Canalis® Busbar Trunking Systems in tile making factories Application Technical Document 00 Application: technical document Contents 1 - General information 1.1 - Field of investigation and object 1.2 - General information about tile making factories 1.3 - Overall layout of a tile making factory 2 – Customer requirements 2.1 - General requirements 2.2 - Specific electrical requirements 2.3 - Power requirements 2.4 - Architecture i General information i Block diagrams 3 – Electrical distribution 3.1 - Electrical distribution using the Canalis Busbar Trunking System i General standards i Specific performances 3.2 - The Canalis Busbar Trunking System solution i Power distribution i Lighting distribution 3.3 - Main distribution types i Low voltage bypass i Clay drying run i Discontinuous mill run i Continuous mill run i Compressor run i Pulveriser run 3.4 - Guarantee by using the right specification i Product/Application pairs M i Technical specifications for each product 4 - References 5 - Acknowledgements Te 1 Application: technical document 1 General information 1.1 - Field of investigation and object Through this document, the entire tile manufacturing process is examined. Due to the complex nature of the manufacturing process, few companies own all the elements that make up the chain. Companies tend mainly to focus their investment on one part of the process. The manufacturing process 1 2 3 4 5 6 7 8 9 10 11 12 13 The raw materials are stored The raw materials are sampled, dosed and weighed The mixture is ground with water and colouring agent The resulting slip is stored in tanks The slip is pulverised The base pulverised material is sampled systematically Unbaked tiles are manufactured by pressing The unbaked tiles are dried They are enamelled and decorated The tiles are stored, taken to the oven, put into the oven and baked, then polished The tiles are sorted They are loaded systematically onto pallets The pallets are covered systematically before outgoing products are stored Object i Tile manufacturing is a highly automated process with special requirements concerning electrical distribution. i The production tool is extremely heavy and requires large amounts of electrical power i The manufacturing process is highly standardised: however, there are some variations in the enamelling phase. All the special conditions, concerning both infrastructure and electrical distribution, are resumed in this application: technical document. 2 Te Application: technical document 1 General information 1.2 - General information about tile making factories There are 3 main stages in tile manufacturing: i Basic material production, from raw materials to clay powder. i Preparation of enamels (not dealt with in this document). i Manufacturing of tiles into finished products. Clay powder production At this stage, different clays are ground, mixed with water, processed and then pulverised to make them into a homogeneous powder. Cycle: 1 - The clay is delivered and stored 2 - The raw materials are sampled, dosed and weighed 3 - The clay is loaded and ground 4 - The clay is mixed with water (slip) 5 - The slip is pulverised and dried (homogeneous powder) The high consumption process, requires a significant daily supply of energy. Some companies use electrical co-generators to make their installation cost-effective by reselling kiloWatt hours to electric utilities. Making tiles into finished products The powder, stored in silos, is sieved and taken to hydraulic presses weighing between 1600 and 2500 tons that provide pressure of up to 450 kg/cm2. Tiles with a 5% water content pass through a high temperature oven (200°c), for around 6 s so that afterwards their water content is only 0.2%. In order for the oven to operate continuously, a compensator is included in the run, thus allowing the flow to be regulated. The dried products are then directed to the enamelling and silk-screen printing run. Monitoring at the end of each stage ensures the perfect quality of the product. The enamelling run consists of several interchangeable modules arranged according to demand. A module consists of a control cabinet and a unit with a programmable logic controller that ensures the monitoring, regulation and control of the variators. The cleaning, trimming, enamelling, monitoring and silk-screen printing stages are set up over a distance of around 160 m. In order to ensure a continual flow, compensator-regulators are inserted along the run. At the end of the run, storing is carried out using trolleys guided by programmable logic controllers, allowing continual management of the taking of tiles to the oven and baking. To ensure that the tiles are perfectly baked, an oven, about 120 m long, is used at a temperature of 1000°c. Cycle 6 - The clay powder is extracted from the silos. 