431a 432a

Training Manual Green Anode Plant
Vedanta - Jharsuguda
138-02-043
Group 431/432 A
DE-060300
PROCESS GROUP 431/432 A - COKE CRUSHING & SCREENING-
9
9.1
9.1.1
9.1.2
9.1.3
9.2
9.2.1
9.2.2
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
9.3.7
9.3.8
9.3.9
9.3.10
9.3.11
9.3.12
9.3.13
9.3.14
9.3.15
Process Group 431/432 A - Coke Crushing & Screening- ..........................................................1

Process .......................................................................................................................................1
Process Flow Sheets...................................................................................................................1
Brief Process Description ............................................................................................................2
Main Process Data & Process Highlights ....................................................................................3
Process Control...........................................................................................................................5
P&Id`s, Operator Screen Images ................................................................................................5
Control Logic Description ............................................................................................................6
Main Equipment ..........................................................................................................................7
Flat Slide Gate (manual) 431/432 A 101 .....................................................................................7
Belt Weigh Feeder 431/432 A 103 ..............................................................................................7
Splitter Gate 431/432 A 105 ........................................................................................................7
Impact Crusher 431/432 A 110 ...................................................................................................7
Bucket Elevator 431/432 A 115...................................................................................................7
Vibrating Trough Feeder 431/432 A 120 .....................................................................................7
Drum-Type Magnetic Separator 431/432 A 125..........................................................................7
Vibrating Screen Feeder 431/432 A 140 .....................................................................................7
Vibrating Screen 431/432 A 145 .................................................................................................7
Screw Conveyor 431/432 A 157..................................................................................................7
Flat Slide Gate (pneumatic) 431/432 A 201 ................................................................................7
Reversing Flap (manual) 431/432 A 210.....................................................................................7
Fraction Bin 431/432 A 300.........................................................................................................7
Knife gate (pneumatic) 431/432 A 415........................................................................................7
Telescopic Chute 431/432 A 420 ................................................................................................7
9.1
Process
9.1.1
Process Flow Sheets

(Work Copy)
Outokumpu Technology GmbH

file: 138-02-043_09_0.doc, Codeword: Vedanta
Revision: 0
Date: 29.09.2006
Page 1 of 7

9.1.2
138-02-043
Group 431/432 A
DE-060300
Brief Process Description

(Work Copy)

Page 2 of 7
Revision: 0
Date: 29.09.2006
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.:
133-50-066
1 (2)
Rev. 00
Brief Process Description

of
Process Group 431 A
- Coke Crushing & Screening Reference:
Process Flow Sheet:
132-01-078 UB
P&I Diagram:
168-01-058 UB Sheet 1-2
The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This operating group is processing Calcined Petroleum Coke as raw material of mainly 030mm grain size with a very little percentage of 30-50mm. The raw material is stored in coke
feed bin (390 A 200) with 15.4 tons capacity.
The coke feed bin (390 A 200) has one outlet isolated by hand operated flat slide gates (431 A
101) which is normally open and which will be closed for maintenance purposes only.
Petroleum coke is continuously withdrawn from the coke feed bin (390 A 200) by means of a
weigh feeder (431 A 103). The feeder is equipped with variable speed drive for controlling the
feed rate.
At normal operation, when both calcined petroleum coke and butts (crushed recycled baked
anodes) in operating group 431 are available, a maximum petroleum coke feed rate of 26
tons/hour can be adjusted.
In case no butts are available in Group 431 B that operating group (431 B) can also be fed
with petroleum coke. The maximum feed rate of coke, measured at weigh feeder (431 A 103)
is then higher (max. limit is 34 tons/hour) because the butts, normally fed to Group 431 B have
now to be replaced by petroleum coke.
By means of a servo-motor operated splitter gate (431 A 105) the material flow can be split
into two part-flows of equal or un-equal rate or the whole flow can be directed to either side.
In most of the cases the operator sets the splitter blade to by-pass the impact crusher (431 A
110) feeding directly the uncrushed material to the bucket elevator (431 A 115) boot.
In very few cases e.g. if the coke delivered is too coarse, the whole flow or only a part of it has
to be fed to the impactor for crushing to prevent overloading of the bucket elevator and the
screen (431 A 145) of the crushing and screening circuit.
The bucket elevator lifts up the material to the top of the building and discharges it on a
vibrating feeder (431 A 120), which spreads the flow for equal feeding of the drum magnet
(431 A 125) underneath.
The magnetic separator is of the permanent-magnet type having a motor driven, rotating drum
and a fixed magnet inside, which is removing iron particles from the material, flowing over the
drum. The iron pieces caught by the magnet are falling down through a chute to the ground
floor into a small container (431 A 130).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
2 (2)
Rev. 00
The petroleum coke flow is now passing a manually operated splitter gate (431 A 135), located
directly under the drum magnet.
By means of this splitter gate either a part of the flow can be sent to Group 431 B (Route No.
2) or the whole flow can be fed to the screen feeder (431 A 140) and the screen (431 A 145)
(Route-No.1).

9.1.3
138-02-043
Group 431/432 A
DE-060300
Main Process Data & Process Highlights

This Process Group is designed for a maximum feed rate (production rate) of 34
t/hour of fresh petroleum coke. This is the rate required if no butts could be
processed through Process Group 431/432 B. In this case butts are replaced by
petroleum coke.
The operator must never set the total coke feed rate to more than 26 t/h, if Coke
through Group 431/432 A only is selected on SCADA because a higher feed rate
would overload the screen, the bucket elevator and the impact crusher.
In case butts are processed through Process Group 431/432 B the feed rate of coke
has to be reduced to 26 t/hour what is sufficient to keep the fraction silos full. This will
be the mostly used operating mode.
The process load of certain equipment like bucket elevator, screen feeder and screen
is much higher than 26 t/hour or 34 t/hour because they are working in a closed circuit
and so getting back material from the impact crusher. The process loads (flow rates),
expressed as t/hour can be found in the Process Flow Sheets in ovals.
The equipment capacity is higher than the maximum process load, based on 34.6
t/h feed rate.
In case of the bucket elevator the process load is 51.0 t/h at a maximum whereas the
equipment capacity is 56 t/h. The equipment capacity of main equipment can be
found in the Process Flow Sheets in a rhombus.
The grain size distribution of incoming petroleum coke should be within the ranges
shown on the screen scale attached (Drawing-No.: 803-59-703 UE, rev.0). If the coke
is coarser, the feed rate probably has to be reduced to avoid overload of the screen
(431/432 A 145), the bucket elevator (431/432 A 115), the vibrating feeder (431/432 A
120) and the screen feeder (431/432 A 140). Overload is indicated by high power
draw (measured as Ampere) of the bucket elevator.
If 110% of the nominal process load (= 110% of nominal Ampere) is indicated for the
bucket elevator, the feed rate of the belt weigh feeder (431/432 A 103) reclaiming
coke out of the coke feed bin is reduced automatically to 85% of its actual feed rate
setting.
If the overload reaches even 120% of the nominal process load the belt weigh feeder
(431/432 A 103) is shut off.
The Feed rate of petroleum coke is controlled by a belt weigh feeder.

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Date: 29.09.2006
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138-02-043
Group 431/432 A
DE-060300
The impact crusher features frequency controlled motor, which allows running the
crusher at different rotor speed. The higher the speed the finer is the product leaving
the crusher and vice versa. The crusher rotor can run clockwise or counter-clockwise.
If after longer clockwise operation the fixed wing-type crusher tool is worn the motor
may run reversed to use the opposite less worn wing for crushing.
The material in the fraction bins can be levelled by a number of splitter gates. The
position of the gates is controlled on SCADA by operator input. As an ideal the level in
all fraction bins always should be equal.
Floor dust, if mainly consisting of coke, butts or green scrap, is reused. The feed rate
should be low because the size distribution and product quality may vary within short
time intervals. If there is not too much material in the floor dust bin a feed rate of 1
t/hour should not be exceeded.
If floor dust is too much contaminated with rubbish, it can be dumped in bulker bags to
be deposited. This can be done during normal production after selection on SCADA.
Packing coke is produced parallel to the generation of coke fractions. The grain size
distribution is adjustable by two splitter gates. Packing coke can be reclaimed from
storage bin any time, independent from the operation of Group 431/432 A but requires
Group 431/432 C (Main Dust Treatment) running.
Recycled packing coke is received from the baking furnace and can be added to the
process at a low feed rate.

