Professional Documents
Culture Documents
Vedanta - Jharsuguda
138-02-043
Group 431/432 F
DE-060300
13
13
13.1
13.1.1
13.1.2
13.1.3
13.2
13.2.1
13.2.2
13.3
13.3.1
13.3.2
13.3.3
13.3.4
13.3.5
13.3.6
13.3.7
13.3.8
13.3.9
13.3.10
13.1
Process
13.1.1
Revision: 0
Date: 29.09.2006
Page 1 of 12
138-02-043
Group 431/432 F
DE-060300
Revision: 0
Date: 29.09.2006
file: 138-02-043_13_0.doc, Codeword: Vedanta
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
1 (2)
Rev. 00
132-01-082 UB
P+I Diagrams
The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This Process Group is required to produce a very fine petroleum coke fraction (grain size 003mm with max. 75% <0.074mm) called Ball Mill Fraction which is used as filler material of
the dry mix to be blend in Group 431 H. This very fine material is ground by a ball mill (431 F
100) of the air-swepped type working in a closed conveying air circuit.
The feed material is continuously withdrawn from the storage bin (431 A 320) by means of
belt-weigh-feeder (431 F 010). The flat slide gate (431 F 005) under the storage bin is always
open except if maintenance has to be done on the weigh-feeder underneath.
The material is continuously fed to the ball mill passing a reversing flap (431 F 015), a screw
conveyor (431 F 022) and a double-pendulum flap (431 F 025). The double pendulum flap is
required because the ball mill air circuit and thus the ball mill are working under negative
pressure. If the weigh-feeder has to be calibrated, the material can be directed into a bulker
bag by manually tilting the reversing flap (431 F 015) for a certain time and weighing the bag
later on a platform scale (431 H 096).
In the ball mill (431 F 100) the feed material is ground by steel balls while the coke is slowly
passing the ball mill tube. The mill is capable to achieve a product grain size of about 0-2mm
containing a large portion of 0- 0.074mm size (- 200 mesh).
The circulating air flow, generated by a fan (431 F 245), is passing the mill tube and carries the
ground material via a vertical duct into the airflow classifier (431 F 210) where oversized
material (> 0.3mm) is separated, which is recycled to the ball mill and via rotary lock (431 F
260) and impact flow meter (431 F 275).
A drum magnet (431 F 265) with permanent magnet is removing fine ground iron (abration
loss of the grinding balls) and also small iron particles coming with the raw material, coke.
The air flow classifier is equipped with a number of adjustable baffles, concentrically located
around a motor driven cage wheel. Both baffles and cage wheel are making the air flow
rotating so that coarse particles are separated at the inner wall and in the separator center by
centrifugal force while the finer product is leaving the classifier through the top outlet. The
cutpoint of the classifier is adjustable by a variable speed drive for the cage wheel and by
adjusting the baffles.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
2 (2)
Rev. 00
Material of required grain size (0-0.3mm) is transported by air flow to the cyclone (431 F 215)
where the fine ground coke is separated from the carrying air flow. Via a rotary lock (431 F
305) the fine ground material is discharged from the cyclone, is then passing an automatic
sampler (431 F 310) and is finally falling either into the fines bin (431 F 400). If the reversing
flap (431 F 325) is switched to the other way, the material is fed to the screw conveyors (431 F
330 / 335) it is conveyed into the Fresh Adsorbent bin (431 F 450). Between automatic
sampler (431 F 310) and reversing flap (431 F 325) is another reversing flap, for fed the
ground material in the first 10 minutes after starting the Ball Mill System via screw conveyor
(431 F 323) in the Filter Dust Bin (431 C 100). The reason for this procedure is the unsteady
quality of the ground material during the start phase of the ball mill.
The air flow leaving the cyclone (431 F 215) is passing the fan (431 F 245) via a motorized
throttle flap (431 F 240), which is closing before start up of the fan and is then opened to a
preset angle to adjust the flow rate.
The throttle flaps (431 F 250 / 255) downstream the fan are used to split the air flow to be send
through the mill and through the mill bypass duct.
A part of the circulation air is withdrawn by a dust collector fan (431 F 230) via a throttle flap
(431 F 225) and through a dust collector (431 F 220) in order to reduce the dust content in the
circulating air and to keep the circulation air system at negative pressure in order to avoid dust
leaks.
