410c

Training Manual Green Anode Plant Vedanta - Jharsuguda

138-02-043 Group 410 C DE-060300

8 PROCESS GROUP 410 C - LIQUID PITCH STIRRING -

8 Process Group 410 C - Liquid Pitch Stirring -..............................................................................1 8.1 Process .......................................................................................................................................1 8.1.1 Process Flow Sheets...................................................................................................................1 8.1.2 Brief Process Description ............................................................................................................2 8.1.3 Main Process Data & Process Highlights ....................................................................................3 8.2 Process Control ...........................................................................................................................5 8.2.1 P&Id`s, Material Route Diagrams, Operator Screen Images.......................................................5 8.2.2 Control Logic Description ............................................................................................................6 8.3 Main Equipment ..........................................................................................................................7 8.3.1 Basket Filter 410 C 015...............................................................................................................7 8.3.2 Positive Displacement Pump 410 C 030 .....................................................................................7

8.1 Process

8.1.1 Process Flow Sheets

(Work Copy)

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138-02-043 Group 410 C DE-060300

Outokumpu Technology GmbH Revision: 0

Date: 29.09.2006Page 2 of 7 file: 138-02-043_08_0.doc, Codeword: Vedanta

8.1.2 Brief Process Description

(Work Copy)

CONTROL PHILOSOPHY 05.10.2006

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Vedanta Alumina Ltd. Jharsuguda – Green Anode Plant Client ref.: VJ/SML/PO/032/1 OTK ref.: DE-060300 Doc. No.: 133-50-063

Rev. 00

Brief Process Description of

Process Group 410 C - Liquid Pitch Stirring -

Reference:

Process Flow Sheet: 132-01-075 UB

P&I Diagram: 168-01-046 UB sheet 4, 168-01-047 UB sheet 1

Material Route Diagram: 133-50-064 UB sheet 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12

The Liquid Pitch Stirring Process Group 410 C stirs liquid pitch in tank 1 (410 A 200) and /or in Tank 2 (410 A 300) and/or in tank 3 (410 A 400) or transfers liquid pitch between tank 1, tank 2 and tank 3.

Group 410 C consists of a set of three pitch pumps and three basket filters. Each pump is connected to a tank discharge nozzle. Pitch is stirred in one tank or transferred to another tank using one pump. This operation is only possible if the basket filter upstream the pump is available and is not plugged. The differential pressure across the basket filters is monitored continuously.

Pitch pump (410 C 030) keeps the pitch in tank 1 homogenous by circulation and thereby stirring the pitch in tank 1 or transfers the pitch to tank 2 or tank 3. Pitch pump (410 C 130) keeps the pitch in tank 2 homogenous by circulation and thereby stirring the pitch in tank 2 or transfers the pitch to tank 1 or tank 3. Pitch pump (410 C 230) keeps the pitch in tank 3 homogenous by circulation and thereby stirring the pitch in tank 3 or transfers the pitch to tank 1 or tank 2. 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 pump (410C 030) is connected to the bottom suction nozzle of tank 1 via basket filter (410 C 015). Pitch pump (410 C 030) circulates pitch within tank 1 via the stirring nozzles (410 C 041, 042, 043, 044) or via nozzle (410 C 055) or to tank 2 via nozzle (410 C 155) or to tank 3 via nozzle (410 C 255). Four route selections – Route 51,52,53,54 – can be made for pitch pump (410 C 030), which are described in detail under chapter 2.2.2. Pitch pump (410C 130) is connected to the bottom suction nozzle of tank 2 via basket filter (410 C 115). Pitch pump (410 C 130) circulates pitch within tank 2 via the stirring nozzles (410 C 141, 142, 143, 144) or via nozzle (410 C 155) or to tank 1 via nozzle (410 C 055) or to tank 3 via nozzle (410 C 255). Four route selections – Route 61,62,63,64 – can be made for pitch pump (410 C 130), which are described in detail under chapter 2.2.3. Pitch pump (410C 230) is connected to the bottom suction nozzle of tank 3 via basket filter (410 C 215). Pitch pump (410 C 230) circulates pitch within tank 3 via the stirring nozzles (410 C 241, 242, 243, 244) or via nozzle (410 C 255) or to tank 1 via nozzle (410 C 055) or to tank 2 via nozzle (410 C 155). Four route selections – Route 71,72,73,74 – can be made for pitch pump (410 C 230), which are described in detail under chapter 2.2.4.

