100A

Training Manual Green Anode Plant
Vedanta - Jharsuguda
138-02-043
Group 100 A
DE-060300
PROCESS GROUP 100 A - COKE UNLOADING & STORAGE-
3
3.1
3.1.1
3.1.2
3.1.3
3.2
3.2.1
3.2.2
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8
3.3.9
3.3.10
3.3.11
Process Group 100 A - Coke Unloading & Storage- ...................................................................1

Process .......................................................................................................................................1
Process Flow Sheets...................................................................................................................1
Brief Process Description ............................................................................................................2
Main Process Data & Process Highlights ....................................................................................3
Process Control...........................................................................................................................4
P&Id`s, Material Route Diagrams, Operator Screen Images.......................................................4
Control Logic Description ............................................................................................................5
Main Equipment ..........................................................................................................................6
Flat Slide Gate (manual) 100 A 004 ............................................................................................6
Vibrating Trough Feeder 100 A 006 ............................................................................................6
Belt Conveyor 100 A 040 ............................................................................................................6
Magnetic Separator, overhead 100 A 043...................................................................................6
Rotary Lock 100 A 045................................................................................................................6
Bag Filter 100 A 050....................................................................................................................6
Fan 100 A 060.............................................................................................................................6
Trough Screw Conveyor 100 A 085 ............................................................................................6
Reversing Flap (pneumatic) 100 A 130 .......................................................................................6
Bin 100 A 200..............................................................................................................................6
Bridge Crane 100 A 605..............................................................................................................6
3.1
Process
3.1.1
Process Flow Sheets

(Work Copy)
Outokumpu Technology GmbH

file: 138-02-043_03_0.doc, Codeword: Vedanta
Revision: 0
Date: 29.09.2006
Page 1 of 6

3.1.2
138-02-043
Group 100 A
DE-060300
Brief Process Description

(Work Copy)

Page 2 of 6
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.:
133-50-046
1 (1)
Rev. 00
Brief Process Description

of
Process Group 100 A
- Coke Unloading Reference:
Process Flow Sheet:
132-01-070 UB
P&I Diagram:
168-01-043 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 three
large silos of 6000 tons capacity. Coke is continuously withdrawn from the feed hoppers (100
A 002), (100 A 012), (100 A 022), (100 A 032) by means of vibrating trough feeders (100 A
006), (100 A 016), (100 A 026), (100 A 036). The operator can select the number of vibrating
feeders in charge.
The maximum feed rate allowed is 90 tons/hour.
Coke is fed from the vibrating trough feeders to the inclining belt conveyor (100 A 040) running
underneath the vibrating trough feeders. A belt scale (100 A 042) and a magnet (422 A 043)
are integrated in the belt conveyor. Dust generated through feeding and conveying of coke is
sucked off from the vibrating feeders and from the belt conveyor to be then drawn by fans (100
A 060) and (100 A 080) through collecting pipes into the dust collectors (100 A 050) and (100
A 070) to be separated. The dust collectors are of jet-cleaning type. A counter-flow
compressed air blow cleans the bags. Separated dust is continuously fed via screw conveyor
(100 A 085) to the belt conveyor (100 A 040) by mean of rotary locks (100 A 045) and (100 A
065).
By means of a pneumatic operated 3-way reversing flap (100 A 130) the material can be fed
direct to the coke main storage bin (100 A 300) or the whole flow can be directed to the
pneumatic operated reversing flap (100 A 135). From the reversing flap, the material is feed
via belt conveyor (100 A 120) and manual slpitter gate (100A 140) into coke main storage bin
or via belt conveyor (100 A 125) and manual splitter gate (100 A 145) into coke main storage
bin (410 A 400).
Dust generated through feeding and conveying of coke is sucked off from the belt conveyors
(100 A 120), (100 A 125) and from the coke main storage bins (100 A 200), (100 A 300), (100
A 400) to be then drawn by fan (100 A 115) through collecting pipes into the dust collectors
(100 A 105) to be separated. The dust collector is of jet-cleaning type. A counter-flow
compressed air blow cleans the bags. Separated dust is continuously fed to belt conveyor
(100 A 040) by mean of rotary locks (100 A 100).
Each silo (100 A 200; 100 A 300; 100 A 400) is equipped with four radar level probes.