Dust separated by the dust collector (431 F 220) is discharged via a rotary lock (431 F 315)
and a screw conveyor (431 F 320) into either the Ball Mill Fraction bin (431 F 400) or into the
bin for Fresh Adsorbent (431 F 450).
With the ball mill operating, filter dust is continuously reclaimed from the Filter Dust bin (431
C 100) by means of the rotary lock (431 F 055), which is equipped with a variable speed drive
so that the feed rate is adjustable. An aeration unit (431 F 051) installed at the Filter Dust bin
bottom avoids bridging of material in the bin. The filter dust is added to the air flow which is
entering the air flow classifier (431 F 210). Filter Dust is only fed to the system when the Ball
Mill System is producing.
Loaded adsorbent from Group 431 G is continuously discharged from the Loaded Adsorbent
storage bin by means of the rotary lock (431 F 355), which is equipped with a variable speed
drive so that the feed rate is adjustable. An aeration unit (431 F 351) installed at the Loaded
Adsorbent bin bottom avoids bridging of material in the bin. The material is added to the chute
feeding the Ball Mill Fraction bin (431 F 400). Loaded Adsorbent is only then fed to the Ball Mill
Fraction bin as long as the bin is filled with fresh Ball Mill Product and is stopped when the
Fresh Adsorbent bin is filled.
For calibration of the rotary lock for Filter Dust (431 F 055) material is fed via the reversing flap
(431 F 060) into a bulker bag (431 F 285). The bulker bag has to be weighed on a platform
scale (431 H 096). Calibration of the impact flow meter (431 F 275) is via reversing flap (431 F
280). Only during automatic run of the complete Group it is possible to switch the reversing
flap (431 F 280) for a short while to the bulker bag.
138-02-043
Group 431/432 F
DE-060300
Advantages:
-
Disadvantages:
-
Revision: 0
Date: 29.09.2006
Page 3 of 12
138-02-043
Group 431/432 F
DE-060300
2) Figure 2 is showing a more advanced closed system with overflow ball mill, bucket
elevator and dynamic classifier. Oversize material is separated by the classifier and
returned to the mill.
Advantages:
-
Disadvantages:
-
3) Figure 3 is showing an often used closed system with overflow ball mill, static or
dynamic air flow classifier, a dust collector and a fan working as an air lift.
Revision: 0
Date: 29.09.2006
file: 138-02-043_13_0.doc, Codeword: Vedanta
138-02-043
Group 431/432 F
DE-060300
Advantages:
-
Disadvantages:
-
Revision: 0
Date: 29.09.2006
Page 5 of 12
138-02-043
Group 431/432 F
DE-060300
4) Figure 4 is showing a typical closed air swept system with air swept ball mill, static or
dynamic air flow classifier, circulation fan, cyclone and dust collector / fan unit as installed
at VEDANTA. This is the most advanced ball mill system nowadays. The airflow through
the mill is adjustable. Grain of the desired product size, wherever generated is
immediately carried off the mill body by air stream. There is no over-grinding. Product
fineness below 200mesh can be in a certain range controlled by air velocity in the mill
body.
Advantages:
-
Disadvantages:
Higher investment cost (additional cyclone, fan and air ducts)
Higher maintenance costs (mill, classifier, cyclone, dust collector, two fans, air
flaps)
The process group is designed for a maximum Fines production rate of 12 t/hour.
At worst operating condition (No Butts) the Ball Mill Fraction requirement is 8.9 t/h.
At this worst condition it was assumed that no recycled butts are available so that
petroleum coke has to be used instead
At operating condition Nominal Butts AA the Ball Mill Fraction requirement is 7.9 t/h
only.
-
Revision: 0
Date: 29.09.2006
file: 138-02-043_13_0.doc, Codeword: Vedanta
138-02-043
Group 431/432 F
DE-060300
Revision: 0
Date: 29.09.2006
Page 7 of 12
138-02-043
Group 431/432 F
DE-060300
0-6mm
1.5 15 t/h
Feed rate can be controlled by belt weigh feeder, electronic ear and impact flow meter
for recycled material from air flow classifier.
Ball Mill Product size (into fines fraction bin):
Design
Normal
Total range adjustable
< 0.075mm
75 +/-2 %
< 0.075mm 65 to 70 +/-2 %
< 0.075mm
55-75 +/-2 %
W = 1 / D 80 out 1 / D 80 in
W = specific grinding work
D80out = product grain size at 80% passing
D80in = feed grain size at 80% passing
Because each ball mill is designed for a maximum specific grinding work and product
fineness there is a capacity limit.
