You are on page 1of 34

Packer Machine

LOGISTICS IMPROVEMENT
YEAR - 2009

Content

Objective. Introduction of Cement Flow to Packer Machine.

Flow Sheet

Packing Machine.

Lay Out Packer Machine. Packer Machine


Packer Machine. Operator Panel. Vento Check Transport Equipment.

Maintenance Recommendation.

2
January 09 report

25.03.2014/ROM

Objective.

Memberikan pengetahuan dasar mengenai Packer Machine dan melakukan pemeliharaan secara rutin.

3
January 09 report

25.03.2014/ROM

Content

Objective. Introduction of Cement Flow to Packer Machine.

Flow Sheet Lay Out Packer Machine. Packer Machine Packer Machine. Operator Panel. Vento Check Transport Equipment.
- Belt Conveyor. - Bag Trap.

Packing Machine.

Maintenance Recommendation.

4
January 09 report

25.03.2014/ROM

Flow Sheet NAR-2

5
January 09 report

25.03.2014/ROM

Flow Sheet NAR-2

6
January 09 report

25.03.2014/ROM

Content

Objective. Introduction of Cement Flow to Packer Machine.

Flow Sheet

Packing Machine.

Lay Out Packer Machine. Packer Machine


Packer Machine. Operator Panel. Vento Check Transport Equipment..

Maintenance Recommendation.

7
January 09 report

25.03.2014/ROM

Lay Out of Packing Machine

8
January 09 report

25.03.2014/ROM

Lay Out of Packing Machine

9
January 09 report

25.03.2014/ROM

Content

Objective. Introduction of Cement Flow to Packer Machine.

Flow Sheet

Packing Machine.

Lay Out Packer Machine. Feature Packer Machine


Packer Machine. Operator Panel. Vento Check Transport Equipment.

Maintenance Recommendation.

10
January 09 report

25.03.2014/ROM

Features of Packer Machine


Fluidization Devices 1. 2. 3. Bronze Filter. Solenoid Valve & Distributor : Regulator.

4.

Main Valve Air pressure

11
January 09 report

25.03.2014/ROM

Features of Packer Machine


4 3

1.

Pneumatic Valve : On / Off butterfly valve.


Rotary Valve : Motorize valve dengan kecepatan tertentu dan konstan. Level Sensor : Untuk menjaga / mengontrol level semen di Bin packer dan interlocking dengan Rotary Valve and Pneumatic gate valve Motor & Gear Box Drive : Motor listrik dengan transmisi gear box sebagai pengerak Packer Mesin yang putarannya di kontrol oleh Variable Speed Drive, dimana kecepatan putaran packer disesuaikan dengan setting capacity secara otomatis.
12
January 09 report

2.

3.

4.

25.03.2014/ROM

Features of Packer Machine


1

1. Magic Box :
Transmisisi data dengan media infrared untuk menghubungkan Ventodigit / the bag filling units di bagian yang berputar dengan operator panel dan control system.

2. Encoder :
Untuk menentukan posisi sequece pengisian bag dan control cycle nya.

3. Vetodigit :
Adalah control timbangan di masingmasing tube / spout yang berbasis microprocessors electronic dan conventional module.

13
January 09 report

25.03.2014/ROM

Filling units
1. Filling Units :
Impeller, fluidisation system, guillotine valve, nozzle and supporting frame, all designed for high weigh accuracy, high out put and low dust emmision. 1

2
3

2. Imppeller : Horizontal shaft impeller configuration for optimal filling according to partical size distribution of the product being packet. 3. Bag Support Sadle:
Available for wide range of bag types and size and for manual or automatic levelling.

14
January 09 report

25.03.2014/ROM

Filling Devices
Guillotine group: slide vale and pinch valve are both available for controlling the material flow

Electric Motor couple with pulleys and belts to the impeller shaft.

Static micro switch for detection of bag present.

Pneumatic actuated bag discharge group.

