Control Philosophy Rev 5 PDF

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SPECIFICATION
Department:
Control Systems
Document No:
I010S
Document Title:
CONTROL PHILOSOPHY
PROJECT REFERENCE
Project No.:
Project Location:
TS120100
Barbil, Odisha, India.
Project Title:
Iron Ore Pelletizing Plant II
Client:
Jindal Steel and Power Ltd.
PM Authorisation:
Date:
Client Authorisation:
Date:
13th July, 2013
APPROVALS
Rev
Issue Date
0
1
2
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16 Oct 2012
20 Nov 2012
28 Nov 2012
6 Mar 2013
25 June 2013 Revised in line with Vendor Control

Philosophy
Revision Description
Prepared Checked Disp.App Proj. App
Issued for Design

Issued for Design
Issued for Design
Issued for Design
13 July 2013 Revised in line with discussion with JSPL
Entire Document
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DOCUMENT ISSUED FOR:
Issued this Revision
In-house Review
Purchase
Revised Pages Only
Client Approval
Construction
Issued this Revision
Enquiry
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Copyright 2010 by Jacobs Engineering Group Inc. All rights reserved. The contents of this document are proprietary and
produced for the exclusive benefit of Jacobs Engineering Groups Inc. and its affiliated companies. No part of this document
may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise, without the prior written approval of Jacobs Engineering Group Inc.
Control philosophy _ JSPL Pellet Plant-II
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TABLE OF CONTENTS
1.0
INTENT OF THE DOCUMENT
2.0
CONVENTIONS
3.0
IRON ORE RECEIVING & WET GRINDING SECTION- AREA 1
4.0
ADDITIVE RECEIVING AND DRY GRINDING -AREA 2
5.0
MIXING AREA 3
6.0
BALLING AREA 4
7.0
INDURATING AREA 5
8.0
PRODUCT SCREENING AREA 6
9.0
POLLUTION CONTROL AREA 7
10.0
UTILITIES AREA 8
11.0
CONTROL SYSTEM OVERVIEW & PHILOSOPHY
12.0
ANNEXURE I PID LOOP LIST
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1.0
INTENT OF THIS DOCUMENT

This document describes the control system for iron ore pelletizing facility, based on the Dravo
Traveling Grate Process, located at the site of Jindal Steel and Power Limited (JSPL) in Barbil,
Odisha, India. This plant is designated as JSPL Pellet Plant 2 and is located adjacent to the
existing JSPL Pellet Plant 1.
Specific vendor document for equipment/package is used as a basis to provide detailed
philosophy.
The pellet plant is conceived as a versatile operation capable of producing a variety of product
types, as predicated by the ore supply and/or the consumer demand. Thus, from time to time,
campaigns may be run to produce varieties ranging from acid pellets to fluxed pellets.
The pellet plant conveyors and hardware will be mechanically designed to handle 4,500,000 direct
reduction grade (DR-grade) ore pellets per year in 330 days of operation (7,920 scheduled hours
per year), taking into account all design safety factors. Actual indurating capacity is dependent
upon the specific ore being utilized, the type of pellets being produced, and quality specifications of
the consumer.
Total plant availability is dependent upon the specific operating and maintenance practice
employed at the site. JSPLs target production is 4,000,000 tonnes per annum of fired pellets.
2.0
CONVENTIONS
The sections on control philosophy for each area include references to Loops with associated
numbers. These loops are instrument loops identified by number on the Piping and Instrumentation
Diagrams (P&IDs).
3.0
IRON ORE RECEIVING & WET GRINDING SECTION- AREA 1

3.1 Iron Ore Receiving (P&ID: R-01-1001)
Blended Iron ore is delivered by owners blended ore conveyor directly onto the Ore Concentrate
Conveyor OF-11 (B43001D). OF-11 discharges blended ore on conveyor OF-12 (B43001C). OF12 delivers ore to OF-13 (B43001B) and finally OF-13 delivers on shuttle conveyor OF-14
(B43001A), which in turn feeds to Ball mill feed bins (B43510-1&2). Conveyor OF-11, 12, 13 and
OF-14 are equipped with standard conveyor control packages for this project. Each conveyor is
equipped with adequate safety switches.
The receiving rates for wet iron ore to the ball mill feed bins at 8% H2O (by weight) are:
Operating
Design
:
:
590
2000
TPH
TPH
Each Ball mill feed bin has a four (4) hour design storage capacity.
Individual start-up of blended ore conveyors OF-11, 12 &13 and shuttle conveyor OF-14 will depend
on healthy signal from the safety switches placed on the conveyors.
Group start up will depend on the level signal from level transmitters placed over bins. Low (20%)
signal from bin level transmitters will start shuttle conveyor OF-14 first followed by blended ore
conveyors OF-13, OF-12 & OF-11 sequentially, provided there is healthy signal from safety
switches of these conveyors.
The unidirectional Ore Concentrate shuttle conveyor OF-14 feeds the Ball Mill Feed Bin2 (B435102) when positioned under the discharge of blended ore conveyor (OF-13). The shuttle car is fitted
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with a chute at the back end. When Bin-2 is full (High alarm), OF-14 moves ahead and the chute
fitted with the shuttle car comes in line with the discharge chute of OF-13 and Bin-1 starts getting
filled up.
The filling of each bin will be controlled by the level transmitter High & Low Set points. The
position for the shuttle car filling BIN-01 directly will be determined by a limit switch installed
corresponding to desired position which will stop the shuttle car motor. On receipt of H signal
(70%) from Bin-01 the shuttle car starts traveling to fill Bin-02. After receipt of H signal from any of
the bins if the shuttle car fails to move to the other bin due to any reason within 2 minutes the
shuttle conveyor will stop and subsequently all upstream conveyors will stop sequentially.
H-H alarm (90%) from both bin level transmitters and/or unhealthy signal from any conveyor safety
switch will stop up-stream conveyors in a sequential manner.
There are 2 weigh belt feeders WF-1 and WF-2 (B55201-1, 2) (Loop No: WIC-01B0107 & WIC01B0117, P&ID: R-01-1001) located under Ball Mill Feed Bins-1 & 2 respectively. The weigh belt
feeders feed blended ore to respective ball mill feed conveyors BMF-1 & BMF-2 (B43002-1&2).
Group start-up of weigh belt feeders and mill feed conveyors will depend on the following factors:
Healthy signal from the safety switches placed on the conveyors

Ball mill (B46201 / B46202) is running
Low-Low alarm not present at the respective bin.
The feed rate set point to the weigh feeders is from the Ball Mill Specific Energy Consumption (JIC01B0206, JIC-01B0506, P&ID: R-01-1002 & R-01-1005). Ball mill feed set point is based on mill
specific energy, kWh/T as formulated below:
Feed (TPH) =
(Mill kWh per h) / (Mill kWh per T)
Mill Specific energy will be set by an operator at 12.5 (Constant) [Refer P&ID: R-01-1001, Note-5]
The action on a bin alarm of low-low (5%) is to stop the belt weigh feeder (B55201-1, 2) under the
bin. This will prevent the bin emptying out with the consequential damage to the belt weigh feeders
caused by material falling from the top of the bin directly on them.
Stopping of weigh belt feeders and mill feed conveyors will depend on the following factors:
Unhealthy signal from the safety switches placed on the conveyors
Ball mill stops
Low-Low alarm at the respective bin
HH, H, and LL, L set points are indicative only and will be finalized by the commissioning engineer.
3.2 Shutdown
Prior to a planned shutdown the decision must be made as to whether or not to empty off all or any
of the conveyors. This decision will determine the sequence and timing of each conveyor shutdown.
The units are designed so they can be safely be restarted if stopped under full load.
3.3 Wet Grinding System (R-01-1002, 1003, 1004, 1005, 1006 & 1007)
(Inputs received from package vendor FLSmidth)
3.3.1
Process Description
Wet Grinding System is a dual motor driven Ball Mill with Hydrocyclone in a closed loop circuit.
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Iron ore feed size of -12mm (F100) with moisture content 8% is fed into the ball mill in a controlled
rate .Water added at the ball mill inlet to cater to grinding and to maintain the consistency in
percentage solids at the trommel discharge. The discharge from ball mill is pumped to a
classifying Hydrocyclone for separating -70 to -75 microns fractions (P80). The oversize will be
recycled to Ball Mill for further grinding. The Product will be collected from the Hydrocyclone over
flow.
Hydrocyclone underflow is taken as a recycle into ball mill feed, this forms the closed circuit.
Required dilution water through flow control valves FV0021/FV1021 can be added to the slurry
tank to maintain density of slurry to the Hydrocyclone (Loop No: FIC-B01-0020 / FIC-B01-1020,
P&ID: R-01-1003 / R-01-1006)
A flow transmitter FIT0037 / FIT1037 and Density meter DIT0036 / DIT1036 (Loop No: DIC-B010036 / 1036, P&ID: R-01-1003 / R-01-1006) is provided in the discharge of the slurry pumps
(331.PU210/B41101-1, 2 / 3, 4) to maintain the slurry density and flow rate to the Hydrocyclone.
The readings of the same will be available at the Main Automation System. A Flow control valve
FCV0044 / FCV1042 located in the ball mill feed water pipe to ensure proper control on the water
addition to mill (Loop No: FIC-B01-0042 / 1040, P&ID: R-01-1002 / R-01-1005).
Protective trips/alarms for the mill motor, lubrication system etc would be actuated from the Main
Automation System. A local control panel monitors girth gear pinion grease lubrication system.
Main Automation System obtains only healthy and unhealthy signals from the Girth gear local
control panel. However, the start/ stop command can be initiated from the Main Automation
System.
3.3.2
Normal Start-up Sequence
This section describes the functional group startup sequence. If the group has an automatic start
sequence, time delays between equipment will also be listed. Any group preconditions required
prior to startup are also listed herein. However, interlocks required for individual or predefined
groups of equipment are listed in the Interlocks section.
3.3.3
Normal Operation
This section describes the functional group normal operation, including operator functions. There
are three modes of operation, as described below:
Automatic
Automatic mode is when functional groups are controlled automatically and in sequence by the
equipment control system. A functional group is a set of items such as motors, valves, etc. which
are started by a single operator action when in Automatic Mode. All Protective, Safety, Machine,
Operational and Start Interlocks must be met in order to operate.
Manual
Manual mode is when items such as motors, valves, etc. are controlled individually by the
operator using the equipment control system. Functional groups have no meaning in Manual
Mode. All Protective, Safety, and Start Interlocks must be met in order to operate.
Local
Local mode is when items such as motors, valves, etc. are controlled individually in the field,
usually by local pushbutton stations located near the equipment. Functional groups have no
meaning in Local Mode. Since the operator interface in Local Mode is often physical devices
rather than a display screen, extra care must be taken to ensure that interlocking continues to be
enforced. All Protective, Safety, and Start Interlocks must be met in order to operate.
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Main Automation System Control

Commands to operate the equipment control system are made by an operator using the Main
Automation System HMI. The Main Automation System can only operate equipment in Automatic
Mode.
3.3.4
Normal Shutdown Sequence
This section describes the group shutdown sequence. If the group has an automatic shutdown
sequence, time delays to allow for equipment cleanout or deceleration will also be listed.
3.3.5
Abnormal and Emergency Shutdowns
This section describes abnormal shutdown conditions caused by isolated process or equipment
abnormalities or activation of individual equipment safety devices. It also describes emergency
shutdowns due to automatic activation of personnel safety systems or field emergency stop
pushbuttons.
3.3.6
Interlocks
The Interlocks section describes all interlocks for the individual equipment or functional group of
equipment within the associated software function group. Interlock is defined herein as an
input/output signal or a Main Automation System/Main Automation System internal logic condition,
which automatically prevents the operation of an individual or functional group of equipment from
the Plant Main Automation System HMI. When the condition of an interlock(s) is such that
operation of a related piece of equipment or an equipment group is permitted, the interlock(s) is
defined as being satisfied.
Specific devices in the Interlock table may be preceded by NOT. This is the condition for the
analog threshold (i.e. NOT Bearing Temperature High-High = Bearing Temperature is NOT
ABOVE the High-High Set point). However, in the case of discrete switches the Interlock is stated
from the ON perspective of the switch. For example the Oil Reservoir Low switch is ON when the
oil level is NOT Low (fail-safe), so the required interlock in the switch being true.
Interlocks consist of five types and are described in detail below:
Safety interlocks:
Safety interlocks are those interlocks which prevent damage to that associated piece of equipment.
As a result, safety interlocks apply when operating in Automatic Mode, Manual Mode and Local
Mode.
Example
Safety interlock for a pump would be no high-high bearing temperature.
Safety interlocks for every motor will also include the MCC/motor ready signal and receipt of a
run confirmation from the motor contactor after a run command is sent. These interlocks apply to
all motors and are not listed in the interlock table for this reason.
Start interlocks:
Start interlocks are those interlocks necessary ONLY for starting the machine. As soon as the
motor is running the start interlock has no influence. As a result, start interlocks apply when
operating in Automatic Mode, Manual Mode and Local Mode.
Example
A start interlock for a fixed speed fan with automatic damper would be that the damper be closed
(limit switch or position transmitter) prior to starting.
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Protective Interlocks:
Protective interlocks are those interlocks for the protection of the motor itself. As a result,
protective interlocks apply when operating in Automatic Mode, Manual Mode and Local Mode.
Example
A protective interlock for an equipment motor would be motor bearing temperature or motor
winding temperature.
Machine Interlocks:
Machine interlocks are those interlocks for the protection of the machine that is operating in
Automatic Mode. As a result, machine interlocks apply only when operating in Automatic Mode.
Example
A machine interlock for a belt conveyor would be a belt drift switch.
Operational Interlocks:
Operational interlocks are those interlocks that are related to the process, but not to the
equipment, that is necessary for the normal operation of the item. As a result, operational
interlocks apply only when operating in Automatic Mode.
Example:
An operational interlock would be downstream equipment running.
3.3.7
Overview
The mill plant incorporates the following features:
Feed system (Described in section 3.1)
Ball mill
Hydrocyclone
Product Slurry system
3.3.7.1
Ball mill
Iron ore size reduction is carried out in the Ball mill. Water spray system is installed on the
discharge chute for cleaning the trommel screen and process water addition is installed at the feed
chute to maintain the percentage solids consistency. Temperature Scanner at the feed end and
discharge end measures the inlet and outlet mill bearing temperature. Slurry from the trommel
discharge is transported to Slurry Tank. The mill is equipped with internal liners and the balls are
charged in different size.
The efficiency of wet grinding action depends mainly on the solids present in the feed slurry to the
Ball mill. The Ball mill outlet is fed to hydro cyclone through slurry pumps for coarser and finer
classification.
Trommel screen functions for the removal of grinding media scats and tramp oversize material
from mill discharge slurry which fed into mill discharge tank. Mill scats are then discharged to the
area below mill and are manually shoveled.
3.3.7.2
Hydrocyclone
Hydrocyclone are density separators that convert pressure energy into rotational momentum. The
rotational momentum provides the centrifugal force to classify solids from slurry. Separation
efficiency is determined by the Hydro cyclone geometrical parameters. The interaction between
parameters dedicates the Hydro cyclone efficiency.
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In operation, pressurized slurry is fed to the Hydro cyclone and the centrifugal force generated
causes the heavier suspended solids to move toward the wall while the radial velocity forces the
liquid and lighter gravity solids to move inward toward the central axis. Primary and secondary
vortex develops. The primary vortex carries the solids to the apex. The apex orifice permits the
heavier solids and a small amount of the liquor to be discharged. A secondary developing vortex
carries the cleaned primary liquid (liquor) and light gravity solids out through the Vortex Finder
Tube.
The performance of the hydro cyclone is based on the particle size distribution of the cyclone
overflow. The underflow slurry from the hydro cyclone is fed in to the ball mill. The hydro cyclone
overflow is fed to the Thickener Feed Well by gravity.
3.3.7.3
Product Slurry System
Each grinding mill will have a dedicated mill discharge slurry pump tank which collects the ground
iron ore slurry from the mill. Each slurry pump tank with conical bottom, is of approximately 50 m3
capacity. The tank base will preferably be above grade level. Water addition to the Ball Mill Slurry
Tank is to control the Density of the slurry being fed to the Hydro Cyclone which is monitored by
density meter at the slurry pump discharge. This is controlled by a Control Valve in the Water
Addition Line to the slurry tank. Slurry Pumps are equipped the Variable speed drive to maintain
consistent pressure in the Hydro Cyclone for better classification and the slurry tank is equipped
with Level transmitter to maintain level in tank.
3.3.8
Operation Philosophy and Plant Sequencing
Starting of the mill system is divided into a number of groups. Each drive/ equipment/ Valves in a
particular group has a specified sequence of operation. Each group in itself has a specified
sequence of operation during start and stop. This means that no equipment can be started before
the subsequent equipment has been started. Inversely, stop of any equipment will cause the stop
of the preceding equipment, unless until specified herein.
This section outlines the division of groups; the basic terminology used in numbering of the groups,
sequential Interlocks between groups and between equipment/ drives/ Valves in every particular
group.
This section basically outlines the various process Interlocks that are to be satisfied for successful
operation of a sequence. The operator has to ensure that the power source, remote selection etc.,
are properly ensured. In case, the same has not been ensured, the HMI would initiate the
respective alarms as described in the earlier section(s)/ sub section(s).
The philosophy goes into details on the various process related Interlocks and sequences only.
Zero speed switch indication has not been included due to the commonality to all drives. Interlocks
like pull chord switch, belt sway switch, instrument air pressure etc, and are not included in the
write up.
General Notes:
a. Temperature, pressure, flow, level and any other process parameter set point will be adjusted
and set during commissioning. Access to the set point is provided only for Engineers and not
for the Operators.
b. For all the analog inputs, trends are configured in the Main Automation System.
c.
Pressure switch is provided in the discharge line of all Slurry pumps for monitoring low
pressure alarm in the Main Automation System.
d. Considering the safety of the equipment, the AUTO changeover of any drives is not permitted
in the mill.
e. During the Re-start of the plant after the power failure, the operator has to ensure that the mill
drive is ready for operation before starting the mill discharge tank group and Hydro cyclone
group to avoid overflow of slurry at the mill feed end and discharge end. (After starting the
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Hydro cyclone and Mill discharge tank group, the mill drive has to be started immediately).
f.
After ensuring that the utilities are ready the operator initiates the starting of the plant.
3.3.9
Equipment Grouping
The various sections of the wet grinding circuit are assigned group numbers to assist the definition
of discrete areas. Groups can be started up individually in preparation for overall plant start-up.
These numbers will also be used for plant start-up and commissioning planning activities. Details
of the groups are included in the relevant sections.
The total process is broken down into four discrete groups to allow for easy description of the
facilities. These are as follows:
Group 1 Slurry Classification
Group 2 Ball mill Lubrication
Group 3 Ball Mill
Group 4 Ball mill Feed
3.3.10
Slurry Classification Group-1 (P&ID: R-01-1003, R-01-1004, R-01-1006, R-011007)
3.3.10.1 Group description:
The ground product from the ball mill discharges into the slurry tank (331. TK200/B35101-1).Slurry
tank is provided with a level transmitter LT0023 to monitor and maintain the level with the slurry
pump speed control.
Pair of slurry pumps (331.PU210/331.PU220/B41101-1, 2), (one operating and the other stand by)
are located adjacent to the tank transport the slurry to the Hydro cyclones. Both slurry pumps are
provided with Variable frequency Drive (VFD).
A low level in the tank (331.TK200/B35101-1), (LAL0023 set at 20%) inhibits the starting of the
slurry pumps. A low low level in the tank (331.TK200 /B35101-1),(LALL0023 set at 30%) is used
to trip the Hydro cyclone feed pumps. The normal operating level is expected to be 65%.Slurry
pump speed shall be varied to maintain the targeted level.
Slurry is classified for fines and coarse in a cluster of hydro-cyclone (331.HN300/B458011,2,3,4).Slurry is distributed to individual cyclones from a common feed distribution manifold.
Pressure transmitter PT0039 located on the hydro cyclone manifold monitors inlet pressure of feed
slurry.
Consistent pressure is maintained for efficient classification in the hydro-cyclone. There are four
cyclones in the cluster. Typically, at rated production one cyclone remain as a spare with all other
cyclones on line. At lower capacity operation it might be necessary to reduce the number of
cyclones in operation to maintain the desired pressure to achieve targeted classification. The field
technician can add or reduce the number of cyclones in operation by opening or closing the
cyclone feed valve.
Overflow and underflow from the hydro-cyclone cluster discharges into common overflow and
underflow launders respectively. The overflow product slurry is sent through pipeline to the storage
tank and flows by gravity.
Coarse underflow Slurry is discharged into the ball mill for further grinding to target fineness.
Transmitters FIT0037 and DIT0036 measure the flow and density of the slurry as fed to the hydrocyclones respectively. The hydro cyclone feed slurry percent solid is maintained at 55% w/w by
adding water to the slurry tank. Water addition is controlled via the automated flow control valve
FCV0021.
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3.3.10.2 Group-1 Equipment summary:

The operator can select only one slurry pump at any point of time. Selection of a pump would
automatically de-select the other pump from operation. By default slurry pump
(331.PU210/B41101-1) is selected for operation.
a.
Suction and Discharge valves (XV0025)for(331 PU210/B41101-1)
b.
Suction and Discharge valves (XV0024)for(331 PU220/B41101-2)
c.
Hydro cyclone feed pumps (331.PU210/331.PU220/B41101-1,2)

3.3.10.3 Group-1 starting sequence:
The SCG group is a single drive group slurry pumps. By default (331. PU210 /B41101-1) pump is
selected for operation. A start command to the SCG group starts the selected pump
(331.PU210/331.PU220/B41101-1, 2).
a. Open discharge knife gate valve XV0034/0035 with respect to the selected pump
(331.PU210/B41101-1) & (331.PU220/B41101-2).
b. Open suction knife gate valve XV0025/0024 with respect to the selected pump
(331.PU210/B41101-1) & (331.PU220/B41101-2).
c.
Start the slurry pump (331.PU210/B41101-1) & (331.PU220/B41101-2).
It will be the responsibility of the Control room operator to confirm from the field technician that the
gland seal water line valve of the selected pump is open and drain valves of the selected pump are
closed and stand by pump is open before embarking a start command. A knife gate valves is
provided at the discharge of the pumps to isolate the non-operating pump.
3.3.10.4 Group-1 Starting interlocks:
The following general interlocks are valid for starting SCG Group.
a. A level low alarm LAL0023 (set at 30%) on the tank (331.TK200/B35101-inhibits starting of
the selected slurry pump.
b. Open Limit switch of the suction and discharge valves (ZSO 0024/0025) and (ZSO0034/0035)
is healthy for the selected pump.
3.3.10.5 Group-1 Running interlocks:
a. A level low low alarm, LALL0023 (Set at 20%) on the tank (331.TK200/B35101-1) inhibits
running of the selected slurry pump.
b. Open Limit switch of the suction and discharge valves (ZSO 0024/0025) and (ZSO0034/0035)
is healthy for the selected pump.
3.3.10.6 Group-1 stopping sequence:
A stop command initiates a stop of the operating selected slurry pump.
a. Stop the selected slurry pump (331.PU210/B41101-1) & (331.PU220/B41101-2).
b. Close limit (ZSC0034/0035) healthy for discharge knife gate valve XV0034/0035 with respect
to the selected pump (331.PU210/B41101-1) & (331.PU220/B41101-2).
c.
Close limit (ZSC0024/0025) healthy for suction knife gate valve XV0025/0024 with respect to
the selected pump (331.PU210/B41101-1) & (331.PU220/B41101-2).
It will be the responsibility of the control room operator to confirm from the field technician that the
gland seal water line valve of the selected pump is closed and drain valves of the selected pump
are opened and flush the casing and discharge line of the selected pump.
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3.3.11
Ball Mill Lubrication Group 2
This group is divided into following functional groups for easy operation and logical control.
1. Ball Mill Main Lubrication system Group 2A
2. Main Gearbox Lubrication system Group 2B
3.3.11.1 Ball Mill Main Lubrication system Group 2A (P&ID: R-01-1009, R-01-1010)
3.3.11.1.1
Group Description:
The mill lubrication system (331.LQ110) consists of 3 parts:
Reservoir assembly and oil conditioning circuit;
HP hydrostatic bearings lube circuit;
Pinion bearings LP lube circuit.
Reservoir Assembly & Oil Conditioning

Capacity of the Reservoir is 2310 litres. Tank utilises the drain lines from the bearing housings to
return the "dirty hot oil" back to tank by gravity. This passes through a basket strainer which is
accessible through a hinged inspection door, for on-line inspection and cleaning.
The sump tank is a 3 compartment design,
1.
Return oil
2.
Settling
3.
Clean compartments.
The clean compartment is approx. 710 litres (3 minutes retention) and the balance 1600 litres in
the dirty side (6 minutes retention). The correct oil temperature in the sump tank is maintained by 3
kW heater elements (3 Nos), monitored by Temperature transmitter (TT4033). Heaters operate
between sump oil temperatures of 32 38C. The dirty compartment temperature transmitter is
indicative and for heater control only. Two oil level transmitters (LT4032/38) are also interlocked for
oil level monitoring.
Oil level sight glasses fitted to the tank gives visual indication of oil level & temperature
(LG4034/36 & TG4035/37). Air breather / filter allow clean air to enter the tank. 3 (nos) BSP drain
valves plugs are available to drain the tank, when required. Access to the tank internals is gained
by removing the tank lid and removal of the man-hole cover, which are bolted down.
The LP conditioning circuit is fitted with 2 LP oil gear pumps LP (One Working & One Standby),
driven by an 18.5 kW TEFC electric motor, fitted with integral pressure relief valves, set at 10 bars.
Suction is isolated from the tank via a butterfly valve; discharge end isolated via both a non return
valve and ball valve.
The LP oil flow rate is approx. 430 lpm, which is supplied to the oil conditioning circuit and the
pinion bearings and returned to tank as a closed loop system via the over-flow and pinion brgs
drain line.
A pressure gauge (PG4009) & pressure transmitter (PT4011), oil flow (FIT4010) and temperature
transmitters (TT4008) in the line confirms that the conditioning circuit is functional, allowing the use
of the pinion LP & hydrostatic HP pumps.
The dirty & hot oil" from the sump tank settling compartment is pumped to a high capacity LP
duplex filter and thereafter to a Plate Heat Exchanger (PHE). The duplex filter unit is fitted with 2
filter clogged visual indicators and a common indicating differential pressure transmitter
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(DPIT4023),which indicates to "change-over and clean filter unit on-line, thereafter, allowing the
artisan to isolate the clogged filter housing ( close both butterfly valves ) and to replace the clogged
filter element with a new unit, resetting the visual indicator, re-opening the isolating butterfly valves
after completion, bleeding and equalising the filter housing pressure, which is now ready for use.
A Manual valve Controls the water flow rate through the cooler, maintaining a constant oil
temperature exiting the cooler of 47C. Temperature gauges (TG4022) before and after(TG4006)
the cooler give visual indication of the water and oil temperature across the cooler. The
temperature transmitter (TT4008) fitted to the cooler oil exit line, interlocked to raise an alarm if the
0
oil Temperature exceeds 52 C.
The conditioned oil (clean & cool oil) exits the cooler and a bleed line return back to the sump tank
clean compartment (414 lpm). Clean compartment oil level and temperatures (level LT4038> 90%
0
and oil temp TT4039> 38 C) shall meet to start the HP pumps. The conditioning pump should run
continuously, even when the mill is stopped.
High Pressure Hydrostatic Oil Lube
The HP oil is pumped to the mill bearings via a 4 port flow divider, as follows: FE (Feed End)
bearing at 118 lpm; 59 lpm per pocket
DE (Discharge End) bearing at 118 lpm; 59 lpm per pocket
HP Pressure gauges, HP pressure transmitters (PT 4050/ 53/ 56/ 59), HP flow transmitter
(FIT4038) exist to monitor and inter-locked. The oil flow rates are balanced using rotary geared
flow divider to achieve the correct flow rates to the various bearing pockets. The HP tandem gear
pumps HP 01 /02 (One Working & One Standby) are isolated from the sump tank by ball valves,
and protected against over-pressure by an individual pressure relief valve, set at 103 bar. Non
return and ball valves isolate the pump feed lines, and a pressure gauge, oil flow transmitter are
fitted for visual and MAIN AUTOMATION SYSTEM interlocking for HP system pressure. The 2750
kW TEFC mill main motors will be tripped if the pressure drops below 25 bar or oil flow drops
<180lpm. Each bearing pocket is fed by an independent HP lube line at 59 lpm each and 100 bar,
monitored & inter-locked by pressure gauges and pressure transmitters (PT). Two Nos in-line
54litre bladder type accumulators are fitted to the HP circuit to store oil under pressure in the event
of a power failure, discharging oil through the flow divider at a reduced rate for 10 seconds until the
mill comes to a complete stop.
Pressure switches & gauges are interlocked with the Main Automation System to ensure sufficient
nitrogen gas pressure exists in the bladder to perform the emergency oil run-down for 10 seconds.
Low Pressure Pinion Bearing Oil Lube
Oil flow to the pinion bearings is controlled by the 4 needle valves (331.XV 4013/15/17/19),
delivering 4 lpm of oil to each pinion bearing. Flow indicating transmitters (FIT4014/16/18/20) give
visual indication of oil flow to each pinion bearing and is interlocked with the Main Automation
System to raise an alarm if the oil flow drops below 3.4 lpm.
3.3.11.1.2
Group 2A equipment summary:
a.
Return compartment heater HE 01
b.
Settling compartment heater HE 02.
c.
Clean compartment heater HE 03
d.
Low pressure pumps LP 01/02 by default start pump LP01, selection to be made available in
MAIN AUTOMATION SYSTEM.
e.
High pressure pumps HP01/02 by default start pump motor HP01, selection to be made
available in MAIN AUTOMATION SYSTEM.
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3.3.11.1.3
Group 2A Start sequence
Start command of the Group 2A initiate the following sequence

a.
Start heater HE 01
b.
Start heater HE 02
c.
Start heater HE 03
0
Note: Start the above sequence if the oil temperature is <38 C.

d.
Start the LP pump, either LP01 or LP02
e.
Start the HP pump, either HP01 or HP02

3.3.11.1.4
Group 2A Starting interlock
This group can start provided that the following conditions are satisfied
a. Settling compartment low level LT4032 25% alarm is false for starting pump LP01 or LP02.
b. Clean compartment low level LT4038 25% alarm is false for starting pump HP01 or HP02.
c.
Reservoir Oil temperature (TT4033) <380C is false for starting Pump.

