Référence 11 janvier 2021

Remplissage en toute sécurité de matières explosives

Processus sous niveau, trou sous bonde, processus sur niveau : tels sont certains des termes employés par les experts en remplissage de fûts. L'entreprise Feige FILLING GmbH basée à Bad Oldesloe figure parmi les leaders du marché pour le remplissage de produits fluides. Les installations de Feige FILLING étant principalement exploitées en milieux à risque d'explosion, l'entreprise située dans le Land du Schleswig Holstein a développé des solutions Ex homologuées pour la catégorie ATEX 1. Afin de répondre à ces exigences, Feige FILLING utilise au niveau E/S le système universel E/S 750 de WAGO.

Ils sont verts, gris, rouges, puis bleus ou noirs et ont toujours une capacité de 200 litres. Les fûts métalliques normalisés sur le plan international sont largement utilisés pour placer dans un conditionnement stable des produits fluides comme les huiles ou les produits chimiques. Pour ces emballages, Feige FILLING a conçu une ligne clé en main qui englobe non seulement le processus principal du remplissage mais aussi la manutention complète avec le flux de matière. « Nos clients veulent mettre leurs produits en fût et les expédier ». Ils ne veulent pas s'occuper de la manière dont les fûts arrivent sous la vanne de remplissage ou plus tard sur la palette d'expédition », déclare Martina Thomsen, directrice Marketing, qui précise que les fûts ne sont qu'un type de conditionnement parmi d'autres pour lequel Feige FILLING fournit les installations de remplissage adaptées. « La gamme comprend à la fois des conteneurs IBC d'une capacité d'un mètre cube, des fûts et des petits conteneurs comme les pots de peinture que l'on trouve dans les magasins de bricolage. »

Avantages du système WAGO-I/O-SYSTEM 750 :

Remplissage en toute sécurité – Même en zone Ex

Les emballages sont aussi différents que leur contenu. Parfois, celui-ci présente des propriétés qui rendent le processus de remplissage extrêmement compliqué: le contenu peut être très visqueux, moussant, inflammable voire explosif. Les installations de remplissage de Feige FILLING doivent donc répondre à certaines exigences, comme la directive ATEX. Celle-ci définit les critères pour la fabrication et l'exploitation de machines utilisés dans des zones explosives. Environ la moitié des installations de remplissage quitte Bad Oldesloe avec une homologation pour la zone 1. Dans l'entreprise Feige FILLING, la protection contre les explosions fait partie intégrante de l'activité quotidienne. La prise en compte de la protection contre les explosions dès la phase de conception des installations est une caractéristique de Feige FILLING : « Nous allons au plus près du processus avec les points d'entrée et de sortie – c'est-à-dire là où les signaux se produisent et là où ils sont émis“, explique Jörn Czysch, ingénieur en technique d'automatisation chez Feige FILLING. « En effet, nous voulons éviter tous les câblages inutiles. »

Le niveau E/S directement placé au niveau du processus

Pour l'automatisation du processus de remplissage, Feige FILLING utilise donc des modules E/S à sécurité intrinsèque du système E/S à distance 750 de WAGO. La technique peut être installée au plus près du processus de remplissage et regroupe principalement des initiateurs et des barrières lumineuses côté entrée et des électrovannes et des vannes pneumatiques au niveau des sorties. En plaçant la technologie de commande au plus près du processus, l'entreprise située dans le Schleswig-Holstein réalise un gain de temps et de place pour la technique d'installation. En effet, comparé à un câblage en étoile, l'entreprise a moins besoin de se soucier de l'emplacement de l'armoire électrique dans un environnement de production. Cela permet de réduire les coûts dans la construction mécanique. De plus, les installations peuvent plus facilement être conçues de manière modulaire. Un autre avantage concret de la proximité de la technologie de commande avec le processus concerne la protection contre les risques d'explosion : les installations avec des signaux à sécurité intrinsèque dans les zones à risque d'explosion doivent toujours être limitées en termes d'énergie. Par conséquent, des installations décentralisées sont nettement mieux adaptées, tout simplement parce que des câbles plus courts emmagasinent nettement moins d'énergie. « Les câbles peuvent potentiellement emmagasiner de l'énergie, c'est pourquoi nous gardons toujours un œil attentif sur les longueurs posées », explique l'expert Jörn Czysch.