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Date: 29.09.2006

9.2
Process Control
9.2.1
P&Id`s, Operator Screen Images
138-02-043
Group 431/432 A
DE-060300
(work copies)

Revision: 0
Date: 29.09.2006
Page 5 of 7

9.2.2
138-02-043
Group 431/432 A
DE-060300
Control Logic Description

(Work Copy)

Page 6 of 7
Revision: 0
Date: 29.09.2006
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
1 (31)
Rev. 00
Control Philosophy
of
Process Group 431 A
- Coke Crushing & Screening Reference:
Process Flow Sheet:
132-01-078 UB
P&I Diagram:
168-01-058 UB Sheet 1-2
Brief Process Description............................................................................................................ 2
2
2.1
2.2
2.3
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 Logic Description ............................................................................................................ 4

Special Terminology For This Group .......................................................................................... 4
Linked Process Groups............................................................................................................... 4
Selection of Operation Modes..................................................................................................... 4
Group Start ................................................................................................................................. 6
Selections Prior to Group Start ................................................................................................... 6
Start Preconditions...................................................................................................................... 6
Setpoints Prior to Group Start ..................................................................................................... 7
Group Start Sequence ................................................................................................................ 9
Restarting the Group................................................................................................................. 11
Normal Operation...................................................................................................................... 11
Shut Down ................................................................................................................................ 16
Normal Shut Down .................................................................................................................... 16
Shut Down by Other Groups ..................................................................................................... 16
Fast Shut Down......................................................................................................................... 17
Trip in Case of Faults ................................................................................................................ 17
Shut Down by Full Bins ............................................................................................................. 28
Local Operation of Special Equipment...................................................................................... 29
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 31
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
1
2 (31)
Rev. 00
BRIEF PROCESS DESCRIPTION

The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This operating group is processing Calcined Petroleum Coke as raw material of mainly 030mm grain size with a very little percentage of 30-50mm. The raw material is stored in coke
feed bin (390 A 200) with 15.4 tons capacity.
The coke feed bin (390 A 200) has one outlet isolated by hand operated flat slide gates (431 A
101) which is normally open and which will be closed for maintenance purposes only.
Petroleum coke is continuously withdrawn from the coke feed bin (390 A 200) by means of a
weigh feeder (431 A 103). The feeder is equipped with variable speed drive for controlling the
feed rate.
At normal operation, when both calcined petroleum coke and butts (crushed recycled baked
anodes) in operating group 431 are available, a maximum petroleum coke feed rate of 26
tons/hour can be adjusted.
In case no butts are available in Group 431 B that operating group (431 B) can also be fed
with petroleum coke. The maximum feed rate of coke, measured at weigh feeder (431 A 103)
is then higher (max. limit is 34 tons/hour) because the butts, normally fed to Group 431 B have
now to be replaced by petroleum coke.
By means of a servo-motor operated splitter gate (431 A 105) the material flow can be split
into two part-flows of equal or un-equal rate or the whole flow can be directed to either side.
In most of the cases the operator sets the splitter blade to by-pass the impact crusher (431 A
110) feeding directly the uncrushed material to the bucket elevator (431 A 115) boot.
In very few cases e.g. if the coke delivered is too coarse, the whole flow or only a part of it has
to be fed to the impactor for crushing to prevent overloading of the bucket elevator and the
screen (431 A 145) of the crushing and screening circuit.
The bucket elevator lifts up the material to the top of the building and discharges it on a
vibrating feeder (431 A 120), which spreads the flow for equal feeding of the drum magnet
(431 A 125) underneath.
The magnetic separator is of the permanent-magnet type having a motor driven, rotating drum
and a fixed magnet inside, which is removing iron particles from the material, flowing over the
drum. The iron pieces caught by the magnet are falling down through a chute to the ground
floor into a small container (431 A 130).
The petroleum coke flow is now passing a manually operated splitter gate (431 A 135), located
directly under the drum magnet.
By means of this splitter gate either a part of the flow can be sent to Group 431 B (Route No.
2) or the whole flow can be fed to the screen feeder (431 A 140) and the screen (431 A 145)
(Route-No.1).
CONTROL PHILOSOPHY
05.10.2006
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DE-060300
Doc. No.:
133-50-066
3 (31)
Rev. 00
Route No.2
Route No.2 is only used, if there are no butts available in Group 431 B (Butts Crushing &
Screening). In this case, as already mentioned above, the feed rate of petroleum coke is
significantly higher to replace the missing butts by coke. The feed rate is about 1 times of
the rate the screen of this Group 431 A could process. Therefore about 30% of the total feed
rate is sent to Group 431 B to be crushed and screened there. Cutting off this part of flow is
done by the manually operated splitter gate 431 A 135.
Route No.1
Route No.1 is the normal way, feeding the screen (431 A 145) via the screen feeder (431 A
140), which is spreading the material flow over the whole width of the screen. That means
sufficient butts are available in Group 431 B and the coke feed is at the normal (= maximum)
rate of 26 tons/hour.
The screen is providing five (5) fractions, OVERSIZE (>12mm), COARSE COKE (6-12mm),
MEDIUM COKE (3-6mm), FINE COKE (0.5-3mm) and PAN PRODUCT (<0.5mm).
Oversize material (>12mm) completely flows back into the impact crusher (431 A 110).
The flow of Coarse Coke (6-12mm) is split into two part-flows by means of splitter gate (431 A
150). A splitter gate is of similar design as a reversing flap but features a servo-drive, which is
remote controlled, which allows stopping of the splitter blade at any position the operator
wants. It only requires an input on the Central Control Room Operator Station (e.g. 80%) and
the motor starts turning the blade to the right position. In most of the cases the mayor part of
material is flowing to the impact crusher for further crushing while the rest is directed via
chutes into the COARSE COKE fraction bin 431 A 330 for intermediate storage.
The MEDIUM COKE screen fraction (3-6mm) is used as Ball Mill Feed, Packing Coke and
Medium Coke Fraction material. All three bins, 431 A 320, 431 A 400 and 431 A 310 and the
impact crusher 431 A 110 shall be fed continuously. The use of three splitter gates (431 A 155;
431 A 160 and 431 A 175) in series makes this possible. It is up to the operators excellence to
adjust the splitter gates in order hold a nearly equal material level in the bins.
The FINE COKE screen fraction (0.83mm) is used as Ball Mill Feed material, FINE COKE
FRACTION material and as Packing Coke blend. With the aid of two splitter gates in series
(431 A 165 / 170) the material flow is split accordingly to keep the material in the two bins
leveled.
The PAN PRODUCT of the screen is very fine in size (0-0.8mm). It is used as Ball mill feed
material only. It flows into the screw conveyor (431 A 157) to be mixed up with a part of the
FINE COKE- and MEDIUM COKE screen fraction and with excess butts fines (0-3mm), if this
material cannot be used in Group 431 B because the bin (431 B 210) is full (normally there is
no excess butts). This blend is flowing via the screw conveyor (431 A 215) into the Ball mill
feed bin (431 A 320).
Screw conveyors (431 A 157, 431 A 180, 431 A 215) are in charge for transport where gravity
flow is not possible.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
4 (31)
Rev. 00
Floor dust (0-30mm) is stored in a bin (431 D 100) in Group 431 D. This dust can be of all
grain sizes starting from dust up to 30mm and is mainly of petroleum coke, butts or green
scrap, what ever has been sucked off from the floors of the GAP building. Floor dust may
contain also some tramp material like aluminium, steel, paper, fabric, timber pieces etc. Floor
dust is withdrawn from the bin by means of two pneumatically operated flat slide gates (431 A
201 and 431 A 202) installed in series. The manual flat slide gate (431 A 200) is always open
and will be closed only for maintenance reason.
The operator may control the feed rate of floor dust from the Operator Station in the Central
Control Room by changing the opening/closing sequence time of the flat slide gates (431 A
201/202).
Downstream the floor dust is added to the petroleum coke blend in screw conveyor (431 A
215). By means of a reversing flap (431 A 210) the floor dust can be diverted into a bulker bag
for calibration of the feed rate or for dumping the material if the carbon material is too much
contaminated with dirt.
Packing coke (0.8-6 mm) is stored in a storage bin (431 A 400). On request of the baking
furnace regime packing coke is taken from that bin after a mobile hopper (431 A 425) has
been placed under the telescopic chute (431 A 420). The chute is lowered to the hopper and
then the pneumatically operated knife gate (431 A 415) is opened and the packing coke is
withdrawn from the bin via screw conveyor (431 A 412) for a period long enough to fill the
hopper. An operator controls filling locally.
2
CONTROL LOGIC DESCRIPTION
2.1
Special Terminology For This Group

