410b

Training Manual Green Anode Plant Vedanta - Jharsuguda

138-02-043 Group 410 B DE-060300

7 PROCESS GROUP 410 B - LIQUID PITCH TRANSFER -

7 Process Group 410 B - Liquid Pitch Transfer -............................................................................1 7.1 Process .......................................................................................................................................1 7.1.1 Process Flow Sheets...................................................................................................................1 7.1.2 Brief Process Description ............................................................................................................2 7.1.3 Main Process Data & Process Highlights ....................................................................................3 7.2 Process Control ...........................................................................................................................5 7.2.1 P&Id`s, Material Route Diagrams, Operator Screen Images.......................................................5 7.2.2 Control Logic Description ............................................................................................................6 7.3 Main Equipment ..........................................................................................................................7 7.3.1 Basket Filter 410 B 050 ...............................................................................................................7 7.3.2 Positive Displacement Pump 410 B 065 .....................................................................................7 7.3.3 Liquid pitch Heat Exchanger 410 B 215 ......................................................................................7 7.3.4 Pressure Holding Valve 410 B 235 .............................................................................................7

7.1 Process

7.1.1 Process Flow Sheets

(Work Copy)

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138-02-043 Group 410 B DE-060300

Outokumpu Technology GmbH Revision: 0

Date: 29.09.2006Page 2 of 7 file: 138-02-043_07_0.doc, Codeword: Vedanta

7.1.2 Brief Process Description

(Work Copy)

CONTROL PHILOSOPHY 05.10.2006

1 (3)

Vedanta Alumina Ltd. Jharsuguda – Green Anode Plant Client ref.: VJ/SML/PO/032/1 OTK ref.: DE-060300 Doc. No.: 133-50-050

Rev. 00

Brief Process Description of

Process Group 410 B - Liquid Pitch Transfer -

Reference:

Process Flow Sheet: 132-01-074 UB

P&I Diagram: 168-01-046 UB sheet 1, 2, 3, 4

Material Route Diagram: 133-50-051 UB sheet 1 & 2 / 133-50-052 UB sheet 1 & 2 / 133-50-053 UB sheet 1 & 2 / 133-50-054 UB sheet 1 & 2 / 133-50-055 UB sheet 1 & 2 / 133 50-056 UB sheet 1 & 2 / 133-50-057 UB sheet 1 & 2 / 133-50-058 UB sheet 1 & 2 / 133-50-059 UB sheet 1 & 2 / 133-50-060 UB sheet 1 & 2 / 133-50-061 UB sheet 1 & 2 / 133-50-062 UB sheet 1 & 2

The Liquid Pitch Transfer Process Group 410 B reclaims liquid pitch from tank 1, tank 2 or tank 3 to Process Group 431 H Proportioning via Pitch/HTM heat exchanger (410 B 215) and /or to Process Group 432 H Proportioning via Pitch/HTM heat exchanger (410 B 315) and back to tank 1, tank 2 or tank 3.

Group 410 B consists of a set of three pitch pumps and three basket filters connected to the suction nozzles of all three tanks and to the feed and return line to the Green Anode Plant Line 1 (431) and /or to the Green Anode Plant Line 2 (432). This operation is only possible if the basket filters are available and are not plugged. For this reason the differential pressure across the basket filters has to be observed regularly.

Pitch pump (410 B 065) is foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the Proportioning Group 431 H in the Green Anode Plant Line 1. Pitch pump (410 B 125) is foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the Proportioning Group 432 H in the Green Anode Plant Line 2. Pitch pump (410 B 165) can be used as stand-by to pump (410 B 065) or to pump (410 B 125). The arrangement of the pitch piping system allows for numerous combinations of tank suction nozzles and pitch pumps. For operation in automatic mode, however only the main combinations are foreseen, which results in 12 different routes that can be selected by the operator in the central control room.

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Rev. 00

Pitch pumps (410 B 065) and pitch pump (410 B 125) can be connected to the bottom suction nozzle of tank 1, tank 2 or tank 3. Pitch Pump (410 B 065) is operated in line with basket filter (410 B 050) and pitch pump (410 B 125) with basket filter (410 B 110). In case that these filters are plugged, an emergency transfer operation with stand-by pitch pump (410 B 165) via basket filter (410 B 150) to Line 1(431) or to Line 2 (432) is possible. Pitch pump (410 B 065) transfers pitch to Line 1 (431) via the liquid pitch heat exchanger (410 B 215) to the pressure holding valve (410 B 235), where the amount of pitch required for anode production is withdrawn by the pitch proportioning pump of Process Group 432 H. Pitch pump (410 B 125) transfers pitch to Line 2 (432) via the liquid pitch heat exchanger (410 B 315) to the pressure holding valve (410 B 335), where the amount of pitch required for anode production is withdrawn by the pitch proportioning pump of Process Group 432 H. The operator has three route selections for each transfer Pump, Route 11, 12, 13 for transfer pump (410 B 065) and Route 31, 32, 33 for transfer pump (410 B 125). For stand-by pump (410 B 165) exists six route selections, Route 21 – 26. The Route selections are described in detail under chapter 2.3.2 – 2.3.4 The pneumatic pitch valve (410 B 080) for Line 1 (431) and the pneumatic pitch valve (410 B 140) for Line 2 (432) are always closed when the transfer pumps are not in operation in order to shut off the long transfer line to the Green Anode Plant 1 and 2 keeping the line full of pitch. In this way, air or vapour, which may affect the correct operation of the Coriolis flow meters in Process Group 431 H and 432 H cannot enter the ring line. After long-term interruptions of the transfer operation, the transfer lines have to be vented by the manual vent valves (410 B 230) for Line 1 (431) and (410 B 330) for Line 2 (432).

The liquid pitch heat exchangers are used to adjust the pitch temperature by heating prior to transfer to the Proportioning Groups 431 H, 432 H.

The setpoint of the liquid pitch temperature after the heat exchangers (410 B 215) and (410 B 315) can be adjusted by the operator or the standard setpoint can be activated which is set to 180°C. The setpoint of the liquid pitch temperature controller is transferred to the HTM systems of Line 1 (431) and Line 2 (432) where it is connected in cascade to the corresponding enabled HTM temperature controller to regulate the temperature in HTM secondary circuit 3 of Line 1 (431) and the temperature in HTM secondary circuit 3 of Line 2 (432).

The selections of simultaneous routes are described under chapter 2.2.