The selections of simultaneous routes are described under chapter 2.2.

Outokumpu Technology GmbH


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The local operator has to open and close the corresponding pitch valves required 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-B2]. 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. In this case the pump will only run at slow speed. 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 (160°C). 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) if the pitch temperature in the tank where the pump is sucking from has a level above 160°C. According to the route selection the level of the corresponding tank where the pitch is directed to has to be below maximum.

Should the pitch temperature drop below 160°C during circulation the pump speed is changed automatically back to slow speed.

If pitch shall be pumped from one tank to another with route 52/53/62/63/72/73 selected the corresponding pump can only be started if the tank is not full, which the pitch is directed to. The actual tank level is displayed on the local control panel.


138-02-043 Group 410 C DE-060300


Date: 29.09.2006file: 138-02-043_08_0.doc, Codeword: Vedanta Page 3 of 7

8.1.3 Main Process Data & Process Highlights • The process group is used to stir pitch stored in the pitch tanks.

- Pitch stirring rate is 10m3/hour (12 t/hour) – pump runs at slow speed - Pitch stirring rate is 20 m3 / hour (24 t/hour) – pump runs at high speed

• 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.

• Each pitch tank can be stirred individually. • Two pitch tanks can be stirred while from the third tank pitch can be pumped to Group

431/432 H or circulated to the same tank. • Pitch is stirred in the 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 10m3/hour (12 t/hour). At high speed the capacity is 20m3/hour (24 t/hour).

• Irregular pump noise may be caused by cavitation. Cavitation may occure 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, at the same time these tanks could filled by group 410 A also. The third tank is only 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 other 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 pitch temperature in the tank not in charge for anode production should be maintained as low as possible to minimise aging of pitch. The lower the pitch temperature the lower is the aging rate but the higher is the viscosity. At the same time pitch has to be stirred continuously to reduce settling of fine grainy pitch matters at the tank bottom but stirring requires a viscosity convenient for pumping. Depending on the pitch quality for each new delivery of pitch a compromise has to be found between aging and pumping requirements. The third factor is the wetting ability of pitch on the coke grain surface during mixing of anode paste. The higher the coke temperature and the higher the pitch temperature the better is the ability of pitch to wet the grain surface. According to actual knowledge 190 - 200°C pitch temperature gives the best results when using pitch of about 110 R+B softening point. If 200°C has been chosen to be the best pitch temperature for making anode paste the temperature of pitch in the tank in charge must be not less than 180°C because of the limited heating capacity of the liquid pitch heat exchanger, which can heat up 12 t / hour pitch by 20°C maximum. The pitch in the tank not actually in charge should be lower in temperature. If the temperature has dropped under 170°C pumping becomes difficult (cavitation) so that the pitch has to be heated up by means of HTM heated coils installed at the pitch tanks bottom until pumping without cavitation noise is possible again. Heating is also supported by the immersion heaters, which are part of tanks heating system.


138-02-043 Group 410 C DE-060300

• 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 unloading allow the manipulation of manual valves, normally during interruptions in production.

