Professional Documents
Culture Documents
Vedanta - Jharsuguda
138-02-043
Group 422 A
DE-060300
5
5.1
5.1.1
5.1.2
5.1.3
5.2
5.2.1
5.2.2
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.3.9
5.3.10
5.3.11
5.1
Process
5.1.1
Revision: 0
Date: 29.09.2006
Page 1 of 6
138-02-043
Group 422 A
DE-060300
Revision: 0
Date: 29.09.2006
file: 138-02-043_05_0.doc, Codeword: Vedanta
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
1 (3)
Rev. 00
132-30-007 UB
P&I Diagram:
168-01-050 UB Sheet 1, 2
The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This subgroup is mainly processing Butts (recycled pre-crushed Baked Anodes from
potrooms, baking furnace and rodding shop) and Green Scrap (recycled, pre-crushed no-go
Green Anodes and Green Anode Paste scrap). For each of the materials a special route has
to be selected by the operator on the SCADA system on the Operator Stations located in the
Central Control Room. A main philosophy is that different materials shall never be mixed up.
Therefore changing of the sort of material requires a run empty of this Group 422 A.
Material Route Butts (Selection SE 2-1 / 2-2 / 2-3)
If this Group shall process Anode Butts the operator must select BUTTS (selection SE 2-1 /
2-2 / 2-3) on SCADA prior to Group start.
Anode Butts of 0-50 mm size are stored in two Main Storage Bins (422 A 200, 422 A 300). It is
up to the operator to withdraw butts from both bins simultaneously or from one of the bins only.
The storage bins can be isolated for maintenance by flat slide gates, one under each bin (422
A 001 and 422 A 011). Normally the flat slide gates are open.
Butts are continuously withdrawn from the bins by means of vibrating trough feeders (422 A
031, 422 A 041). Both vibrating feeders are equipped with variable speed drives for controlling
the feed rate in a range of 10-50 tons/hour. The operator can select the number of vibrating
feeders in charge and can remote adjust the feed rate of the feeders. It is a common
procedure to blend butts from two silos to maintain constant raw material quality and grain size
but it is also common practice to discharge from one silo only.
The maximum feed rate allowed for Line 1 & 2 is 48 tons/hour and for one line only, is 24
tons/hour.
Butts are fed to the inclining belt conveyor (422 A 060) running underneath the vibrating trough
feeders. A belt scale (422 A 062) and a magnet (422 A050) is integrated in the belt conveyor.
Dust generated through feeding and conveying of butts is sucked off from the vibrating feeders
and from the belt conveyor to be then drawn by a fan (422 A 080) through collecting pipes into
the dust collector (422 A 070) to be separated. The dust collector is of jet-cleaning type. A
counter-flow compressed air blow cleans the bags. Separated dust is continuously fed to the
belt conveyor (422 A 060) by mean of a rotary lock (422 A 065).
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
2 (3)
Rev. 00
By means of a servo-motor operated splitter gate (422 A 130) the material flow can be split
into two part-flows of equal or un-equal rate or the whole flow can be directed to either side.
The material is feed via reversing flap (422 A 132) into butts feed bin (422 A 200 of Line 1)
and/or via belt conveyor (422 A 135) and reversing flap (422 A 140) into butts feed bin (422 A
300 of Line 2).
Dust generated through feeding and conveying of butts is sucked off from the butts feed bin
(422 A 200) and the belt conveyors (422 A 135 and 422 A 060)) to be then drawn by a fan
(422 A 115) through collecting pipes into the dust collector (422 A 105) to be separated. The
dust collector is of jet-cleaning type. A counter-flow compressed air blow cleans the bags.
Separated dust is continuously fed upside the splitter gate (422 A 060) by mean of a rotary
lock (422 A 100). Belt conveyor (422 A 135) and butts feed bin (422 A 300) are sucked off by
the main dust treatment group 432 C.
If both or one of both butts fraction bins (422 A 200 / 300) are nearly full, the operator stops
this Group using the normal Group Shut Down. In this case the equipment of this Group is
running empty, what is absolutely required before the Group can be restarted to process
Green Scrap instead of Butts.