3.1.3
138-02-043
Group 100 A
DE-060300
Main Process Data & Process Highlights

This Process Group is designed for a maximum feed rate (unloading rate) of 90
t/hour of petroleum coke.
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 allowed feed rate of 90 t/h.
The equipment capacity is 100 t/h. The equipment capacity can be found in the
Process Flow Sheets in a rhombus.
Coke is continuously withdrawn from the feed hoppers by means of vibrating feeders.
The feed rate is measured by a belt scale and is displayed on SCADA. The operator
has to observe the displayed rate and if the rate differs too much from the target feed
rate he has to adjust the feed rate by deselect an adequate quantity of vibrating
feeders.
The coke could store in three main storage bins each with a capacity of 6000 tons. If
the selected coke main storage bin that will be stored, is full this group is shut down.

Revision: 0
Date: 29.09.2006
Page 3 of 6

3.2
Process Control
3.2.1
P&Id`s, Material Route Diagrams, Operator Screen Images
138-02-043
Group 100 A
DE-060300
(work copies)

Page 4 of 6
Revision: 0
Date: 29.09.2006

3.2.2
138-02-043
Group 100 A
DE-060300
Control Logic Description

(Work Copy)

Revision: 0
Date: 29.09.2006
Page 5 of 6
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-046
1 (18)
Rev. 00
Control Philosophy
of
Process Group 100 A
- Coke Unloading Reference:
Process Flow Sheet:
132-01-070 UB
P&I Diagram:
168-01-043 UB Sheet 1+2
Brief Process Description............................................................................................................ 2
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.4
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 ............................................................................................................ 2

Special Terminology For This Group .......................................................................................... 2
Linked Process Groups............................................................................................................... 2
Selections ................................................................................................................................... 3
Selection of Operation Modes (SE 1).......................................................................................... 3
Material Route (SE 2).................................................................................................................. 3
Coke Unloading Vibrating Trough Feeders (SE 3)...................................................................... 4
Group Start ................................................................................................................................. 4
Selections Prior to Group Start ................................................................................................... 4
Start Preconditions...................................................................................................................... 4
Setpoints Prior to Group Start ..................................................................................................... 5
Group Start Sequence ................................................................................................................ 5
Restarting the Group................................................................................................................... 6
Normal Operation........................................................................................................................ 6
Shut Down .................................................................................................................................. 8
Normal Shut Down ...................................................................................................................... 8
Shut Down by Other Groups ....................................................................................................... 9
Fast Shut Down (FASTOP)......................................................................................................... 9
Trip in Case of Faults .................................................................................................................. 9
Shut Down by Full Bins ............................................................................................................. 17
Local Operation of Special Equipment...................................................................................... 18
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 18
CONTROL PHILOSOPHY
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Doc. No.:
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2 (18)
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 three
large silos of 6000 tons capacity. Coke is continuously withdrawn from the feed hoppers (100
A 002), (100 A 012), (100 A 022), (100 A 032) by means of vibrating trough feeders (100 A
006), (100 A 016), (100 A 026), (100 A 036). The operator can select the number of vibrating
feeders in charge.
The maximum feed rate allowed is 90 tons/hour.
Coke is fed from the vibrating trough feeders to the inclining belt conveyor (100 A 040) running
underneath the vibrating trough feeders. A belt scale (100 A 042) and a magnet (422 A 043)
are integrated in the belt conveyor. Dust generated through feeding and conveying of coke is
sucked off from the vibrating feeders and from the belt conveyor to be then drawn by fans (100
A 060) and (100 A 080) through collecting pipes into the dust collectors (100 A 050) and (100
A 070) to be separated. The dust collectors are of jet-cleaning type. A counter-flow
compressed air blow cleans the bags. Separated dust is continuously fed via screw conveyor
(100 A 085) to the belt conveyor (100 A 040) by mean of rotary locks (100 A 045) and (100 A
065).
By means of a pneumatic operated 3-way reversing flap (100 A 130) the material can be fed
direct to the coke main storage bin (100 A 300) or the whole flow can be directed to the
pneumatic operated reversing flap (100 A 135). From the reversing flap, the material is feed
via belt conveyor (100 A 120) and manual slpitter gate (100A 140) into coke main storage bin
or via belt conveyor (100 A 125) and manual splitter gate (100 A 145) into coke main storage
bin (410 A 400).
Dust generated through feeding and conveying of coke is sucked off from the belt conveyors
(100 A 120), (100 A 125) and from the coke main storage bins (100 A 200), (100 A 300), (100
A 400) to be then drawn by fan (100 A 115) through collecting pipes into the dust collectors
(100 A 105) to be separated. The dust collector is of jet-cleaning type. A counter-flow
compressed air blow cleans the bags. Separated dust is continuously fed to belt conveyor
(100 A 040) by mean of rotary locks (100 A 100).
Each silo (100 A 200; 100 A 300; 100 A 400) is equipped with four radar level probes.
2
CONTROL LOGIC DESCRIPTION
2.1
Special Terminology For This Group