• 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_08_0.doc, Codeword: Vedanta


138-02-043 Group 410 C DE-060300

8.2 Process Control

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

(work copies)

Outokumpu Technology GmbH Revision: 0 Date: 29.09.2006file: 138-02-043_08_0.doc, Codeword: Vedanta Page 5 of 7


138-02-043 Group 410 C DE-060300


Date: 29.09.2006Page 6 of 7 file: 138-02-043_08_0.doc, Codeword: Vedanta

8.2.2 Control Logic Description

(Work Copy)


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Rev. 00

Control Philosophy of

Process Group 410 C - Liquid Pitch Stirring -

Reference:

Process Flow Sheet: 132-01-075 UB

P&I Diagram: 168-01-046 UB sheet 4, 168-01-047 UB sheet 1

Material Route Diagram: 133-50-064 UB sheet 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12

1 Brief Process Description............................................................................................................ 1 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 Stirring Pump 410 C 030 (SE 2) ..................................................... 5 2.3.3 Selection of Material Route Stirring Pump 410 C 130 (SE 3) ..................................................... 9 2.3.4 Selection of Material Route Stirring Pump 410 C 230 (SE 4) ................................................... 12 2.4 Group Start ............................................................................................................................... 15 2.4.1 Selections Prior to Start ............................................................................................................ 15 2.4.2 Start Preconditions.................................................................................................................... 15 2.4.3 Setpoints Prior to Group Start ................................................................................................... 16 2.4.4 Group Start Sequence .............................................................................................................. 16 2.5 Normal Operation...................................................................................................................... 17 2.5.1 High Level Storage Tank........................................................................................................... 17 2.5.2 Pitch Temperature Storage Tank.............................................................................................. 17 2.6 Shut Down ................................................................................................................................ 17 2.6.1 Normal Shut Down.................................................................................................................... 17 2.6.2 Shut Down by other Groups......................................................................................................17 2.6.3 Fast Shut Down......................................................................................................................... 18 2.6.4 Trip in Case of Faults................................................................................................................ 18 2.7 Local Operation of Special Equipment...................................................................................... 22 2.8 Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 23

1 BRIEF PROCESS DESCRIPTION

The Liquid Pitch Stirring Process Group 410 C stirs liquid pitch in tank 1 (410 A 200) and /or in Tank 2 (410 A 300) and/or in tank 3 (410 A 400) or transfers liquid pitch between tank 1, tank 2 and tank 3.

Group 410 C consists of a set of three pitch pumps and three basket filters. Each pump is connected to a tank discharge nozzle. Pitch is stirred in one tank or transferred to another tank using one pump. This operation is only possible if the basket filter upstream the pump is available and is not plugged. The differential pressure across the basket filters is monitored continuously.



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Pitch pump (410 C 030) keeps the pitch in tank 1 homogenous by circulation and thereby stirring the pitch in tank 1 or transfers the pitch to tank 2 or tank 3. Pitch pump (410 C 130) keeps the pitch in tank 2 homogenous by circulation and thereby stirring the pitch in tank 2 or transfers the pitch to tank 1 or tank 3. Pitch pump (410 C 230) keeps the pitch in tank 3 homogenous by circulation and thereby stirring the pitch in tank 3 or transfers the pitch to tank 1 or tank 2. 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 pump (410C 030) is connected to the bottom suction nozzle of tank 1 via basket filter (410 C 015). Pitch pump (410 C 030) circulates pitch within tank 1 via the stirring nozzles (410 C 041, 042, 043, 044) or via nozzle (410 C 055) or to tank 2 via nozzle (410 C 155) or to tank 3 via nozzle (410 C 255). Four route selections – Route 51,52,53,54 – can be made for pitch pump (410 C 030), which are described in detail under chapter 2.2.2. Pitch pump (410C 130) is connected to the bottom suction nozzle of tank 2 via basket filter (410 C 115). Pitch pump (410 C 130) circulates pitch within tank 2 via the stirring nozzles (410 C 141, 142, 143, 144) or via nozzle (410 C 155) or to tank 1 via nozzle (410 C 055) or to tank 3 via nozzle (410 C 255). Four route selections – Route 61,62,63,64 – can be made for pitch pump (410 C 130), which are described in detail under chapter 2.2.3. Pitch pump (410C 230) is connected to the bottom suction nozzle of tank 3 via basket filter (410 C 215). Pitch pump (410 C 230) circulates pitch within tank 3 via the stirring nozzles (410 C 241, 242, 243, 244) or via nozzle (410 C 255) or to tank 1 via nozzle (410 C 055) or to tank 2 via nozzle (410 C 155). Four route selections – Route 71,72,73,74 – can be made for pitch pump (410 C 230), which are described in detail under chapter 2.2.4.