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
3 (3)
Rev. 00
Dust generated through feeding and conveying of green scrap is sucked off from the butts
feed bin (422 A 200) and the belt conveyors (422 A 135 and 422 A 060)) to be then drawn by
a fan (422 A 115) through collecting pipes into the dust collector (422 A 105) to be separated.
The dust collector is of jet-cleaning type. A counter-flow compressed air blow cleans the bags.
Separated dust is continuously fed upside the splitter gate (422 A 060) by mean of a rotary
lock (422 A 100). Belt conveyor (422 A 135) and butts feed bin (422 A 300) are sucked off by
the main dust treatment group 432 C.
If Group 431 B Butts Crushing and Screening and/or Group 432 B Butts Crushing and
Screening both or one of both groups could stop by the operator using the normal Group Shut
Down. In this case the equipment of this Group is running empty, what is absolutely required
before the Group can be restarted to process Green Scrap instead of Butts.
138-02-043
Group 422 A
DE-060300
The equipment capacity is higher than the maximum process load, based on 40 t/h
feed rate.
The process load is 40 t/h at a maximum whereas the equipment capacity is 50 t/h.
The equipment capacity can be found in the Process Flow Sheets in a rhombus.
Butts can be reclaimed either from only one or from both main storage bins. Both
vibrating feeders are frequency controlled. Green Scrap can be reclaimed by one
frequency controlled vibrating feeder. The feed rate is measured by a belt scale and is
displayed on SCADA. The operator has to observe the displayed rate and if the rate
differs too much from the target feed rate he has to readjust the frequency of the
vibrating feeders. Adjustment of the frequency (feed rate) is also on SCADA.
If Green Scrap is used in group 431/432 B this group has first to run empty, to avoid
mixing butts with green scrap. To do this the operator is first shutting down and
running empty group 422 A (butts and green scrap reclaiming). Then Group 431/432
B has to run empty, as it is a feature of the Normal Shut Down procedure. Then he
may restart the Group after he has selected to process green scrap.
The similar procedure has to be followed when the Group is actually processing green
scrap and butts are required in group 431/432 B.
The time required to change the process material is about 20 minutes, counted from
initiating the Normal Shut Down and to that moment the Group is fed by the other
material again.
If one of the two butts feed bins (422 A 200, 422 A 300) is full, or one the two
subsequent groups 431/432 B is shut down the feed rate of the selected vibrating
feeders (422 A 031, 422 A 041 for butts and 422 A 051 for green scrap) is halved
automatically.
Revision: 0
Date: 29.09.2006
Page 3 of 6
5.2
Process Control
5.2.1
138-02-043
Group 422 A
DE-060300
(work copies)
Revision: 0
Date: 29.09.2006
file: 138-02-043_05_0.doc, Codeword: Vedanta
138-02-043
Group 422 A
DE-060300
Revision: 0
Date: 29.09.2006
Page 5 of 6
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
1 (27)
Rev. 00
Control Philosophy
of
Process Group 422 A
- Butts Reclaiming Reference:
Process Flow Sheet:
132-30-007 UB
P&I Diagram:
168-01-050 UB Sheet 1, 2
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.5
2.5.1
2.5.2
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.7
2.8
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
1
2 (27)
Rev. 00
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
3 (27)
Rev. 00
If both or one of both butts fraction bins (422 A 200 / 300) are nearly full, the operator stops
this Group using the normal Group Shut Down. In this case the equipment of this Group is
running empty, what is absolutely required before the Group can be restarted to process
Green Scrap instead of Butts.
CONTROL PHILOSOPHY
24.10.2006
4 (27)
Rev. 00
2.1
2.2
The exchange of control signals is described in the following chapters and especially under 2.8
below.