3.3.11.1.5
Group 2A Running interlock
This group can run successful provided the following conditions are satisfied
a. Settling compartment low-low level alarm false LT 4032 15% for pump LP01 or LP02
b. Clean compartment low-low level alarm false LT 4038 15% for pump HP01 or HP02.
c. Settling compartment temperature high-high alarm false TT4033> 620C for running pump LP01
or LP02
d. Clean compartment temperature high-high alarm false TT4039>520C for running HP01 or
HP02.
e. Flow low-low alarm(FI 4014/4016/4018/4020)(Set at (34lpm) alarm is generated, if any of the
pinion lube line oil flow low low alarm FITS (3lpm) is not true then mill main motor trips.
f. Flow low-low alarm FI4048 (Set at <200lpm) alarm is generated, if flow low alarm
FT4048<180lpm is not true then mill motor (HP01 or HP02) will trip.
g. Pressure low alarm false, if any of the main bearing lube line pressure low alarm PITS
PT4050/53/56/59 is <25bar true for more than preset time (say, 20secs) mill motor (HP01 or
HP02) will trip.
h. Mill trips if the temperature TI4008>650C.
i. Accumulator Pressure low alarm (<20bar) false for PSL4044/4046.
3.3.11.1.6
Group 2A Stop sequence
Stop command of the Group 5A initiate the following sequence

a.
Stop heater HE1
b.
Stop heater HE2
c.
Stop heater HE3
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d.
Stop mill main motor.
e.
Stop the running HP pump, either HP01 or HP02
f.
Stop the running LP pump, either LP01 or LP02
3.3.11.2 Main Gearbox Lubrication system Group 2B (R-01-1011, R-01-1012)

The ball mill main gear reducer is lubricated utilizing a forced lubrication system.
The reducer lube system 331.LQ145 contains an oil reservoir. Two oil-circulating pumps 331.GB
01/02 (one working + one standby) are utilized for oil circulation inside the reducer. An oil-water
cooler is provided in the downstream to cool the oil before entering the main reservoir.
The pressure of oil to the gearbox lubrication system and the oil circulation pump discharge line
will be monitored by the pressure switches PSL4081. TemperatureTG4080 and pressure gauges
PG4083 are provided in the line for local display. The discharge piping of the pump is connected to
a differential pressure switch DPSH4084 monitors the pressure drop across the filter unit. The
switch provides an input to the control system to alarm on high-pressure drop across the filter
alerting the operator to change the filter.
The pumps used for oil recirculation, in case failure of main pump auxiliary shall be manually
started by the standby pump and will trip the working pump by the low pressure switch PSL is
activated will trip the oil pump.
3.3.13
Ball Mill Group 3 (P&ID: R-01-1002, R-01-1005, R-01-1010, R-01-1012)
3.3.12.1 Group description:

Ground ore from the Ball mill (331.BM100/B46201) discharge to the tank (331.TK200/B35101-1)
and pumped through slurry pumps (331.PU210/B41101-1) to the hydro cyclone cluster
(331.HN300/B45801-1, 2, 3, 4) for classification.
Ball mill Inching Mode
It is to be noted that inching drive engage or disengage status has also to be monitored locally. A
proximity Switch (ZSC0017) is provided in the jaw clutch coupling to ensure the disengage before
the start-up of the mill main motor.
3.3.12.2 Group 3 equipment summary:
a.
Ball mill Main Drive 331.MD 135/140
b.
Ball mill grease spray system 331.GS137

3.3.12.3 Ball Mill Girth-gear grease spray system Group
Prior to mill start up, the Main Automation System should have a healthy signal from the grease
drum low level switch.
As soon as the mill main motor runs, the Main Automation System will energises the 3/2 way air
solenoid valve which operates the pneumatic grease pump, and a monitoring timer is activated.
The grease is pumped through the grease strainer via the tubing to the Master distributor, splitting
the flow equally to the 2 Slave distributors, which in turn discharges fixed quantities of grease into
all 10 nozzles. Once this cycle is complete, the indicator pin on the slave distributors will activate
the limit switches (ZS4064/71), which re-sets the monitoring timer and the Main Automation
System will energise the 2/2 way air spray solenoids for a set time period (time required for the mill
to do 1 full revolution, approx. 4 sec. plus time required complete the 7 distributor cycles)
The air pressure switches (PSL4062) in the air line will confirm to the Main Automation System that
the solenoid valves are operational and that the plant air pressure is sufficient. The grease pump
runs for the duration of the set pulses, pulsed by the distributor limit switches ZS. As soon as the
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pulses are complete, i.e. 7 pulses, the Main Automation System will de-energise the pump
solenoid valve and the system is put on PAUSE for a set time period (10 minutes).
The above cycle will be repeated as long as the mill runs.
The indicator pin will not activate the limit switches if:
no grease flow to the nozzles occurs
the nozzles are blocked
the pipeline is broken / blocked
the distributor and/or limit switch is faulty
the grease strainer is blocked
The air pressure switch PSL4062 will fail to signal the Main Automation System if the 2/2 way
solenoid valve is faulty, or if the plant air pressure is low or off line. The pressure gauge gives
visual indication of the system air & grease pressure. The pump should trip if no pulses are
generated from the distributors, or the air pressure switches are not activated. The mill should then
also trip.
3.3.12.4 Group 3 starting Sequence:
Start command of the Group 3 initiate the following sequence
a.
Start Lube System 331.LQ110
b.
Start Ball mill main motors 331. MD 135 & 140.
c.
Start the Grease spray system 331.GS137.
d.
Start Reducer Lube system 331.LQ145

3.3.12.6 Group 3 starting interlocks:
The ball mill 331.BM100 can start if the following conditions are met:
0
Pinion bearing temperature TI0018 high alarm not true (Set at 80 C)
Feed end trunnion bearing temperature TI0011 high alarm not true (Set at 60oC)
Discharge end trunnion bearing temperature TI0019 high alarm not true (Set at 600C)
Mill main bearing lubrication system 331 LQ110 operation is valid for a minimum period of
600 seconds prior to start of mill drive
Mill main motor gearbox lubrication system 331 LQ145 operation is valid for a minimum
period of 600 seconds prior to start of mill drive
Motor bearing temperature T1 0014/0004 high alarm not true (Set at 650C) Motor winding
0
temperature T1 0012/0006 high alarm not true (Set at 65 C) Mill discharge slurry tank
331.TK200 level LAH0023 high alarm not true
Grease spray system false alarm is not present.
Inching Drive (ZSC0017) engaged limit is not true.
3.3.12.6 Group 3 running interlocks:

The ball mill (331.BM100/B46201) can remain in operation if the following conditions are met:
Mill bearing lube oil pumps is in valid operation.
'Low Low oil reservoir level LSL LT4032 alarm 15% is not true. 'Low Low
oil reservoir level LSL LT4038 alarm 15% is not true. Lubrication Oil
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pressure low low alarm <25bar PT is not true.
Lubrication Oil flow low low alarm FT4048 (<180lpm) on the low pressure oil line is not
true
Lubrication Oil flow low low alarm FT4014/16/18/20 (<3lpm) on the high pressure oil line
is not true
Pinion bearing temperature TI0018 high high alarm not true (high-high alarm set at 75 C)
Feed end trunnion bearing temperature alarm TI0011 high high alarm not true (high-high
0
alarm set at 65 C)
Discharge end trunnion bearing temperature TI0019 high high alarm not true (high-high
alarm set at 650C)
Mill main gearbox lubrication system 331.LQ145 run feedback healthy.
Motor bearing temperature TI0004/0014 high high alarm not true (high-high alarm set at
650C)
Motor winding temperature high high TI0006/0012 alarm not true (high-high alarm set at
650C)
Grease spray lubrication system healthy. The ball mill drive shall trip, if the panel fault
indication is true during the delay timer of 1200seconds
If Mill discharge tank level LAHH0023 high high alarm > 90% mill trips.
Hydro Cyclone slurry feed pumps (331.PU210/B41101-2)(331.PU220/B41101-1) run

feedback healthy.
3.3.12.7 Grinding section stopping sequence

A stop command to Ball mill Group initiates the stopping of the ball mill main drive 331.MD 135/140
followed by the grease spray system within 2seconds (set during Commissioning).
NOTE: Group3 interlocks are also applicable when the mill is running using Inching drive.
3.3.13
General
3.3.13.1 Cleaning Mill Feed Chute Blockage

Feed chute can block mainly due to following.
Loss of water to the mill.
Reduced quantity of water with respect to set ratio.
Improper operation of weigh feeder.
In all cases, addition or correction of water and recycle slurry can solve the problem.
Occasionally, poking of feed chute with controlled addition water will be required. Utmost care
needs to be taken while poking the chokes, so as not to damage the linings over the feed chute or
accidentally drop the poking device into the chute. These might aggravate the problem.
If need be, a shutdown of mill might be warranted.
3.3.13.2 Cleaning Mill Discharge Trommel Screen
Mill discharge trommel screen could get blocked due to the following reasons.
Stray material like cloth, wood, jute or plastic material that might have been fed along with the feed
ore.
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Mill operation with high solid percentage by weight than that recommended and a subsequent
emergency shutdown.
The permanent remedy for case one would be to feed clean ore in to the mill.
In both cases jamming could possibly be cleared by pressurized fresh water into the trommel
screen and carefully extracting with proper tools from the discharge of the mill.
If needed, stop the mill operation to clear the jam.
3.3.13.3 Integrated Start Sequence
In summary the system is started with the following sequence.
Start the Group 1

Start the Group 2
Start the Group 3
Start the Group 4
Put the liquor flow controllers in to cascade Control.

3.3.14
Integrated Stop Sequence
In summary the system is stopped with the following sequence.
Put the liquor flow controllers in to Auto mode to maintain their current set points
Stop the Group 4
Wait for the mill to empty of solids
Stop the Group 3

Stop mill main drives
Set the liquor flow rates to low values
Wait for the mill discharge tank to empty of solids
Flushing the mill discharge slurry transfer pipe
Close the water flow control valves
Stop the Group 1
Drain the slurry from mill discharge tanks.
Stop the Group 2
Allowance is also made for flushing the mill and tanks as much as possible after an equipment trip.
This sequence is still initiated by the operator.
3.3.14
Emergency Operation
If any trip or failures occur in any of the drives in this group, all preceding equipment will also stop
as a result of the interlock system.
This could result in increased difficulty while re-starting the group due to the improper shut down. If
the quantity of the material is huge that remain in the system, it might be necessary for the
operator to resort to the Individual mode of start during re-start of group.
3.3.14.1 Failure of feeding arrangement to Mill
In this instance, a number of simultaneous interlock actions need to occur. Those include
immediately.
Mill main motor stops if the weigh feeder operation is not restored within 300 seconds from the
fault occurred.
Mill water controls automatically with the ratio control.
Main bearing lubrication system stops after 600sec if run feedback of mill main motor fails.
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Mill discharge pumps speed would come to a preset value (Say 50%) if the mill discharge tank
level reaches Low-Low (30%).
3.3.14.2 Failure of main bearing lubrication system
immediately.
Failure of mill main bearing lubrication system will stop the mill main motor.
Mill feed system (apron feeder & mill feed conveyor) trips immediately if mill main motor
stops/trips.
Mill water addition controls automatically with the ratio control.
Speed of mill discharge pumps would come to a preset value if the mill discharge slurry tank level
reaches Low-Low (30%).
3.3.14.3 Failure of Gearbox lubrication system
In this instance, the simultaneous interlock actions need to occur. Those include immediately.
Mill main motor stops if the gearbox lubrication system is not resorted within 300 seconds from the
fault occurred.
3.3.14.4 Failure of Grease Spray system
In this instance, the simultaneous interlock actions need to occur. Those include immediately.
Mill main motor stops if the grease spray system is not resorted within 1200 seconds from the fault
occurred.
3.3.14.5 Failure of mill discharge slurry pump
immediately.
Mill discharge slurry pump feedback fails.
Mill main motor stops if the mill discharge slurry tank level remains High-High for 240 seconds.
Mill feed system (apron feeder & mill feed conveyor) trips if mill discharge slurry tank level reaches
High-High.
Mill water controls automatically with the ratio control.
Main bearing lubrication system stops after 600sec if run feedback of mill main motor fails.
The drain valve should be opened manually to drain the slurry in the pump and the line.
3.3.14.6 Failure of mill
Mill Weigh feeder operation stops.
Mill Water controls automatically with the ratio control.
3.4 Thickener & Flocculent dosing system

(Inputs received from package vendor Outotec)
The thickener treats the concentrate from the wet grinding section using a flocculent solution to
produce thickened concentrate for transport to the next process and Clarified water for reuse in the
plant.
Local control of the thickener is via the control panel mounted on the bridge. The drive can be
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started and stopped and the rakes raised and lowered via pushbuttons on the front of the panel.
The panel displays all of the alarms as well as the main process signals, viz: Torque.
3.4.1
Principle of Operation
Feed slurry enters the thickener from the top via a feed pipe, and is discharged tangentially into the
feed well. The slurry is diluted with filtrate (From Filtrate tank) and a chemical agent (a poly
electrolyte) is added to bind solid particles to form suitably large and stable flocs that settle under
gravitational forces. The flocculated slurry settles over a bed with a well-defined interface with
clarified water above it. Clarified water flows to a peripheral collection launder at the top of the
thickener and finally flow into the process water tank and again re-circulated as process water.
Rake arms fastened to the drive shaft coupled with gear box, scrape the precipitated and
deposited sludge towards to the centre of thickener bottom cone. Concentrated Sludge is
withdrawn from central underflow nozzle located at base of the thickener and then pumped to the
slurry holding tanks (B36101-1&2).
3.4.2
Control Logic for Thickener Local Control Panel
The main controls for the Thickener are as follows:

1.
Manually Start or Stop the Hydraulic power pack Electric motor through local control
panel.
2.
Manually raise and lower the rake base.
3.
Rake raising and lowering through Auto mode.
4.
Manual trip Reset.
5.
Selection of operation (Auto/Manual operation) through selector switch.
3.4.2.1
Manual operation
Manual mode shall be selected in the selector switch.

The electric motor shall be started manually. The motor shall start only if oil level is above the
specified level in the power pack and the pressure switch has not exceeded the maximum set
pressure (95% of set pressure).
The Hydraulic Cylinder is actuated manually up to the maximum stroke or the rake base raised up
to maximum level. Once the cylinder reaches to max. Stroke, the Upper limit switch turn NC
thereby restricting further raising of the rake.
The Hydraulic Cylinder is retracted manually or the rake base is lowered up to the minimum level.
Once it reaches to the minimum set point, the Lower limit switch turn NC, thereby restricting further
lowering.
When the oil level reaches low level in the hydraulic power pack or pressure switch experience
maximum pressure (95%) or pre-set pressure governed by the pressure transmitter is more than
60% - The Hooter siren turns ON.
While lifting the rake mechanism, the rake arms shall continuously rotate and scrape the slurry.
Hooter will turn OFF if trip reset is being activated.
The electric motor shall be stopped manually.
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3.4.2.2
Auto operation
1. Auto Mode shall be selected by selector switch.

2. The Hydraulic Power pack electric motor shall be manually started. The motor shall start only if
oil level is just above the specified level in the power pack and pressure switch has not
exceeded maximum set pressure (95%).
3. If torque is less than 60% of the set pressure in the pressure transmitter, rake shall rotate at
the lower most position and lower limit switch shall turn NC.
4. Accordingly indication shows as Rake is fully lowered.
5. Once torque reaches to 60 % or more of the preset pressure transmitter reading, rake shall
raise automatically and will be held at the position so that pressure drops to 60 % of the set
pressure. In any case if rake pressure reaches 95% of the set pressure, pressure switch shall
be activated and the electric motor turns OFF.
6. If the rake lift carriage reaches the maximum level and still the pressure shows more than
95%, the electric motor shall turn OFF (Upper limit switch turn to NC).
7. Accordingly indication shows as Rake is fully raised.
8. After lifting, if pressure drops to less than 40% of set pressure, rake shall lower automatically
by timer circuit relay. Rake shall lower every 180 sec. interval and spike of 2 sec ON, process
shall be repeated till this reaches the lower most position.
9. When oil level reaches the low level in the hydraulic power pack or pressure switch
experiences maximum pressure (95%) or more than 60% of pre set pressure governed by the
pressure transmitter, the Hooter siren turns ON.
3.4.2.3
Local control panel Indication
a) Hydraulic power pack electric motor ON.

b) Hydraulic power pack electric motor TRIP.
c) Rake fully RAISED (max. stroke).
d) Rake fully LOWERED.
e) High torque TRIP.
f)
Low hydraulic oil level TRIP.
g) High torque ALRAM (Hooter turned ON).

3.4.2.4
Local control panel PUSH BUTTON
a) Hydraulic power pack electric motor START.

b) Hydraulic power pack electric motor STOP.
c) Rake RAISED.
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d) Rake fully LOWERED

e) Trip RE-SET.
f)
Lamp TEST.
g) Emergency STOP.
h) Selector switch (Manual/Auto Mode)
i)
Duel set controller (Micro process based).
j)
Hooter
3.4.2.5
Feed back to Main Automation System (Potential free contacts)
a. Pressure transmitter/Torque transducer (4 to 20 mA)

b. Rake Fully lowered.
c.
Rake fully raised.
d. Hydraulic oil level-Low trip.

e. High torque trip (Pressure switch).
f.
Hydraulic Power pack Motor ON.
g. Hydraulic Power pack Motor TRIP.

Note:
1.
In primary duel set controller, 100% (20 mA) set point corresponds to 120 bar/Maximum
operating pressure/torque and 0% (4 mA) set point (Torque Duel set Controller) corresponds to 0
bar.
2.
In secondary duel set controller, 100% (20 mA) set point corresponds to height from sensor face
and free board and 0% (4 mA) set point corresponds to 2 mtr depth from the dual crystal
sensor/source.
3.4.3
Control Logic For Flocculent Dosing System
The operation logic for complete flocculent dosing system is designed and defined to prepare and
dose the required quantity of flocculent automatically from Main Automation System.
Provision for manual operation is also enabled through a selector switch.
The flocculent solution of 0.25% concentration gets pumped by the dosing pump. If required,
further dilution will be done by addition of water. Proper mixing takes place inside the static mixture
before the diluted flocculent solution enters the thickener.
Once the flocculent drops below certain level (1-FDS-LS-04) in dosing tank (1-FDS-DOT-02), the
level switch gives the signal to Transfer Pump (1 - FDS - TP 01), which starts and pumps the
prepared solution from preparation tank (1-FDS-PRT-01) to dosing tank (1-FDS-DOT-02).The
Transfer Pump (1 - FDS - TP 01) Stops at LL level of the tank. This batch Displacement volume
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is pre calculated. Dosing Tank Volume above Low level (1-FDS-LS-04) is slightly more than this
Pre calculated Volume (Effective Volume). Hence there is no possibility of overflow.
When the preparation tank (1-FDS-PRT-01) gets emptied, this signal is transferred to panel by
level switch (1-FDS-LS-03) and the Transfer Pump stops (1 - FDS - TP 01). Simultaneously,
water inlet solenoid valve (1-FDS-SOV-01) actuates to open & allow water inside preparation tank
(1-FDS-PRT-01). When the water just submerges agitator blades, level switch (1-FDS-LS-02)
gives signal again to panel, which in turn starts Screw feeder (1-FDS-SF-01) and agitator (1-FDSAG-01).
Screw feeder is allowed to operate only for few seconds thro timer (T2) to allow just enough
quantity of flocculent powder required for preparing fresh batch of solution at 0.25% concentration.
It will be automatically stopped through Timer. It will also invariably stop at high level (1-FDS-LS01), overriding the timer as a safety interlock, depending on the status.
The water inlet to the preparation tank stops when the high level (1-FDS-LS-01) is reached.
Agitator (1-FDS-AG-01) continues to mix water and powder to make homogeneous solution
and stops when solution is transferred to dosing tank.
The whole cycle repeats when the dosing tank level hits low level again.
The safety interlock is provided, in case the level goes further low (very low) (1-FDS-LS-05) in
dosing tank (approximately 50mm. lower than low level), very low level switch is actuated, trips the
dosing pump (1-FDS-DP-01)
In such conditions, manual building up of level in dosing tank needs to be done, till very low level
signal goes off.
The auto manual switch is provided on panel which enables following operations manually
provided the very low dosing tank level alarm is not actuated.
1. Transfer valve operation
2. Agitator operation
3. Screw feeder operation
4. Water feed valve operation
3.5 Thickener Underflow Slurry Handling
The Thickener (B45701) receives slurry from many sources. The ball mill area sump pumps and
filter area sump pumps go to the Sieve Bend (B45451) to reject trash and oversize material.
Density and flow meters (DT-01B0820), (DT-01B0830) and (FT-01B0821), (FT-01B0831) measure
the Thickener Underflow Pumps (B41101-1, 2, 3) discharge. There are two underflow pumps
running with one spare. Thickener underflow slurry density is maintained at a specific gravity of
approximately 2.13. There are two density controllers that control the discharge either to the slurry
distributer or to the thickener. Underflow travels to the Slurry Distributor (B48201) and is directed
by two Dart Valves (B48201-1, 2) to the Slurry Holding Tanks (B36101-1, 2). An overflow at the
Distributor returns slurry to the thickener.
The three Thickener Underflow Pumps have individual Hand Speed Controllers at the Main
Automation System.
The thickener underflow rate will be controlled to maintain equilibrium between the solids going
into the thickener from all sources and the solids pumped as underflow at the proper density to the
slurry holding tanks. One indication that the thickener is not in equilibrium is that the level in the
slurry tank will begin dropping. Another indication is the torque measured from the thickener rake
will increase as a result of excessive solids building. The underflow pump rate may then be
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adjusted by the operator to re-establish the solids balance. The variable speed control will only be
used for small adjustments. The operator may also increase the solids flow to the upstream ball
mills to balance the solids into and out of the thickener.
If there are large changes in the flow of solids to the thickener, then the thickener underflow will be
recycled until the desired density has been re-established. One of the thickener underflow pumps
may be shutdown if the one of the upstream ball mills is shutdown.
The flow and density instruments on the thickener underflow pumps allow operators to compute
the mass flow from the thickener. Once equilibrium is reached in the thickener, the underflow pump
speed may be adjusted to yield the same mass flow to the distributor as the new solids feeding the
thickener. The primary source of new solids enters the thickener from the cyclone overflow.
3.6 Thickener Overflow Water handling
Overflow from the thickener goes to Process Water sump (B15701) fitted with pumps (B41105-1, 2,
3). Two pumps would be in operating condition and 1 pump will be standby.
The process water sump level controller (Loop No: LIC-01B-0804, P&ID: R-01-1023) will control
makeup water addition through LV-01B0804A in case of low level of the sump or divert water to
Blow down through LV-01B0804B in case of High High level of the sump. At Low Low level of the
sump, process water pumps will stop.
3.7 Slurry Holding tanks
Two Dart Valves (B48201-1, 2) direct the thickener underflow slurry to Slurry holding tanks. The
dart valves are operated manually from Main Automation System. Operator will allow the Dart
valves to fill one Slurry Holding Tank at a time. The third dart valve is for future.
Agitators (B39102-1, 2) are fitted to keep the slurry in suspension in the Slurry Holding Tanks.
Slurry level (LIT-01B1304 and LIT-01B1305) should be maintained to keep the agitator below slurry
level.
3.8 Filter Press Feed Pumps
Manual valves allow the Filter Press Pumps (B41103-1, 2, 3) to be fed from either Slurry Holding
Tank. If both Slurry Holding tanks are empty, then all three Filter Press Feed pumps (B41103-1, 2,
3) stop. The Filter Press Feed Pumps are designed for one pump for (2) Filter Presses. The logic
will allow the pump to fill only one filter press at a time.
3.9 Pressure filter
(Inputs received from package vendor METSO)
The pressure filter operates on a batch basis and comprises a series of filter plates supported in a
fabricated frame with a hydraulic system to open and close the filter plate pack.
Slurry is fed into the chambers; the filtrate formed in the filter plates passes through the filter cloths
while the solids are retained in the chambers. After filtration the membranes are activated to
stabilize the cake and the filter cake is air dried by passing Compressed air through the cake. The
filter is then opened to discharge the cake, the cloths are rinsed and the filter starts next cycle.
The operation of the VPA Pressure Filter (VPA 20 of METSO) is fully automatic requiring only
periodical operator routine inspection and operational checks.
A complete filter cycle comprises of following individual steps
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Low pressure closing

High pressure closing
Feed - filtration
Membrane compression
Air through blow
Top blow
High pressure drainage
Cake chute doors opening
Filter opening cake discharge
Cloth vibration (only if required)
Cake chute doors closing
Cloth washing with vibrations
Waiting for next cycle to commence
These individual steps are generally described as follows reference is also made to the valve
sequence diagram.
3.9.1
Low pressure closing
The cycle begins with filter closing where the low-pressure high-capacity hydraulic pump is started
and oil is directed by appropriate valves to retract the cylinder rods. This pump actually consists of
multiple pumps mounted on a common shaft. Each pump operating one cylinder to ensure equal
extension and retraction speed of all cylinders to maintain parallel movement of the pressure piece
and filter plates.
When the movable head reached the inner closed position indicated by proximity switches the filter
Low Pressure is closed.
3.9.2
High pressure Closing
When the filter has reached the low pressure closed position, the step high pressure closing will
commence. The hydraulic high pressure pump will create the required pressure to retract the
cylinder rods a little bit further to accomplish compressive closing. High pressure closing pressure is
indicated by a pressure transmitter.
3.9.3
Feed - filtration
The feed pump needs be controlled by a variable speed drive unit. The pump speed control is
necessary to cater for the difference in the pump operating conditions at the start and end of the
filtering step, where high flow/low pressure and low flow/high pressure conditions are required
respectively.
With this system, the feed pump speed will be controlled to provide a filling rate of the correct flow
m/hr, which should fill the filter under controlled forms. As the pressure increases, the pump speed
will be increased to achieve and maintain the required 6-8 bar filtering pressure. Signals to start and
stop the feed pump, as well as the pump speed reference signals could be provided from the filter
control system.
Feed - Filtration starts as soon as the correct filter closing pressure is reached.
Feed valve V1 opens and the feed pump starts. An automatic feed control system will control the
speed of the pump, the first part of the feed step under flow control to limit the flow rate, then a
ramped speed increase until the 6-8 bar filtering pressure is achieved and maintained. The pump
speed reference signals can be provided by the filter control system.
The cloth damage detection system is activated a short time after the filtration starts to avoid the
normal initial turbid filtrate flow period.
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Filtration continues for the timed period, or by using derivative calculation algorithm. The feed pump
then stops and feed valve V1 closes.
3.9.4
Membrane Compression
The membrane air evacuation valve (V10) closes and the membrane compression air feed valve
(V7) opens to inflate the membranes.
The primary membrane compression step continues for the timed period.
3.9.5
Air Through Blow
The filtrate valve V3 (V3, V12 and V13 on VPA 20 size filters) closes, air valve V5 opens and air is
entering into the filter via two of the side channels and further into the surface of the membrane
plates. The air has to pass through the filter cake forcing the water around the particles, out on the
drainage surface on the filter plates, and out again of the filter through the two filtrate ports.
The membranes are kept inflated with a higher pressure than the air through blow pressure during
the complete step to compensate for the reduction in the filter cake volume as the moisture is
displaced.
To secure a higher pressure behind the membranes during the air through blow, the valve V11
opens for booster air to pressurize the membranes at the same time as valve V5 opens for air
through-blow.
The booster air is delivered from a booster air compressor.
The procedure described above will prevent the filter cake from cracking and consequently minimize
the air consumption.
The air through-blow step continues for the timed period and then valve V5 is closed.
3.9.6
Top Blow
The filtrate valve V3 (V3, V12 and V13 on the VPA 20 size machines) opens. The Slurry return
valve V4 and valve V41 opens.
The air inlet valve V6 and water inlet valve V8 opens for a short time (V8 only if needed), to displace
slurry from the feed channel in the filter plate pack.
The Top blow step continues for the timed period. The top blow step is completed when valve V4
and valve V41 are closed.
Then the membrane air valves V7 and V11 close and the membrane air evacuation valve V10
opens to release the membrane pressure.
3.9.7
High Pressure Drainage (Hydraulic)
The hydraulic closing pressure in the hydraulic cylinders is relieved allowing the filter to
open slightly to drain any remaining filtrate from the filter.
The filter weighing system records the filter weight. High pressure drainage completion is
indicated by a pressure transmitter.
3.9.8
Cake Chute Doors opening
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The two chute doors open, operated by hydraulic cylinders. Proximity switches indicate
when the both doors are in open position.
3.9.9
Filter Opening cake discharge
The relevant hydraulic system valves are activated and the low pressure high capacity
pumps extend the cylinders, pushing the movable head open.
The filter plates are connected together to the movable head by a link system so as the
movable head starts to move the plate pack is opened according to the concertina style
allowing the cake to fall from the filter by gravity in the chambers one by one.
When the movable head reached the outer limit of its travel indicated by proximity switches
the filter is open.
3.9.10
Cloth Vibration
When the machine is in open position the weight will be checked.

If the weight is above maximum allowed empty weight, the motor vibrators will start and
run for short timed period to vibrate the filter cloths and to ensure that all cakes are
removed from the filter cloths.
If the empty weight is too high after the automatically repeated vibrations, the machine will
stop. An alarm will follow which is visible on the screen and the remaining weight needs to
be removed manually by further vibrations or washing.
3.9.11
Cake Chute Doors Closing
The two chute doors operated by hydraulic cylinders close. Proximity switches indicate
when the both doors are in closed position.
3.9.12
Cloth wash
When the cake chute doors are closed the wash water valve V9 opens and cloth flushing
starts. During flushing the vibrators may be activated to ensure that all remaining cake
residue is removed.
The cloth flushing step continues for the timed period and a after valve 9 closes.
3.9.13
Waiting time
A waiting time setting between the cycles can be used. Waiting continues for the timed
period. The VPA Pressure Filter is then ready to start next cycle.
OPERATION DESCRIPTION
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Automatic Cycle Steps Schematic
3.10
Control system VPA-press filter
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The VPA-press filter control system consists mainly of the following items:
Main control cabinet, -K1 containing PLC, Industrial-PC and MCC functions, (designed to be
installed on the filter platform).
Pneumatic valve control, -PV1-2, (designed to be installed on the filter platform). Hydraulic control,
-HV1 the hydraulic junction box, (preinstalled on the hydraulic unit). Weight system with 4 load
cells and a weight central.
3.10.1
Description
The VPA-press filter is operated from the Industrial PC screen on the main control cabinet -K1
located on the filter platform. The industrial PC is connected to a PLC which handles the control
logics. The VPA-press filter can be operated either in Automatic, Semi-automatic or Manually.
In AUTO the VPA-press filter operates automatically by the programmed sequence.
In SEMI-AUTOMATIC the filter is operated step by step through the sequence and in MANUAL
some of the filter functions can be manually operated from the monitor.
All process specific Data & Parameters can be set and adjusted in the Settings-menu.
Statistics, like Cycle time, Press weight etc. is presented on the Statistics-menu.
Alarm & Fault handling is implemented in the operators panel; each alarm will be displayed with
text, status, date and time in the Alarm-menu.
The main power supply are connected to the Main control cabinet, all other supply and control
voltages are created internally by use of transformers and distributed to all other different units.
The cabinet are placed on rubber dampers to eliminate vibrations from the environment.
The process air supply will only be connected to one point at the Pneumatic control panel, -PV1,
that together with PV2 controls all pneumatic process valves located around the press filter.
Inductive proximity switches supervise the process valve positions.
The Hydraulics will be controlled from the Main control cabinet via the junction box located on the
hydraulic station. Inductive proximity switches supervise all hydraulic movements.
A number of sensors, pressure switches, inductive proximity switches etc. for control and
supervision of the process are connected to the Main control cabinet via junction boxes.
A weighing system consisting of 4 load cells, (one in each corner of the VPA -press filter),
connected to the weight-central via a junction box delivers the actual weight of the pressed
material to the control system for process control and statistics.
3.10.2
Interfaces Between Metso And Customer
There are two types of interfaces between Metso VPA-press filter control system and JSPL.
One is for the process control and the other is for starting & stopping the VPA Press filter from
a Remote location. Both interfaces will preferably be Ethernet TCP/IP between the different
units.
3.10.2.1 Process equipment interface
Following signals will be exchanged between the Metso VPA control system and JSPL
process equipment:
From Metso JSPL
From JSPL Metso
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Start order Slurry pump

Start order Wash water pump
Conveyor Increase speed order
Control Room Emergency Stop

Slurry tank OK = Tank level OK and/or Density OK
Dry Air OK = Pressure OK or Flow OK
Wash Water OK = Tank level, or Pressure or Flow OK
Slurry Pump is running, acknowledge signal
Slurry Pump Fault
Wash water pump is running, acknowledge signal
Wash water Fault
Conveyor is running, acknowledge signal
Conveyor Fault
3.10.2.2 Remote control interface

The VPA Press filter can be Started & Stopped from Main Automation System, (i.e. an overriding
computer).
Following signals will be exchanged between the Metso VPA Press filter control system and
customer overriding control:
From Metso JSPL
Remote mode is selected
VPA in operation
VPA No Fault
Completed press cycle, (pulse)
In Neutral
In Parking
3.11
From JSPL Metso

Run/Stop order, (pulse, toggle Run and Stop)
To Neutral, (pulse)
To Parking, (pulse)
Filter cake and Filtrate handling
Pressure filtration occurs in several steps to dewater the iron ore concentrate. The typical filtration
cycle starts with the feeding step, followed by compression, followed by air drying, then cake
discharge, and finally cloth washing. In the Feeding step, slurry is pumped to the operating filter via
the Filter Press Feed Pumps. Pumping pressure provides the pressure for the initial dewatering of
the slurry. When the pumping pressure is no longer high enough to dewater the slurry, the feeding
step is complete. The Filter Press Feed Pump then begins pumping either to another filter press or
back to the three-way slurry distributor. Filtrate from the pressure filter drains to the Filtrate and
Wash Water Tank.
In the compression step, a pressurized bladder in the filter press compresses the filter cake to
remove additional water from the filter cake.
In the drying step, compressed air from the Drying Air Compressors removes additional water from
the filter cake.
Commands from each filter press will signal the Main Automation System to supply high pressure
slurry. When not filling, the Filter Press Feed Pumps recycle slurry to the Slurry Distributor
(B48201).
There are six (6) Filter Presses (B45101, 2, 3, 4, 5, and 6). These presses work on a cycle that is
part of the METSO supplied PLC system with Profibus link to the Main Automation System. If
Slurry is not needed at a filter press, the slurry is recycled back to the Slurry Distributor (B48201).
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High Pressure water sprays are also used to clean the cloth when the filter frames are opened.
There are 4 air compressors feeding 6 Filter Presses. The Filter Cake drops on the Filter Cake
Conveyor (FC-11A, B, C, D, E & F) (B43010-1, 2, 3, 4, 5, 6) and is transported to common
conveyor FC-12 (B43015).
From here the filter cake will travel over conveyors FC- 13, 14, 15 & 16.
Individual start-up of Filter cake collecting conveyors (FC-11A to F) and Filter cake transport
conveyors FC-12, 13, 14, 15 & 16 will depend on healthy signal from the safety switches placed on
the conveyors.
Group start of FC-12, 13, 14, 15 & 16 will depend on the low level signal from level transmitters
placed over filter cake storage bins (43502-1,2). Low signal from bin level transmitters will start FC16 first then filter cake conveyors FC-15, 14, 13 & 12 in a sequential manner provided there is
healthy signal from safety switches on these conveyors.
The Filter cake conveyor plow (B48005) is lowered to the conveyor in order to fill Iron ore filter
cake storage bin-2 (B43502-2). Plow is equipped with two position switches, up and down. They
signal the DCS which indicates to the control room operator the position of the plow. The plow is
operated in manual mode; the operator raises and lowers the plow to suit. Full (High, High) bin will
cause its plow to raise by the operator manually.
HH alarm from both bin level transmitters and unhealthy signal from any conveyor safety switch
will stop up-stream conveyors in a sequential manner.
The Filtrate and Wash Water Tank (B35104) has two variable speed pumps (B41104-1, 2) to move
the filtrate back to the Thickener. If the Filtrate level gets below the set point of LIT-01B1801A,
then makeup water enters through LV-01AB1801. Level controller (Loop No: LIC-01B1801B, P&ID:
R-01-1019) controls the speed of the Filtrate Pumps (B41104-1, 2).
The set point of Level Controller (Loop No: LIC-01B1801A, P&ID: R-01-1019) is set at about 25 %
while level controller LIC-01B1801B is set to 60 %. When the level reduces to 25% the control
valve will attain its full opening condition in order to fill the tank. When the rising level is at 60% the
valve will attain its full close condition and the pumps will start in order to pump-out the filtrate from
the tank.
4.0
ADDITIVE RECEIVING AND DRY GRINDING -AREA 2
4.1
Additive Receiving & Storage (P&ID: R-02-1001)
Additive Feed can travel to Line 1 or Line 2. When directed to line 2, the material travels
from reversing shuttle conveyor AF-4 (B43120) to Additive Feed Conveyor AF-15
(B43110) to reversing shuttle AF-16 (B43115). The shuttle car (B43120A) of AF-4 can
position at the existing limestone bin, the existing coal bin, or at the Additive Feed
conveyor AF-15.
AF-15 will feed AF-16 (additive feed bin reversing shuttle conveyor, B43115). AF-16 will fill
limestone bin (B16207) and coal bin (B16205).
Individual start-up of blended ore conveyors AF-15 and shuttle conveyor AF-16 will depend on
healthy signal from the safety switches placed on the conveyors.
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Group start up will depend on the level signal from level transmitters placed over bins. Low (20%)
signal from bin level transmitters will start shuttle conveyor AF-16 first then additive feed conveyors
AF-15 in a sequential manner provided there is healthy signal from safety switches of these
conveyors.
The Additive feed bin reversing shuttle conveyor AF-16 feeds the Lime stone feed bin (B16207)
and Coal feed bin (B16205) depending on the high level signal from level transmitters LIT 2212 &
2213 placed at the bins. The position limit switch (ZS 0132 & ZS 0134) placed suitably for lime
stone bin and coal bin positions will allow the shuttle car to stop over the respective bins in order to
achieve un-interrupted filling of the bins.
When the limestone bin (B16207) and coal bin (B16205) level reaches the High (70%) level (LAH02B2212 and LAH-02B2213) a light will blink at the filling location to warn operators that the bin is
nearly full. If the level in both the bins should continue to rise to High, High (95%) the feed belt and
feed shuttle conveyor will stop.
Lime stone feed bin and Coal feed bin are equipped with individual weigh belt feeders (B43119 &
B43068). Belt feeders discharge material to conveyors AMF-11 (B43079) at a controlled rate, set
by the operator (Loop No: WIC - 2215 & 2216, P&ID: R-02-1001) for a capacity which is
compatible with the Mill grinding capacity for that particular additive. Once the system is started,
operator controls the respective belt feeder speed to obtain the desired set point as mentioned
below:
Low-Low (5%) bin level will stop the Weigh Belt Feeders LSF-11, CF-11 and subsequently additive
mill feed conveyor AMF-11.
The receiving rates for coal (10% H2O) and Lime stone (8% H2O) to the feed bins are:
Coal:
Lime Stone:
Design - TPH
100
100
Operating - TPH
100
100
Storage capacity of Coal and Lime stone storage bin is as follows:

Coal feed bin:
Lime Stone:
Operating - Hours
9
16
Design - Hours
4
9
The feed rate to the Additive mill feed conveyor is as follows:

Operating
Design:
Coal - TPH
21.2
43.5
Lime stone - TPH

22.7
43.5
The additive mill feed conveyor (AMF-11) feeds the additives to the Ball mill (B46203)
4.2
Dry Grinding System
4.2.1
Process Description (P&ID: R-02-1003, R-02-1005)

(Inputs received from package vendor FL Smidth)
The proposed Limestone-Anthracite coal mixture Additive dry grinding system consists of an air
swept Ball Mill with its accessories. The mill is sized for grinding Limestone-Anthracite coal mixture
at a maximum moisture content of 9% with a feed size of Limestone as -7 mm (100%) & Anthracite
coal as -7 mm (100%) to a product fineness of 80% < 53 microns, with a residual moisture content
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of 1% at a combined Bond Work Index of 16 KWH/MT. Hot Air Generator Supplies hot air to the
mill which will dry the limestone-Anthracite coal mixture during grinding.
Mill exhaust Gases are vented through a dynamic Classifier which recycles coarser particles back
to the mill through a flap valve and an air slide. Ground product is collected in a cyclone and a bag
filter placed after the dynamic Classifier. In this system, air flow is induced by two fans, mill ID fan
and filter ID fan. The clean air from Bag filter shall be released to atmosphere through a stack.
Product collected by the cyclone and bag filter is transferred to a product bin which is located
inside mixer building.
4.2.2
Normal Start-up Sequence

This section describes the functional groups start-up sequence. If the group has an automatic start
sequence, time delays between equipment will also be listed. Any group preconditions required
prior to start-up are also listed herein. However, interlocks required for individual or predefined
groups of equipment are listed in the Interlocks section.
4.2.4
Normal Operation
This section describes the functional groups normal operation, including operator functions. There
are three modes of operation, as described below:
Automatic: Automatic mode is when functional groups are controlled automatically and in
sequence by the control system. A functional group is a set of items such as motors, valves, etc.
which are started by a single operator action when it is in Automatic Mode. All Protective, Safety,
Machine, Operational and Start Interlocks must be met in order to operate.
Manual: Manual mode is when items such as motors, valves, etc. are con-trolled individually by
the operator using the control system. Functional groups have no meaning in Manual Mode. All
Protective, Safety, and Start Interlocks must be met in order to operate.
Local: Local mode is when items such as motors, valves, etc. are controlled individually in the
field, usually by local pushbutton stations located at the item. Functional groups have no meaning
in Local Mode. Since the operator interface in Local Mode is often physical devices rather than a
display screen, extra care must be taken to ensure that interlocking continues to be enforced. All
Protective, Safety, and Start Interlocks must be met in order to operate.
Main Automation System Control: Commands to operate the control system are made by an
operator using the Main Automation System HMI. Main Automation System can only operate in
Automatic Mode. Main Automation System sets the equipment control mode to Main Automation
System control.
4.2.4
Normal Shutdown Sequence

This section describes the group shutdown sequence. If the group has an automatic shutdown
sequence, time delays to allow for equipment cleanout or deceleration will also be listed.
4.2.5
Abnormal and Emergency Shutdowns

This section describes abnormal shutdown conditions caused by isolated process or equipment
abnormalities or activation of individual equipment safety devices. It also describes emergency
shutdowns due to automatic activation of personnel safety systems or field emergency stop
pushbuttons.
4.2.6
Interlocks
The Interlocks section describes all interlocks for the individual equipment or functional groups of
equipment within the associated software function group. Interlock is defined herein as an
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input/output signal or a Main Automation System/Main Automation System internal logic condition,
which automatically prevents the operation of an individual or functional group of equipment from
the Plant MAIN AUTOMATION SYSTEM HMI. When the condition of an interlock(s) is such that
operation of a related piece of equipment or an equipment group is permitted, the interlock(s) is
defined as being satisfied.
Specific devices in the Interlock table may be preceded by NOT. This is the condition for the
analog threshold (i.e. NOT Bearing Temperature High-High = Bearing Temperature is NOT
ABOVE the High-High Set point). However, in the case of discrete switches the Interlock is stated
from the ON perspective of the switch. For example the Oil Reservoir Low switch is ON when the
oil level is NOT Low (fail-safe), so the required interlock is the switch being true
Interlocks consist of five types and are described in detail below:
Safety interlocks: Safety interlocks are those interlocks which prevent damage to that associated
piece of equipment. As a result, safety interlocks apply when operating in Automatic Mode,
Manual Mode and Local Mode.
Example
Safety interlock for a fan or pump would be no high-high bearing temperature.
Safety interlocks for every motor will also include the MCC/motor ready signal and receipt of a
run confirmation from the motor contactor after a run command is sent. These interlocks apply to
all motors and are not listed in the interlock table for this reason.
Start interlocks: Start interlocks are those interlocks necessary ONLY for starting the machine. As
soon as the motor is running the start interlock has no influence. As a result, start interlocks apply
when operating in Automatic Mode, Manual Mode and Local Mode.
Example
A start interlock for a fixed speed fan with automatic damper would be that the damper be closed
(limit switch or position transmitter) prior to starting.
Protective Interlocks: Protective interlocks are those interlocks for the protection of the motor itself.
As a result, protective interlocks apply when operating in Automatic Mode, Manual Mode and
Local Mode.
Example
A protective interlock for a crusher motor would be motor bearing temperature or motor winding
temperature.
Machine Interlocks: Machine interlocks are those interlocks for the protection of the machine that is
operating in Automatic Mode. As a result, machine interlocks apply only when operating in
Automatic Mode.
Example
A machine interlock for a belt conveyor would be a belt drift switch.
Operational Interlocks: Operational interlocks are those interlocks that are related to the process,
but not to the equipment, that is necessary for the normal operation of the item. As a result,
operational interlocks apply only when operating in Automatic Mode.
Example:
An operational interlock would be downstream equipment running.
4.2.7
Overview (P&ID: R-02-1003, R-02-1005)

The mill plant incorporates the following features:
Feed system (Described Earlier)
Ball Mill
Hot Air Generator
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Dynamic Classifier (SEPAX)

Cyclone
Bag Filter
ID Fans.
4.2.7.1 Ball mill
Size reduction of Limestone-Anthracite coal mixture is carried out in Ball mill .The Gas-Solid
mixture is swept to Dynamic Classifier after grinding. Temperature Scanner at the feed end and
discharge end measures the inlet and outlet mill bearing temperature. Ball mill is equipped with
internal liners and the balls are charged in different size from the ball charge hopper.
4.2.7.2 Hot air Generator
The hot air generator uses furnace oil for combustion and serves the purpose of generating hot air
to dry the limestone and Anthracite coal mixture. The hot air is supplied to the mill via a hot gas
duct.
4.2.7.3 Dynamic Classifier
Dynamic Classifier (SEPAX) separates the fine portion of ground material from gas solid mixture of
Ball mill. The fines vented from the Classifier in the ascending air stream are further subjected for
separation in a cyclone, bag house, subsequently being collected as the finished product. The
Coarse particles are returned back to the Ball Mill.
The Dynamic classifier is equipped with Variable Frequency Drive; the material fineness can be
maintained by varying the rotor speed of Dynamic Classifier. Part of the Exhaust gases from Ball
Mill ID Fan is recirculated to the system via recirculation damper to keep Gas-Solid mixture at the
Ball mill outlet in suspension.
4.2.7.4 Cyclone
Cyclone is a Gas-Solid separator that converts pressure energy into rotational momentum. The
rotational momentum provides the centrifugal force to separate solids from a gas stream. In
operation, Gas-solid mixture is fed to the cyclone and the centrifugal force generated causes the
heavier suspended solids to move towards the wall while the radial velocity forces lighter solids to
move inward towards the central axis.
4.2.7.5 Bag Filter
The dust from the dust laden gases is collected in a bag house. The cleaned exhaust gases are
vented to the atmosphere, through the stack. Whenever Ball mill exit gas temperature (measured
by temperature transmitter) exceeds beyond set value, fuel to the Hot Air Generator is reduced for
controlling inlet temperature of Bag Filter.
4.2.7.6 ID Fans
The purpose of the Bag Filter ID fan is to vent the exhaust gases. The negative draught developed
by the fan regulated by means of a louver damper.
Ball Mill ID fan is equipped with Variable Speed Drive to regulate the air flow to the Dynamic
classifier.
4.2.8
Operation Philosophy and Plant Sequencing

Starting of the mill system is divided into a number of groups. Each drive/ equipment/ Valves in a
particular group has a specified sequence of operation. Each group in itself has a specified
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sequence of operation during start and stop. This means that no equipment can be started before
the subsequent equipment has been started. Inversely, stop of any equipment will cause the stop
of the preceding equipment, unless specified herein.
This section outlines the division of groups; the basic terminology used in numbering of the groups,
sequential Interlocks between groups and between equipment/ drives/ valves in every particular
group.
This section basically outlines the various process Interlocks that are to be satisfied for successful
operation of a sequence. The operator has to ensure that the power source, remote selection etc.,
are properly ensured. In case, the same has not been ensured, the HMI would initiate the
respective alarms as described in the earlier section(s)/ sub section(s).
General Notes:
a. Temperature, pressure, flow, level and any other process parameter set point will be adjusted
and set during commissioning. Access to the set point is provided only for Engineers and not for
the Operators.
b. For all the analog inputs, trends are configured in the Main Automation System.
c. All the electrical Interlocks for the drives and the feeders are not described in this document and
shall be taken care in accordance with the general philosophy of the plant.
d. Pressure switch is provided in the discharge line of all air slide fans for monitoring low pressure
alarm in the Main Automation System.
e. Considering the safety of the equipments, the AUTO changeover of any drives is not permitted
in the mill and Dynamic classifier Lubrication system.
f. During the Re-start of the plant after the power failure, the operator has to ensure that the mill
drive is ready for operation before starting the mill discharge conveying group and Dynamic
Classifier group to avoid overfilling of the material at the mill feed end and discharge end. (After
starting the mill discharge group and Dynamic Classifier group, the mill drive has to be started
immediately).
g. After ensuring that the utilities are ready the operator initiates the starting of the plant.
4.2.9
Equipment Grouping
The various sections of the plant are assigned group numbers to assist the definition of discrete
areas of the plant. Groups can be started up individually in preparation for overall plant start-up.
These numbers will also be used for plant start-up and commissioning planning activities. Details
of the groups are included in the relevant sections.
The total process is broken down into seven discrete groups to allow for easy description of the
facilities. These are as follows:
Group 1 ID fan
Group 2 Product Handling System
Group 3 Mill ID Fan
Group 4 HAG
Group 5 Dynamic Classifier
Group 6 Ball Mill
Group 7 Feed System (Described in section 4.1)
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4.2.9.1 Group 1 - ID fan (P&ID: R-02-1003)

4.2.9.1.1
Group Description
The ID fan (333FN 550/B46203Q) is responsible for the primary draught and airflow through the
mill system. The ID fan is located at the outlet of Bag Filter (333BF 500/B46203N) and exhausts
directly to atmosphere via stack (333SK 590/B46203T).
A pneumatically operated damper (333LD551/B46203QA) with louver arrangement is placed at the
ID fan inlet. The damper is opened during normal operation.
4.2.9.1.2
Group 1 equipment summary
a. ID fan (333FN550/B46203Q)
b. Pneumatically operated damper (333LD551/B46203QA)
c.
4.2.9.1.3
Bag filter Isolation damper(333BV546/B46203U),(333BV545/B46203H)

Group 1 Start Sequence
Start command of the Group initiate the following sequence:

d. Close ID fan damper (333LD551/B46203QA) close limit ZAC2056 healthy.
e. Start ID fan (333FN550/B46203Q) at 15% speed.
f. Open ID fan damper (333LD551/B46203QA) to 10% and release it to manual mode. Normally,
damper position shall be varied to maintain the draught as per requirement.
g. Open Bag filter Isolation damper (333BV546/B46203U) and (333BV545/B46203H).
4.2.9.1.4
Group 1 Starting Interlocks
ID Fan group can start provided that the following pre-requisites are satisfied
a. Fan inlet damper (333LD551/B46203QA) is 100% close (close limit ZAC2056 healthy)
b. ID fan bearing temperature TI 2057 high alarm is false (set at 80oC)
c.
4.2.9.1.5
ID fan inlet temperature TI 2055 high alarm is false (set at 125 C)

Group 1 Running Interlock
Conditions to be fulfilled in order to run the Group 1 is as follows,

- ID fan inlet temperature TI 2055 high high alarm is false (set at, 140oC)
o
- ID fan bearing temperature TI 2057 high high alarm is false (set at 90 C )

- ID fan suction pressure PI 2054 high high alarm is false (set at negative 220 mmwc)
- Bag filter Isolation damper 333BV545/546 (B46203H/B46203U) open limit switch ZSO2080 and
ZSO2072 is healthy.
4.2.9.1.6
Group 1 Stop Sequence
Stop command of the Group initiate the following sequence:
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- Stop ID fan (333FN550/B46203Q)

- Close Pneumatically operated Damper (333LD551/B46203QA)
- Close Bag filter inlet damper (333BV545/B46203H)
- After a time delay
(333BV546/B46203U).
(set
during
commissioning)
close
Bag
filter
outlet
damper
4.2.9.2 Group 2- Product Handling System (P&ID: R-02-1005)

4.2.9.2.1
Group 2 description
The product handling group is responsible for handling the coarse Lime-Anthracite Coal mixture
from Dynamic Classifier (333SR300/B46203A).The product collected from the cyclone (333
CN400/B46203B) and bag filter 333 BF500/B46203N) is conveyed to the pneumatic transfer feed
hopper (B43303).
4.2.9.2.2
a. Bag Filter rotary airlock (333 RF511/B46203V)

b. Bag Filter (333 BF500/B46203N) purging control panel.
c.
Cyclone rotary Air lock (333 RF402/B46203C)
d. Pneumatic transfer feed hopper (B43303)

4.2.9.2.3

a.
Start Bag filter rotary airlock (333 RF511/B46203V)
b.
Start Cyclone rotary airlock (333 RF402/B46203C)
c.
Start Bag filter (333 BF500/B46203N) Purging.
4.2.9.2.4
Group 2 Starting & Running Interlocks
Product handling group can start provided that the following pre-requisites are satisfied:
4.2.9.2.5
Pneumatic transfer feed hopper Level Switch high high alarm unhealthy
Group 1 Run feedback healthy
Bag Filter Hopper Level switch high high alarm (LAH 2051) not activated.
Bag Filter Differential Pressure Transmitter high high alarm (DPI 2053) not activated.

a.
Stop Bag filter (333 BF500/B46203N) Purging
b.
Stop Bag filter rotary airlock (333 RF511/B46203V)
c.
Stop Cyclone rotary airlock (333 RF402/B46203C)
4.2.9.4 Group 3 Mill ID Fan
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4.2.9.3.1
Group 3 description (R-02-1003)
Mill ID Fan (333FN450/B46203F) is equipped with Variable Frequency drive which maintains the
draught required for product classification. Part of the flue gases are routed from the fan discharge
to the Mill outlet for maintaining the ground product from the mill to Dynamic Classifier (333
SR300/B46203A) in suspension.
4.2.9.3.2
a. Mill ID fan (333 FN 450/B46203F)

b. Pneumatically operated damper (333LD451/B46203FA)
c.
4.2.9.3.3
Recirculation damper (333TV 575/B46203G)


a. Open Mill ID fan damper (333LD451/B46203FA) open limit Switch ZSO2042 healthy.
b. Start Mill ID fan (333FN450/B46203F) at 10% speed.
c.
Mill ID fan speed shall be varied to maintain the draught as per the requirement.
d. Open Recirculation
commissioning).
4.2.9.3.4
damper
(333TV575/B46203G)
as
per
requirement
(set
during
Group 3 Starting Interlocks
Mill ID Fan group can start provided that the following pre-requisites are satisfied
a. Group 2 run feedback healthy.
b. Mill ID Fan inlet damper(333LD451/B46203FA)is 100%open (open limit ZSO2042 healthy)
c.
Mill ID fan bearing temperature TI 2044 high alarm is false(set at 80)
d. Mill ID fan motor winding temperature TI 2031 high alarm is false (set at 110 )
e. Mill ID fan motor bearing temperature TI 2032 high alarm is false (set at 70 )
f.
Mill ID fan vibration VI 2043 high alarm is false (set at 6mm/sec)
g. Mill ID fan motor vibration VI 2036 high alarm is false (set at 6mm/sec)
4.2.9.3.5
Conditions to be fulfilled in order to run the Group 3 is as follow

a. Group 2 run feedback healthy.
b. Mill ID Fan Recirculation damper (333TV575/B46203G) is opened, as per requirement (set
during commissioning).
c.
Mill ID fan bearing temperature TI 2044 high high alarm is false (set at 90 )
d. Mill ID fan motor winding temperature TI 2031 high-high alarm is false (set at 120 )
e. Mill ID fan motor bearing temperature TI 2032 high-high alarm is false (set at 80 )
f.
Mill ID fan vibration VI 2043 high high alarm is false (set at 8mm/sec)
g. Mill ID fan motor vibration VI 2038 high high alarm is false (set at 8mm/sec)
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h. Mill ID fan inlet vacuum PI 2038 high high alarm is false (set at negative 701 mmwc)
4.2.9.3.6

i.
Stop Mill ID fan (333FN450/B46203F)
j.
Close fan inlet damper (333LD451/B46203FA)
k.
Recirculation Damper (333TV575/B46203G) is 100% closed.
4.2.9.4 Group-4 Hot Gas Generator System (R-02-1004, R-08-1003)

4.2.9.4.1
Group Description
The Limestone and Anthracite coal is dried by the hot air, supplied by hot gas generator (333
HG600 / B46203I).HGG is equipped with combustion air fan (333 FN610/46203J),dilution air fan
(333FN620/42203IA) with inlet dampers (333TV621(46203ZB)/333 TV611(46203ZA)) respectively
along with pumping and filtration unit (with standby arrangement).
The HGG is a single shell construction, horizontal fired system, which can produce the rated
quantity of hot air on continuous basis. The system works on 100% FO fuel and has a turndown
ratio of 4:1 without changing the nozzle. Apart from heat generation, this system also caters the
principle quantity of airflow required in the milling system.
The fuel oil is pumped from a day oil tank (of 1m3 capacity) by a set of pumps (333FP656/B410031/333FP655/B41003-2) one operating and the other standby. The filter unit (one operating + one
stand by) at the suction end (SF 201/202) and the discharge end (DF201/202) of the pumps
enable a clean flow of fuel to the burner valve stand and the HGG. Each filter unit (SF201/202) and
(DF201/202) is installed with a filter clog indicating differential pressure switch (DPI 3003 & DPI
3007) respectively. 0.1kg/cm2 differential pressure gauge reading ensures that there is a clog at
the discharge filter. The operator then turns the standby filter into operation for maintenance of the
clogged filter.
The fuel oil flow rate is controlled by a flow controlling valve (XV3014) and metered by a flow meter
FM 201. The fuel oil is atomized by dry compressed air. Liquefied petroleum gas (LPG) forms the
pilot gas for burning the fuel and is used during start up. An ignition transformer is used to create
the heat flux to burn the pilot gas.
An air assisted scavenging arrangement of the burner is used to clear off any residual fuel in the oil
line between the main oil valve (XV3016) and the burner in the event of a burner failure. The flame
is monitored by a flame scanner FS 901.
The combustion air fan (333FN610/46203J) provides the required quantity of combustion air to
meet the air fuel demand. Dilution air fan (333FN620/42203IA) helps in controlling the gas
temperature at HGG outlet.
The pump suction and discharge valves, filter valves are manually operated. The valve stand is
provided with manual valves. The operator has to check if the manually operated valves are in the
right position before attempting to start the burner.
4.2.9.4.2
HGG Group 4 Equipment Summary
The HGG group mainly consist of the operation of the following drives:
a. Combustion air fan (333FN610/46203J)
b. Dilution air fan (333FN620/42203IA)
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c.
4.2.9.4.3
Fuel Oil transfer pump (333FP656/B41003-1/333FP655/B41003-2)

HGG Group 4 Starting Interlock
a) Group 1 & 3 ON feedback healthy for starting combustion air fan 333.FAN610/B46203J and
dilution air fan 333FAN620/B42203IA.
b) Day oil tank level 333FT651/ B34032 LSL 3038 not low (set at 30%) to start the transfer oil
pumps (333FP656/B41003-1) or (333.FP655/B41003-2)
Hot gas generator burner start interlocks are as follows:
a) Either of the oil pumps 333FP656/B41003-1 or 333FP655/B41003-2 is selected. (Only one
pump can be selected at a time, by default 333FP656/B41003-1 will be selected.)
b) Day oil tank level LSL3038 (set at 30%) not low to start the fuel oil 333FP656/B41003-1 or
333FP655/B41003-2.
c) Temperature of oil at tank outlet TIS3036 not healthy to start tank heater (Electric heater starts
at below 50 Deg.C).
d) Oil pressure at valve stand low alarm PSL3013 (set at 7kg/cm2 (g)) is not healthy.
e) Atomizing air pressure at valve stand low alarm PSL3021 (set at 7 kg/cm2 (g)) is not healthy.
f)
Instrument air pressure at valve stand low alarm PSL3036 (set at 6kg/cm2 (g)) is not healthy.
g) Main oil valve XV3016 is close (ZSC3016 healthy).

h) Return oil valve XV3015 is open (ZSO3015 healthy).
i)
Fuel Oil Control valve XV3014 is reduced to minimum firing position of 22% (ZT3013).
j)
Scavenging valve XV3022 is close (ZSC3022 healthy).
k) Combustion air fan 333FN610/ B46203J ON feedback healthy.

l)
Dilution air fan 331FN620/ B42203IA ON feedback healthy.
m) Pilot gas pressure low alarm PSL3025 (set at 2 kg/cm2(g)) is not healthy.
n) Pilot gas solenoid valve XV3035 is close (de-energized).
o) No flame inside the furnace (FS 901).
p) Emergency press button not pressed.
4.2.9.4.4
HGG Group 4 Start Sequence
BMS will check for the above mentioned hot gas generator burner start interlocks for the purge
sequence to start.
Purge Sequence
a) Once all the above conditions are satisfied, PURGE READY indication will be illuminated on
Local as well BMS Panel. Now the operator would press PURGE START push button either
from BMS or Local Panel (as selected).
b) With Purge Start command, BMS PLC will generate 100% command to Combustion Air Blower
and PURGE-IN-PROGRESS" will start to flicker on the Local panel
c) BMS PLC will monitor the damper position and after it reaches to 100%, BMS PLC will start
purging timer; Purge-In-Progress lamp will stop flickering and glow steadily in Local Panel.
Purging time will be 5 minutes. Delay is to be ensured. After purge period over, "Purge
Complete" will start to flicker on the Local panel. Also with purge complete, BMS PLC will
generate low fire command (25% command)
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d) BMS PLC will monitor the combustion damper position and when the same remains between
(25 to 30 %), Purge Complete lamp will stop flickering and glow steadily on Local panel.
Respective message will be displayed on BMS and Main Automation System.
Note: When given command of High fire or Low Fire, if respective combustion air damper position
is not achieved within one minute, sequence will trip and Purge Sequence Fail alarm will appear on
BMS and MAIN AUTOMATION SYSTEM. Operator has to start from Purge ready condition.
4.2.9.4.5
HGG burner start-up sequence
With Purge is completed and above mentioned startup condition satisfied, Burner Ready to fire
indication lamp will be illuminated on Local Panel respective message will be displayed on BMS
and Main Automation System. Now the operator could start the oil burner by pressing "BURNER
START Push button, either from Local Panel or HMI on BMS Panel or from Main Automation
System (depending upon Local/BMS/MAIN AUTOMATION SYSTEM selection). If the burner start
command has not been executed within 10 min of purge complete then Purge Cycle would trip
and needs to be restarted.
Now the operator has to execute Oil Burner start command (either from Local Panel or BMS
Panel, as selected). This would initiate the following sequence:
1. Ignition Transformer will be energized for 15 seconds; LPG Solenoid Valve (XV3035) will also
be energized to open and atomizing air shut off valve (XV3023) will be energized to open. Pilot
flame will be established and "PILOT ON" & "IGNITION ON" indications will be illuminated on
both Local as well as BMS Panel.
2. If flame will not be sensed by flame scanner (FS 901) within ignition period, then after ignition
period with ignition transformer, pilot valve (XV3035) and atomising air shutoff valve (XV3023)
will be de-energized and "FLAME FAILURE" annunciation will glow on BMS panel. Operator
has to re-start the system from PURGE READY Cycle.
3. With Flame Sense by the scanner (FS901) during ignition period, "FLAME ON indication will
be illuminated on BMS panel & Local Panel.
4. Pilot solenoid valve (XV3035) will remain energised for another 30sec and Pilot ON indication
will be illuminated on local panel, respective message will be displayed on BMS & Main
Automation System.
5. Five seconds after the Pilot flame established and proved, oil main shut off valve (XV3016) will
be energized to open. If Position of the valve will be proved (ZSO-3016), BURNER ON
indicating lamp will flicker on the BMS panel & Local Panel.
6. After energizing main Oil (XV3016), pilot valve (XV3035) will remain in operation for another
30 sec. to establish main oil burner. After ignition period at any time if scanner FS 901 will not
sense the flame then all the valves will be de-energized and both main as well as pilot burner
will TRIP. And the system will go back to the purge ready condition after completion of
scavenging cycle.
7. With flame proved by flame scanner (FS 901) (after energizing oil valves), BURNER ON"
indication will be illuminated on Local as well as BMS Panel.
8. After 45 seconds delay of main burner established and proved low fire hold on both oil Flow
Control Valve (XV3014) and Combustion Air Damper (333.TV621) will be released and
"BURNER ON" indicating lamp will glow steadily on Local as well as BMS Panel. The
Combustion controller will now modulate the air Flow Control Valve to meet the demand.
System will continuously monitor following interlocks and in case of failure of any one of below
mentioned interlock, burner will trip and system will go back to ready for purge status.
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4.2.9.4.6
HGG Group 4 Running Interlock
a) Group 1 & 3 ON feedback healthy for running combustion air fan 333.FN610 and Dilution air
fan 333.FN620.
b) Day oil tank level 333FT651/B34032 LSL3038 not low low (set at 20%) to start the transfer oil
pumps 333.FP656/B41003-1 or 333FP655/B41003-2
c) Hot gas generator burner run interlocks are as follows:
1. Day oil tank level LSL 3038 not low (Set at 20%) to start the fuel oil 333FP656/B41003-1 or
333FP655/B41003-2.
2. Temperature of oil at tank outlet TIS 3036 NOT healthy to start tank heater (Electric heater
0
0
starts at below 50 C Stops above 60 C).
3. Oil pressure at valve stand low low alarm PSL3013 (set at 7kg/cm2 (g)) is not healthy.
4. Oil pressures at valve stand high high alarm PSL3018 (set during commissioning) is not
healthy.
5. Atomizing air pressure at valve stand low alarm PSL3021 (set at 7 kg/cm2 (g)) is not
healthy.
6. Instrument air pressure at valve stand low alarm PSL3036 (set at 6kg/cm2 (g)) is not
healthy.
7. Main oil valve XV3016 is open (ZSO3016 healthy).
8. Return oil valve XV3015 is close (ZSC3015 healthy).
9. Combustion air fan 333FN610 ON feedback healthy.
10. Dilution air fan 331FN620 ON feedback healthy.
11. No flame inside the furnace (FS 901)
12. Emergency press button not pressed
13. HGG Refractory temperature TIC 3033 high high alarm is false (set during
commissioning)
4.2.9.4.7
Oil Gun Scavenging Cycle
Whenever the Oil Burner trips or withdrawn from service by pressing the "BURNER STOP Push
button, oil gun scavenging cycle for the burner will be initiated so that the oil line after Shut off
valve (XV3016) is kept clean. Following sequence of operation would be adopted:a) After burner trip Oil shut off valve (XV3016) will be de-energized to close. Scavenging Cycle
will be started only after close valve position proved (ZSC3016).
b) Ignition transformer (IT), Pilot solenoid valve (XV3035) and atomizing line shut off (XV3023)
would be energized for 15 seconds to establish the pilot flame. After 15 seconds, ignition
transformer would be de-energized. If the flame proved during the pilot trial period, then the
pilot valve (XV3035) will be kept in energized condition for 60 more seconds.
c) Flame scanner will continuously check for the burner flame. If the flame is not sensed by the
flame scanner (FS901) within the ignition period (15 seconds), Pilot solenoid valve along with
atomizing shut off valve will be de-energized to close. Flame Failure annunciation will be
displayed on the Local Panel and respective message will be display on Main Automation
System and BMS.
d) With Pilot flame proved, oil gun scavenging valve (XV3022) will be energized to open for 60
seconds. Pilot flame should be present during all the 60 seconds. Flame scanner will
continuously check for the burner flame. If the flame is not sensed by the flame scanner
(FS901) within the ignition period (15 seconds), Pilot solenoid valve along with atomizing shut
off valve will be de-energized to close. Flame Failure annunciation will be displayed on the
Local Panel and respective message will be display on Main Automation System and BMS.
After these (60 seconds), pilot solenoid valve, scavenging valve will be de-energized.
e) System will continuously monitor following interlocks and in case of failure of any of these
interlocks, scavenging cycle will be trip. Conditions to be fulfilled in order to run scavenging
cycle:
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a. Emergency stop not pressed

b. Flame healthy (FS901)
c.
LPG Pressure not Low (PSL3025 not healthy)
d. Instrument Air Pressure not Low (PSL3036 not healthy)

e. Combustion Air Fan (333FN610) Running
f.
Atomizing Air Pressure not Low (PSL3021 not healthy)
If scavenging cycle trip / not started due to any of above mentioned condition then the oil collected
at the downstream of the shut off valve shall be manually drained by the operator to keep the oil
line down-stream of shut off valve clean.
After completion of scavenging cycle and with all startup interlocks healthy, operator can restart
the system from ready to purge cycle.
4.2.9.5 Groups 5 Dynamic Classifier main drive, Grease spray system and Air slide system description
(P&ID: R-02-1003)
4.2.9.5.1
Group Description
The purpose of Dynamic Classifier (333SR 300/ B46203A) is to separate the grounded dust
particles in to fines and coarse. The coarse particles are fed back to the mill for further grinding via
single gravity flap valve (333 FV306/B46203K), air slide (333AS370/B6203L) and double gravity
flap valve (333FV065/B46203Z). The fine particles are carried to product Cyclone (333
CN400/B46203B) where it is collected as a product.
Dynamic Classifier is equipped with Variable Frequency Drive, Speed shall be varied for the
desired the fines to be achieved in the product size.
Solid flow meter (333FM380) located at the discharge of Airslide (333 AS370/B46203L) to
measure the mass of the material recycle to the mill.
The grease level LSL 6045 in the reservoir must be OK as shown by the absence of low level
indication. With above healthy condition, and the controller in local / remote mode, the pump starts
automatically and grease is pumped into the main line through the progressive distributor ZS 6047.
The distributor is fitted with a visual indication and Monitoring switch. As soon as sufficient
pressure PG 6046 builds up into the line, the distributor changes from 0 position to position 1 and
actuates the Monitoring switch. The pump continues to pump grease into the other line and on
attaining a certain pressure the distributor again changes over from position 1 back to position 0
and brings the limit switch back to starting position. This marks the completion of one cycle. At this
point the pump will stop. After a pause (which is settable through a timer) the pump and the
system will restart and complete the cycle as above. The cycle continues. In case Monitoring
Switch fails to give signal before preset time of distributor fault timer then Distributor Fault will
generate. The starting position of the distributor could be either 0 or 1 since both are stable
mechanical positions. If the starting position is 0, then the cycle operates as 0-1-0 and if the
starting position is 1 then the cycle operates 1-0-1. The ON time of the timer is set in such a
manner that the pump is switched off after the Monitoring switch comes back to the starting
position which marks the end of one cycle. The OFF time decides the pause between two
consecutive cycles.
4.2.9.5.2
a. Dynamic Classifier (333SR 300/B46203A)

b. Air slide fan (333FN 371/B46203M)
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c.
4.2.9.5.3
Grease spray system (333GS 305).

Group 5 Start sequence

a. Group 4 run feedback to be healthy
b. Start air slide fan (333FN 371/B46203M)
c.
Start Dynamic Classifier motor (333MD302) at a minimum speed as per the requirement.
d. Start the grease spray system (333GS305).

4.2.9.5.4
Group 5 Starting Interlock
Conditions to be fulfilled before starting Group 5A Dynamic Classifier drive

a. Grease spray system (333GS305) fault alarm is not present.
b. Dynamic Classifier shaft temperature TI2028 high alarm not activated
c.
4.2.9.5.5
Shaft bearing Temperature TI2082 high alarm is not true.

Conditions to be fulfilled in order to run the Group 5B is as follow

a. Dynamic Classifier shaft temperature TI2028 high high alarm not activated
b. Grease spray system run feedback is healthy .The separator drive trips after a time delay of
1200 seconds elapses and the grease spray control panel fault indication persist.
c.
4.2.9.5.6
Shaft bearing Temperature TI 2082 high high alarm is not true.

