Referentie 3 juni 2022

Explosieve vulling - explosieve stoffen veilig afvullen

Bovenspiegel, onderspongat, onderspiegel - zo klinkt het als insiders over het afvullen van vaten praten. Feige FILLING GmbH uit het Noord-Duitse Bad Oldesloe is wereldwijd toonaangevend op het gebied van het afvullen van alle vloeibare media. Aangezien de systemen van Feige FILLING vooral in explosiegevaarlijke omgevingen worden gebruikt, ontwikkelt WAGO toegelaten Ex-oplossingen voor de ATEX-categorie 1. Om aan de hiervoor geldende eisen te voldoen, maakt Feige FILLING op I/O-niveau gebruik van het universele WAGO I/O-SYSTEM 750.

Ze zijn groen, grijs of rood, en soms ook blauw of zwart – en hebben altijd eenzelfde inhoud van 200 liter. Internationaal genormeerde stalen vaten worden wereldwijd gebruikt om vloeibare producten zoals olie of chemische stoffen in een stabiele verpakking te kunnen vervoeren. Voor deze verpakkingen heeft Feige FILLING een gebruiksklare serie ontwikkeld die niet alleen het afvullen zelf, maar ook de complete handling inclusief materiaalstroom omhelst. "Onze klanten willen hun producten afvullen en verschepen. Met de vraag hoe de vaten onder de vulklep terechtkomen of later op de palletten geplaatst worden, willen ze zich niet bezighouden", aldus Martina Thomsen, hoofd marketing bij Feige FILLING. Ze benadrukt dat vaten slechts één verpakkingssoort zijn waarvoor Feige FILLING geschikte afvulsystemen levert. "Het assortiment reikt van IBC's met een inhoud van één kubieke meter over vaten tot en met kleine verpakkingen zoals de welbekende verfemmer bij de bouwmarkt."

Voordelen van het WAGO-I/O-SYSTEM 750:

Veilig afvullen - ook in Ex-omgevingen

Zo verschillend de verpakkingen, zo variabel de inhoud - en die wordt soms gekenmerkt door eigenschappen die het afvulproces uitermate veeleisend maken: hoogviskeus, schuimend, ontvlambaar of explosief. De vulsystemen van Feige FILLING moeten dan ook voldoen aan speciale eisen, bijvoorbeeld aan die van de ATEX-richtlijn. Deze richtlijn bepaalt de criteria voor de bouw en het gebruik van machines en installaties die in explosiegevaarlijke omgevingen worden gebruikt. Ongeveer de helft van alle afvulsystemen verlaat de fabriek in het Duitse Bad Oldesloe met een toelating voor zone 1. De Ex-beveiliging behoort tot de dagelijkse gang van zaken bij Feige FILLING. Hiermee reeds tijdens de projectering rekening houden, kenmerkt Feige FILLING: "We benaderen het proces met de in- en uitgangspunten zo nauwkeurig mogelijk, dus daar waar de signalen gegenereerd en uitgegeven worden", legt bijvoorbeeld Jörn Czysch, ingenieur voor automatiseringstechniek bij Feige FILLING, uit, "omdat we iedere onnodige bedrading willen vermijden."

I/O-niveau direct bij het proces

Voor de automatisering van het afvulproces maakt Feige FILLING daarom gebruik van intrinsiek veilige I/O-modules van het remote I/O-SYSTEM 750 van WAGO. De technologie kan dichtbij het eigenlijke afvulproces worden toegepast, en bundelt er aan ingangszijde overwegend de initiatoren en de foto-elektrische beveiligingen en aan uitgangszijde de magneetkleppen en de pneumatische kleppen. Door de besturingstechniek dicht bij het proces toe te passen, kan Feige FILLING bij de installatietechniek op ruimte én tijd besparen. In tegenstelling tot bij de stervormige bedrading hoeft Feige FILLING niet per se rekening te houden met de positie van de schakelkast in de productie. Dit verlaagt de kosten in de machinebouw. Bovendien kunnen installaties eenvoudiger modulair ontwikkeld worden. Een ander belangrijk voordeel van de toepassing van de besturingstechniek in de buurt van het proces is de Ex-beveiliging: bij installaties met intrinsiek veilige signalen in Ex-omgevingen moet de energie altijd beperkt zijn. Hiervoor zijn decentrale installaties veel beter geschikt, gewoonweg omdat kortere kabels minder energie opslaan. "Kabels slaan vrij veel energie op. Daarom houden wij ook altijd rekening met de lengte van de kabels", licht Jörn Czysch toe.

