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Kundapplikation 25 juli 2018

Väl utrustad för farliga områden

Tankfartyg på flygplatser runt om i världen måste ta med sitt A-spel varje dag. Närmaste flygtider och strikta säkerhetsföreskrifter avgör den dagliga arbetsbelastningen för fordon och förare. Det brasilianska företaget Rucker är specialiserat på att utrusta tankbilar med flygplan och har precis avslutat ett stort projekt för Infraero, Brasiliens nationella flygbolag.

På de flesta stora flygplatser försörjs passagerar- och fraktplan med hjälp av underjordiska jetbränsleledningar. En Airbus A380 kan till exempel ta upp till 310 000 liter bränsle, medan en genomsnittlig tankbil bara kan rymma 40 000 liter. Tankning från tankbilar skulle uppenbarligen ta lång tid, varför flygplatser använder så kallade brandposter. De pumpar flygbränslet från rörledningarna till flygplanen. Förutom enorma tidsbesparingar minskar denna metod även riskerna med mobila jetbränsletankar. Det ser enkelt ut när de specialutbildade flygplanstankarna på ett sakkunnigt sätt ansluter slangar och styr bränslepåfyllningen med fjärrkontrollen; denna enkelhet döljer dock ett komplext tekniskt system. Bland andra funktioner tar tankbilarna bort bränslet från de underjordiska rörledningarna, som är trycksatta till 10 bar, och minskar trycket till 3,5 bar. Om trycket är för högt kan tankarna i planets vingar skadas. Hydranttankfartyg kan starta, övervaka och avsluta hela tankningsprocessen. Rucker tillhandahåller automations- och regleringstekniken för dessa krävande applikationer.

Så här hjälper WAGO dig i ex-området:

WAGO 750 XTR I/O-SYSTEM för Ex områdesapplikationer tål även de mest extrema förhållanden.
Det tillåtna omgivande lufttemperaturintervallet på −40 C till +70 C gör att modulerna kan användas i alla klimatzoner utan behov av ytterligare skydd från luftkonditionering eller värmesystem.
Den ökade immuniteten mot impulsspänningar och störningar tillåter till och med att den kan användas i mellanspänningssystem.
Deras extrema vibrations- och stöttålighet uppfyller även kraven för rälsfordon och installation på marina dieselmotorer.

Konvertering till PLC:er och fjäderanslutningsteknik

Under moderniseringen av sin tankfartygsflotta anförtrodde det brasilianska flygbolaget Infraero Rucker designen och implementeringen av en lösning för att övervaka driftlogiken. Detta system skulle utrustas med en PLC och I/O-moduler för signaldetektering och installeras i ett styrskåp i tankbilarnas hytt. Ingenjörerna på Rucker hade länge velat konvertera de gamla tankbilssystemen från reläkontroller till PLC-teknik. ”Ett första försök genomfördes med skruvsystem; det ledde dock inte till tillfredsställande resultat. Dynamiken i tankfartygen var problematisk på grund av den konstanta rörelsen och förändringar i omgivande lufttemperaturer. Fordon skulle helt enkelt stanna på grund av felaktiga kontakter, vilket gjorde hela systemet opålitligt”, rapporterar Rafael Mendes, VD för Rucker.

Ökade krav för flygplatsapplikationer

För att lösa de nuvarande problemen, förlitade Rucker sig på fjäderanslutningsteknik från Planen Automação, en WAGO-försäljningspartner baserad i São Paulo, för att tillhandahålla en komplett lösning baserad på styrenheter och I/O-moduler för farliga områden. Dessa kunde installeras, tillsammans med standard I/O-moduler, på en buss, vilket gjorde det tidigare kravet på inneboende barriärer överflödigt. Konceptet anpassades specifikt till de ökade kraven på användning på flygplatser, i synnerhet interaktioner med farliga atmosfärer. Det största hindret låg dock i att certifiera komponenterna.

Certifiering enligt brasilianska standarder

Infraero krävde att en av certifieringarna för farliga zoner skulle utföras av National Institute of Metrology, Standardization, and Industrial Quality, INMETRO. Planen Automação initierade de processer som var nödvändiga för att erhålla den nationella certifieringen från TÜV-certifieringsförbundet i Brasilien. I samband med detta lanserades också ett godkännandeförfarande för aggregatprodukterna. Support gavs av WAGO Minden, av specialister på dessa typer av certifieringsprocesser.

Enkel installation och tydligare sikt

Efter att formaliteterna slutligen var avslutade kunde projektgenomförandet påbörjas. Rucker kunde minska storleken på styrskåpet tack vare egensäkra Ex i-moduler, som delar samma mjukvara för programmering och kommunikation som andra moduler. Före WAGO-lösningen monterade företaget Ex i-barriären separat från styrenheterna, vilket krävde ett mjukvarupaket för att programmera barriären, och ett annat för styrenheterna. De kompakta modulerna möjliggör optimal placering i styrskåpet, vilket leder till enklare montering och bättre transparens.

Styr kommunikation via ETHERNET-kabel

Eftersom modulerna har fjäderklämmande anslutningar gick monteringen både snabbare och anslutningarna är mer tillförlitliga. Den lättillgängliga styrkommunikationen via ETHERNET-kablar är en annan fördel med det nuvarande systemet. Tidigare krävdes separata kommunikationskablar för styrenheterna och Ex i-barriären. Fokus i de nya systemen ligger i första hand på snabba och enkla justeringar och optimering av parametrar samt möjligheten att lägga till funktioner på plats enligt kundens önskemål. Dessutom förbättrar den användarvänliga programvaran och ETHERNET-kommunikationskabeln teknisk support genom att lägga till fjärrsupport via Internet.

Milstolpar för WAGO-produkter i Brasilien

Från fyra originaltankbilar som var utrustade med WAGO-satsen 2014 har flottan vuxit, från 14 2016 till 21 2015 till de nuvarande 39 WAGO-utrustade fordonen. Varje systemkonfiguration inkluderar en 750-881 PLC, digitala in-/utgångskort för 24 V och Ex i digitala in-/utgångsmoduler. I paketet ingår även andra I/O-moduler och reläer från WAGO. Ruckers tankfartyg inkluderar nu nästan 9 200 WAGO-produkter för anslutning, automation, gränssnitt och identifiering. "Nu kan vi lita på ett felfritt system, som kan underhållas enkelt och till och med på distans av våra tekniker, inklusive mjukvaruuppgraderingar", säger Mendes glatt. Sedan genomförandet av projektet för Rucker är WAGO fortfarande en av de få tillverkarna av styrenheter och I/O-moduler vars hela produktportfölj är certifierad för farliga zoner av INMETRO.

Text: Rodrigo Rodrigues | WAGO Brasilien

Foto: WAGO

Produktöversikt

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Som partner och innovationsledare gör WAGO många intressanta projekt till verklighet. Läs mer om våra kreativa och effektiva processtekniklösningar.

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