7 - The tiles are moulded. 8 - The tiles are routed along the enamelling run. 9 - The enamel is prepared and injected. Te 3 Application: technical document 1 General information 1.3 - Overall layout of a tile making factory The clay powder production area Its area is 2000 m2, with a height of up to 30 m. The distinctive feature of this area is its high dust level. Due to the significant height of these sites, lighting is provided using high power projectors. The lighting used for the enamelling run is provided using 400W bulbs. The enamelling run Its floor space varies between 10,000 and 80,000 m2. Average production is around 1m2 of tiles per 1m2 of floor space. It can be estimated that, for an average floor space of 10,000 m2, 10,000 m2 of tiles are produced per day. The use of high pressure water to clean the machines is additional stress on the electrical equipment. 1 Zone for storing, sampling, dosing and weighing raw materials. 2 Zone for manufacturing and pulverising slip. 3 Zone for manufacturing by pressing and drying the tiles. 4 Zone for enamelling and decorating. 5 Zone for storing, baking and then polishing. 6 Zone for sorting, loading onto pallets and storing of finished products, then shipping. 1 2 4 3 4 Te 1 2 6 3 4 5 6 5 Te 5 Application: technical document 2 Customer requirements 2.1 - General requirements 2.1.1 - Continuity of operation One of the technical requirements for this type of factory is continuity of supply. A break in the power supply leads to significant financial losses. Even a short break can cause a halt in production at the sensitive areas in the chain which are: The ovens A break in the current leads to the tripping of the solenoid valves, which stop the burners. Since they have to be manually reset, which can take several minutes, this can cause a drop in oven temperature. The cooling of the oven leads to large scale operations that are a source of production losses. The tiles that experience a fall in temperature during their 45 min. route become either concave or convex, causing a jam at the oven rollers. The intervention is conducted in three stages: i the oven is completely cooled i the jam inside the oven is manually cleared i the burners are set into operation and the temperature stabilised In order to avoid these consequences, the oven’s electrical supply needs to be precisely managed. This consists of adding an electrical generator as an auxiliary power source and the thorough monitoring of the primary source. In order to avoid short breaks, the primary and auxiliary sources are synchronised at critical times. The enamelling run There are many consequences of a break in the power supply. Among the most significant are: i stabilisation of the enamel coating, an extremely precise process that takes into account viscosity, speed and product uniformity. i flow continuity to avoid shut down of the oven and cleaning the production line after a prolonged halt. i setting of the automatic devices. In general, there are around 30 programmable logic controllers per run. Not to mention the consequences of an operating loss related to the clay powder production process and which are similar to the financial losses of heavy industries, such as the iron and steel or glass industries. 2.1.2 - Development Due to their size, investments are made progressively. Extensions are made according to market demand, for both heavy industry and enamelling runs. The increase in production capacity leads to the addition of equipment. In general, the site’s infrastructure is built for a given capacity, with areas for future extensions, of which the majority are: i addition of a mill i addition of an enamelling run 2.1.3 - Ease of installation linked to design Adapting to market demand in a competitive context implies a high degree of reactivity. This means looking for time savings, ease of installation and maintenance solutions. Investors regard design as a differentiating value and proof of quality. 6 Te Application: technical document 2 Customer requirements 2.2 - Electrical specificity Electrical specificity General needs are broken down into specific requirements for the site as a whole. The electrical aspect is also concerned by this requirement. The busbar trunking system is being used more and more in order to better satisfy these technical constraints. - When implementing the project Although the power of the machines is known in advance, the exact layout is never known in advance. The products are progressively integrated into the architecture of the building, and care is taken to respect deadlines and control costs. There are often last minute changes, mainly due to the complex nature of the metallic structure supporting the machines. The busbar