The local operator has to open and close the corresponding pitch valves for the selected route. With valves in the correct position the control room operator receives the confirmation by a signal on the operator display. Simultaneously the local operator receives the confirmation for the corresponding pump by a pilot light on the local panel [410 LOP-B1]. He has to start the pump from the local panel. The local operator should always start the pump at slow speed by pushing the "START SLOW" pushbutton. Slow speed is used to flush the piping system from possible obstructions caused by cold spots. Slow speed should also be used as long as the pitch temperature is low. If the operator pushes the “START FAST” pushbutton the pump speed is controlled in auto mode. In this case the pump will start at slow speed and will change to fast speed after a pre-set time delay (setting in PLC: 4 minutes) for Routes 11/12/13 or Routes 21/22/23/24/25/26 or Routes 31/32/33 if the pitch temperature in the tank where the pumps sucking from has a level above 160°C.

Transfer to the Green Anode Plant with routes 11/12/13 21/22/23/24/25/26 31/32/33 is possible with slow speed and fast speed of the pump (410 B 065), pump (410 B 125) and/or pump (410 B 165).



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Rev. 00


Should the pitch temperature drop below 160°C during transfer with routes 11/12/13, routes 21/22/23/24/25/26 and routes 31/32/33 the pump speed is changed back to slow speed.


138-02-043 Group 410 B DE-060300


Date: 29.09.2006file: 138-02-043_07_0.doc, Codeword: Vedanta Page 3 of 7

7.1.3 Main Process Data & Process Highlights • The process group is used to supply liquid pitch to Group 431/432 H (Proportioning)

- Pitch supply rate is 5m3/hour (6 t/hour) – pump runs at slow speed - Pitch supply rate is 10 m3 / hour (12 t/hour) – pump runs at high speed

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The control room operator has to communicate with the local operator for selection of the desired pump and pipe route. The local operator is then responsible for the opening and closing of the corresponding valves. Whenever a route is selected that has not been used for some time, the local operator has to make sure that the temperature of the heating jacket is sufficiently high by checking the HTM temperature in the return spool of the corresponding pitch lines.

Pump 410 B 065 is foreseen for transfer liquid pitch to Group 431 H (Proportioning). Pump 410 B 125 is foreseen for transfer liquid pitch to Group 432 H (Proportioning). Pump 410 B 165 can be used as stand-by pump to pump (410 B 065) or to pump (410 B 165).

From one tank only pitch can be taken at a time. Pitch reclaimed should be pumped into the same tank

Pitch reclaimed can be heated up through a heat exchanger 410 B 215/315. The heating capacity is 125 kW, what is sufficient to heat up a flow of 10 m3/hour by 20°C. It is most important that the pitch temperature is constant when metered to the mixer of Group 431/432 H. It shall not vary more than +/-1°C. Pitch is reclaimed from storage tanks by positive displacement pumps. Pitch pumps are equipped with two speed motors to run at low or high capacity. At slow speed the capacity is 5m3/hour (6 t/hour). At high speed the capacity is 10m3/hour (12 t/hour).

Irregular pump noise may be caused by cavitation. Cavitation may occur by plugged nozzle in the tank, plugged basket filter or because the pitch temperature in the tanks is too low. In all cases the operator has to switch the pump drive to low speed (if the pump is running at high speed) in order to reduce the pitch flow rate. If the pump runs already at low speed, the operator has to decide either to stop the pump to prevent it from damage or to keep the pump running under strict observation.

Normally, the pitch in two of the three tanks is stirred for homogenisation while one of the tanks is used to feed pitch to Group 431/432 H. If the feeding tank gets empty it is possible to use the stirring pumps to fill the tank in charge from the tanks, which has been stirred in order not to interrupt the anode production. During this transfer period, stirring in the corresponding tank has to be interrupted.

The heat exchanger (410 B 215/315) can be bypassed for cleaning or other maintenance purposes. The bypass route is via open pitch valve (410 B 225/325).


138-02-043 Group 410 B DE-060300

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All liquid pitch valves (with exception to the tank drain valves) have to be operated at regular intervals by the local operator in agreement with the central control room operator. This has to be done when the corresponding routes for transfer allow the manipulation of manual valves, normally during interruptions in production.

In case that a basket filter is plugged indicated by alarm signal or in case that cavitation noise indicates that the filter is close to getting plugged, the filter has to be inspected and cleaned instantaneously in order to keep the full flexibility for reclaiming. In order to do so, the proportioning and mixing group 431/432 J has to be run empty (e.g. by a quick stop) and this Group 410 B has to be stopped. The route with the stand-by basket filter and pump has then to be selected and this Group can be started again. The anode production with Group 431/432 J can be resumed a few minutes after restart of this Group.

Frequent cleaning is absolutely necessary for a safe and healthy operation. The operators and maintenance people have to make sure that no foreign material (e.g. bags, tools, debris, rags, petrol coke dust, etc.) spoils the area of the liquid pitch unloading, the pitch pumps and liquid pitch tanks and other floors where heated equipment is located. In case of a leakage foreign material may get soaked with oil, which increases a hazard of a fire and may hinder the access to the equipment, especially in case of emergency.

The tank drain valves are only opened for maintenance of an empty tank or in case that samples for testing purpose have to be drawn from the tank. These valves should be tagged and locked for unintentional operation. In case that these valves have to be opened for maintaining the empty tank the other valves on the pipe connections to this tank have to be safely locked in order to avoid unintended re-filling.

Smoking and open fire is strictly prohibited in the pitch unloading area and on and around the pitch storage tanks.

In case that maintenance work like grinding, burning or welding has to be done, special rules have to be established by VEDANTA that have to be strictly obeyed.

The operators have to be aware that the facility includes heated equipment – avoid burns on hot machine parts, tanks, valves, pipes, etc.

Outokumpu Technology GmbH Revision: 0 Date: 29.09.2006Page 4 of 7 file: 138-02-043_07_0.doc, Codeword: Vedanta


138-02-043 Group 410 B DE-060300

7.2 Process Control

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

(work copies)

Outokumpu Technology GmbH Revision: 0 Date: 29.09.2006file: 138-02-043_07_0.doc, Codeword: Vedanta Page 5 of 7


138-02-043 Group 410 B DE-060300


Date: 29.09.2006Page 6 of 7 file: 138-02-043_07_0.doc, Codeword: Vedanta

7.2.2 Control Logic Description

(Work Copy)


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Rev. 00

Control Philosophy of

Process Group 410 B - Liquid Pitch Transfer -

Reference:

Process Flow Sheet: 132-01-074 UB

P&I Diagram: 168-01-046 UB sheet 1, 2, 3, 4

Material Route Diagram: 133-50-051 UB sheet 1 & 2 / 133-50-052 UB sheet 1 & 2 / 133-50-053 UB sheet 1 & 2 / 133-50-054 UB sheet 1 & 2 / 133-50-055 UB sheet 1 & 2 / 133 50-056 UB sheet 1 & 2 / 133-50-057 UB sheet 1 & 2 / 133-50-058 UB sheet 1 & 2 / 133-50-059 UB sheet 1 & 2 / 133-50-060 UB sheet 1 & 2 / 133-50-061 UB sheet 1 & 2 / 133-50-062 UB sheet 1 & 2

