Machine manual
en-CL.CPT.001.A
Coal silo
Code word
Order number
POLYSIUS Order Code (POC)
Machine manual Contents
Coal silo
Contents
1 Safety 1-1
2 Technical data 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-10
4 Transport and assembly 4-1
4.1 Transport and storage instructions 4-1
4.2 Assembly 4-1
4.3 Sequence of assembly 4-2
5 Lubrication 5-1
6 Commissioning 6-1
6.1 Checks prior to the test run 6-1
6.2 Setting and adjustment 6-2
7 Maintenance 7-1
7.1 Safety instructions 7-1
7.2 Inspection 7-1
7.3 Servicing 7-2
7.4 Repair 7-3
8 Trouble shooting 8-1
9 Spare parts9-1
9.1 Suggestions for enquiries and orders of spare parts 9-1
9.2 Spare parts9-1
10 Appendix 10-1
10.1 Technical drawings 10-1
10.2 Subsuppliers' documentation 10-1
en-CL.CPT.001.A
Machine manual Safety
Coal silo 1
1 Safety
Note
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
● The coal silo is only intended for storing dry, powdery to fine-grained,
fluidisable bulk materials.
Be sure to comply with the specification of the intended use in section
Technical data.
● Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owner's own risk.
● The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Transport and assembly
● All transportation instructions in this machine manual refer exclusively to
transportation of the machine at the plant site.
● Only use suitable hoisting and load-carrying equipment which is in serviceable
order and has a sufficient load-bearing capacity.
● Never work under a suspended load.
Operation
● Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
● If changes in the machine or its operating behaviour relevant to safety occur,
shut it down immediately.
● Fire, smoking and open flame, as well as any sources of heat, are strictly
forbidden in the vicinity of the coal silo because of fire and explosion hazard!
Be sure to comply with the explosion and fire prevention regulations.
en-CL.CPT.001.A
Safety Machine manual
2 Coal silo
Maintenance
● Eliminate any deposits of dust outside the coal silo.
● Directly after the machine has been shut down, you must only enter the
interior wearing breathing apparatus with independent ventilation. You are not
allowed to enter the interior without breathing apparatus until you have
sufficiently purged it with fresh air. Make sure that there is sufficient oxygen in
the interior and that no inert gases can enter it.
● When work is being performed inside the coal silo, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents. Aeration with pure oxygen is
forbidden.
● The interior of the coal silo may only be entered when the silo is empty.
● The coal silo may only be entered by a cable winch and cage operated
exclusively by suitable, reliable personnel who are familiar with this kind of
work. It is forbidden for one person to work alone (always post a safety
watchman).
● Before carrying out any maintenance work inside the coal silo, make sure that
all dust deposits have been removed.
● Before you start any flame-cutting, grinding or welding work, you have to
obtain the written permission of the plant manager, and you must shut down
the plant section in which the coal silo is installed.
● Make sure that the working areas are thoroughly soaked with water.
● Throughout the entire time that the work is being performed, a fire watch must
be posted. After completing the repair work, make absolutely sure that all
possible ignition sources in the working area (e.g. red-hot welding or grinding
residues) are extinguished and removed.
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Ensure that all rotating parts of the machine have come to a complete
standstill before you remove any protection devices or open any flaps.
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.
en-CL.CPT.001.A
Machine manual Safety
Coal silo 3
● Switch off the power supply to the electrical components before beginning any
maintenance work.
● Make sure that the pneumatic piping is relieved of pressure before
disconnecting it.
● After all maintenance work, check that there are no leaks in joints and
connections.
● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
● Never situate the source of the welding current in a confined space where
walls have conductive properties. Only use 24-Volt lamps for illuminating the
interior of the machine.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● Remount all protection devices when maintenance work has been finished.
Make absolutely sure that no persons are inside the plant component before
you properly close the inspection and service covers.
● The access hatch of the coal silo must be kept securely closed with the screw
fastening or must be secured with padlocks.
en-CL.CPT.001.A
Machine manual Technical data
Coal silo 1
2 Technical data
Note
Information concerning the electrical equipment is contained in the separate
electrical documentation or in the subsuppliers' documentation.
