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Training Manual Green Anode Plant

Vedanta - Jharsuguda

138-02-043
Group 422 A
DE-060300

PROCESS GROUP 422 A - BUTTS RECLAIMING-

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

Process Group 422 A - Butts Reclaiming-...................................................................................1


Process .......................................................................................................................................1
Process Flow Sheets...................................................................................................................1
Brief Process Description ............................................................................................................2
Main Process Data & Process Highlights ....................................................................................3
Process Control...........................................................................................................................4
P&Id`s, Material Route Diagrams, Operator Screen Images.......................................................4
Control Logic Description ............................................................................................................5
Main Equipment ..........................................................................................................................6
Flat Slide Gate (manual) 422 A 001 ............................................................................................6
Vibrating Trough Feeder 422 A 031 ............................................................................................6
Magnetic Separator, overhead 422 A 055...................................................................................6
Belt Conveyor 422 A 060 ............................................................................................................6
Belt Scale 422 A 062...................................................................................................................6
Rotary Lock 422 A 065................................................................................................................6
Bag Filter 422 A 070....................................................................................................................6
Fan 422 A 080.............................................................................................................................6
Splitter Gate 422 A 130 ...............................................................................................................6
Reversing Flap (pneumatic) 422 A 132 .......................................................................................6
Bin 422 A 200..............................................................................................................................6

5.1

Process

5.1.1

Process Flow Sheets


(Work Copy)

Outokumpu Technology GmbH


file: 138-02-043_05_0.doc, Codeword: Vedanta

Revision: 0
Date: 29.09.2006
Page 1 of 6

Training Manual Green Anode Plant


Vedanta - Jharsuguda
5.1.2

138-02-043
Group 422 A
DE-060300

Brief Process Description


(Work Copy)

Outokumpu Technology GmbH


Page 2 of 6

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

Brief Process Description


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

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).

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

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.

Material Route Green Scrap (Selection SE 3-1 / 3-2 / 3-3)


If this Group shall process Green Scrap the operator must select Green Scrap (selection SE
3-1 / 3-2 / 3-3) on SCADA prior to Group start.
Green Scrap of 0-50 mm size is stored in a Main Storage Bin (421 A 400). The storage bin can
be isolated for maintenance by a flat slide gate (422 A 020). Normally the flat slide gate is
open.
Green Scrap is continuously withdrawn from the bin by means of a vibrating trough feeder
(422 A 051). The feeder is equipped with a variable speed drive for controlling the feed rate in
a range of 10-50 tons/hour. The operator can remote adjust the feed rate of the feeder.
The maximum feed rate allowed for Line 1 & 2 is 44 tons/hour and for one line only, is 22
tons/hour.
Green Scrap is 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 green scrap 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).
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) to Group 431 B Butts Crushing and
Screening and/or via belt conveyor (422 A 135) and reversing flap (422 A 140) to Group 432
B Butts Crushing and Screening.

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

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.

Outokumpu Technology GmbH

Training Manual Green Anode Plant


Vedanta - Jharsuguda
5.1.3

138-02-043
Group 422 A
DE-060300

Main Process Data & Process Highlights


This Process Group is designed for a maximum feed rate (production rate) of 40
t/hour of butts or green scrap.
The operator must never set the total green scrap feed rate to more than 20 t/h (only if
one line 431 or 432 is in operation) or 40 t/h (if two lines 431 and 432 in operation), if
Green Scrap is selected on SCADA, because a higher feed rate would overload the
screen, the bucket elevator and the impact crusher of the subsequent groups 431
/432 B.
The process loads (flow rates), expressed as t/hour can be found in the Process Flow
Sheets in ovals.

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.