Group 5 Stop sequence
Stop command of the Group 5B initiate the following sequence:

a. Stop Dynamic Classifier motor (333MD302)
b. Stop grease spray system (333GS305)
c.
Stop air slide fan motor (333FN371/B46203M)
4.2.9.6 Group 6 - Mill System

The Mill system is divided in to two sub groups.
Group 6A Mill main bearing lubrication system (333LQ110)
Group 6B Mill drive (333MD140) and Grease spray system (333GS137)
4.2.9.6.1
Group 6A Mill Main bearing lubrication Group Description (P&ID:R-02-1006)
The mill lubrication system consists of 3 parts:
a. Sump tank
b. Oil conditioning & LP mill bearings lube
c.
HP Jacking system
SUMP TANK:
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Capacity of the sump tank is 250 litres. Tank utilizes 2 drain lines from bearing ("dirty hot oil")
housing for oil return to the tank by gravity. This passes through a basket strainer which is
accessible through a hinged inspection door for easy cleaning. Each return line is fitted with an oil
flow sight glass.
The correct oil temperature in the sump tank is maintained by 3 kW heater elements, monitored by
a Temperature transmitter (TT6008). The heater operates between oil temperatures of 32-38.
From a cold start-up, the 3kW heater will raise the oil temperature from 1538 within 2-3 hrs.
An oil level transmitter (LT6007) is Interlocked for oil level monitoring. If oil level drops below the
15% of tank height, all auxiliary equipment must be tripped (pump motors & heater). An alarm is
raised if the oil level drops below 25% of tank height.
The oil level sight glass fitted to the tank gives visual indication of oil level & temperature. Air
breather / filter allow clean air to enter the tank. Drain valve plug is available to drain the tank,
when required. Access to the tank internals is gained by removing the tank lid, which is bolted
down.
Conditioning & LP Circuit
The sump tank is fitted with 2 LP oil gear pumps (One Working & One Standby) integral pressure
relief valves (PSV6003 & PSV6034) (set @ 20 bar), driven by a 3 kW TEFC electric motor. The
pump suction is isolated from the tank via a ball valve; discharge end is isolated via a non return
and ball valve. The oil flow rate in the LP circuit is 47 lpm, which is monitored by pressure gauges,
flow transmitter (FIT6032), temperature gauges and oil temperature transmitter (TT6012) exiting
the cooler.
If the oil flow falls below 36 lpm, an alarm is raised. Oil exiting the cooler should be maintained @
50oC, and an alarm is raised if it is higher than 590C.
The dirty & hot oil" from the sump tank is pumped to a high capacity LP duplex filter and
thereafter, to a Plate Heat Exchanger (PHE). The duplex filter unit is fitted with filter clogged visual
indication and electrical differential pressure transmitter (DPI6025), which indicates the operator to
"change-over' of the clean unit on-line, thereafter, to replace the clogged filter element with a new /
cleaned element, bleeding the filter bowl & equalizing the filter pressure.
A manual valve controls water flow through the cooler, the water flow rate monitored by the
rotameter flow meter, maintaining an oil temperature exiting the cooler 50 degC. Temperature
gauges before and after the cooler give visual indication of oil. Water temperature & Pressure
gauges before and after the cooler monitors its pressure and temperature respectively.
The conditioned oil (clean & cool oil) exits the cooler and is fed to the field LP circuit; the oil flow is
split into 50-50 to feed the 2 hydrodynamic bearings LP port, 22 lpm each. If the flow drops below
16 lpm, an alarm is raised.
An oil flow transmitter (FIT6001 & FIT6002) visually monitors and inter-locked with the PLC for low
& low-low flow. The conditioning & LP circuits should run continuously, even when the mill is
stopped.
HP Jacking System:
The HP radial piston pumps (One Working & One Standby) are isolated from the sump tank by ball
valves and protected against over-pressure by an individual pressure relief valve
(PSV6015/18/19/23) per outlet, set @ 310 bar. Non return and ball valves isolate the pump feed
lines, and a pressure gauge gives visual pressure monitoring. The 2.2 kW TEFC motors will be
tripped when the pressure exceeds 350 bar, or drop below 50 bar.
The HP oil is pumped to the mill bearings jacking pocket, to lift the journal off the bearing,
creating on oil film. Oil pressure transmitters (PT 6004/6006) and gauges are fitted for visual and
PLC Interlocking for HP system jacking pressure. Each bearing is fed by an independent HP
jacking line, @ 1.5 lpm each and 310 bar.
HP jacking > 250 bar, hydrostatic < 60 bar with loaded mill standing and hydrodynamic between 25
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& 35 bar with mill running pressures are inter-locked with the PLC and trips the mill if it is incorrect.
The HP pump shall be started 10 minutes prior to Mill Main drive and stops 10 minutes after
complete stop of the Mill Main drive, to allow for accurate hydrodynamic pressure monitoring.
Above values given are estimates, and should be fine tuned on commissioning
4.2.9.6.2
Group 6A equipment summary
a. Settling compartment heater HE1.

b. Operation and Control Philosophy for Additive Dry Grinding System
c. High pressure pumps motor or by default start pump motor selection to be made available in
d. Low pressure pumps motor or by default start pump motor selection to be made available in
4.2.9.6.3
Group 6A Start sequence
Start command of the Group 6A initiate the following sequence

a. Start heater HE1
b. Start the selected HP pump motor 10 minutes before startup of the mill and stop after few
minutes (set during commissioning) when the mill is running.
c.
4.2.9.6.4
Start the selected LP pump motor

Group 6A Starting Interlock
a. Sump tank low level LT6007 (Set at 25%) alarm is false for starting motor.
o
b. Sump tank temperature low alarm TT6008 (set at <32 C) is false to put heater ON and
o
TT6008 (Set at >38 C) to put heater OFF.
c.
Conditioned compartment temperature low TG for motor.
d. Differential Pressure across the filter DPI6025 (> 2.2 bar) high alarm is not true.
e. Flow low alarm FT6032 (<40lpm) is false.
f.
Flow low alarm FI6001&6002 (<18lpm) is false.
g. High pressure pumps trips for low pressure PT6004 & 6006.
4.2.9.6.5
Group 6A Running Interlock
This group can run successful provided the following conditions are satisfied
a. Sump tank low-low level alarm false LT6007 (Set at 15%) for motor.
b. Differential Pressure across the filter DPI 6025 (>3.5bar) high high alarm is not true.
c.
Flow low alarm FT6032 <40 lpm is generated, if any of the pinion lube line oil flow lowlow
alarm FT6032 <36lpm is generated is true then the corresponding pump will trip which will trip
the mill.
d. Flow low alarm <18 lpm is generated FIT6001 & 6002, if flow low low alarm (16lpm) is true
then the corresponding pump motor will trip and it will trip the mill.
e. High pressure pump will trip if the pressure PT6004 & 6006 (>350bar) and if drops below
50bar.
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f.
4.2.9.6.6
Oil temperature at cooler exit TT6012 (>59 C) high high alarm is not true.
Group 6A Stop sequence
Stop command of the Group initiate the following sequence

a. Stop heater HE1
b. Stop the HP pump motor 10minutes after the mill stops.
c.
4.2.9.6.7
Stop the LP pump motor

Main Gearbox Lubrication system
The ball mill main gear reducer is lubricated utilizing water cooling system with 8lpm of water for
cooling the Gear Box system.
4.2.9.6.8
Group 6B Mill Main Drive and grease spray lubrication system (P&ID: R-02-1007)
Group 6B Description:
Ball Mill drive
Lime stone and Anthracite Coal mixture size reduction takes place in ball mill (333BM
100/B46203). The off gases with materials are directed to Dynamic Classifier (333SR
300/B46203A). The heavy materials recycled from Dynamic Classifier to the ball mill via sluice flap
(333FV 306/B46203K), Air slide (333AS 370/B46203L) and sluice flap (333FV 065/B46203Z).
The operator has to ensure that the Mill is not operated without feed material.
Ball Mill Inching Mode
It is to be noted that inching drive engage or disengage status has also to be monitored locally. A
proximity Switch (ZSC2018) is provided in the jaw clutch coupling to ensure the disengage before
the start-up of the mill main motor.
Grease Spray System
As soon as the mill main motor runs, the PLC will energizes the 3/2 way air solenoid valve which
operates the pneumatic grease pump, and a monitoring timer is activated. The grease is pumped
through the grease strainer via the tubing to the SLAVE distributor, which in turn discharges fixed
quantities of grease into all 5 nozzles. Once this cycle is complete, the indicator pin on the slave
distributor will activate the limit switch which re-sets the monitoring timer T1 and the PLC will
energize the 2/2 way air spray solenoid for a set time period (time required for the mill to do 1 full
revolution, approx. 4 sec. plus time required complete the 6 distributor cycles)
The air pressure switch (PSL6038) in the air line will confirm to the PLC that the solenoid valve is
operational and that the plant air pressure is sufficient.
The grease pump runs for the duration of the set pulses, pulsed by the distributor limit switch
(ZSO).
As soon as the pulses are complete, i.e. 6 pulses, the PLC will de-energize the pump solenoid
valve and the system is put on PAUSE for a set time period (10 minutes).
The indicator pin will not activate the limit switches if:
a. No grease flow to the nozzles occurs
b. The nozzles are blocked
c.
The pipeline is broken / blocked
d. The distributor and/or limit switch is faulty
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e. The grease strainer is blocked

The air pressure switch PSL6038 will fail to signal the PLC if the 2/2 way solenoid valve is faulty,
or if the plant air pressure is low or off line. The pressure gauge gives visual indication of the
system air & grease pressure. The pump should trip if no pulses are generated from the
distributors, or the air pressure switches are not activated. The mill should then also trip.
4.2.9.6.9
Group 6B equipment summary
a. Ball mill main drive (333MD 140)

b. Grease spray system (333 GS137)
4.2.9.6.10
Group 6B start sequence:
a. Start Main bearing lubrication system (333LQ110)

b. Start mill main drive(s) (333MD140).
It is started after 600 seconds of main lubrication system operation (HP pump) and 300 seconds of
water cooling system. Stop the HP pump after 10 minutes, start HP pump when the stop command
is initiated for the main drive
c.
4.2.9.6.11
Start the grease spray system (333 GS137)

Group 6B starting Interlock
a. ID fan (333FN 550/B46203Q) running feedback healthy.
b. Group 5 running feedback healthy.
c.
Mill ID fan (333FN 450/B46203F) running feedback healthy
d. Mill outlet gas temperature TI2030 high alarm is false (Set at 110)
e. Air slide fan (333FN 371/B46203L) running feedback healthy
f.
Ball mill feed end bearing temperature TI2012 high alarm is false (set at 60 )
g. Ball mill discharge end bearing temperature TI2020 high alarm is false (set at 60 )
h. Ball mill pinion bearing temperature TI 2019 high alarm is false (set at 70 )
i.
Mill motor bearing temperature TI2015 high alarm is false (set at, 70 )
j.
Mill motor winding temperature TI2013 high alarm is false (set at, 110 )
k.
Mill motor vibration VI2014 high alarm is false.
m. Mill bearing lubrication system (333 LQ110) - Group 6B system running feedback healthy
(15mins before starting the mill)
n. Inching drive 333.AD147 (ZSC2018) engaged limit not true.
o. Grease spray system (333 GS137) fault alarm is not present
4.2.9.6.12
Group 6B running Interlock
Operation of this group is considered successful (running or in operation Interlocks) provided that
the following conditions are satisfied.
a. ID fan (333FN 550/B46203Q) running feedback healthy
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b. Group 5 running feedback healthy

c.
Mill ID fan (333FN 371/B46203L) running feedback healthy
d. Dynamic Classifier (333 SR300/B46203A) Running feedback to be healthy

e. Air slide (333AS 370) fan (333FN 371) running feedback healthy
f.
Ball mill feed end bearing temperature TI2012 high-high alarm is false (set at, 65 )
g. Ball mill discharge end bearing temperature TI2020 high-high alarm is false (set at, 65 )
h. Ball mill pinion temperature TI2019 high-high alarm is false (set at, 75 )
i.
Mill motor bearing temperature TI2015 high-high alarm is false (set at, 80 )
j.
Mill motor winding temperature TI2013 high-high alarm is false (set at, 120 )
k.
Mill motor vibration VI2014 high high alarm is false
l.
Mill bearing lubrication system (333 LQ110) - Group 6B system running feedback healthy
n. Grease spray system (333 GS137) run feedback is healthy The drive trips after a time delay of
1200 seconds elapses and the grease spray control panel fault indication persist
4.2.9.6.13
Group 6B Stop sequence

a. Start HP pump
b. After 10minutes stop mill motor (333 BM100/B46203)
c.
Stop Grease spray pump (333GS137)
d. After 10minutes stop HP pump

NOTE: Group 6 Interlocks are also applicable when the mill is run using Inching Drive.
4.2.9.7 Mill System safety Interlocks

The following additional Interlocks are required for the safety of the equipments and safe operation
of the mill:
a. Group 4 should stop if Mill ID fan (333FN450/ B46203F) trips
b. Suction damper (333LD451/B46203FA) closes to 100% if Mill ID fan (333FN450/B46203F)
trips.
c.
Safety Interlocks for Bag filter (333 BF500/B46203N) dampers are described below:
The damper (333.BV545/B46203H) will be installed at the inlet of the Bag Filter. The damper
(333.BV546/B46203U) will be installed at the outlet of the Bag Filter.
These dampers need to be zero leak proof and fast acting (quick shut-off) so that when the
inertisation system (CO2 / N2) / fire extinguishing system is activated, N2/CO2 does not leak out in
to the process duct work. Hence, these dampers require fast acting pneumatic actuators.
If the dampers (inlet & outlet) are closed as soon as the CO2 / N2 system is activated, there will be
an immediate pressure build-up in the Bag Filter. Hence, to avoid the pressure build-up in the
system, the inlet damper (333.BV545/B46203H) will close immediately after the N2/CO2 system is
activated. The outlet damper (333.BV546/B46203U) will close 90% as soon as the N2/CO2 system
is activated. After the N2/CO2 is completely discharged in to the Bag Filter, a signal will be
received from the CO2 system. At this time the damper (333.BV546/B46203U) will be closed for
the remaining 10% and is now seal tight.
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The initial 90% closing and delay in closing final 10% will be done by mounting two pneumatic
cylinders back to back. First air cylinder is activated on receiving signal and it will close damper
90%, then second air cylinder after receiving signal will close damper remaining 10 % to seal it
tight. The damper shall also be complete with fail-safe design which shall close damper upon loss
of air and electric control signal and provide low air pressure alarm signal.
For inlet damper (333.BV545/B46203H), proximity switches shall be provided for indication of open
ZSO2072 and closed ZSC2072 positions. For outlet damper (333.BV546/B46203U), proximity
switches shall be provided for indication of open ZSO2080, 90% closed ZSC2080 (90%) and
closed positions ZSC2080.
4.2.9.7.1
Emergency Power
Emergency power availability is envisaged for the following drives.
Mill main bearing lubrication system (333 LQ110)
Mill Cooling water control system
The above drives should continue to run / start immediately when there is a power failure. The
operator can decide and stop the system based on the requirement.
HGG-Closed Control Loop: Dilution Air Damper
Control:
a. Dilution Air Damper actuator will be operated with respect to the HGG outlet temp. Increase in
HGG outlet temperature will increase the damper opening (towards open position) and
decrease in HGG outlet temperature will decrease the damper opening (towards close
position).
b. The outlet temperature of the HGG will be sensed by Thermocouple (TC3033) and converted
in 4-20mA by Temp. Transmitter (TT3033) provided at the HGG outlet & the signal will be fed
into BMS PLC as input to control loop. The control loop needs to be configured in the BMS
PLC
c.
Damper can be controlled either in Manual mode or in Auto Mode. BMS will generate the 420mA signal for controlling the damper. The dilution air damper position can be read from the
HMI provided on the BMS Panel for Indication. 4-20mA signals for pneumatic damper position
will be generated by BMS.
FUEL OIL FLOW AND COMBUSTION AIR FLOW CONTROL LOOP

a. Fuel Oil flow along with the combustion air damper position could be increased or decreased
by the operator manually depending on the requirement.
b. 4-20mA generated from the BMS will be fed into I/P converter & the Pneumatic signal from the
I/P converter will be fed into fuel oil flow Control valve and combustion air damper pneumatic
actuator.
c.
100% heat duty and corresponding comb. Air flow is furnished in the P& ID.
d. In order to maintain the ratio between the firing rate and combustion air flow (same throughout
the firing rate), a characteristics for fuel oil flow control valve opening Vs Combustion air
damper opening shall be prepared at the time of commissioning of HGG system and the
operator shall operate the HGG thereafter as per the said characteristics.
e. The position of control valve and combustion air damper could be read from the HMI on BMS
Panel.
f.
Operator should ensure that combustion air flow is increased followed by fuel oil flow during
increasing demand & the oil flow is decreased followed by combustion air flow during
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decreasing demand. (Lead-lag control between fuel oil and combustion air)
PHF UNIT LOGIC
a. Before starting the process, operator has to start Oil pump 1 or 2 (as per selection from Main
Automation System).
b. Before starting any of the pumps, Main Automation System will check day Oil tank level not
low. If the same is unhealthy operator has to first fill-up the tank up to sufficient level. If the
pump is not able to deliver sufficient pressure at Pump outlet (PG3004) then operator should
start the second pump and stop the first one.
c.
Along with the pump, operator has to start line heater-1 or 2 (depending on the selection from
Main Automation System). Line Heater is used to keep PHF unit outlet oil temperature at
120C. This is achieved with the help of Temperature indicating switch mounted at the outlet of
each heater (TIS 3006 and TIS 3005 respectively). There are two set-points (First Set-point at
118C and Second Set-point at 120C) in each TIS. These set-points are taken as an interlock
in MCC Panel (by client) for controlling ON-OFF operation of each bank of Line Heaters. Line
heaters (1 and 2) are consisting of two banks each (Bank-1 of 9 kW and Bank-2 of 6 kW).
d. Along with Temperature indicating switch, both Line Heaters are also provided with 1 no.
Thermostat, which will be used to trip electrical heater in case the temperature inside electrical
heater rises above 130C. This is used for protection of Electrical heater. This needs to be
terminated to MCC Panel in electrical heater trip circuit.
4.2.10 Control Philosophy
4.2.10.1
Introduction
The system operation is evaluated on a continuous basis with the help of the various instruments
in the system. The major control parameters and controlling Variables are vital for smooth
operation of the system. This section details on the various control parameters and controlling
Variables.
This section also describes various abnormal control operations that would be required from time
to time as the system may demand and that could either be programmed or the operator can
initiate a manual control of the parameters.
4.2.10.2
Control modes
The control modes are either MAN or AUTO. In MAN mode, the operator does all initiatives as the
system may demand or the situation deems. The AUTO mode is a programmed operation of the
control. The AUTO mode can either be a sequence of operation or an automatic control of
Variables and controlling the parameters.
The AUTO mode having sequence of operation may be applied to both normal and abnormal
operation and more often with abnormal conditions and used as safe guards of equipment and
system.
The AUTO mode on controllable Variables and controlling parameters are generally structured
control loops of PID control nature and applied during normal operation of the system.
4.2.10.3
PID controller units
The following controller units will be required:
1. Standard
2. Cascade
3. Ratio
4.2.10.4
PID controller operational description
The standard PID controller allows intelligent analogue control of field equipment. That is, a
required set point for a PV is entered and the PID controller attempts to modulate field equipment
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to achieve this set point.

4.2.10.5
PID controller unit structure
A standard PID controller will have the following requirements:
1. Mode of selection
2. Failsafe operation
3. Alarm generation and masking
4. Bad PV handling
4.2.10.6
Mode selection
All PID controller units will have the following modes of operations:
1. Auto - the controller output is calculated such that the PV matches the set point;
2. Manual - the controller output is directly set by the CRO.
4.2.10.7
Fail safe mode
In the event that the PV drifts out of range to an unsafe Value, the controller unit will divert to
manual mode and a failsafe output. The PV must be corrected and the controller unit placed in
auto before the output will again function in auto control.
4.2.10.8
Alarm generation and masking
In addition to alarms generated for the Bad PV, alarms will also be generated for excessive
deviation from the set point. The deviation alarms will include dead band levels to prevent spurious
operation.
Any masking requirements for controller units will be more complex than for analogue devices
because the masking is based on process conditions. PV alarm masking may be implemented for
each individual limit, based on different process conditions. The alarm masking is defined in the
PID Controller Functional Descriptions.
4.2.10.9
Bad PV handling
If a Bad PV is detected in either the control loop of the Standard controller unit or the slave loop of
a Cascade or Ratio controller unit, the output of that unit will be set to the fail-safe Value specified
in the Functional Description and then the unit will be tripped into manual mode and an alarm will
be generated.
If a Bad PV is detected on the master loop of a Cascade or Ratio controller unit when the unit is in
cascade or ratio mode, the controller will set the output (i.e. slave set point) to the failsafe Value
and unit will be tripped into auto (disabled) mode and an alarm will be generated. If the unit is
already operating in auto (disabled), or manual mode the unit will not be affected.
4.2.10.10
System Control
A PID loop can use any or a combination of controller (proportional, integral or differential) for
controlling the auto mode operation.
4.2.10.11
Draft indication at the mill outlet gas duct, feed end and across bag house
These draft indication will quickly point out any blockage in the system and where it occurs. The
operator can take corrective actions based on these data. The draft indicators are mill outlet gas PI
2021 mill feed end PI 2010, Bag filter inlet PI 2049 and Bag house outlet PI 2054.
4.2.10.12
Bag house inlet temperature control
These temperature indications will point out any blockage in the system and where it occurs. The
operator can take corrective actions based on these data. The temperature indicators are installed
at mill exhaust gas TI 2030, Bag filter inlet TI 2050 and Bag filter outlet TI 2055.
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4.2.10.13
Feed Control
The desired set value of feed is given in the MAIN AUTOMATION SYSTEM. The in built PID
controller in the Limestone & Anthracite Coal weigh-feeder (JSPL Scope) panel varies the belt
speed to achieve the desired target value. This mode of operation also called gravimetric mode, is
the desired mode of feed control by the weigh-feeder. This mode of operation can independently
maintain the mass flow rate irrespective of changes in feed granulometry, bulk density or moisture.
The weigh-feeder can also enable to operate in the volumetric mode in which the belt speed will be
fixed as set point. This is a direct control on the weigh-feeder belt and does not respond to the
physical changes (like granulometry, bulk density etc.) in the raw material. Volumetric mode
operation is possible only from the feeder panel.
This PID loop is generally a part of the complete system in the weigh-feeder locally situated control
panel and might not require any programming in the centralized control system unless specified.
However, the centralized control system will have provisions to give material flow (in TPH wet) set
point.
4.2.10.14
Differential pressure drop across the bag filter
The pressure difference across the bag filter DPI2053 initiates and stops the bag cleaning system.
It is also a real indication on the status of the system in terms of airflow and fineness apart from the
condition of the bag filter.
4.2.10.15
Operation Sequences
4.2.10.16
Integrated Start Sequence
The integrated start sequence is given as a guideline for starting the plant. Automatic start
sequence is not recommended.
a. Start ID Fan Group 1
b. Start Product Classification & Handling System Group 2.
c.
Start Mill ID Fan Group 3.
d. Start Dynamic Classifier Group 5

e. Start HAG Group 4.
f.
Start Mill System - Group 6
g. Start Mill Feed System Group 7

4.2.10.17
Integrated Stop Sequence
The integrated stop sequence is given as a guideline for stopping the plant. Automatic stop
sequence is not recommended.
a. Stop Mill Feed System Group 7
b. Stop HAG Group 4.
c.
Stop Dynamic Classifier Group 5.
d. Stop Mill System - Group 6

e. Stop Mill ID Fan Group 3
f.
Stop Product Classification & Handling System Group 2
g. Stop ID Fan Group 1
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4.3
Pneumatic Conveying System for Grounded Coal/Limestone (R-02-1005)

(Inputs received from package vendor Macawber)
A pneumatic conveying system is installed for Coal/Limestone transfer in the Additive Grinding
Building.
The MACAWBER Model 75/12 Denseveyor is a low velocity, dense phase pneumatic conveying
system that consists of a Pneumatic transfer feed Hopper (B43303), a Transport Vessel with a
dome valve, terminal box, automatic controls and a local control panel. The relatively low velocities
employed minimize conveying air consumption, conveying pipe wear and the size of dust collection
system on the receiving end.
The expected capacities of flow for the two additives are as follows:
Additive (TPH)
Average Flow
Design Flow
Limestone
20.9
40.0
Coal
19.1
40.0
The Pneumatic Transfer System receives solid material from the Additive Grinding Mill and must
be activated during the Mill start-up procedure. Dry, fine additives flow to the Pneumatic System
Feed Hopper from the Grinding System Cyclone and Dust Collector. The Feed Hopper is equipped
with high and low level switches. When the Feed Hopper is full, the high level switch signals the
central system to open the vent valve on the Transport Vessel and position the dome valve in the
fill position. Material then flows from the Feed Hopper into the Transport Vessel until it is full. This
dome valve is a patented MACAWBER design which reliably closes and seals through either a
static or dynamic column of material. When the filling cycle is complete, the dome valve closes and
the Transport Vessel is pressurized with dry compressed air at a controlled rate. The conveying
gas is introduced at the top and bottom of the Transport Vessel and transfers the material to the
appropriate Additive Storage Bin.
As a standard configuration, there shall be a manual knife gate valve (KGV) at the outlet of the
hopper for maintenance of any Denseveyor components. This shall be followed by the Dome Valve
and the Denseveyor package complete with its set of Instrumentation controls.
A low level probe mounted in the Hopper's conical section will signal the presence of material
which will cause the Dome Valve to open and the material to fill the vessel. The Dome Valve will
then close and seal. Compressed air / nitrogen will be introduced into the vessel which will aerate
the material and material will be conveyed to the Reception storage silo via the conveying pipeline
and terminal box.
Entire operation of the Pneumatic Conveying System shall be automated.
A Reverse pulse jet filter mounted on top of each reception silo will filter & separate gas/material
from each other.
The logic for the working of the pneumatic conveying system is as follows:
(a) A start command from PLC/Main Automation System is given
(b) Once the start command is given, a check is made for convey pressure through pressure
switch. If pressure is low, then an alarm is generated.
(c) If convey pressure is sufficient, a check is made for instrument pressure through pressure
switch. If pressure is low, then an alarm is generated.
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(d) If the above condition is satisfied along with sufficient level of feed hopper for conveying and
Bypass timer not on, a check is made for discharge silo level (is not high) and diff pressure
across venting arrangement is normal (50-70mmWG). If level is high and if diff pressure is
high, alarms are generated.
(e) If discharge silo level is low and venting diff pressure is ok as mentioned above, material inlet
dome valve and vent dome valve SOVs are energized.
(f) After the valves are energized, a check is made for seal confirmation through the pressure
switches for inlet dome and vent valves. If there is not sufficient pressure, an alarm is
generated.
(g) If there is sufficient pressure, then solenoid valve is energized which will start the material
conveying.
(h) When the material conveying starts, a timer for minimum blow for duration of 15 sec and a
timer for pipe blocked for duration of 75 sec starts.
(i) After both timers duration is over, a check for low pressure is made via the pressure
transmitter. If pressure is high, an alarm is generated for pipe blocked and the system is taken
into manual operation.
(j) If the pressure is low, then convey on SOV is de-energized and seal delay timer for inlet and
vent dome valve starts.
(k) When the seal delay timer is over, seal SOV for Inlet dome and vent valve is de-energized and
the timer is again restarted for another round of conveying operation.
Coal and Lime stone Storage Bin (B43501) is equipped with two load cells and a weight indicator
(WI) which produces an indirect measurement of the solids level in the bin. If the bin level reaches
total capacity, the WI sounds an alarm and shuts down the Pneumatic Conveying System.
High, High level from both Pneumatic transfer feed Hopper and Coal and Lime stone Storage Bin
will stop the additive grinding system.
5.0
MIXING AREA 3 (Hold. Inputs Awaited From Eirich)
5.1
Iron Ore Filter Cake Storage Bin Discharge Rate Control (P&ID: R-03-1001)
Discharge from the ore storage bin is controlled by a weigh belt feeder. Weight and speed signals
are received by weight transmitters (WIT 3111/3121). The actual weight flow rate is controlled by
the weight indicating controller (Loop No: WIC 3111/3121). Provision for both automatic and
manual control is envisaged from the main automation system logic controller WIC-0400. The
controller compares the actual weight flow rate to the set point and adjusts the variable speed drive
for the weigh belt feeder to achieve the required flow rate. The set point is the desired flow rate
manually set through the Main Automation System. The Main Automation System totalizes the flow
rate with time and displays both instantaneous weight flow rate and totalized flow.
The weigh belt feeder is equipped with conveyor safety switches. Alarms from these are displayed
at the DCS.
The Dry Ore Storage Bin (B43506) can also supply through Rotary Weigh Feeder (B55005) to the
Mixer Feed Conveyor MF-11 (B43026) with the same philosophy as mentioned above. This bin is
filled from a Pneumatic Transfer System (by JSPL).
5.2
Ground Coal/Lime stone Storage Bin -- Discharge Rate Control (P&ID: R-03-1002)
Discharge from Coal/Limestone storage bin is controlled by a loss in weight feeder (B55001) fitted
with a geared motor. The actual weight flow rate is controlled by the weight indicating controller
(Loop No: WIC 3211). Provision for both automatic and manual control is envisaged from the
main automation system logic controller WIC-0400. The controller compares the actual weight flow
rate to the set point and adjusts the geared motor on the LIW feeder to achieve the required flow
rate. The set point is the desired flow rate manually set through the Main Automation system. The
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Main Automation system totalizes the flow rate with time and displays both instantaneous weight
flow rate and totalized flow.
5.3
Ground Bentonite Storage Bin -- Discharge Rate Control (P&ID: R-03-1003)

Discharge from Bentonite storage bin (B43504) is controlled by a loss in weight feeder (B55003)
fitted with a geared motor. The actual weight flow rate is controlled by the weight indicating
controller (Loop No: WIC - 3311). Provision for both automatic and manual control is envisaged
from the main automation system logic controller WIC-0400. The controller compares the actual
weight flow rate to the set point and adjusts the geared motor on the LIW feeder to achieve the
required flow rate. The set point is the desired flow rate manually input through the DCS. The DCS
totalizes the flow rate with time and displays both instantaneous weight flow rate and totalized flow.
5.4
Ore And Additives -- Proportion Control

Required feed rates can be calculated off line and entered manually as set points at the Main
Automation system for each controller to achieve the desired total feed rate and proportioning on a
dry basis. The Main Automation system can also automatically calculate the required feed rates
as remote set points to the controllers.
The Main Automation system controls the feed rates of iron ore filter cake (10% H2O), coal +
limestone and bentonite to achieve a total desired feed rate of these components in their desired
proportions. The Main Automation system interface permits the operator to enter the desired total
feed rate, component fractions for bentonite and coal + limestone. The ore fraction equals one
minus the sum of the bentonite and coal + limestone fractions.
5.5
General
Three separate controllers are required in the mixing control system
5.5.1
WIC-3111/3121
WIC-3211
WIC-3311
Iron Ore Filter Cake Feed Rate to the Mixer, TPH

Coal / Limestone feed rate to mixer, TPH
Bentonite feed rate to mixer, TPH
Startup
Before feeding to mixer, the following should be verified:
1. Sufficient levels in ore and additive storage bins
2. Mixer operating
3. Feed recipe has been implemented (feed fractions in Main Automation System for
automatic set point generation; or proper feed rate set points entered)
5.5.2
Normal Operation
Normal operation is completely automatic.
5.5.3
Shutdown
Normal shutdown should permit belts to clear
5.6
Mixing
5.6.1
Process Description
The chemical composition of the fired pellets is controlled by proper proportioning of the ore and
additives. Filter cake is fed onto a Mixer Feed Conveyor MF-11 (B43026) by two variable speed
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belt conveyors (B43087-1,-2) with weigh scales (WIC-03B3111 and WIC-03B3112) and Rotary
Weigh Feeder (B55005).
Additives, Coal/Limestone, Bentonite, and Organic Binder are metered by loss-in-weight feeders
(B55001, B55003, and B55004) onto the Mixer Feed Conveyor MF-11 (B43026), which will
discharge into a vertical mixer (B45110).
Individual start-up of blended ore conveyors FCF-11& 12 and mixer feed conveyor MF-11 will
depend on healthy signal from the safety switches placed on the conveyors.
5.6.2
Mixer Function
(Preliminary description furnished. Details awaited from Mixer vendor Eirich)
Mixing pan rotates with eccentrically positioned rotating mixing rotors and fixed multi-purpose tool
as flow deflector. The multi-purpose tool divides and deviates the material stream. Split material
streams are created and produce a macromixing effect. The rotor acts upon the circulating material
stream which is caused by mixing pan and flow deflector and produces a micromixing effect.
5.6.3
Mixed Material Handling