Specification of the intended use
Bulk material
Bulk density t/m3
Particle size mm
Permissible temperature max.
Surface moisture content %
Basic data
Year of manufacture
Clear construction height mm
Clear diameter mm
Total volume m3
Effective volume m3
Negative pressure / excess pressure relief device (1.3)
Qty.
Size
Type
Opening pressure (overpressure)
Opening pressure (negative pressure)
Filling level limit switch (1.6)
Qty.
Design
Type
en-CL.CPT.001.A
Technical data Machine manual
2 Coal silo
Bin weighing device (1.5)
Number of load cells
Type
Gate valve (3)
yes/no
Type
Trace heating (4.1)
yes/no
Design
Insulation (4.2)
yes/no
Design
Thickness
en-CL.CPT.001.A
Machine manual Components and mode of functioning
Coal silo 1
3 Components and mode of functioning
3.1 Components
Note
Some details of the drawings in this manual may not be identical with the
drawings supplied under the contract.
en-CL.CPT.001.A
Components and mode of functioning Machine manual
2 Coal silo
The coal silo consists of the following subassemblies
Fig. 1: Subassemblies
en-CL.CPT.001.A
Machine manual Components and mode of functioning
Coal silo 3
No. Name Description
1 Coal silo
2 Aeration system
3 Gate valve
4 Trace heating with insulation
en-CL.CPT.001.A
Components and mode of functioning Machine manual
4 Coal silo
Items shown in the drawing of the coal silo (1)
Fig. 2: Coal silo (1)
en-CL.CPT.001.A
Machine manual Components and mode of functioning
Coal silo 5
No. Name Description
1.1 Silo
1.2 Filter
1.3 Negative pressure / excess
pressure relief device
1.4 Connecting dome for the CO analyser
1.5 Bin weighing device
1.6 Filling level limit switch
1.7 Inlet opening
1.8 Connection for inertisation piping
1.9 Temperature sensor
en-CL.CPT.001.A
Components and mode of functioning Machine manual
6 Coal silo
Items shown in the drawing of the aeration system (2)
Fig. 3: Aeration system (2)
en-CL.CPT.001.A
Machine manual Components and mode of functioning
Coal silo 7
No. Name
2.1 Air distribution pipe
2.2 Aeration nozzle
2.3 Hose
2.4 Throttle valve
2.5 2/2-way ball valve
2.6 Pressure gauge
2.7 Non-return valve
2.8 Pressure reducing valve
2.9 Filter
2.10 2/2-way ball valve
2.11 Ball valve
en-CL.CPT.001.A
Components and mode of functioning Machine manual
8 Coal silo
Items shown in the drawing of the trace heating (4)
Fig. 4: Trace heating (4)
en-CL.CPT.001.A
Machine manual Components and mode of functioning
Coal silo 9
No. Name
4.1 Trace heating
4.2 Insulation
en-CL.CPT.001.A
Components and mode of functioning Machine manual
10 Coal silo
3.2 Mode of functioning
The coal silo is designed as a cone silo and is used for the interim storage of dry,
powdery to fine-grained bulk materials that can be fluidised by aeration,
particularly fine coal.
The coal silo essentially consists of:
● the silo
● the pressure relief device with integral negative pressure relief device
● the filling level measuring devices
● the aeration system with its valves
● the trace heating with insulation as an option
The coal silo is used for interim storage of dry, fluidisable bulk material. The
material to be stored is fed in via the inlet openings (1.7).
The maximum filling height is limited by filling level limit switches (1.6).
Air can be blown through the aeration nozzles on the silo cone, fluidising the bulk
material and making it free-flowing.
The fluidised bulk material flows through the outlet to the downstream dosing and
conveying equipment.
Air is supplied from outside to the aeration devices through piping.
The aeration system on the silo cone consists of aeration nozzles that are
arranged in two levels and are divided into aeration sectors. These sectors are
aerated in turns and are activated or deactivated by 2/2-way ball valves. Every
aeration nozzle has a fitted filter set and a preceding throttle valve which is used
for setting the air volume.
en-CL.CPT.001.A
Machine manual Transport and assembly
Coal silo 1
4 Transport and assembly
4.1 Transport and storage instructions
The machine is transported in individual parts or in subassemblies. Make
absolutely sure that suitable lifting equipment is employed for lifting all the parts
from the transport vehicles and transferring them to the storage area.