trunking system solution offers a good integration into the architecture of the building, made even easier thanks to its extremely low space requirements. - During operation Continuity of supply is an essential factor in the choice of the electrical distribution type, for the same reason as its ease of adaptation to extensions. The versatility of the modules in an enamelling run’s design is an additional technical constraint when choosing a solution. Installation convenience linked to rapid mounting time for run extensions or modifications is a technical-financial condition that can be a deciding factor in the technological choice of electrical distribution. The solutions that fulfil these technical requirements will be studied at a later date with regard to the advantages of distribution using the busbar trunking system. Power requirements Energy requirements depend on production capacity, which develops over time and leads to the use of new machines and new runs. The system’s power load is broken down according to the following configuration: i Clay processing area, from 3x1600 kVA to 6x1600 kVA i Enamelling run, from 1000 kVA to 2000 kVA In order to ensure continuity of supply of the sensitive areas, the installation is fitted with generating sets: a main 200 kW set for the general supply of the enamelling run and a small set of around 50 kW for each oven. Distribution by sector (for information only): Zones Use Average power used Energy requirement Lighting Distribution Clay processing Clay reception 100 A Weak Medium Grinding and mixing 800 – 1250 A (per mill) Weak High Pulverising 800 – 1250 A Weak High Pressing and shaping 2200 A Weak High Coating and silk-screen printing 800 A Weak High Storing 800 A Medium Weak Baking 800 A Weak Medium Enamelling run Te 7 Application: technical document 2 Customer requirements 2.3 - Architecture General information Medium Voltage power from the public distribution network is used to supply production sites. Bearing in mind the amount of power consumed, these producers generate surplus electricity thanks to the use of co-generators, which allow the steam used in the clay powder production process to be recycled. This surplus is then sold to electric utilities. In this way, they reduce the kWh price to a minimum. In general, several transformer substations are used for the low voltage distribution of a single site. In order to adapt to production variations, a bypass system is built between the transformers, thus allowing the distribution of power to be regulated. Particularly in the enamelling zone, there are generating sets in parallel with the transformers, thus allowing breaks in electrical supply to be managed. A capacitor bank allows the sensitive area of the oven to be supplied and thus allows uninterrupted operation to be guaranteed. Block diagram i Clay production area Incoming medium voltage Transformation centre 1 Transformation centre 3 Transformation centre 2 Bypass Continuous mill(s) Discontinuous mill(s) Pulveriser Compressor Sub-distribution switchboards 8 Te Clay drying run Application: technical document 2 Customer requirements i Enamelling run area A generating set is added in parallel to the main circuit to ensure continuity of supply at the main circuit level, i.e. the oven and the enamelling run. The automatic source reversing switch located at the main switchboard level carries out the changeover and ensures the automatic load restoration of the main points. In the event of a break in the current, a lower powered generator ensures the stand-alone supply of the oven. Moreover, UPS and a capacitor bank are used to avoid breaks at the vital points, i.e. the burners’ solenoid valves. Generating set control unit 250 kVA Diesel motor Incoming medium voltage Gen MV MV 1250 to 2500 kVA 1250 to 2500 kVA LV LV 2 Masterpact circuit-breakers Automatic source reversing switch Main SwitchBoard set/transformer Compact NS circuit-breakers Canalis KBA/KS/KT Oven Presses Conveying of clay powder Preparing the enamelling Enamelling run Lighting Te Palettisation 9 Application: technical document 3 Electrical distribution 3.1 - Electrical distribution using the busbar trunking system General standards The busbar trunking system complies with all the rules stated in standard IEC 439-1 and 2. Certain electrical properties must be known for the different phases: i average ohmic resistance per metre i average reactance per metre i impedance per metre The busbar trunkings must be designed to bear mechanical loads. The whole of the trunking, including its tap-off points, must be designed in such a way as to prevent indirect contact as well as incorrect connections with the live parts. The overheating limits of the casing and the conductors at the most sensitive areas are