The Green Fines Return conveyor (GFR-11B) (B43042) deposits fines returns along with mixer
discharge to the Mixed Ore Conveyor MO-12 (B43026). The MO-11 (B43027) conveyor transfers
material to MO-12 (B43026) and MO-13 (B43032), and MO-14. At this point, the appropriate belt
plow will dump mixed material to Balling Disc Feed Bins (B16215-1, 2, 3, 4, 5 & 6) or directly to
Balling Disc Feed Bin 7 (B16215-7). MO-13 will discharge into mixed ore conveyor MO-14.
Individual start-up of mixed ore conveyors MO-11, 12, 13 & 14 and green fines return conveyor
GFR-11B will depend on healthy signal from the safety switches placed on each conveyor. Mixer
will start / stop once MO-11 starts / stops.
Group start in a sequential manner (MO-14 MO-13 MO-12 MO-11) will depend on the lower
level signal of the Balling disc feed bins and / or healthy signal from conveyor safety switches.
Emergency stop of the conveyors and mixer will result from unhealthy signal from conveyor safety
switches and / or HH alarm from all bin level transmitters.
6.0
BALLING - AREA 4
(Inputs received from package vendor METSO)
6.1
Pellet Formation
6.1.1
Process Description
In order to obtain an end product of good quality fired pellets, it is necessary to have uniformly
sized, adequately strong green balls. The balling disc is the mechanical means of forming these
agglomerates. A feed mix of finely ground ore, fluxes and moisture, and a binder, combine in a
rolling action of the disc to form these green balls.
The ore mixture received from the mixing area is deposited in the seven balling feed bins, from the
transporting conveyor, by means of sequence controlled plows. It is then withdrawn from the bins,
at a controlled rate, by the disc feed conveyor and fed to the balling disc, which is rotating about an
axis of 45 to 50 degrees to the horizontal.
The discs rotation carries the feed material to the top of the disc where, under its own weight, the
particles roll back towards the bottom. Fine sprays of water are directed at the rolling mass as it
descends. The particles of ore, coated with water, collide with adjacent particles and, because of
the surface tension effects of the water coating, combine to form larger particles and start to form
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seed pellets, which comprise the nucleus of the pellet. Further rolling in the disc causes the
seeds to grow. Within the disc charge, the balls segregate into flow paths according to size and
density, the smaller and less dense particles being carried, by the rotation, closer to the top of the
disc before falling back under their own weight. As the seeds become larger they gradually
migrate from the disc bottom to the charge surface achieving the desired product size range. At
this time they reach the lip of the disc sidewall and overflow to the green pellet- collecting
conveyor. This is a continuous operation as long as balling feed is continually introduced to the
disc.
The rate of growth of the green balls can be controlled by the disc speed and the addition of spray
water as necessary. However, too much spray water addition will result in the production of
oversize and wet plastic balls which will tend to deform on their passage to the furnace. Too little
moisture in the balling mix will restrict the formation of seeds and result in a build-up of
unagglomerated material in the disc and a dry, friable, undersize product. The correct disc axis
angle must be established during startup. This angle combined with the disc speed establishes the
most beneficial balling path for the material. The discs will be initially set at 47 degrees.
In summary, the operator controlled parameters which govern the balling operation are primarily
feed moisture, disc speed, feed rate, and water spray location. Additional parameters usually
determined at startup are disc angle, the point at which feed is introduced to the disc, and plow
location and angle. Ore size structure, Blaine particle surface area, and level of binder additive are
also important factors for quality balling feed.
The seven (7) balling discs discharge onto seven (7) green pellet conveyors GP-11A through GP11G which in turn discharge the pellets to collecting conveyor GP-12.
Conveyor GP-12 transports the green pellets to the indurating area. There, the pellets are
transferred to wide belt conveyor GP-14 which then deposits the pellets onto the upper roller
conveyor (B43037E). The function of the upper roller conveyor is to screen out oversize balls. The
lower roller conveyor screens undersize green balls before finally depositing product size green
balls onto the grate for induration.
The oversize green pellets screened at the upper roller conveyor are passed through a shredder
where they are broken into fines and added to the green fines screened at the lower roller
conveyor. The total stream is recycled to the mixer discharge stream for feed to the balling disc
feed bins.
6.1.2
Control Philosophy (P&ID: R-04-1001 to R-04-1004)
6.1.2.1 Balling Bin Plow Feed System

Each of the seven (7) balling feed bins mounted on load cells are filled from conveyor MO 14 using
belt discharge plows (B48004-1 to 6). Bin levels are indicated on the Main Automation system. The
plows are lowered to the conveyor one at a time to deflect the mixed ore into the bin as it passes
the lowered plow. Each plow is equipped with position switches, up and down. They signal the
Main Automation System which indicates to the control room operator the position of each plow.
The plows are operated in manual mode. In manual mode, the operator raises and lowers the
plows to suit. A full (High, High) bin will cause its plow to raise or prevent the bin filling system from
lowering its plow. When all bins are full, conveyor MO-14 will stop.
Low bin levels are indicated by alarms only. They provide sufficient time for the operator to take
corrective action.
Alarms are provided to indicate High bin levels so that the operator has sufficient time to take
corrective action and avoid High High level.
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6.1.2.2 Balling Disc Feed

There are seven balling circuits, each consisting of a balling feed bin; a variable speed disc feed
conveyor, BDF-11A to G, with a belt scale, a balling disc and a disc discharge conveyor, GP-11A
to G.
Mixed ore is withdrawn from each bin by the variable speed conveyor controlled by a weight
indicating controller in conjunction with the belt weigh scale (Loop No: WIC0106/4101/0203/0223/0303/0323/0403). The controlling parameters of balling discs are disc feed
rate as indicated above, manually adjusted disc spray water addition and manually adjusted disc
rotational speed (rpm).
Spray water addition is automatically stopped when the balling disc stops.
Each disc is equipped with field rotational speed indication, spray water flow indication, and disc
position tilt angle.
6.1.2.3 Start-Up
There are three cases to consider:
-
Initial disc start-up
Starting a disc under full load
Starting a disc that has been cleaned out (operated for several minutes without
feed prior to shutdown).
A new disc must have its mesh lining filled in with mixed ore (bedded). A mixed ore material with
elevated bentonite (2-3%) and moisture (10-12%) contents should be used for this bedding
procedure. The disc should be operated at low speed (<4rpm) and feed rate (<50tph) during this
procedure. As the mesh begins to fill in, the disc speed and feed rate can be adjusted as required
to produce a stable disc lining (both floor and walls). As the mesh is filled, disc scraper position
must be evaluated and adjustments made as required.
When starting a disc which has a full load of ore on it, the moisture content of ore load must be
evaluated. (E.g. How long has the disc been down? How dry is the ore in it?) Based on this
evaluation the amount of spray water initially turned on and whatever time lag, if any, between
starting the disc and the feed conveyor must be determined. Constant monitoring of the disc for the
first few minutes of operation is required as adjustments are made until steady state is achieved
regarding spray water addition, disc speed and disc feed rate.
When starting a cleaned out disc, initial disc speed, spray water addition and feed rate should be
at levels just slightly below normal settings for the ore mixture being processed. (Spray water
addition must account for the dryness of the bed.) As the disc fills up constant monitoring is
required to insure proper green ball formation. Once the disc begins to discharge material then
adjustments for speed, feed rate and spray water can be made to achieve steady state operation.
Balling discs have variable speed drives with individual speed controls.
All the settings mentioned above will be determined by the commissioning engineer of the package
supplier.
Individual start-up of each balling disc will be in the following sequence,
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a)
Green pellet conveyor, GP-11A thru G (B43031-1 thru 7) will start first provided Green
pellet collecting conveyor GP-12 (B43034) running and healthy signal from conveyor safety
switches.
b)
Balling disc (B46005-1 thru 7) will start up on receiving running signal from Green pellet
conveyor.
c)
Once balling disk starts high pressure water solenoid valves will be open.
d)
Balling disc feed conveyor, BDF-11A thru G will start once balling disc starts and healthy
signal from conveyor safety switches.
In order to process different ore types, balling disc speed, scraper position, water sprays, disc
angle, and feed point will be adjustable. Normally, only minor adjustments to water addition and
disc speed will be needed to produce good quality green pellets. Following the initial setup for the
disc, the other adjustments will be necessary only when there is a significant change in the ore
characteristics. Speed is adjusted by field operator. Other adjustments are manual.
6.1.2.4 Normal Operations
The balling disc is used to form pre-wetted ore into nominal 1/2" diameter balls called "green balls"
or "green pellets".
The strength of the green pellet is determined by the natural surface tension of water and other
adhesive forces, causing capillary action of the water in the spaces between the small particles of
ore.
The finer the material, the more the adhesive forces are capable of forming strong agglomerates.
A controlled amount of pre-wetted ore is fed to the balling disc. The rolling action on the disc
initially forms seed pellets which grow larger by picking up additional particles of new feed as they
roll across the disc. Based upon controlled disc parameters, the pellet then discharges at the
desired diameter or product size over the lip of the disc.
The process parameters necessary for a controlled continuous disc operation are:
Constant disc feed rate

Constant disc feed moisture (0.2%)
Constant material size (% minus 45 microns)
2
Constant material fineness (cm /g-Blaine surface area)
Disc Speed (R.P.M.) rate.
Disc slope (angle)
Feed location
Water spray location (for additional moisture if needed)
Disc side wall height
In order to sustain controlled continuous operation, it is also necessary to maintain the bottom and
side scrapers so that a uniform smooth and level coating is maintained on these surfaces. Ridges
on the bed change the pattern of the material and cause some breakage of the pellets.
When analyzing the operation of a disc, it helps to think of the material rolling down the disc as
three distinct streams as shown in the illustration:
Stream No. 1 contains on-size and near-size product,
Stream No. 2 contains intermediate size balls, and
Stream No. 3 contains seed balls and free fines.
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A good operator will learn how the three streams look under normal operation, and take corrective
action when a change becomes apparent in the third or second stream. If corrective action is
delayed until an upset is apparent in the product, stable operation will be difficult to achieve.
When the disc is operating in a continuous or steady state condition, the on size discharge rate will
equal the new feed material rate to the disc.
The discharge size analysis will remain very stable as long as the moisture content of the feed
material does not vary.
If the moisture content of the feed material to the disc is not controlled, the disc will operate in an
inconsistent manner.
If the feed material moisture increases slightly, the pellets on the disc will increase in size. This
takes a little time but the product being discharged will be larger. To correct this:
-
If water is being added on the disc, reduce the amount of water addition. This should
be done in steps, rather than cutting all of the water. Wait for the change to take effect.
This can take from ten to twenty minutes to see the results.
If no water is being added, increase the feed rate slightly. A rule of thumb is to not
add more than 10% of the feed rate at one time.
If the feed material moisture increases quite a bit, + 0.5% or more, the pellets on the disc will
increase in size very rapidly. Usually the on-size pellets will travel to the second and at times the
third stream.
When this happens the larger pellets pick up the seeds and any fines available on the disc. The
disc fills with over-size product, the discharge rate is reduced, the seed formation and intermediate
size pellet growth is eliminated. Unless immediate steps are taken, this condition will continue. To
improve this condition:
(Record water flow meter readings, and return to original settings when material is back to normal
conditions).
- If water is being added on the disc, turn off all sprays. This will help to stop pellet growth, but
further changes are usually necessary.
- Check the RPM rate and reduce the rate. This reduces the retention time of the material on the
disc. (Return to original RPM rate when material returns to normal).
These are operator controlled (near term) changes.
If the above changes are not adequate, more involved changes are required. Change the feed
location. By moving the feed location farther from the first stream to the second or third stream
operator can reduce the size of pellets on the disc. (Return to original location when material
returns to normal).
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BALLING DISC MATERIAL STREAM
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If the pellets are still too large the operator has one option left. He can change the disc angle. This
change should be done in one degree increments, for example change from 47 to 48. When
operator changes the angle, he usually has to make slight adjustments to the r.p.m to balance the
disc operation. If the operator increases the angle, he needs to increase the RPM slightly. (Return
to original setting when material returns to normal).
When the feed material is very wet it is not a good idea to increase the feed rate. The disc carries
a heavy load of material and classification is very poor.
If the feed material moisture decreases slightly, the pellets on the disc will decrease in size. This
change also takes time. Operator will have time to make changes without upsetting the disc
operation. To correct this condition, take a reading on the flow meter, then increase the amount of
water addition on the disc. This should be the only change needed. Allow sufficient time to see the
results (Return to normal setting when material returns to normal).
If the feed to the disc quickly becomes very dry, if water is not immediately increased, the on size
product will discharge very quickly and the disc will be filled with seeds. With a disc full of seeds it
can take up to 30 minutes to sufficiently wet the seeds to force pellet growth. In some cases it may
also be necessary to reduce the disc feed rate to compensate for the feed moisture loss.
When bringing the disc back from a dry condition, it is very important to reduce the high volume of
spray water at the correct time or the pellets could grow very quickly due to their wet state. If the
pellets grow larger than desired, reduce the spray water in steps rather than all at once. The disc
could again go dry, discharging the growing pellets and leaving only a disc full of seeds again.
Controlling the disc water sprays is really a balancing operation which requires observation and a
lot of patience by the disc operator. Knowledge of disc feed material and the proper water addition
with the sprays can only be gained by experimenting and observing the reaction of the total disc
and the final results.
6.1.2.5 Summary
Rules for reasonably constant feed on a continuous disc operation:
-
Watch the total disc pattern when you are operating under stable conditions. If the feed changes it
will affect the third and second streams before it is noticed at the discharge point. If operator
makes minor adjustments when the change occurs, the disc will continue to operate in a stable
condition.
If operator watches only the eye of the disc or the discharge point, by the time a change affects
this area, it is too late to compensate for the change. This usually leads to an upset condition
which may take a lot of time and adjustments to recover.
Fine tune or control the disc with one spray regardless of the number of sprays in use. The use of
sprays, like the feed location, affects the product being discharged. The closer the spray is to the
eye of the disc the larger the product size. When more than one spray is used, the water addition
must be balanced.
Make only one change at a time.
Experiment - make very slight changes and watch what effect it has on the disc.
Have patience - wait long enough to see the effect of a change on the disc.
If sudden drastic upsets occur, take quick action to try to control the disc in as stable operation as
is possible.
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Shutdown
As is obvious from the earlier start-up procedures a disc can be shut down either fully loaded or
with a reduced load. This will be driven by operator preference or whether the shut down was
unplanned. In any case, whenever the feed to a disc is stopped, the spray water addition must be
stopped. If the disc is stopped, design is for this to occur automatically. However, due to the severe
problems that can result, spray water shut-off should be checked locally in the field.
6.1.2
Balling Disc Grease Lubrication System (P&ID: R-04-1005, R-04-1006)

Compressed Air and grease are directed to each disc via the Gear Lubrication Systems (B46005A1, 2). Compressed air is used to provide the grease to disc drives.
The system supplies lubrication to 7 nos of Palletizing Disc Units. All the 7 lubrication units are fed
by a common Pumping station but each system has its own, separate functional components for
independent working. The operation is automatic. The 7 disc lubrication units are normally
operated simultaneously. A provision has been made for selective operation so that lubrication on
one or more discs, if so desired, can be suspended temporarily, for maintenance etc. Though the
units operate simultaneously, each unit has its own separate initiation signal. Hence the 7 cycles
may or may not run synchronously depending upon the start signal for each. Each disc lubrication
unit can be run in local or remote mode.
Description of Automatic Operation:
The automatic operation can be initiated locally or from remote by means of a selector switch. The
operation in both modes is identical except for the initiation signal. In the local mode, the operation
starts through Local mode selector switch. In the remote mode, the operation starts through a
signal from the VFD for the corresponding pelletizing disc through the main automation system.
As soon as the system gets a start signal, the pneumatic solenoid valve for the grease pump
energizes and the pump starts delivering grease to the system.
The greasing cycle sequence of all the Pelletizing discs is identical. The sequence of one disc is
described below:
As soon as the pump starts, the solenoid on the grease line energizes and the grease from the
pump flows to the distributor. The distributor operates cyclically due to the pressure of the grease.
The distributor cycle is monitored by means of a proximity switch actuated by the in/out movement
of a pin on the distributor. The distributor delivers a metered quantity of grease to the nozzles.
When the distributor cycle is complete, the grease solenoid valve is de energized and the pump
stops. The spray air solenoid valve for the nozzles energizes and remains ON for a pre determined
period and then becomes OFF. The grease at the nozzles is sprayed. This completes one
greasing cycle. When the spray air solenoid valve is de energized, a pause timer starts counting.
At the end of the pause time, a new cycle starts as described above. The cycles continue as long
as there is a start signal from the Local switch or from the Pelletizing disc VFD.
At the end of the cycle, the pump becomes off only if there is no cycle start signal for any of the
other disc lubrication systems of the group.
System Interlocks and faults
The cycle starts only if the following healthy conditions prevail:
1.
2.
3.
The grease level at the pump station is OK.

There is sufficient air pressure at the compressed air unit.
The ball valve on the grease line of the corresponding disc is open.
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During the operations, system fault is generated under following conditions:

1.
2.
3.
4.
5.
6.
The compressed air pressure falls below set point.

The grease level at the pump station becomes low.
The grease pressure at the distributor drops below the set point.
The distributor cycle is not completed within a preset time period after the start signal.
The spray air pressure at the nozzles drops below the set point.
The ball valve on the grease line of the corresponding grease line is not open.
The system fault is annunciated by a hooter. The system stops functioning. The system stoppage
is either for all the Discs or only for the faulty unit depending upon the nature of the fault. The
system can be restarted after the faulty condition is rectified.
7.0
INDURATING - AREA 5
Green pellets from the balling discs will drop onto green pellet conveyors GP-11A thru GP-11B
which in turn feed onto green pellet conveyor GP-12 (B43034). GP-12 conveyor has a
reciprocating head (B43034A) dumping onto the Wide Belt Conveyor (B43036). Pellets are
distributed across a wide belt conveyor (B43036) by a reciprocating Head pulley mechanism. The
pellets are screened and conveyed to the pellet induration machine by a double deck roller screen
(DDRS). The off-size pellets are screened by the DDRS ahead of the indurating machine and
recycled back to the balling circuit. Oversize pellets travel through Green Oversize Return
Conveyor (B43037A) to the Oversize Pellet Shredder (B43037D) onto Green Fines Return Fines
Conveyors GFR-11A, B, (B43037C, B43042) to MO-12 (B43026). The green pellet conveyors and
DDRS reject conveyors are sized for a rejection rate of 40 percent, although recycle rates of 25%
or less are anticipated.
7.1
Green feed to machine starting sequence

1) On receiving group start command from HMI lower roller conveyor (B43037F) will start first
depending on healthy signal from conveyor safety switches.
2) On receiving running status of lower roller conveyor, upper roller conveyor (B43037E) will start
3) On receiving running status of upper roller conveyor, wide belt GP conveyor (B43036) will start
4) On receiving running status of wide belt GP conveyor, GP collecting conveyor (B43034) will
start depending on healthy signal from conveyor safety switches.
7.2
Green fines return sequence

1) On receiving group start command from HMI GF return conveyor (B43042) will start first
2) On receiving running signal from GF return conveyor, GFR-11B (B43042) will start depending
on healthy signal from conveyor safety switches.
3) On receiving running signal from GFR-11B, Green oversize return conveyor GOR-11 (B43037A)
& Oversize green pellet shredder (B43037D) will start depending on healthy signal from conveyor
safety switches.
The design for the traveling grate iron ore pellet plant will incorporate the Dravo Process. In this
process, the unfired green pellets are dried, preheated, indurated, and cooled on a continuous
traveling grate, without intermediate transfers. Process air introduced for pellet cooling is
circulated from the cooling zone of the grate in a multi-pass manner to the other process zones to
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obtain thermal efficiency. Only relatively cool, moisture laden gases are discharged to process gas
cleaning and then to the atmosphere.
During normal operation, the 75 mm to 100 mm thick bed of hearth layer will perform three
important functions.
A. It will create a temperature gradient between the bottom of the new bed and the metal grate
components, so that the grate components are exposed to gases cooler than the roughly 1300 C
at the bottom of the new bed.
B. The high level heat, which is stored in the hearth layer, is efficiently returned to the process
during updraft cooling.
C. It will diffuse the gas flow passing through the relatively small fraction of open grate area, thus
ensuring uniform gas flow through the new bed.
The hearth layer thickness is adjustable by the operator to a maximum height of 300mm.
This feature will also permit idling the machine by re-circulating full depth hearth layer, while
maintaining the gas temperatures in all zones, and to gradually increase the green pellet feed rate
from zero without producing any off-specification product. During interruptions in green pellet feed,
the hearth layer gate is raised to cover the grate and to maintain grate speed.
Side layer chutes (B400011) are used to protect side plates from high temperatures and to
maintain pellet quality.
Pellet induration will occur on the 4.0 m wide traveling grate. The anticipated total bed height of
hearth layer plus green pellets will be constant up to approximately 500 mm. The speed of the
traveling grate is variable and automatically controlled to maintain a constant bed height.
The indurating machine (B40001) will have five furnace processing zones, updraft drying,
downdraft drying, preheating, firing and cooling. In the updraft drying zone, gas flow will remove
free water from the lower portion of the pellet bed while heating that layer to a temperature at
which condensation will not form when the gas flow reverses in downdraft drying. The updraft
drying off-gas is exhausted to atmosphere following dust removal. The heat for updraft drying is
recovered from the second section of the cooling zone.
The next process zone is downdraft drying where free water is removed from the upper portion of
the pellet bed. The heat for downdraft drying is supplied from the firing zone windboxes. Gases
from the downdraft windboxes are discarded via the windbox exhaust fan until the off-gas reaches
sufficient temperature for use in downdraft drying. The air for the remainder of the heating cycle
comes from the first cooling zone via the direct recuperation duct.
The pellets are preheated to intermediate temperatures in the third processing zone. Provision is
made to temper the initial stages of preheat with cooler air to allow better control of the heat-up
rate of the pellets. The slow temperature ramp will prevent thermal shock and avoid damage from
rapidly evolving steam or gases resulting from crystalline water in the ore, calcination of the flux,
and combustion of the coal.
After preheating, the pellets are fired at high temperature. The hood temperature in the latter part
of the firing zone is slightly lower as the residual heat in the upper portion of the pellet bed is drawn
down to the bottom layer to ensure uniform product quality. Windboxes 13 through 22 are used for
firing.
Cooling of the pellets is accomplished with an updraft flow of air to lower the temperature of the
grate components quickly and to recuperate the sensible heat from the pellet bed at the highest
possible temperature.
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The gas flow scheme is designed to recuperate a significant amount of sensible heat from the
process gas streams. High level heat is recuperated directly from the first cooling zone, while low
level heat is recuperated from the second cooling zone for drying at temperatures, which avoid the
use of exotic materials of construction for the updraft drying fan. Process parameters may be reset
to optimize the induration pattern as campaigns of different types of pellets are run.
Additional heat for indurating is supplied by burners firing either fuel oil or fuel gas. Oil heaters,
pipe insulation, and electric heat tracing of oil lines are incorporated into the plant design.
7.3
Hearth Layer Bin

Load cells sense the weight of fired pellets in the hearth layer bin (B54013). A level transmitter
(LT-05B0206) sends the signal to the DCS which compares the signal with the bin level set point
and accordingly regulates the variable speed drive on HL-12 conveyor (B43071).
Hearth layer bin level is maintained at approximately 85% full. Abnormal bin level alarms are
provided on the HMI for high level (95% full) and low level (50% full). Hearth layer bin set-point is
entered via the HMI.
7.4
Indurating Details
7.4.1
Indurating Machine Pellet Bed Depth (Primary System)

The primary pellet bed depth control system uses three (3) ultrasonic level probes to monitor total
bed depth and one (1) ultrasonic level probe to monitor the hearth layer bed depth. The difference
between the average total bed depth and the hearth layer depth equals the green bed depth. Total
bed depth is controlled by means of machine speed modulation via the bed depth controller on the
HMI. Hearth layer depth is fixed by setting the position of the hearth layer gate. All three (3)
signals, total bed depth, green bed depth and hearth layer bed depth are displayed on the HMI. A
DCS selector switch is used to choose the active level instrument: Average, East, Center, or West.
The hearth layer is measured by the hearth layer transmitter (LIT-05B0210 A thru D)
Indurating Machine Pellet Bed Depth (Alternate System)
The alternate system of bed depth control is provided for backup control. Its three (3) signals;
calculated green bed depth, hearth layer gate position and the sum of the two (2) for a total bed
depth are also displayed on the HMI for comparison.
The belt scale on conveyor GP-12 (B43034) sends a signal proportional to the weight rate of
material across the scale to the DCS. This signal is delayed to allow for the time it takes the green
pellets to travel from the scale to the indurating machine. The belt scale on conveyor GFR-11B
(B43042) (WIT-05B0126) also sends a signal proportional to the weight of the material rejected to
the DCS. The DCS calculates a difference between the weight of material on conveyors GP-12
and GFR-11B. The position of the hearth layer gate is sensed and transmitted to the DCS. The
bulk density of the green pellets is input manually to the DCS by way of the HMI. The speed of the
traveling grate is sensed and transmitted to the DCS. Based on these inputs the DCS varies the
machine speed to maintain a constant total bed depth on the grate.
Derivation of the control algorithm is shown below.
LT= LHL + LGP
Where:
LT =
LHL =
LGP =
Total Bed Depth

Level of Hearth Layer (manually set, does not vary with machine speed)
About 100 mm normal
Level of green pellets which is calculated based on area as follows:
(LGP x GW) x S x D = W or Solving for LGP:
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LGP = W/GWSD
Where:
GW=
S=
D=
W=
return)
Grate width (fixed) less width of side layer (made up of fired pellets)
Grate Speed
Green Pellets density (manual set)
Weight rate of green pellets feed to machine (measured total less green fines
Substituting to solve for Total Bed Depth, LT

LT= LHL + W/GWSD
about 400- 450 mm
Using SI units of measurement (CGS system)

L=
W=
G=
S=
D=
Millimeters (mm)
Metric Tons/Hr (t/h)
M (Meters)
M/min
MT/meter3 = about 2.4
LT = LHL + K1 W
GwSD
Where K1 is a constant of dimension mm
Value of K1:
K1 =
1000 mm/M
60 min
Hr
or K1 = 16.666
.
Then combine dimensional constant K1 with Gw for a dimensionless constant K2

K2 = K1
Gw
For this machine:
Grate Width = 4 meters
Side Layer = 50 mm per side
Gw = 4000 - (2 x 50) = 3900 mm= 3.9 M
K2 =
16.664 = 4.273
3.9
LT =
LHL + (4.273) W
SD
Or
LT =
LHL +
W
SD *(0.234)
4,000,000 mtpy and 7920 hrs/yr

Example at 505 t/h, Speed S= 3.00 M/min
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The DCS compares the bed depth with its set point bed depth and modifies the grate speed
accordingly through the variable frequency drive. As green pellet feed rate is increased, the
calculated total bed depth will exceed the set point and the grate speed is increased proportionally.
Conversely, for a decrease in green pellet feed rate, the calculated total bed depth is less than the
set point and the grate speed is decreased proportionally. The machine speed varies continuously
to maintain the set point bed depth.
In the event of a loss of green pellet feed, the operator must take action. The course of action
taken by the operator will depend on the cause of the loss of green pellet feed, as well as the
overall needs of the plant. This area is covered thoroughly during the training phase of plant startup. An alarm, differentiated from other alarms by tone and volume, indicates loss of feed to the
machine.
7.4.2
Process Fan Protection

The five (5) process fans:
Windbox Recup Fan (B42005)

Updraft Drying Fan (B42006)
Cooling Air Fan (B42004)
Windbox Exhaust Fan (B42007)
Hood Exhaust Fan (B42008)
Temperature elements located on both motor bearings and fan bearings are wired to the fan
monitoring system (FMS), which then sends alarms to the HMI when a high or high-high
temperature exists in any bearing. High-High temperature in a motor bearing or fan bearing is a
fan shutdown.
The motor current is indicated on the HMI.
Fan and motor vibration is also monitored by the fan monitoring system at the inboard and
outboard bearings. An alarm is activated to the HMI at high and at high-high vibration for any
bearing. The fan will shut down at a high-high condition.
Each fan has an inlet damper closed start permissive interlock.
Each fan lube system measures, alarms, or acts upon certain conditions according to the following:
Low oil level - (not) permits start, then alarm only
High oil temperature - (not) permits start, then alarm only
At least 1 oil pump running permits start
Low oil pressure (not) permits start
Low oil pressure after short delay, start standby oil pump
Low oil pressure continues after longer delay, trip fan
Low oil flow return from fan bearings alarm only; no trip.
Cooling water to the fans has a low flow alarm only
Three (3) RTD's, one on each winding of the process fan motor, are wired directly to the
switchgear for that process fan motor, and the switchgear will shutdown the fan on high motor
windings temperature.
After stopping a process fan motor, the motor must remain off for the period recommended by the
motor vendor, based upon the number and duration of its prior runs, before a restart can be
attempted. When any of the 5 process fans are stopped, the DCS operator must close the inlet
dampers manually.
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7.4.3
Updraft Drying Zone Hood Pressure

A pressure transmitter (PT-05B0401) in the updraft drying zone hood provides the signal for the
DCS controller that regulates the fan speed of the hood exhaust fan. A slightly negative pressure
of about -1 to -2 mm water column is normally maintained.
This pressure (PSL-05B0401) must be negative as a permissive to light the burners and after light
off if a positive pressure occurs the DCS will force the burners to low fire after a time delay. The
burners will go to low fire when the pressure at the cooling air duct is low (PSL-05B1335). Settings
will be determined in the field. The DCS will lock in the low fire condition until reset at the HMI. A
Low Fire Bypass switch is provided in the HMI to allow modulation of burners above low fire
during startup.
The fan inlet damper position and motor speed are indicated on the HMI and can be manually
adjusted from the screen. Fan amps are also indicated on the HMI screen.
The pressure set-point for (Loop No: PIC-0401, P&ID: R-05-1003, R-05-1017) is entered via the
HMI.
On an out of tolerance pressure condition, an alarm is displayed on the HMI.
7.4.4
Downdraft Drying Zone Hood Pressure

A pressure transmitter (PT-05B0403) in the downdraft drying zone hood provides the primary
signal that is transmitted to the DCS. Should the pressure in the downdraft drying zone increase, a
damper (B54810) will open to discharge excess gas to the updraft drying hood. If the downdraft
drying hood pressure continues above the desired set-point, the Downdraft drying bleed off
damper (B54809) will open to bleed gas to the Hood Exhaust ESP (Loop No: PIC-0403, P&ID: R05-1003).
Set-point pressure is normally maintained at a slightly negative value of about -3 mm water
column.
The pressure set-point is entered via the HMI.
On an out of tolerance pressure condition, an alarm is displayed on the HMI.
7.4.5
Downdraft Zone Hood Pressure

A pressure transmitter in the firing zone hood (PT-05B1815) sends a signal to the DCS, which
compares the signal with the set point and accordingly regulates the cooling air fan speed. Fan
motor current will be displayed to the operator. The set-point of the controller is normally set at a
slightly negative value of about -4 mm water column. The pressure is not much below atmospheric
otherwise leakage of cold air into the furnace could cause incomplete burnthrough along the sides
of the machine. The position of the fan inlet dampers and motor speed can be adjusted manually
from the HMI.
The set point for the pressure is entered via the HMI.
On an out of tolerance pressure condition, an alarm will be displayed on the HMI.
In case of failure of pressure transmitter, (PT-05B1815), a switch is provided on the HMI to allow
the operator to manually switch the backup firing zone pressure transmitter, (PT-05B0932), into the
cooling air fan speed control loop until the (PT-05B1815) signal is restored.
Second Cooling Zone Hood Pressure and Updraft Drying (UDD) Fan High Temperature Protection
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A pressure transmitter (PT-05B0602) in the second cooling zone hood sends a signal to the DCS,
which compares the signal with the set-point and accordingly regulates the updraft drying fan
speed (Loop No: PIC-0602, P&ID: R-05-1008). Normal set-point pressure for the second cooling
zone is -4 to -9 mm water column.
The fan inlet damper position can be manually adjusted from the HMI.
The set-point pressure is entered via the HMI.
In the event of an out of tolerance pressure condition, an alarm is displayed on the HMI.
As long as the measured temperature at the updraft drying gas header (TE-05B0407) does not
exceed the set-point for fan protection purposes (the set-point temperature is below maximum fan
structural temperature), the second cooling isolation damper (B54828) remains in the open
position and the updraft drying bleed-in damper (B54806) will modulate as needed. If the gas
temperature continues to rise after the primary bleed-in damper is fully open, the DCS will then
start closing the isolation damper (B54828) to reduce the flow of hot gas mixing with the ambient
bleed-in air (Loop No: TIC-0407, P&ID: R-05-1003 & R-05-1008).
Set-point temperature for fan protection is about 270C. The fan speed and position of the bleedin damper, the duct damper and the UDD fan inlet damper are shown on the HMI. Motor amps are
also displayed on the HMI.
The set-point temperature for fan protection is entered via the HMI.
In the event of an out of tolerance temperature condition, an alarm is displayed on the HMI.
7.4.6
Downdraft Zone Windbox Pressure

The pressure in the firing zone windboxes is determined by the burnthrough temperature control
and is not directly controlled.
Windbox exhaust duct pressure control (PIC-05B1821) is provided. There is an option for ratio
control set-point to (PIC-05B1821) by way of a HMI selector (HS-05B1821).
The output of the controller (PIC-05B1821) modifies the speed of the Windbox Exhaust Fan. An
increased speed will lower the windbox exhaust duct pressure, reduced speed will increase the
pressure in the duct.
Normal pressure for the windbox exhaust duct is about -500 mm water column.
If the operator chooses, the windbox exhaust header pressure can be maintained at a specific
value by placing the DCS controller in "DIRECT CONTROL" instead of "RATIO CONTROL". The
windbox exhaust duct pressure can then be directly controlled by entering the desired pressure
set-point on the HMI. The ratio is a number from 0 to 2.0. When RATIO is active, the set-point of
the Windbox Exhaust Header (PIC-05B1821) is set to the ratio times the windbox recuperation
header pressure (PT-05B0501).
The ratio set-point for the windbox exhaust header pressure is entered via the HMI at (HS05B1821).
The position of the windbox exhaust fan inlet dampers and motor speed can be manually adjusted
from the HMI.
The motor amps are displayed on the HMI.
7.4.7
Updraft Drying Zone Windbox Pressure
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A pressure transmitter (PT-05B0405) in the updraft drying duct sends a signal to the DCS, which
compares the signal with the set-point and accordingly regulates the updraft drying bleed-off
damper (B54807) (Loop No: PIC-0405, P&ID: R-05-1003). The damper opens to relieve excess
pressure under the grate to prevent any disturbances of the bed due to excessive undergrate
pressure. Normal set-point pressure is about 500 mm water column.
The set-point for the pressure is entered via the HMI.
The position of the bleed off damper is shown on the HMI.
7.4.8
Wind box Recuperation Fan Temperature

A thermocouple (TE-05B1235) located on the downstream side of the wind box recuperation fan
sends a signal to the DCS, which compares the signal with the set-point and accordingly regulates
the two bleed-in dampers (B54808-1, 2) (Loop No: TIC-1235, P&ID No. R-05-1012).
The dampers allow ingress of ambient air at the inlet side of the wind box recuperation fan if the
temperature rises above the set-point temperature. The position of the bleed-in dampers is
indicated on the HMI.
The temperature set-point for (TIC-05B1235) is entered via the HMI.
On an out of tolerance temperature condition, an alarm is displayed on the HMI.
7.4.9
Burnthrough Temperature
Two thermocouples are located in windbox 22 (TE-05B0731) (TE-05B0732). The temperatures are
transmitted to the DCS where the temperatures are averaged and compared with the set-point.
The DCS then regulates the windbox recuperation fan speed, increasing fan speed as necessary
to control the flow of hot gases through the bed and control the temperature in the windboxes as
necessary. Set-point temperature is approximately 550C (setting may be adjusted to maintain
pellet quality). The motor speed can be manually adjusted from the HMI.
The temperature set-point (TIC-05B0734) is entered via the HMI. The position of the dampers,
motor speed and motor amps are displayed on the HMI.
On an out of tolerance temperature condition, an alarm is displayed on the HMI.
7.4.10 Wind box Vent Doors