Outokumpu Technology GmbH


file: 138-02-043_05_0.doc, Codeword: Vedanta

Revision: 0
Date: 29.09.2006
Page 3 of 6

Training Manual Green Anode Plant


Vedanta - Jharsuguda

5.2

Process Control

5.2.1

P&Id`s, Material Route Diagrams, Operator Screen Images

138-02-043
Group 422 A
DE-060300

(work copies)

Outokumpu Technology GmbH


Page 4 of 6

Revision: 0
Date: 29.09.2006
file: 138-02-043_05_0.doc, Codeword: Vedanta

Training Manual Green Anode Plant


Vedanta - Jharsuguda
5.2.2

138-02-043
Group 422 A
DE-060300

Control Logic Description


(Work Copy)

Outokumpu Technology GmbH


file: 138-02-043_05_0.doc, Codeword: Vedanta

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

Brief Process Description............................................................................................................ 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

Control Logic Description ............................................................................................................ 4


Special Terminology For This Group .......................................................................................... 4
Linked Process Groups............................................................................................................... 4
Selections ................................................................................................................................... 4
Selection of Operation Modes (SE 1).......................................................................................... 4
Material Route for Butts (SE 2) ................................................................................................... 4
Material Route for Green Scrap (SE 3) ....................................................................................... 5
Butts Discharge Feeders (SE 4) .................................................................................................5
Group Start ................................................................................................................................. 5
Selections Prior to Group Start ................................................................................................... 5
Start Preconditions...................................................................................................................... 6
Setpoints Prior to Group Start ..................................................................................................... 6
Group Start Sequence ................................................................................................................ 8
Restarting the Group................................................................................................................. 10
Normal Operation...................................................................................................................... 10
Normal Operation after SE 2-1 or 2-2 or 2-3 Material Routes for Butts has been selected.... 10
Normal Operation after SE 3-1 or 3-2 or 3-3 Material Routes for Green Scrap has been
selected..................................................................................................................................... 12
Shut Down ................................................................................................................................ 14
Normal Shut Down .................................................................................................................... 14
Shut Down by Other Groups ..................................................................................................... 14
Fast Shut Down (FASTOP)....................................................................................................... 16
Trip in Case of Faults ................................................................................................................ 17
Shut Down by Full Bins ............................................................................................................. 25
Local Operation of Special Equipment...................................................................................... 26
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 27

2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.7
2.8

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
1

2 (27)

Rev. 00

BRIEF PROCESS DESCRIPTION


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).
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.

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

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.

Material Route Green Scrap (Selection SE 3-1 / 3-2 / 3-3)


If this Group shall process Green Scrap the operator must select Green Scrap (selection SE
3-1 / 3-2 / 3-3) on SCADA prior to Group start.
Green Scrap of 0-50 mm size is stored in a Main Storage Bin (421 A 400). The storage bin can
be isolated for maintenance by a flat slide gate (422 A 020). Normally the flat slide gate is
open.
Green Scrap is continuously withdrawn from the bin by means of a vibrating trough feeder
(422 A 051). The feeder is equipped with a variable speed drive for controlling the feed rate in
a range of 10-50 tons/hour. The operator can remote adjust the feed rate of the feeder.
The maximum feed rate allowed for Line 1 & 2 is 44 tons/hour and for one line only, is 22
tons/hour.
Green Scrap is 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 green scrap 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).
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) to Group 431 B Butts Crushing and
Screening and/or via belt conveyor (422 A 135) and reversing flap (422 A 140) to Group 432
B Butts Crushing and Screening.
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.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
24.10.2006

4 (27)

Rev. 00

Vedanta Alumina Ltd.


Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065

CONTROL LOGIC DESCRIPTION

2.1

Special Terminology For This Group


There is no special terminology for this group.

2.2

Linked Process Groups


The following Process Groups are linked with this Group 422 A:

Main Dust Treatment 432 C


Butts Crushing & Screening 431 B
Butts Crushing & Screening 432 B

The exchange of control signals is described in the following chapters and especially under 2.8
below.
2.3

Selections

2.3.1

Selection of Operation Modes (SE 1)


The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA.
The operator has two options:

2.3.2

CENTRAL operation mode

After this selection this Group is ready to start in CENTRAL


operation mode, if all preconditions (see 2.4.2) below are
fulfilled.

LOCAL operation mode

(details please see under 2.7 below)

Material Route for Butts (SE 2)


The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA prior to Group start only.
The operator has three options:
SE 2-1 Butts to Butts Feed Bin (422 A 200)
This is the normal selection when the butts are feed to butts feed bin 422 A 200.
SE 2-2 Butts to Butts Feed Bin (422 A 300)
This is the normal selection when the butts are feed to butts feed bin 422 A 300.
SE 2-3 Butts to Butts Feed Bin (422 A 200 and 422 A 300)
This is the normal selection when the butts are feed to butts feed bins 422 A 200 and 422 A
300.