The selections of simultaneous routes are described under chapter 2.2.

The local operator has to open and close the corresponding pitch valves required 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-B2]. 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. In this case the pump will only run at slow speed. 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 (160°C). 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) if the pitch temperature in the tank where the pump is sucking from has a level above 160°C. According to the route selection the level of the corresponding tank where the pitch is directed to has to be below maximum.

Should the pitch temperature drop below 160°C during circulation the pump speed is changed automatically back to slow speed.

If pitch shall be pumped from one tank to another with route 52/53/62/63/72/73 selected the corresponding pump can only be started if the tank is not full, which the pitch is directed to. The actual tank level is displayed on the local control panel.



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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 Panel 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.

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



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*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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2.2 Linked Process Groups

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

• Liquid Pitch Unloading & Storage 410 A • Liquid Pitch Transfer 410 B • 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-B2] to run the stirring pumps 410 C 030 and/or 410 C 130 and/or 410 C 230 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-B2] 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 Stirring Pump 410 C 030 (SE 2)

The operator has four 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-B2] 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 51: Stirring Pump 410 C 030 from tank 410 A 200 to tank 410 A 200 via stirring nozzles” This material route can be selected simultaneous with following Routes:

• Route 71 (SE 4-1) and/or Route 61/62/63/64 (SE 3-1/3-2/3-3/3-4)



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or Route 61 (SE 3-1) and/or Route 72/73/74 (SE 4-2/4-3/4-4)

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

OPEN: (410 B 010)

(410 C 010)

(410 C 025)

(410 C 035)

(410 C 040)

a minimum of two of the following valves (410 C 041), (410 C 042), (410 C 043), (410 C 044)

CLOSE: (410 A 230)

(410 B 017)

(410 C 020)

(410 C 050)

This Route Selection cannot be made if:

• pump (410 C 030) is in operation with a different route (Route 52/53/54 SE 2-2/2-3/2-4) • pump (410 B 065) is in operation with route 11 (SE 2-1) • pump (410 B 165) is in operation with route 21 (SE 3-1) or 24 (SE 3-4) • pump (410 B 125) is in operation with route 31 (SE 4-1)

With the verification of the above valve positions this route is set in the PLC.

SE 2-2: “Route 52: Stirring Pump 410 C 030 from tank 410 A 200 to tank 410 A 300” This material route can be selected simultaneous with following Routes:

• Route 71 (SE 4-1) and/or Route 61 (SE 3-1)


OPEN: (410 B 010)

(410 C 010)

(410 C 025)

(410 C 035)

(410 C050)

(410 C 155)

CLOSE: (410 A 330)

(410 B 017)

(410 C 020)



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(410 C 040)

(410 C 055)

(410 C 150)

(410 C 250)

(410 C 255)

This Route Selection cannot be made:






OPEN: (410 B 010)

(410 C 010)

(410 C 025)

(410 C 035)

(410 C 050)

(410 C 255)

CLOSE: (410 A 430)

(410 B 017)

(410 C 020)

(410 C 040)

(410 C 055)

(410 C 150)

(410 C 155)

(410 C 250)


• pump (410 C 030) is in operation with a different route (Route 51/52/54 SE 2-1/2-2/2-4) • pump (410 B 065) is in operation with route 11 (SE 2-1)



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• pump (410 B 165) is in operation with route 21 (SE 3-1) or 24 (SE 3-4) • pump (410 B 125) is in operation with route 31 (SE 4-1)