The windbox vent doors, one in the windbox exhaust header (B54001) and one in the windbox
recuperation header (B54002), are equipped with electric motor operators. The vent doors are to
be opened when a stop grate hold is initiated. The vent doors are opened manually from the DCS
or a local control station.
7.4.11 Preheat and Firing Zone Hood Temperature
In Preheat Zone, the temperatures in the north and south sides are monitored through
thermocouples (TE- 1801 to 1809) mounted on direct recuperation header. Flow of UDD air is
controlled by dampers (ZT-1801A to 1809A for north side & ZT-1801B to 1809B for south side)
depending on the header temperature (Loop No: TIC-1801A to 1809A for north side & TIC-1801B
to 1809B for south side).
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7.4.12 The DCS sends the master burner permissive, ready for purge, and at purge flow signals to the
Main Panel. Details of these signals can be found in the Burner Operation section of the Operating
Manual and the vendors burner operation manual.
All downcomer temperatures are monitored for each burner. These same temperatures are
available at the DCS.
A purge and burner restart must then be completed if temperatures are below the auto-ignition
temperature at any burner or zone.
7.4.13 The firing zone is heated with 38 burners. Each burner can be controlled individually. The operator
can select oil or gas firing, with separate selector switches available on the main burner panel.
In minimum flow position, the burner light-off is allowed as long as permissives are satisfied. The
low fire indicating position is available to the DCS. Normally the furnace is started with oil and
switched over to gas once control temperatures are maintained.
Double block valves are used for both oil and gas for burner management. Refer to the vendors
operation manual for specifics of this control and interlocking.
The combustion system uses combustion air, ambient cooling pilot air, and atomizing air.
The burners turn down by reducing fuel flow and run excess air operation.
Cooling Air is maintained to the burners at all times, whether the burners are firing or in standby.
The pressure both high and low are monitored by the burner management system. Refer to the
vendors operation manual for specifics of this interlocking.
The system run permit is removed if:
Emergency Stop is pressed, Combustion Air blower is not running, Main Combustion Air pressure
is low, atomizing air pressure is low, or pilot air pressure is low , fuel pressure is low or any safety
fault exists.
The furnace requires a full purge for initial start. A full purge is timed for four volumetric air
changes. If full purge is required, it is initiated at the Main Panel.
For a full purge, the system run permit must be on and the purge conditions satisfied. The Main
Panel verifies the main burner gas safety shutoff valves are closed , all burner primary fuel valves
closed , all fuel valves closed, all secondary upstream and downstream fuel valves are closed. The
full purge must be completed before any burners are lit. When the purge is complete, all fuel
control valves go to low fire lightoff position.
There is a burner run permissive for each burner. If flameout occurs, the DCS will automatically
turn off the permissives to the failed burner zone. A reset is required from both the DCS and flame
safety for relight.
Burner start sequence includes the following steps: prove valves at low fire, ignition transformer
on, flame proven, ignition off, main fuel valves open. With all these steps completed, the burner is
modulated as needed to maintain desired temperatures.
For zone control, each zone has its own temperature control. By software, the individual burners
can be directed to follow the zone temperature selected.
The Main Panel transfers BMS data to the DCS via hardwire. A listing of interlocks and other
functions are included in the Vendor Manual .
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7.4.14 Lintel Cooling Surge Tank Level

A level transmitter (LIT-05B2701) sends a signal to the DCS, which compares the signal with its
set-point and accordingly regulates the throttling valve (LV-05B2701) for make-up water (Loop No:
LIC-2701, P&ID No: R-05-1016). For normal operation only a relatively small quantity of make-up
soft water addition is required.
The Lintel Cooling Tank level set-point is entered via the DCS HMI.
Lintel Cooling Pumps (B41101-1, 2) supply lintel water through the two Lintel Cooling Water Heat
Exchangers (B31201-1, 2) to the furnace lintels, baffles and hood seals. The temperature of the
lintel water is monitored and alarmed. (TE-05B2709)
In the event of an emergency condition where the water temperature (TE-05B2704) from the
furnace lintels is too high, the DCS will open a valve (TV-05B2704) to introduce emergency makeup water from the emergency head tank into the furnace lintel cooling water supply header. When
the emergency water valve is open the lintel cooling water storage tank could overfill and the water
may temporarily overflow to drain. It should be an operator action to close this emergency valve
when it has opened for any reason. Cooling water distribution must be balanced using manual
valves and observing the collection boxes.
The emergency head tank is only used until the emergency standby generator can be started to
run the lintel cooling water pumps.
7.4.15 Machine Discharge Hopper Level
Load cells sense the weight (LIT-05B0305) of fired pellets in the discharge hopper. A level
transmitter sends the load cell signals to the DCS, which compares the signal with the set-point
and varies the speed of feeders (B55017-1, 2).
This control need not be overly tight; the bin level should be allowed to float up or down. A
proportional or gap control scheme should be used for this controller.
The set-point is entered via the HMI.
The (LIC-05B0305) output signal from the DCS (LIT-05B0305) is common to both vibrating
feeders.
In the event that the discharge level rises beyond the set-point, normally 50% of the full bin, an
alarm is activated at the HMI. If the level continues to rise to the second set-point (75%) an
additional alarm is activated at the HMI and the machine drive will be alarmed for manual
shutdown. Low level is usually set for 25%. The Indurating Machine is not interlocked to Discharge
Hopper Level. The operator must take action to prevent overfilling of the Hopper.
The level set-point is entered via the HMI.
7.4.16 Product conveyor P-11 (B43050) Temperature Protection
There is a temperature element/transmitter (TE-05B0301) located in the second cooling zone hood
at the end of the furnace which senses the temperature above the fired pellets and transmits it to
the DCS. Logic in the DCS uses this information to control the discharge end hood cooling water
sprays (TV-05B0301 A, B, C) to prevent hot pellets from damaging conveyor P-11 (B43050) or any
downstream conveyors. There are three sets of sprays in the hood. The first set comes on at
425C, the second set at 480C, and the third set at 540C. The set-points may need to be reset
during startup.
Downstream of the machine discharge chutes there are two sets of belt water sprays above the P11 (B43050) product conveyor to protect the belt from high temperature product, discharging from
the indurating machine. A temperature transmitter (TT-05B0316) monitors the discharge hood. The
DCS will turn on the first set of sprays (process water system) (XV-05B0314) at 100C and the
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second set (firewater system) (TV-05B0315) at 150C. The set-points may need to be reset during
startup.
All of the above mentioned automatic spray water temperature controls should have some amount
of deadband programmed into the set-points to minimize cycling the valves.
Additionally there is a pair of infrared temperature detectors (TE-05B0315) for belt fire protection
above the belt itself downstream of the discharge chute which send pellet/belt temperature
readings to the DCS. These signals should drive logic which will turn on the second set of belt
sprays (firewater system) (TV-05B0315) to provide quench water when high temperatures are
detected.
The temperature set-point for the pellet/belt temperature control is dependent on the limits of the
selected belt material. A specific alarm should display on the HMI to indicate a high temperature
has been detected on the belt by these sensors and that the spray valve is open. Once opened by
these sensors, it should require operator action to close the spray valve and reset the system.
7.4.17 Indurating Machine Drive Control
A vendor supplied control system interfaces the DCS and the machine drives. Signals are sent
between these systems to achieve control and monitoring. The indurating machine drive can be
controlled from four locations, with only one location in control at any one time. An indicator light
on each of the machine bridge, pallet change and drive station indicates when that station has
control of the grate.
7.4.18 Control from the Control Room
The DCS provides start/stop control through HMI screens. The DCS provides a speed reference
signal to the variable frequency drive from the machine speed/bed depth controller.
7.4.19 Control from the Machine Bridge Control Station
The machine operator requests the DCS operator to give the bridge operator control of the
machines speed. The DCS operator gives speed control to the bridge by clicking on the
appropriate control area on the HMI. The local switch at the bridge station can now be turned
ON, giving control of the machine speed to the bridge station. The Machine Control should
indicate that the bridge has control by lighting a pilot light on the bridge control station. The
variable frequency unit sets the speed reference circuit to accept the speed reference signal from
the speed control pushbuttons (Increase and Decrease) located on the bridge control station.
When the bridge operator has completed his operating task, he calls the DCS operator and informs
him, and then returns speed control to the DCS by turning off the switch on the bridge control
panel.
The variable frequency unit resets the speed control circuits to receive speed control from the
DCS, and the machine continues to run, at the previous speed sent out by the DCS. The E-stop
functions from both the DCS and the bridge control stations are active when either the control
room is in control or the bridge is in control.
The local Machine start and Normal stop on the bridge panel are active only when the bridge
panel is enabled by the DCS and the switch on the local panel.
7.4.20 Control from the Pallet Change Station
This is a logic system, not a true group-starting situation. It is operated from its own local panel,
with pushbuttons and data entry/display screen.
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The pallet change station operator requests the DCS operator to give the pallet change station
control of the machine.
The DCS operator gives control to the pallet change station by clicking on the appropriate control
area of the HMI screen. The DCS sends a signal to the pallet change control system signifying to
the variable frequency unit that the pallet change station can take control.
The pallet change station operator takes control when the Control Active Light is on. The
variable frequency unit also sets the VF control signal circuits to accept jog forward and jog
reverse signals from the pallet change station control panel. The speed of the machine is
controlled by a preset speed signal in the variable frequency unit.
Change-Out Mode:
The operator will use the HMI Change-Out Mode selector to choose Replace, Remove, Load or
View after turning the Pallet On-Off selector to On - Pallet Change Station control.
Replace Mode:
The operator is prompted to Enter Pallet ID to be inserted and the operator presses ENTER"
after keying in the ID number.
For Remove Mode:
Remove multiple pallets from the machine after first ID number is entered.
For Load Mode:
The pallet ID must be entered by the operator. After the first pallet is loaded, the operator can load
other pallets in sequence.
View Mode:
The operator views the pallet stack. Data displayed is Position #, Pallet #, and the value of Sag.
When the pallet change station operator has completed his operating task, he calls the DCS
operator and informs him, and then turns the Pallet On-Off selector to Off.
When the selector switch is switched to DCS control, the variable frequency unit resets the speed
signal circuits and control circuits to receive the DCS signals.
7.4.21 Control from the Machine Drive Station
The machine drive station operator requests the DCS operator to give the machine drive station
control of the machine. The DCS operator gives control to the machine drive station by clicking on
the appropriate control area of the HMI screen. The DCS sends a signal to the variable frequency
unit that the machine drive station can take control. The machine drive station operator takes
control by acknowledging acceptance of the control through a selection switch.
The DCS receives the take control signal and indicates the machine drive station has control by
lighting a pilot light on the machine drive station control panel.
The variable frequency (VF) unit also sets the VF control signal circuits to accept jog forward and
jog reverse signals from the machine drive station control panel. The speed of the machine is
controlled by a preset speed signal in the variable frequency unit. When the machine drive station
operator has completed his maintenance task, he calls the DCS operator and informs him, and
then turns the selector switch to the DCS control position.
When the selector switch is switched to DCS control, the variable frequency unit resets the speed
signal circuits and control circuits to receive the DCS signals.
7.4.22 Pallet Sag Measurement
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The pallet sag measurement is recorded as it passes the Sag Monitor laser distance detector. The
sag measurement is recorded in the Indurating Machine PLC and is tabulated for each of the
respective pallet positions. The data is available on the local Touchscreen Unit. Sagging pallets
are disassembled. The center casting is reversed. The pallet is then reassembled. The operator
must periodically replace pallets that have deformed beyond design limits.
7.4.23 Hood Seal Flow
The hood seal flow is automatically controlled with the fan inlet damper.
There is a cross tie to the combustion air fans with crossover dampers (B54812). These dampers
only open when the combustion air blowers fail. Normally these dampers are closed. (Revision
may occur See Latest Design)
The dampers open to keep air going to the burners when there is a combustion air failure.
Hood seal flow control is designed to keep a low differential pressure between the hood seal
pressure (PT-05B0601) and the furnace pressure (PT-05B0610).
Hood seal fan inlet damper (B42009A) is controlled by a flow controller (Loop No: FIC-0611, P&ID:
R-05-1008) which receives a differential pressure set value from a pressure controller (Loop No:
PIC-0610, P&ID: R-05-1008).
Hood Seal Fan flow controller (FIC-05B611) is limited to 30% minimum to maintain the seal under
all conditions. For added protection, the hood seal fan has emergency power available.
7.5
Burner Management System

The BMS provides furnace operational safeguards. The operational safeguards are implemented
through hard-wired circuitry, interlocking safety devices, combustion safeguards and a Safety PLC.
The BMS is designed to comply with NFPA 86:2011Standard for Ovens and Furnaces. The BMS
will perform only the burner management system functions listed. No Combustion Management
System (CMS) functions (air/fuel ratio, flow control, temperature control, etc.) will be implemented
as part of the BMS.
The furnace consists of thirty eight Fives North American model 6535 burners. These burners
incorporate both a pilot burner element and a dual-fuel main burner element. Each burner is
supplied with an ultra-violet flame supervision device. The BMS will control burner ignition in an
interrupted pilot sequence, where the pilot burner element is shut-off after the main burner
element is lit.
The main burner element of the 6535 burner requires physical adjustment of the oil atomizer for
selecting gas or oil operation. Limit switches mounted to the burner body provide indication to the
BMS of the burners atomizer position (fuel setting). The BMS will turn off any burner in which the
selected fuel mode is different than the burners fuel setting or any burner where the fuel setting
changes during operation. The BMS will permit any arrangement of burners to be selected as gas
or oil to operate within the furnace.
The thirty eight burners are physically arranged between two sides of the furnace, North Side and
South Side. Six Remote I/O panels, three per side, provide the electrical interface to furnace
devices. Data from the Remote I/O panels is conveyed to the BMSs central processing unit
(Safety PLC) using a ProfiNet ring topology. Thirty eight remote push button stations are provided,
one dedicated to each burner, for operator control and operational status of each burner. The
remote push button stations are hard-wired to the Remote I/O panels.
The thirty eight burners are logically grouped into eight control zones. Each control zone is
governed by an individual Excess Temperature Limit Interlock and 1400 F Bypass Interlock. All
burners within a zone will be permitted to operate or will be shut-down based on the status of the
Excess Temperature Limit and 1400 F Bypass Interlock.
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Operational status and configuration of the BMS is available through Operator Interface Terminals
(Human / Machine Interfaces). A total of two Human / Machine Interfaces (HMI) devices are
provided, one located at the Main Control Panel (North Side) and one on the Remote Operator
Interface panel (South Side). Communications between the HMIs and the BMSs central
processing unit are implemented through a ProfiNet star topology. Access to the BMSs
operational data values by the customers DCS system can be accessed through this network.
Note: The Remote I/O ProfiNet network and the HMI/DCS ProfiNet networks are physically
separate networks.
7.5.1
Control System Functions

The control system functions are all provided new. The functional scope of this system includes the
following items:
Burner Flame Safety
Excess Temperature Limit Interlocks
1400 F Bypass Interlocks
Combustion Safeguards
Flame proving and monitoring
Master Fuel Trip Relay
Purge interlocks and timing
Safety shutdowns
Status monitored by BMS
Combustion Control
Ignition and Shutdown of burners
Operator Interface
Burner/equipment mode & status
Burner/equipment alarms
BMS control data entry
7.5.2
Control System Hardware

The control system hardware is all provided new. The hardware scope of this system includes the
following items:
Control Processor
Siemens S7-417-5H PLC
Siemens S7-300 Fail-Safe and Standard I/O
ProfiNet Communications
Human / Machine Interface (HMI)
Siemens MP377 MMI, 15 TFT Touch screen MMI
ProfiNet Communications
Fireye Simplicity 65UV5 self-checking scanner
Ultra-violet flame detection
7.5.3
Burner Management System

The Burner Management System (BMS) is the part of a combustion control system that manages
burner operation safeguards including pre-ignition furnace purge, burner ignition, flame monitoring,
fuel routing, and safety shutdowns. The BMS functions are implemented through hard-wired
circuitry, interlocking safety devices, combustion safeguards and a Safety PLC.
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The BMS circuitry is designed to shut off fuel to the burner system, by removing power (holding
medium) to the Safety Shutoff Valves, through one or more of the interlocking safety devices,
combustion safeguards or operating controls.
Each hardware component and the overall operation of the burner management system are
described in detail below:
7.5.4
Excess Temperature Limit Interlocks

The furnace consists of eight control zones, each equipped with an Excess Temperature Limit
Interlock (ETLI) controller. All ETLI safety devices will be mounted on the Main Control Panel.
The ETLI controller is a panel-door-mounted, FM-approved temperature switch. The controller
output contact opens whenever the thermocouple input indicates a temperature greater than a set
point value. The output contact remains de-energized until both the temperature is below set point
and the controller has been manually reset.
7.5.5
1400 F (760 C) Bypass Interlock

A 1400F Bypass Interlock is provided for each of the eight furnace control zones. The 1400 F
Bypass Interlock devices will be mounted on three of the six Remote I/O Control Panels. The 1400
F Bypass Interlock indicates, by relay contact closure to the Safety PLC that the temperature of
the associated control zone is above 1400 F. Burners within a zone may be ignited only following
the completion of a furnace purge cycle or if the 1400 F Bypass Interlock indicates that the control
zone temperature is above 1400 F.
7.5.6
Manual Emergency Switches

Mounted at each control location are Manual Emergency Switches, labeled Fuel-Stop, that are
hard-wired into the BMS circuitry. The contacts of the switches are arranged in series such that
operation of any Manual Emergency Switch removes power to the Safety Shutoff Valves for ALL
burners (oil, gas and pilot) within the system.
7.5.7
Each burner is equipped with a Combustion Safeguard that monitors both the pilot element and the
main burner element. The Combustion Safeguard is a safety device that senses the presence or
absence of flame using an ultra-violet sensor. The Combustion Safeguard contains an internal selfcheck mechanism designed to detect failure of the UV sensor in the flame detected state.
Indication of the presence (or absence) of flame and device failure is conveyed to the Safety PLC
through contact closure. The Safety PLC will remove power to the Safety Shutoff Valves of the
individual burner being monitored depending on the status from the Combustion Safeguards. The
logic sequence related to the Combustion Safeguard is described in detail later within this section.
7.5.8
Safety PLC
The Safety PLC is implemented using a Siemens S7 F/FH fail-safe automation system (FSystem).
The F-System is designed to control a process to an immediately achievable safe state in the
event of a hardware or software failure. Safety functions are contained in the safety program within
the fail-safe CPU (F-CPU) and within the fail-safe inputs and outputs (F-I/O). In addition to
providing fail-safe functionality, the F-System hardware provides fault tolerance. Fault tolerance is
accomplished through a redundant structure including the F-CPU, the power supply, the
associated hardware for linking and synchronizing the F-CPUs. The F-System will automatically
switch from the primary F-CPU to secondary F-CPU control in the event of a primary F-CPU
failure. Therefore a F-CPU or power supply may fail without impairing the functionality of the
overall system, increasing furnace reliability and availability.
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All Remote I/O for the F-CPUs is implemented using Siemens S7-300 ET 200M Distributed I/O
Devices which employ Siemens S7-300 Fail-Safe and Standard I/O modules. Communication of
the module I/O data to/from the F-CPUs occurs over a ProfiNet communication ring. The Safety
PLC is responsible for control of pre-ignition furnace purge, burner ignition; flame monitoring and
BMS related alarm detection. The Safety PLC can interrupt power to the Safety Shutoff Valve(s) in
the event of a shutdown condition, if a device failure is detected or an operational system-stop
control is issued.
7.5.9
Remote Push Button Stations

A remote push button station is supplied for each burner. Each push button station contains push
buttons and status lamps for control of the individual burner to which it is associated. All push
button stations contain the same discrete arrangement of devices, which are as follows:
Fuel-Stop Push Button
Local / Remote Selector Switch
Gas / Oil Selector Switch
Start Permissive Ready Indicator Lamp
Burner Start / On Illuminated Push Button
Pilot On Lamp
Burner Stop / Flame Fail Illuminated Push Button
Low Temperature Bypass Active Lamp
7.5.10 Human / Machine Interfaces (HMI)

Operational status and configuration functions are available through the Human / Machine
Interfaces (HMI). The system includes two HMI, each executing the same program. The HMI
program shall include the following pre-engineered BMS graphic displays at a minimum:
Overview of BMS status
Purge Cycle status and control.
Burner Status & Mode
Igniter Status
Master Fuel Trip Status
ETLI Status
Alarm Message Display and Acknowledgement.

7.5.11 Power On/Off Selector Switch
The Power On/Off selector switch, located on the door of the Main Control Panel, will remove
power from the Safety PLC and other control devices within the Main Control Panel. The Power
On/Off Selector switch can be locked-out to perform non-electrical maintenance to the furnace.
7.5.12 Pilot Burner Element Fuel Gas Limits
The pilot fuel gas for the furnace is supplied from a main pilot fuel gas supply line. The main pilot
fuel gas supply line branches into two headers, one located on each side of the furnace. Each
header is isolated from the main pilot fuel gas supply with two, series connected, automatic Safety
Shutoff Valves (SSOVs). The pilot fuel gas supply from a header to each individual burner is
equipped with two, series connected, SSOV solenoid valves. The de-energized state of all SSOVs
is closed. The fail-safe state of the Remote I/O points to which the SSOVs are connected is deenergized. Power to all pilot burner gas SSOVs is dependent upon the following:
7.5.13 Manual Emergency Stop (Fuel-Stop)
The Manual Emergency Stop is hard-wired to interrupt power to all pilot gas SSOVs.
7.5.14 Main pilot fuel gas pressure
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The main pilot fuel gas pressure is monitored using high and low pressure limit switches (customer
supplied) mounted to the main pilot fuel gas supply. These limit switches are connected to discrete
inputs of the Safety PLC. The Safety PLC continuously monitors the discrete inputs and will shut
off power at all Remote I/O discrete output points connected to the pilot gas blocking valves and
SSOVs if either the high or the low pressure limit switch input is detected to be de-energized. The
fail-safe values of the Remote I/O point to which the main pilot gas pressure switches are
connected is de-energized.
7.5.15 Combustion Safeguard
The Safety PLC monitors the Combustion Safeguards for the presence of flame at each burner.
The Safety PLC will turn off the discrete Remote I/O output points connected to an individual
burners pilot gas SSOVs, where the Combustion Safeguard at that burner has failed or has
reported the absence of a flame signal for more than 5 seconds and the and the 1400 F Bypass
Interlock indicates that the temperature of the control zone is below 1400 F. The fail-safe value of
the Remote I/O points to which the Combustion Safeguard signals are connected is 0V (flame
loss).
7.5.16 Main Burner Element Fuel Gas Limits
The main fuel gas supply consists of a header at each side of the furnace. There are no SSOVs
located on the main fuel gas header that are controlled by the BMS. A connection to the main fuel
gas supply header, for each burner, provides primary gas to each burner. Each burners primary
gas supply is isolated from the main fuel gas supply with two, series connected, automatic Safety
Shutoff Valves (SSOVs). The de-energized state of the primary gas SSOVs is closed. The fail-safe
state of the Remote I/O points to which the SSOVs are connected is de-energized.
Power to each burners primary gas SSOVs is dependent upon the following:
7.5.16.1
Manual Emergency Stop (Fuel-Stop)
The Manual Emergency Stop is hard-wired to interrupt power to the primary gas SSOVs of all
burners.
7.5.16.2
Excess Temperature Limit Interlock
An Excess Temperature Limit Interlock (ETLI) will interrupt primary gas SSOV power to all burners
located within a control zone in the event the ETLI for that zone trips. The ETLI controllers are
hard-wired into the SSOV power circuit. Failure of the thermocouple input results in an overtemperature trip by the controller. As a result, all Safety Shutoff Valves of the burners within the
associated control group are de-energized.
7.5.16.3
1400 F Bypass Interlock
The Safety PLC monitors the 1400 F Bypass Interlock status contact for all eight control zones.
The Safety PLC will inhibit burners in a control zone from starting if a purge sequence has not
been completed and the 1400 F Bypass Interlock indicates that the temperature of the control
zone is below 1400 F. The Safety PLC will permit a burner within a control zone to remain lit when
its Combustion Safeguard fails or reports loss of flame, if the 1400 F Bypass Interlock, of that
control zone, indicates that the temperature of the control zone is above 1400 F. When the 1400
F Bypass Interlock indicates that the temperature of the control zone is below 1400 F and the
Combustion Safeguard fails or reports loss of flame, the Safety PLC will turn off the discrete
Remote I/O output points connected to the individual burners primary gas SSOVs. Failure of the
thermocouple input results in an under-temperature (temperature is below 1400 F) indication by
the controller. The Safety PLC will perform the required action based on the status of the
Combustion Safeguard at each individual burner within the control zone.
7.5.16.4
Main fuel gas pressure
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The main fuel gas pressure is monitored using high and low pressure limit switches (customer
supplied) mounted to the main fuel gas supply. These limit switches are connected to discrete
inputs of the Safety PLC. The Safety PLC continuously monitors the discrete inputs and will shut
off power at all Remote I/O discrete output points connected to the fuel gas SSOVs of all burners if
either the high or the low pressure limit switch input is detected to be de-energized. The fail-safe
value of the Remote I/O points to which the fuel gas pressure limit switches are connected is deenergized.
7.5.16.5
Combustion Safeguard
burners primary gas SSOVs, where the Combustion Safeguard at that burner has failed or has
reported the absence of a flame signal for more than 5 seconds and the and the 1400 F Bypass
Interlock indicates that the temperature of the control zone is below 1400 F. The fail-safe value of
the Remote I/O input points to which the Combustion Safeguard signals are connected is 0V
(flame loss).
7.5.16.6
Atomizer Position
Limit switches are mounted to the burner body (of each burner) and provide indication to the Safety
PLC of the burners atomizer position. The Safety PLC monitors the position of all burner atomizers
and will remove power to the primary gas SSOVs of any burner in which the selected fuel mode is
gas and the atomizer position is not fully retracted.
7.5.17 Main Burner Element Fuel Oil Limits
The main fuel oil supply consists of a header at each side of the furnace. There are no SSOVs
located on the main fuel oil header that are controlled by the BMS. A connection to the main fuel oil
supply header, for each burner, provides fuel oil to each burner. Each Burners fuel oil supply is
isolated from the main fuel oil supply with two, series connected, automatic Safety Shutoff Valves
(SSOVs). The de-energized state of the fuel oil SSOVs is closed. The fail-safe state of the Remote
I/O points to which the SSOVs are connected is de-energized.
Power to each burners fuel oil SSOVs is dependent upon the following:
Manual Emergency Stop (Fuel-Stop)
The Manual Emergency Stop is hard-wired to interrupt power to the fuel oil SSOVs of all burners.
Excess Temperature Limit Interlock
An Excess Temperature Limit Interlock (ETLI) will interrupt fuel oil SSOV power to all burners
located within a control zone in the event the ETLI for that zone trips. The ETLI controllers are
hard-wired into the SSOV power circuit. Failure of the thermocouple input results in an overtemperature trip by the controller. As a result, all Safety Shutoff Valves of the burners within the
associated control group are de-energized.
1400 F Bypass Interlock
The Safety PLC monitors the 1400 F Bypass Interlock status contact for all eight control zones.
The Safety PLC will inhibit burners in a control zone from starting if a purge sequence has not
been completed and the 1400 F Bypass Interlock indicates that the temperature of the control
zone is below 1400 F. The Safety PLC will permit a burner within a control zone to remain lit when
its Combustion Safeguard fails or reports loss of flame, if the 1400 F Bypass Interlock, of that
control zone, indicates that the temperature of the control zone is above 1400 F. When the 1400
F Bypass Interlock, indicates that the temperature of the control zone is below 1400 F and the
Combustion Safeguard fails or reports loss of flame, the Safety PLC will turn off the discrete
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Remote I/O output points connected to the individual burners fuel oil SSOVs. Failure of the
thermocouple input results in an under-temperature (temperature is below 1400 F) indication by
the controller. The Safety PLC will perform the required action based on the status of the
Combustion Safeguard at each individual burner within the control zone.
Compressed Air Supply pressure
The Compressed Air Supply pressure is monitored using high and low pressure limit switches
(customer supplied) mounted to the compressed air supply. These limit switches are connected to
discrete inputs of the Safety PLC. The Safety PLC continuously monitors the discrete inputs and
will shut off power at all Remote I/O discrete output points connected to the fuel oil SSOVs if either
the high or the low pressure limit switch input is detected to be de-energized. The fail-safe value of
the Remote I/O points to which the compressed air supply pressure limit switches are connected is
de-energized.
Main Fuel Oil Pressure
The main fuel oil pressure is monitored using high and low pressure limit switches (customer
supplied) mounted to the main fuel oil supply. These limit switches are connected to discrete inputs
of the Safety PLC. The Safety PLC continuously monitors the discrete inputs and will shut off
power at all Remote I/O discrete output points connected to the fuel oil SSOVs of all burners if
either the high or the low pressure limit switch input is detected to be de-energized. The fail-safe
value of the Remote I/O points to which the fuel oil pressure limit switches are connected is deenergized.
Main Fuel Oil Temperature
The main fuel oil temperature is monitored using high and low temperature limit switches
(Customer supplied) mounted to the main fuel oil supply. These limit switches are connected to
discrete inputs of the Safety PLC. The Safety PLC continuously monitors the discrete inputs and
will shut off power at all Remote I/O discrete output points connected to the fuel oil SSOVs of all
burners if either the high or the low temperature limit switch input is detected to be de-energized.
The fail-safe value of the Remote I/O points to which the fuel oil temperature limit switches are
connected is de-energized.
burners fuel oil SSOVs, where the Combustion Safeguard at that burner has failed or has reported
the absence of a flame signal for more than 5 seconds and the and the 1400 F Bypass Interlock
indicates that the temperature of the control zone is below 1400 F. The fail-safe value of the
Remote I/O points to which the Combustion Safeguard signals are connected is 0V (flame loss).
The Safety PLC monitors the output contact of the Atomizing Air Low Pressure switch at each
burner. The Safety PLC will remove power to the fuel oil SSOVs of any burner in which is in Oil
Mode mode and the Atomizing Air Pressure switch indicates the atomizing air pressure supply has
fallen below the safe operating set point. The fail-safe value of the Remote I/O point to which the
Atomizing Air Low Pressure signals are connected is 0V (pressure is below the safe operating set
point).
Atomizer Position
Limit switches are mounted to the burner body (of each burner) and provide indication to the Safety
PLC of the burners atomizer position. The Safety PLC monitors the position of all burner atomizers
and will remove power to the fuel oil SSOVs of any burner in which the selected fuel mode is oil
and the atomizer position is not fully inserted.
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7.5.18 Pre-Ignition Purge

