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Training Manual Green Anode PlantVedanta - Jharsuguda

138-02-043Group 422 ADE-060300

5 PROCESS GROUP 422 A - BUTTS RECLAIMING-

5 Process Group 422 A - Butts Reclaiming-...................................................................................15.1 Process .......................................................................................................................................15.1.1 Process Flow Sheets...................................................................................................................15.1.2 Brief Process Description............................................................................................................25.1.3 Main Process Data & Process Highlights....................................................................................35.2 Process Control...........................................................................................................................45.2.1 P&Id`s, Material Route Diagrams, Operator Screen Images.......................................................45.2.2 Control Logic Description ............................................................................................................55.3 Main Equipment ..........................................................................................................................65.3.1 Flat Slide Gate (manual) 422 A 001 ............................................................................................65.3.2 Vibrating Trough Feeder 422 A 031............................................................................................6

5.3.3

Magnetic Separator, overhead 422 A 055...................................................................................65.3.4 Belt Conveyor 422 A 060 ............................................................................................................6

5.3.5 Belt Scale 422 A 062...................................................................................................................65.3.6 Rotary Lock 422 A 065................................................................................................................65.3.7 Bag Filter 422 A 070....................................................................................................................65.3.8 Fan 422 A 080.............................................................................................................................65.3.9 Splitter Gate 422 A 130 ...............................................................................................................65.3.10 Reversing Flap (pneumatic) 422 A 132.......................................................................................65.3.11 Bin 422 A 200..............................................................................................................................6

5.1 Process

5.1.1 Process Flow Sheets

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5.1.2 Brief Process Description

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CONTROL PHILOSOPHY24.10.2006

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Vedanta Alumina Ltd.Jharsuguda Green Anode PlantClient ref.: VJ/SML/PO/032/1OTK ref.: DE-060300Doc. No.: 133-50-065

Rev. 00

Brief Process Description

ofProcess Group 422 A- Butts Reclaiming -

Reference:

Process Flow Sheet: 132-30-007 UB

P&I Diagram: 168-01-050 UB Sheet 1, 2

The process is described in order to the material flow whereas the control philosophy is writtenin order to the signal flow, which is counter current to the material flow.

This subgroup is mainly processing Butts (recycled pre-crushed Baked Anodes frompotrooms, baking furnace and rodding shop) and Green Scrap (recycled, pre-crushed no-goGreen Anodes and Green Anode Paste scrap). For each of the materials a special route hasto be selected by the operator on the SCADA system on the Operator Stations located in theCentral Control Room. A main philosophy is that different materials shall never be mixed up.Therefore changing of the sort of material requires a run empty of this Group 422 A.

Material Route Butts (Selection SE 2-1 / 2-2 / 2-3)

If this Group shall process Anode Butts the operator must select BUTTS (selection SE 2-1 /2-2 / 2-3) on SCADA prior to Group start.

Anode Butts of 0-50 mm size are stored in two Main Storage Bins (422 A 200, 422 A 300). It isup to the operator to withdraw butts from both bins simultaneously or from one of the bins only.The storage bins can be isolated for maintenance by flat slide gates, one under each bin (422A 001 and 422 A 011). Normally the flat slide gates are open.

Butts are continuously withdrawn from the bins by means of vibrating trough feeders (422 A031, 422 A 041). Both vibrating feeders are equipped with variable speed drives for controllingthe feed rate in a range of 10-50 tons/hour. The operator can select the number of vibratingfeeders in charge and can remote adjust the feed rate of the feeders. It is a common

procedure to blend butts from two silos to maintain constant raw material quality and grain sizebut it is also common practice to discharge from one silo only.

The maximum feed rate allowed for Line 1 & 2 is 48 tons/hour and for one line only, is 24tons/hour.

Butts are fed to the inclining belt conveyor (422 A 060) running underneath the vibrating troughfeeders. A belt scale (422 A 062) and a magnet (422 A050) is integrated in the belt conveyor.

Dust generated through feeding and conveying of butts is sucked off from the vibrating feedersand from the belt conveyor to be then drawn by a fan (422 A 080) through collecting pipes intothe dust collector (422 A 070) to be separated. The dust collector is of jet-cleaning type. Acounter-flow compressed air blow cleans the bags. Separated dust is continuously fed to the

belt conveyor (422 A 060) by mean of a rotary lock (422 A 065).

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By means of a servo-motor operated splitter gate (422 A 130) the material flow can be splitinto two part-flows of equal or un-equal rate or the whole flow can be directed to either side.The material is feed via reversing flap (422 A 132) into butts feed bin (422 A 200 of Line 1)and/or via belt conveyor (422 A 135) and reversing flap (422 A 140) into butts feed bin (422 A300 of Line 2).

Dust generated through feeding and conveying of butts is sucked off from the butts feed bin(422 A 200) and the belt conveyors (422 A 135 and 422 A 060)) to be then drawn by a fan(422 A 115) through collecting pipes into the dust collector (422 A 105) to be separated. Thedust collector is of jet-cleaning type. A counter-flow compressed air blow cleans the bags.Separated dust is continuously fed upside the splitter gate (422 A 060) by mean of a rotary

lock (422 A 100). Belt conveyor (422 A 135) and butts feed bin (422 A 300) are sucked off bythe main dust treatment group 432 C.