2.3
Selections
2.3.1
2.3.2
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
2.3.3
5 (27)
Rev. 00
2.3.4
2.4
Group Start
2.4.1
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
2.4.2
6 (27)
Rev. 00
Start Preconditions
New Setpoint
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
7 (27)
Rev. 00
Previous Setpoint
Standard Setpoint
2.4.3.1 Vibrating Trough Feeders for Butts 422 A 031, 422 A 041 Individual - (Setpoint SP 1-1;SP 12)
The operator may set the feed rate of each vibrating feeder at any time. Feed rates can be
set within a range of 35% to 100% for each of the feeders individually. The operator also
has the choice of a Standard Setpoint, which can be selected on SCADA individually for
each feeder (first approach for Standard Setpoint is 50%). Setting is on SCADA. On
SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint all overriding the actual setpoint.
2.4.3.2 Vibrating Trough Feeders for Butts 422 A 031, 422 A 041 - Master- (Setpoint SP 2)
The operator may set a MASTER FEED RATE for these vibrating feeders at any time. The
MASTER FEED RATE can be set within a range of 60% to 140% for all these feeders.
The MASTER FEED RATE is a factor (0.6 1.4) by which the individual feed rate (see
2.4.3.1 above) of these feeders is multiplied. At 100% (factor = 1.0) the feed rate of the
single feeders is equal to the individual feed rate set above. On SCADA the operator has
the choice to select one of three options, New setpoint, Previous setpoint and
Standard setpoint all overriding the actual setpoint.
2.4.3.3 Vibrating Trough Feeder for Green Scrap 422 A 051 (Setpoint SP 3)
The operator may set the feed rate of the vibrating feeder at any time. Feed rate can be
set within a range of 35% to 100%. The operator also has the choice of a Standard
Setpoint, which can be selected on SCADA individually for each feeder (first approach for
Standard Setpoint is 50%). Setting is on SCADA. On SCADA the operator has the choice
to select one of three options, New setpoint, Previous setpoint and Standard setpoint
all overriding the actual setpoint.
2.4.3.4 Splitter Gate 422 A 130 (Setpoint SP 4)
If Selection SE 2-3 or 3-3 is selected, the operator may set the splitter blade position at
any time in a range of 0% to 100% [0% = limit switch position 422 A 130-ZL]. Setting and
display of the actual position is on SCADA. On SCADA the operator has the choice to
select one of three options, New setpoint, Previous setpoint and Standard setpoint all
overriding the actual setpoint (Standard setpoint: 50%).
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
2.4.4
8 (27)
Rev. 00
2.4.4.1 Group Start Sequence after SE 2-1/2-2/2-3 Material Route for Butts has been selected
The operator is enabling this Group 422 A to start and to run the selected equipment. To
initiate the start he is using the SCADA system on the Operator Station in the Central Control
Room.
If SE 2-2 or SE 2-3 is selected a Signal from Group 432 C (Main Dust Treatment) is
required (Group is running in CENTRAL mode and is not in Group Start (START) or any
Group Stop sequence (RESTOP or FASTOP))
The horn starts to sound permanently for 15 seconds prior to start of the first equipment,
then it sounds instantly until the last drive is running.
Reversing Flap (422 A 140) tilts to limit switch [422A140-ZH] automatically
Reversing Flap (422 A 132) tilts to limit switch [422A132-ZH] automatically
Splitter Gate 422 A 130 is enabled
If SE 2-1 is selected and the splitter gate (422 A 130) is not adjusted at 100% material
flow to butts feed bin (422 A 200) [limit switch 422 A 330-ZH is not actuated] the
splitter blade tilts to limit switch [422 A 130-ZH] automatically.
If SE 2-2 is selected and the splitter gate (422 A 130) is not adjusted at 100% material
flow to belt conveyor (422 A 135) [limit switch 422 A 130-ZL is not actuated] the
splitter blade tilts to limit switch [422 A 130-ZL] automatically.
If SE 2-3 is selected and the butts feed bin (422 A 200) is not full [422 A 200-LAH2] is
not indicating high level and/or [422 A 200-LAHH] is not indicating high-high level and
the butts feed bin (422 A 300) is not full [422 A 300-LAH2] is not indicating high level
and/or [422 A 300-LAHH] is not indicating high-high level, than the splitter gate (422 A
130) is adjusted to the actual value of setpoint SP-4 automatically.