There is no special terminology for this group.
2.2
Linked Process Groups

The following Process Groups are linked with this Group 390 A:
Main Dust Treatment 431 C

Coke Reclaiming 390 A
Butts Crushing & Screening 431 B
Fines Packing Coke Supply (VEDANTA)
The exchange of control signals is described in the following chapters and especially under 2.8
below.
2.3
Selections
2.3.1
Selection of Operation Modes (SE 1)

The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA.
The operator has two options:
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
2.3.2
5 (31)
Rev. 00
CENTRAL operation mode
After this selection this Group is ready to start in CENTRAL

operation mode, if all preconditions (see 2.4.2) below are
fulfilled.
LOCAL operation mode
(details please see under 2.7 below)
Material Route (SE 2)

The operator has the choice between two options:
Selection and indication of the state of selection is on SCADA prior to Group start only. Beside
the selection on SCADA physically the operator has to move the splitter Blade of the manual
splitter gate (431 A 135) in a correct position.
SE 2-1 - Coke through Group 431 A only
This is the normal selection when butts are available in Group 431 B Butts Crushing &
Screening.
In this case the manual splitter gate (431 A 135) must indicate [431 A 135-ZH]. If this condition
is not fulfilled this Group is not ready to start and an alarm on the SCADA system is generated.
SE 2-2 - Coke through Group 431 A and 431 B
This selection is used if there are no butts available in Group 431 B Butts Crushing &
Screening.
In this case the manual splitter gate (431 A 135) must not indicate [431 A 135-ZH], weigh
feeder (431 B 103) must not be in operation and Group 431 B must operate in CENTRAL
mode and must not be in run empty operation (RESTOP). If one of these conditions is not
fulfilled this Group is not ready to start and an alarm on the SCADA system is generated.
If the selection is changed to SE 2-2 during normal operation of group 431 A the manual gate
(431 A 135) must not remain in position 100% to group 431 A limit switch [431 A 135-ZH] for a
period of 3 minutes. The operator has 3 minutes to move the splitter gate for adjustment.
2.3.3
Floor Dust (SE 3)

The operator has three options:
SE 3-1 Add Floor Dust
The operator may select Add Floor Dust at any time. Straight with the selection change both
flat slide gates (431 A 201/202) are closing. Selection requires the reversing flap limit switch
[431 A 210-ZL] to be initiated (flap to screw conveyor (431 A 157)). On the Local Operator
Panel [431 A 201-LOP] the pilot light [431 A 201-H3] indicates CENTRAL operating mode.
SE 3-2 Floor Dust LOCAL
The operator may select LOCAL at any time. Straight with the selection change both flat slide
gates (431 A 201/202) are closing. Selection requires the reversing flap limit switch [431 A
210-ZH] to be initiated (flap to calibration). On the Local Operator Panel [431 A 201-LOP] the
pilot light [431 A 201-H4] indicates LOCAL operating mode what releases the push buttons on
this local panel and allows local operation of the flat slide gates.
SE 3-3 NO FLOOR DUST
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
6 (31)
Rev. 00
The operator may select NO FLOOR DUST at any time. Straight with the selection change
both flat slide gates (431 A 201/202) are closing.
2.3.4
Fines Packing Coke (SE 4)

The operator has two options:
SE 4-1 Add Fines Packing Coke
The operator may select Add Fines Packing Coke at any time as long as CENTRAL
operation mode is selected and if the reversing flap (431 A 445) is in correct position [limit
switch 431 A 445-ZH activated] so that Fines Packing Coke will be fed to ball mill feed bin.
SE 4-2 Fines Packing Coke LOCAL
The operator may select Fines Packing Local at any time. Straight with the selection the
rotary lock (431 A 440) stops feeding. Starting the rotary lock requires the reversing flap limit
switch [431 A 445-ZH] is not initiated (flap to calibration). On the Local Operator Panel [431 A
440-LOP1] the pilot light [431 A 440-H2] indicates the rotary lock is stopped and thus the
LOCAL operating mode is released (at Add Fines packing Coke selection all pilot lights on
the local panel are off) and so are the push buttons on this local panel.
SE 4-3 No Fines Packing Coke
The operator may select No Fines Packing Coke at any time as long as CENTRAL
operation mode is selected so that no Fines Packing Coke will be fed to ball mill feed bin.
2.4
Group Start
2.4.1
Selections Prior to Group Start

CENTRAL operation mode must be selected.
2.4.2
Start Preconditions
2.4.2.1 Process Group 431 C - Main Dust Treatment

The Group Main Dust Treatment must be running in CENTRAL operation mode prior to
start this Group. It must not be tripped and not be in a stop (RESTOP or FASTOP)
sequence.
2.4.2.2 Process Group 431 B (Selection SE 2-2 - Coke through Group 431 A and 431 B)
If selection SE 2-2 (Coke through Group 431 A and 431 B) is set, Group 431 B must be
running in CENTRAL operation mode prior to start this Group. It must not be tripped and
not be in a stop (RESTOP or FASTOP) sequence.
If selection SE 2-2 (Coke through Group 431 A and 431 B) is set, the manual splitter gate
(431 A 135) must not indicate [431 A 135-ZH]
2.4.2.3 Ball Mill Feed Bin 431 A 320
If the bin (431 A 320) is full [431 A 320-LAH2 or 431 A 320-LAHH is indicating very high-or
high-high level] this Group does not start.
2.4.2.4 Fine Coke Fraction Bin 431 A 300
CONTROL PHILOSOPHY
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OTK ref.:
DE-060300
Doc. No.:
133-50-066
7 (31)
Rev. 00
If the Fine Coke Fraction bin is full [431 A 300-LAH2] is indicating very high level and/or
431 A 300-LAHH] is indicating high-high level and the splitter gate (431 A 165) is not
adjusted at 100% material flow to the screw conveyor (431 A 157) [limit switch 431 A 165ZL is not actuated] this Group does not start.
2.4.2.5 Emergency stop

If the Emergency Stop of the Group has been activated it has to be RESET.
2.4.2.6 Alarms
If an Alarm of this Group has been activated it has to be RESET.
2.4.2.7 MCC`s of this Group
The MCCs signal of this group must be OK.
2.4.2.8 FASTOP Signal
If a FASTOP signal is valid this Group does not start.
2.4.2.9 RESTOP Signal
If a RESTOP signal is valid this Group can be restarted by overriding the RESTOP signal
by the Group Start signal.
2.4.2.10 Vibrating Screen Feeder 431 A 140 -plugged chute switch
If the plugged chute switch [431 A 140-LAH] is indicating Plugged Chute in the chute
above the screen feeder (431 A 140), this Group does not start.
2.4.2.11 Compressed Air Pressure 431 G 120
Compressed air pressure in Group G [431 G 120-PAL] shall be higher than 6 bar (P>6
bar).
2.4.3
Setpoints Prior to Group Start