If finer product is required it can be achieved by readjusting the cut point of the airflow
classifier and by reducing the feed rate of fresh material at the same time.
If only the cut point of the classifier is changed to a smaller size without reducing the
feed rate then the amount of oversize returned to the mill is increasing. This would
only raise with each air cycle more and more the material level in the mill until the
material overflows the mill at the discharge end.
During automatic operation of the mill level control system overflowing of the mill
should be impossible because the flow meter and the sonic ear control the feed rate
automatically.
Revision: 0
Date: 29.09.2006
file: 138-02-043_13_0.doc, Codeword: Vedanta
138-02-043
Group 431/432 F
DE-060300
The feed size has also a significant impact on the product size of a ball mill system. It
would be ideal to feed continuously the same rate of coke to the mill but this cannot
be achieved all time. If the feed rate of one fraction has to be changed because there
is a lack or a surplus of material in the Ball Mill Feed bin the change should be
moderate. If a lot filter dust has been added to the Ball Mill Feed bin the product grain
size is shifted to a finer size immediately because filter dust is much finer as ball mill
dust and so is taken directly by the air stream out of the mill body. If much Fine Coke
(3-6 mm) has been fed to the Ball Mill Feed bin then the ball mill product is finally
coarser than usual.
Ball mill:
Manufacturer:
McNally Bharat Engineering Co. Limited
Size:
2.60m dia x 5.75m long
Dynamic Air Flow Classifier:
Manufacturer:
Type:
cut point:
Revision: 0
Date: 29.09.2006
Page 9 of 12
13.2
Process Control
13.2.1
138-02-043
Group 431/432 F
DE-060300
(work copies)
Revision: 0
Date: 29.09.2006
file: 138-02-043_13_0.doc, Codeword: Vedanta
138-02-043
Group 431/432 F
DE-060300
Revision: 0
Date: 29.09.2006
Page 11 of 12
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
1 (28)
Rev. 00
Control Philosophy
of
Process Group 431-F
- Ball Mill System Reference:
Process Flow Sheet
132-01-082 UB
P+I Diagrams
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.5
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.7
2.8
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
1
2 (28)
Rev. 00
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
3 (28)
Rev. 00
The throttle flaps (431 F 250 / 255) downstream the fan are used to split the air flow to be send
through the mill and through the mill bypass duct.
A part of the circulation air is withdrawn by a dust collector fan (431 F 230) via a throttle flap
(431 F 225) and through a dust collector (431 F 220) in order to reduce the dust content in the
circulating air and to keep the circulation air system at negative pressure in order to avoid dust
leaks.
Dust separated by the dust collector (431 F 220) is discharged via a rotary lock (431 F 315)
and a screw conveyor (431 F 320) into either the Ball Mill Fraction bin (431 F 400) or into the
bin for Fresh Adsorbent (431 F 450).
With the ball mill operating, filter dust is continuously reclaimed from the Filter Dust bin (431
C 100) by means of the rotary lock (431 F 055), which is equipped with a variable speed drive
so that the feed rate is adjustable. An aeration unit (431 F 051) installed at the Filter Dust bin
bottom avoids bridging of material in the bin. The filter dust is added to the air flow which is
entering the air flow classifier (431 F 210). Filter Dust is only fed to the system when the Ball
Mill System is producing.
Loaded adsorbent from Group 431 G is continuously discharged from the Loaded Adsorbent
storage bin by means of the rotary lock (431 F 355), which is equipped with a variable speed
drive so that the feed rate is adjustable. An aeration unit (431 F 351) installed at the Loaded
Adsorbent bin bottom avoids bridging of material in the bin. The material is added to the chute
feeding the Ball Mill Fraction bin (431 F 400). Loaded Adsorbent is only then fed to the Ball Mill
Fraction bin as long as the bin is filled with fresh Ball Mill Product and is stopped when the
Fresh Adsorbent bin is filled.
For calibration of the rotary lock for Filter Dust (431 F 055) material is fed via the reversing flap
(431 F 060) into a bulker bag (431 F 285). The bulker bag has to be weighed on a platform
scale (431 H 096). Calibration of the impact flow meter (431 F 275) is via reversing flap (431 F
280). Only during automatic run of the complete Group it is possible to switch the reversing
flap (431 F 280) for a short while to the bulker bag.
