ESA ELECTRONIC ENGINEERING
ELECTRONIC   EQUIPMENT   SYSTEMS   FILTRATION   AIR/GAS
 
 
App
ESA PRODUCT APPLICATIONS
   
•   Respect for the Environment •   Safety in Industrial Production
•   Savings on Electricity and Management Costs •   Maintenance cost savings
   
 
 
USE OF EQUIPMENT IN INDUSTRIAL FILTRATION
 
In most industrial production processes, solid materials are handled that can generate harmful dust dispersed in the environment.

To prevent the dust generated by production from being dispersed into the environment, air/gas filtration systems are used.

These systems are equipped with electronic control units, called sequencers or cyclic timers, which control the valves that make up the cleaning cycle also known as the washing cycle.

The cleaning cycle keeps the filtering parts, whether bags or cartridges, within the dP values (differential pressure between points P1 and P2) indicated by the system manufacturer.

The sequencers are connected to the valves that activate the washing cycle.

The valves are in turn inserted into the compressed air system.

Activating the washing cycle causes the valves to open that allow compressed air to enter the filtering areas (sleeves or cartridges), cleaning them from dust with the vibrating action of the shots.
 
WASHING CYCLE OPERATION WITH dP CONTROL
 
Another important parameter for the proper functioning of the dedusting system is the adjustment of the dP thresholds

dP = differential pressure of the filter between the dust inlet area and the air outlet area after filtering media.
 
dP values. During the operation of the system, the filtering system, by retaining dust on its surface, causes the dP value to increase reaching the ON threshold.

This condition activates the cleaning cycle CYCLE ON and stops the cleaning cycle at another preset threshold CYCLE OFF.

This adjustment is very important and allows the filter to operate properly within the values prescribed by the system manufacturer with relative savings in compressed air consumption.

Alarm values max dP which establishes the maximum operating value of the system beyond which the emergency must be signalled through the alarm contacts
 
ENVIRONMENTAL SAFETY WITH TC TRIBO-ELECTRIC PROBES
 
The dusty particles produced by processing, in addition to being harmful to the health of plant workers, can be very dangerous for the environment and in some cases cause fires or explosions.

To prevent the spread of dust in the environment, ESA offers triboelectric probes of our production.

The TC probes positioned in the air/gas outlet area after the filtration system, report dust emissions into the environment, caused by breakages in the filtering parts such as bags or cartridges.

In the presence of possible explosive emissions, the use of equipment with ATEX marking is mandatory according to the characteristics of the work area.
See ATEX tables
 
ELECTRICITY COST SAVINGS
 
With an adequate adjustment of the operating parameters of the control unit, following the indications of the system manufacturer (washing cycles / h and dP values of system operation), considerable cost savings are guaranteed.

Experience has shown savings of up to 30% in electricity with good fine-tuning of the operating parameters, avoiding waste of compressed air used by the washing system.

The primary objective is to keep the filtering system in optimal conditions with the least number of washing cycles and with minimum firing times following the instructions of the valve manufacturer.

Incorrect firing time adjustments are often made with unnecessary waste of air

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COST SAVINGS OF FILTER MATERIALS
 
The aspect relating to the wear of the filtering components and valves should not be overlooked either, which, if stressed due to incorrect adjustments of the operating parameters, significantly reduce their operating life over time, with related additional costs.

To this end, the correct setting of the following parameters must be carefully evaluated:

Working time also known as firing time of solenoid valves or pilots in the case of pneumatic valves (it is advisable to follow the valve manufacturer's instructions)

Pause time between one shot and the next, paying attention to the sizing of the compressed air system which must guarantee the operating pressure at the time of firing.

Pause times between the activation of one valve and the next prevent the compressed air system from reaching the expected operating values.

This situation is very dangerous for the proper functioning of the washing system, in fact if the pressure at the valves is lower than the pre-established value e.g. 5 ATM, but only 2 ATM, the effect of the compressed air firing on the filtering parts (bags or cartridges) is nullified with faulty cleaning.
 
COST SAVINGS IN THE PREVENTIVE CONTROL OF OPERATING ANOMALIES
The control to prevent malfunction costs is essentially based on three points:

1 Check for broken sleeves with TC probes

Breakages in the filtering parts allow polluting dust to escape into the atmosphere, with serious consequences for the surrounding environment, with significant costs and penalties.

2 Check the smooth operation of the firing valves.Proper operation of the valves is essential to ensure that the filtration system operates as intended.

The valves, due to accidental abnormalities, may have electrical, pneumatic or mechanical problems.

By using the TP30 pressure transducer you can prevent and report such problems.

Comparing the pressure drop in the compressed air tank via TP30 with the activation of the valve, the response to valve operation is obtained.

If the TP30 does not respond, the valve has not been activated and therefore not working.
3 Checking Alarm Values for Max dP

The increase beyond the limits of regular operation of the dP value, differential pressure between the air inlet and outlet of the filtration system, can cause serious problems to the production cycle where the filtration system is located.

This alarm is signalled by contact in the terminal block

The causes of these problems can be pneumatic or electrical (faulty electrical connection, broken solenoid).

Lack of compressed air can be one of the main causes of the increase beyond the alarm threshold of the max dP value.

It is recommended to install a pressure switch on the compressed air tank that gives consent to the cleaning system. TP30 can be used for the dual function of shot control and pressure switch.

Electrical problems can affect both the electrical system of the valves and the proper functioning of the sequencer.

With appropriate precautions, it is possible to prevent and report such anomalies with alarms.
 
SAVINGS THROUGH CONTINUOUS MONITORING OF PLANT OPERATION
 
Another important control to plan the maintenance of the systems consists in the monitoring and collection of operating data, reducing shutdowns due to breakdowns.

The collection of plant operating data allows you to have a history of the parameters, and to highlight malfunctions that allow you to schedule maintenance interventions when production is stopped such as during holiday breaks or other.

This control can be done by connecting the equipment concerned to a remote PC. Dedicated software must be installed on the PC for this purpose such a: ESANET

Alternatively, it is possible to connect the equipment to PLCs via FIELDBUS.
For more information and details contact the technical department: ESA Electronic Engineering