precisely defined. Together, these criteria ensure a safe and reliable electrical distribution for an economical solution for the operation. Decentralised distribution using the “Canalis” busbar trunking system completely fulfils the requirements regarding: i safety of equipment and people i continuity of supply i reliability i ease of maintenance Specific performances An upgradable installation The constraints of progressive investment are perfectly controlled with the Busbar trunking system solution, which allows lengths along the run to be interchanged, added and recovered. The factorybuilt tap-offs guarantee flexibility to upgrade the installation. The modular nature of the lengths allows all or part of the installation to be reused. Price and quality suitability More than 30 years of expertise and a product design that guarantees the safety of people and equipment contribute towards obtaining an installation, the economic performance of which is favourable compared with the other solutions. A well-established production tool together with lengths that are easy and safe to mount guarantee a time saving and control over unforseen work site problems. Reduced space requirements The compact nature of the trunking allows the space requirements to be reduced by 2 to 6 times in comparison with a traditional solution. Changes in direction are made at right angles. Good protection in the event of fire High power distribution trunkings are guaranteed against the propagation of toxic gases (IEC 754) and thick smoke (IEC 1034). The insulating materials used are halogen-free and self-extinguishing (IEC 695.2.1). The minimum fire withstand is 2 hours, in accordance with ISO 834. Very good degree of protection The basic degree of protection is IP 52, with an anticorrosion treatment allowing installations to be built in demanding environments. 10 Te Application: technical document 3 Electrical distribution 3.2 - The busbar trunking system solution The most important part of electrical distribution is power, representing around 95 % of the power consumed. Lighting is always present in the storing and palettisation zone. Typical installation (see paragraph 3.3, different types of distribution runs) Clay drying 1 Mill 1 Mill 2 Canalis KT 2 Canalis KT 4 Canalis KT Transformer Station 3 Canalis KT Compressor Mixers station Pulveriser Silos 5 Canalis KT Transformer Station 7 Canalis KS Enamelling run Presses 6 9 Canalis KS Oven Palettisation Zone 8 Canalis KBA Power distribution Ref. Run Product Distribution 1 Clay drying KTA Turbine, stirrer, thinner, drying apparatus. 2 Mills/grinders KTA Unloading grains, mill, conveyor, thinner, stirrer, filter. 3 Compressors KTA Lighting, auxiliary services, stirrer, conveyor, compressor, unloading. 4 Pulveriser KTA Filter, pulveriser, stirrer, conveyor, thinner, workshop, loading lorries, unloading silos. Enamelling run distribution Ref. Run Product Distribution 5 Press KTA Conveying, filter, press, drying, enamelling run feed. 6 Oven supply KS Oven, lighting runs, palettisation, storing. 7 Enamelling run KS UPS, coating, silk-screen printing, drying, enamelling, mixer. 8 Lighting run KBA 400W bulbs 9 Burner run KBA Te 11 Application: technical document 3 Electrical distribution 3.3 - Main distribution types Low Voltage Bypass Present transformation centre Feed unit Future transformation centre Feed unit Canalis KTA-30 Present transformation centre Feed unit Feed unit Clay drying run A - Turbine (future) B - Stirrers (future) C - Thinners (future) D - Thinners (future) E - Clay drying F D Canalis KTA-30 C B A Feed unit 12 Te Application: technical document 3 Electrical distribution Discontinuous mill run A - Unloading clay B - Unloading clay (future) C - Discontinuous mills D - Conveyors for mills E - Thinners F - Stirrers G - Filters (future) G Canalis KTA-10 A Feed unit F D Canalis KTA-30 C B Feed units E Continuous mill run A - Continuous mills B - Continuous mills (future) C - Filters D - Filters (future) D C A B Canalis KTA-30 Feed unit Te 13 Application: technical document 3 Electrical distribution Compressor run A - Lighting B - Auxiliary services C - Pulveriser (future) D - Pulveriser-shakers E - Conveyors for pulveriser (future) F - Compressors C - Offices F - Unloading silo 1 G - Unloading silo 2 Canalis KTA-30 F B G E D C A Feed unit Feed units Canalis KTA-10 H I Pulveriser run A - Dehumidifying filters B - Pulveriser C - Pulveriser-shakers D - Conveyors for pulveriser E - Pulveriser F - Pulveriser-shakers G - Conveyors for pulveriser H - Colour thinner (future) I - Workshops J - Loading lorries K - Unloading silo 3 Feed unit Canalis KTA-30 A K J G I H Canalis KTA-10 Feed units 14 Te F E D C B Application: technical document 3 Electrical distribution 3.4 - Guarantee by using