1 Brief Process Description............................................................................................................ 2 2 Control Logic Description............................................................................................................ 3 2.1 Special Terminology for this Group.............................................................................................3 2.2 Linked Process Groups............................................................................................................... 5 2.3 Selections ................................................................................................................................... 5 2.3.1 Selection of Operation Modes (SE 1).......................................................................................... 5 2.3.2 Selection of Material Route Transfer Pump 410 B 065 (SE 2).................................................... 5 2.3.3 Selection of Material Route Stand-By Pump 410 B 165 (SE 3) .................................................. 9 2.3.4 Selection of Material Route Transfer Pump 410 B 125 (SE 4).................................................. 17 2.4 Group Start ............................................................................................................................... 20 2.4.1 Selections Prior to Start ............................................................................................................ 20 2.4.2 Start Preconditions.................................................................................................................... 20 2.4.3 Setpoints Prior to Group Start ................................................................................................... 20 2.4.4 Group Start Sequence .............................................................................................................. 22 2.5 Normal Operation...................................................................................................................... 23 2.5.1 Pitch Temperature Storage Tank.............................................................................................. 23 2.5.2 Pitch Temperature Liquid Pitch Heat Exchanger (410 B 215) (410 B 315)............................... 23 2.5.3 Vent valve (410 B 230).............................................................................................................. 24 2.5.4 Vent valve (410 B 330).............................................................................................................. 24 2.6 Shut Down ................................................................................................................................ 24 2.6.1 Normal Shut Down.................................................................................................................... 24 2.6.2 Shut Down by other Groups......................................................................................................24 2.6.3 Fast Shut Down......................................................................................................................... 24 2.6.4 Trip in Case of Faults ................................................................................................................ 25 2.7 Local Operation of Special Equipment...................................................................................... 30 2.8 Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 31



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Rev. 00

1 BRIEF PROCESS DESCRIPTION

The Liquid Pitch Transfer Process Group 410 B reclaims liquid pitch from tank 1, tank 2 or tank 3 to Process Group 431 H Proportioning via Pitch/HTM heat exchanger (410 B 215) and /or to Process Group 432 H Proportioning via Pitch/HTM heat exchanger (410 B 315) and back to tank 1, tank 2 or tank 3.

Group 410 B consists of a set of three pitch pumps and three basket filters connected to the suction nozzles of all three tanks and to the feed and return line to the Green Anode Plant Line 1 (431) and /or to the Green Anode Plant Line 2 (432). This operation is only possible if the basket filters are available and are not plugged. For this reason the differential pressure across the basket filters has to be observed regularly.

Pitch pump (410 B 065) is foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the Proportioning Group 431 H in the Green Anode Plant Line 1. Pitch pump (410 B 125) is foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the Proportioning Group 432 H in the Green Anode Plant Line 2. Pitch pump (410 B 165) can be used as stand-by to pump (410 B 065) or to pump (410 B 125). The arrangement of the pitch piping system allows for numerous combinations of tank suction nozzles and pitch pumps. For operation in automatic mode, however only the main combinations are foreseen, which results in 12 different routes that can be selected by the operator in the central control room.

Pitch pumps (410 B 065) and pitch pump (410 B 125) can be connected to the bottom suction nozzle of tank 1, tank 2 or tank 3. Pitch Pump (410 B 065) is operated in line with basket filter (410 B 050) and pitch pump (410 B 125) with basket filter (410 B 110). In case that these filters are plugged, an emergency transfer operation with stand-by pitch pump (410 B 165) via basket filter (410 B 150) to Line 1(431) or to Line 2 (432) is possible. Pitch pump (410 B 065) transfers pitch to Line 1 (431) via the liquid pitch heat exchanger (410 B 215) to the pressure holding valve (410 B 235), where the amount of pitch required for anode production is withdrawn by the pitch proportioning pump of Process Group 432 H. Pitch pump (410 B 125) transfers pitch to Line 2 (432) via the liquid pitch heat exchanger (410 B 315) to the pressure holding valve (410 B 335), where the amount of pitch required for anode production is withdrawn by the pitch proportioning pump of Process Group 432 H. The operator has three route selections for each transfer Pump, Route 11, 12, 13 for transfer pump (410 B 065) and Route 31, 32, 33 for transfer pump (410 B 125). For stand-by pump (410 B 165) exists six route selections, Route 21 – 26. The Route selections are described in detail under chapter 2.3.2 – 2.3.4 The pneumatic pitch valve (410 B 080) for Line 1 (431) and the pneumatic pitch valve (410 B 140) for Line 2 (432) are always closed when the transfer pumps are not in operation in order to shut off the long transfer line to the Green Anode Plant 1 and 2 keeping the line full of pitch. In this way, air or vapour, which may affect the correct operation of the Coriolis flow meters in Process Group 431 H and 432 H cannot enter the ring line. After long-term interruptions of the transfer operation, the transfer lines have to be vented by the manual vent valves (410 B 230) for Line 1 (431) and (410 B 330) for Line 2 (432).

The liquid pitch heat exchangers are used to adjust the pitch temperature by heating prior to transfer to the Proportioning Groups 431 H, 432 H.



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Rev. 00

The setpoint of the liquid pitch temperature after the heat exchangers (410 B 215) and (410 B 315) can be adjusted by the operator or the standard setpoint can be activated which is set to 180°C. The setpoint of the liquid pitch temperature controller is transferred to the HTM systems of Line 1 (431) and Line 2 (432) where it is connected in cascade to the corresponding enabled HTM temperature controller to regulate the temperature in HTM secondary circuit 3 of Line 1 (431) and the temperature in HTM secondary circuit 3 of Line 2 (432).

The selections of simultaneous routes are described under chapter 2.2.

The local operator has to open and close the corresponding pitch valves for the selected route. With valves in the correct position the control room operator receives the confirmation by a signal on the operator display. Simultaneously the local operator receives the confirmation for the corresponding pump by a pilot light on the local panel [410 LOP-B1]. He has to start the pump from the local panel. The local operator should always start the pump at slow speed by pushing the "START SLOW" pushbutton. Slow speed is used to flush the piping system from possible obstructions caused by cold spots. Slow speed should also be used as long as the pitch temperature is low. If the operator pushes the “START FAST” pushbutton the pump speed is controlled in auto mode. In this case the pump will start at slow speed and will change to fast speed after a pre-set time delay (setting in PLC: 4 minutes) for Routes 11/12/13 or Routes 21/22/23/24/25/26 or Routes 31/32/33 if the pitch temperature in the tank where the pumps sucking from has a level above 160°C.

Transfer to the Green Anode Plant with routes 11/12/13 21/22/23/24/25/26 31/32/33 is possible with slow speed and fast speed of the pump (410 B 065), pump (410 B 125) and/or pump (410 B 165).