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

There are no Process Groups linked with this Group 100 A
CONTROL PHILOSOPHY
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3 (18)
Rev. 00

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2.3
Selections
2.3.1
Selection of Operation Modes (SE 1)

The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA.
The operator has two options:
2.3.2
CENTRAL operation mode
After this selection this Group is ready to start in CENTRAL

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

Selection and indication of the state of selection is on SCADA prior to Group start only.
The operator has three options:
SE 2-1 - Coke to Coke Main Storage Bin 100 A 200
This selection is used if coke is fed into Coke Main Storage Bin 100 A 200
The operator may select Coke to Coke Main Storage Bin 100 A 200 at any time. Selection is
possible if there is no high or high-high level in this bin (see 2.4.2.1 for details).
Selection made prior to group start

See 2.4 for details
Selection made when group is in normal operation

Operator changes the selection
Operator initiated group restart by actuation of group start pushbutton
Belt conveyor (100 A 120) is started. Reversing flap (100 A 135) tilts to 100% material flow to
belt conveyor (100 A 120), limit switch [100 A 135-ZL] is actuated. Three-way reversing flap
(100 A 130) tilts to 100% material flow to reversing flap (100 A 135) [limit switch 100 A 130ZH2.1 and 100 A 130-ZH2.2 is actuated].

See 2.4 for details

Operator initiates group restart by actuation of group start pushbutton
Three-way reversing flap (100 A 130) tilts to 100% material flow to coke main storage bin (100
A 300) [limit switch 100 A 130-ZL1.1 and 100 A 130-ZL1.2 is actuated]. Belt conveyor (100 A
120) or (100 A 125) are stopped after 4 minutes run empty time if in normal operation.
CONTROL PHILOSOPHY
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Doc. No.:
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See 2.4 for details

Operator initiates group restart by actuation of group start pushbutton
Belt conveyor (100 A 125) is started. Reversing flap (100 A 135) tilts to 100% material flow to
belt conveyor (100 A 125), limit switch [100 A 135-ZH] is actuated. Three-way reversing flap
(100 A 130) tilts to 100% material flow to reversing flap (100 A 135) [limit switch 100 A 130ZH2.1 and 100 A 130-ZH2.2 is actuated].
2.3.3
Coke Unloading Vibrating Trough Feeders (SE 3)

The operator may select the vibrating through feeders discharging the Feed hoppers (100 A
002; 100 A 012; 100 A 022; 100 A 32) at any time.
Selection and indication of the state of selection is on SCADA.
SE 3-1 - vibrating trough feeder (100 A 004)
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 Level Coke Main Storage Bins (100 A 200)

If SE 2-1 is selected and if the coke main storage bin is full (bin level is >/= 95% [100 A
200-LAH1.2/LAH2.2/LAH3.2/LAH4.2]) and/or >/= 100% [100 A 200-LAHH1/LAHH2]) this
Group does not start
CONTROL PHILOSOPHY
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2.4.2.4 Emergency stop

