additive weigher basics

2. What is a additive hopper?
It is a weighing scale for additives

4. Double Acting
Cylinder valve
Manifold
Valve
Additive Hopper Parts

5. Double Acting
Cylinder valve
Funnel(Receiving Hopper)
Kinetrol Actuator
Pressure
blower
Pressure Tank
Discharging
actuator
Load cell
Additive Hopper Parts

6. Discharging
actuator going to
premix or
letdown tanks
Additive Hopper Parts

7. Additive pipeline
from additive
hopper going to
letdown tank
Additive Hopper Parts

8. Additive pipeline
from additive
hopper going to
premix tank
Additive Hopper Parts

11. KINETROL
ACTUATOR
Specification

12. Cylinder Valve
Specification

13. Ball valve
specification

14. Load Cell Specification

16. ADDITIVE HOPPER PIPELINE(for BAY2-4)
The inlet pipeline of additive
hopper are connected to the
horizontal and additive
tanks. The additive tanks are
the source of additives that
you can withdraw in the
additive hopper. The
horizontal tanks(HT#5-8)
that contain process water is
connected also to the
hopper. The process water is
used to wash the pressure
tank.
The discharge pipeline is
connected to the premix and
letdown tank. This means
that the weighted additives
can be discharge either on
premix or letdown tank..

17. ADDITIVE HOPPER PIPELINE(for BAY1)
The set up of the pipeline for BAY1 is almost the same for the bay 2-4, the only difference is that the overhead
tank was used except of horizontal tank. The reason for this is that the Bay1 is design for solvent based paint so
that the main component was kerosene . The kerosene tank is located at the tank farm .

19. HELIUS – a computer program
that sends data to the unitronics
about what additives to
withdraw and where to
discharge it.

20. “PANTHER”
This device is the one that
convert the signal send by the
load cell to a readable seven
segment display. It shows the
current weight of the additive
hopper
“UNITRONICS VISION280”
This device is a combination of PLC
and HMI. The plc is a device that
perform several calculation to make
the process possible. And the HMI is
a device that display the current
status of the equipment or the process
and this can also act as an input
signal devices. This device is
responsible on closing and opening of
valves of the additive hopper.

21. WIRING DIAGRAM

23. ADDITIVE HOPPER OPERATION
From additive tanks
The additive operation start in withdrawing additives from
the additive tanks . The cylinder valve and the kinetrol actuator will
opens at the same time in the withdrawal process. The additives is
directly drop to the tank by means of gravitational force. While
withdrawing, the additives will be weighted at the same time through
the load cell beneath the tank. When the target weight is near the
cylinder valve will start to jog. This jogging of cylinder helps to achieve
much accurate weight and to avoid overcharging . When the target
weight reach, the discharging process will start.
In discharging, the discharge actuator of the pressure tank
will open and at the same time one of the six discharge actuator going to
the tank will open. This six actuator is responsible on setting what tank
the additives must be discharge. The process engineer is the one who
will set where the additives must be discharge. When the two actuator
is already open, the pressure blower start to works . The pressure
blower is used to push the additives to the desired tank.
Discharge
actuator
Kinetrol
actuator
Discharge
actuator
going to the
tank
Pressure
blower
Pressure tank
Load
Cell
Cylinder
valve

24. End of
Program
PROCESS CYCLE
The Process
Engineer will
set a program
what additive
to be
withdraw and
where to
discharge
To execute
the program
the
production
operator will
need to press
the enter to
the proface
Additive
hopper will
start to
withdraw
additives to
get the target
batch
weight(or
target weight
per batch).
When the
target batch
weight
achieved, the
Discharge stage
start. The
additives will be
discharge to the
tank.
The Additive
hopper will
repeat the
withdrawal and
discharging
process until it
reaches the
total number of
batches.
The additive
hopper start
to withdraw
process water
to wash the
funnel and the
pressure tank
and discharge
to the same
tank.
When enter has
pressed, the
computer will
send the data to
the unitronics .
The unitronics
will start to
compute how
many batch is
needed to get
the target
weight.

25. PROGRAM CYCLE
Set a
program
on
HELIUS
does
enter
was
pressed
?
Helius will
send program
to the
unitronics
Press
enter on
proface
# of batch = Target weight
tank capacity
Target batch weight = Target weight
# of batch
completed batch = 0
n=0
Unitronic
will start
calculation
NO?
YES?
Withdrawal
stage
Target batch weight - current batch weight
= perlim weight?
Jogging of
cylinder valve
Target batch
weight
=current batch
weight?
Discharging
stage
current batch
weight = 0?
completed Batch = n+1
n=completed batch
Completed
batch = # of
batch?
IDLE(end of
program)
YES?
NO?
NO?
NO?
NO?
YES?
YES?
YES?
YES?

27. PROBLEM POSSIBLE CAUSE
Unstable Weight •Unbalance load cell
•Check the alignment of funnel
•Check the hose installation it must not touch
the ground
•Vibration of hose when discharging
•Loss contact of load cell wires connection
Continues increase on weight •Check if there is a leak on the cylinder valve
inside the funnel
•Unbalanced hopper
Leak on cylinder valve •Defective shaft seal
•Defective O-ring on the thread
Malfunction of cylinder valve and
actuator
•The cylinder valve is not aligned
•To tight bolts
•Air leak on the exhaust of the solenoid
Air leak on exhaust of the solenoid
valve
•Cylinder valve seal is already damaged causing
an air leak
•Actuator valve seal is already damage causing
air leak