Should the pitch temperature drop below 160°C during transfer with routes 11/12/13, routes 21/22/23/24/25/26 and routes 31/32/33 the pump speed is changed back to slow speed.

2 CONTROL LOGIC DESCRIPTION

2.1 Special Terminology for this Group

Operation Modes to be selected at the Central Control Room

CENTRAL There is no CENTRAL mode foreseen for this Process Group. Equipment of this exceptional Group is started and stopped locally only for observing leakages, noise etc.

AUTOMATIC For this process group, AUTOMATIC mode is available from the corresponding Local Operator Panels. For this process group, equipment is started and stopped in AUTOMATIC mode from a Local Operator when both the Central Control Room operator and the local operator have selected AUTOMATIC mode for this group. Details are explained in the description for this individual process group. In AUTOMATIC mode all equipment related devices and safety devices are interlocked. Alarms are always indicated on SCADA, independent of the operation mode.



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MAINTENANCE For this process group, MAINTENANCE mode is available from the corresponding Local Control Switches when both the Central Control Room operator and the local operator have selected MAINTENANCE mode for this group. Maintenance mode allows running equipment in jogging operation without any process and equipment related interlocks foreseen in AUTOMATIC mode. Alarms are always indicated on SCADA, independent of the operation mode.

Operation Modes to be selected on Local Operator Panels (LOP)

AUTOMATIC For this process group, AUTOMATIC mode is available from the corresponding Local Operator Panels, if AUTOMATIC mode is both selected on the corresponding LOP and on an Operator Station in the Central Control Room.

MAINTENANCE For this process group, MAINTENANCE mode is available from the corresponding Local Control Switches, if MAINTENANCE mode is both selected on the corresponding LOP and on an Operator Station in the Central Control Room.

Pushbuttons and lights on Local Operator Panel

E_STOP Mushroom PB stops equipment instantly

HORN OFF PB resets horn sounding

ALARM ACKNOWLEDGEMENT PB resets alarm

LAMP TEST PB powers all lights in LOP

*AUTOMATIC / MAINTENANCE Selector switch for operation mode

*PUMP START SLOW PB initiates start sequence of this pump

*PUMP START FAST PB allows fast start sequence of this pump

*PUMP STOP PB initiates stop sequence of this pump

*ROUTE OK Light indicates correct route selection

FAULT HTM CIRCUIT Light indicates fault of HTM circuit

*PUMP RUNNING SLOW Light indicates pump operates in low speed

*PUMP RUNNING FAST Light indicates pump operates in fast speed

**PITCH TEMP. LOW Light indicates low level of pitch temperature

**LOW PITCH FLOW Light indicates low differential pressure at filter

**FILTER PLUGGED Light indicates high differential pressure at filter

LI-410 A 200 Digital indication (0-100%) of tank 1 level



* one individual Pushbutton / Light for each pump ** one individual Light for each basket filter



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Rev. 00

2.2 Linked Process Groups

The following Process Groups are linked with this Group 410 B:

• Liquid Pitch Unloading & Storage 410 A • Liquid Pitch Stirring 410 C • HTM System 431 S / 432 S

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 local operator shall determine by individual selector switch for each pump at the local control panel [410 LOP-B1] to run the transfer pumps 410 B 065 and/or 410 B 125 and/or 410 B 165 in “Automatic” or “Maintenance” mode. The central control room operator has to confirm the selection on the Operator Station in the CCR for the corresponding pump individually. If a selector switch at [410 LOP-B1] is moved during automatic operation, the drive of the corresponding pump is stopped immediately.

“AUTOMATIC” operation mode” After this selection the pumps could start if all start preconditions are met.

“MANTENANCE” operation mode” (details please see under 2.7 below). Operation mode to start equipment strictly for maintenance, particularly from their individual local switches if installed. Functional machine interlocks such as overload relays and self-evident safety circuits are still active. Sequence and logic interlocks for automatic operation and interlocks from related Process Groups are not active. This operation mode allows field adjustments but requires local operator survey in case that material is conveyed. (For geared pitch pumps only very short running intervals are allowed without pitch)

2.3.2 Selection of Material Route Transfer Pump 410 B 065 (SE 2)

The operator has three options: The selection is made on the Operator Station located in the Central Control Room (CCR). The state of selection is on the Operation Station (OS) indicated. A “Route o.k.” light on the local operator panel [410 LOP-B1] indicates the correct position of the manual pitch valves for the selected route. If the correct valve position for the selected route is not confirmed by “Route o.k.” indication, the local operator has to verify the correct open or closed valve position.

SE 2-1 “Route 11: Transfer Pump 410 B 065 from tank 410 A 200 to tank 410 A 200” This material route can be selected simultaneous with following Routes:

• Route 31 (SE 4-1) or Route 24 (SE 3-4)



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Rev. 00

The local operator has to verify this Route Selection by manual control of the following valve positions:

OPEN: (410 B 010)

(410 B 017)

(410 B 040)

(410 B 045)

(410 B 060)

(410 B 070)

(410 B 100)

(410 B 210)

(410 B 220)

(410 B 240)

(410 B 250)

CLOSE: (410 A 230)

(410 B 005)

(410 B 015)

(410 B 025)

(410 B 027)

(410 B 037)

(410 B 055)

(410 B 075)

(410 B 105) if Route 31 is not selected


(410 B 205)

(410 B 225)

(410 B 305)

(410 B 340) if Route 31 or Route 24 is not selected

(410 C 010)

THREE WAY VALVE: (410 B 255) has to be open in direction from tank 2 to tank 3 (closed position) indicated by limit switch [410B255-ZX].

The pitch vent valve (410 B 230) has to be closed during the start of pitch pump (410 B 065) but may be opened after the start for minimum periods for venting (time adjusted in PLC: 40 seconds).

This Route Selection cannot be made if:

• pump (410 B 065) is in operation with a different route (Route 12/13, SE 2-2/2-3)



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Rev. 00

• pump (410 C 030) is in operation with route 51, 52, 53, 54 (SE 2-1/2-2/2-3/2-4)

With the verification of the above valve positions and the presence of signal “Group 431 S in Operation” this route is set in the PLC.

SE 2-2: “Route 12: Transfer Pump 410 B 065 from tank 410 A 300 to tank 410 A 300” This material route can be selected simultaneous with following Routes:



OPEN: (410 B 020)

(410 B 027)

(410 B 040)

(410 B 045)

(410 B 060)

(410 B 070)

(410 B 100)

(410 B 210)

(410 B 220)

(410 B 240)

CLOSE: (410 A 330)

(410 B 005)

(410 B 015)

(410 B 017)

(410 B 025)

(410 B 037)

(410 B 055)

(410 B 075)



(410 B 205)

(410 B 225)

(410 B 250)

(410 B 305)




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Rev. 00

(410 C 110)

THREE WAY VALVE: (410 B 255) has to be open in direction from tank 1 to tank 2 indicated by limit switch [410B255-ZL].