If both or one of both butts fraction bins (422 A 200 / 300) are nearly full, the operator stopsthis Group using the normal Group Shut Down. In this case the equipment of this Group isrunning empty, what is absolutely required before the Group can be restarted to processGreen Scrap instead of Butts.

Material Route Green Scrap (Selection SE 3-1 / 3-2 / 3-3)

If this Group shall process Green Scrap the operator must select Green Scrap (selection SE3-1 / 3-2 / 3-3) on SCADA prior to Group start.

Green Scrap of 0-50 mm size is stored in a Main Storage Bin (421 A 400). The storage bin can

be isolated for maintenance by a flat slide gate (422 A 020). Normally the flat slide gate isopen.

Green Scrap is continuously withdrawn from the bin by means of a vibrating trough feeder(422 A 051). The feeder is equipped with a variable speed drive for controlling the feed rate ina range of 10-50 tons/hour. The operator can remote adjust the feed rate of the feeder.


Green Scrap is fed to the inclining belt conveyor (422 A 060) running underneath the vibratingtrough feeders. A belt scale (422 A 062) and a magnet (422 A050) is integrated in the beltconveyor.

Dust generated through feeding and conveying of green scrap is sucked off from the vibratingfeeders and from the belt conveyor to be then drawn by a fan (422 A 080) through collectingpipes into the dust collector (422 A 070) to be separated. The dust collector is of jet-cleaningtype. A counter-flow compressed air blow cleans the bags. Separated dust is continuously fedto the belt conveyor (422 A 060) by mean of a rotary lock (422 A 065).

By means of a servo-motor operated splitter gate (422 A 130) the material flow can be splitinto two part-flows of equal or un-equal rate or the whole flow can be directed to either side.The material is feed via reversing flap (422 A 132) to Group 431 B Butts Crushing andScreening and/or via belt conveyor (422 A 135) and reversing flap (422 A 140) to Group 432B Butts Crushing and Screening.


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Dust generated through feeding and conveying of green scrap is sucked off from the buttsfeed bin (422 A 200) and the belt conveyors (422 A 135 and 422 A 060)) to be then drawn bya fan (422 A 115) through collecting pipes into the dust collector (422 A 105) to be separated.The dust collector is of jet-cleaning type. A counter-flow compressed air blow cleans the bags.Separated dust is continuously fed upside the splitter gate (422 A 060) by mean of a rotarylock (422 A 100). Belt conveyor (422 A 135) and butts feed bin (422 A 300) are sucked off bythe main dust treatment group 432 C.

If Group 431 B Butts Crushing and Screening and/or Group 432 B Butts Crushing andScreening both or one of both groups could stop by the operator using the normal Group ShutDown. In this case the equipment of this Group is running empty, what is absolutely required

before the Group can be restarted to process Green Scrap instead of Butts.

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138-02-043Group 422 ADE-060300


5.1.3 Main Process Data & Process Highlights

Date: 29.09.2006


This Process Group is designed for a maximum feed rate (production rate) of 40t/hourof butts or green scrap.

The operator must never set the total green scrap feed rate to more than 20 t/h (only ifone line 431 or 432 is in operation) or 40 t/h (if two lines 431 and 432 in operation), ifGreen Scrap is selected on SCADA, because a higher feed rate would overload thescreen, the bucket elevator and the impact crusher of the subsequent groups 431/432 B.

The process loads (flow rates), expressed as t/hour can be found in the Process FlowSheets in ovals.

The equipment capacity is higherthan the maximum process load, based on 40 t/hfeed rate.

The process load is 40 t/h at a maximum whereas the equipment capacity is 50 t/h.The equipment capacity can be found in the Process Flow Sheets in a rhombus.

Butts can be reclaimed either from only one or from both main storage bins. Bothvibrating feeders are frequency controlled. Green Scrap can be reclaimed by onefrequency controlled vibrating feeder. The feed rate is measured by a belt scale and isdisplayed on SCADA. The operator has to observe the displayed rate and if the ratediffers too much from the target feed rate he has to readjust the frequency of thevibrating feeders. Adjustment of the frequency (feed rate) is also on SCADA.

If Green Scrap is used in group 431/432 B this group has first to run empty, to avoidmixing butts with green scrap. To do this the operator is first shutting down andrunning empty group 422 A (butts and green scrap reclaiming). Then Group 431/432B has to run empty, as it is a feature of the Normal Shut Down procedure. Then hemay restart the Group after he has selected to process green scrap.The similar procedure has to be followed when the Group is actually processing greenscrap and butts are required in group 431/432 B.

The time required to change the process material is about 20 minutes, counted frominitiating the Normal Shut Down and to that moment the Group is fed by the othermaterial again.

If one of the two butts feed bins (422 A 200, 422 A 300) is full, or one the twosubsequent groups 431/432 B is shut down the feed rate of the selected vibratingfeeders (422 A 031, 422 A 041 for butts and 422 A 051 for green scrap) is halvedautomatically.