It makes sense to check and, if required, to readjust setpoints prior to a start of this Group.
Actual Setpoint
The PLC program is storing all actually used setpoints as

Actual Setpoint The Actual Setpoint is automatically used
for the next start after the Group has been stopped or for a
restart after the Group has tripped. The Actual Setpoint is
displayed on SCADA.
New Setpoint
The operator has the opportunity to override the actual

setpoint by the New Setpoint any time Changing of setpoint
is on SCADA.
Previous Setpoint
Did the operator change an Actual Setpoint while the Group is

running in CENTRAL mode the previous one is also stored in
the PLC as Previous Setpoint for possible later use. The
operator may override the actual setpoint by the Previous
Setpoint at any time. Selection of the Previous Setpoint is on
SCADA.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
Standard Setpoint
8 (31)
Rev. 00
The operator may also override the actual setpoint by the

Standard Setpoint any time. Selection of the Standard
Setpoint is on SCADA. The Standard Setpoint can be edited
on the SCADA system any time but by a Shift Leader only,
after using his Password.
2.4.3.1 Weigh Feeder 431 A 103 - (Setpoint SP 1)

The operator may set the feed rate at any time in a range of 4.0 to 40.0 tons/hour. Setting
and 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.
2.4.3.2 Impact Crusher 431 A 110 - (Setpoint SP 2)
The operator may set the rotor speed at any time. The speed can be set within a range of
40% to 100%, equal to a rotor tip speed range of 20-45 m/s. 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 80%) all overriding the actual
setpoint.
2.4.3.3 Splitter Gate 431 A 105 - (Setpoint SP 3)
The operator may set the splitter blade position at any time in a range of 0% to 100% [0%
= limit switch position 431 A 105-ZL]. Setting and display of the actual position is on
SCADA. On SCADA the operator has the choice to select one of three options, New
setpoint, Previous setpoint and Standard setpoint all overriding the actual setpoint
(Standard setpoint: 0% - by-pass impact crusher -).
= limit switch position 431 A 150-ZH]. Setting and display of the actual position is on
setpoint, Previous setpoint and Standard setpoint all overriding the actual setpoint.
If the Coarse Coke Fraction bin is full [431 A 330-LAH2] is indicating very high level
and/or 431 A 330-LAHH] is indicating high-high level and the splitter gate (431 A 150) is
not adjusted at 100% material flow to the impact crusher (431 A 110) [limit switch 431 A
150-ZL is not actuated] the splitter blade tilts to this limit switch [431 A 150-ZL]
automatically during Group Start.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
9 (31)
Rev. 00
If the Packing Coke bin (431 A 400) is full [431 A 400-LAH2 is indicating very high level
and/or limit switch 431 A 400-LAHH is indicating high-high level] and the splitter gate (431
A 160) is not adjusted at 100% material flow to the splitter gate (431 A 175) [limit switch
431 A 160-ZH is not actuated] the splitter blade tilts to limit switch [431 A 160-ZH]

A 170) is not adjusted at 100% material flow to the Fine Coke Fraction bin (431 A 300)
[limit switch 431 A 170-ZL is not actuated] and the Fine Coke Fraction bin is not full the
splitter blade tilts to limit switch [431 A 170-ZL] automatically during Group Start.
If the Medium Coke Fraction bin is full [431 A 310-LAH2] is indicating very high level
175-ZL is not actuated] the splitter blade tilts to limit switch [431 A 175-ZL] automatically
during Group Start.
2.4.3.10 Floor Dust Feed Rate Flat Slide Gates 431 A 201/202 - (Setpoint SP 10)
The operator may set the feed rate for floor dust at any time in a range of 0% to 100%
[100% = 3.0 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 (first approach is 33% = 1.0 ton/hour) all
overriding the actual setpoint.
2.4.3.11 Fines Packing Coke Feed Rate Rotary Lock 431 A 440 - (Setpoint SP 11)
The operator may set the feed rate for fines packing coke at any time in a range of 30% to
100% [100% = 1.0 tons/hour]. Setting and display of the actual position is on SCADA. On
2.4.4
Group Start Sequence
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
10 (31)
Rev. 00
The start sequence depends on the Material Route selected. There are 2 different material
routes. One of the routes must have been selected prior to the Group Start.
SE 2-1 - Coke through Group 431 A only This is the normal selection when butts are
available in Group 431 B.
SE 2-2 - Coke through Group 431 A and 431 B This selection is used if there are no
butts available in Group 431 A Butts Crushing & Screening.
Both start sequences are nearly identical. The only difference is that selection SE 2-2 requires
Group 431 B (Butts Crushing & Screening) running and that the blade of splitter gate (431 A
135) has to be not in position of limit switch [431 A 135-ZH]. Because of this only one start
sequence for both selections is described below.
The operator is enabling this Group 431 A to start and to run the selected equipment. To
initiate the start he is using the SCADA system on the Operator Station in the Central
Control Room.
Signal from Group 431 C (Main Dust Treatment) is required (Group is running in
CENTRAL mode and is not in Group Start (START) or any Group Stop sequence
(RESTOP or FASTOP)).
If SE 2-2 (Coke through Group 431 A and 431 B) is selected,
a signal from Group 431 B (Butts Crushing & Screening) is required (Group is running
in CENTRAL mode and is not in Group Start (START) or any Group Stop sequence
(RESTOP or FASTOP)).
limit switch [431 A 135] must not be in position [431 A 135-ZH].
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 A 180) starts.
Splitter gate (431 A 150) is enabled - If the Coarse Coke Fraction bin is full [431 A 330LAH2] is indicating very high level and/or 431 A 330-LAHH] is indicating high-high level
and the splitter gate (431 A 150) is not adjusted at 100% material flow to the impact
crusher (431 A 110) [limit switch 431 A 150-ZL is not actuated] the splitter blade tilts to this
limit switch [431 A 150-ZL] automatically.
Splitter gate (431 A 155) is enabled.
Splitter gate (431 A 160) is enabled - If the Packing Coke bin (431 A 400) is full [431 A
400-LAH2 is indicating very high level and/or limit switch 431 A 400-LAHH is indicating
high-high level] and the splitter gate (431 A 160) is not adjusted at 100% material flow to
the splitter gate (431 A 175) [limit switch 431 A 160-ZH is not actuated] the splitter blade
tilts to limit switch [431 A 160-ZH] automatically.
Splitter gate (431 A 165) is enabled.
Splitter gate (431 A 170) is enabled - If the Packing Coke bin (431 A 400) is full [431 A
400-LAH2 is indicating very high level and/or limit switch 431 A 400-LAHH is indicating
high-high level] and the splitter gate (431 A 170) is not adjusted at 100% material flow to
the Fine Coke Fraction bin (431 A 300) [limit switch 431 A 170-ZL is not actuated] and
the Fine Coke Fraction bin is not full the splitter blade tilts to limit switch [431 A 170-ZL]
automatically.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
2.4.5
11 (31)
Rev. 00
Splitter gate (431 A 175) is enabled - If the Medium Coke Fraction bin is full [431 A 310LAH2] is indicating very high level and/or 431 A 310-LAHH] is indicating high-high level
and the splitter gate (431 A 175) is not adjusted at 100% material flow to the impact
crusher (431 A 110) [limit switch 431 A 175-ZL is not actuated] the splitter blade tilts to
limit switch [431 A 175-ZL] automatically.
Splitter gate (431 A 105) is enabled
Impact crusher (431 A 110) starts.
Delay of 30 seconds for impact crusher rotor run-up.
Vibrating screen (431 A 145) starts.
Screen feeder (431 A 140) starts.
Drum-type magnet (431 A 125) starts.
Vibrating feeder (431 A 120) starts.
Bucket elevator (431 A 115) starts.
Belt weigh feeder (431 A 103) starts.
Flat slide gates (431 A 201 / 202) start feeding sequence, if SE 3-1 is selected.
Aeration unit (431 A 190) starts aerating sequence, if SE 3-1 is selected.
Rotary Lock ( 431 A 440) starts if SE 4-1 is selected.
Aeration unit (431 A 436) starts aerating sequence, if SE 4-1 is selected.
Group 431 A is running completely in CENTRAL mode.
Restarting the Group

If the Group is in a run-empty stop sequence, (after Normal Shut Down (RESTOP)) and a
part of the Group is still running, it is possible to restart this Group by activating the START
button. Restarting is only possible after all faults have been eliminated and reset. The Restart
follows the same sequence like the normal Group Start including the horn sequence as
described above.
2.5
Normal Operation
2.5.1
Belt Weigh Feeder 431 A 103

If the weigh feeder is not tripped this Group is in normal operation.
The operator may set the feed rate at any time in a range of 4.0 to 40.0 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
2.5.2
Splitter gate 431 A 105

If the splitter gate is not tripped this Group is in normal operation.
setpoint, Previous setpoint and Standard setpoint all overriding the actual setpoint
(Standard setpoint: 0% - by-pass impact crusher -).
2.5.3
Impact Crusher 431 A 110
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
12 (31)
Rev. 00
If the crusher is not tripped this Group is in normal operation.