Bag Support
15
January 09 report

25.03.2014/ROM

Ventodigit III
VENTODIGIT III electronic weighing system : The microprocessor controlled weighing system, located at each bag filling module, allow : to handle nominal weight ranging from 10 kg to 50 kg; to programmed 24 different menus for different types of products to be bagged; automatic on-board weight correction units; supply of performance data to the operator

Ventodigit GEO 8

Ventodigit III
January 09 report

Ventodigit

16

25.03.2014/ROM

Operator Panel ( Siemens PC ) go to Siemens PC module

17
January 09 report

25.03.2014/ROM

System Configuration & Communication

Movicon
January 09 report

PC Siemens

18

25.03.2014/ROM

Content

Objective. Introduction of Cement Flow to Packer Machine.

Flow Sheet

Packing Machine.

Lay Out Packer Machine. Packer Machine


Packer Machine. Operator Panel. Vento Check Transport Equipment.
- Belt Conveyor. - Bag Trap.

Maintenance Recommendation.

19
January 09 report

25.03.2014/ROM

Description of Maintenance and Control Step


Description Symbol Frequency 24 h 200 h 5000 h

Verify the efficiency of all safety devices. Check the functional and integrity of the pushbuttons, selectors excitation distance of all sensors and micro switch. Check the efficient of the power divider installed in the main switch board and in the neigh burring one installed at customers care. Check the temperature and functionality of the transformer. Check the calibration and thermal relays. It will further be appropriate to check for a proper tightening of the screws on the relays which are subject to numerous actuating cycles. Control the integrity of the feed cables and of the protective sheaths. Check the attachment of the cable terminal, clamps, relay switches, etc and their eventual oxidation condition.

1000 h

20
January 09 report

25.03.2014/ROM

Description of Maintenance and Control Step


Description PNEUMATIC SYSTEM

Symbol

Frequency

The air pressure must be kept as steady as possible in any case not less than 5.5 bar and not more than 7 bar. Check for any plugging and discharge the condensate from the compressed air regulating assembly. Clean the transparent cup with water and soap. - Clean the filter element with a solvent and by jetting compressed air. - Check for losses or slippages from the plant. - Check to ensure the presence of lubrication in the appropriate cup on the compressed air distributing assembly.

21
January 09 report

25.03.2014/ROM

Description of Maintenance and Control Step


Description Pneumatic electrical control valves

Symbol

Frequency

The pneumatic electrical control valves area component capable of withstanding many millions of cycles. Their installation on the base plate makes their removal and reassembly very quick and simple. The overhaul consist in verifying that there are no air leakages under any operating condition ( active or de-activated valve ). If this should be the case replace the entire set of gaskets.

Cleaning

At the end of each work shift clean the weighing area ( from load cell to the seat ) by jetting with compressed air, while the packer is rotating and free of any bags. Also clean off the signs and instrumentations

Controlling the tare

Check the weigh read on every control panel (under no load). Normally a positive value below 1 kg should result. If not call for service of an instrumentation technician.
22
January 09 report

25.03.2014/ROM

Description of Maintenance and Control Step


Description Bag evacuating Cylinder

Symbol

Frequency

The action of the bag evacuating cylinder or expelling mechanism must be fast and without hesitation, check for eventual slippages.

Bag Presence

Make sure that there are no impediment , blockages, blow buys, disconnected or ruptures tubes or badly positioned micro device

Gear reducer

Replacement oil every 5.000 work hour. 04 Replacement oil every 10.000 work hour. 63

Level Indicator.

If an indicator of a capacity type is installed, check the sensitivity of the if necessary adjust it.

23
January 09 report

25.03.2014/ROM

Description of Maintenance and Control Step


Description Motion Control / Bag Filling Device ( Cylinder ).

Symbol

Frequency

Make sure the motion of the gate must be smoothly and continuously. Check if the losses of product from the gate are excessive; if necesaary adjust the pressure of the counter plate (by acting on the loading of the appropriate loading spring for gate seal).

Bag Locking.