If SE 2-3 is selected and the butts feed bin (422 A 200) is full [422 A 200-LAH2] is
indicating high level and/or [422 A 200-LAHH] is indicating high-high level and the
splitter gate (422 A 130) is not adjusted at 100% material flow to the belt conveyor
(422 A 135) [limit switch 422 A 130-ZL is not actuated] the splitter blade tilts to limit
switch [422 A 130-ZL] automatically.
If SE 2-3 is selected and the butts feed bin (422 A 300) is full [422 A 300-LAH2] is
indicating high level and/or [422 A 300-LAHH] is indicating high-high level and the
splitter gate (422 A 130) is not adjusted at 100% material flow to the butts feed bin
(422 A 200) [limit switch 422 A 130-ZH is not actuated] the splitter blade tilts to limit
switch [422 A 130-ZH] automatically.
Fan (422 A 115) starts.
Fan (422 A 080) starts.
Delay of 20 seconds for fan impeller run-up.
Belt conveyor (422 A 135) starts if SE 2-2 or SE 2-3 is selected
Magnet (422 A 055) starts
Belt Scale (422 A 062) is enabled
Jet cleaning of dust collector (422 A 105) is enabled.
Rotary lock (422 A 100) starts.
Belt conveyor (422 A 060) starts.
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
9 (27)
Rev. 00
2.4.4.2 Group Start Sequence after SE 3-1/3-2/3-3 Material Route for Green Scrap has been
selected
The operator is enabling this Group 422 A to start and to run the selected equipment. To
initiate the start he is using the SCADA system on the Operator Station in the Central Control
Room.
If SE 3-2 or SE 3-3 is selected a Signal from Group 432 C (Main Dust Treatment) is
required (Group is running in CENTRAL mode and is not in Group Start (START) or any
Group Stop sequence (RESTOP or FASTOP))
If SE 3-1 or SE 3-3 is selected a Signal from Group 431 B (Butts Crushing & Screening) is
required (Group is running in CENTRAL mode and is not in Group Start (START) or any
Group Stop sequence (RESTOP or FASTOP))
If SE 3-2 or SE 3-3 is selected a Signal from Group 432 B (Butts Crushing & Screening) is
required (Group is running in CENTRAL mode and is not in Group Start (START) or any
Group Stop sequence (RESTOP or FASTOP))
The horn starts to sound permanently for 15 seconds prior to start of the first equipment,
then it sounds instantly until the last drive is running.
Reversing Flap (422 A 140) tilts to limit switch [422A140-ZL] automatically
Reversing Flap (422 A 132) tilts to limit switch [422A132-ZL] automatically
Splitter Gate 422 A 130 is enabled
If SE 3-1 is selected and the splitter gate (422 A 130) is not adjusted at 100% material
flow to reversing flap (422 A 132) [limit switch 422 A 330-ZH is not actuated] the
splitter blade tilts to limit switch [422 A 130-ZH] automatically.
If SE 3-2 is selected and the splitter gate (422 A 130) is not adjusted at 100% material
flow to belt conveyor (422 A 135) [limit switch 422 A 130-ZL is not actuated] the
splitter blade tilts to limit switch [422 A 130-ZL] automatically.
If SE 3-3 is selected and Group 431 B (Butts Crushing & Screening) is running in
CENTRAL operation mode and Group 432 B (Butts Crushing & Screening) is
running in CENTRAL operation mode, than the splitter gate (422 A 130) is adjusted
to the actual value of setpoint SP-4 automatically.
If SE 3-3 is selected and Group 431 B (Butts Crushing & Screening) is not running in
CENTRAL operation mode and the splitter gate (422 A 130) is not adjusted at 100%
material flow to the belt conveyor (422 A 135) [limit switch 422 A 130-ZL is not
actuated] the splitter blade tilts to limit switch [422 A 130-ZL] automatically.