If the Emergency Stop of the Group has been activated it has to be RESET.
2.4.2.5 Alarms
If an Alarm of this Group has been activated it has to be RESET.
2.4.2.6 MCC`s of this Group
The MCCs signal of this group must be OK.
2.4.2.7 FASTOP Signal
If a FASTOP signal is valid this Group does not start.
2.4.2.8 RESTOP Signal
If a RESTOP signal is valid this Group can be restarted by overriding the RESTOP signal
by the Group Start signal.
2.4.2.9 Compressed Air Pressure 100 A 050
Compressed air pressure in Group A [100 A 050-PAL] shall be higher than 6 bar (P>6
bar).
2.4.2.10 Local Control Stations
Equipment selected to run the ON switches must be activated.
2.4.3
Setpoints Prior to Group Start

There are no set points to be set for this Group.
2.4.4
Group Start Sequence

The operator is enabling this Group 100 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.
The horn starts to sound permanently for 15 seconds prior to start of the first equipment,
then it sounds instantly until the last drive is running.
Fan (100 A 115) starts.
Delay of 20 seconds for fan impeller run-up.
Belt Conveyor (100 A 120) starts, only if selected (SE 2-1)
Belt Conveyor (100 A 125) starts, only if selected (SE 2-3)
Reversing flap (100 A 135) is enable
Reversing flap (100 A 130) is enable
Delay of 20 seconds for fans impeller run-up.
Belt scale (100 A 042) is enable
Magnet (100 A 043) is enable
Belt Conveyor (100 A 040) starts
Jet cleaning of dust collector (100 A 105) is enabled.
Rotary lock (100 A 100) starts.
CONTROL PHILOSOPHY
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Doc. No.:
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2.4.5
6 (18)
Rev. 00
Screw conveyor (100 A 085) starts

Vibrating trough feeder (100 A 006) starts, if selected (SE 3-1).
Vibrating trough feeder (100 A 016) starts, if selected (Se 3-2).
Group 100 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
Vibrating Trough Feeders (100 A 006/016/026/036)

If the selected feeders are not tripped this Group is in normal operation.
The operator may select or deselect a feeder any time.
2.5.2
Belt Conveyor (100 A 040)

If the conveyor is not tripped this Group is in normal operation.
2.5.3
Belt Scale (100 A 042)

If the belt scale is not tripped this Group is in normal operation.
2.5.4
Magnet (100 A 043)

2.5.5
Rotary Lock (100 A 045)

If the rotary lock is not tripped this Group is in normal operation.
2.5.6
Dust Collector (100 A 050)

If the dust collector is not tripped this Group is in normal operation.
The jet-type pneumatic bag cleaning system is controlled by the actually measured
differential pressure across the filter bags. If the differential pressure measuring system
detects the differential pressure is above 12.5 mbar [100 A 050-PDH2], the Local Control
Panel [100 A 050-LOP1] gets a signal from 422 PLC 02 to start a bag cleaning cycle .The
bags are cleaned with a compressed air stream blown into the bags countercurrent to the
normal air flow. The cleaning cycle ends with a second signal from 422 PLC 02, if the
differential pressure did fall below 11 mbar [100 A 050-PDH1]. The next cleaning cycle
starts with the next un-cleaned bag row.
CONTROL PHILOSOPHY
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Doc. No.:
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Rev. 00
2.5.7
Fan (100 A 060)

If the fan is not tripped this Group is in normal operation.
2.5.8

2.5.9
Dust Collector (100 A 070 )

2.5.10
Fan (100 A 080)

2.5.11
Screw conveyor (100 A 085)

If the screw conveyor is not tripped this Group is in normal operation.
2.5.12

2.5.13
Dust Collector (100 A 105)

2.5.14
Fan (100 A 115)

2.5.15

2.5.16

2.5.17
Reversing Flap (100 A 130)

If the reversing flap is not tripped this Group is in normal operation
CONTROL PHILOSOPHY
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Rev. 00
If SE 2-1/SE 2-3 Coke to Coke Main Storage Bin 100 A 200/400 is selected and if the
reversing flap is positioned correctly so that limit switch [100 A 130-ZH2.1] and limit switch
[100 A 130-ZH2.2] is activated (flow to reversing flap 100 A 135), this Group is in normal
operation.
If SE 2-2 Coke to Coke Main Storage Bin 100 A 300 is selected and if the reversing
flap is positioned correctly so that limit switch [100 A 130-ZL1.1] and limit switch [100 A
130-ZL1.2] is activated (flow to Coke Main Storage Bin 100 A 300), this Group is in normal
operation.
2.5.18
Reversing Flap (100 A 135)