the right specification “Product/Application” pairs As has already been explained earlier in this booklet, two stages in the manufacturing process can be distinguished, the uncoated tile production stage and the enamelling and finishing stage. The first stage will involve high power distribution and the second stage will involve medium power distribution and lighting. Each application is associated with a product that satisfies a set of technical criteria called “technical specification”. Stages Applications Canalis Products Uncoated tiles Preparing the clay Pulverising Grinding Compressor KTA-30 KTA-30 and KTA-10 KTA-30 and KTA-10 KTA-30 and KTA-10 Enamelling Press Oven Enamelling run Lighting KHF-26 KS-800 and KBA-40 KS-100 KBA-40 Te 15 Application: technical document 3 Canalis KBA specification Conforms to standards IEC 60439-2 and EN 60439-2 Degree of protection: IP 54 Number of live conducteurs: 2 or 4 Rated current (I NC): 25 or 40 A Rated insulation voltage: 660 V Fire performance: Resists flame propagation (as in IEC 60332-part 3). Resistance of materials to abnormal heat (glow wire test as in standard IEC 60695-2-1). Straight lengths form the structure of the run and comprise: 1 - A RAL 9010 crimped carrier rail made of sheet steel (hot-galvanised or white prelacquered). This rail also acts as a protective earth conductor (PE). 2 - A ribbon cable with 2 or 4 insulated tinned copper conductors with a cross-section of 2.5 mm2 for 25 A and 6 mm2 for 40 A. 3 - Tap-offs at 0.5m intervals are provided on one side of the trunking. 4 - An additional twisted cable (2 x 0.75 mm2, remote control circuit) on request. 5 - An electrical joint that ensures the automatic and simultaneous connection of all the live conductors. The contacts (clamp + spring type), prevent any strain from being placed on the plastic material. 6 - A mechanical joint and its locking spring ensure that the assembly of the two lengths is rigid. Two straight lengths are assembled instantaneously. The electrical and mechanical junctions are simultaneous. The continuity of the protective earth is automatic. The tightening of a captive screw with a notched base completes the assembly operation. 7 - The fixing system ensures the mounting of the trunking and the light fittings by simply rotating part of the fastener which has a final automatic lock. 8 - Pre-wired 10 A colour coded connectors or 16 A connectors with terminals or fuses allow lighting equipment to be supplied and installed while live. 9 - A metal cable duct (optional) ensures the routing of adjacent trunkings (telephony, emergency lighting, etc.). 10 - Flexible lengths allow all types of directional changes or the skirting of obstacles. 16 Te Application: technical document 3 Canalis KSA specification Conforms to standards IEC 60439-2 and EN 60439-2 Degree of protection: IP 52, IP 54 Number of live conductors: 4 Rated current (I NC): 100 to 800 A Rated insulation voltage: 660 V Protective earth conductor’s size is half that of the phase cross-section. Fire performance: - Integrity of electric circuits maintained in fire conditions (fire barrier compartment, in accordance with the manufacturer’s recommendations). Standard ISO 1182 (DIN 4102-part 12). - Verification of the fire barrier condition of bushing that passes through a partition (as in standard ISO 834 (DIN 4102-part 9). - Resists flame propagation (as in standard IEC 60 332-part 3). - Resistance of materials to abnormal heat (glow wire test as in standard IEC 60695-2-1). 1 - The galvanised steel casing has one tap-off every metre on both sides. 2 - The tap-off outlets are fitted with an automatic shutter that prevents any accidental contact with the live parts. The protective earth conductor (PE) is electrically connected to the casing at each junction. 3 - The 4 aluminium conductors are mounted on fibreglass-reinforced polyester insulators. All electrical contacts are made of silvered copper. 4 - Electrical junction between two lengths is ensured by flexible contacts designed to absorb the differential expansion between the conductors and the casing. Verification of the electrical junction is possible using a visual check. 5 - Mechanical junction between two lengths is ensured using 5 captive screws. 6 - The fixing brackets are designed to be either hung or attached to the wall every three metres, except when indicated otherwise. 7 - Specific lengths are used for all directional changes or skirting of obstacles. 