Een systeem voor twee toepassingsgebieden

Bij het afvulsysteem voor vaten is de besturingstechniek in een gasdichte schakelkast geïnstalleerd. In de schakelkast is sprake van een lichte overdruk, zodat het binnendringen van explosieve gassen veilig uitgesloten kan worden. Om het systeem direct ter plaatse te kunnen bedienen en bewaken, is een Touch Panel in de deur van de schakelkast geïntegreerd. Het volledige actuator- en sensorsysteem voor het afvullen van de vaten is netjes in de schakelkast geplaatst - zowel voor de Ex-omgeving, bestaande uit het directe afvulbereik in de hermetisch afgesloten cabine, als voor het standaardbereik van het systeem waarop geen speciale ATEX-eisen van toepassing zijn (bijv. de transporttechniek). Voor het aansluiten van de veldapparatuur in de Ex-omgeving van het systeem maakt Feige FILLING gebruik van de intrinsiek veilige modules van het WAGO I/O-SYSTEM 750. Een speciale voedingsmodule is hierbij verantwoordelijk voor de voeding. Deze voedingsmodule zorgt ook voor de Ex i-bewaking van het nageschakelde segment en scheidt het intrinsiek veilige gedeelte van het niet-intrinsiek veilige gedeelte van het WAGO I/O-SYSTEM 750. Voor de machineruimten zonder bijzondere eisen aan de explosiebeveiliging maakt Feige FILLING eveneens gebruik van het I/O-SYSTEM van WAGO – in dit geval echter in de standaarduitvoering.

Hoge mate van beschikbaarheid dankzij standaardisering

Het voordeel: vanuit engineering oogpunt is slechts één oplossing voor de automatisering van het systeem nodig - onafhankelijk van het feit of apparaten in een Ex- of in een niet-Ex-omgeving worden aangesloten. "Wij vinden het belangrijk dat onze systemen niet al te veel van elkaar verschillen", aldus Axel Frank, hoofd automatiseringstechniek bij Feige FILLING. "Als we onze systemen grotendeels standaardiseren, helpt ons dat natuurlijk ook om de kans op een uitval van het systeem tot een minimum te beperken". Aangezien het remote I/O-SYSTEM 750 van WAGO op eenvoudige wijze zowel Ex- als niet-Ex-omgevingen in één systeem afdekt, kan Feige FILLING de automatisering van de systemen altijd functioneel vormgeven, zonder de standaardisering hierbij uit het oog te verliezen.

Altijd gereed voor innovatie

Volgens Jörn Czysch is er nog een belangrijk aspect dat voor de samenwerking met WAGO spreekt: "WAGO heeft de wil om te innoveren. Bij het I/O-SYSTEM 750 ging WAGO altijd een stap verder, en wist ook bij extra eisen een overtuigende oplossing te creëren". De blauwe, intrinsiek veilige I/O-modules voor Ex-omgevingen zijn hiervan een goed voorbeeld: "Die waren er ook niet van begin af aan."

Tekst: Benjamin Böhm | WAGO

Foto: Thorsten Sienk

Productoverzicht

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WAGO in de praktijk

Referenties uit het vakgebied van procestechniek.

Als partner en innovatieleider implementeert WAGO vele interessante projecten. Ontdek onze creatieve en efficiënte oplossingen in het bereik van de procestechniek.

Het tanken van vliegtuigen en automatisering

Eindelijk storingsvrij: de tankwagens op de Braziliaanse luchthavens zijn dankzij de omschakeling op veerklemtechniek van WAGO betrouwbaarder dan ooit.

Automatisering voor pijpleidingen

Tracing systemen voorkomen dat de pijpleidingen bevriezen bij Siberische temperaturen. Hierbij wordt gebruik gemaakt van explosieveilige componenten van WAGO.

Betrouwbare kwaliteit

De eisen die aan de technische uitrusting van schepen worden gesteld zijn extreem hoog. Het I/O-systeem van WAGO voldoet aan alle vereisten.

Uw contactpersoon bij WAGO

Nuttige links

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Meer uit het domein van de procestechniek

Of het nu gaat om modulaire procesautomatisering, explosiebeveiliging, cyber-security of proces 4.0 - WAGO biedt oplossingen voor elke uitdaging in de branche.

Modulaire procesautomatisering

Procesautomatisering van de toekomst

Aanpasbare productieprocessen zijn de sleutel tot flexibiliteit, efficiëntie en lot size 1. Met WAGO kunnen productiemodules individueel en onafhankelijk van de fabrikant worden gecombineerd.

Energiemanagement

Potentieel herkennen en gebruiken

Energiebesparing is goed voor het milieu en voor uw bedrijf. Wie hierbij goed analyseert en handelt, kan duurzaam profiteren. WAGO is uw partner voor effectief energiemanagement.

smartDATA

Intelligente planning voor de intelligente fabriek

De digitalisering van bestel- en productieprocessen is voor ieder bedrijf een geweldige kans. WAGO helpt u alle mogelijkheden in uw voordeel te gebruiken.

Aanbevelingen om verder te lezen

WAGO in andere branches

Automatisering- en contacttechnologie van WAGO is niet alleen vertegenwoordigd in de proces- en productietechniek. Ontdek welke oplossingen WAGO biedt in andere industrieën.

Scheepvaart

Onderweg op het schip van de toekomst

Moderne aandrijftechnologie, koppeling van subsystemen - automatisering en digitalisering zijn standaard op het schip.

Energie

Een industrie in transitie

Moderne automatisering- en digitaliseringstechnologieën creëren communicatieve smart grids.