Prior to powering any fuel or oil SSOVs within a control zone whos temperature is less than 1400
F, a pre-ignition purge of the entire pelletizing furnace chamber must be performed. The pre
ignition purge is performed to remove all flammable vapors and gases from the heating chamber
during a shut-down period. The system must be purged with fresh air for a minimum of five (5)
volumetric air changes in the heating chamber prior to introducing a source of ignition.
The Safety PLC will generate a Ready to Purge indication for each of the eight control zones.
The Ready to purge indication results from the all of the following conditions being satisfied:
All four of the SSOVs located on the main pilot gas headers are closed.
Both primary gas SSOVs, at each burner in the control zone, are closed.
Both fuel oil SSOVs, at each burner in the control zone, are closed.
The fuel gas flow control valve, at each burner in the control zone, is in the low-fire position.
The fuel oil flow control valve, at each burner in the control zone, is in the At Low-Fire
position.
The Ready to Purge status of all eight control zones can be visually monitored on the HMI. Note:
The Ready to Purge and other status registers that are available to be read from the Safety PLC,
by the customer DCS system, over the ProfiNet HMI/DCS network, are listed within Section 5 of
this document.
A Start Purge command is initiated by an operator pressing the Start Purge soft-button on the HMI
screen. The customer DCS is expected to prove purge air flow and supply an At Purge Flow
indication as a discrete/hard-wired input to the Safety PLC. When all eight control zones are
Ready to purge and the At Purge Flow indication is received by the Safety PLC, the Safety PLC
will initiate a pre-ignition purge sequence.
When the pre-ignition purge sequence has been initiated, the Safety PLC will set the System
Purge Status and eight individual Zone Purge Status registers to Active. The Safety PLC will
then start will start two internal timers:
Purge Timer The Purge Timer will accumulate time as long as the System Purge Status is
Active. If the At Purge Flow limit or any of the Ready to purge limits is lost, even momentarily, the
Purge Timer is reset and all accumulated time will be lost. The HMI will annunciate an alarm
indicating the condition that caused the Purge Timer to be reset. The Purge Timer will begin again
when the At Purge Flow limit and the Ready to purge limits are satisfied and the System Purge
Status is Active. The duration of the Purge timer is not adjustable and will be set as the time
required to move five volumetric air changes through the heating chamber, given the dimensions of
the heating chamber and the customers minimum purge air flow rate. Once the accumulated time
of the Purge Timer exceeds that of the configured duration, the System Purge Status and the eight
Zone Purge Status registers are set to Complete.
Purge Taking Too Long Timer - The Purge Taking Too Long (PTTL) Timer will accumulate time
as long as the System Purge Status is Active. The PTTL Timer is NOT reset on loss of a purge
limit. The duration of the PTTL Timer is adjustable via the HMI.
When the accumulated time of the PTTL exceeds that of the configured duration, an alarm is
displayed on the HMI indicating this condition, the purge sequence is halted, the System Purge
Status and the Zone Purge Status registers are set to Inactive.
When the System Purge Status has been set to Complete, the Safety PLC starts an internal timer
for each control zone:
Purge Response Timers - The Purge Response Timers will accumulate time as long as the
associated Zone Purge Status is Complete. The duration of the Purge Response Timers is
adjustable via the HMI. When the accumulated time of a Purge Response Timer exceeds that of
the configured duration, an alarm is displayed on the HMI indicating this condition and the
associated Zone Purge Status is set to Inactive. For each control zone where the Zone Purge
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Status register is Complete, burners within that zone may be may be ignited, given their Burner
Start Permissive is also active. The Burner Start Permissive are written to the Safety PLC from the
customer DCS. When an attempt to ignite a burner within a control zone is made, the associated
Zone Purge Status register is set to Inactive. Loss of any Ready to Purge limit while the Zone
Purge status is Complete will cause an alarm is displayed on the HMI indicating this condition and
the Zone Purge Status is set to Inactive. The transition of any of the Zone Purge Status registers
to Inactive causes the System Purge Status to be set to Inactive.
7.5.20 Burner Ignition
For each control zone, burners may be ignited if their Burner Start Permissive is TRUE and any
of the conditions are satisfied:
1) 1400 F Bypass Interlock is indicating that the zone temperature is above 1400 F.
2) The Zone Purge Status is Complete.
3) The status of at least one burner within the control zone is Released to Control.
Burner Ignition can be individually initiated via the Remote Push Button Stations or using the
individual Burner Start soft-buttons on the HMI. An Automatic Ignition Sequence to start all
burners can be initiated using the Start All Burners soft-button on the HMI. When the Start All
Burners soft-button is pressed, not all burners are start at once. The ignition sequence for one
burner in each control zone will be started immediately, with additional burners in each zone stared
every 3 seconds thereafter, until the ignition sequence has been started for all burners within all
control zones. Burners will be started in order of their associated wind box numbers.
Starting with the A-North burner with the lowest wind box number within the group and alternating
next to the A-South burner, followed by B-North and lastly B-South. The same sequence is
repeated (if necessary) for the next set of four burners within the group. Any burners in which the
corresponding Burner Start Permissive has not be set by the DCS will be excluded from the
Automatic Ignition Sequence.
Failure of a combustion limits during ignition will result in termination of ignition sequence(s). A list
of the combustion limits and a description of the corresponding effect upon the ignition sequences
is as follows:
Manual Emergency Stop All burners are shut-down and the ignition sequences for all burners
are terminated.
Excess Temperature Limit Interlock All burners within the associated control zone are shutdown and all ignition sequences for the burners within that control zone are terminated.
Main Fuel Gas Pressure All burners in which the fuel setting is Gas will be shut-down and their
ignition sequence terminated.
Main Fuel Oil Pressure All burners in which the fuel setting is Oil will be shut-down and their
ignition sequence terminated.
Main Fuel Oil Temperature All burners in which the fuel setting is Oil will be shutdown and
their ignition sequence terminated.
Atomizing Air Low Pressure All burners in which the fuel setting is Oil will be shutdown and
their ignition sequence terminated.
Atomizer Position Any burner in which the Atomizer Position changes during ignition or during
operation will be immediately shut-down and/or the ignition sequence terminated.
The ignition sequence for each burner operates independently once initiated. During the automatic
ignition sequence, failure of a single burner to ignite will not halt the remaining burners from
entering their ignition sequence. A burners ignition sequence begins with the Safety PLC
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energizing the burners pilot gas SSOVs and the burners ignition transformer. The Safety PLC will
set the burners status to Pilot Starting.
The PLC will monitor the status of the burners Combustion Safeguard for a Flame Detected
signal. The trial for ignition period is defined as the time from which the pilot gas SSOV is
energized and a Flame Detected signal is reported by the Combustion Safeguard. The trial for
ignition period is set within the Safety PLC not to exceed 15 seconds. Failure of the Combustion
Safeguard to report a Flame Detected signal within the trial for ignition period will cause the
Safety PLC to remove power from the burners pilot gas SSOVs and ignition transformer,
annunciate an alarm on the HMI and change the burners status to Faulted.
When a Flame Detected is received from the burners Combustion Safeguard (within the trial for
ignition period), the pilot flame will be given time to stabilize. The pilot flame stabilization time is
configurable from the HMI.
Following the pilot flame stabilization time, the Safety PLC will apply power to the burners primary
fuel gas SSOVs (or fuel oil SSOVs depending on the burners fuel selection), given that the fuel
flow control valve is in the At Low Fire Switch position. The Safety PLC will set the burners status
to Main Flame Starting.
The DCS must command the fuel flow control valve to a position such that the Safety PLC receives
contact closure of the valves At Low Fire Switch. The At Low Fire Switch must be maintained
until the Safety PLC has changed the burner status to Released to Control. Failure to maintain
the At Low Fire Switch will result in the Safety PLC shutting down the burner.
After the main fuel gas/oil SSOVs have been opened, the Safety PLC will allow the main burner
flame time to stabilize. The main flame stabilization time is configurable from the HMI. Once the
main flame stabilization time has expired, the Safety PLC will set the burners status to Released
to Control. At this point, the Safety PLC will remove power from the burners pilot gas SSOVs,
thus turning off the pilots.
When the burner has reached the Released to Control state, the DCS can command the
corresponding fuel control valve away from the At Low Fire position and control fuel flow to the
burner as required by the process.
7.5.20 Burner Stop
Burners can be individually stopped via the Remote Push Button Stations, or using the individual
Burner Stop soft-buttons on the HMI. All burners can be stopped using the Stop All Burners
soft-button on the HMI. When the Stop All Burners soft-button is initiated the Fuel GAS SSOVs
on all burners are immediately de-energized (closed) by the Safety PLC and the burners status is
set to Stopped. Burners that are firing in Oil Mode will undergo a Fuel Oil Post-Purge Sequence
before shutting down. The Fuel Oil Post-Purge is necessary to evacuate fuel oil from the burner
and associated piping. Failure to complete a Fuel Oil Post-Purge can result in clogged oil
passages and failure of the burner to be re-lit using fuel oil.
7.5.21 Fuel Oil Post-Purge
Burners that are firing in Oil Mode will undergo a Fuel Oil Post-Purge Sequence after a normal
stop command has been received from the HMI or the DCS. A burner that has been stopped by a
loss of any of the Fuel Limits (outlined within Section 2.2 above) will not undergo a Fuel Oil PostPurge. The Safety PLC will annunciate an alarm on the HMI for any burner in which a required
Fuel Oil Post-Purge was not completed. The Fuel Oil Post-Purge sequence is outlined as follows:
1) The Safety PLC energizes the burners ignition transformer and pilot gas SSOVs.
2) The Safety PLC will set the burners status to Post-Purge Starting.
3) The DCS should begin driving the fuel oil flow control valve to the low-fire position.
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4) The pilot flame is will be given time to stabilize. The post-purge pilot flame stabilization
time is configurable from the HMI.
5) The burners fuel oil SSOVs are de-energized by the Safety PLC.
6) The Safety PLC will set the burners status to Post-Purge Active.
7) The DCS should begin driving the fuel oil flow control valve to the high-fire position.
8) The Safety PLC opens (energizes) the burners fuel oil purge valve. The amount of time
that the fuel oil purge valve is held open is configurable on the HMI.
9) Once the fuel oil purge valve time has expired, the fuel oil purge air valve is closed.
10) The Safety PLC de-energizes the burners pilot gas SSOVs.
11) The burners status is set to Stopped.
8.0
PRODUCT SCREENING AREA 6

Product screen feed bin (B43611) is used to distribute fired product pellets to the product
screens (B43522-1, 2). This separation occurs as pellets pass through the screens. Product
pellets go to the P-12 (B43047) Product Conveyor. Hearth layer chute pellets (12.5 x19mm) go
to HL-12 (B43071) hearth layer conveyor which feeds HL-13, HL-14 to the Hearth Layer Bin
(B54013).
The emergency product vibrating feeder is programmed to operate based on the product
screen feed bin level or the hearth layer bin level. If the product screens are down, the feed to
the screens is stopped by closing the screen feed gates. The emergency gate to feed pellets
to the HL-13 (B43776) is opened. A software switch now allows the emergency product feeder
run at based on hearth layer bin level.
An emergency hearth layer hopper is fed by mobile equipment. The reclaimed material travels
to the Hearth Layer Bin (B54013).
Product pellets on P-12 (B43047) are measured by belt scale (B55221) (WIT-06B0122) and
supply the JSPL Product Conveyor.
Screened Sinter Fines travel to SF-11, SF-12 to the Sinter Fines Loading Bin (B43520). A
sinter fines sampling system (B55402) extracts pellets periodically. The pellets are recovered
in a container and taken to a lab for analysis of physical and chemical properties. A Product
Screening Bag house (B50006) collects tramp dust from screening.
The Product Screening Bag house (B50007) receives dust from the Hearth Layer Separation
pickup points. Process Water is used to slurry the bag house dust into the bag house sump
(B35010). The product screening bag house sump pumps (B41027-1, 2) pump the slurry to the
thickener for Line 1.
9.0
POLLUTION CONTROL- Area 7 (P&ID: R-07-1001, 1002, 1003, 1004 & 1006)
(Inputs received from package vendor THERMAX)
The pellet plant will convert high grade iron ore into heat hardened pellets. The process steps in
the core plant will consist of receiving iron ore, Iron ore wet grinding, preparation of additives,
blending and mixing of raw materials into a pelletizing mix, green pellet formation, heat hardening
of the pellets, and conveying of the final pellet product. Raw materials will include predominantly
iron ore with the following additives: coke/coal, bentonite, organic binder and limestone. Additives
are mixed with the concentrate to facilitate the process and to influence the product quality. The
burner fuel for pelletizing is fuel oil or fuel gas. Coke/coal in the blend of pelletizing feed will supply
about 25% to 45% of the total Indurating fuel to the process.
The plant is designed with electrostatic precipitators (ESPs) to remove particulate from the gas
discharge:
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9.1
Hood Exhaust ESP (B50025)
9.1.1
System Description
This is flue gas cleaning system for cleaning the gases from Hood Exhaust circuit of Pallet plant.
The system consists of ESP model TE-1.
The hot gases having maximum temperature of 105C is allowed to pass through the inlet nozzle.
Gas distribution plates inside the nozzle ensure equal distribution of the gases through different
parallel paths formed by the arrangement of collecting plates and e-Tubes. The collecting area is
divided into four sections. Each section is fed by TR set of 900 mA (Total 4 Nos. for chamber-1 &
4Nos. for chamber-2), mounted on the ESP rooftop. High voltage of 120 KV DC (peak value) is
applied to the e-Tubes. The ash gets collected on the collecting plates.
The collecting plates and e-Tubes are continuously rapped from the top by rappers whose
operation is controlled by PLC based Microtapper panel located in the control room.
Due to rapping, the ash collected on collecting plates is dislodged and collected in the hopper.
The ash is discharged to the dust discharge equipment through hopper.
9.1.2
Control And Interlock Provided For The System

Mechanical door interlock system
The system ensures that no person can enter inside the ESP unless all the Transformer Rectifier
units are de-energised, isolated and grounding switches of TR sets GS-1 to GS-8 (For chamber-1
& chamber-2) are in ESP grounded position.
Thermostatically controlled Insulator Heater
700 W air heater is provided around each support insulator. A thermostat is provided in the pent
house (TC-5 & TC-11) for chamber-1 & chamber-2 to maintain the temperature at 85C.
Thermostatically controlled hopper heaters
Hopper heating pads (HH-1 to HH-8) are provided in bottom one-third part of the hoppers to
avoid condensation & ensure free flow of dust. The heating pads are thermostatically controlled
(TC-1 to TC-4 & TC-7 to TC-10) for chamber-1 & chamber-2. The temperature is maintained upto
110C . Max. (Adjustable).
Level switches in the hopper
R.F. capacitance type level switches (LSH1 to LSH8) for chamber-1 & chamber-2 is provided in
each hopper. The level switch operates when ash level inside the hopper rises & touches the
level switch probe. The first set point level switch gives signal to the audio visual alarm
annunciator provided in the Motor Control Center to indicate high ash level in the hopper & trips
the TR Set. Even after tripping of TR Set, an ash continues to build up in Hopper, and If the high
level alarm is persisting, an Auxiliary Contact High hopper level relay provided in MCC. it is
recommended to stop the Furnace after one hour time delay. This prevents ash building up in the
hoppers, which ultimately shorts the e-Tubes & collecting plates. Potential free contacts shall be
provided in ACP to wire the same for Furnace tripping / stopping & signal to DCS.
9.1.3
Purge Air Blower

Purge air blower ensures positive air pressure inside the pent house with respect to ESP casing.
The air flows along the inside surface of the support insulators thereby keeping the insulators
clean. All the TR sets are wired for tripping in case the Purge Air Blower Trips.
Start Sequence
Purge air blower ON
Then purge air heater will be started (start interlock of PAB with PAH)
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Stop Sequence
Purge air heater OFF
If the heater is OFF, then the blower will be switched off after a time delay of 5 sec approximately.
Purge Air heater
Thermostat (TC-6 & TC-12) is provided in the purge air heater to protect the purge
air heating elements from over temperature
9.1.4
MTP (Micro Tapper Panel)

Rapper control system is designed specifically for electrostatic precipitator application. This
rapper control system is designed to be use with electrical solenoid type impact Rappers. These
Rappers are also called as Thermax impulse gravity impact (TIGI) Rappers.
Rapping system is an ONLINEoperation (i.e. Rappers can be turned ON, when TR sets are
energised.)
The working principle of the rapping system is as follows:
A short duration pulse of high current amplitude is applied to the rapper solenoid coil.
Once the coil is energized the rapper rod inside the coil lifts up. The longer the duration of the
pulse the higher is the lift. On withdrawal of pulse the rapper rod falls down by gravity. The falling
rod makes impact with the e-Tube/collecting electrodes causing the dust accumulated on it to
dislodge and maintain their electric field.
The rapper coils are energised by MTP through a DC controller individually. The DC controller
provides a high current & high voltage pulse of short duration.
The +Ve & -Ve ends of the dc controller get connected across each rappers thus selected rapper
coil is energized and makes impact on the respective electrode.
Rapping system shall be put ON all the time when ID Fan is running irrespective of ESP is
charged or not.
9.1.5
Dust conveying system

Dust conveying system shall be ON (Running) all the time. If dust conveying system tripped /
stopped, then all TR sets & all dust discharge equipment shall be trip.
Dust discharge equipment
If the dust discharging equipment stopped/tripped, then corresponding TR set shall be trip.
I.D. Fan interlock
If ash discharge equipment stopped or tripped, then ID fan to be stopped or tripped & signal to
Main Automation System to be provided. Provision has to be made for this interlock in Main
Automation System.
9.1.6
Theory Of Operation
ESP construction & operation is based on the fact that dust particles are passed between a highly
charged & grounded electrode. The particles get collected on the grounded electrode.
Accordingly, the Thermax ESP is designed to:
a) Apply a highly negative charge to gas-borne dust particles.
b) Collect the particles on grounded metal plates, which are rapped periodically to dislodge
the dust into hoppers.
The particles are charged by rows of vertical high-voltage electrodes mounted in parallel frames.
The frames are connected at the top to the negative terminal of a high-voltage DC power supply.
The collecting plates (grounded electrodes) are parallel to the rows of e-Tubes & alternate with
them i.e., plate, e-Tube frame; plate, e-Tube frame.
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In operation, the high potential between the negative & grounded electrodes ionizes the
surrounding gas & produces a large number of negative ions. (This is known as corona effect.)
These negative ions collide with the dust particles & impact their negative charges to them. The
negatively charged particles then are drawn to the grounded collecting plates, from which they
are periodically dislodged by means of a rapping mechanism.
9.1.6
Voltage Control
As the dust laden flue gas passes through the collecting electrodes and e-Tube, the ESP can be
considered as a capacitance having variable di-electric strength. The di-electric strength varies
due to changing parameters of the flue gases.
The high D.C. voltage applied to the ESP has to be continuously adjusted to minimize sparking
across the e-Tubes and collecting plates. The voltage controller provided in the Transformer
Rectifier control cabinet senses the current feedback from the ESP and does the following
functions.
i) It maintains the voltage across the ESP at the spark threshold level in all the conditions to
achieve maximum efficiency.
ii)
During no sparking conditions, maximum power is made available across the ESP.
iii) In case of spark, it brings down the voltage by preset value. The voltage is gradually raised to
spark threshold level if no further spark is detected.
iv) In case of arc it brings down the voltage to zero and blocks it for preset time. The voltage is
restored to the preset value by fast ramp and then to the spark threshold level by slow ramp.
9.1.7
ESP Start Up Procedure

Energise hopper heaters, insulator heaters & Purge air heaters twelve hours prior to flue gas
passing through the precipitator from Motor Control Center.
Start the dust discharge equipment below the Hopper.
About one hour before the Furnace is fired, energize the e-Tube and collecting electrode
rapper through the Microtapper Panel.
Start the Purge air blower from MCC. If purge air system is not working trip TR sets.
Ensure all the level switches are switched ON and no annunciation is persisting on the MCC.
Ensure that the Furnace and ID fans are running and flue gas temperature is above the acid
dew point temperature. If the flue gas temperature is less than the acid dew point temperature
then damp acid sludge will form on the precipitator internals, and scaling will take place. This
will reduce the life of e-Tubes and collecting electrodes. If dust conveying system or dust
discharge equipment trips / fail, then trip I.D. Fan
After the flue gas temperature reaches above the acid dew point temperature the TR units
should be energized. Ensure that TRCC panels are in Auto mode before switching on.
After all the TR sets are energized the electrical meter readings should be observed.
9.1.8
Precipitator Shutdown
During normal Furnace shutdown the TR sets should be de-energized before I.D. fan is switched
off.
After all the TR sets are de-energized the e-Tube and collecting electrode rappers should be
maintained in service for approx. two hours.
Switch ÒFF purge air blower after I.D. Fan is switched ÒFF & TR sets are de-energized.
Dust discharge equipment should be in service for one hour after Microtapper panel is stopped.
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9.1.9
Caution
a) It is a must that initially, after shutdown of Furnace or initial charging, the ID fan should be run
for at least one hour, to remove explosive gases, if any in ESP, before Switching ON the TR
sets.
b) It is a must that dust discharge equipment below ESP hopper must be running whenever I.D.
fan is running. It is always to be ensured that there is no dust accumulation whatsoever in the
hoppers. The dust accumulation in the hopper may damage the ESP internals.
c) ESP hopper door to be opened, only after I.D. fan is stopped. This is necessary to avoid
sudden ingress of fresh air in the hopper which contains dust with high carbon content.
d) Dust discharge equipment shall be running all the time.
e) Rapping system shall be ON (running) all the time when ID fan is running irrespective of ESP
is charged or not.
f)
Purge air system is not running then trip the TR sets.
9.1.10 Process Interlock

Provision of upstream & downstream process / equipment interlock has been provided in the
TRCC panel for tripping purpose. Generally such interlocks are process related & JSPL has to
identify for tripping of TRCC in case of unhealthy condition.
9.1.11 Alarms
Following alarms will be provided on Motor Control Centre:
High ash level in the hoppers (for chamber-1).
Purge air blower tripped (for chamber-1).
Purge air blower tripped (for chamber-2)
Spare.
Spare.
9.1.13 Transformer-Rectifier control panel

(Note: The following alarms will be indicated on the TRCC controller LCD display)
Transformer oil temperature high alarm.
Transformer oil temperature high trip.
Transformer Buchlotz relay alarm.
Transformer Buchlotz relay trip.
SCR temperature high trip.
Over voltage trip.
Under voltage trip.
Thermal overload trip.
9.1.14 Following indications will be provided on Motor Control Centre
Incomer feeder: R, Y, B phase indicating lamp.
Breaker ON, OFF & TRIP
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T/R set feeders : Supply ON & OFF Lamp.
Microtapper panel feeder : Supply ON & Off lamp.
Hopper heater 1 to 8 : On, Off & Temp. trip lamp.
Insulator heater 1 & 2 : On, Off & Temp. trip lamp.
Control transformer feeder : Control supply ON lamp.
Purge air blower feeder 1 & 2 : On, Off & over-load trip lamp.
Purge Air heater feeder 1 & 2 : Oc, Off & Temp. trip lamp.
Annunciator + Level switch feeder : Level high lamp for each level switch.
9.1.15 Transformer Rectifier Control Panel
Mains on lamp.
HT on lamp.
Alarm / Trip lamp.
9.1.16 Microtapper Panel
Mains ON
Rapper ON
Rapper Fault
HMI Disply - 1) Rapper short circuit
Rapper open circuit
Rapper Fault Indication
9.2
Wind box Exhaust ESP (B50026)
9.2.1
System Description
This is flue gas cleaning system for cleaning the gases from Wind Box circuit of Pallet plant.
The system consists of ESP model TE-1.
The hot gases having max. Temperature of 111C is allowed to pass through the inlet nozzle.
Gas distribution plates inside the nozzle ensure equal distribution of the gases through different
parallel paths formed by the arrangement of collecting plates and e-Tubes. The collecting area is
divided into four sections. Each section is fed by TR set of 1300 mA (Total 4 Nos. for chamber-1
& 4Nos. for chamber-2), mounted on the ESP rooftop. High voltage of 120 KV DC (peak value) is
applied to the e-Tubes. The ash gets collected on the collecting plates.
The collecting plates and e-Tubes are continuously rapped from the top by rappers whose
operation is controlled by PLC based Microtapper panel located in the control room.
Due to rapping, the ash collected on collecting plates is dislodged and collected in the hopper.
The ash is discharged to the dust discharge equipment through hopper.
9.2.1
Control And Interlock Provided For The System
9.2.1.1 Mechanical door interlock system

The system ensures that no person can enter inside the ESP unless all the Transformer Rectifier
units are de-energised, isolated and grounding switches of TR sets GS-1 to GS-8 (For chamber-1
& chamber-2) are in ESP grounded position.
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9.2.1.2 Thermostatically controlled Insulator Heater

700 W air heater is provided around each support insulator. A thermostat is provided in the pent
house (TC-9 & TC-19) for chamber-1 & chamber-2 to maintain the temperature at 85C.
9.2.1.3 Thermostatically controlled hopper heaters
Hopper heating pads (HH-1 to HH-8 & HH-9 to HH-16) are provided in bottom one-third part of
the hoppers to avoid condensation & ensure free flow of dust. The heating pads are
thermostatically controlled (TC-1 to TC-8 & TC-11 to TC-18) for chamber-1 & chamber-2. The
temperature is maintained up to 110C. Max. (Adjustable).
9.2.1.4 Level switches in the hopper
R.F. capacitance type level switches (LSH1 to LSH16) for chamber-1 & chamber-2 is provided in
each hopper. The level switch operates when ash level inside the hopper rises & touches the
level switch probe. The first set point level switch gives signal to the audio visual alarm
annunciator provided in the Motor Control Center to indicate high ash level in the hopper & trips
the TR Set. Even after tripping of TR Set, an ash continues to build up in Hopper, and If the high
level alarm is persisting, an Auxiliary Contact High hopper level relay provided in MCC. it is
recommended to stop the Furnace after one hour time delay. This prevents ash building up in the
hoppers, which ultimately shorts the e-Tubes & collecting plates. Potential free contacts shall be
provided in ACP to wire the same for Furnace tripping / stopping & signal to DCS.
9.2.1.5 Purge Air Blower
Purge air blower ensures positive air pressure inside the pent house with respect to ESP casing.
The air flows along the inside surface of the support insulators thereby keeping the insulators
clean. All the TR sets are wired for tripping in case the Purge Air Blower Trips.
Start Sequence:
Purge air blower ON
Then purge air heater will be started (start interlock of PAB with PAH)
Stop Sequence:
Purge air heater OFF
If the heater is OFF, then the blower will be switched off after a time delay of 5 sec approximately.
9.2.1.6 Purge Air heater
Thermostat (TC-10 & TC-20) is provided in the purge air heater to protect the purge air heating
elements from over temperature.
9.2.1.7 MTP (Micro Tapper Panel)
Rapper control system is designed specifically for electrostatic precipitator application. This
rapper control system is designed to be use with electrical solenoid type impact Rappers. These
Rappers are also called as Thermax impulse gravity impact (TIGI) Rappers.
Rapping system is an ONLINEoperation (i.e. Rappers can be turned ON, when TR sets are
energised.)
The working principle of the rapping system is as follows:
A short duration pulse of high current amplitude is applied to the rapper solenoid coil.
Once the coil is energized the rapper rod inside the coil lifts up. The longer the duration of the
pulse the higher is the lift. On withdrawal of pulse the rapper rod falls down by gravity. The falling
rod makes impact with the e-Tube/collecting electrodes causing the dust accumulated on it to
dislodge and maintain their electric field.
The rapper coils are energised by MTP through a DC controller individually. The DC controller
provides a high current & high voltage pulse of short duration.
The +Ve & -Ve ends of the dc controller gets connected across each rappers thus selected
rapper coil is energized and makes impact on the respective electrode.
Rapping system shall be put ON all the time when ID Fan is running irrespective of ESP is
charged or not.
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9.2.1.8 Dust conveying system

Dust conveying system shall be ON (Running) all the time. If dust conveying system tripped /
stopped, then all TR sets & all dust discharge equipments shall be trip.
9.2.1.9 Dust discharge equipment
If the dust discharging equipment stopped/tripped, then corresponding TR set shall be trip.
9.2.1.10
I.D. Fan interlock
If ash discharge equipment stopped or tripped, then ID fan to be stopped or tripped & signal to
DCS to be provided. Provision has to be made for this interlock in Main Automation System.
9.2.2
Theory Of Operation
ESP construction & operation is based on the fact that dust particles are passed between a highly
charged & grounded electrode. The particles get collected on the grounded electrode.
Accordingly, the Thermax ESP is designed to:
Apply a highly negative charge to gas-borne dust particles.
Collect the particles on grounded metal plates, which are rapped periodically to dislodge the dust
into hoppers.
The particles are charged by rows of vertical high-voltage electrodes mounted in parallel frames.
The frames are connected at the top to the negative terminal of a high-voltage DC power supply.
The collecting plates (grounded electrodes) are parallel to the rows of e-Tubes & alternate with
them -- i.e., plate, e-Tube frame; plate, e-Tube frame.
In operation, the high potential between the negative & grounded electrodes ionizes the
surrounding gas & produces a large number of negative ions. (This is known as corona effect.)
These negative ions collide with the dust particles & impact their negative charges to them. The
negatively charged particles then are drawn to the grounded collecting plates, from which they
are periodically dislodged by means of a rapping mechanism
9.2.3
Voltage Control
As the dust laden flue gas passes through the collecting electrodes and e-Tube, the ESP can be
considered as a capacitance having variable di-electric strength. The di-electric strength varies
due to changing parameters of the flue gases.
The high D.C. voltage applied to the ESP has to be continuously adjusted to minimize sparking
across the e-Tubes and collecting plates. The voltage controller provided in the Transformer
Rectifier control cabinet senses the current feedback from the ESP and does the following
functions.
It maintains the voltage across the ESP at the spark threshold level in all the conditions to
achieve maximum efficiency.
During no sparking conditions, maximum power is made available across the ESP.
In case of spark, it brings down the voltage by preset value. The voltage is gradually raised to
spark threshold level if no further spark is detected.
IV. In case of arc it brings down the voltage to zero and blocks it for preset time. The voltage is
restored to the preset value by fast ramp and then to the spark threshold level by slows ramp.
9.2.4
ESP Start Up Procedure

Energise hopper heaters, insulator heaters & Purge air heaters twelve hours prior to flue gas
passing through the precipitator from Motor Control Center.
Start the dust discharge equipment below the Hopper.
About one hour before the Furnace is fired, energize the e-Tube and collecting electrode
rapper through the Microtapper Panel.
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Start the Purge air blower from MCC. If purge air system is not working trip TR sets.
Ensure all the level switches are switched ON and no annunciation is persisting on the MCC.
Ensure that the Furnace and ID fans are running and flue gas temperature is above the acid
dew point temperature. If the flue gas temperature is less than the acid dew point temperature
then damp acid sludge will form on the precipitator internals, and scaling will take place. This
will reduce the life of e-Tubes and collecting electrodes. If dust conveying system or dust
discharge equipment trips / fail, then trip I.D. Fan
After the flue gas temperature reaches above the acid dew point temperature the TR units
should be energized. Ensure that TRCC panels are in Auto mode before switching on. After all
the TR sets are energized the electrical meter readings should be observe
9.2.5
Precipitator Shutdown
During normal Furnace shutdown the TR sets should be de energized before I.D. fan is switched
off.
After all the TR sets are de-energized the e-Tube and collecting electrode rappers should be
maintained in service for approx. two hours.
Switch ÒFF purge air blower after I.D. Fan is switched ÒFF & TR sets are de-energized
Dust discharge equipment should be in service for one hour after Microtapper panel is stopped.
9.2.6
Caution
It is a must that initially, after shutdown of Furnace or initial charging, the ID fan should be run for
at least one hour, to remove explosive gases, if any in ESP, before Switching ON the TR sets.
It is musts that dust discharge equipment below ESP hopper must be running whenever I.D. fan
is running. It is always to be ensured that there is no dust accumulation whatsoever in the
hoppers. The dust accumulation in the hopper may damage the ESP internals.
ESP hopper door to be opened, only after I.D. fan is stopped. This is necessary to avoid sudden
ingress of fresh air is the hopper which contains dust with high carbon content.
Dust discharge equipment shall be running all the time.
Rapping system shall be ON (running) all the time when ID fan is running irrespective of ESP is
charged or not.
Purge air system is not running then trip the TR sets.
9.2.7
Process Interlock
Provision of upstream & downstream process / equipment interlock has been provided in the
TRCC panel for tripping purpose. Generally such interlocks are process related & JSPL has to
identify for tripping of TRCC in case of unhealthy condition.
9.2.8
Alarms
Following alarms will be provided on Motor Control Centre:
Purge air blower tripped (for chamber-1).
Purge air blower tripped (for chamber-2)
Spare.
Spare.
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9.2.9
Transformer-Rectifier control panel

(Note: The following alarms will be indicated on the TRCC controller LCD display)
Transformer oil temperature high alarm.
Transformer oil temperature high trip.
Transformer Buchlotz relay alarm.
Transformer Buchlotz relay trip.
SCR temperature high trip.
Over voltage trip.
Under voltage trip.
Thermal overload trip.
9.2.10 Following indications will be provided on Motor Control Centre
Incomer feeder : R, Y, B phase indicating lamp.
Breaker ON, OFF & TRIP
T/R set feeders : Supply ON, Off Lamp.
Microtapper panel feeder : Supply ON, Off lamp.
Hopper heater 1 to 16 : On, Off & Temp. trip lamp.
Insulator heater 1 & 2 : On, Off & Temp. trip lamp.
Control transformer feeder : Control supply ON lamp.
Purge air blower feeder 1 & 2 : On, Off & over-load trip lamp.
Purge Air heater feeder 1 & 2 : On, Off & Temp. trip lamp.
Annunciator + Level switch feeder : Level high lamp for each level switch.
9.2.11 Transformer Rectifier Control Panel
Mains on lamp.
HT on lamp.
Alarm / Trip lamp.
9.2.12 Microtapper Panel
9.3
Mains ON
Rapper ON
Rapper Fault
HMI Disply - 1) Rapper short circuit
Rapper open circuit
Rapper Fault Indication
Slurry sump pumps discharge to the plant thickener.
LIT-1022 monitors the level of Hood Exhaust ESP Sump and for low sump level, process water is
mixed into the sump which is controlled by LV-1022 (Loop No: LIC-1022, P&ID No. R-05-1010).
Low low level of the sump will stop the Hood Exhaust sump pumps.
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9.4
LIT-3022 monitors the level of Windbox Exhaust ESP Sump and for low sump level, process water
is mixed into the sump which is controlled by LV-3022 (Loop No: LIC-3022, P&ID No. R-05-1011).
Low low level of the sump will stop the Windbox Exhaust sump pumps.
Housekeeping scrubbers and a baghouse are used to collect fugitive dust:
9.5
Scrubbers
9.5.1
Machine Discharge Scrubber (B50005)

This scrubber includes a Machine Discharge Scrubber Fan, and local water sprays. The water
valve (XV-07B6262) will open any time that the scrubber is in operation.
LIT-6206 monitors the level of Machine Discharge Scrubber Sump and for low sump level, process
water is mixed into the sump which is controlled by LV-6206 (Loop No: LIC-6206, P&ID No. R-071002). Low low level of the sump will stop the Machine Discharge Scrubber sump pumps.
9.5.2
Hearth Layer Bin Scrubber (B50007)

This scrubber includes Hearth Layer Exhaust Fan, and local water sprays. The water valve (XV07B7262) will open any time that the scrubber is in operation.
Similar to the ESPs, the wet discharge from these scrubbers is collected in sumps and pumped to
the plant thickener. The baghouse dust is slurried and pumped to the thickener.
9.5.3
Product Screening Baghouse (B50006) includes a fan (B50006A) and dust handling valves (XV2626- 2627).
The dust from product screening baghouse is collected in a sump. LIT-2017 monitors the level of
Product Screening Baghouse Sump and for low sump level, process water is mixed into the sump
which is controlled by LV-2017 (Loop No: LIC-2017, P&ID No. R-07-1004). Low low level of the
sump will stop the Product Screening Baghouse sump pumps.
9.5.4
LIT-5363 monitors the level of Indurating Transfer Sump and for low sump level, process water is
mixed into the sump which is controlled by LV-5363 (Loop No: LIC-5363, P&ID No. R-07-1008).
Low low level of the sump will stop the pumps.
9.5.5
Gaseous Emissions
Products of combustion are discharged from the indurating waste gas stack. The indurating waste
gas stack will also contain CO2 (carbon dioxide) resulting from the calcination of carbonates in the
additives or the ore and SOx (sulfur dioxide) from combustion of the sulfur-containing compounds
in the fuel. Other compounds in the flue gases will include low concentration nitrous oxides, carbon
monoxide, and volatile organic compounds, as well as carbon dioxide, water vapor, nitrogen, and
oxygen. Jacobs scope of the project does not include any abatement systems for gaseous
emissions. Restrictions on the level of sulfur in the fuel and the height of the exhaust stacks must
be determined after performing atmospheric dispersion modeling.
The dispersion modeling is also not included in Jacobs scope.
10.0
UTILITIES AREA 8
10.1
Fuel Oil
Fuel Oil is unloaded by JSPL to the existing Fuel Oil Storage Tanks #1 and #2. New fuel oil
expansion tanks (B35601) shall supply fuel oil to the indurating fuel oil circulation pumps (B410021, 2).
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Each set of pumps are one operating and one stand by. Each circulation loop provides heater
controls (B48002-1, 2 & 3) for pumps (B41002-1, 2). Oil heaters heat oil to 125 degrees C and
decrease oil viscosity to meet burner atomizing requirements.
Primary pressure control for indurating machine circulating pumps (B41002-1, 2) is be
accomplished utilizing primary pressure loop (Loop No: PIC-0234, P&ID: R-08-1002) with a
secondary pressure loop (Loop No: PIC-0246, P&ID: R-08-1002).
Oil Supply to the Indurating furnace and Additive Grinders, is from the fuel oil tanks. Oil
composition is given below:
Fuel Oil Properties
Table 6.4.1
Furnace Oil, MV2
Composition, wt.%
Fuel Oil Composition

Carbon
Hydrogen
Oxygen
84
11
0.5
Table 6.4.2
Characteristics
Inorganic acidity
Ash, % wt. Max
Gross Calorific Value, cal/gm
Density at 15C
Flash Point C. Min
Kinematic Viscosity, centistokes @ 50C
Sediment, % wt , Max
Sulfur, total % wt. Max
Water content, % v/v, Max
Pour Point, C, Max
10.2
Nitrogen
0.4
Sulfur
3.5
Water
0.5
Ash
0.1
Fuel Oil Properties

Grade MV2 Requirements
Nil
0.1
10,000
Assume 0.95
66
125 - 180
0.25
4.0
1.0
27
Compressed Air
Compressed Plant air for general pellet plant use is supplied at 7.0 kg/cm2. Plant Air is dried in
Refrigerant Dryers (B52404-1,2) to 5 degree C.
Dry, oil-free instrument air will also be supplied at a pressure of 9.0 kg/cm2 by a dedicated
instrument air compressor and receiver system. The air is treated and dried at the Instrument Air
Dryers (B47051-1, 2) to -40 degree C.
10.3
Make-up Water is provided by JSPL to the Thickener Overflow Sump.
10.4
Standby Power is provided by the standby generator.
10.5
Process Water Supply

Process water to users is from the Process Water Pumps at the Thickener Overflow.
The Process Water Pumps have two pumps operating and one pump as backup. The plant water
balance is maintained by either makeup, or blowdown to battery limits, from the Thickener
Overflow Sump.
10.6
Soft Water Supply

Soft water at 3.5 kg/cm2 is supplied by JSPL for miscellaneous users such as lintel cooling
makeup water.
10.7
Gland Seal Water
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Pumps in the plant that handle heavy iron ore slurries have flushed mechanical seals. Seal water
supply system for wet grinding includes a Gland Seal Water Tank (B34031) and pumps (B41034-1,
2) producing water at 7.0 kg/cm2 or pressure determined by the supplier. Seal water supply
system for other areas includes a Gland Seal Water Tank (B34030) and pumps (B41033-1, 2).
The flow of process water to seal water tank is controlled by a level control valve LV-2306 (Loop
No: LIC-2306, P&ID: R-01-1022)
10.8
Potable water for plant offices and associated areas is supplied by JSPL.
Fire protection water is supplied from JSPLs fire water supply system. A separate header system
from the fire water supply is provided depending on the approval of local regulatory agencies.
Normal fire water loop pressure is 7.0 kg/cm2.
10.9
Fuel Gas
Gas is available to the burners. The burner system is selected for use on fuel oil or fuel gas but not
both at the same time. Safety shutoff valves are connected to the appropriate burner management
system. Fuel gas is for use only with the Indurating System.
FUEL GAS PROPERTIES (To be confirmed by JSPL)
Table 6.4.3
FUEL GAS PROPERTIES
Compound
CO
CO2
Unit
% Volume
% Volume
Value
25
6
H2
% Volume
13
CH4
% Volume
1.5
N2
% Volume
53
C2H
% Volume
% Volume
0
0.6
O2
H2S
% Volume
0.2
H2O Max
Dust
Pressure
% Volume
mg/Nm3
2
kg/cm
Temperature
Heating Value
C
3
kcal/Nm
5
5
0.97 minimum at burner
valve stand
50 Maximum
1350 minimum
Fuel gas pressure and cleanup are by JSPL.