2
2.1
2.2
The exchange of control signals is described in the following chapters and especially under 2.8
below.
CONTROL PHILOSOPHY
05.10.2006
4 (28)
Rev. 00
Selection
2.3.1
2.3.2
2.3.3
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
5 (28)
Rev. 00
SE 3-3 - Sample
If SE 3-2 is selected and the operator is clicking on the Sample button (SE 3-3) on SCADA a
single sample is taken.
2.3.4
2.3.5
the fresh coke feed rate provided by the belt weigh feeder (431 F 010)
the recycling rate of oversize material coming back from the air flow classifier (431 F 210)
the feed size of fresh coke and recycled coke
the grindability of the feed material (coke)
the mill size (grinding capacity) of the ball mill.
The grindability varies with the source of coke but is more or less fix for short term (hours /
days) and the feed size (fresh and oversize) should be kept in a small range but still is a
variable. The mill size is a design figure and is another fix value.
Thus for short term operation mainly the feed rate of fresh coke and oversize coke from the
classifier have the main impact on the material level in the ball mill. The rate of oversize coke
is a function of the feed size, the grindability and other impacts like the stability of the
circulating air flow and therefore is not fix
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
6 (28)
Rev. 00
The higher the total feed rate is the higher is the mill level and the shorter is the retention time
of material passing the mill body. A typical retention time is 15 minutes.
At low retention time (high feed rate) the chance of a coke grain to be ground to fine mill dust
is relatively low while at a higher retention time (lower feed rate) the chance is much higher.
However the level control system must be able to balance the rate of fresh coke and recycled
coke from the air flow classifier in order to attain the required fineness of the ball mill product.
SE 5-1 Auto Level
The operator may select Auto Level at any time as long as CENTRAL operation mode is
selected.
At this selection the material level in the mill is controlled automatically by variation of the feed
rate of belt weigh feeder (431 F 010) using the following command variables:
electronic ear [431 F 100-LY] material level impact flow meter [431 F 275-FY] recycled material -
Both are input variables for a software-type PID Controller, which delivers the control value
[431 F 010-FY] for the belt weigh feeder (431 F 010).
SE 5-2 Auto Electronic Ear
The operator may select Auto Electronic Ear at any time as long as CENTRAL operation
mode is selected.
At this selection the material level in the mill is controlled automatically by variation of the belt
weigh feeder (431 F 010) feed rate using the following command variable:
At this selection this is the only input variable for a software-type PID Controller, which delivers
the control value [431 F 010-FY] for the belt weigh feeder (431 F 010). In this case the impact
flow meter is just used for display of the recycled material flow rate.
SE 5-3 Auto Flow Meter
The operator may select Auto Flow Meter at any time as long as CENTRAL operation mode
is selected.
At this selection the total feed rate, fresh feed from the belt weigh feeder plus recycled material
from the air flow classifier shall be kept constant automatically while the material level in the
mill is only displayed but not controlled. The command variable in this case is:
In this case the electronic ear is just used for display of the material level in the mill but shuts
off the belt weigh feeder, if the level increases too much or gives alarm, if the level is too low.
SE 5-4 Manual Level
The operator may select Manual Level at any time as long as CENTRAL operation mode is
selected.
At this selection the material level in the mill is controlled manually by the operator using
the Operator Station in the Central Control Room.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
7 (28)
Rev. 00
In this case the electronic ear is just used for display of the material level in the mill but shuts
off the belt weigh feeder when the level increases too much and for display of the flow of
recycled material the impact flow meter is used.
Note: This selection shall be used for each start of this Group and shall be kept at
minimum for a time of 20 minutes after the start of the ball mill (431 F 100) until the ball
mill system is in stable operation.
2.3.6
2.3.7
Reversing Flap 431 F 322 (stable operation of ball mill system) (SE 7)
This selection shall be used for each start of this Group and shall be kept at minimum for a
time of 10 minutes after the start of the ball mill (431 F 100) until the ball mill product has a
steady quality.
The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA.
The operator has two options:
SE 7-1 - Auto Select
At this selection the ground material is fed to the filter dust bin (431 C 100) during the start
phase of the ball mill (first approach for Standard Setpoint SP 7 is 10 minutes). After the start
phase the ground material is fed to the ball mill fraction bin (431 F 400) or fresh adsorbent bin
(431 F 450).
