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Haver & Boecker provides electrical engineering and automation for Swedish cement terminal

World Cement,

Haver & Boecker’s subsidiary company, IBAU Hamburg served as general contractor for the construction of a cement terminal for Cementa AB, part of the HeidelbergCement Group. The terminal, which is located at the port of Malmö, Sweden, is fed by a mechanical-pneumatic ship unloading system and provides the automatic loading of tanker trucks and wagons 365 days a year. The 30 000 t multi-chamber cement terminal silo has a dia. of 26 m and is 100 m tall.

Haver & Boecker supplied the complete electrical system and automation for the project, including: PCS7 process control system with CEMAT; 11kV gas-isolated medium voltage switchgear; dry-type transformer 1600 kVA; low voltage main distributor with compensation; switching and control cabinet with S7-400/ET 200M; electrical grounding and lightning protection; cable and installation material; IT network and infrastructure; video-monitoring of the loading stations, as well as the entrances and exits; interior and exterior lighting; and engineering and complete electrical installation and start-up.

During the planning phase, IBAU worked in close cooperation with the HeidelbergCement Technology Centre in Brussels. It was decided that the control room in the multi-chamber silo would be moved to Level 1. This offered the advantage of considerably reduced cable paths through silo walls. As space for the switching and control cabinets, energy distribution and transformers was limited, the companies opted for maintenance-free, gas-isolated medium switchgear.

The electrical installation involved a number of demanding challenges for personnel. Installation of the cable works and laying the cable in the bucket conveyor tower – from Level 0 to 100 m – required special cranes and had to be carried out by workers who were not afraid of heights.

One challenge for the automation systems supplied by Haver & Boecker was adapting the PCS7 process control system to the silo processes so that clear and well-arranged process groups resulted, thereby allowing easy operation and rapid fault detection. The tanker trucks and wagons are automatically loaded according to the shipping orders thanks to data exchange between the process control unit and the shipping system provided by Cementa AB. By cooperating closely with HeidelbergCement Technology Centre, the processes were optimised so that the terminal could function without operating personnel.

The terminal was successfully handed over to Cementa AB in March 2012, after almost two years of planning and construction work.

Adapted from press release by Louise Fordham.

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