SE 2-4; “Route 54: Stirring Pump 410 C 030 from tank 410 A 200 to tank 410 A 200” This material route can be selected simultaneous with following Routes:



OPEN: (410 B 010)

(410 C 010)

(410 C 025)

(410 C 035)

(410 C 050)

(410 C 055)

CLOSE: (410 A 230)

(410 B 017)

(410 C 020)

(410 C 040)

(410 C 150)

(410 C 155)

(410 C 250)

(410 C 255)






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The operator has four 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-B2] 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 61: Stirring Pump 410 C 130 from tank 410 A 300 to tank 410 A 300 via stirring nozzles” This material route can be selected simultaneous with following Routes:

• Route 71 (SE 4-1) and/or Route 51/52/53/54 (SE 2-1/2-2/2-3/2-4) or Route 51 (SE 2-1) and/or Route 72/73/74 (SE 4-2/4-3/4-4)


OPEN: (410 B 020)

(410 C 110)

(410 C 125)

(410 C 135)

(410 C 140)


CLOSE: (410 A 330)

(410 B 027)

(410 C 120)

(410 C 150)








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OPEN: (410 B 020)

(410 C 055)

(410 C 110)

(410 C 125)

(410 C 135)

(410 C 150)

CLOSE: (410 A 230)

(410 B 027)

(410 C 050)

(410 C 120)

(410 C 140)

(410 C 155)

(410 C 250)

(410 C 255)







OPEN: (410 B 020)

(410 C 110)

(410 C 125)

(410 C 135)

(410 C 150)

(410 C 255)



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CLOSE: (410 A 430)

(410 B 027)

(410 C 050)

(410 C 055)

(410 C 120)

(410 C 140)

(410 C 155)

(410 C 250)







OPEN: (410 B 020)

(410 C 110)

(410 C 125)

(410 C 135)

(410 C 150)

(410 C 155)

CLOSE: (410 A 330)

(410 B 027)

(410 C 050)

(410 C 055)

(410 C 120)

(410 C 140)

(410 C 250)

(410 C 255)



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The operator has four 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-B2] 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 4-1: “Route 71: Stirring Pump 410 C 230 from tank 410 A 400 to tank 410 A 400 stirring nozzles”

This material route can be selected simultaneous with following Routes:

• Route 51 (SE 2-1) and/or Route 61/62/63/64 (SE 3-1/3-2/3-3/3-4) or Route 61 (SE 3-1) and/or Route 52/53/54 (SE 2-2/2-3/2-4)


OPEN: (410 B 030)

(410 C 210)

(410 C 225)

(410 C 235)

(410 C 240)


CLOSE: (410 A 430)

(410 B 037)

(410 C 220)

(410 C 250)


• pump (410 C 230) is in operation with a different route (Route 72/73/74 SE 4-2/4-3/4-4) • pump (410 B 065) is in operation with route 13 (SE 2-3) • pump (410 B 165) is in operation with route 23 (SE 3-3) or 26 (SE 3-6)



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• pump (410 B 125) is in operation with route 33 (SE 4-3)





OPEN: (410 B 030)

(410 C 055)

(410 C 210)

(410 C 225)

(410 C 235)

(410 C 250)

CLOSE: (410 A 230)

(410 B 037)

(410 C 050)

(410 C 150)

(410 C 155)

(410 C 220)

(410 C 240)

(410 C 255)









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OPEN: (410 B 030)

(410 C 155)

(410 C 210)

(410 C 225)

(410 C 235)

(410 C 250)

CLOSE: (410 A 330)

(410 B 037)

(410 C 050)

(410 C 055)

(410 C 150)

(410 C 220)

(410 C 240)

(410 C 255)







OPEN: (410 B 030)

(410 C 210)

(410 C 225)

(410 C 235)

(410 C 250)

(410 C 255)

CLOSE: (410 A 430)