When they arrive at the site, all parts must be inspected for transport damage and
placed on wooden beams with the provision of suitable protection against
moisture, soiling and damage. Never place the parts directly on the ground.
Make absolutely sure that valves, measurement and control equipment are stored
in well-ventilated rooms and protected against moisture.
4.2 Assembly
Required personnel
To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.
Note
It is a prerequisite of our warranty that assembly supervision and assembly
inspection are performed by a specialist from POLYSIUS AG.
Required tools
It is a prerequisite for the correct performance of the work that all tools,
appliances and hoisting gear are carefully selected.
No special tools are required. However, you may need torque wrenches and
hydraulic pumps of a bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
mounting supports, depends on the conditions in your plant.
CAUTION
Welding current
Moving connecting elements or sliding surfaces could be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.
en-CL.CPT.001.A
Transport and assembly Machine manual
2 Coal silo
Note
The following assembly description does not detail the individual steps for
assembling the machine but rather gives an overview of the work to be
performed.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.
4.3 Sequence of assembly
● Preassemble the silo in accordance with local conditions.
● Mount the supports for the silo, inserting a spacer (dummy) of the same height
instead of the load cell (1.5).
● Check the axes and heights of the supports and correct them if necessary by
inserting shims.
● For transportation, attach the silo (1.1) to the provided lifting points, lift it into
position, set it down on the supports and bolt it / weld it onto these.
● Install the filter (1.2) and connect it to the external air supply system.
● Install the negative pressure / excess pressure relief devices (1.3) in
accordance with the subsupplier's instructions and set them o the required
values.
● Install the aeration system (2) and connect it to the external air supply system.
● Install the connecting dome (1.4) with the CO analyser.
● Connect the material feed piping to the inlet opening (1.7).
● Mount the filling level limit switch (1.6). Proper functioning is only assured if
there is a metallic bright connection between the filling level limit switch and
the silo to provide a good earth connection
● Connect the inertisation piping to the sockets (1.8).
● Install the temperature sensor (1.9).
● Install the trace heating, carry out a functional test and then insulate the silo
cone.
● Check the inside of the silo for foreign bodies and remove them. If applicable,
install the gate valve (3).
● Replace the spacer (dummy) with the real load cell (1.5). Comply with the
subsupplier's instructions when installing and calibrating the device.
Note
In order to ensure proper functioning of the load cell, make sure that all
connections to subsequent units are flexible.
● Connect the coal silo to earth.
Note
Pay special attention to the earthing of the coal silo. Be sure to comply with the
local explosion protection directives.
en-CL.CPT.001.A
Machine manual Lubrication
Coal silo 1
5 Lubrication
Note
The POLYSIUS table of lubricants with the lubricant reference numbers is
contained in the supplement Important notes on the documentation. The
supplement is contained in this folder or at the beginning of the overall
documentation. Each lubricant has a unique reference number to which the
lubrication instructions in this section relate. The table gives a complete list of all
suppliers and products approved by POLYSIUS AG. It is the responsibility of the
lubricant supplier to select appropriate lubricants corresponding to the lubricant
reference numbers. POLYSIUS AG accepts no liability for the correctness of
these data. If you wish to use a lubricant that is not included in the Table of
lubricants, you have to first obtain the express permission of POLYSIUS AG.
The supplement Important notes on the documentation also contains the
generally valid Notes on lubrication.
CAUTION
Lubricants that are not properly stored, used and disposed of are an
environmental hazard.
They can harm humans, animals and plants.
Ensure that the environment is not polluted when lubricants are stored,
used and disposed of and carefully observe the relevant national
legislation for the protection of the environment when handling lubricants.
Lubrication points
No. Qty. Designation Comment:
1 1 Filter (1.2)
See subsuppliers' documentation
3 1 Gate valve (3) if installed
en-CL.CPT.001.A
Machine manual Commissioning
Coal silo 1
6 Commissioning
Note
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
6.1 Checks prior to the test run
After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the list below. Make absolutely sure that all
material remnants, tools and auxiliary assembly devices have been carefully
removed.