SE 7-2 - Manual Select
At this selection the operator controls manually the fed of the ground material to the filter dust
bin (431 C 100) or in direction to the ball mill fraction bin (431 F 400) or fresh adsorbent bin
(431 F 450).
2.4
Group Start
2.4.1
2.4.2
Start Preconditions
CENTRAL operation mode must be selected.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
8 (28)
Rev. 00
The Group Main Dust Treatment must be running in CENTRAL operation mode prior to
start of this Group. It must not be tripped and not be in a stop (RESTOP or FASTOP)
sequence.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
9 (28)
Rev. 00
New Setpoint
Previous Setpoint
Standard Setpoint
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
10 (28)
Rev. 00
This throttle flap is equipped with a servo drive for remote adjustment of the flap position.
(Setpoint SP 3)
The speed can be varied between 20 % and 100 %.corresponding a feed rate between
0.2 and 2.0 tons/hour. If Add Floor Dust (SE 2-1) is selected, this feed rate can be
varied any time.
On SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint (first approach for Standard Setpoint is 50%)
all overriding the actual setpoint.
The speed can be varied between 20 % and 100 %.corresponding a feed rate between
0.5 and 2.5 tons/hour. Setting and display of the actual position is on SCADA at any time.
On SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint (first approach for Standard Setpoint is 50%)
all overriding the actual setpoint.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
11 (28)
Rev. 00
2.4.3.5 Ball Mill Level Control System 431 F 275 (Setpoints SP 5-1 to 5-3)
The actual level of coke in the mill body is measured by a sonic level measuring system
(electronic ear) [431 F 100-LY].
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
12 (28)
Rev. 00
Signal from Sub-Group 431 F 100 required, indicating the equipment and controls of this
Sub-Group is healthy. (Details please refer to machine documentation of the ball mill (431
F 100) prepared by MBE)
The horn starts to sound permanently for 15 seconds prior to start of the first equipment,
then it sounds intermittently until the last drive is running.
Screw conveyor (431 F 335) starts.
Screw conveyor (431 F 330) starts.
Reversing flap (431 F 325) is enabled.
Screw conveyor (431 F 320) starts
Rotary lock (431 F 315) starts.
Jet cleaning of dust collector (431 F 220) is enabled.
Fan (431 F 230) starts.
Delay of 20 seconds for fan impeller run-up.
Screw conveyor (431 F 323) starts.
Reversing flap (431 F 322) is enabled.
Automatic sampler (431 F 310) is tilting to limit switch [431 F 310-ZH].
Rotary lock (431 F 305) starts after limit switch [431 F 310-ZH] is activated.
Drum magnet (431 F 265) starts.
Rotary lock (431 F 260) starts.
Impact flow meter (431 F 275) is enabled.
Air flow separator cage rotor (431 F 210) starts.
Throttle flap (431 F 240) closes until limit switch [431 F 240-ZL] is activated.
Delay of 20 seconds for cage rotor run-up.
Fan (431 F 245) starts, if limit switch [431 F 240-ZL] is indicating the throttle flap is closed.
Delay of 30 seconds for fan impeller run-up.
Throttle flap (431 F 240) opens until setpoint (SP 1-1 or SP 1-2 see 3.3.3 above) is
reached.
Sub-Group 431 F 100 -Ball mill is initiated to start
Note: Start details to be described by MBE
Sub-Group 431 F 100 completely started (ball mill 431 F 100 runs).
Screw conveyor (431 F 022) starts.
Belt weigh feeder (431 F 010) starts.
Rotary lock (431 F 055) starts if SE 4-1 is selected.
Rotary lock (431 F 355) starts.
Aeration unit (431 F 351) is enabled.
Aeration unit (431 F 051) is enabled if rotary lock (431 F 055) runs.
Group 431 F is running completely in CENTRAL mode.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
2.4.5
13 (28)
Rev. 00
2.5
Normal Operation
2.5.1
Belt Weigh Feeder 431 F 010 If the weigh feeder is not tripped this Group is in normal operation.
If SE 5-1 (Auto Level) is selected, the feed rate of the belt weigh feeder (431 F 010) is
automatically controlled by the electronic ear [431 F 100-LY] (ball mill material level) and
by the impact flow meter [431 F 275-FY] (recycled material from the air flow classifier).