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138-02-043Group 422 ADE-060300

5.2 Process Control

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

(work copies)


Date: 29.09.2006

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Date: 29.09.2006


5.2.2 Control Logic Description

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Rev. 00

Control Philosophy

ofProcess Group 422 A- Butts Reclaiming -

Reference:

Process Flow Sheet: 132-30-007 UB

P&I Diagram: 168-01-050 UB Sheet 1, 2

1

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

2 Control Logic Description............................................................................................................42.1 Special Terminology For This Group .......................................................................................... 42.2 Linked Process Groups...............................................................................................................42.3 Selections ................................................................................................................................... 42.3.1 Selection of Operation Modes (SE 1).......................................................................................... 42.3.2 Material Route for Butts (SE 2) ................................................................................................... 42.3.3 Material Route for Green Scrap (SE 3) ....................................................................................... 52.3.4 Butts Discharge Feeders (SE 4) ................................................................................................. 52.4 Group Start ................................................................................................................................. 52.4.1 Selections Prior to Group Start ................................................................................................... 52.4.2

Start Preconditions......................................................................................................................6

2.4.3 Setpoints Prior to Group Start.....................................................................................................62.4.4 Group Start Sequence ................................................................................................................ 82.4.5 Restarting the Group................................................................................................................. 102.5 Normal Operation......................................................................................................................102.5.1 Normal Operation after SE 2-1 or 2-2 or 2-3 Material Routes for Butts has been selected.... 102.5.2 Normal Operation after SE 3-1 or 3-2 or 3-3 Material Routes for Green Scrap has been

selected..................................................................................................................................... 122.6 Shut Down ................................................................................................................................ 142.6.1 Normal Shut Down.................................................................................................................... 142.6.2 Shut Down by Other Groups..................................................................................................... 14

2.6.3

Fast Shut Down (FASTOP).......................................................................................................16

2.6.4

Trip in Case of Faults................................................................................................................ 17

2.6.5 Shut Down by Full Bins............................................................................................................. 252.7 Local Operation of Special Equipment...................................................................................... 262.8 Signal Exchange with Sub-Groups of this Group and Other Process Groups..........................27


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1 BRIEF PROCESS DESCRIPTION

The process is described in order to the material flow whereas the control philosophy is writtenin order to the signal flow, which is counter current to the material flow.

This subgroup is mainly processing Butts (recycled pre-crushed Baked Anodes frompotrooms, baking furnace and rodding shop) and Green Scrap (recycled, pre-crushed no-goGreen Anodes and Green Anode Paste scrap). For each of the materials a special route hasto be selected by the operator on the SCADA system on the Operator Stations located in theCentral Control Room. A main philosophy is that different materials shall never be mixed up.Therefore changing of the sort of material requires a run empty of this Group 422 A.

Material Route Butts (Selection SE 2-1 / 2-2 / 2-3)

If this Group shall process Anode Butts the operator must select BUTTS (selection SE 2-1 /2-2 / 2-3) on SCADA prior to Group start.

Anode Butts of 0-50 mm size are stored in two Main Storage Bins (422 A 200, 422 A 300). It isup to the operator to withdraw butts from both bins simultaneously or from one of the bins only.The storage bins can be isolated for maintenance by flat slide gates, one under each bin (422A 001 and 422 A 011). Normally the flat slide gates are open.

Butts are continuously withdrawn from the bins by means of vibrating trough feeders (422 A031, 422 A 041). Both vibrating feeders are equipped with variable speed drives for controllingthe feed rate in a range of 10-50 tons/hour. The operator can select the number of vibratingfeeders in charge and can remote adjust the feed rate of the feeders. It is a commonprocedure to blend butts from two silos to maintain constant raw material quality and grain sizebut it is also common practice to discharge from one silo only.


Butts are fed to the inclining belt conveyor (422 A 060) running underneath the vibrating troughfeeders. A belt scale (422 A 062) and a magnet (422 A050) is integrated in the belt conveyor.

Dust generated through feeding and conveying of butts is sucked off from the vibrating feedersand from the belt conveyor to be then drawn by a fan (422 A 080) through collecting pipes intothe dust collector (422 A 070) to be separated. The dust collector is of jet-cleaning type. A

counter-flow compressed air blow cleans the bags. Separated dust is continuously fed to thebelt conveyor (422 A 060) by mean of a rotary lock (422 A 065).

By means of a servo-motor operated splitter gate (422 A 130) the material flow can be splitinto two part-flows of equal or un-equal rate or the whole flow can be directed to either side.The material is feed via reversing flap (422 A 132) into butts feed bin (422 A 200 of Line 1)and/or via belt conveyor (422 A 135) and reversing flap (422 A 140) into butts feed bin (422 A300 of Line 2).

Dust generated through feeding and conveying of butts is sucked off from the butts feed bin(422 A 200) and the belt conveyors (422 A 135 and 422 A 060)) to be then drawn by a fan(422 A 115) through collecting pipes into the dust collector (422 A 105) to be separated. Thedust collector is of jet-cleaning type. A counter-flow compressed air blow cleans the bags.

Separated dust is continuously fed upside the splitter gate (422 A 060) by mean of a rotarylock (422 A 100). Belt conveyor (422 A 135) and butts feed bin (422 A 300) are sucked off bythe main dust treatment group 432 C.


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If both or one of both butts fraction bins (422 A 200 / 300) are nearly full, the operator stopsthis Group using the normal Group Shut Down. In this case the equipment of this Group isrunning empty, what is absolutely required before the Group can be restarted to processGreen Scrap instead of Butts.

