To carry out our engineering, we determine all relevant parameters and define the design of the facility. This includes designing pumps and control valves, as well as determining nominal widths and pressure levels. We draw the P&I diagram and optionally prepare detailed equipment and signal lists. Of course, the project is fully documented to ensure that the technology and processes can be quickly followed even after years of use.

Exact knowledge of the characteristics of our nozzles is very important. Only a complete system coordinated according to how the nozzles work and operate will ensure the smooth and economical operation of the gas cooling system. The service life of the products used is the key to the profitability of a cement plant. Unexpected malfunctions can quickly lead to plant shutdowns and costly production outages. Thats why we equip our pumps and control slides with high-quality components from well-known manufacturers as standard, and even the most important functional components are implemented in redundant design. The components are interconnected by pipes and mounted on a sturdy base frame with perforations for transport by crane, while ensuring that all components are easily accessible for operation and maintenance.

Design (e.g. dimensioning of nominal widths) and production comply with the latest technology and all relevant standards. As with final acceptance, they are also subject to the DIN EN ISO 9001 certified Lechler quality management system. Before delivery, the pump and control skid are pressure and leakproof tested and checked by our experienced engineers. This will prevent any problems during commissioning.

The numerous installations of VarioCool systems, many years of commissioning experience and expertise in nozzle technology all contribute to the continuous improvement and optimization of Lechler control systems. By installing a Lechlerin control solution, you will benefit significantly from this wealth of experience. The flexible and fully automatic concept can be perfectly adapted to your process. With our solution you will have perfect control of startup and shutdown scenarios and dynamic process conditions.

Option packages for our VarioCool pump and control skids

All components except the pump motors are connected to a junction box within the pump and control skid. This ensures that the customer has a central connection point for further processing in high-level control for all electrical components and measuring devices.

All components, including pumps, are wired to a control cabinet. The control cabinet is integrated into the base frame of the pump and control skid. The complete injection control is tested in accordance with applicable electrical standards and regulations and allows all relevant process parameters to be visualized via a control panel in the control cabinet. Custom configuration and extensive testing make commissioning much faster. Communication and signal exchange (setpoint, plant status, error messages) with the customers logic system are carried out via PROFIBUS or PROFINET. The control has various operating modes, including automatic mode and manual mode for testing during plant outages. In case of malfunction, our engineers can quickly perform remote diagnosis via the installed modem, without the need for an on-site visit.

Ring mains (1): Ring mains are generally used to feed spears. Lechler supplies ring mains and headers with corresponding brackets for welding the flue gas duct. Accessories such as pressure transmitters and manometers as well as suitable connections for nozzles and supply lines are also included in the scope of delivery. Purge air connection (2): Individual spears or groups of spears can be connected or disconnected to increase the injection throttle ratio. If the disconnected nozzles are in the flue gas duct, the remainder of the liquid must be drained. In this way, evaporation and accumulation of debris in the blow pipe can be prevented.

The water tank made of steel or plastic serves as a reservoir for the pump and control skid and guarantees injection operation for a certain period of time in case of interruption of the water supply. Its size is adapted to the injection amount. Tank filling and level monitoring components are included in the scope of delivery.

Barrier air is often applied to nozzles and spears to protect them from dust accumulations and/or high temperatures. For this purpose Lechler supplies fans for specific application with various optional attachments such as throttle valve, intake filter and silencer.