The operator may select Auto Level at any time as long as CENTRAL operation mode is
selected.
If SE 5-2 (Auto Electronic Ear) is selected, the feed rate of the belt weigh feeder (431 F
010) is automatically controlled by the electronic ear [431 F 100-LY] (ball mill material
level) only. - The operator may select Auto Electronic Ear at any time as long as
CENTRAL operation mode is selected.
If SE 5-3 (Auto Flow Meter) is selected, the feed rate of the belt weigh feeder (431 F 010)
is automatically controlled by the impact flow meter [431 F 275-FY] (recycled material from
air flow classifier) only.
The operator may select Auto Flow Meter at any time as long as CENTRAL operation
mode is selected.
If SE 5-4 (Manual Level) has been selected the feed rate of the belt weigh feeder is set by
the operator.
The operator may set the feed rate at any time in a range of 1.5 to 15.0 tons/hour. Setting
and display of the actual position is on SCADA. On SCADA the operator has the choice to
select one of three options, New setpoint, Previous setpoint and Standard setpoint all
overriding the actual setpoint.
The operator may select Manual Level at any time as long as CENTRAL operation mode
is selected.
2.5.2
2.5.3
2.5.4
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
14 (28)
Rev. 00
This rotary lock is equipped with a variable speed drive. The speed can be varied between
20 % and 100 % corresponding a feed rate between 0.2 and 2.0 tons/hour. If Add Floor
Dust (SE 2-1) is selected, this feed rate can be varied any time.
On SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint (first approach for Standard Setpoint is 50%)
all overriding the actual setpoint.
2.5.5
2.5.6
2.5.7
2.5.8
2.5.9
2.5.10
2.5.11
2.5.12
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
15 (28)
Rev. 00
2.5.13
2.5.14
2.5.15
2.5.16
2.5.17
2.5.18
2.5.19
2.5.20
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
16 (28)
Rev. 00
If Auto Select SE 2-3 is selected and if the Fresh Adsorbent bin (431 F 450) is full [431
F 450-LAH2 is indicating very high level] and this reversing flap (431 F 325) is not
adjusted at 100% material flow to the Ball Mill Fraction bin (431 F 400) [limit switch 431 F
325-ZH is not actuated] and the Ball Mill Fraction bin (431 F 400) is not full the flap tilts to
limit switch [431 F 325-ZL] automatically.
If Auto Select SE 2-3 is selected and if the Ball Mill Fraction bin (431 F 400) is nearly
empty [431 F 400-LAL is indicating low level 10% of maximum level -] and this reversing
flap (431 F 325) is not adjusted at 100% material flow to the Ball Mill Fraction bin [limit
switch 431 F 325-ZH is not actuated] the flap tilts to limit switch [431 F 325-ZH]
automatically.
If Auto Select SE 2-3 is selected and if the Fresh Adsorbent bin (431 F 450) is nearly
empty [431 F 450-LAL is indicating low level 10% of maximum level -] and this reversing
flap (431 F 325) is not adjusted at 100% material flow to the Fresh Adsorbent bin [limit
switch 431 F 325-ZL is not actuated] the flap tilts to limit switch [431 F 325-ZL]
automatically but only if there is no low level at the Ball Mill fraction bin [431 F 400-LAL]
indicated.
2.5.21
2.5.22
2.5.23
2.5.24
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
17 (28)
Rev. 00
2.5.25
2.5.26
2.6
2.6.1
The operator stops this Group using the RESTOP push button on SCADA.
Ball mill Sub-Group (431 F 100) stop sequence is initiated. (Details of the stop sequence
of this Sub-Group to be prepared by MBE)
Rotary lock (431 F 055) stops.
Rotary lock (431 F 355) stops.
Aeration unit (431 F 051) cycle is disabled and solenoid [431 F 051-ZY1] closes.
Aeration unit (431 F 351) cycle is disabled and solenoid [431 F 351-ZY1] closes.
Screw conveyor (431 F 022) stops.
Delay of 2 minutes (run-empty time for circulation air pipework)
Circulation fan (431 F 245) stops.
Delay of 5 minutes (run-empty time for rest of equipment)
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
18 (28)
Rev. 00
All equipment of this Group stops or is disabled. Equipment perhaps in motion like the
automatic sampler (431 F 310) or the reversing flap (431 F 325) is finishing the actual
operation step first.