3
The fuel gas will initially be at a lower CV value (1350 kcal/Nm ), with future Cv value (2250
3)
kcal/Nm .
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10.10
Cooling Water
10.10.1 Area-1
Wet Grinding Cooling Water is supplied by cooling water pumps (B41060). The cooling water
return goes to a cooling tower. Makeup water is supplied by JSPL. Make up water supply is
controlled by a control valve LV2106 at the inlet of cooling tower basin based on cooling tower
basin level (Loop No: LIC - 2106, P&ID: R-01-1021).
Soft water make up to wet grinding cooling water surge tank (B35103) is controlled by a control
valve LV0901 at the inlet of surge tank based on surge tank level (Loop No: LIC - 0901, P&ID: R01-1028).
10.10.2 Area-2 to 8
Cooling Water is supplied by cooling water pumps. The cooling water return goes to a cooling
tower. Makeup water is supplied by JSPL. Make up water supply is controlled by a control valve
LV0801 at the inlet of cooling tower basin based on cooling tower basin level (Loop No: LIC - 0801,
P&ID: R-08-1008).
Soft water make up to Service cooling water surge tank (B35102) is controlled by a control valve
LV0891 at the inlet of surge tank based on surge tank level (Loop No: LIC - 0891, P&ID: R-011009).
A closed loop system for service water is used in area 1 as well as in area 2 to 8.
11.0
CONTROL SYSTEM OVERVIEW & PHILOSOPHY
11.1
The control system shall consist of a distributed control system (Main Automation System) which
interfaces with analog and discrete field signals. It is referred to generically as a Main Automation
System but may in fact also incorporate and/or interface one or more programmable logic
controller (PLC) systems for discrete logic functions and control of third party equipment.
There is a link from the Main Automation System to each MCC for motor control.
11.1.1 The control system shall be programmed to monitor and/or control all equipment associated with
the pelletizing plant, from the Main Automation System Human Machine Interface (HMI) or local
control stations.
11.1.2 Vendor packages are interfaced to the Main Automation System.
11.2
Control System Configuration
11.2.1 The process control and automation for the pellet plant, feed preparation and product loadout
areas is a Main Automation System. The operator functions at each HMI station will include alarm
handling and controller manipulation, i.e. set point change and manual control.
11.2.2 Printed documents available at operator command will include operating reports and alarm logs.
The format of the reports is configurable and set during design configuration of the Main
Automation System. Alarm reporting prints out a list of the alarms, including the date and time of
the alarm, the alarm description, the time the alarm was acknowledged and the time at which the
alarm cleared. A printout of the controller configurations and copies of the process screens can be
made via the color graphics printer. HMI is in SI units of measure.
11.2.3 Analog inputs into the Main Automation System are provided by field instrumentation, including
smart transmitters for relaying flow, pressure and temperature signals from the process.
Alternately, devices like motor control centers, weigh systems, bin level systems, third-party control
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systems and variable speed drives have the capability to communicate directly to the plant control
system, minimizing wiring and facilitating startup. Wherever possible, OPC can be used to reduce
CPU loading of Main Automation System.
11.2.4 Control Room and Process Control
The process control and automation for the pellet plant and feed preparation areas are a combined
system, placed into a central control room. Programmable logic controllers (PLCs) for motor
control will be integrated with a distributed control system (Main Automation System) for process
control and human/machine interface (HMI).
The central control room is located in the same building as the indurating area office facilities.
11.3
CONTROL PHILOSOPHY
11.3.1 The control philosophy follows the control philosophy of existing Plant 1.
11.3.2 Screens showing interlocks and permissives should be provided for equipment as required to allow
the operator to troubleshoot items not satisfied.
11.3.3 Main Automation System setpoints are switched from internal to external operation as needed.
When an external setpoint is entered, the system will ignore the value calculated by the control
algorithm. These modes can be referred to as CALCULATED SP and OPERATOR SP. Transfer
between modes should be bumpless.
11.3.4 Motors, Drives and Valves
The motor control philosophy is based on the referenced motor control schematics, R-00-1003
through R-00-1007. For LT motors run command will be single maintained output but for HT
motors run command will be a pulse only.
A switch at the motor shall be able to select remote, which enables the Main Automation System
software to operate the motor, or local which enables the motor to be started in the field by a
pushbutton. Local/Remote selector switch to be provided. Off position is not envisaged.
On a stoppage due to a motor fault, the equipment must be put into HMI manual and stop selected
to clear the fault before a restart can be initiated. (Reset PB is generally provided on the motor
faceplate to reset faults)
The local start button, when permitted, shall run the motor. In case of communication failure, start
is inhibited.
Safety regulations require that any emergency stop button, safety pull-rope, or other similar device
will be hardwired directly to the motor control center (MCC) circuit, so as to be able to stop the
drive regardless of the operating conditions or mode.
The starter shall report back to the MAIN AUTOMATION SYSTEM the motor status available via
software communications.
More complex drives may report back additional status data as required.
Drawings R-00-1003 through R-00-1007 detail the various types of motor control. MAIN
AUTOMATION SYSTEM software shall include all functionality described for the various motor
types.
The HMI screen shall display one or more of the following operators for individual motors:
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Auto/Off/Man switch; auto signifies automatic mode and when selected the motor responds to
logical commands to run or starts as part of a group-start; man indicates manual mode and the
motor can be controlled by the individual HMI pushbuttons
When a group of drives have been group-started in auto, turning any particular drive in that group
to man will not stop that drive, but will only give the operator access to stop or restart that drive
individually.
However, if that drive is interlocked with other drives (usually to prevent the upstream equipment
from continuing to feed the stopped item), the interlock will still be active, and stop the other
equipment upstream.
When in auto, there are two ways to stop a group of drives (usually conveyors). Either or both of
these stopping modes can be programmed, depending on the situation. Programmed stop, used
to shut down a group of material feeding equipment in an orderly fashion and leaving it empty.
In this mode, group stop will first shut down the feed to the first item in the group; then wait until
the next item runs empty, and stop it; and so on down the line until the entire group is stopped and
left empty. Immediate stop, used to instantly stop material delivery from the group. In this mode,
group stop will stop all the items in the group simultaneously, but leaving the conveyors in the
group full of material.
In this case, the next group start will restart all the items right away (or as quickly as starting
power loading will allow). This mode must be selected with care, being sure that all the material
handling items in the group are able to restart under full load. Immediate stop can be operated but
immediate start mode is not recommended except for emergency.
Start/Stop Main Automation System pushbuttons or their graphic equivalent, are used to operate
the motor in the MAIN AUTOMATION SYSTEM-man mode.
11.3.5 Automated On-Off Valves
In general, all automated on-off control valves are shown schematically on the HMI screens and
except where explicitly noted will bring up a display when selected allowing the operator to
manually control the valve position. Generally manual control bypasses any interlocks.
If feedback from position switches is available, the valve position is indicated on the graphic based
on switch status. A valve position fault should be generated if the valve does not respond in a
reasonable time to a command to move or loses position feedback.
If position feedback is not available, the valve graphic will change status based solely on the output
logic state.
Some valves require a single output while others will have two outputs. Some valves will require
an energized output to open, some de-energized. The specific logic blocks for each type of valve
should be developed and applied consistently.
Regardless of the logic required to operate a valve, the HMI graphic convention and functionality
should be consistent throughout all screens.
When AUTO mode is selected the valve responds only to control system logic. In cases where the
logic latches the valve in position and an action is required by the operator to reset it, placing the
valve in MANUAL and selecting close or open can be one way to provide the logic reset.
The above sections also apply to shutoff dampers, gates, and vent doors controlled by the MAIN
AUTOMATION SYSTEM.
11.4
Process Pumps
11.4.1 These are pumps which handle slurry or process water in the system, not sump pumps.
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11.4.1.1
All process pumps have the following logical attributes:
Pumps are normally started from the HMI screen manually as required; unless otherwise indicated
below, pumps are not part of equipment starting groups, but are started individually ahead of time
as required, and normally left on.
After the pump is started from the MAIN AUTOMATION SYSTEM; and after a time delay, if the
drive feedback indicates that the pump has been stopped other than by the operator, a drive fault
alarm sounds.
On a stoppage due to a drive fault, the equipment must be put into HMI manual and stop selected
to clear the fault before a restart can be initiated. If the vessel, which feeds the pump, reaches lowlow level (below the point where the low-level alarm sounds), the pump will shut down (or can not
be started).
High-high level from the vessel being pumped into is not an interlock to the pumps. The high-level
alarm in that vessel only warns the operator of this impending possibility. Exceptions to this
strategy are noted on the P&IDs.
The accumulated run time for all process and lube pumps shall be recorded in the MAIN
AUTOMATION SYSTEM (and be able to be displayed), so that the operator, if he has a choice, (or
the MAIN AUTOMATION SYSTEM logic, if able to make the choice) can start the one in any group
with the least service, or periodically change over to evenly distribute the wear.
The total accumulated time can be reset at the MAIN AUTOMATION SYSTEM screen.
11.4.2 Process Pump Pairs with Automatic Backup Starts
All process pumps in groups of two (one normally operating and one standby), which pump clear
water or other non-settling process fluid will have the non-running, backup pump try to start
automatically if the initially started pump has a drive fault alarm as described above and the pump
is selected for MAIN AUTOMATION SYSTEM AUTO.
Normally both such pumps will be valved open, and non-return valves provided so that no backflow
through the standby pump can occur.
See Drawing R-00-1005 Detail 4 for Process Pumps with Automatic Backup.
11.4.3 Process Pump Pairs with Manual Backup Starts
All process slurry pumps in groups of two (one normally operating and one standby), will have the
non-running, backup pump started manually by the operator on receipt of a fault alarm.
Slurry pump pairs require manual flushing. When a switchover occurs, the operator must promptly
attend to the valving and flushing before the slurry remaining in the stopped pump settles out.
11.4.4 Oil and Lube Pumps
See Drawing R-00-1005 Detail 4 for Lube Pumps with Automatic Backup.
11.4.5 Reciprocating Conveyor Control
The reciprocating conveyor and wide belt conveyor are supplied by METSO. The components
consist of a hydraulic power unit, reciprocating conveyor with dual hydraulic cylinders, and wide
belt (B43036). The system includes a local control panel used to perform maintenance as well as
speed control.
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Included with the reciprocating conveyor are both a hydraulic pump and hydraulic flushing motor
drives.
Control signals from the Main Automation System include;
Interlock-(Permit to run)
Reciprocating Run Command
Position the Cylinders Output
Cooling Fan Run
Heater Run
Status Inputs to the Main Automation System include:
Flush Pump Filter OK
Cooling Water Filter OK
Main Pump Filter OK
Local Maintenance Inputs to Main Automation System from JSPL Local Panel include;
Cylinder Forward
Cylinder Reverse
Cylinder Stop
Wide Belt Run, Stop
Pumps Start, Stop
Remote, Maintenance Switch
Reciprocating Conveyor Start, Stop
Cylinder Speed Setting (4-20 mA)
Wide Belt Speed Setting (4-20 mA)
Reciprocating Conveyor Speed Setting (4-20 mA)
Start Sequence:
Start Double Deck Roller Screen (B43037E, B43037F)
Start Wide Belt ( Machine is Running )
Active Horn 5 seconds
Start Hydraulic Pumps
Start Reciprocating Belt and prove at desired speed
Start Reciprocating Cylinder operation at desired speed.
Allow Alarms to monitor speed switch and other alarm actions.
Reciprocating Cylinder Operation:
The output of the Main Automation System Reciprocating Cylinder controller is vendor defined.
The time for the cycle is adjusted to meet the reciprocating conveyor speed. The maximum
reciprocating time will equal the maximum reciprocating conveyor speed.
11.4.6 Sump Pumps
These are pumps which collect surface runoffs or other minor waste liquids or slurries and are
controlled as follows:
A level switch with a wide band between off at low level and on at high level is connected to the
pump starter through the Main Automation System.
This operates the pump as required, without any intervention from the operator. If this switch
indicates run the sump pump and the pump does not come on after a time, a fault alarm is
indicated on the HMI. No level indication or alarms other than the above are required in the Main
Automation System.
11.4.7 Pump Seal System
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Each process slurry pumps or dust collection slurry pumps in Area 1 ,has water seals, controlled
as follows:
There is a flow switch in each seal water supply. If the flow switch does not register minimum flow,
an alarm is set.
This low flow alarm does not shut down the pump, but should be promptly attended to by the
operator.
11.4.8 Conveyor Systems
Standard Single Speed Conveyors
Single speed conveyors are shown on Motor Detail 1 on R-00-1003.
General Logic For Conveyors
Conveyors can be operated in Automatic or Manual modes.
Conveyor operation is conditional based on the status of the start permissives and run interlocks.
Conveyor statuses (Ready, running, etc.) and alarms (zero-speed, belt side travel, fault, plugged
chute, E-stop) are indicated on the HMI.
All side travel switches for a conveyor are wired in series as a single input to the control system.
E-stops are hardwired into the motor control circuit with a parallel contact input to the control
system for monitoring.
Each conveyor in a "GROUP" is interlocked to the conveyor preceding it.
starting a warning horn is sounded.
Prior to conveyor
Conveyor GP-12 (B55016) and GP-14 (B43036) are variable speed conveyors; however, the
speed is adjusted locally to give proper bed depth. Because the speed of GP-12 and GP-14 are
adjusted manually, from a control system standpoint, their operation is the same as a standard
conveyor.
On a stoppage due to a drive fault, the equipment must be put into HMI manual and stop selected
to clear the fault before a restart can be initiated.
11.4.9 Automatic Mode
When its local three (3) position selector switch is in the "REMOTE" position, each conveyor is
operated via the HMI. Conveyors are group started by clicking on the "GROUP START" command
on the HMI and group stopped by pressing the "GROUP STOP" command on the HMI.
For each group, it is desirable to have some easy way to know that all members of any group are
ready, signified by all starters MCC ready, all turned to auto, and all individual interlocks
satisfied, and that any other groups or items which need to be running as a precondition are in fact
running. There are several ways to do this, depending on the HMI design. One way is to have all
the objects in a group show up on a single overview graphic from which the group commands are
given. Such a graphic could be designed so that it shows a uniform looking green-board when
everything is ready or, conversely, highlights any unfulfilled precondition in some visually obvious
manner. Another approach is to have a pop-up list of all the groups preconditions, highlighting any
precondition not made in a distinctive color.
Service items like lube systems, pumps., etc. which serve items in any group are not part of the
sequence-start order, They should be started up ahead of time, and be running and ready to work
Project No.
TS120100
Revision
Document Title.
CONTROL PHILOSOPHY
Page
106 of 106
Document No.
I010S
Date
13 July 2013
before the group is started. Where appropriate, a ready status with no critical alarm may be a
logical qualification to permit the group to start.
11.4.10
Equipment Starts/Stops. Operator will start the system from the last conveyor, backwards
through to the feed equipment.
See Operating Manual for details.
11.4.11 Warning Horn System

Prior to the start of any conveyor, or any other machinery such as a screen that can endanger
personnel by suddenly starting to move, a warning horn or horns shall sound for a predetermined
time.
Horns are not necessarily assigned to each individual piece of machinery, but rather to areas of
the plant such that the entire area near every piece of machinery, or groups of machinery which
may be started together, are covered by the warning sound.
Therefore, horns are not driven directly by starter contacts in each drive, but by the Main
Automation System. It is the responsibility of the detail engineering designer to lay out the horns
and assign them to various devices or groups to insure proper coverage. The Indurating Machine
does not have a warning horn before starting.
Depending on the mode of starting, the horn logic is as follows:
When an individual drive is commanded to start from an image on the HMI, the associated horn (or
horns in the case of a long conveyor) shall blow for a period, before the drive run command is
sent from the Main Automation System to the MCC.
When a group is started from the HMI, all the horns covering the groups area shall blow for a time,
then the components of the group shall sequentially start in their normal order. It is not necessary
for each piece in the group to have its own horn blow delay, unless the start sequence is
interrupted.
When an item is started from the field in local mode, there is no way that the Main Automation
System can know that a horn blow is needed. Therefore, a warning horn pushbutton, connected
to the Main Automation System is provided at the local station for all such equipment.
The local operator has to blow the horn manually before starting the equipment.
ANNEXURE I- PID LOOP LIST AREA 1

Sl No.
Description
Ball Mill #1 Weigh Belt Feeder control
PID Loop Number
Calculation
block
Set point from
Feed back from
Final control Element
Status
Area
EFD Ref
EFD Rev
Set Value
Unit
WIC-B01-0107,
WFC-0108
JIC-0206
WIT-B01-0107
Weigh feeder motor
PKG
01
R-01-1001
294.8
TPH
12.5
kWh/Ton
Weigh feeder motor
PKG
01
R-01-1001
294.8
TPH
12.5
kWh/Ton
JIC-0206
JY-0206
Operator
Summation of Power from

Drive 1 and drive 2
WIC-B01-0117,
WFC-0118
JIC-0506
WIT-B01-0117
JIC-0506
JY-0506
Operator
Summation of Power from

Drive 1 and drive 2
FY-0042
Ball Mill #2 Weigh Belt Feeder control
Ball Mill 1
FIC-B01-0042
Ball Mill 1
FIC-B01-0020
HYDROCYCLONE DENSITY
MEASSUREMENT
DIC-B01-0036
Ball Mill 2
FIC-B01-1040
6
7
8
TANK PROCESS WATER FLOW

MEASUREMENT
TANK PROCESS WATER FLOW
CONTROL VALVE
OPERATOR
FIT-B01-0042
FCV-B01-0044
PKG
01
R-01-1002
FIT-B01-0020
FV-0021
PKG
01
R-01-1003
DY-0036
OPERATOR
DIT-B01-0036
PKG
01
R-01-1003
FY-1040
OPERATOR
FT-B01-1040
FCV-B01-1042
PKG
01
R-01-1005
Package Vendor to Provide
DIC-B01-1036
FIT-B01-1020
FV-1021
PKG
01
R-01-1006
OPERATOR
DIT-B01-1036
PKG
01
R-01-1006
Instrumentation
01
R-01-1019
DY-1036
Operator
LV-B01-1801, (upto 25%

sp)Motor41104-1 and 2(from
60% sp)

1905
Filtrate and Wash Water Tank Radar
10
Outlet of Wet Grinding Cooling Water

Strainer
TIC-B01-2101
TT-B01-2101
Cooling Tower fan motor
Instrumentation
01
R-01-1021
34
11
Wet Grinding Cooling Tower
LIC-B01-2106
LIT-B01-2106
LV-B01-2106
Instrumentation
01
R-01-1021
10000
12
W.G. Seal Water Surge Tank-Flanged
LIC-B01-2306
LIT-B01-2306
LV-B01-2306
Instrumentation
01
R-01-1022
13
Thickener overflow sump inlet
LIC-B01-0804
LIT-B01-0804
LV-B01-0804A AND LV-B010804B
Instrumentation
01
R-01-1023
14
Cooling water tank 35103
LIC-B01-0901
LIT-B01-0901
LV-B01-0901
Instrumentation
01
R-01-1028
LIC-B01-1801
Remarks
DIC-B01-0036
FIC-B01-1020
DIC-B01-1036
Control Valve
% Opening
LIT-B01-1801
25000
kg/m3
kg/h
50.5
FISHER offer considered
kg/h
32.4
18000
kg/h
43.8
13100 /
10000
kg/h
22.1 / 19
1000
kg/h
67.2
% Opening to re-check / Fisher offer

considered

Sl No.
Description
PID Loop Number
Calculation
block
1
2
Weight Belt Feeder LSF-11
WIC-B02- 2215
WFC-2215
WFC-2215
WIT-B01-0107
Weigh feeder motor
PKG
01
R-02-1001
22.7
TPH
Weight Belt Feeder CF-11
WIC-B02-2216,
WFC-2216
WFC-2216
WIT-B01-0107
Weigh feeder motor
PKG
01
R-02-1001
21.2
TPH
Set point from
Feed back from
Status
Area
EFD Ref
EFD Rev
Set Value
Unit
Control Valve
% Opening
Remarks

Sl No.
Description
PID Loop Number
Calculation
block
1
2
Iron Ore Filter Cake Feeder FCF-11
WIC-B03- 3111
WFC-3111
WIC-0400
WIT-B03-3111
Weigh feeder motor
PKG
03
R-03-1001
301.3
TPH
3
4
Iron Ore Filter Cake Feeder FCF-12

Ground Coal/Limestone Storage Bin
Loss-in-Weight Screw Feeder
Ground Bentonite Storage Bin Loss-inWeight Screw Feeder
Set point from
Feed back from
Status
Area
EFD Ref
EFD Rev
Set Value
Unit
WIC-B02-3121
WFC-3121
WIC-0400
WIT-B03-3121
Weigh feeder motor
PKG
03
R-03-1001
301.3
TPH
WIC-B03-3211
WFC-3211
WIC-0400
WE-B03-3211
Weigh feeder motor
PKG
03
R-03-1002
16.6
TPH
WIC-B03-3311
WFC-3311
WIC-0400
WE-B03-3311
Weigh feeder motor
PKG
03
R-03-1003
3.8
TPH
Control Valve
% Opening
Remarks

Sl No.
Description
PID Loop Number
1
2
3
4
5
6
7
Conveyor BDF-11F
Calculation
block
Set point from
Feed back from
Status
Area
EFD Ref
EFD Rev
Set Value
Unit
WIC-B04-0106
Operator
WIT-B04-0106
Weigh feeder motor
PKG
04
R-04-1001
130
TPH
Conveyor BDF-11G
WIT-B01-4101
Operator
WIT-B01-4101
Weigh feeder motor
PKG
04
R-04-1001
130
TPH
Conveyor BDF-11E
WIT-B04-0203
Operator
WIT-B04-0203
Weigh feeder motor
PKG
04
R-04-1002
130
TPH
Conveyor BDF-11D
WIT-B01-0020
Operator
WIT-B04-0223
Weigh feeder motor
PKG
04
R-04-1002
130
TPH
Conveyor BDF-11C
WIT-B04-0303
Operator
WIT-B04-0303
Weigh feeder motor
PKG
04
R-01-1003
130
TPH
Conveyor BDF-11B
WIT-B04-0323
Operator
WIT-B04-0323
Weigh feeder motor
PKG
04
R-04-1003
130
TPH
Conveyor BDF-11A
WIT-B04-0403
Operator
WIT-B04-0403
Weigh feeder motor
PKG
04
R-04-1004
130
TPH
Control Valve
% Opening
Remarks

Sl No.
1
2
3
Description
Indurating Machine- Downdraft Drying
Zone Pressure
Indurating Machine- Updraft Drying Duct
Pressure
Indurating Machine- Updraft Drying Duct
Temperature
PID Loop Number
Status
Area
EFD Ref
EFD Rev
Set Value
Unit
PT-0403
PD-0403A & B
Instrumentation
05
R-05-1003
76
mmwg
% opening of Damper is required
mmwg
PT-0405
PD-0405
Instrumentation
05
R-05-1003
432
TE-0407
TT-0407 A&B
Instrumentation
05
R-05-1003
260
ZT-1801A
Instrumentation
05
R-05-1004
111
ZT-1801B
Instrumentation
05
R-05-1004
111
ZT-1802A
Instrumentation
05
R-05-1004
111
ZT-1802B
Instrumentation
05
R-05-1004
111
ZT-1803A
Instrumentation
05
R-05-1004
111
ZT-1803B
Instrumentation
05
R-05-1004
111
TIC-B05-1801A
Indurating Machine- Preheate Zone

Temperature
TIC-B05-1802A

Temperature
TIC-B05-1803A
TE-B05-1801
TE-B05-1802
TIC-B05-1802B
TE-B05-1803
TIC-B05-1803B

Temperature
TIC-B05-1804A

Temperature
TIC-B05-1805A
TE-B05-1804
TIC-B05-1804B
TE-B05-1805
TIC-B05-1805B

Temperature
TIC-B05-1806A
10

Temperature
TIC-B05-1807A
TE-B05-1806
TIC-B05-1806B
TE-B05-1807
TIC-B05-1807B
11

Temperature
TIC-B05-1808A
12

Temperature
TIC-B05-1809A
13
Indurating Machine-1st Cooling Zone

Pressure
PIC-B05-0610
15
TIC-B05-0407
TIC-B05-1801B
TE-B05-1808
TIC-B05-1808B
TE-B05-1809
TIC-B05-1809B
FIC -0611
PIC-B05-0602
Control Valve
% Opening
Feed back from
PIC-B05-0405

Temperature
14
Set point from
PIC-B05-0403
Indurating Machine-2nd Cooling Zone

Pressure
Windbox Recupreration Air Fan Outlet
Temperature
Calculation
block
C
C
C
C
C
C
C
ZT-1804A
Instrumentation
05
R-05-1004
111
ZT-1804B
Instrumentation
05
R-05-1004
111
ZT-1805A
Instrumentation
05
R-05-1004
111
111
ZT-1805B
Instrumentation
05
R-05-1004
C
C
C
C
ZT-1806A
Instrumentation
05
R-05-1004
111
ZT-1806B
Instrumentation
05
R-05-1004
111
ZT-1807A
Instrumentation
05
R-05-1004
111
111
ZT-1807B
Instrumentation
05
R-05-1004
Remarks
C
C
C
C
ZT-1808A
Instrumentation
05
R-05-1004
111
ZT-1808B
Instrumentation
05
R-05-1004
111
ZT-1809A
Instrumentation
05
R-05-1004
111
O
O
C
C
C
ZT-1809B
Instrumentation
05
R-05-1004
111
FD-0611
Instrumentation
05
R-05-1008
635
C
mmwc
FD-0611
Instrumentation
05
R-05-1008
635
mmwc
PT-0602
42006VS
Instrumentation
05
R-05-1008
-25
mmwg
PT-0610 & PT-0601

PIC-B05-0610
TIC-B05-1235
TE-1235
TD-1235 A&B
Instrumentation
05
R-05-1012
235
16
Lintel Cooling Water Tank
LIC-B05-2701
LIT-2701
LV-2701
Instrumentation
05
R-05-1016
1000
kg/h
23.7
17
Hood Exhaust ESP Sump
LIC-B05-1022
LIT-B05-1022
LV-1022
Instrumentation
05
R-05-1010
12000
kg/h
55.5
17
Windbox Exhaust ESP Sump
LIC-B05-3022
LIT-B05-3022
LV-3022
Instrumentation
05
R-05-1011
12000
kg/h
55.5
18
Indurating Machine- Updraft Drying Zone

Pressure
PIC-B05-0405
PT-0401
B42008VS
Instrumentation
05
R-05-1003
-30
mmwg

Sl No.
Description
B35008 Machine Discharge Scrubber

Sump
B35010 Product Screening Scrubber
Effluent Sump
B35011 Indurating Transfer Sump
Feed back from
Status
Area
EFD Ref
EFD Rev
Set Value
Unit
Control Valve
% Opening
Remarks
LIC-B07-6206
LIT-6206
LV-B07-6206
Instrumentation
07
R-07-1002
64000
kg/h
66.2
LIC-B07-2017
LIT-2017
LV-B07-2017
Instrumentation
07
R-07-1004
12000
kg/h
55.5
LIC-B07-5363
LIT-5363
LV-B07-5363
Instrumentation
07
R-07-1006
21000
kg/h
27.0
Minimum Flow / FISHER offer

considered
PID Loop Number
Calculation
block
Set point from

Feed back from
Status
Area
EFD Ref
EFD Rev
Set Value
Unit
Control Valve
% Opening
Remarks
PIC-B08-0234
PIT-0234
PV-B08-0234
Instrumentation
08
R-08-1002
23503
kg/h
69.4
Samson offer considered
PIC-B08-0246
PIT-0246
PV-B08-0246
Instrumentation
08
R-08-1002
15669
kg/h
76.1
Samson offer considered
Sl No.
Description
PID Loop Number
B41002 Indurating Fuel Oil Circulation

PumpW/internal Bypass one
Operating/One Stand By
B41002 Indurating Fuel Oil Circulation

PumpW/internal Bypass one
Operating/One Stand By
Calculation
block
Set point from
Service Cooling Water Heat Exchanger
TIC-B08-8202
TT-0802
44101A-1VS
Instrumentation
08
R-08-1008
34
B15705 Service Cooling Tower Basin
LIC-B08-0801
LIT-0801
LV-0801
Instrumentation
08
R-08-1008
7500
kg/h
28.3
Service system surge Tank Level
LIC-B08-0891
LIT-0891
LV-0891
Instrumentation
08
R-08-1009
1000
kg/h
23.7
Tag LV-B08-0901 has been mentioned

in offer instead of 0891 / FISHER offer
considered

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Page 1 of 106

Iron Ore Pelletizing Plant II

Jindal Steel and Power Ltd.

13th July, 2013

25 June 2013 Revised in line with Vendor Control

Prepared Checked Disp.App Proj. App

Issued for Design

13 July 2013 Revised in line with discussion with JSPL

DOCUMENT ISSUED FOR:

Issued this Revision

Revised Pages Only

Issued this Revision

Control philosophy _ JSPL Pellet Plant-II

INTENT OF THE DOCUMENT

IRON ORE RECEIVING & WET GRINDING SECTION- AREA 1

ADDITIVE RECEIVING AND DRY GRINDING -AREA 2

PRODUCT SCREENING AREA 6

POLLUTION CONTROL AREA 7

CONTROL SYSTEM OVERVIEW & PHILOSOPHY

ANNEXURE I PID LOOP LIST

Control philosophy _ JSPL Pellet Plant-II

INTENT OF THIS DOCUMENT

IRON ORE RECEIVING & WET GRINDING SECTION- AREA 1

Control philosophy _ JSPL Pellet Plant-II

Healthy signal from the safety switches placed on the conveyors

(Mill kWh per h) / (Mill kWh per T)

Unhealthy signal from the safety switches placed on the conveyors

Ball mill stops

Low-Low alarm at the respective bin

Control philosophy _ JSPL Pellet Plant-II

Normal Start-up Sequence

Control philosophy _ JSPL Pellet Plant-II

Main Automation System Control

Normal Shutdown Sequence

Abnormal and Emergency Shutdowns

Control philosophy _ JSPL Pellet Plant-II

The mill plant incorporates the following features:

Feed system (Described in section 3.1)

Product Slurry system

Control philosophy _ JSPL Pellet Plant-II

Product Slurry System

Operation Philosophy and Plant Sequencing

Control philosophy _ JSPL Pellet Plant-II

Control philosophy _ JSPL Pellet Plant-II

3.3.10.2 Group-1 Equipment summary:

Suction and Discharge valves (XV0025)for(331 PU210/B41101-1)

Suction and Discharge valves (XV0024)for(331 PU220/B41101-2)

Hydro cyclone feed pumps (331.PU210/331.PU220/B41101-1,2)

Start the slurry pump (331.PU210/B41101-1) & (331.PU220/B41101-2).

Control philosophy _ JSPL Pellet Plant-II

Ball Mill Lubrication Group 2

The mill lubrication system (331.LQ110) consists of 3 parts:

Reservoir assembly and oil conditioning circuit;

HP hydrostatic bearings lube circuit;

Pinion bearings LP lube circuit.

Reservoir Assembly & Oil Conditioning

Control philosophy _ JSPL Pellet Plant-II

Group 2A equipment summary:

Return compartment heater HE 01

Settling compartment heater HE 02.

Clean compartment heater HE 03

Control philosophy _ JSPL Pellet Plant-II

Group 2A Start sequence