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
2.3.3

5 (27)

Rev. 00

Material Route for Green Scrap (SE 3)


The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA prior to Group start only.
The operator has three options:
SE 3-1 Green Scrap to Group 431 B
This selection is used if there are no butts available in Group 431 B Butts Crushing &
Screening.
In this case the manual splitter gate (431 A 135) must not indicate [431 A 135-ZH], weigh
feeder 431 B 103 must not running and Group 431 B must be running in CENTRAL mode
and must not be in run empty operation (RESTOP). If one of these conditions is not fulfilled
this Group is not ready to start and an alarm on the SCADA system is generated.
SE 3-2 Green Scrap to Group 432 B
This selection is used if there are no butts available in Group 432 B Butts Crushing &
Screening.
In this case the manual splitter gate (432 A 135) must not indicate [432 A 135-ZH], weigh
feeder 432 B 103 must not running and Group 432 B must be running in CENTRAL mode
and must not be in run empty operation (RESTOP). If one of these conditions is not fulfilled
this Group is not ready to start and an alarm on the SCADA system is generated.
SE 3-3 Green Scrap to Group 431 B and Group 432 B
This selection is used if there are no butts available in Group 431 B / 432 B Butts Crushing
& Screening.
In this case the manual splitter gates (431 A 135 and 432 A 135) must not indicate [431 A 135ZH] and [432 A 135-ZH], weigh feeders (431 B 103) and (432 B 103) must not running and
Group 431 B and Group 432 B must be running in CENTRAL mode and must not be in run
empty operation (RESTOP). If one of these conditions is not fulfilled this Group is not ready to
start and an alarm on the SCADA system is generated.

2.3.4

Butts Discharge Feeders (SE 4)


The operator may select the vibrating through feeders discharging the two Main Storage Bins
for butts (421 A 200; 421 A 300) at any time.
The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA.
SE 4-1 - vibrating trough feeder (422 A 031)
SE 4-2 - vibrating trough feeder (422 A 041)

2.4

Group Start

2.4.1

Selections Prior to Group Start


CENTRAL operation mode must be selected.

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
2.4.2

6 (27)

Rev. 00

Start Preconditions

2.4.2.1 Process Group 432 C - Main Dust Treatment


If SE 2-2 or 2-3 or 3-2 or 3-3 is selected (butts or green scrap to Line 2 (432)), the Group
432 C Main Dust Treatment must be running in CENTRAL operation mode prior to start
this Group. It must not be tripped and not be in a stop (RESTOP or FASTOP) sequence.
2.4.2.2 Process Group 431 B (Butts Crushing & Screening)
If SE 3-1 (Green Scrap to Group 431 B) or SE 3-3 (Green Scrap to Group 431 B and
Group 432 B ) 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)
2.4.2.3 Process Group 432 B (Butts Crushing & Screening)
If SE 3-2 (Green Scrap to Group 432 B) or SE 3-3 (Green Scrap to Group 431 B and
Group 432 B ) 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)
2.4.2.4 Emergency stop
If the Emergency Stop of the Group has been activated it has to be RESET.
2.4.2.5 Alarms
If an Alarm of this Group has been activated it has to be RESET.
2.4.2.6 MCC`s of this Group
The MCCs signal of this group must be OK.
2.4.2.7 FASTOP Signal
If a FASTOP signal is valid this Group does not start.
2.4.2.8 RESTOP Signal
If a RESTOP signal is valid this Group can be restarted by overriding the RESTOP signal
by the Group Start signal.
2.4.2.9 Compressed Air Pressure 410 A 009
Compressed air pressure in Group A [410 A 009-PAL] shall be higher than 6 bar (P>6
bar).
2.4.3

Setpoints Prior to Group Start


It makes sense to check and, if required, to readjust setpoints prior to a start of this Group.
Actual Setpoint

The PLC program is storing all actually used setpoints as


Actual Setpoint The Actual Setpoint is automatically used
for the next start after the Group has been stopped or for a
restart after the Group has tripped. The Actual Setpoint is
displayed on SCADA.