• pump (410 B 065) is in operation with a different route (Route 11/13 SE 2-1/2-3) • pump (410 C 130) is in operation with route 61, 62, 63, 64 (SE 3-1/3-2/3-3/3-4)





OPEN: (410 B 030)

(410 B 037)

(410 B 040)

(410 B 045)

(410 B 060)

(410 B 070)

(410 B 100)

(410 B 210)

(410 B 220)

(410 B 240)

CLOSE: (410 A 430)

(410 B 005)

(410 B 015)

(410 B 017)

(410 B 025)

(410 B 027)

(410 B 055)

(410 B 075)




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Rev. 00


(410 B 205)

(410 B 225)

(410 B 250)

(410 B 305)


(410 C 210)

THREE WAY VALVE: (410 B 255) has to be open in direction from tank 1 to tank 3 indicated by limit switch [410B255-ZH].





2.3.3 Selection of Material Route Stand-By Pump 410 B 165 (SE 3)

The operator has six options: The selection is made on the Operator Station located in the Central Control Room (CCR). The state of selection is on the Operation Station (OS) indicated. A “Route o.k.” light on the local operator panel [410 LOP-B1] indicates the correct position of the manual pitch valves for the selected route. If the correct valve position for the selected route is not confirmed by “Route o.k.” indication, the local operator has to verify the correct open or closed valve position.

SE 3-1 “Route 21: Stand-By Pump 410 B 165 from tank 410 A 200 via Line 1 (431) to tank 410 A 200” This material route can be selected simultaneous with following Routes:

• Route 31 (SE 4-1)


OPEN: (410 B 010)

(410 B 017)

(410 B 075)

(410 B 100)

(410 B 145)

(410 B 160)



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(410 B 170)

(410 B 210)

(410 B 220)

(410 B 240)

(410 B 250)

CLOSE: (410 A 230)

(410 B 027)

(410 B 037)

(410 B 040)

(410 B 070)


(410 B 135)

(410 B 155)

(410 B 205)

(410 B 225)

(410 B 305)


(410 C 010)




• pump (410 B 165) is in operation with a different route (Route 22/23/24/25/26 SE 3-2/3-3/3-4/3-5/3-6)




• Route 32 (SE 4-2)




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Rev. 00

OPEN: (410 B 020)

(410 B 027)

(410 B 075)

(410 B 100)

(410 B 145)

(410 B 160)

(410 B 170)

(410 B 210)

(410 B 220)

(410 B 240)

CLOSE: (410 A 330)

(410 B 017)

(410 B 037)

(410 B 040)

(410 B 070)


(410 B 135)

(410 B 155)

(410 B 205)

(410 B 225)

(410 B 250)

(410 B 305)

(410 B 340) if Route 32 is not selected)

(410 C 110)









12 (31)


Rev. 00


• Route 33 (SE 4-3)


OPEN: (410 B 030)

(410 B 037)

(410 B 075)

(410 B 100)

(410 B 145)

(410 B 160)

(410 B 170)

(410 B 210)

(410 B 220)

(410 B 240)

CLOSE: (410 A 430)

(410 B 017)

(410 B 027)

(410 B 040)

(410 B 070)


(410 B 135)

(410 B 155)

(410 B 205)

(410 B 225)

(410 B 250)

(410 B 305)

(410 B 340) if Route 33 is not selected)

(410 C 210)




13 (31)


Rev. 00




• pump (410 C 230) is in operation with route 71/72/73/74 (SE 4-1/4-2/4-3/4-4)



• Route 11 (SE 2-1)


OPEN: (410 B 010)

(410 B 017)

(410 B 100)

(410 B 135)

(410 B 145)

(410 B 160)

(410 B 170)

(410 B 250)

(410 B 310)

(410 B 320)

(410 B 340)

CLOSE: (410 A 230)

(410 B 027)

(410 B 037)


(410 B 075)

(410 B 105 and/or 410 B 130)

(410 B 155)

(410 B 205)

( 410 B 240) if Route 11 is not selected



14 (31)


Rev. 00

(410 B 305)

(410 B 325)

(410 C 010)


The pitch vent valve (410 B 330) has to be closed during the start of pitch pump (410 B 0165) but may be opened after the start for minimum periods for venting (time adjusted in PLC 40 seconds).





SE 3-5: “Route 25: Stand-By Pump 410 B 165 from tank 410 A 300 via Line 2 (432) to tank 410 A 300” This material route can be selected simultaneous with following Routes:

• Route 12 (SE 2-2)


OPEN: (410 B 020)

(410 B 027)

(410 B 100)

(410 B 135)

(410 B 145)

(410 B 160)

(410 B 170)

(410 B 310)

(410 B 320)

(410 B 340)

CLOSE: (410 A 330)

(410 B 017)

(410 B 037)


(410 B 075)



15 (31)


Rev. 00

(410 B 105 and/or 410 B 130)

(410 B 155)

(410 B 205)


(410 B 250)

(410 B 305)

(410 B 325)

(410 C 110)








• Route 13 (SE 2-3)


OPEN: (410 B 030)

(410 B 037)

(410 B 100)

(410 B 135)

(410 B 145)

(410 B 160)

(410 B 170)

(410 B 310)

(410 B 320)

(410 B 340)



16 (31)


Rev. 00

CLOSE: (410 A 430)

(410 B 017)

(410 B 027)


(410 B 075)

(410 B 105 and /or 410 B 130)

(410 B 155)

(410 B 205)


(410 B 250)

(410 B 305)

(410 B 325)

(410 C 210)









17 (31)


Rev. 00

2.3.4 Selection of Material Route Transfer Pump 410 B 125 (SE 4)

The operator has three options: The selection is made on the Operator Station located in the Central Control Room (CCR). The state of selection is on the Operation Sation (OS) indicated. A “Route o.k.” light on the local operator panel [410 LOP-B1] indicates the correct position of the manual pitch valves for the selected route. If the correct valve position for the selected route is not confirmed by “Route o.k.” indication, the local operator has to verify the correct open or closed valve position.




