PSY Systems: New control system for 15 ton gas fired melting furnace
August 2012System Integration & Control Systems Design
Zimalco produces in-house workable aluminium products from raw scrap of all shapes and forms. The transformation of these products requires large amounts of heat, after a feasibility study the company chose gas as the most economical option. The furnace configuration is based on dual burners with all the safety systems and interlocks to meet the latest ISO specifications.
Aluminium smelting.
The control system is based on the ABB AC500 PLC and HMI. To comply with ISO 138 49-1, additional ABB Jokab emergency stop equipment is incorporated and to comply with gas standards, double valve proofing on the main feed and flame relay pre-burners were also integrated into the controls.
Control philosophy
PSY Systems designed a user-friendly operator interface, offering clear status and control information, incorporating gas proofing, low fire risk and modulating operations. The control philosophy is one of safety first, so the Jokab emergency stop system inputs must always be present and the system resets at the control panel door.
In the ‘Low Fire Mode’, on initial start with the furnace door open, the blower will run at maximum levels to purge the furnace. Once the purge time has elapsed at the required pressure, the system will automatically perform a gas leakage sequence for double valve proofing. Once the proofing is acceptable, the flame relays are enabled and ignition and gas flow is controlled to the burners. If no flame is detected, the system will set off an alarm and initiate a shut down.
‘Burn Mode’ is enabled from the ‘Low Fire Mode’ and works in conjunction with the furnace door. If the door is open, the furnace will operate in ‘Low Fire Mode’, when the door is lowered (via pushbuttons at control panel or the operator’s remote control pendant) the furnace will switch to ‘Burn Mode’ and control at the required temperature set-point.
On final acceptance of the system, the furnace passed all production performance and safety criteria.
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