● Have all bolted connections been properly tightened?
● Have the connecting flanges been screwed on tightly?
(Have the designated seals been correctly fitted?)
● Has the aeration system (screwed connections, hose connections and
aeration nozzles) been checked for leaks?
Seal any leaky points with, for example, LOCKTITE.
● Has the negative pressure / excess pressure relief device (1.3) on the coal
silo been correctly set and is it functioning correctly?
● Has the inertisation system been connected and checked for proper
functioning?
● Is the filling level limit switch (1.6) operating properly?
● Has the bin weighing device (1.5) been correctly installed and calibrated?
● Has the CO analyser in the connecting dome (1.4) been correctly installed
and calibrated?
● Is the dust collection filter ready for operation?
● Do the electrical data of the network correspond with the data of the electrical
equipment?
● Are the downstream shut-off and dosing devices ready for operation?
● Has the trace heating (if applicable) been correctly installed and checked for
proper functioning?
● Is the entire coal silo free of moisture?
● Is the downstream conveying equipment ready for operation?
● Have all flexible connections been mounted correctly?
● Has the earth connection of the coal silo been correctly mounted?
● Have all signs and protection devices been mounted?
en-CL.CPT.001.A
Commissioning Machine manual
2 Coal silo
6.2 Setting and adjustment
At the start of commissioning, open all the manual valves in the aeration systems.
You cannot make exact settings until the coal silo has been filled during the
commissioning.
Calibrate the filling level limit switch (1.6) and the bin weighing device (1.5) in
accordance with the manufacturer’s instructions and set the switching points.
Set the negative pressure / excess pressure relief device (1.3) in accordance with
the manufacturer's instructions and check for proper functioning. For the opening
pressures, see section Technical data.
Calibrate the CO analyser in the connecting dome (1.4).
en-CL.CPT.001.A
Machine manual Maintenance
Coal silo 1
7 Maintenance
7.1 Safety instructions
DANGER
Fire and explosion hazard in the vicinity of the coal silo.
Fire, smoking and open flame, as well as any sources of heat, are strictly
forbidden in the entire area!
I. Be sure to comply with the explosion and fire prevention regulations.
II. Eliminate any deposits of dust outside the coal silo.
7.2 Inspection
No. Work to be performed Frequency Comments
1 General visual inspection of the silo for leaks Every 26
weeks
2 Inspection work on the negative pressure / excess See
pressure relief device (1.3) subsupplier's
instructions
3 Checking the bin weighing device (1.5) See
subsupplier's
instructions
4 Inspection work on the filling level limit switch (1.6) See
subsupplier's
instructions
5 Inspection work on the gate valve (3) if installed See
subsupplier's
instructions
6 Inspection work on the trace heating (4.1) if installed See
subsupplier's
instructions
7 Draining condensation water from the piping system Weekly Open the
hose cocks
8 Checking the air hoses Every 4
weeks
9 Checking the throttle valves (2.4) for correct functioning Every 4
weeks
10 Checking the aeration system (2) Annually The silo must
be completely
emptied
11 Checking the aeration nozzles (2.2) Annually
en-CL.CPT.001.A
Maintenance Machine manual
2 Coal silo
7.3 Servicing
No. Work to be performed Frequency Comments
1 Maintenance work on the negative pressure / excess See
pressure relief device (1.3) subsupplier's
instructions
2 Maintenance work on the bin weighing device (1.5) See
subsupplier's
instructions
3 Maintenance work on the filling level limit switch (1.6) See
subsupplier's
instructions
4 Maintenance work on the gate valve (3) if installed See
subsupplier's
instructions
5 Maintenance work on the trace heating (4.1) if installed See
subsupplier's
instructions
6 Maintenance work on the valves and fittings See
subsupplier's
instructions
7 Replacement of dirty filter insert elements in the As required
aeration nozzles (2.2)
en-CL.CPT.001.A
Machine manual Maintenance
Coal silo 3
7.4 Repair
Required personnel
To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required for repair work on the machine.
However, you may need torque wrenches of a bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoists,
depends on the operating conditions in your plant.
General
Switch off the power supply to all electrical components before beginning any
repair work.