Both during the expulsion of the bag, the motion of the bag locker must occur in a correct manner( the lifting of the rubber shoe must be about 5 mm ); check occasionally for wear of the rubber shoe.

24
January 09 report

25.03.2014/ROM

Description of Maintenance and Control Step

25
January 09 report

25.03.2014/ROM

Content

Objective. Introduction of Cement Flow to Packer Machine.

Flow Sheet

Packing Machine.

Lay Out Packer Machine. Packer Machine


Packer Machine. Operator Panel. Vento Check Transport Equipment.
- Belt Conveyor. - Bag Trap.

Maintenance Recommendation.

26
January 09 report

25.03.2014/ROM

Operator Panel.
Operator panel Ventoshort dan sudah di design untuk linkungan yang berdebu yaitu standard protection indec IP 65. Namun dengan berbagai faktor, maka diperlukan perhatian khusus dan perawatan diantaranya :
Cleaning Panel. Regular Back up data Check or replace battery UPS periodically. Shutdown and clean up the hardware in site periodically.

27
January 09 report

25.03.2014/ROM

Content

Objective. Introduction of Cement Flow to Packer Machine.

Flow Sheet

Lay out of Packer Machine.

Lay Out Packer Machine. Packer Machine


Packer Machine. Operator Panel. Vento Check Transport Equipment.
- Belt Conveyor. - Bag Trap.

Maintenance Recommendation.

28
January 09 report

25.03.2014/ROM

Ventocheck / Check Weigher.

INTRODUCTION. The belt weigher Ventocheck is equipped with an electronic control unit EWU010. Such unit is equipped with a display with 8 lines for 16 columns, and a key board made of 16 keys. The control units allows to display the weigh of the bag, to set all the parameters which are unit necessary for the proper operation of the weigher as well as to display the statistical information about production. The sensing device of belt weigher consist of 2 units load cell to sensing the weigh, 2 units photo cell to detect bag in and bag out. All of the sensor connect to electronic control unit EWU010.

29
January 09 report

25.03.2014/ROM

Ventocheck / Check Weigher.


Adjustment of screen contrast. Adjust the screen contrast rotating the power meter RT1 with a small screwdriver to get the power meter remove the protection cover on the side of the control panel.

30
January 09 report

25.03.2014/ROM

Ventocheck / Check Weigher.


Hardware. The unit EWU/010 is an electronic weighing unit. The main module consists of a motherboard and of a CPU controlling the weighing process. On such board the weighing module is equipped with an analog/digital converter and with a CPU, which processes the signal from load cells as well as the calibration process.

31
January 09 report

25.03.2014/ROM

Ventocheck / Check Weigher.


CLEANING AND CHECKING AT THE END OF OPERATION. Once the plant has been stopped, clean all the plant components in detail:
The Belt
Photocells The instrumentation The signal.

Note: Do not use compressed air on the electronic component.

32
January 09 report

25.03.2014/ROM

Ventocheck / Check Weigher.


MONTHLY CHECKING - 400 HOURS. Therefore every month you shall check :
That all the mechanic lifting equipment and the relevant connections are

properly linked one another and that they do not show parts partially unscrewed or having too much clearance.
That no oil leak from the reduction gears and the oil level is stable within its

allowed limits.
That the chain, the belts and the relevant screw coupling do not show

excessive clearance or elongation.


That the dust, dirt or rust laying on the motion groups do not hinder their

movement uselessly overloading the movers.


That all the components are in good conditions. The smoothness of the bearings.

33
January 09 report

25.03.2014/ROM

Ventocheck / Check Weigher.


MAINTENANCE OF THE VENTOCHECK BELT. (see. Monthly checking ) The maintenance interventions on the belt weigher are the following :
400 hours
800 hours 2000 hours 4800 hours

: Tension and adjust the belt. Check the driving belt


: Check the wear of the sliding plate. : Check the oil of the reduction unit. : Check the wear of the belt.( change if necessary ).

12000 hours : Change the oil in the reduction units.

34
January 09 report

25.03.2014/ROM