Material Route Green Scrap (Selection SE 3-1 / 3-2 / 3-3)

If this Group shall process Green Scrap the operator must select Green Scrap (selection SE3-1 / 3-2 / 3-3) on SCADA prior to Group start.

Green Scrap of 0-50 mm size is stored in a Main Storage Bin (421 A 400). The storage bin canbe isolated for maintenance by a flat slide gate (422 A 020). Normally the flat slide gate is

open.Green Scrap is continuously withdrawn from the bin by means of a vibrating trough feeder(422 A 051). The feeder is equipped with a variable speed drive for controlling the feed rate ina range of 10-50 tons/hour. The operator can remote adjust the feed rate of the feeder.


Green Scrap is fed to the inclining belt conveyor (422 A 060) running underneath the vibratingtrough feeders. A belt scale (422 A 062) and a magnet (422 A050) is integrated in the beltconveyor.

Dust generated through feeding and conveying of green scrap is sucked off from the vibrating

feeders and from the belt conveyor to be then drawn by a fan (422 A 080) through collectingpipes into the dust collector (422 A 070) to be separated. The dust collector is of jet-cleaningtype. A counter-flow compressed air blow cleans the bags. Separated dust is continuously fedto the belt conveyor (422 A 060) by mean of a rotary lock (422 A 065).

By means of a servo-motor operated splitter gate (422 A 130) the material flow can be splitinto two part-flows of equal or un-equal rate or the whole flow can be directed to either side.The material is feed via reversing flap (422 A 132) to Group 431 B Butts Crushing andScreening and/or via belt conveyor (422 A 135) and reversing flap (422 A 140) to Group 432B Butts Crushing and Screening.

Dust generated through feeding and conveying of green scrap is sucked off from the buttsfeed bin (422 A 200) and the belt conveyors (422 A 135 and 422 A 060)) to be then drawn by

a fan (422 A 115) through collecting pipes into the dust collector (422 A 105) to be separated.The dust collector is of jet-cleaning type. A counter-flow compressed air blow cleans the bags.Separated dust is continuously fed upside the splitter gate (422 A 060) by mean of a rotarylock (422 A 100). Belt conveyor (422 A 135) and butts feed bin (422 A 300) are sucked off bythe main dust treatment group 432 C.

If Group 431 B Butts Crushing and Screening and/or Group 432 B Butts Crushing andScreening both or one of both groups could stop by the operator using the normal Group ShutDown. In this case the equipment of this Group is running empty, what is absolutely requiredbefore the Group can be restarted to process Green Scrap instead of Butts.


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2 CONTROL LOGIC DESCRIPTION

2.1 Special Terminology For This Group

There is no special terminology for this group.

2.2 Linked Process Groups

The following Process Groups are linked with this Group 422 A:

Main Dust Treatment 432 C

Butts Crushing & Screening 431 B

Butts Crushing & Screening 432 B

The exchange of control signals is described in the following chapters and especially under 2.8below.

2.3 Selections

2.3.1 Selection of Operation Modes (SE 1)

The selection is made on the Operator Station located in the Central Control Room (CCR).Selection and indication of the state of selection is on SCADA.

The operator has two options:CENTRAL operation mode After this selection this Group is ready to start in CENTRAL

operation mode, if all preconditions (see 2.4.2) below arefulfilled.

LOCAL operation mode (details please see under 2.7 below)

2.3.2 Material Route for Butts (SE 2)

The selection is made on the Operator Station located in the Central Control Room (CCR).Selection and indication of the state of selection is on SCADA prior to Group start only.

The operator has three options:

SE 2-1 Butts to Butts Feed Bin (422 A 200)

This is the normal selection when the butts are feed to butts feed bin 422 A 200.

SE 2-2 Butts to Butts Feed Bin (422 A 300)

This is the normal selection when the butts are feed to butts feed bin 422 A 300.

SE 2-3 Butts to Butts Feed Bin (422 A 200 and 422 A 300)

This is the normal selection when the butts are feed to butts feed bins 422 A 200 and 422 A300.


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2.3.3 Material Route for Green Scrap (SE 3)

The selection is made on the Operator Station located in the Central Control Room (CCR).Selection and indication of the state of selection is on SCADA prior to Group start only.

The operator has three options:

SE 3-1 Green Scrap to Group 431 B

This selection is used if there are no butts available in Group 431 B Butts Crushing &Screening.

In this case the manual splitter gate (431 A 135) must not indicate [431 A 135-ZH], weigh

feeder 431 B 103 must not running and Group 431 B must be running in CENTRAL modeand must not be in run empty operation (RESTOP). If one of these conditions is not fulfilledthis Group is not ready to start and an alarm on the SCADA system is generated.

SE 3-2 Green Scrap to Group 432 B

This selection is used if there are no butts available in Group 432 B Butts Crushing &Screening.

In this case the manual splitter gate (432 A 135) must not indicate [432 A 135-ZH], weighfeeder 432 B 103 must not running and Group 432 B must be running in CENTRAL modeand must not be in run empty operation (RESTOP). If one of these conditions is not fulfilledthis Group is not ready to start and an alarm on the SCADA system is generated.