OPEN: (410 B 010)

(410 B 017)

(410 B 105)

(410 B 120)

(410 B 130)

(410 B 250)

(410 B 310)

(410 B 320)

(410 B 340)

CLOSE: (410 A 230)

(410 B 027)

(410 B 037)


(410 B 115)

(410 B 135)

(410 B 205)


(410 B 305)

(410 B 325)

(410 B 330)

(410 C 010)



18 (31)


Rev. 00




• pump (410 B 125) is in operation with a different route (Route 32/33 SE 4-2/4-3) - pump (410 C 030) is in operation with route 51, 52, 53, 54 (SE 2-1/2-2/2-3/2-4)


SE 4-2: “Route 32: Transfer Pump 410 B 125 from tank 410 A 300 to tank 410 A 300” This material route can be selected simultaneous with following Routes:



OPEN: (410 B 020)

(410 B 027)

(410 B 105)

(410 B 120)

(410 B 130)

(410 B 310)

(410 B 320)

(410 B 340)

CLOSE: (410 A 330)

(410 B 017)

(410 B 037)


(410 B 115)

(410 B 135)

(410 B 205)


(410 B 250)

(410 B 305)

(410 B 325)

(410 B 330)



19 (31)


Rev. 00

(410 C 110)







• Route 13 (SE 2-3) and/or Route 23 (SE 3-3)


OPEN: (410 B 030)

(410 B 037)

(410 B 105)

(410 B 120)

(410 B 130)

(410 B 310)

(410 B 320)

(410 B 340)

CLOSE: (410 A 430)

(410 B 017)

(410 B 027)


(410 B 115)

(410 B 135)

(410 B 205)


(410 B 250)

(410 B 305)

(410 B 325)



20 (31)


Rev. 00

(410 B 330)

(410 C 210)






2.4 Group Start

2.4.1 Selections Prior to Start • “AUTOMATIC” operation mode must be selected.

2.4.2 Start Preconditions

2.4.2.1 Process Group 410 S – HTM System • “HTM Secondary 5 in Operation” signal shall be present • “HTM Secondary 6 in Operation” signal shall be present

for details see Group 431 S / 410 S and 432 S / 410 S

2.4.2.2 Route Settings • Start pitch pump (410 B 065): Route 11, 12 or 13 have to be set. • Start pitch pump (410 B 165): Route 21, 22, 23, 24, 25 or 26 have to be set. • Start pitch pump (410 C 125): Route 31, 32 or 33 have to be set.

2.4.2.3 Emergency stops • If the Emergency Stop of the Group has been activated it has to be RESET.

2.4.2.4 Alarms • If an Alarm of this Group has been activated it has to be RESET.

2.4.2.5 Compressed Air Pressure 410 A 009 • Compressed air pressure in Group 410 A [410 A 009-PAL] shall be higher than 6 bar (P>6

bar).

2.4.3 Setpoints Prior to Group Start

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



21 (31)


Rev. 00

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

Standard Setpoint The operator may also override the actual setpoint by the “Standard Setpoint” any time. Selection of the “Standard Setpoint” is on SCADA. The “Standard Setpoint” can be edited on the SCADA system any time but by a Shift Leader only, after using his Password.

2.4.3.1 SP 1 Pitch Temperature Storage Tank 1 (410 A 200) The operator in the CCR may determine the setpoint of the liquid pitch temperature in the tank. Any value between 160°C and 200°C is accepted. If the "standard setpoint" is activated, the controller uses a fix value, which has been proven to cover most of the operating conditions for liquid pitch – set value is 180°C. If the "New setpoint” is not accepted, the "actual setpoint" remains activated. The liquid pitch temperature controller [TY-410 A 200] for storage tank 1 sends the setpoint to the HTM temperature controller in secondary circuit 5 [TY-410 S 541]. The signal superimposes the HTM temperature controller in a cascade.





22 (31)


Rev. 00

2.4.3.4 SP 4 Pitch Temperature downstream LP Heat Exchanger (410 B 215 and 410 B 315) The operator in the CCR may determine the setpoint of the liquid pitch temperature downstream the liquid pitch heat exchanger (410 B 215 and 410 B 315). Any value between 160°C and 200°C is accepted. If the "standard setpoint" is activated, the controller uses a fix value, which has been proven to cover most of the operating conditions for liquid pitch – set value is 180°C. If the "New setpoint” is not accepted, the "actual setpoint" remains activated. The liquid pitch temperature controller [TY-410 A 200] for storage tank 1 sends the setpoint to the HTM temperature controller in secondary circuit 3 Line 1 (431) [TY-431 S 330] and in secondary circuit 3 Line 2 (432) [TY-432 S 330]. The signal superimposes the HTM temperature controller in a cascade.

2.4.4 Group Start Sequence

The local operator has to get instructions from the Central Control Room operator which Route will be determined for the corresponding pump.

The operator starts the pitch pumps (410 B 065), (410 B 125) and (410 B 165) individually from the local control panel [410 LOP-B1]. A start is only initiated if the operator pushes the "SLOW" Start pushbutton of the corresponding pump.

2.4.4.1 Start Transfer Pump (410 B 065) • The Operator actuates "SLOW" start pushbutton for pitch pump (410 B 065). Flashing light

indicates that start up sequence is initiated. • Pneumatic Valve (410 B 080) is opened. • Pitch pump (410 B 065) is started at slow speed.

Condition: - Route 11/12/13 selected and verified

• The local operator can switch the pump to high speed by actuating "FAST" pushbutton for pitch pump (410 B 065) observing the pump operation at slow speed. The pump is then switched to fast speed after 4 minutes operation at slow speed. Condition: - pitch temperature at pump above low level 160°C [410 B 045-TL] when operating with route 11/12/13 - differential pressure at pitch filter between low level 0,5 mbar [410 B 050-PDSL] and high level 10 mbar [410 B 050-PDSH] when operating with route 11/12/13/14.

2.4.4.2 Start Transfer Pump (410 B 125) • The Operator actuates "SLOW" start pushbutton for pitch pump (410 B 125). Flashing light

indicates that start up sequence is initiated. • Pneumatic Valve (410 B 140) is opened. • Pitch pump (410 B 125) is started at slow speed.




23 (31)


Rev. 00

• The local operator can switch the pump to high speed by actuating "FAST" pushbutton for pitch pump (410 B 125) observing the pump operation at slow speed. The pump is then switched to fast speed after 4 minutes operation at slow speed. Condition: - pitch temperature at pump above low level 160°C [410 B 105-TL] when operating with route 61/62/63/64 - differential pressure at pitch filter between low level 0,5 mbar [410 C 115-PDSL] and high level 10 mbar [410 C 115-PDSH] when operating with route 61/62/63/64

2.4.4.3 Start Stand-By Pump (410 B 165) • The Operator actuates "SLOW" start pushbutton for pitch pump (410 B 165). Flashing light

indicates that start up sequence is initiated.

Route 21/22/23 for pump (410 B 165) is set:

• Pneumatic Valve (410 B 080) is opened. • Pitch pump (410 B 165) is started at slow speed.


Route 24/25/26 for pump (410 B 165) is set:

• Pneumatic Valve (410 B 140) is opened. • Pitch pump (410 B 165) is started at slow speed.