If SE 3-3 is selected and Group 432 B (Butts Crushing & Screening) is not running in
CENTRAL operation mode and the splitter gate (422 A 130) is not adjusted at 100%
material flow to reversing flap (422 A 132) [limit switch 422 A 130-ZH is not actuated]
the splitter blade tilts to limit switch [422 A 130-ZH] automatically.
Belt conveyor (422 A 135) starts if SE 3-2 or SE 3-3 is selected
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
2.4.5
10 (27)
Rev. 00
2.5
Normal Operation
2.5.1
Normal Operation after SE 2-1 or 2-2 or 2-3 Material Routes for Butts has been selected
2.5.1.1 Vibrating Trough Feeders for Butts 422 A 031; 422 A 041 -variable speed If the selected feeders are not tripped this Group is in normal operation.
The operator may set the feed rate of each vibrating feeder at any time (Setpoint SP 1).
Feed rates can be set within a range of 35% to 100% for each of the feeders individually.
On SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint (first approach for Standard Setpoint is 50%)
all overriding the actual setpoint.
The operator may set a MASTER FEED RATE for these vibrating feeders at any time. The
MASTER FEED RATE can be set within a range of 60% to 140% for all these feeders.
The MASTER FEED RATE is a factor (0.6 1.4) by which the individual feed rate (see
2.4.3.1 above) of these feeders is multiplied. At 100% (factor = 1.0) the feed rate of the
single feeders is equal to the individual feed rate set above. On SCADA the operator has
the choice to select one of three options, New setpoint, Previous setpoint and
Standard setpoint all overriding the actual setpoint.
The operator may select or deselect a feeder any time.
2.5.1.2 Magnet 422 A 055
If the magnet is not tripped this Group is in normal operation.
2.5.1.3 Belt Conveyor 422 A 060
If the conveyor is not tripped this Group is in normal operation.
Outokumpu Technology GmbH
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
11 (27)
Rev. 00
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
12 (27)
Rev. 00
Normal Operation after SE 3-1 or 3-2 or 3-3 Material Routes for Green Scrap has been
selected
2.5.2.1 Vibrating Trough Feeder for Green Scrap 422 A 051 -variable speed If the selected feeder is not tripped this Group is in normal operation.
The operator may set the feed rate of the vibrating feeder at any time. Feed rate can be
set within a range of 35% to 100%. The operator also has the choice of a Standard
Setpoint (first approach for Standard Setpoint is 50%). Setting is on SCADA. On SCADA
the operator has the choice to select one of three options, New setpoint, Previous
setpoint and Standard setpoint all overriding the actual setpoint.
2.5.2.2 Magnet 422 A 055
If the magnet is not tripped this Group is in normal operation.
2.5.2.3 Belt Conveyor 422 A 060
If the conveyor is not tripped this Group is in normal operation.
2.5.2.4 Belt Scale 422 A 062
If the belt scale is not tripped this Group is in normal operation.
Outokumpu Technology GmbH
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
13 (27)
Rev. 00
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
14 (27)
Rev. 00
Shut Down
After a shut down of the Group or of a part of the Group all actual setpoints of this Group are
memorized as Actual Setpoint.
2.6.1
2.6.2
The operator stops this Group using the RESTOP push button on SCADA.
Vibrating trough feeder (422 A 031) stops if it is selected and running
Vibrating trough feeder (422 A 041) stops if it is selected and running
Vibrating trough feeder (422 A 051) stops if it is selected and running
All actual setpoints of this Group are memorized as Actual Setpoint
Delay of 7 minutes (run-empty time)
All equipment of this Group stops.
The whole group is stopped.
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
15 (27)
Rev. 00
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
-
16 (27)
Rev. 00
The operator may initiate the Fast Shut Down of this Group at any time on the SCADA
system actuating the FASTOP button.