SE 3-3 Green Scrap to Group 431 B and Group 432 BThis selection is used if there are no butts available in Group 431 B / 432 B Butts Crushing& Screening.

In this case the manual splitter gates (431 A 135 and 432 A 135) must not indicate [431 A 135-ZH] and [432 A 135-ZH], weigh feeders (431 B 103) and (432 B 103) must not running andGroup 431 B and Group 432 B must be running in CENTRAL mode and must not be in runempty operation (RESTOP). If one of these conditions is not fulfilled this Group is not ready tostart and an alarm on the SCADA system is generated.

2.3.4 Butts Discharge Feeders (SE 4)

The operator may select the vibrating through feeders discharging the two Main Storage Bins

for butts (421 A 200; 421 A 300) at any time.

The selection is made on the Operator Station located in the Central Control Room (CCR).Selection and indication of the state of selection is on SCADA.

SE 4-1- vibrating trough feeder (422 A 031)

SE 4-2- vibrating trough feeder (422 A 041)

2.4 Group Start

2.4.1 Selections Prior to Group Start

CENTRAL operation mode must be selected.


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2.4.2 Start Preconditions

2.4.2.1 Process Group 432 C - Main Dust Treatment

If SE 2-2 or 2-3 or 3-2 or 3-3 is selected (butts or green scrap to Line 2 (432)), the Group432 C Main Dust Treatment must be running in CENTRAL operation mode prior to startthis Group. It must not be tripped and not be in a stop (RESTOP or FASTOP) sequence.

2.4.2.2 Process Group 431 B (Butts Crushing & Screening)

If SE 3-1 (Green Scrap to Group 431 B) or SE 3-3 (Green Scrap to Group 431 B andGroup 432 B ) is selected a signal from Group 431 B (Butts Crushing & Screening) isrequired (Group is running in CENTRAL mode and is notin Group Start (START) or any

Group Stop sequence (RESTOP or FASTOP)2.4.2.3 Process Group 432 B (Butts Crushing & Screening)

If SE 3-2 (Green Scrap to Group 432 B) or SE 3-3 (Green Scrap to Group 431 B andGroup 432 B ) is selected a signal from Group 432 B (Butts Crushing & Screening) isrequired (Group is running in CENTRAL mode and is notin Group Start (START) or anyGroup Stop sequence (RESTOP or FASTOP)

2.4.2.4 Emergency stop

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

2.4.2.5 Alarms

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

2.4.2.6 MCC`s of this Group

The MCCs signal of this group must be OK.

2.4.2.7 FASTOP Signal

If a FASTOP signal is valid this Group does not start.

2.4.2.8 RESTOP Signal

If a RESTOP signal is valid this Group can be restarted by overriding the RESTOP signalby the Group Start signal.

2.4.2.9 Compressed Air Pressure 410 A 009

Compressed air pressure in Group A [410 A 009-PAL] shall be higher than 6 bar (P>6bar).

2.4.3 Setpoints Prior to Group Start

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

Actual Setpoint The PLC program is storing all actually used setpoints asActual Setpoint The Actual Setpoint is automatically usedfor the next start after the Group has been stopped or for arestart after the Group has tripped. The Actual Setpoint isdisplayed on SCADA.

New Setpoint The operator has the opportunity to override the actual

setpoint by the New Setpoint any time Changing of setpointis on SCADA.


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Previous Setpoint Did the operator change an Actual Setpoint while the Group isrunning in CENTRAL mode the previous one is also stored inthe PLC as Previous Setpoint for possible later use. Theoperator may override the actual setpoint by the PreviousSetpoint at any time. Selection of the Previous Setpoint is onSCADA.

Standard Setpoint The operator may also override the actual setpoint by theStandard Setpoint any time. Selection of the StandardSetpoint is on SCADA. The Standard Setpoint can be editedon the SCADA system any time but by a Shift Leader only,

after using his Password.2.4.3.1 Vibrating Trough Feeders for Butts 422 A 031, 422 A 041 Individual - (Setpoint SP 1-1;SP 1-

2)

The operator may set the feed rate of each vibrating feeder at any time. Feed rates can beset within a range of 35% to 100% for each of the feeders individually. The operator alsohas the choice of a Standard Setpoint, which can be selected on SCADA individually foreach feeder (first approach for Standard Setpoint is 50%). Setting is on SCADA. OnSCADA the operator has the choice to select one of three options, New setpoint,Previous setpoint and Standard setpoint all overriding the actual setpoint.

2.4.3.2 Vibrating Trough Feeders for Butts 422 A 031, 422 A 041 - Master- (Setpoint SP 2)

The operator may set a MASTER FEED RATE for these vibrating feeders at any time. TheMASTER FEED RATE can be set within a range of 60% to 140% for all these feeders.The MASTER FEED RATE is a factor (0.6 1.4) by which the individual feed rate (see2.4.3.1 above) of these feeders is multiplied. At 100% (factor = 1.0) the feed rate of thesingle feeders is equal to the individual feed rate set above. On SCADA the operator hasthe choice to select one of three options, New setpoint, Previous setpoint andStandard setpoint all overriding the actual setpoint.