If the reversing flap is not tripped this Group is in normal operation
flap is positioned correctly so that limit switch [100 A 135-ZL] is activated, this Group is in
normal operation.
flap is positioned correctly so that limit switch [100 A 135-ZH] is activated, this Group is in
normal operation.
2.5.19
Coke Main Storage Bin (100 A 200)

If the fraction bin level measurement is not tripped this Group is in normal operation.
If the coke main storage bin is not full (bin level is not >/= 95% [100 A 200LAH1.2/LAH2.2/LAH3.2/LAH4.2]) and/or not >/= 100% [100 A 200-LAHH1/LAHH2]) this
Group is in normal operation
2.5.20

2.5.21

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.
Vibrating trough feeder (100 A 006) stops, if selected and running
CONTROL PHILOSOPHY
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2.6.2
9 (18)
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Delay of 14 minutes (run-empty time)

All equipment of this Group stops.
The whole group is stopped.
Shut Down by Other Groups

There is no shut down by other groups.
2.6.3
Fast Shut Down (FASTOP)

If this Group 100 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
The whole Group is stopped now with full load of material on conveyors.
Trip in Case of Faults

If this Group 100 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.
Note: All instruments mounted on equipment or located somewhere in the field or anywhere
else are to be wired fail-safe.
2.6.4.1 Vibrating Trough Feeders 100 A 006/016/026/036

If one or more of the feeders, which are selected and which are running, trip(s)
-
an alarm is generated only

The faulty feeder(s) can be deselected and another feeder(s) can be selected and this
Group can be restarted.
[100 A 006/016/026/036M1] If there is a fault detected in the electric motor or in the MCC of
this motor
-
cause an alarm
equipment trips
[100 A 006/016/026/036M2] If there is a fault detected in the electric motor or in the MCC of
this motor
-
cause an alarm
equipment trips
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2.6.4.2 Belt Conveyor 100 A 040

[100 A 040-SAL] The conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the tail pulley. If the frequency of the tail
pulley is too low or the switch fails
-
cause an alarm
equipment trips
[100 A 040M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
[100 A 040-ZXA1 to ZXA4] The conveyor is equipped with 4 side travel switches, two installed
close to the drive pulley and another two close to the tail pulley. If a side travel switch is
showing the belt is off-track for more than 2 seconds or if a switch fails
-
causes an alarm
equipment trips
[100 A 040-HSSA] The conveyor is equipped with 2 pull cord switches (This safety switch is
hard-wired to the MCC), one at each conveyor side. If a pull cord is drawn or if a switch fails
-
causes an alarm
equipment trips
[100 A 040-ZAL and ZAH] The conveyor is equipped with 2 take-up switches, one detecting
low take-up pulley position and another detecting high take-up pulley position. If one of the
switches is detecting an excessive position of the take-up pulley for more than 2 seconds or if
a switch fails
-
causes an alarm
equipment trips
If the belt conveyor trips

-
an alarm is generated
all vibrating trough feeders (100 A 006/016/026/036), which are selected and which
are running stopped instantly
rotary locks (100 A 045 and 100 A 065) stops instantly
screw conveyor (100 A 085) stops instantly
After 14 minutes delay time the rest of equipment of this Group is stopped.
2.6.4.3 Belt Scale (100 A 042)

If a collective alarm of the scale is detected
-
Normal Shut Down (see 3.5.1 above) will be initiated automatically.
[100 A 042-FAL] {< 3 t/h} If low feed rate is detected for more than 60 seconds
-
cause an alarm.
[100 A 042-FAH] {> 90 t/h} If high feed rate is detected for more than 20 seconds
-
cause an alarm.
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[100 A 042-FAHH] {> 100 t/h} If high-high feed rate is detected for more than 5 seconds
-
cause an alarm.
if after another 60 seconds the fault is still detected a Normal Shut Down of this Group
(see 2.6.1 above) is initiated automatically
2.6.4.4 Magnet 100 A 043

measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-
cause an alarm
equipment trips
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
-
cause an alarm
equipment trips
2.6.4.5 Rotary Lock 100 A 045