New Setpoint

The operator has the opportunity to override the actual


setpoint by the New Setpoint any time Changing of setpoint
is on SCADA.

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Rev. 00

Previous Setpoint

Did the operator change an Actual Setpoint while the Group is


running in CENTRAL mode the previous one is also stored in
the PLC as Previous Setpoint for possible later use. The
operator may override the actual setpoint by the Previous
Setpoint at any time. Selection of the Previous Setpoint is on
SCADA.

Standard Setpoint

The operator may also override the actual setpoint by the


Standard Setpoint any time. Selection of the Standard
Setpoint is on SCADA. The Standard Setpoint can be edited
on the SCADA system any time but by a Shift Leader only,
after using his Password.

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%).

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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2.4.4

8 (27)

Rev. 00

Group Start Sequence

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.

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Rev. 00

Jet cleaning of dust collector (422 A 070) is enabled.


Rotary lock (422 A 060) starts.
Vibrating trough feeder (422 A 031) starts, if selected (SE 4-1).
Vibrating trough feeder (422 A 041) starts, if selected (SE 4-2).
Group 422 A is running completely in CENTRAL mode.

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

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
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2.4.5

10 (27)

Rev. 00

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 3-2 or SE 3-3 is selected
Magnet (422 A 055) is enable
Belt Scale (422 A 062) is enable
Jet cleaning of dust collector (422 A 105) is enabled.
Rotary lock (422 A 100) starts.
Belt conveyor (422 A 060) starts.
Jet cleaning of dust collector (422 A 070) is enabled.
Rotary lock (422 A 060) starts.
Vibrating trough feeder (422 A 051) starts
Group 422 A is running completely in CENTRAL mode.

Restarting the Group


If the Group is in a run-empty stop sequence, (after Normal Shut Down (RESTOP)) and a
part of the Group is still running, it is possible to restart this Group by activating the START
button. Restarting is only possible after all faults have been eliminated and reset. The Restart
follows the same sequence like the normal Group Start including the horn sequence as
described above.

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.
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Rev. 00

2.5.1.4 Belt Scale 422 A 062


If the belt scale is not tripped this Group is in normal operation.
2.5.1.5 Rotary Lock 422 A 065
If the rotary lock is not tripped this Group is in normal operation.
2.5.1.6 Dust Collector 422 A 070
If the dust collector is not tripped this Group is in normal operation.
The jet-type pneumatic bag cleaning system is controlled by the actually measured
differential pressure across the filter bags. If the differential pressure measuring system
detects the differential pressure is above 12.5 mbar [422 A 070-PDH2], the Local Control
Panel [422 A 070-LOP1] gets a signal from 422 PLC 02 to start a bag cleaning cycle .The
bags are cleaned with a compressed air stream blown into the bags countercurrent to the
normal air flow. The cleaning cycle ends with a second signal from 422 PLC 02, if the
differential pressure did fall below 11 mbar [422 A 070-PDH1]. The next cleaning cycle
starts with the next un-cleaned bag row.
2.5.1.7 Fan 422 A 080
If the fan is not tripped this Group is in normal operation.
2.5.1.8 Rotary Lock 422 A 100
If the rotary lock is not tripped this Group is in normal operation.
2.5.1.9 Dust Collector 422 A 105
If the dust collector is not tripped this Group is in normal operation.
The jet-type pneumatic bag cleaning system is controlled by the actually measured
differential pressure across the filter bags. If the differential pressure measuring system
detects the differential pressure is above 12.5 mbar [422 A 105-PDH2], the Local Control
Panel [422 A 105-LOP1] gets a signal from 422 PLC 02 to start a bag cleaning cycle .The
bags are cleaned with a compressed air stream blown into the bags countercurrent to the
normal air flow. The cleaning cycle ends with a second signal from 422 PLC 02, if the
differential pressure did fall below 11 mbar [422 A 105-PDH1]. The next cleaning cycle
starts with the next un-cleaned bag row.
2.5.1.10 Fan 422 A 115
If the fan is not tripped this Group is in normal operation.
2.5.1.11 Splitter Gate 422 A 130
If the splitter gate is not tripped this Group is in normal operation.
If SE 2-3 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%).
2.5.1.12 Reversing Flap 422 A 132
If SE 2-1 or 2-3 (Butts to Line 1 (431)) is selected and the reversing flap is not tripped this
Group is in normal operation.