Any route 21/22/23/242/25/26 for pump (410 B 165) is set:

• The local operator can switch the pump to high speed by actuating "FAST" pushbutton for pitch pump (410 B 165) observing the pump operation at slow speed. The pump is then switched to fast speed after 4 minutes operation at slow speed. Condition: - pitch temperature at pump above low level 160°C [410 B 145-TL] when operating with route 21/22/23/24/25/26 - differential pressure at pitch filter between low level 0,5 mbar [410 B 150-PDSL] and high level 10 mbar [410 B 150-PDSH] when operating with route 21/22/23/24/25/26

2.5 Normal Operation

2.5.1 Pitch Temperature Storage Tank

The operator may vary the set value for the liquid pitch temperature [410 A 200-TIC], [410 A 300-TIC], [410 A 400-TIC] during operation. Normally, a variation of the pitch temperature setpoint during operation is only necessary when pitch is stirred in the tanks and if liquid pitch was received at a too low temperature.

2.5.2 Pitch Temperature Liquid Pitch Heat Exchanger (410 B 215) (410 B 315)

The operator may vary the set value for the liquid pitch temperature [410 B 215-TIC], [410 B 315-TIC] during operation. Normally, a variation of the pitch temperature setpoint during operation is only necessary when pitch with a different softening point was received from a different source and requires a different temperature level for mixing.



24 (31)


Rev. 00

2.5.3 Vent valve (410 B 230)

When operating pump (410 B 065) with Route 11/12/13 or pump (410 B 165) with Route 21/22/23, the local operator may open the vent valve (410 B 230) for maximum periods of 40 seconds in order to remove air from the pitch pipeline.

2.5.4 Vent valve (410 B 330)

When operating pump (410 B 125) with Route 31/32/33 or pump (410 B 165) with Route 24/25/26, the local operator may open the vent valve (410 B 330) for maximum periods of 40 seconds in order to remove air from the pitch pipeline.

2.6 Shut Down

2.6.1 Normal Shut Down

The equipment of this Group is only started and stopped from the local operating panel [410 LOP-B1] respectively.

There is no “Normal Shut Down” from the SCADA in the Central Control Room (CCR).

2.6.2 Shut Down by other Groups

This Group is not shut down by other Groups.

2.6.3 Fast Shut Down

The equipment of this Group is stopped from the local operating panel [410 LOP-B1].

2.6.3.1 Fast Shut Down of pump (410 B 065) from local operating panel [410 LOP-B1]

The operator actuates the “STOP” pushbutton for transfer pump (410 B 065).

- Pump (410 B 065) is stopped immediately - Pneumatic Valve (410 B 080) is closed


The operator actuates the “STOP” pushbutton for transfer pump (410 B 125).



The operator actuates the “STOP” pushbutton for Stand-by pump (410 B 165).

Pump (410 B 165) is operating with Route 21/22/23


Pump (410 B 165) is operating with Route 24/25/26




25 (31)


Rev. 00

2.6.4 Trip in Case of Faults

If this Group 410 B is running in AUTOMATIC mode and an equipment or an instrument of this Group fails an Alarm is initiated and, if the fault is of the serious sort, the corresponding part of this Group is stopped. All faults listed below will cause a Fast Shut Down of the respective part of this Group.

An E-Stop will cause a Fast Shut Down of this Group.

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 Pitch Transfer Pump (410 B 065)

MCC: [410 B 065] fault

- alarm is initiated - drive is stopped - Fast Shut Down of this part of the group (see 2.6.3.1 above) will be initiated.

2.6.4.2 Pitch Transfer Pump (410 B 125)



2.6.4.3 Stand-By Pump (410 B 165)



2.6.4.4 Pitch Valve (410 B 080)

If both limit switches [410 B 080-ZSL] and [410 B 080-ZSH] of the pitch valve are actuated or if limit switch [410 B 080 ZSH] is lost an alarm is initiated and when operating with Route 11/12/13 pitch pump (410 B 065) is stopped, when operating with Route 21/22/23 pitch pump (410 B 165) is stopped.

2.6.4.5 Pitch Valve (410 B 140)

If both limit switches [410 B 140-ZSL] and [410 B 140-ZSH] of the pitch valve are actuated or if limit switch [410 B 140 ZSH] is lost an alarm is initiated and when operating with Route 31/32/33 pitch pump (410 B 125) is stopped, when operating with Route 24/25/26 pitch pump (410 B 165) is stopped.

2.6.4.6 Route Selection SE 2-1/2-2/2-3

In case that a valve is moved during operation and the valve position required for the selected route 11/12/13 is lost

- alarm is initiated - "Route selection o.k." symbol starts flashing



26 (31)


Rev. 00

- Pump (410 B 065) is stopped immediately - Pneumatic valve (410 B 080) is closed

2.6.4.7 Route Selection SE 3-1/3-2/3-3/3-4/3-5/3-6

In case that a valve is moved during operation and the valve position required for the selected route 21/22/23/24/25/26 is lost

- alarm is initiated - "Route selection o.k." symbol starts flashing - Pump (410 B 165) is stopped immediately - Pneumatic valve (410 B 080) is closed when operated with route 21/22/23 - Pneumatic valve (410 B 140) is closed when operated with route 24/25/26

2.6.4.8 Route Selection SE 4-1/4-2/4-3

In case that a valve is moved during operation and the valve position required for the selected route 31/32/33 is lost

- alarm is initiated - "Route selection o.k." symbol starts flashing - Pump (410 B 125) is stopped immediately - Pneumatic valve (410 B 140) is closed

2.6.4.9 Pitch Valve (410 B 230)

In case that the vent valve is kept open for more than 40 seconds

operating with Route 11/12/13 - alarm is initiated - "Route selection o.k." symbol starts flashing - Pump (410 B 065) is stopped immediately - Pneumatic valve (410 B 080) is closed operating with Route21/22/23

alarm is initiated - "Route selection o.k." symbol starts flashing - Pump (410 B 165) is stopped immediately - Pneumatic valve (410 B 080) is closed

2.6.4.10 Pitch Valve (410 B 330)

In case that the vent valve is kept open for more than 40 seconds

operating with Route 31/32/33 - alarm is initiated - "Route selection o.k." symbol starts flashing - Pump (410 B 125) is stopped immediately - Pneumatic valve (410 B 140) is closed

operating with Route 24/25/26



27 (31)


Rev. 00

- alarm is initiated - "Route selection o.k." symbol starts flashing - Pump (410 B 165) is stopped immediately - Pneumatic valve (410 B 140) is closed

2.6.4.11 Pitch Temperature Valve (410 B 045) low

[410 B 045-TY] pitch temperature is lower than 160 °C

operating with Route 11/12/13 - alarm is initiated - "Pitch Temperature Filter 410 B 050 low" symbol starts flashing - He has then 3 minutes time to find the reason for that alarm (e.g. bottom suction

nozzle too cold). In case that the operator cannot eliminate the reason for the alarm he has to actuate the "SLOW" start pushbutton for pitch pump (410 B 065) or he has to stop the pump (410 B 065). If operating at fast speed pump (410 B 065) is automatically stopped after 3 minutes delay time and pneumatic valve (410 B 080) is closed.









operating with Route 24/25/26 - alarm is initiated - "Pitch Temperature Filter 410 B 150 low" symbol starts flashing



28 (31)


Rev. 00

- He has then 3 minutes time to find the reason for that alarm (e.g. bottom suction nozzle too cold). In case that the operator cannot eliminate the reason for the alarm he has to actuate the "SLOW" start pushbutton for pitch pump (410 B 165) or he has to stop the pump (410 B 165). If operating at fast speed pump (410 B 165) is automatically stopped after 3 minutes delay time and pneumatic valve (410 B 140) is closed.