(410 B 037)



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(410 C 050)

(410 C 055)

(410 C 150)

(410 C 155)

(410 C 220)

(410 C 240)




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 410 S

2.4.2.2 Pitch Storage Tank • Storage Tank 1 [410 A 200-LSHH] indicates high-high level

- Route 62, 72 directed to this storage tank cannot be selected. • Storage Tank 2 [410 A 300-LSHH] indicates high-high level

- Route 52, 73 directed to this storage tank cannot be selected. • Storage Tank 3 [410 A 400-LSHH] indicates high-high level

- Route 53, 63 directed to this storage tank cannot be selected.

2.4.2.3 Seal pot • Seal pot of tank 1 [410 A 210-LSHH] indicates high-high level

- Route 62, 72 directed to this storage tank cannot be selected. • Seal pot of tank 2 [410 A 310-LSHH] indicates high-high level

- Route 52, 73 directed to this storage tank cannot be selected. • Seal pot of tank 3 [410 A 410-LSHH] indicates high-high level

- Route 53, 63 directed to this storage tank cannot be selected.

2.4.2.4 Route Settings • Start pitch pump (410 C 030): Route 51, 52, 53 or 54 have to be set.



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• Start pitch pump (410 C 130): Route 61, 62, 63 or 64 have to be set. • Start pitch pump (410 C 230): Route 71, 72, 73 or 74 have to be set.

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

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

2.4.3 Setpoints Prior to Group Start

There are no setpoints in this group.

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 C 030), (410 C 130) and (410 C 230) individually from the local control panel [410 LOP-B2]. A start is only initiated if the operator pushes the "SLOW" Start pushbutton of the corresponding pump.

2.4.4.1 Start Stirring Pump (410 C 030) • The Operator actuates "SLOW" start pushbutton for pitch pump (410 C 030). Flashing light

indicates that start up sequence is initiated. • Pitch pump (410 C 030) is started at slow speed.

Condition: Route 51/52/53/54 selected and verified

• The local operator can switch the pump to high speed by actuating "FAST" pushbutton for pitch pump (410 C 030) 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 C 010-TL] when operating with route 51/52/53/54 - differential pressure at pitch filter between low level 0,5 mbar [410 C 015-PDSL] and high level 10 mbar [410 C 015-PDSH] when operating with route 51/52/53/54



Condition: - Route 61/62/63/64 selected and verified




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Condition: - Route 71/72/73/74 selected and verified


2.5 Normal Operation

2.5.1 High Level Storage Tank • Storage Tank 1 [410 A 200-LSH] indicates High Level

operating with Route 62 or 72 - acoustic signal in the local panel - alarm on the operator station in the CCR

• Storage Tank 2 [410 A 300-LSH] indicates High Level operating with Route 52 or 73 - acoustic signal in the local panel - alarm on the operator station in the CCR

• Storage Tank 3 [410 A 400-LSH] indicates High Level operating with Route 53 or 63 - acoustic signal in the local panel - alarm on the operator station in the CCR

2.5.2 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.

2.6 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-B2] 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.



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2.6.3 Fast Shut Down • The equipment of this Group is stopped from the local operating panels [410 LOP-B2].

2.6.3.1 Fast Shut Down of pump (410 C 030) from local operating panel [410 LOP-B2] • The operator actuates the “STOP” pushbutton for stirring pump (410 C 030)

- Pump (410 C 030) is stopped immediately.

2.6.3.2 Fast Shut Down of pump (410 C 130) from local operating panel [410 LOP-B2] • The operator actuates the “STOP” pushbutton for stirring pump (410 C 130).

- Pump (410 130) is stopped immediately.

2.6.3.3 Fast Shut Down of pump (410 C 230) from local operating panel [410 LOP-B2] • The operator actuates the “STOP” pushbutton for stirring pump (410 C 230).

- Pump (410 C 230) is stopped immediately.