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
2.6.4
17 (27)
Rev. 00
2.6.4.1 Vibrating Trough Feeders for Butts 422 A 031, 422 A 041
If one of these two feeders, which is selected and which is running, trips
-
cause an alarm
motor(s) stops
cause an alarm
pertinent VFD-unit is shut off
an alarm is generated
if after a delay time of 10 minutes this feeder is still faulty and could not be restarted, a
Normal Shut Down (see 2.6.1 above) will be initiated automatically
cause an alarm
motor stops
cause an alarm
pertinent VFD-unit is shut off
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
18 (27)
Rev. 00
cause an alarm
equipment trips
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
[422 A 055M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
cause an alarm
equipment trips
[422 A 060M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
[422 A 060-ZXA1 to ZXA4] The conveyor is equipped with 4 side travel switches, two installed
close to the drive pulley and another two close to the tail pulley. If a side travel switch is
showing the belt is off-track for more than 2 seconds or if a switch fails
-
causes an alarm
equipment trips
[422 A 060-HSSA] The conveyor is equipped with 2 pull cord switches (This safety switch is
hard-wired to the MCC), one at each conveyor side. If a pull cord is drawn or if a switch fails
-
causes an alarm
equipment trips
[422 A 060-ZAL and ZAH] The conveyor is equipped with 2 take-up switches, one detecting
low take-up pulley position and another detecting high take-up pulley position. If one of the
switches is detecting an excessive position of the take-up pulley for more than 2 seconds or if
a switch fails
-
causes an alarm
equipment trips
an alarm is generated
all vibrating feeders (422 A 031, 422 A 041, 422 A 051), which are selected and which
are running are stopped instantly
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
-
19 (27)
Rev. 00
cause an alarm
equipment trips
an alarm is generated
if after a delay of 30 minutes this rotary lock is still faulty and could not be restarted, a
Normal Shut Down (see 2.6.1 above) will be initiated automatically.
[422 A 065M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated
but this Group is kept running until the differential pressure across the bags reaches
high-high differential pressure
[422 A 070-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or if
the switch fails for more than 5 seconds
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
NOTE: During Start or Restart of this Group there is an override of this function of 20
seconds to allow the fan to run up.
[422 A 070-PDAH] {> 13mbar} If high differential pressure is detected across the filter bags or
if the switch fails for more than 5 seconds
-
[422 A 070-PDAHH] {> 15mbar} If high-high differential pressure is detected across the filter
bags or if the switch fails for more than 5 seconds
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
cause an alarm
equipment trips
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
20 (27)
Rev. 00
[422 A 065-SAL] The fan is equipped with a proximity type low-speed switch measuring the
frequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low or
the switch fails
-
cause an alarm
equipment trips
an alarm is generated
all vibrating feeders (422 A 031, 422 A 041, 422 A 051), which are selected and which
are running, stopped instantly
rotary lock (422 A 065) stops instantly
belt conveyor (422 A 060) stops instantly
The rest of equipment of this Group is kept running.
[422 A 062-FAL] {< 3 t/h} If low feed rate is detected for more than 60 seconds
-
[422 A 062-FAH] {> 44 t/h} If SE 2-3 or 3-3 is selected and high feed rate is detected for more
than 20 seconds
-
cause an alarm
[422 A 062-FAH] {> 22 t/h} If SE 2-1 or 2-2 or 3-1 or 3-2 is selected and high feed rate is
detected for more than 20 seconds
-
cause an alarm
[422 A 062-FAHH] {> 48 t/h} If SE 2-3 or 3-3 is selected and high-high feed rate is detected for
more than 5 seconds
-
cause an alarm.
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 422 A 031, 422 A 041) and the setpoint SP 3 (Setpoint for the vibrating
trough feeder 422 A 051) by multiplying the actual setpoint with a factor of 0.85 in
order to reduce the feed rate automatically and if after another 60 seconds the fault is
still detected
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically
[422 A 062-FAHH] {> 24 t/h} If SE 2-1 or 2-2 or 3-2 or 3-2 is selected and high-high feed rate
is detected for more than 5 seconds
-
cause an alarm.