Un système, deux domaines d'application

Dans l'installation de remplissage de fûts, la technologie de commande est logée dans une armoire de commande étanche aux gaz. Il règne dans celle-ci une légère surpression afin d'exclure tout risque de pénétration de gaz explosifs. L'installation peut ainsi être commandée et surveillée directement sur place, un écran tactile a été intégré dans la porte de son armoire de commande. L'ensemble des capteurs et des actionneurs pour le remplissage des fûts fonctionne à l'intérieur de l'armoire de commande – à la fois ceux pour la zone explosible, c'est-à-dire la zone directe de remplissage à l'intérieur de la cabine fermée hermétiquement et aussi ceux pour la zone standard de l'installation, qui ne présentent pas d'exigences ATEX particulières, comme la technique complète de convoyeurs. Pour la liaison de tous les appareils de terrain se trouvant à l'intérieur de la zone explosible de l'installation, l'entreprise Feige FILLING utilise les modules à sécurité intrinsèque du système E/S WAGO 750. L'approvisionnement est assuré par un module d'alimentation spécial qui surveille aussi l'alimentation du segment Ex i placé en aval et qui sépare la partie à sécurité intrinsèque de la partie à sécurité non intrinsèque du système E/S WAGO 750. Pour les zones de la machine qui ne sont pas soumises à des exigences spéciales concernant la protection contre les explosions, Feige FILLING mise aussi sur le système E/S de WAGO dans sa version standard.

Disponibilité élevée grâce à la standardisation

Avantage : sur le plan de l'ingénierie, une seule solution est utilisée pour l'automatisation de l'installation que les appareils soient raccordés ou non dans une zone explosible ou non explosible. « Nous attachons une grande importance à ce que nos installations diffèrent le moins possible les unes des autres sur le plan de la conception » déclare Axel Frank, responsable Technique d'automatisation chez Feige FILLING. « En standardisant le plus possible l'équipement de nos installations, nous réduisons aussi la probabilité de panne des sous-groupes ». Étant donné que le système E/S à distance 750 de WAGO recouvre à la fois la zone explosive et la zone non explosive dans un même système, Feige FILLING peut procéder à l'automatisation des installations toujours de manière fonctionnelle, sans s'éloigner de l'objectif de standardisation.

Orientation continue vers l'innovation

Un autre argument parle en faveur de la collaboration avec WAGO selon Jörn Czysch : « Nous avons trouvé en WAGO un partenaire résolument tourné vers l'innovation. WAGO a sans cesse proposé des nouveautés avec le système E/S 750 et était à l'écoute quand nous avions des exigences supplémentaires ». Les modules E/S bleus à sécurité intrinsèque pour les milieux à risque d'explosion sont un exemple significatif : « ils n'existaient pas au début ».

Texte : Benjamin Böhm | WAGO

Photo : Thorsten Sienk

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WAGO en pratique

Des références dans le domaine de la technique des procédés industriels

En tant que partenaire et leader de l'innovation, WAGO met en œuvre de nombreux projets intéressants. Découvrez ce que nous pouvons faire pour des solutions créatives et efficaces dans le domaine de la technologie des procédés industriels

Ravitaillement en carburant et automatisation

Enfin sécurisé : les camions-citernes pour avions des aéroports brésiliens sont plus fiables que jamais grâce à la conversion à la technologie à ressort de WAGO.

Automatisation pour pipelines

Les installations de traçage thermique empêchent le givrage des pipelines aux températures sibériennes. Des composants contre les risques d'explosion de WAGO sont utilisés.

Qualité absolument fiable

Les exigences en matière d'équipement technique des navires sont extrêmement élevées. Le système d'E/S de WAGO les remplit toutes.

Votre interlocuteur chez WAGO

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Davantage dans le domaine de la technologie des procédés

Qu'il s'agisse d'automatisation de processus modulaire, de protection contre les explosions, de cybersécurité ou de Process 4.0 - WAGO propose des solutions pour tous les défis de l'industrie.

Une automatisation des processus du futur

Des processus de production qui s'adaptent sont la clé de la flexibilité, de l'efficacité et des volumes 1. Avec WAGO, les modules de production peuvent être combinés individuellement et indépendamment du fabricant.

Reconnaître et utiliser les potentiels

L'économie d'énergie est une bonne chose pour l'environnement et pour l'entreprise. À cette occasion, ceux qui analysent et agissent ont un bénéfice durable. WAGO est votre partenaire pour une gestion efficace de l'énergie.

Planification intelligente pour l'usine intelligente

La numérisation des processus de commande et de production est une belle opportunité pour toutes les entreprises. WAGO vous aide à utiliser tout le potentiel à votre avantage.