-
cause an alarm
equipment trips
if after a delay of 30 minutes this rotary lock is still faulty and could not be restarted, a
-
cause an alarm
equipment trips
2.6.4.6 Dust Collector 100 A 050

[100 A 050-LCP1] If the bag cleaning device trips
-
alarm is generated
but this Group is kept running until the differential pressure across the bags reaches
high-high differential pressure
[100 A 050-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or if
the switch fails for more than 5 seconds
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
NOTE: During Start or Restart of this Group there is an override of this function of 20
seconds to allow the fan to run up.
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[100 A 050-PDAH] {> 13mbar} If high differential pressure is detected across the filter bags or
if the switch fails for more than 5 seconds
-
cause an alarm only
[100 A 050-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
2.6.4.7 Fan 100 A 060

-
cause an alarm
equipment trips
[100 A 060-SAL] The fan is equipped with a proximity type low-speed switch measuring the
frequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low or
the switch fails
-
cause an alarm
equipment trips
If the fan trips

-
vibrating trough feeders (100 A 026/036), which are selected and which are running,
stop instantly
Normal Shut Down (see 2.6.1 above), will be initiated automatically.
2.6.4.8 Rotary Lock 100 A 065

[100 A 065-SAL] The rotary lock is equipped with a proximity type low-speed detector
low or the detector fails
-
cause an alarm
equipment trips
-
cause an alarm
equipment trips

-
alarm is generated
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-046
13 (18)
Rev. 00
-
cause an alarm
-
cause an alarm only
-
cause an alarm
2.6.4.10 Fan 100 A 080

-
cause an alarm
equipment trips
the switch fails
-
cause an alarm
equipment trips
If the fan trips

-
2.6.4.11 Rotary Lock 100 A 100

-
cause an alarm
equipment trips
-
cause an alarm
equipment trips
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-046
14 (18)
Rev. 00

-
alarm is generated
-
cause an alarm
-
cause an alarm only
-
cause an alarm
2.6.4.13 Fan 100 A 115

-
cause an alarm
equipment trips
the switch fails
-
cause an alarm
equipment trips
If the fan trips

-

-
cause an alarm
equipment trips
-
cause an alarm
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-046
-
15 (18)
Rev. 00
equipment trips
-
causes an alarm
equipment trips
-
causes an alarm
equipment trips
a switch fails
-
causes an alarm
equipment trips

-
If selection SE2-1 is selected a fast Shut Down (see 2.6.3 above) of the group is
initiated.

-
cause an alarm
equipment trips
-
cause 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.:
133-50-046
16 (18)
Rev. 00
a switch fails
-
causes an alarm
equipment trips

-
If selection SE2-3 is selected a fast Shut Down (see 2.6.3 above of the group is
initiated.
2.6.4.16 Reversing Flap 100 A 130

[100 A 130 ZSL1.1/ZSL1.2/ZSH2.1/ZSH2.2] The three-way reversing flap is equipped with four
limit switches, one pair ZSL/ZSH for each blade. If after actuation and start signal the limit
switch for the selected position is not reached within 10 seconds, the maximum operation time
is exceeded (runtime supervision)
-
causes an alarm
equipment trips
If the limit switch indication is not in agreement with the selected position (limit switch lost) or if
ZSL and ZSH are indicated simultaneously
-
causes an alarm
equipment trips
If the reversing flap trips

-
cause an alarm
Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically
2.6.4.17 Reversing Flap 100 A 135

[100 A 135 ZSL / ZSH] The reversing flap is equipped with two limit switches. If after actuation
and start signal the limit switch for the selected position is not reached within 10 seconds, the
maximum operation time is exceeded (runtime supervision)
-
causes an alarm
equipment trips
If the limit switch indication is not in agreement with the selected position (limit switch lost) or if
ZSL and ZSH are indicated simultaneously
-
causes an alarm
equipment trips
If the reversing flap trips