The operator may set the rotor speed at any time. The speed can be set within a range of
40% to 100%, equal to a rotor tip speed range of 20-45 m/s. 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 80%) all overriding the actual
setpoint.
2.5.4
Bucket Elevator 431 A 115

If the bucket elevator is not tripped this Group is in normal operation.
[431 A 115-IAH1] {> 110% of the current at nominal process load} The current drawn by
the bucket elevator motor is measured continuously. If the current is too high for more
than 15 seconds, this causes an alarm. This signal is overriding the setpoint SP 1
(setpoint for the belt weigh feeder 431 A 103) by multiplying the actual setpoint with a
factor of 0.85 in order to reduce the feed rate automatically thus reducing the actual
capacity of the bucket elevator.
[431 A 115-IAH2] {> 120% of the current at nominal process load} The current drawn by
the bucket elevator motor is measured continuously. If the current is too high for more
than 15 seconds, this causes an alarm and belt weigh feeder (431 A 103) stopped
instantly. The rest of equipment of this Group is kept running.
2.5.5
Vibrating Feeder 431 A 120

If the vibrating feeder is not tripped this Group is in normal operation
2.5.6
Drum-type Magnet 431 A 125

If the magnet is not tripped this Group is in normal operation
2.5.7
Splitter Gate, manual 431 A 135

SE 2-1 - Coke through Group 431 A only This is the normal selection when butts are
available in Group 431 B. In this case the manual splitter gate (431 A 135) must indicate
[431 A 135-ZH].
Note: It is not allowed to change the blade position during Normal Operation if SE 2-1 is
selected.
SE 2-2 - Coke through Group 431 A and 431 B This selection is used if there are no
butts available in Group 431 A Butts Crushing & Screening. In this case the manual
splitter gate (431 A 135) must not indicate 0% [limit switch 431 A 135-ZH]. The operator
may change the splitter blade position any time but never at 0%. Target position should
be set to attain a material flow to Group 431 B in a range of 20% 45% of the feed rate to
the splitter gate. The flow rate feeding Group 431 B must never increase 20 tons/hour.
2.5.8
Screen Feeder 431 A 140

If the screen feeder is not tripped this Group is in normal operation
2.5.9
Screen 431 A 145

If the screen is not tripped this Group is in normal operation
2.5.10

If the splitter gate is not tripped this Group is in normal operation
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
13 (31)
Rev. 00
If the Coarse Coke Fraction bin is full [431 A 330-LAH2] is indicating very high level
150-ZL is not actuated] the splitter blade tilts to this limit switch [431 A 150-ZL]
2.5.11

If the splitter gate is not tripped this Group is in normal operation
2.5.12

If the splitter splitter gate is not tripped this Group is in normal operation
A 160) is not adjusted at 100% material flow to the splitter gate (431 A 175) [limit switch
431 A 160-ZH is not actuated] the splitter blade tilts to limit switch [431 A 160-ZH]
automatically.
2.5.13

2.5.14

A 170) is not adjusted at 100% material flow to the Fine Coke Fraction bin (431 A 300)
[limit switch 431 A 170-ZL is not actuated] and the Fine Coke Fraction bin is not full the
splitter blade tilts to limit switch [431 A 170-ZL] automatically.
2.5.15
CONTROL PHILOSOPHY
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OTK ref.:
DE-060300
Doc. No.:
133-50-066
14 (31)
Rev. 00
If the Medium Coke Fraction bin is full [431 A 310-LAH2] is indicating very high level
175-ZL is not actuated] the splitter blade tilts to limit switch [431 A 175-ZL] automatically
2.5.16
Fraction Bin 431 A 300 Fine Coke

If the fraction bin level measurement is not tripped this Group is in normal operation.
If the fraction bin is not full (bin level is not >/= 95% [431 A 300-LAH2] and/or not >/=
100% [431 A 300-LAHH]) this Group is in normal operation.
If the fraction bin is full (bin level is >/= 95% [431 A 300-LAH2] and/or >/= 100% [431 A
300-LAHH]) and splitter gate (431 A 165) is after a travel time of 90 seconds at 100%
material flow to screw conveyor 431 A 157 [limit switch 431 A 165-ZL actuated] this Group
is in normal operation.
2.5.17
Fraction Bin 431 A 310 Medium Coke

material flow to impact crusher (431 A 110) [limit switch 431 A 175-ZL actuated] this
Group is in normal operation.
2.5.18
Ball Mill Feed Bin 431 A 320

If the ball mill feed bin level measurement is not tripped this Group is in normal operation.
If the ball mill feed bin is not full (bin level is not >/= 95% [431 A 320-LAH2] and/or not >/=
2.5.19
Fraction Bin 431 A 330 Coarse Coke

material flow to impact crusher (431 A 110) [limit switch 431 A 150-ZL actuated] this
Group is in normal operation.
2.5.20
Packing Coke Bin 431 A 400

If the Packing Coke bin level measurement is not tripped this Group is in normal operation.
If the Packing Coke bin is not full (bin level is not >/= 95% [431 A 400-LAH2] and/or not
>/= 100% [431 A 400-LAHH]) this Group is in normal operation.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
15 (31)
Rev. 00
and/or 431 A 400-LAHH is indicating high-high level] and the splitter gate (431 A 170) is
not adjusted at 100% material flow to the Fine Coke Fraction bin (431 A 300) [limit switch
431 A 170-ZL is not actuated] and the Fine Coke Fraction bin is not full the splitter blade
tilts to limit switch [431 A 170-ZL] automatically and if the splitter gate (431 A 160) is not
adjusted at 100% material flow to splitter gate (431 A 175) [limit switch 431 A 160-ZH is
not actuated] the splitter blade tilts to limit switch [431 A 160-ZH] automatically.
2.5.21
Rotary Lock 431 A 440

If the rotary lock is not tripped this Group is in normal operation.
The operator may select Add Fines Packing Coke (SE 4-1) at any time. Straight with
the selection change rotary lock (431 A 440) starts immediately, and aeration unit (431 A
436) starts aerating sequence.
This rotary lock is equipped with a variable speed drive. The speed can be varied between
30 % and 100 % corresponding a feed rate between 0.3 and 1.0 tons/hour. 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
2.5.22
Flat Slide Gate 431 A 201/202