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 422 A 031, 422 A 041) and the setpoint SP 3 (Setpoint for the vibrating
trough feeder 422 A 051) by multiplying the actual setpoint with a factor of 0.85 in
order to reduce the feed rate automatically and if after another 60 seconds the fault is
still detected
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
-
21 (27)
Rev. 00
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically
cause an alarm
equipment trips
an alarm is generated
if after a delay of 30 minutes this rotary lock is still faulty and could not be restarted, a
Normal Shut Down (see 2.6.1 above) will be initiated automatically.
[422 A 100M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated
but this Group is kept running until the differential pressure across the bags reaches
high-high differential pressure
[422 A 105-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or if
the switch fails for more than 5 seconds
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
NOTE: During Start or Restart of this Group there is an override of this function of 20
seconds to allow the fan to run up.
[422 A 105-PDAH] {> 13mbar} If high differential pressure is detected across the filter bags or
if the switch fails for more than 5 seconds
-
[422 A 105-PDAHH] {> 15mbar} If high-high differential pressure is detected across the filter
bags or if the switch fails for more than 5 seconds
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
cause an alarm
equipment trips
[422 A 115-SAL] The fan is equipped with a proximity type low-speed switch measuring the
frequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low or
the switch fails
Outokumpu Technology GmbH
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
-
22 (27)
Rev. 00
cause an alarm
equipment trips
an alarm is generated
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
causes an alarm
equipment trips
[422 A 130-XAL / XAH] The splitter gate is equipped with two torque switches, incorporated in
a control box fitted to the drive unit. If a switch is actuated or a switch fails
-
causes an alarm
equipment trips
[422 A 130M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
The maximum time required between start and stop of the actuator drive, which is tilting the
blade of a splitter gate, shall not be more than 90 seconds. If after 90 seconds the motor has
not been stopped automatically because the target position has not been reached
-
an alarm is generated
equipment trips
an alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
cause an alarm
equipment trips
[422 A 135M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
[422 A 135-ZXA1 to ZXA 4] The conveyor is equipped with 4 side travel switches, two installed
close to the drive pulley and another two close to the tail pulley. If a side travel switch is
showing the belt is off-track for more than 2 seconds or if a switch fails
-
causes an alarm
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
-
23 (27)
Rev. 00
equipment trips
[422 A 135-HSSA] The conveyor is equipped with 2 pull cord switches (This safety switch is
hard-wired to the MCC), one at each conveyor side. If a pull cord is drawn or if a switch fails
-
causes an alarm
equipment trips
[422 A 135-ZAL and ZAH] The conveyor is equipped with 2 take-up switches, one detecting
low take-up pulley position and another detecting high take-up pulley position. If one of the
switches is detecting an excessive position of the take-up pulley for more than 2 seconds or if
a switch fails
-
causes an alarm
equipment trips
an alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
an alarm is generated
splitter gate (422 A 130) tilts at 100% material flow to reversing flap 422 A 132 [limit
switch 422 A 135-ZH actuated]
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 422 A 031, 422 A 041) and the setpoint SP 3 (Setpoint for the vibrating
trough feeder 422 A 051) by multiplying the actual setpoints with a factor of 0.5 in
order to reduce the feed rate automatically.