2.6.4 Trip in Case of Faults

If this Group 410 C 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 Stirring Pump (410 C 030) • MCC: [410 C 030] 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.





2.6.4.4 Route Selection SE 2-1/2-2/2-3/2-4 • In case that a valve is moved during operation and the valve position required for the

selected route 51/52/53/54 is lost, - alarm is initiated



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- "Route selection o.k." symbol starts flashing - pump (410 C 030) is stopped immediately.


selected route 61/62/63/64 is lost, - alarm is initiated - "Route selection o.k." symbol starts flashing - pump (410 C 130) is stopped immediately.


selected route 71/72/73/74 is lost, - alarm is initiated - "Route selection o.k." symbol starts flashing - pump (410 C 130) is stopped immediately.

2.6.4.7 Tank 1 High-High Level

[410 A 200-LSHH] indicates High-high level

• operating with Route 62 - alarm is initiated - “Route Selection O.K.“ symbol starts flushing - pump (410 C 130) stops

• operating with Route 72. - alarm is initiated - “Route Selection O.K.“ symbol starts flushing - pump (410 C 230) stops







• operating with Route 53 - alarm is initiated



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Rev. 00

- “Route Selection O.K.“ symbol starts flushing - pump (410 C 030) stops


2.6.4.10 Seal pot Tank 1 High-High Level

[410 A 210-LSHH] indicates “High-high level”













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2.6.4.13 Pitch Temperature Valve (410 C 010) low

[410 C 010-TY] pitch temperature is lower than 160 °C

• operating with Route 51/52/53/54 - alarm is initiated - "Pitch Temperature Filter 410 C 015 low" symbol starts flashing - low temperature indication is prevailing for more than 3 minutes corresponding pump

(410 C 030) is stopped immediately if running fast.









2.6.4.16 Pitch Filter 410 C 015 Low Differential Pressure [410 C 015-PDSL]

[410 C 015-PDSL] differential pressure at the filter is too low <0,5 mbar

• operating with Route 51/52/53/54 - The operator is warned by an acoustic signal - pilot light in the local panel " LOW PITCH FLOW" [410 C 015-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 stop the corresponding pump (410 C 030). If operating at fast speed the corresponding pump is automatically stopped after 3 minutes delay time.







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2.6.4.19 Pitch Filter (410 C 015) High Differential Pressure [410 C 015-PDSH]

[410 C 015-PDSH] differential pressure at the filter is too high >10 mbar

• operating with Route 51/52/53/54 - The operator is warned by an acoustic signal - pilot light in the local panel when the "FILTER PLUGGED" [410 C 015-PDSH] - In case that the reason for the alarm is prevailing for 3 minutes pump (410 C 030) is

automatically stopped if operating at fast speed. The reason for this alarm may be too high pitch viscosity normally together with too low pitch temperature or a dirty filter.









2.7 Local Operation of Special Equipment

Not applicable



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2.8 Signal Exchange with Sub-Groups of this Group and Other Process Groups Signal Description Sort of Signal 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 C Pitch Valve 410 A 230 closed “DRAIN TANK 1 CLOSED”

Digital signal within 410 PLC 01





from Group 410 A to Group 410 C High-high level [410 A 210-LSHH] in Seal pot tank 1 “OVERFLOW TANK 1”






from Group 410 A to Group 410 C High-high level [410 A 200-LSHH] in tank 1 “HIGH-HIGH LEVEL TANK 1”






from Group 410 A to Group 410 C High level [410 A 200-LSH] in tank 1 “HIGH LEVEL TANK 1”






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

Analogue 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 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


138-02-043 Group 410 C DE-060300

Outokumpu Technology GmbH Revision: 0 Date: 29.09.2006file: 138-02-043_08_0.doc, Codeword: Vedanta Page 7 of 7

8.3 Main Equipment

8.3.1 Basket Filter 410 C 015

8.3.2 Positive Displacement Pump 410 C 030

410c

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