2.4.3.3 Vibrating Trough Feeder for Green Scrap 422 A 051 (Setpoint SP 3)

The operator may set the feed rate of the vibrating feeder at any time. Feed rate can beset within a range of 35% to 100%. The operator also has the choice of a StandardSetpoint, which can be selected on SCADA individually for each feeder (first approach for

Standard Setpoint is 50%). Setting is on SCADA. On SCADA the operator has the choiceto select one of three options, New setpoint, Previous setpoint and Standard setpointall overriding the actual setpoint.

2.4.3.4 Splitter Gate 422 A 130 (Setpoint SP 4)

If Selection SE 2-3 or 3-3 is selected, the operator may set the splitter blade position atany time in a range of 0% to 100% [0% = limit switch position 422 A 130-ZL]. Setting anddisplay of the actual position is on SCADA. On SCADA the operator has the choice toselect one of three options, New setpoint, Previous setpoint and Standard setpoint alloverriding the actual setpoint (Standard setpoint: 50%).


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2.4.4 Group Start Sequence

2.4.4.1 Group Start Sequence after SE 2-1/2-2/2-3 Material Route for Butts has been selected

The operator is enabling this Group 422 A to start and to run the selected equipment. Toinitiate the start he is using the SCADA system on the Operator Station in the Central ControlRoom.

If SE 2-2 or SE 2-3 is selected a Signal from Group 432 C (Main Dust Treatment) isrequired (Group is running in CENTRAL mode and is notin Group Start (START) or anyGroup Stop sequence (RESTOP or FASTOP))

The horn starts to sound permanently for 15 seconds prior to start of the first equipment,then it sounds instantly until the last drive is running.

Reversing Flap (422 A 140) tilts to limit switch [422A140-ZH] automatically

Reversing Flap (422 A 132) tilts to limit switch [422A132-ZH] automatically

Splitter Gate 422 A 130 is enabled

- If SE 2-1 is selected and the splitter gate (422 A 130) is not adjusted at 100% materialflow to butts feed bin (422 A 200) [limit switch 422 A 330-ZH is not actuated] thesplitter blade tilts to limit switch [422 A 130-ZH] automatically.

- If SE 2-2 is selected and the splitter gate (422 A 130) is not adjusted at 100% materialflow to belt conveyor (422 A 135) [limit switch 422 A 130-ZL is not actuated] thesplitter blade tilts to limit switch [422 A 130-ZL] automatically.

- If SE 2-3 is selected and the butts feed bin (422 A 200) is not full [422 A 200-LAH2] isnot indicating high level and/or [422 A 200-LAHH] is not indicating high-high level andthe butts feed bin (422 A 300) is not full [422 A 300-LAH2] is not indicating high leveland/or [422 A 300-LAHH] is not indicating high-high level, than the splitter gate (422 A130) is adjusted to the actual value of setpoint SP-4 automatically.

- If SE 2-3 is selected and the butts feed bin (422 A 200) is full [422 A 200-LAH2] isindicating high level and/or [422 A 200-LAHH] is indicating high-high level and thesplitter gate (422 A 130) is not adjusted at 100% material flow to the belt conveyor(422 A 135) [limit switch 422 A 130-ZL is not actuated] the splitter blade tilts to limitswitch [422 A 130-ZL] automatically.

- If SE 2-3 is selected and the butts feed bin (422 A 300) is full [422 A 300-LAH2] is

indicating high level and/or [422 A 300-LAHH] is indicating high-high level and thesplitter gate (422 A 130) is not adjusted at 100% material flow to the butts feed bin(422 A 200) [limit switch 422 A 130-ZH is not actuated] the splitter blade tilts to limitswitch [422 A 130-ZH] automatically.

Fan (422 A 115) starts.


Delay of 20 seconds for fan impeller run-up.

Belt conveyor (422 A 135) starts if SE 2-2 or SE 2-3 is selected

Magnet (422 A 055) starts

Belt Scale (422 A 062) is enabled

Jet cleaning of dust collector (422 A 105) is enabled.

Rotary lock (422 A 100) starts.

Belt conveyor (422 A 060) starts.


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Vibrating trough feeder (422 A 031) starts, if selected (SE 4-1).

Vibrating trough feeder (422 A 041) starts, if selected (SE 4-2).

Group 422 A is running completely in CENTRAL mode.

2.4.4.2 Group Start Sequence after SE 3-1/3-2/3-3 Material Route for Green Scrap has beenselected

The operator is enabling this Group 422 A to start and to run the selected equipment. To

initiate the start he is using the SCADA system on the Operator Station in the Central ControlRoom.

If SE 3-2 or SE 3-3 is selected a Signal from Group 432 C (Main Dust Treatment) isrequired (Group is running in CENTRAL mode and is notin Group Start (START) or anyGroup Stop sequence (RESTOP or FASTOP))

If SE 3-1 or SE 3-3 is selected a Signal from Group 431 B (Butts Crushing & Screening) isrequired (Group is running in CENTRAL mode and is notin Group Start (START) or anyGroup Stop sequence (RESTOP or FASTOP))

If SE 3-2 or SE 3-3 is selected a Signal from Group 432 B (Butts Crushing & Screening) isrequired (Group is running in CENTRAL mode and is notin Group Start (START) or anyGroup Stop sequence (RESTOP or FASTOP))

The horn starts to sound permanently for 15 seconds prior to start of the first equipment,then it sounds instantly until the last drive is running.