causes an alarm
equipment trips
If the limit switch indication is not in agreement with the selected position (limit switch lost) or if
ZSL and ZSH are indicated simultaneously
-
causes an alarm
equipment trips
cause an alarm
Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
24 (27)
Rev. 00
causes an alarm
equipment trips
If the limit switch indication is not in agreement with the selected position (limit switch lost) or if
ZSL and ZSH are indicated simultaneously
-
causes an alarm
equipment trips
cause an alarm
Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically
2.6.4.16 Butts Feed Bin 422 A 200
If SE 2-1 is selected
[422 A 200-LY] The bin is equipped with a continuous level measurement (load cell system). If
the level measurement fails
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically
[422 A 200-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
Fast Shut Down of this Group (see 2.6.1 above) is initiated automatically
If SE 2-3 is selected
[422 A 200-LY] The bin is equipped with a continuous level measurement (load cell system). If
the level measurement fails
-
cause an alarm
splitter gate (422 A 130) tiltis at 100% material flow to belt conveyor 422 A 135 [limit
switch 422 A 135-ZL actuated]
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 422 A 031, 422 A 041) by multiplying the actual setpoint with a factor of 0.5 in
order to reduce the feed rate automatically
[422 A 200-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
splitter gate (422 A 130) tiltis at 100% material flow to belt conveyor 422 A 135 [limit
switch 422 A 135-ZL actuated]
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 422 A 031, 422 A 041) by multiplying the actual setpoint with a factor of 0.5 in
order to reduce the feed rate automatically
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
25 (27)
Rev. 00
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically
[422 A 300-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
Fast Shut Down of this Group (see 2.6.1 above) is initiated automatically
If SE 2-3 is selected
[422 A 300-LY] The bin is equipped with a continuous level measurement (load cell system). If
the level measurement fails
-
cause an alarm
splitter gate (422 A 130) tiltis at 100% material flow to reversing flap 422 A 132 [limit
switch 422 A 135-ZH actuated]
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 422 A 031, 422 A 041) by multiplying the actual setpoint with a factor of 0.5 in
order to reduce the feed rate automatically
[422 A 300-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
2.6.5
cause an alarm
splitter gate (422 A 130) tiltis at 100% material flow to reversing flap 422 A 132 [limit
switch 422 A 132-ZH actuated]
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 422 A 031, 422 A 041) by multiplying the actual setpoint with a factor of 0.5 in
order to reduce the feed rate automatically
belt conveyor 422 A 135 stops instantly
an alarm is created
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If the butts feed bin is totally full (bin level >/= 100% [422 A 200-LAHH])
-
cause an alarm
Fast Shut Down (2.6.3 above) of this Group is initiated automatically.
If SE 2-3 is selected
CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
26 (27)
Rev. 00
If the butts feed bin is full (bin level is >/= 95% [422 A 200-LAH2]) and if splitter gate (422 A
130) is after a travel time of 90 seconds not at 100% material flow to belt conveyor (422 A 135)
[limit switch 422 A 130 ZL not actuated] or if the butts feed bin (422 A 300) is full (bin level is
>/= 95% [422 A 300-LAH2] and/or >/= 100% [422 A 300-LAHH])
-
an alarm is created
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If the butts feed bin is totally full (bin level >/= 100% [422 A 200-LAHH]) and if splitter gate
(422 A 135) is not at 100% material flow to belt conveyor 422 A 135 [limit switch 422 A 135-ZL
actuated]
-
cause an alarm
Fast Shut Down (2.6.3 above) of this Group is initiated automatically.
an alarm is created
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If the butts feed bin is totally full (bin level >/= 100% [422 A 300-LAHH])
-
cause an alarm
Fast Shut Down (2.6.3 above) of this Group is initiated automatically.
If SE 2-3 is selected
If the butts feed bin is full (bin level is >/= 95% [422 A 300-LAH2]) and if splitter gate (422 A
130) is after a travel time of 90 seconds not at 100% material flow to reversing flap (422 A
132) [limit switch 422 A 130 ZH not actuated] or if the butts feed bin (422 A 200) is full (bin
level is >/= 95% [422 A 200-LAH2] and/or >/= 100% [422 A 200-LAHH])
-
an alarm is created
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If the butts feed bin is totally full (bin level >/= 100% [422 A 300-LAHH]) and if splitter gate
(422 A 135) is not at 100% material flow to reversing flap 422 A 132 [limit switch 422 A 135-ZH
actuated]
-
2.7
cause an alarm
Fast Shut Down (2.6.3 above) of this Group is initiated automatically.
CONTROL PHILOSOPHY
24.10.2006
Rev. 00
Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal
Description
Sort of Signal
27 (27)
5.3
Main Equipment
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.3.9
5.3.10
5.3.11
138-02-043
Group 422 A
DE-060300
Revision: 0
Date: 29.09.2006
file: 138-02-043_05_0.doc, Codeword: Vedanta