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Rev. 00

2.5.1.13 Belt Conveyor 422 A 135


If SE 2-2 or 2-3 (Butts to Line 2 (432)) is selected and the conveyor is not tripped this
Group is in normal operation.
2.5.1.14 Reversing Flap 422 A 140
If SE 2-2 or 2-3 (Butts to Line 2 (432)) is selected and the reversing flap is not tripped this
Group is in normal operation.
2.5.1.15 Butts Feed Bin 422 A 200
If the fraction bin level measurement is not tripped this Group is in normal operation.
If SE 2-1 is selected and the fraction bin is not full (bin level is not >/= 95% [422 A 200LAH2] and/or not >/= 100% [422 A 200-LAHH]) this Group is in normal operation.
If SE 2-3 is selected and the fraction bin is full (bin level is >/= 95% [422 A 200-LAH2]
and/or >/= 100% [422 A 200-LAHH]), 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, and splitter gate
(422 A 130) is after a travel time of 90 seconds at 100% material flow to belt conveyor 422
A 135 [limit switch 422 A 130-ZL actuated] this Group is in normal operation.
2.5.1.16 Butts Feed Bin 422 A 300
If the fraction bin level measurement is not tripped this Group is in normal operation.
If SE 2-2 is selected and the fraction bin is not full (bin level is not >/= 95% [422 A 300LAH2] and/or not >/= 100% [390 A 300-LAHH]) this Group is in normal operation.
If SE 2-3 is selected and the fraction bin is full (bin level is >/= 95% [422 A 300-LAH2]
and/or >/= 100% [422 A 300-LAHH]), 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, and splitter gate
(422 A 130) is after a travel time of 90 seconds at 100% material flow to butts feed bin 422
A 200 [limit switch 422 A 130-ZH actuated] this Group is in normal operation.
2.5.2

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.
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CONTROL PHILOSOPHY
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13 (27)

Rev. 00

2.5.2.5 Rotary Lock 422 A 065


If the rotary lock is not tripped this Group is in normal operation.
2.5.2.6 Dust Collector 422 A 070
If the dust collector is not tripped this Group is in normal operation.
The jet-type pneumatic bag cleaning system is controlled by the actually measured
differential pressure across the filter bags. If the differential pressure measuring system
detects the differential pressure is above 12.5 mbar [422 A 070-PDH2], the Local Control
Panel [422 A 070-LOP1] gets a signal from 422 PLC 02 to start a bag cleaning cycle .The
bags are cleaned with a compressed air stream blown into the bags countercurrent to the
normal air flow. The cleaning cycle ends with a second signal from 422 PLC 02, if the
differential pressure did fall below 11 mbar [422 A 070-PDH1]. The next cleaning cycle
starts with the next un-cleaned bag row.
2.5.2.7 Fan 422 A 080
If the fan is not tripped this Group is in normal operation.
2.5.2.8 Rotary Lock 422 A 100
If the rotary lock is not tripped this Group is in normal operation.
2.5.2.9 Dust Collector 422 A 105
If the dust collector is not tripped this Group is in normal operation.
The jet-type pneumatic bag cleaning system is controlled by the actually measured
differential pressure across the filter bags. If the differential pressure measuring system
detects the differential pressure is above 12.5 mbar [422 A 105-PDH2], the Local Control
Panel [422 A 105-LOP1] gets a signal from 422 PLC 02 to start a bag cleaning cycle .The
bags are cleaned with a compressed air stream blown into the bags countercurrent to the
normal air flow. The cleaning cycle ends with a second signal from 422 PLC 02, if the
differential pressure did fall below 11 mbar [422 A 105-PDH1]. The next cleaning cycle
starts with the next un-cleaned bag row.
2.5.2.10 Fan 422 A 115
If the fan is not tripped this Group is in normal operation.
2.5.2.11 Splitter Gate 422 A 130
If the splitter gate is not tripped this Group is in normal operation.
If SE 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%).
2.5.2.12 Reversing Flap 422 A 132
If SE 3-1 or 3-3 (Green Scrap to Line 1 (431)) is selected and the reversing flap is not
tripped this Group is in normal operation.
2.5.2.13 Belt Conveyor 422 A 135
If SE 3-2 or 3-3 (Green Scrap to Line 2 (432)) is selected and the conveyor is not tripped
this Group is in normal operation.
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CONTROL PHILOSOPHY
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14 (27)