If the flat slide gates are not tripped this Group is in normal operation
The operator may select NO FLOOR DUST (SE 3-3) at any time. Straight with the
selection change both flat slide gates (431 A 201/202) are closing until limit switches [431
A 201-ZL] and [431 A 202-ZL] are activated.
The operator may select ADD FLOOR DUST (SE 3-1) at any time. Straight with the
selection change both flat slide gates (431 A 201/202) are closing until limit switches [431
A 201-ZL] and [431 A 202-ZL] are activated.
The operator may set the feed rate for floor dust at any time in a range of 0% to 100%
[100% = 3.0 tons/hour]. Setting and display of the actual position is on SCADA. On
The feed rate is controlled by the number of opening and closing sequences per hour of
the flat slide gates (431 A 201/202).
The sequence is like follows:
select SE 4-1 of this Group on SCADA
Reversing flap (431 A 210) tilts until limit switch [431 A 210-ZL] is activated.
operator gives start command FEED FLOOR DUST on SCADA.
Pneumatically operated flat slide gate (431 A 201) open until limit switch [431 A 201ZH] is activated.
delay of 3 seconds
Pneumatically operated flat slide gate (431 A 201) closes until limit switch [431 A 201ZL] is activated.
Pneumatically operated flat slide gate (431 A 202) opens until limit switch [431 A 202ZH] is activated.
delay of 5 seconds
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
-
16 (31)
Rev. 00
Flat slide gate (431 A 202) closes until limit switch [431 A 202-ZL] is activated.
delay of variable seconds ( the variable delay time is calculated using setpoint SP 11
above)
Aeration unit (431 A 190) starts blowing (blow time = 1 second, followed by delay time
of 15 seconds, blow/delay; blow/delay; .....)
next sequence starts with step 4. and ends with step 10. until this Group is stopped
completely (by RESTOP or FASTOP) or feeding of floor dust is stopped on SCADA by
command STOP FLOOR DUST.
2.6
Shut Down
2.6.1
Normal Shut Down

To initiate this sort of shut down the operator uses the RESTOP button on the SCADA
system.
The operator stops this Group using the RESTOP push button on SCADA.
Belt weigh feeder (431 A 103) stops
Splitter gate (431 A 150) tilts to limit switch [431 A 150-ZH].
Splitter gate (431 A 175) tilts to limit switch [431 A 175-ZH].
Delay of 5 minutes (further run-empty time)
Splitter gate (431 A 150) tilts to its previous position using the Actual Setpoint and stops
Splitter gate (431 A 175) tilts to its previous position using the Actual Setpoint and stops
flat slide gates (431 A 201/202) are both closing, if Add Floor Dust (SE 3-1) is selected
rotary lock (431 A 440) stops, if Add Fines Packing Coke (SE 4-1) is selected
Delay of 2 minutes
All equipment of this Group stops.
The whole group is stopped.
Exception: Packing Coke discharge through screw conveyor (431 A 412), knife gate (431 A
415) and telescopic chute (431 A 420) is not affected because this is locally controlled only.
2.6.2
Shut Down by Other Groups

If this Group 431 A is running in CENTRAL mode it requires the following other Groups also
running in CENTRAL operation mode:
431 C Main Dust Treatment
431 B Butts Crushing & Screening if Coke through Group 431 A & 431 B is selected
(selection SE 2-2)
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 A 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.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
17 (31)
Rev. 00
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 all equipment of Group 431 A stops instantly (FASTOP). Packing Coke discharge
through screw conveyor (431 A 412), knife gate (431 A 415) and telescopic chute (431 A
420) is also stopped (knife gate 431 A 415 closes).
2.6.2.2 Group 431 B Butts Crushing & Screening

This Group 431 B is only then required to run in CENTRAL mode if no butts are available
for feed.
If Group 431 B is selected to run with coke as feed instead of butts (selection SE 2-2) but
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 all
equipment of Group 431 A stops instantly (FASTOP). Exception: Packing Coke discharge
through screw conveyor (431 A 412), knife gate (431 A 415) and telescopic chute (431 A
420) is not affected because this is pure local operation.
2.6.3
Fast Shut Down

If this Group 431 A is running in CENTRAL mode and an operator has detected a serious
fault, which did not automatically trip this Group the operator is able to stop this Group as Fast
Shut Down (FASTOP).
2.6.4
The operator may initiate the Fast Shut Down of this Group at any time on the SCADA
system actuating the FASTOP button.
All equipment of this Group stops instantly except of motorized splitter gates (431 A
150/155/160/165/170/175) and except of flat slide gates (431 A 201/202).
All actual setpoints of this Group are memorized as Actual Setpoint
Motorized splitter gates (431 A 150/155/160/165/170/175) are finishing their operating
step, if this step has been started prior to the FASTOP signal and are stopping, when the
target position is reached.
Flat slide gates (4331A 201/202) both are closing, if Add Floor Dust (selection SE 4-1) is
selected.
The whole Group is stopped now with full load of material in crusher and screen and on
conveyors.
Trip in Case of Faults

If this Group 431 A is running in CENTRAL mode and equipment or an instrument of this
Group fails this may cause an Alarm only and, if the fault is of the serious sort, this whole
Group or a part of this Group is stopped. Different faults may cause different stop sequences,
depending on the equipment and on the impact of this fault on the whole process of this
Group. In some cases a Normal Shut Down (RESTOP) will commence, in other cases a Fast
Shut Down (FASTOP) is the safer way and in few cases a special stop sequence may be
required.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
18 (31)
Rev. 00
Note: All instruments mounted on equipment or located somewhere in the field or anywhere
else are to be wired fail-safe.
2.6.4.1 Belt Weigh Feeder 431 A 103
A collective fault signal
-
causes an alarm
drive stops
This is causing a Normal Shut Down as described above (see 2.6.1).
2.6.4.2 Splitter gate with servo drive 431 A 105

[431 A 105-ZL / ZH] The splitter gate is equipped with two limit switches, incorporated in a
control box fitted to the drive unit. If a limit switch fails
-
causes an alarm
equipment trips
[431 A 105-XAL / XAH] The splitter gate is equipped with two torque switches, incorporated in
a control box fitted to the drive unit. If a switch is actuated or a switch fails
-
causes an alarm
equipment trips
[431 A 105M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
The maximum time required between start and stop of the actuator drive, which is tilting the
blade of a splitter gate, shall not be more than 90 seconds. If after 90 seconds the motor has
not been stopped automatically because the target position has not been reached
-
cause an alarm
equipment trips
If the splitter gate trips

-
an alarm is generated
belt weigh feeder (431 A 103) stops instantly
flat slide gates (431 A 201 / 202) both are closing, if SE 3-1 Add Floor Dust is
selected.
The rest of equipment of this Group is kept running.
2.6.4.3 Impact Crusher 431 A 110

[431 A 110-VFD] frequency controller fails
-
cause an alarm
motor stop
[431 A 110] MCC fails

-
cause an alarm
pertinent VFD-unit is shut off
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
19 (31)
Rev. 00
[431 A 110-SAL] The crusher is equipped with a low speed switch measuring the frequency of
a target rotating with the crusher rotor. If the frequency of the rotor is too low or the switch fails
this
-
cause an alarm
equipment trips
If the crusher trips

-
Fast Shut Down (see 2.6.3 above) of this Group 431 A is executed.
2.6.4.4 Bucket Elevator 431 A 115

[431 A 115-SAL] The bucket elevator is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the boot pulley. If the frequency of the boot
pulley is too low or the switch fails
-
cause an alarm
equipment trips
-
cause an alarm
equipment trips
[431 A 115-ZXA1 to ZXA4] The bucket elevator is equipped with 4 side travel switches, two
installed close to the head pulley and another two close to the boot pulley. If a side travel
switch is showing the belt is off-track for more than 2 seconds or if a switch fails
-
causes an alarm
equipment trips
By means of a jog type push button (one push button for 2 side travel switches at head
and boot) it is possible to override the side travel signal as long as the button is
pressed in order to readjust the belt.
[431 A 115-ZAL] The bucket elevator is equipped with a limit switch detecting low boot pulley
position. If the limit switch is detecting the boot pulley is too low positioned for more than 2
seconds or if the switch fails
-
causes an alarm
equipment trips
[431 A 115-LAH] The bucket elevator is equipped with a level switch detecting the material
level in the bucket elevator boot. If the level switch is detecting the material level in the boot
pulley is too high for more than 5 seconds or if the switch fails
-
causes an alarm
equipment trips
[431 A 115-IAH1] {> 110% of the current at nominal process load} The current drawn by the
bucket elevator motor is measured continuously. If the current is too high for more than 15
seconds
-
causes an alarm.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
-
20 (31)
Rev. 00
This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough
feeders 431 A 031/034/041/044) by multiplying the actual setpoint with a factor of 0.85
in order to reduce the feed rate automatically.
[431 A 115-IAH2] {> 120% of the current at nominal process load} The current drawn by the
bucket elevator motor is measured continuously. If the current is too high for more than 15
seconds,
-
causes an alarm
selected
The rest of equipment of this Group is kept running
[431 A 115-IAHH] {I > ??MBE??]} The current drawn by the bucket elevator motor is
measured continuously. If the current is too high for more than 5 seconds
-
causes an alarm
equipment trips
If the bucket elevator trips

