Summary
The control panels of two ASFLOC®-brand Flocculant Preparation Units, models EPFCA25/100/304/440 and EPFCL25/50/304/440, were upgraded and modernized through the complete replacement of the operating cabinets and the addition of power panels. Furthermore, the flow meter and powder sensor of the first unit were replaced.
Problem
The Flocculant Preparation Units (FPU) operated through a control panel with obsolete components, which created operation difficulties, spare parts replacement and maintenance.
One of the main issues in the FPU model EPFCA/25/100/304/440 involved the VFD, the flow meter and the dust sensor. Also, the existing operating interface had significant limitations, as the system control was carried out through buttons and a low-visibility screen, making the equipment difficult for operators to handle.
In the FPU model EPFCL25/50/304/440, the main issue was the touchscreen which was obsolete and had no available spare parts, making operation and parameter adjustment almost impossible.
It is worth noting that the FPU’s maintained continuous and stable operation for years without significant failures until their upgrade became necessary.
Solutions and Results
The control panels for the Flocculant Preparation Units, both the alternating-chamber and in-line chamber types, were designed, built and integrated, for the complete replacement of the cabinets and their electrical components.
The project included:
- A completely new and updated control panel with a Siemens PLC and touchscreen
- The addition of a power panel
And, for the EPFCA25/100/304/440:
- The replacement of the dust presence sensor for the polymer storage
hopper - Change of the water flow meter
The original operating logic of both units was kept, including the automatic sequences and alarms already in place.
Commissioning and operator training were also carried out, covering touchscreen navigation, concentration adjustment, parameter review, alarm interpretation and general use of the new control panel.
Benefits
- Complete modernization of the control system
- New PLC with the option to connect to the clients control room for equipment monitoring
- Greater operational reliability
- Availability of spare parts
- Easier operation for the personnel
- Better alarm display and management
- Reduced operator intervention
