

84.6 - ____ =

073.7
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - 20.7 =

031.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

42
P19 Weighfeeders
Calibration: Loss in Weight method

84.6 - ____ =

070.5
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - 20.7 =

034.6
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

43
P19 Weighfeeders
Calibration: Loss in Weight method

84.6 - ____ =

067.8
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - 20.7 =

037.6
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

44
P19 Weighfeeders
Calibration: Loss in Weight method
Bin Near Critical Lev.
84.6 - ____ =

064.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

_____ - 20.7 =

040.5
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

45
P19 Weighfeeders
 Calibration: Loss in Weight method
Process Complete
84.6 - 61.1=
Record Final Weight
061.1
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

Record Final Reading

43.4 - 20.7 =

043.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Click for Totalizer

Next Page
46
P19 Weighfeeders
Calibration: Loss in Weight method
Process Complete
84.6 - 61.1= 23.5 T
Calculate Net
061.1
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Bin Weight

Calculate Net

43.4 - 20.7 = 22.7 T

043.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer
The difference will be considered on the Span value
47
P19 Weighfeeders
Calibration: Drop Test Method

48
P19 Weighfeeders
Calibration: Drop Test Method

061.1
1 2 3
ESC

Ent
4 5 6
Del
7 8 9
>
* 0 #

Totalizer

043.4
ESC
1 2 3
Ent
4 5 6
Del
7 8 9
>
* 0 #

Truck Scale

49
P19 Weighfeeders
 50
P19 Weighfeeders