2.6.4.14 Pitch Filter 410 B 050 Low Differential Pressure [410 B 050-PDSL]

[410 B 050-PDSL] differential pressure at the filter is too low <0,5 mbar

operating with Route 11/12/13 - The operator is warned by an acoustic signal - pilot light in the local panel " LOW PITCH FLOW" [410 B 050-PDSL]

He has then 3 minutes time to find the reason for that alarm (e.g. bottom suction nozzle too cold). In case that the operator cannot eliminate the reason for the alarm he has to actuate the "SLOW" start pushbutton for pitch pump (410 B 065) or he has to stop the pump (410 B 065). If operating at fast speed pump (410 B 065) is automatically stopped after 3 minutes delay time and pneumatic valve (410 B 080) is closed.












29 (31)


Rev. 00


2.6.4.17 Pitch Filter (410 B 050) High Differential Pressure [410 B 050-PDSH]

[410 B 050-PDSH] differential pressure at the filter is too high >10 mbar

operating with Route 11/12/13 - The operator is warned by an acoustic signal - pilot light in the local panel when the "FILTER PLUGGED" [410 B 050-PDSH] - In case that the reason for the alarm is prevailing for 3 minutes pump (410 B 065) is

automatically stopped if operating at fast speed and pneumatic valve (410 B 080) is closed.

The reason for this alarm may be too high pitch viscosity normally together with too low pitch temperature or a dirty filter.



operating with Route 31/32/33 - The operator is warned by an acoustic signal - pilot light in the local panel when the "FILTER PLUGGED" [410 B 110-PDSH] - In case that the reason for the alarm is prevailing for 3 minutes pump (410 B 125) is





operating with Route 21/22/23/ - The operator is warned by an acoustic signal - pilot light in the local panel when the "FILTER PLUGGED" [410 B 150-PDSH] - In case that the reason for the alarm is prevailing for 3 minutes pump (410 B 165) is


operating with Route 24/25/26/ - The operator is warned by an acoustic signal - pilot light in the local panel when the "FILTER PLUGGED" [410 B 150-PDSH] - In case that the reason for the alarm is prevailing for 3 minutes pump (410 B 165) is




30 (31)


Rev. 00


2.7 Local Operation of Special Equipment

Not applicable



31 (31)


Rev. 00


2.8 Signal Exchange with Sub-Groups of this Group and Other Process Groups Signal Description Sort of Signal from Group 431 S to Group 410 B “GROUP 431 S IN OPERATION”

Group 431 S is running in AUTOMATIC mode, minimum 2 primary pumps in operation, minmum 1 pump of secondary 1 & 2 & 3 & 4 in operation, no Heater Common Fault

Digital signal from PLC Number 431 PLC 11 410 PLC 01

from Group 432 S to Group 410 B “GROUP 432 S IN OPERATION” Group 432 S is running in AUTOMATIC mode, minimum 2 primary pumps in operation, minmum 1 pump of secondary 1 & 2 & 3 & 4 in operation, no Heater Common Fault

Digital signal from PLC Number 432 PLC 22 to 410 PLC 01

from Group 431 S / 410 S to Group 410 B

“HTM SECONDARY 5 IN OPERATION” Group 431 S / 410 S is running in AUTOMATIC mode, minimum 2 primary pumps in operation, minimum 1 pump of secondary 5 in operation, minimum 1 Heater no Common Fault

Digital signal from 431 PLC 11 to 410 PLC 01 and within PLC Number 410 PLC 01

from Group 431 S / 410 S to Group 410 B

“HTM SECONDARY 6 IN OPERATION” Group 431 S / 410 S is running in AUTOMATIC mode, minimum 2 primary pumps in operation, minimum 1 pump of secondary 6 in operation, minimum 1 Heater no Common Fault

Digital signal from 431 PLC 11 to 410 PLC 01 and within PLC Number 410 PLC 01

from Group 410 A to Group 410 B Compressed air pressure above 6 bar (no low-pressure indicated by 410 A 009-PE1)

Digital signal within 410 PLC 01

from Group 410 B to Group 431 H Pump 410 B 065 operating with route 11-13 or pump 410 B 165 operating with route 21-23 “PITCH AVAILABLE FOR PROPORTIONING”

Digital signal from 410 PLC 01 to 431 PLC 15

from Group 410 B to Group 432 H Pump 410 B 125 operating with route 31-33 or pump 410 B 165 operating with route 24-26 “PITCH AVAILABLE FOR PROPORTIONING”

Digital signal from 410 PLC 01 to 432 PLC 25

from Group 410 A to Group 410 B Pitch Valve 410 A 230 closed “DRAIN TANK 1 CLOSED”






from Group 410 A to Group 410 B Actual level [410 A 200-LI] in tank 1 “LEVEL TANK 1”

Analogue signal within 410 PLC 01





from Group 410 C to Group 410 B Pitch Valve 410 C 010 closed Digital signal within 410 PLC 01 from Group 410 C to Group 410 B Pitch Valve 410 C 110 closed Digital signal within 410 PLC 01 from Group 410 C to Group 410 B Pitch Valve 410 C 210 closed Digital signal within 410 PLC 01 from Group 410 B to Group 410 C Pitch Valve 410 B 010 open Digital signal within 410 PLC 01 from Group 410 B to Group 410 C Pitch Valve 410 B 017 closed Digital signal within 410 PLC 01 from Group 410 B to Group 410 C Pitch Valve 410 B 020 open Digital signal within 410 PLC 01 from Group 410 B to Group 410 C Pitch Valve 410 B 027 closed Digital signal within 410 PLC 01 from Group 410 B to Group 410 C Pitch Valve 410 B 030 open Digital signal within 410 PLC 01 from Group 410 B to Group 410 C Pitch Valve 410 B 037 closed Digital signal within 410 PLC 01


138-02-043 Group 410 B DE-060300

Outokumpu Technology GmbH Revision: 0 Date: 29.09.2006file: 138-02-043_07_0.doc, Codeword: Vedanta Page 7 of 7

7.3 Main Equipment

7.3.1 Basket Filter 410 B 050

7.3.2 Positive Displacement Pump 410 B 065

7.3.3 Liquid pitch Heat Exchanger 410 B 215

7.3.4 Pressure Holding Valve 410 B 235

410b

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