-
cause an alarm
2.6.4.18 Coke Main Storage Bin 100 A 200

CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-046
17 (18)
Rev. 00
[100 A 200-LY1/LY2/LY3/LY4] The bin is equipped with four continuous level measurements
(radar level probe system). If one level measurement fails
-
cause an alarm
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically
[100 A 200-LAHH1/LAHH2] The bin is equipped with a two level probe. If one the two level
measurement fails
-
cause an alarm

-
cause an alarm
[100 A 300-LAHH1/LAHH2] The bin is equipped with two level probe. If one the two level
measurement fails
-
cause an alarm

-
cause an alarm
[100 A 400-LAHH1/LAHH2] The bin is equipped with a two level probe. If one the two level
measurement fails
-
2.6.5
cause an alarm
Shut Down by Full Bins
2.6.5.1 Coke Main Storage Bin (100 A 200)

If the coke main storage bin is full (bin level is >/= 95% [100 A 200LAH1.2/LAH2.2/LAH3.2/LAH4.2])
-
an alarm is created
Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.
If the coke feed bin is totally full (bin level >/= 100% [100 A 200-LAHH1/LAHH2])
-
cause an alarm
Fast Shut Down (2.6.3 above) of this Group is initiated automatically.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-046
18 (18)
Rev. 00
-
an alarm is created
-
cause an alarm

-
an alarm is created
-
2.7
cause an alarm
Local Operation of Special Equipment

-Not applicable-
2.8
Signal Exchange with Sub-Groups of this Group and Other Process Groups
There are no Signal Exchange with Sub-Groups of this Group and Other Process Groups

3.3
Main Equipment
3.3.1
Flat Slide Gate (manual) 100 A 004
3.3.2
Vibrating Trough Feeder 100 A 006
3.3.3
Belt Conveyor 100 A 040
3.3.4
Magnetic Separator, overhead 100 A 043
3.3.5
Rotary Lock 100 A 045
3.3.6
Bag Filter 100 A 050
3.3.7
Fan 100 A 060
3.3.8
Trough Screw Conveyor 100 A 085
3.3.9
Reversing Flap (pneumatic) 100 A 130
3.3.10
Bin 100 A 200
3.3.11
Bridge Crane 100 A 605

Page 6 of 6
138-02-043
Group 100 A
DE-060300
Revision: 0
Date: 29.09.2006

100A

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Training Manual Green Anode Plant

PROCESS GROUP 100 A - COKE UNLOADING & STORAGE-

Process Group 100 A - Coke Unloading & Storage- ...................................................................1

Process Flow Sheets

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Brief Process Description

Outokumpu Technology GmbH

Brief Process Description

168-01-043 UB Sheet 1+2

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Main Process Data & Process Highlights

Outokumpu Technology GmbH

Training Manual Green Anode Plant

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

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Control Logic Description

Outokumpu Technology GmbH

168-01-043 UB Sheet 1+2

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

Control Logic Description ............................................................................................................ 2

Outokumpu Technology GmbH

BRIEF PROCESS DESCRIPTION

CONTROL LOGIC DESCRIPTION

Special Terminology For This Group

Linked Process Groups

Outokumpu Technology GmbH

Vedanta Alumina Ltd.

Selection of Operation Modes (SE 1)

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)

Selection made prior to group start

Selection made when group is in normal operation

Selection made prior to group start

Selection made when group is in normal operation

SE 2-3 - Coke to Coke Main Storage Bin 100 A 400

Selection made prior to group start

Selection made when group is in normal operation

Coke Unloading Vibrating Trough Feeders (SE 3)

Selections Prior to Group Start

2.4.2.1 Level Coke Main Storage Bins (100 A 200)

2.4.2.4 Emergency stop

Setpoints Prior to Group Start

Group Start Sequence

Outokumpu Technology GmbH

Screw conveyor (100 A 085) starts

Restarting the Group

Vibrating Trough Feeders (100 A 006/016/026/036)

Belt Conveyor (100 A 040)

Belt Scale (100 A 042)

Magnet (100 A 043)

Rotary Lock (100 A 045)

Dust Collector (100 A 050)

Outokumpu Technology GmbH

Fan (100 A 060)

Rotary Lock (100 A 065)

Dust Collector (100 A 070 )

Fan (100 A 080)

Screw conveyor (100 A 085)