2.6.2
After a shut down of the Group or of a part of the Group all actual setpoints of this Group are
memorized as Actual Setpoint.
2.6.2.1 Group 431 C Main Dust Treatment
Because a mayor part of equipment of this Group 431 F is connected to the Main Dust
Treatment it is essential that Group 431 C is running in CENTRAL control mode and is not
in a START or STOP sequence.
If Group 431 C is not running anymore in CENTRAL mode because it has been stopped
by a Normal Shut Down (RESTOP), by a Fast Shut Down (FASTOP) or is tripped through
a fault a Fast Shut Down (see 2.6.3 below) is initiated.
2.6.3
All equipment of this Group stops instantly except of the ball mill Sub-Group 431 F 100,
which stops according to the normal stop sequence as described above.
All actual setpoints of this Group are memorized as Actual Setpoint
Reversing flap (431 F 325) is finishing the operating step, if this step has been started
prior to the FASTOP signal and stops, when the target position is reached.
Automatic sampler (431 F 310) is finishing the operating step, if this step has been started
prior to the FASTOP signal and stops, when the target position is reached.
The whole Group is stopped now with full load of material in conveyors.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
2.6.4
19 (28)
Rev. 00
causes an alarm
drive stops
This is causing a Normal Shut Down as described above (see 2.6.1).
causes an alarm
Normal Shut Down as described above (see 2.6.1).
cause an alarm
equipment trips
[431 F 022M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated
Normal Shut Down as described above (see 2.6.1).
cause an alarm
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
-
20 (28)
Rev. 00
equipment trips
[431 F 055M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated.
alarm is generated
Normal Shut Down (see 2.6.1 above) of this Group 431 F is executed.
cause an alarm
shut down of this equipment.
cause an alarm
shut down of this equipment.
cause an alarm
shut down of this equipment.
alarm is generated
Normal Shut Down (see 2.6.1 above) of this Group 431 F is executed.
an alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically.
[431 F 220-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or if
the switch fails for more than 5 seconds
-
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
-
21 (28)
Rev. 00
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
NOTE: During Start or Restart of this Group there is an override of this function of 20
seconds to allow the fan to run up.
[431 F 220-PDAH] {> 13mbar} If high differential pressure is detected across the filter bags or
if the switch fails for more than 5 seconds
-
cause an alarm
[431 F 220-PDAHH] {> 15mbar} If high-high differential pressure is detected across the filter
bags or if the switch fails for more than 5 seconds
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
an alarm is generated
fan (431 F 230) is shut down instantly
cause an alarm
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
causes an alarm
equipment trips
[431 F 240-XAL / XAH] The throttle flap is equipped with two torque switches, incorporated in
a control box fitted to the drive unit. If a switch is actuated or a electric motor: [431 F 240M1]
If there is a fault detected in the motor or in the MCC of this motor
-
cause an alarm
equipment trips
The maximum time required between start and stop of the actuator drive, which is tilting the
throttle of the throttle flap, shall not be more than 90 seconds. If after 90 seconds the motor
has not been stopped automatically because the target position has not been reached
-
cause an alarm
equipment trips.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
22 (28)
Rev. 00
alarm is generated
flap (431 F 240) is shut down instantly
This will cause an alarm
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
2.6.4.10 Fan 431 F 245 Circulation Fan [431 F 245M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an
equipment trips
[431 F 245-SAL] The fan is equipped with a proximity type low-speed switch measuring the
frequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low or
the switch fails
-
cause an alarm
equipment trips
[431 F 245-VAH] The fan is equipped with a vibration switch. If vibration is too high
-
fan trips
alarm is generated
fan (431 F 245) is shut down instantly
This will cause an
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
cause an alarm
equipment trips
[431 F 260M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
cause an alarm
equipment trips
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
23 (28)
Rev. 00
[431 F 265-SAL] The magnetic separator is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the magnetic drum. If the frequency of the
drum is too low or the switch fails
-
cause an alarm
equipment trips
alarm is generated
Fast Shut Down (see 2.6.3 above) of this Group 431 F is executed.
causes an alarm
Fast Shut Down as described above (see 2.6.3).