Rev. 00

2.5.2.14 Reversing Flap 422 A 140


If SE 3-2 or 3-3 (Green Scrap to Line 2 (432)) is selected and the reversing flap is not
tripped this Group is in normal operation.
2.6

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

Normal Shut Down


To initiate this sort of shut down the operator uses the RESTOP button on the SCADA
system.

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.

Shut Down by Other Groups


If this Group 422 A is running in CENTRAL mode it requires the following other Groups also
running in CENTRAL operation mode:
432 C Main Dust Treatment only if SE 2-2 or 2-3 or 3-2 or 3-3 is selected
431 B Butts Crushing & Screening only if SE 2-1 or 2-3 or 3-1 or 3-3 is selected
432 B Butts Crushing & Screening only if SE 2-2 or 2-3 or 3-2 or 3-3 is selected

2.6.2.1 Group 432 C Main Dust Treatment


If SE 2-2 or 2-3 or 3-2 or 3-3 is selected (Because belt conveyor (422 A 135) and butts
feed bin (422 A 300) of this Group 422 A is connected to the Main Dust Treatment) it is
essential that Group 432 C is running in CENTRAL control mode and is not in a START
or STOP sequence.
If SE 2-2 or 3-2 is selected and if Group 432 C is not running anymore in CENTRAL
mode because it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut
Down (FASTOP) or is tripped through a fault
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically
If SE 2-3 is selected and if Group 432 C is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down
(FASTOP) or is tripped through a fault and if splitter gate (422 A 130) is after a travel time
of 90 seconds not at 100% material flow to butts feed bin (422 A 200) [limit switch 422 A
130-ZH is 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])
alarm is generated
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Rev. 00

Normal Shut Down (see 2.6.1 above) will be initiated automatically


If SE 3-3 is selected and if Group 432 C is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down
(FASTOP) or is tripped through a fault, 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 is not actuated] or if Group 432 B is not running anymore in CENTRAL mode
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically
-

2.6.2.2 Group 431 B Butts Crushing And Screening


If SE 2-1 is selected and if Group 431 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down
(FASTOP) or is tripped through a fault
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically.
If SE 2-3 is selected and if Group 431 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down
(FASTOP) or is tripped through a fault, 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 SE 3-1 is selected and if Group 431 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP)
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically
If SE 3-1 is selected and if Group 431 B is not running anymore in CENTRAL mode
because it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a fault
alarm is generated
Fast Shut Down (see 2.6.3 below) will be initiated automatically
If SE 3-3 is selected and if Group 431 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP) 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 is not actuated] or if Group 432 B is not running
anymore in CENTRAL mode
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically
If SE 3-3 is selected and if Group 431 B is not running anymore in CENTRAL mode
because it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a fault
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 is not actuated] or if Group
432 B is not running anymore in CENTRAL mode
alarm is generated
Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
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Doc. No.:
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-

16 (27)