The interior of the coal silo may only be entered after all residual material has
been completely discharged.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives, the hydraulic system or other sensitive
parts of the machine or plant.
Cordon off the entire working area to prevent unauthorised persons from gaining
access.
Note
After you have completed the repair work, you must check the machine/plant
again in accordance with the section Preparation for test run.
The following repair work can be carried out when the coal silo is full:
● Repair or replacement of the negative pressure / excess pressure relief device
(1.3)
● Repair or replacement of the bin weighing device (1.5)
● Repair or replacement of the filling level limit switch (1.6)
● Repair or replacement of the insulation (4.2) of the trace heating if installed
See subsuppliers' documentation for this
en-CL.CPT.001.A
Machine manual Trouble shooting
Coal silo 1
8 Trouble shooting
Note
Consult the subsupplier's documentation for additional information on faults,
their causes and their elimination.
Fault Cause Elimination
Material is escaping Defective flange seal(s) Repair the flange seal(s)
Too little or no bulk material is No aeration air, because: Check and repair the
flowing out of the coal silo ● there is a fault in the compressed air supply system
central compressed air
supply system
● the blower is not working Start the blower
● the throttle valves are Open the throttle valves
closed
● the solenoid valves are not ● Check the control system
activated or are faulty and the feed piping
● Repair or replace the
solenoid valves
● the piping is defective Repair the piping
A foreign body is blocking the Remove the foreign body
silo outlet
en-CL.CPT.001.A
Machine manual Spare parts
Coal silo 1
9 Spare parts
9.1 Suggestions for enquiries and orders of spare parts
Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part order
placements as easy and efficient as possible. For this purpose we have prepared
a table containing all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble-free manner.
Please copy the title page as well as the page with the respective table, and mark
those parts which you require with a cross in the column "Order" or in the column
"Enquiry". Send the title page, together with the table, to the spare parts
department of POLYSIUS AG.
If the table relates to more than one machine, please also inform us of the
POLYSIUS Order Code (POC) of the machine for which you require the spare
parts.
9.2 Spare parts
en-CL.CPT.001.A
Spare parts Machine manual
2 Coal silo
The coal silo consists of the following subassemblies
Fig. 5: Subassemblies
en-CL.CPT.001.A
Machine manual Spare parts
Coal silo 3
No. Name Qty. Unit Order Enquiry
3 Gate valve Piece
4 Trace heating Piece
en-CL.CPT.001.A
Spare parts Machine manual
4 Coal silo
Items shown in the drawing of the coal silo (1)
Fig. 6: Coal silo (1)
en-CL.CPT.001.A
Machine manual Spare parts
Coal silo 5
No. Name Qty. Unit Order Enquiry
1.2 Filter Piece
1.3 Negative pressure / excess pressure relief device Piece
1.5 Bin weighing device Piece
1.6 Filling level limit switch Piece
1.9 Temperature sensor Piece
en-CL.CPT.001.A
Spare parts Machine manual
6 Coal silo
Items shown in the drawing of the aeration system (2)
Fig. 7: Aeration system (2)
en-CL.CPT.001.A
Machine manual Spare parts
Coal silo 7
No. Name Qty. Unit Order Enquiry
2.1 Air distribution pipe Piece
2.2 Aeration nozzle Piece
2.2.1 Filter insert element Set
2.2.2 Circular filter cloth Piece
2.3 Hose Piece
2.4 Throttle valve Piece
2.5 2/2-way ball valve Piece
2.6 Pressure gauge Piece
2.7 Non-return valve Piece
2.8 Pressure reducing valve Piece
2.9 Filter Piece
2.10 2/2-way ball valve Piece
2.11 Ball valve Piece
2.12 T-piece Piece
2.13 Plug Piece
2.14 Double nipple Piece
2.15 Bolted connection Piece
2.16 Pipe fastener Piece
en-CL.CPT.001.A
Machine manual Appendix
Coal silo 1
10 Appendix
10.1 Technical drawings
Assembly drawing
10.2 Subsuppliers' documentation
Negative pressure / excess pressure relief device
Bin weighing device
Filling level limit switch
Gate valve
2/2-way ball valve
en-CL.CPT.001.A