8 - The tap-off units have the following properties: - Plug-in and withdrawal only possible with the door open. - The contact of the protective earth conductor automatically opens the shutter and polarises the tap-off. - When the tap-off unit is plugged in, the earth contact is established first, followed by the phase contacts. - The live parts are inaccessible when the tap-off unit door is open (IP 2). - The unit can be positioned on the trunking without using tools. - The unit door cannot be closed if the unit is not mechanically locked on to the trunking. - Units can be fitted with fuses, modular products or circuit breakers. Te 17 Application: technical document 3 Canalis KTA specification Conforms to standards IEC 60439-2 and EN 60439-2 Degree of protection: IP 52, IP 54 Number of live conductors: 3 or 4 Rated current (I NC): 1000 to 4000 A Rated insulation voltage: 1000 V Fire performance: - Integrity of electrical circuits maintained in fire conditions (fire barrier compartment, as in the manufacturer’s recommandations). Standard ISO 1182 (DIN 4102-part 12). - Verification of the fire barrier condition of bushing that passes through a partition (as in standard ISO 834 (DIN 4102-part 9). - Resists flame propagation (as in standard IEC 60332-part 3). - Resistance of materials to abnormal heat (glow wire test as in standard IEC 60695-2-1). 1 - The “Compact” trunking casing comprises 4 prelacquered galvanised sheet steel rails with a thickness of 15/10, assembled using “clinch bolts”. It also acts as a protective earth conductor and can be reinforced with a copper conductor. 2 - The distribution lengths can receive either bolt-on type no load removable units (up to 2 units from 400 to 1250 A) for horizontal or floor distribution, or spring connection type live removable units (up to 2 x 3 units from 25 to 400 A) for horizontal or vertical distribution. 3 - Live conductors comprise 1 or 2 bars with identical cross-sections. These aluminium bars are fitted with silver plated or electrolytical copper contacts, insulated from each other using 4 thicknesses of class “B” 130 °C polyester. 4 - Electrical junction is made using a connection block, of which the tightening torque is automatically controlled. An indictator light allows the correct execution of this operation to be remotely checked. 5 - Polarisation between lengths is ensured by the mounting of the mechanical junction, comprised of 2 covers and 8 screws. 6 - A fixing device provides the trunking with support every three metres at most on a horizontal run. For floor distribution, a special bracket is needed for each level. 7 - A variety of lengths that can be specially fitted, such as the straight length, elbow or tee, make it easier to adapt to the constraints imposed by the site. 8 - The cover of units fitted with a circuit breaker or switch can only be opened when they are in the “OFF” position. When the door is open, the degree of protection is at least IP 2 (protected against finger contact). The live removable tap-off units have the following properties: -The plug-in/withdrawal operation requires prior isolation either by the cover (using a tool) or by putting the apparatus in the ”OFF” position. - Protective earth (PE) continuity between the unit and the trunking is established first, before that of the live conductors and inside the trunking. - The contact bracket of the protective earth conductor opens the shutter at the tap-off point and polarises both. - At the tap-off point, the contacts are made silver to silver or copper to silver. 18 Te Application: technical document 4 References Country Tile making industries Lighting Power Low Medium High i Spain Alfa Ceràmicas Spain Ceramicàs l’Alcalaten i Spain Arciblansa i Spain Azteca Spain Azuliber Spain Azuvi Spain Cerdec Iberica i Spain ColorKer i Spain Estilos Ceràmicos Spain Gres de Nules i Spain Keraben i Spain Marazzi Spain Ceramicas Mercury Spain Novogres Spain Pamesa Ceramicas i Spain Saloni Ceramicas i Spain Safont Ceramicas i Spain Taulell-Taugres Spain Todagres Spain Torrecid Spain Zirconio Spain Fanal Spain Roca Ceramicas i i i i i i i i i i i i i i i i i i i i i i i i i Te 19 Application: technical document 4 Acknowledgements We would like to thank the people mentioned below for their participation in the drawing up of this document. Through this technical document, we hope to provide the entire tile making activity with the assistance it requires. TALLERES FORO Mr. Antonio LONJEDO MONZO INSTALACIONES ELECTRICAS “ALCAS” SL Mr. Juan VICENTE SANZ NEGRE INGENIERIA CHILLIDA Mr. Luis CHILLIDA DOLS L’ALCALATEN Mr. Juanjo RIBELLES TERRADELLAS ARCIBLANSA Mr. Miguel BARRA CHINA 20 Te Art 00000 Postal address: Rue Lavoisier F-21601 Longvic Cedex Tel. +33 (0)3 80 70 86 00 Fax +33 (0)3 80 70 87 87 DEBU005EN Schneider Electric Industries SA As standards, specifications and designs develop from time to time, the information given in this publication is not legally binding. Design and layout by: BTS activity Commercial development Printed by: 01/2001
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