Reversing Flap (422 A 140) tilts to limit switch [422A140-ZL] automatically

Reversing Flap (422 A 132) tilts to limit switch [422A132-ZL] automatically

Splitter Gate 422 A 130 is enabled

- If SE 3-1 is selected and the splitter gate (422 A 130) is not adjusted at 100% materialflow to reversing flap (422 A 132) [limit switch 422 A 330-ZH is not actuated] thesplitter blade tilts to limit switch [422 A 130-ZH] automatically.

- If SE 3-2 is selected and the splitter gate (422 A 130) is not adjusted at 100% materialflow to belt conveyor (422 A 135) [limit switch 422 A 130-ZL is not actuated] the

splitter blade tilts to limit switch [422 A 130-ZL] automatically.- If SE 3-3 is selected and Group 431 B (Butts Crushing & Screening) is running in

CENTRAL operation mode and Group 432 B (Butts Crushing & Screening) isrunning in CENTRAL operation mode, than the splitter gate (422 A 130) is adjustedto the actual value of setpoint SP-4 automatically.

- If SE 3-3 is selected and Group 431 B (Butts Crushing & Screening) is not running inCENTRAL operation mode and the splitter gate (422 A 130) is not adjusted at 100%material flow to the belt conveyor (422 A 135) [limit switch 422 A 130-ZL is notactuated] the splitter blade tilts to limit switch [422 A 130-ZL] automatically.

- If SE 3-3 is selected and Group 432 B (Butts Crushing & Screening) is not running inCENTRAL operation mode and the splitter gate (422 A 130) is not adjusted at 100%

material flow to reversing flap (422 A 132) [limit switch 422 A 130-ZH is not actuated]the splitter blade tilts to limit switch [422 A 130-ZH] automatically.



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Delay of 20 seconds for fan impeller run-up.


Magnet (422 A 055) is enable

Belt Scale (422 A 062) is enable



Belt conveyor (422 A 060) starts.



Vibrating trough feeder (422 A 051) starts

Group 422 A is running completely in CENTRAL mode.

2.4.5 Restarting the Group

If the Group is in a run-empty stop sequence, (after Normal Shut Down (RESTOP)) and apart of the Group is still running, it is possible to restart this Group by activating the STARTbutton. Restarting is only possible after all faults have been eliminated and reset. The Restartfollows the same sequence like the normal Group Start including the horn sequence as

described above.

2.5 Normal Operation

2.5.1 Normal Operation after SE 2-1 or 2-2 or 2-3 Material Routes for Butts has been selected

2.5.1.1 Vibrating Trough Feeders for Butts 422 A 031; 422 A 041 -variable speed-

If the selected feeders are not tripped this Group is in normal operation.

The operator may set the feed rate of each vibrating feeder at any time(Setpoint SP 1).Feed rates can be set within a range of 35% to 100% for each of the feeders individually.On SCADA the operator has the choice to select one of three options, New setpoint,Previous setpoint and Standard setpoint (first approach for Standard Setpoint is 50%)

all overriding the actual setpoint. The operator may set a MASTER FEED RATE for these vibrating feeders at any time. The

MASTER FEED RATE can be set within a range of 60% to 140% for all these feeders.The MASTER FEED RATE is a factor (0.6 1.4) by which the individual feed rate (see2.4.3.1 above) of these feeders is multiplied. At 100% (factor = 1.0) the feed rate of thesingle feeders is equal to the individual feed rate set above. On SCADA the operator hasthe choice to select one of three options, New setpoint, Previous setpoint andStandard setpoint all overriding the actual setpoint.

The operator may select or deselect a feeder any time.

2.5.1.2 Magnet 422 A 055

If the magnet is not tripped this Group is in normal operation.2.5.1.3 Belt Conveyor 422 A 060

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


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2.5.1.4 Belt Scale 422 A 062

If the belt scale is not tripped this Group is in normal operation.

2.5.1.5 Rotary Lock 422 A 065

If the rotary lock is not tripped this Group is in normal operation.

2.5.1.6 Dust Collector 422 A 070

If the dust collector is not tripped this Group is in normal operation.

The jet-type pneumatic bag cleaning system is controlled by the actually measureddifferential pressure across the filter bags. If the differential pressure measuring systemdetects the differential pressure is above 12.5 mbar [422 A 070-PDH2], the Local ControlPanel [422 A 070-LOP1] gets a signal from 422 PLC 02 to start a bag cleaning cycle .Thebags are cleaned with a compressed air stream blown into the bags countercurrent to thenormal air flow. The cleaning cycle ends with a second signal from 422 PLC 02, if thedifferential pressure did fall below 11 mbar [422 A 070-PDH1]. The next cleaning cyclestarts with the next un-cleaned bag row.

2.5.1.7 Fan 422 A 080

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

2.5.1.8 Rotary Lock 422 A 100


2.5.1.9 Dust Collector 422 A 105 If the dust collector is not tripped this Group is in normal operation.


2.5.1.10 Fan 422 A 115


2.5.1.11 Splitter Gate 422 A 130

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

If SE 2-3 is selected, the operator may set the splitter blade position at any time in a rangeof 0% to 100% [0% = limit switch position 422 A 130-ZL]. Setting and display of the actualposition is on SCADA. On SCADA the operator has the choice to select one of threeoptions, New setpoint, Previous setpoint and Standard setpoint all overriding theactual setpoint (Standard setpoint: 50%).

