PEME has successfully completed an Engineering Compliance project that involved the electrical rewiring of two rubber mills for an international packaging and print media company. The project has been delivered to budget and timescales with a major improvement in safety and functionality.
The mills were originally built and installed in 1974 and whilst the safety systems complied with the legislation in force at the time of installation, the systems needed updating to current regulations. Furthermore, the control panels did not comply to BS EN 60204 and the equipment was also obsolete.
The mills mix the ingredients to manufacture rubber to the exact type used to produce the cement that covers the roller sleeves and blankets produced for the print industry. The mills produce the base product on which which the whole process is dependant upon.
This Engineering Compliance project included an initial investigation into the condition of existing control systems, safety circuits and operation of the mills. This investigation concluded that if any parts in the control panels needed replacing in the future, the parts could no longer be sourced due to obsolescence. It was also noted that the resulting downtime would be unacceptable to the client due to the criticality of the mills as they are the ‘backbone’ of the process. The original panels were also found to be un-shrouded and the safety circuits were only single channel.
We designed and manufactured new Control Panels which included PLC and HMI. The safety circuits were upgraded to current legislation. New operator panels were also designed, built and installed. All panels were tested before delivery to site in our workshop facility to ensure functionality, safety and accuracy. This significantly reduced the time to install the panels.
A new ladder rack containment system was also installed as the original installation had degraded over-time and was no longer acceptable. The containment and cabling were installed around our client’s production schedule and so limited the downtime needed to complete the project.
The original control system was relay logic. We incorporated a PLC and HMI into the new control system so that indications and alarms could be viewed without the need to open the panel. Additionally, remote viewing and control was provided. As there is the potential for a new extract system to be installed in the future we provided additional functionality to allow for a signal to be sent to the extract control panel to auto start/stop the extract system. This helps to ‘future-proof’ the system.
The mill control panel now complies with the following standards:
- BS EN 60204; Safety of machinery, electrical equipment of machines general requirement
- BS EN 13849; Safety of machinery, Safety-related parts of control systems. General principles for design
- BS EN 1417; Plastics and rubber machines. Two roll mills. Safety requirements