-
2.6.4.5 Vibrating Trough Feeder 431 A 120

[431 A 120-M1/M2] If there is a fault detected in a electric motor or in the MCC of the motors
-
cause an alarm
equipment trips
If the feeder trips

-
Fast Shut Down (see 2.6.3 above) of this Group 431 A is executed
2.6.4.6 Drum-Type Magnetic Separator 431 A 125

[431 A 125-M1] If there is a fault detected in the electric motor or in the MCC of the motor
-
cause an alarm
equipment trips
[431 A 125-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
If the magnet drive trips

-
Fast Shut Down (see 2.6.3 above) of this Group 431 A is executed
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
21 (31)
Rev. 00
2.6.4.7 Splitter Gate manual - 431 A 135

[431 A 125-ZH] If SE 2-1 - Coke through Group 431 A only is selected and the switch does
not detect this position or if the switch fails
-
cause an alarm
equipment trips

-
selected
The rest of equipment of this Group is kept running
2.6.4.8 Screen Feeder 431 A 140

-
cause an alarm
equipment trips
If the screen feeder trips

-
2.6.4.9 Screen 431 A 145

-
cause an alarm
equipment trips
If the screen trips

-

-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
cause an alarm
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
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-
22 (31)
Rev. 00
equipment trips
-
cause an alarm
equipment trips

-
selected.

-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
cause an alarm
equipment trips
-
equipment trips

-
selected.

CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
-
23 (31)
Rev. 00
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips

-
selected

-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips

CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
-
24 (31)
Rev. 00
selected

-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips

-
selected

-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
25 (31)
Rev. 00
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips

-
selected
2.6.4.16 Screw Conveyor 431 A 157

[431 A 157-SAL] The screw conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the screw. If the frequency of the screw is too
low or the switch fails
-
cause an alarm
equipment trips
-
cause an alarm
equipment trips
If the conveyor trips

-

-
cause an alarm
equipment trips
-
cause an alarm
equipment trips

-
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
-
26 (31)
Rev. 00

-
cause an alarm
equipment trips
-
cause an alarm
equipment trips

-
2.6.4.19 Fine Coke Fraction Bin 431 A 300

[431 A 300-LY] The bin is equipped with a continuous level measurement (load cell system). If
the level measurement fails
-
will cause an alarm

Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically
[431 A 300-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
selected.
2.6.4.20 Medium Coke Fraction Bin 431 A 310

-
cause an alarm
-
cause an alarm
selected.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
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27 (31)
Rev. 00

[431 A 320-LY]The bin is equipped with a continuous level measurement (load cell system). If
-
cause an alarm
-
cause an alarm
selected.
2.6.4.22 Coarse Coke Fraction Bin 431 A 330

-
cause an alarm
[431 A 330-LAHH]The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
selected.
2.6.4.23 Packing Coke Bin 431 A 400

-
cause an alarm
[431 A 400-LAHH]The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
selected.
2.6.4.24 Rotary Lock 431 A 440

[431 A 440-SAL] The rotary lock is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
-
cause an alarm
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
-
28 (31)
Rev. 00
equipment trips
-
cause an alarm
equipment trips
If the rotary lock trips

-
2.6.5
alarm is generated.
Shut Down by Full Bins
2.6.5.1 Fraction Bin 431 A 300 Fine Coke

If the fraction bin is full (bin level is >/= 95% [431 A 300-LAH2]) and if splitter gate (431 A 165)
is after a travel time of 90 seconds not at 100% material flow to screw conveyor 431 A 157
[limit switch 431 A 165-ZL not actuated] or if the Ball Mill Feed bin is full (bin level is >/= 95%
[431 A 320-LAH2] and/or >/= 100% [431 A 320-LAHH])
-
an alarm is created
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 A 300-LAHH]) and if splitter gate (431 A
165) is not at 100% material flow to screw conveyor 431 A 157 [limit switch 431 A 165-ZL
actuated]
-
cause an alarm
selected
2.6.5.2 Fraction Bin 431 A 310 Medium Coke

If the fraction bin is full (bin level is >/= 95% [431 A 310-LAH2]) and splitter gate (431 A 175) is
after a travel time of 90 seconds not at 100% material flow to impact crusher (431 A 110) [limit
switch 431 A 175-ZL not actuated]
-
an alarm is created
If the fraction bin is totally full (bin level >/= 100% [431 A 310-LAHH]) and splitter gate (431 A
175) is not at 100% material flow to impact crusher (431 A 110) [limit switch 431 A 175-ZL not
actuated]
-
cause an alarm
selected

If the ball mill feed bin is full (bin level is >/= 95% [431 A 320-LAH2])
-
an alarm is created
CONTROL PHILOSOPHY
05.10.2006
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DE-060300
Doc. No.:
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-
29 (31)
Rev. 00
If the ball mill feed bin is totally full (bin level >/= 100% [431 A 320-LAHH])
-
cause an alarm
selected
2.6.5.4 Fraction Bin 431 A 330 Coarse Coke

If the fraction bin is full (bin level is >/= 95% [431 A 330-LAH2]) and splitter gate (431 A 150) is
after a travel time of 90 seconds not at 100% material flow to impact crusher (431 A 110) [limit
switch 431 A 150-ZL not actuated]
-
an alarm is created
If the ball mill feed bin is totally full (bin level >/= 100% [431 A 330-LAHH]) and splitter gate
(431 A 150) is not at 100% material flow to impact crusher (431 A 110) [limit switch 431 A 150ZL not actuated]
-
cause an alarm
selected
2.6.5.5 Packing Coke Bin 431 A 400

and/or limit switch 431 A 400-LAHH is indicating high-high level] and the splitter gate (431 A
170) is not adjusted at 100% material flow to the Fine Coke Fraction bin (431 A 300) [limit
switch 431 A 170-ZL is not actuated] and if the splitter gate (431 A 160) is not adjusted at
100% material flow to splitter gate (431 A 175) [limit switch 431 A 160-ZH is not actuated]
-
cause an alarm
selected
2.7
Local Operation of Special Equipment
2.7.1
Calibration and Dumping of Floor Dust

