?

Clinker coolerLevel control with capacitance probe and monitoring electronic

High temperature probe Separate locatedelectronic unit

Discharge bins of clinker fines

Nivotester FTC625

Features

• Process temperatures up to 400 °C (752 °F)

• Display and electronics can be mounted separately

• Extra data transmission safety due to 2-wire technology

Advantages

• Maintenance reduced to a minimum due to no moving parts

• Preventive maintenance possible with digital communication between transmit-ter on FXA gateway as an option

• Optimised process availability due to remote access of process failure signals via FXA gateway

• Simple mounting and no calibration means lower installation costs

The Challenge

In cement production, the clinker burning process with the cyclone preheater, the kiln and the clinker cooler, is the heart of the process. The design and the process technology selected along with the relevant process automation have an important influence in cement quality. The speed of

cooling influences the clinker properties considerably: • with quicker cooling the crystal structure

will be finer and the required energy in the grinding process reduced

• rapid cooling in the high temperature zone will reduce the water demand of the finished cement

A clear detection and control of material flow as well as the air volume in the clinker cooler is therefore necessary to secure the requested product quality standards. For these reasons, reliable and robust sensors to monitor the clinker cooler are required.

High temperature probe T12656Fieldgate

FXA520

Instruments International

Endress+Hauser GmbH+Co. KGInstruments InternationalP.O. Box 222279574 Weil am RheinGermanyTel. +49 7621 975 02Fax +49 7621 975 345http://www.endress.cominfo@ii.endress.com

CS 012B/11/en/01.0555001834IMPR/INDD 2.0

The SolutionAt each clinker fines discharge outlet air is blown into the cooler at the required volume to bring down the temperature. The air flow volume is individually adjusted to optimize the clinker cooling process. Uncontrolled build-up of clinker fines in the discharge outlets will considerably affect this cooling air flow and cause mechanical damage to cooler grates. To safeguard the grate system each fines discharge outlet is equipped with a capacitance high tempera-ture point level probe. This level informa-tion will control the double pendulum flap at the discharge and maintain constant conditions in the discharge outlet with correct air flow.

Due to high temperatures the electronic unit is installed separate to the probe. High temerature capacitance point level probes are designed for a max. process tempera-ture of 400 °C (752 °F) and equipped with a special sword shaped probe end. This sword option has a wide surface area to give large changes in capacitance (good sig-nals) while presenting only a small resistive surface to the discharging material.

As the Clinker cooler area is seen as a cri-tical process, it is necessary that all sensors offer self testing and safe failure functionali-ty and signal transmission. This data integri-ty is attained using digital communications with the EC27 smart electronic insert and the Nivotester FTC625 electronic unit . The Nivotester is specially designed for reliable and safe level detection based on two-wire technology. Sensor failures and cable breakages are also detected; in this case the Nivotester FTC625, depending on the set Fail to Safe mode, will activate or deactivate the level output relay and activates the separate alarm relay on the unit.

BenefitsThe signals of the Nivotester FTC625 are transmitted independent of the process control system using a Fieldgate FXA520 gateway via a HART®-Protocol and Ethernet or GSM direct to the maintenance department. Remote monitoring of process critical limit values with alarm signalling makes it possible to react directly to any changes on-site. The data transfer in XML format allows simple analysis and proces-sing of the measured data. Condition moni-toring and predictive maintenance is made possible with the Endress+Hauser suite of programming tools featuring ToF-Tool and FieldCare®.

Being able to monitor process measurement trends and spot automation failures quickly allows proactive maintenance which avoids costly shut downs and improves inventory management. Reduced operational costs in the cooler process can be achieved whilst maintaining and even improving required quality and safety standards.

Further improvements in operational safety are possible by comparing the level data with other measurement data from the control system. High temperature capacitance probe with separate

located electronic unitTransmitter Nivotester FTC625