cause an alarm
equipment trips
[431 F 305M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
2.6.4.16 Automatic Sampler 431 F 310 pneumatic [431 F 310-ZH / ZL] The sampler is equipped with two proximity type limit switches. If one of
the switches fails
-
cause an alarm
equipment trips
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
24 (28)
Rev. 00
The maximum time required by the pneumatic drive for tilting the pelican type sampler from
one limit switch to the other one shall not be more than 10 seconds. If after 10 seconds the
limit switch is not reached
-
cause an alarm
equipment trips
alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
cause an alarm
equipment trips
[431 F 315M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
2.6.4.19 Reversing Flap 431 F 325 pneumatic [431 F 325-ZH / ZL] The flap is equipped with two proximity type limit switches. If one of the
switches fails
-
causing an alarm
equipment trips
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
25 (28)
Rev. 00
The maximum time required by the pneumatic drive for tilting the reversing blade from one
limit switch to the other one shall not be more than 10 seconds. If after 10 seconds the limit
switch is not reached
-
causing an alarm
equipment trips
alarm is generated
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
cause an alarm
equipment trips
[431 F 330M1] If there is a fault detected in the motor or in the MCC of this electric motor
-
cause an alarm
equipment trips
alarm is generated
if the reversing flap (431 F 325) is positioned to feed this screw conveyor [limit switch
431 F 325-ZL is activated] a Fast Shut Down for this Group (see 3.5.3 above) is
initiated automatically.
cause an alarm
equipment trips
[431 F 335M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
alarm is generated
if the reversing flap (431 F 325) is positioned to feed the screw conveyor (431 F 330)
[limit switch 431 F 325-ZL is activated] a Fast Shut Down for this Group (see 3.5.3
above) is initiated automatically.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
26 (28)
Rev. 00
cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZL is not
activated] to feed the screw conveyor (431 F 330) a Normal Shut Down of this Group
(see 2.6.1 above) is initiated automatically.
[431 F 400-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZL is not
activated] to feed the screw conveyor (431 F 330) a Fast Shut Down of this Group
(see 2.6.3 above) is initiated automatically.
cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZH is not
activated] to feed the Ball Mill Feed bin (431 F 400) a Normal Shut Down of this Group
(see 2.6.1 above) is initiated automatically.
[431 F 450-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZH is not
activated] to feed the Ball Mill Fraction bin (431 F 400) a Fast Shut Down of this Group
(see 3.5.3 above) is initiated automatically.
2.6.5
2.6.5.1
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If Manual Select SE 2-4 is selected and if the fraction bin is full (bin level is >/= 95% [431 F
400-LAH2]) and the flap of reversing flap (431 F 325) is not at 100% material flow to screw
conveyor (431 F 330) [limit switch 431 F 325-ZL is not actuated]
-
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If the fraction bin is totally full (bin level >/= 100% [431 F 400-LAHH]) and the flap of reversing
flap (431 F 325) is not at 100% material flow to screw conveyor (431 F 330) [limit switch 431 F
325-ZL actuated]
-
Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically.
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
27 (28)
Rev. 00
If the fraction bin is full (bin level is >/= 95% [431 F 400-LAH2]) and if the Fresh Adsorbent bin
(431 F 450) is also full (bin level is >/= 95% [431 F 450-LAH2 and/or bin level >/= 100% [431 F
450-LAHH])
-
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If Manual Select SE 2-4 is selected and if the bin is full (bin level is >/= 95% [431 F 450LAH2]) and the flap of reversing flap (431 F 325) is not at 100% material flow to the Ball Mill
Feed bin (431 F 400) [limit switch 431 F 325-ZH is not actuated]
-
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If the bin is totally full (bin level >/= 100% [431 F 450-LAHH]) and the flap of reversing flap
(431 F 325) is not at 100% material flow to the Ball Mill Feed bin (431 F 330) [limit switch 431
F 325-ZH is not actuated]
-
Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically.
If the bin is full (bin level is >/= 95% [431 F 450-LAH2]) and if the Ball Mill Feed bin (431 F
400) is also full (bin level is >/= 95% [431 F 400-LAH2 and/or bin level >/= 100% [431 F 400LAHH])
-
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
2.7
2.7.1
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
2.8
Rev. 00
Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal
Description
Sort of Signal
28 (28)
13.3
Main Equipment
13.3.1
13.3.2
13.3.3
13.3.4
13.3.5
13.3.6
13.3.7
13.3.8
13.3.9
138-02-043
Group 431/432 F
DE-060300
Revision: 0
Date: 29.09.2006
file: 138-02-043_13_0.doc, Codeword: Vedanta