If floor dust shall be dumped because one is afraid that too much dirt is mixed up with
petroleum coke, butts or green scrap stored in the Floor Dust bin (431 D 100) or if the
operator wants to check the feed rate of the flat slide gates (431 A 201 / 202) feeding
sequence he may select Floor Dust LOCAL (selection SE 3-2) floor dust discharge on
SCADA at any time.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-066
2.7.2
30 (31)
Rev. 00
Straight with the selection change both flat slide gates (431 A 201/202) are closing.
Selection requires the reversing flap limit switch [431 A 210-ZH] to be initiated (flap to
calibration). On the Local Operator Panel [431 A 201-LOP] the pilot light [431 A 201-H4]
indicates LOCAL operating mode what releases the push buttons on this local panel and
allows local operation of the flat slide gates.
If the operator wants to dump or calibrate floor dust the following fully PLC controlled
sequence applies:
select SE 3-2 Floor Dust LOCAL - of this Group on SCADA
Operator tilts manual reversing flap (431 A 210) until limit switch [431 A 210-ZH] is
activated.
Operator gives start command START AUTO DUMP [push button 431 A 201-HS3 on
Local Operator Panel 431 A 201-LOP] .
Pneumatically operated flat slide gate (431 A 201) opens until limit switch [431 A 201ZH] is activated. [pilot light 431 A 201-H2 on local operator panel 431 A 201-LOP :
ON]
delay of 3 seconds
Pneumatically operated flat slide gate (431 A 201) closes until limit switch [431 A 201ZL] is activated. [pilot light 431 A 201-H1 on local operator panel 431 A 201-LOP : ON]
Pneumatically operated flat slide gate (431 A 202) opens until limit switch [431 A 202ZH] is activated. [pilot light 431 A 202-H2 on local operator panel 431 A 201-LOP :
ON]
delay of 5 seconds
Flat slide gate (431 A 202) closes until limit switch [431 A 202-ZL] is activated. [pilot
light 431 A 202-H1 on local operator panel 431 A 201-LOP : ON]
delay of variable seconds ( the variable delay time is calculated using setpoint SP 11
above)
next sequence starts with step 4. and ends with step 10. until the operator stops the
floor dust discharge by pressing the button STOP AUTO DUMP [push button 431 A
201-HS4 on local operator panel 431 A 201-LOP]
The operator may set the feed rate for floor dust discharge on SCADA at any time in a
range of 0% to 100% [100% = 3.0 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 (first approach is 33% = 1.0 ton/hour)
all overriding the actual setpoint. The feed rate is controlled by the number of opening /
closing sequences per hour of the flat slide gates (431 A 201/202).
In case STOP AUTO DUMP [push button 431 A 201-HS4 on local operator panel 431 A
201-LOP] has been pressed, both flat slide gates (431 A 201 / 202) may be operated
(opened or closed) manually by push buttons [431 A 201-HS1 / HS2] [431 A 202-HS1 /
HS2]. In this operation mode the pilot lights on the Local Operator Panel are showing the
position of the gates and on SCADA also.
Packing Coke Discharge

Packing Coke can be discharged from the Packing Coke bin (431 A 400) at any time. The
screw conveyor (431 A 412), knife gate (431 A 415) and the telescopic chute (431 A 420) are
operated from the Local Operator Panel [431 A 415-LOP1] only.
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-066
2.8
31 (31)
Filling a container (431 A 425) with packing coke requires the following working steps:
Before the container can be placed under the telescopic chute (431 A 420) the chute
must be lifted [limit switch 431 A 420-ZH is activated; pilot light 431 A 420-H1: ON],
the knife gate (431 A 415) is closed [limit switch 431 A 415-ZL is activated; pilot light
431 415-H2: ON] and the level switch [431 A 420-LH] doesn`t show high level [pilot
light 431 420-H3: OFF.
With the container in place the telescopic chute is lowered until the chute is lasting on
the container feed socket [limit switch 431 A 420-ZL; pilot light 431 A 420-H2:ON].
Start screw conveyor [431 A 412]
The limit switch [431 A 420-ZL] gives the release to open the knife gate (431 A 415)
so that the operator may now open the gate by pressing the push button [431 A 415HS1]. As long he is pushing the button, the knife gate opens and stops, when the
button is released (jog-operation). Finally the open-position [limit switch 431 A 415ZH; pilot light 431 A 415-H1: ON] stops the knife gate as long as the button is still
pressed.
The operator may close the knife gate at any time, using the push button [431 A 415HS2] or he is waiting until the level switch [431 A 420-LH] is indicating high level in the
container. Both, push button and level switch are closing the knife gate (431 A 415)
completely until limit switch [431 A 415-ZL; pilot light 431 A 415-H2] is activated.
Before the operator is taking off the container he must lift the telescopic chute (431 A
420) until limit switch [431 A 420-ZL; pilot light 431 A 420-H1] is activated.
On the Local Control Panel [431 A 415-LOP1] a pilot light [431 A 400-H1: ON] gives signal
to the operator that the packing coke bin (431 A 400) is empty.
Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal
Description
Sort of Signal
from Group 431 A to

Group 390 A
Digital signal from PLC

Number 431 PLC 12 to PLC
Number 422 PLC 02
from Group 431 G to

Group 431 A
Group 431 A is running in

CENTRAL mode and is not
in any Group START or
STOP sequence
Group 432 C is running in
STOP sequence
Group 431 B is running in
STOP sequence
Compressed Air: low
pressure
from Group 431 A to

Group 431 B
from Group 431 A to
Group (???) VEDANTA
Ball Mill Feed Bin

431A320 is full
Fines Packing Coke Bin
431A430 is full
from Group 432 C to

Group 431 A
from Group 431 B to
Group 431 A

Number 431 PLC 12
Digital signal within PLC
Number 431 PLC 12
Number 431 PLC 15 to 431
PLC 12
Digital signal within PLC
Number 431 PLC 12
Number ??? (VEDANTA to
check)

9.3
Main Equipment
9.3.1
Flat Slide Gate (manual) 431/432 A 101
9.3.2
Belt Weigh Feeder 431/432 A 103
9.3.3
Splitter Gate 431/432 A 105
9.3.4
Impact Crusher 431/432 A 110
9.3.5
Bucket Elevator 431/432 A 115
9.3.6
Vibrating Trough Feeder 431/432 A 120
9.3.7
Drum-Type Magnetic Separator 431/432 A 125
9.3.8
Vibrating Screen Feeder 431/432 A 140
9.3.9
Vibrating Screen 431/432 A 145
9.3.10
Screw Conveyor 431/432 A 157
9.3.11
Flat Slide Gate (pneumatic) 431/432 A 201
9.3.12
Reversing Flap (manual) 431/432 A 210
9.3.13
Fraction Bin 431/432 A 300
9.3.14
Knife gate (pneumatic) 431/432 A 415
9.3.15
Telescopic Chute 431/432 A 420

138-02-043
Group 431/432 A
DE-060300
Revision: 0
Date: 29.09.2006
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Training Manual Green Anode Plant

PROCESS GROUP 431/432 A - COKE CRUSHING & SCREENING-

Process Group 431/432 A - Coke Crushing & Screening- ..........................................................1

Process Flow Sheets

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Brief Process Description

Outokumpu Technology GmbH

Brief Process Description

168-01-058 UB Sheet 1-2

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Main Process Data & Process Highlights

The Feed rate of petroleum coke is controlled by a belt weigh feeder.

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Outokumpu Technology GmbH

Training Manual Green Anode Plant

P&Id`s, Operator Screen Images

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Control Logic Description

Outokumpu Technology GmbH

168-01-058 UB Sheet 1-2

Brief Process Description............................................................................................................ 2

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

Outokumpu Technology GmbH

BRIEF PROCESS DESCRIPTION

Outokumpu Technology GmbH

Outokumpu Technology GmbH

CONTROL LOGIC DESCRIPTION

Special Terminology For This Group

Linked Process Groups

Main Dust Treatment 431 C

Selection of Operation Modes (SE 1)

Outokumpu Technology GmbH

CENTRAL operation mode

After this selection this Group is ready to start in CENTRAL

LOCAL operation mode

(details please see under 2.7 below)

Material Route (SE 2)

Floor Dust (SE 3)

Outokumpu Technology GmbH

Fines Packing Coke (SE 4)

Selections Prior to Group Start

2.4.2.1 Process Group 431 C - Main Dust Treatment

Outokumpu Technology GmbH

2.4.2.5 Emergency stop

Setpoints Prior to Group Start

The PLC program is storing all actually used setpoints as

The operator has the opportunity to override the actual

Did the operator change an Actual Setpoint while the Group is

Outokumpu Technology GmbH

The operator may also override the actual setpoint by the

2.4.3.1 Weigh Feeder 431 A 103 - (Setpoint SP 1)

Outokumpu Technology GmbH

2.4.3.7 Splitter Gate 431 A 165 - (Setpoint SP 7)

Group Start Sequence

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Outokumpu Technology GmbH

Restarting the Group

Belt Weigh Feeder 431 A 103

Splitter gate 431 A 105