Rev. 00

Fast Shut Down (see 2.6.3 below) will be initiated automatically

2.6.2.3 Group 432 B Butts Crushing And Screening


If SE 2-2 is selected and if Group 432 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down
(FASTOP) or is tripped through a fault
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically.
If SE 2-3 is selected and if Group 432 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down
(FASTOP) or is tripped through a fault, and if splitter gate (422 A 130) is after a travel time
of 90 seconds not at 100% material flow to butts feed bin (422 A 200) [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 SE 3-2 is selected and if Group 432 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP)
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically
If SE 3-2 is selected and if Group 432 B is not running anymore in CENTRAL mode
because it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a fault
alarm is generated
Fast Shut Down (see 2.6.3 below) will be initiated automatically
If SE 3-3 is selected and if Group 432 B is not running anymore in CENTRAL mode
because it has been stopped by a Normal Shut Down (RESTOP) 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 is not actuated] or if Group 431 B is not running
anymore in CENTRAL mode
alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically
If SE 3-3 is selected and if Group 432 B is not running anymore in CENTRAL mode
because it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a fault
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 is not actuated] or if Group
432 B is not running anymore in CENTRAL mode
alarm is generated
Fast Shut Down (see 2.6.3 below) will be initiated automatically
2.6.3

Fast Shut Down (FASTOP)


If this Group 422 A is running in CENTRAL mode and an operator has detected a serious
fault, which did not automatically trip this Group the operator is able to stop this Group as Fast
Shut Down (FASTOP).

The operator may initiate the Fast Shut Down of this Group at any time on the SCADA
system actuating the FASTOP button.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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OTK ref.:
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2.6.4

17 (27)

Rev. 00

All equipment of this Group stops instantly


All actual setpoints of this Group are memorized as Actual Setpoint
The whole Group is stopped now with full load of material on conveyors.

Trip in Case of Faults


If this Group 422 A is running in CENTRAL mode and equipment or an instrument of this
Group fails this may cause an Alarm only and, if the fault is of the serious sort, this whole
Group or a part of this Group is stopped. Different faults may cause different stop sequences,
depending on the equipment and on the impact of this fault on the whole process of this
Group. In some cases a Normal Shut Down (RESTOP) will commence, in other cases a Fast
Shut Down (FASTOP) is the safer way and in few cases a special stop sequence may be
required.
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.
Note: All instruments mounted on equipment or located somewhere in the field or anywhere
else are to be wired fail-safe.

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
-

an alarm is generated only


The faulty feeder can be deselected and the other feeder can be selected and this
Group can be restarted.

[422 A 031/041-VFD] If there is a fault detected in the frequency controller


-

cause an alarm
motor(s) stops

[422 A 031/041] If there is a fault detected in the MCC


-

cause an alarm
pertinent VFD-unit is shut off

2.6.4.2 Vibrating Trough Feeder for Green Scrap 422 A 051


If the feeder is selected and is running, trips
-

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

[422 A 051-VFD] If there is a fault detected in the frequency controller


-

cause an alarm
motor stops

[422 A 051] If there is a fault detected in the MCC


-

cause an alarm
pertinent VFD-unit is shut off

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
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OTK ref.:
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18 (27)

Rev. 00

2.6.4.3 Magnet 422 A 055


[422 A 055-SAL] The conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-

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.

2.6.4.4 Belt Conveyor 422 A 060


[422 A 060-SAL] The conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the tail pulley. If the frequency of the tail
pulley is too low or the switch fails
-

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

If the belt conveyor 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

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
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Doc. No.:
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-

19 (27)

Rev. 00

rotary lock (422 A 065) is stopped instantly


if after a delay time of 20 minutes this conveyor is still faulty and could not be
restarted, a Normal Shut Down (see 2.6.1 above) will be initiated automatically

2.6.4.5 Rotary Lock 422 A 065


[422 A 065-SAL] The conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-

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

2.6.4.6 Dust Collector 422 A 070


[422 A 070-LCP1] If the bag cleaning device 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
-

cause an alarm only

[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.

2.6.4.7 Fan 422 A 080


[422 A 080M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an alarm
equipment trips

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CONTROL PHILOSOPHY
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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

If the fan 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.

2.6.4.8 Belt Scale 422 A 062


If a collective alarm of the scale is detected
-

Normal Shut Down (see 2.6.1 above) will be initiated automatically.

[422 A 062-FAL] {< 3 t/h} If low feed rate is detected for more than 60 seconds
-

cause an alarm. This alarm is suspended during a run empty cycle.

[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

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
-

21 (27)

Rev. 00

Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically

2.6.4.9 Rotary Lock 422 A 100


[422 A 100-SAL] The conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-

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

2.6.4.10 Dust Collector 422 A 105


[422 A 105-LCP1] If the bag cleaning device 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
-

cause an alarm only

[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.

