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Avoca - PN2447

Project Name:

PN2447 – Completed Jan 25

Project:

Gauntlet Machine Compliance

Client

Avoca

Main Contractor::

CX Controls Ltd

Location:

CXC HQ – Rebuild and FAT

Manchester – Client tested

Slovenia – Final Destination

Value:

Confidential

Sectors:

Textiles Manufacturing

Services:

HAZOP and LOPA

CE Compliance

Design and Build

Panel Manufacture

System Integration

Install, FAT, Commission

Overview

CXControls were engaged by Avoca initially to perform a Machine Safety Gap Analysis on their imported gauntlet machine to establish operational readiness in order to meet CE Compliance.

The machine weighed 8 tons, with two sperate sections, consisting of a:

  • Reel-feed end section.
  • Pre-heat and main oven sections.
  • Pneumatic clamping and cylinder sections.
  • Several linear servo motors and drives for rod insertion.
  • Hotwire cutting station.
  • Conveying and end collection.

The Challenge

To meet harmonised standards for machinery in the European market and ensure CE Compliance.

The Solution

The solution was delivered in two phases….

Phase 1:

Perform a Gap Analysis on the imported machine including Machine Safety HAZOP and resulting LOPA (Layers of protection analysis), to establish a baseline design criteria for improvements.

Phase 2

  • Redesign and replacement control panel builds for Oven temperature and fans controls panel, PLC and Servo Controls panel, Clamps and fail-safe pneumatics panel & Hot Wire Cutter Controls panel to meet Machinery Regulation (EU) 2023/1230.
  • A complete strip out of all non-compliant electrical circuits and wiring.
  • The introduction of a functional safety architecture to meet a minimum of SIL 2 (Safety Integrity level).
  • Re-write of existing software code using Mitsubishi GS Works 3 for the existing PLC and servo axis controllers.
  • Supply and installation of new SIL 2 rated field switches/devices.
  • The fabrication and installation of machine access and guarding
  • Complete rewiring of the machine including all new and existing motors and control devices.
  • Final Factory Acceptance Testing, site commissioning and performance testing with client witnessing.
  • CE Compliance pack and handover.

The Results

A successful project resulting in a fully CE compliant machine for use in Europe.

Post operational trials were carried out successfully and the machine was then exported by our client to a final site in Slovenia, and is operating successfully to meet plant demand.

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