2.6.4.11 Fan 422 A 115


[390 A 115M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

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.
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Doc. No.:
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-

22 (27)

Rev. 00

cause an alarm
equipment trips

If the fan trips


-

an alarm is generated
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.

2.6.4.12 Splitter gate with servo drive 422 A 130


[422 A 130-ZL / ZH] The splitter gate is equipped with two limit switches, incorporated in a
control box fitted to the drive unit. If a limit switch fails
-

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

If the splitter gate trips


-

an alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.

2.6.4.13 Belt Conveyor 422 A 135


[422 A 135-SAL] The conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the tail pulley. If the frequency of the tail
pulley is too low or the switch fails
-

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

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
-

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

If SE 2-2 or 3-2 is selected and the belt conveyor trips


-

an alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.

If SE 2-3 or 3-3 is selected and the belt conveyor trips


-

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.

2.6.4.14 Reversing Flap 422 A 132


[422 A 132 ZSL / ZSH] The reversing flap is equipped with two limit switches. If after actuation
and start signal the limit switch for the selected position is not reached within 10 seconds, the
maximum operation time is exceeded (runtime supervision)
-

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

If the reversing flap trips


-

cause an alarm
Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
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Doc. No.:
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24 (27)

Rev. 00

2.6.4.15 Reversing Flap 422 A 140


[422 A 140 ZSL / ZSH] The reversing flap is equipped with two limit switches. If after actuation
and start signal the limit switch for the selected position is not reached within 10 seconds, the
maximum operation time is exceeded (runtime supervision)
-

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

If the reversing flap 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

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
24.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
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Doc. No.:
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25 (27)

Rev. 00

2.6.4.17 Butts Feed Bin 422 A 300


If SE 2-1 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
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

Shut Down by Full Bins

2.6.5.1 Butts Feed Bin (422 A 200)


If SE 2-1 is selected
If the butts feed bin is full (bin level is >/= 95% [422 A 200-LAH2])
-

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

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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.

2.6.5.2 Butts Feed Bin (422 A 300)


If SE 2-2 is selected
If the butts feed bin is full (bin level is >/= 95% [422 A 300-LAH2])
-

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.

Local Operation of Special Equipment


-Not applicable-

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
24.10.2006
Rev. 00

Vedanta Alumina Ltd.


Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-065
2.8

Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal

Description

Sort of Signal

from Group 432 C to


Group 422 A

Group 432 C is running in


CENTRAL mode and is not
in any Group START or
STOP sequence
Group 431 B is running in
CENTRAL mode and is not
in any Group START or
STOP sequence
Group 432 B is running in
CENTRAL mode and is not
in any Group START or
STOP sequence
Compressed air pressure
above 6 bar (no lowpressure indicated by 410
A 009-PE1)

Digital signal from


PLC Number 432
PLC 22 to PLC
Number 422 PLC 02
Digital signal from
PLC Number 431
PLC 12 to PLC
Number 422 PLC 02
Digital signal from
PLC Number 432
PLC 22 to PLC
Number 422 PLC 02
Digital signal from
PLC Number 410
PLC 01 to 422 PLC
02

from Group 431 B to


Group 422 A
from Group 432 B to
Group 422 A
from Group 410 A to
Group 422 A

Outokumpu Technology GmbH

27 (27)

Training Manual Green Anode Plant


Vedanta - Jharsuguda

5.3

Main Equipment

5.3.1

Flat Slide Gate (manual) 422 A 001

5.3.2

Vibrating Trough Feeder 422 A 031

5.3.3

Magnetic Separator, overhead 422 A 055

5.3.4

Belt Conveyor 422 A 060

5.3.5

Belt Scale 422 A 062

5.3.6

Rotary Lock 422 A 065

5.3.7

Bag Filter 422 A 070

5.3.8

Fan 422 A 080

5.3.9

Splitter Gate 422 A 130

5.3.10

Reversing Flap (pneumatic) 422 A 132

5.3.11

Bin 422 A 200

Outokumpu Technology GmbH


Page 6 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

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