2.5.1.12 Reversing Flap 422 A 132

If SE 2-1 or 2-3 (Butts to Line 1 (431)) is selected and the reversing flap is not tripped thisGroup is in normal operation.


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2.5.1.13 Belt Conveyor 422 A 135

If SE 2-2 or 2-3 (Butts to Line 2 (432)) is selected and the conveyor is not tripped thisGroup is in normal operation.


If SE 2-2 or 2-3 (Butts to Line 2 (432)) is selected and the reversing flap is not tripped thisGroup is in normal operation.

2.5.1.15 Butts Feed Bin 422 A 200

If the fraction bin level measurement is not tripped this Group is in normal operation.

If SE 2-1 is selected and the fraction bin is not full (bin level is not >/= 95% [422 A 200-LAH2] and/or not >/= 100% [422 A 200-LAHH]) this Group is in normal operation.

If SE 2-3 is selected and the fraction bin is full (bin level is >/= 95% [422 A 200-LAH2]and/or >/= 100% [422 A 200-LAHH]), this signal is overriding the setpoint SP 2 (Mastersetpoint for the vibrating trough feeders 422 A 031, 422 A 041) by multiplying the actualsetpoint with a factor of 0.5 in order to reduce the feed rate automatically, and splitter gate(422 A 130) is after a travel time of 90 seconds at 100% material flow to belt conveyor 422A 135 [limit switch 422 A 130-ZL actuated] this Group is in normal operation.

2.5.1.16 Butts Feed Bin 422 A 300

If the fraction bin level measurement is not tripped this Group is in normal operation.

If SE 2-2 is selected and the fraction bin is not full (bin level is not >/= 95% [422 A 300-LAH2] and/or not >/= 100% [390 A 300-LAHH]) this Group is in normal operation.

If SE 2-3 is selected and the fraction bin is full (bin level is >/= 95% [422 A 300-LAH2]and/or >/= 100% [422 A 300-LAHH]), this signal is overriding the setpoint SP 2 (Mastersetpoint for the vibrating trough feeders 422 A 031, 422 A 041) by multiplying the actualsetpoint with a factor of 0.5 in order to reduce the feed rate automatically, and splitter gate(422 A 130) is after a travel time of 90 seconds at 100% material flow to butts feed bin 422A 200 [limit switch 422 A 130-ZH actuated] this Group is in normal operation.

2.5.2 Normal Operation after SE 3-1 or 3-2 or 3-3 Material Routes for Green Scrap has beenselected

2.5.2.1 Vibrating Trough Feeder for Green Scrap 422 A 051 -variable speed-

If the selected feeder is not tripped this Group is in normal operation.

The operator may set the feed rate of the vibrating feeder at any time. Feed rate can beset within a range of 35% to 100%. The operator also has the choice of a StandardSetpoint (first approach for Standard Setpoint is 50%). Setting is on SCADA. On SCADAthe operator has the choice to select one of three options, New setpoint, Previoussetpoint and Standard setpoint all overriding the actual setpoint.

2.5.2.2 Magnet 422 A 055

If the magnet is not tripped this Group is in normal operation.


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

2.5.2.4 Belt Scale 422 A 062

If the belt scale is not tripped this Group is in normal operation.


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2.5.2.5 Rotary Lock 422 A 065




The jet-type pneumatic bag cleaning system is controlled by the actually measureddifferential pressure across the filter bags. If the differential pressure measuring systemdetects the differential pressure is above 12.5 mbar [422 A 070-PDH2], the Local ControlPanel [422 A 070-LOP1] gets a signal from 422 PLC 02 to start a bag cleaning cycle .Thebags are cleaned with a compressed air stream blown into the bags countercurrent to the

normal air flow. The cleaning cycle ends with a second signal from 422 PLC 02, if thedifferential pressure did fall below 11 mbar [422 A 070-PDH1]. The next cleaning cyclestarts with the next un-cleaned bag row.

2.5.2.7 Fan 422 A 080


2.5.2.8 Rotary Lock 422 A 100





2.5.2.10 Fan 422 A 115


2.5.2.11 Splitter Gate 422 A 130

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

If SE 3-3 is selected, the operator may set the splitter blade position at any time in a rangeof 0% to 100% [0% = limit switch position 422 A 130-ZL]. Setting and display of the actualposition is on SCADA. On SCADA the operator has the choice to select one of threeoptions, New setpoint, Previous setpoint and Standard setpoint all overriding theactual setpoint (Standard setpoint: 50%).


If SE 3-1 or 3-3 (Green Scrap to Line 1 (431)) is selected and the reversing flap is nottripped this Group is in normal operation.


If SE 3-2 or 3-3 (Green Scrap to Line 2 (432)) is selected and the conveyor is not trippedthis Group is in normal operation.


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If SE 3-2 or 3-3 (Green Scrap to Line 2 (432)) is selected and the reversing flap is nottripped this Group is in normal operation.

2.6 Shut Down

After a shut down of the Group or of a part of the Group all actual setpoints of this Group arememorized as Actual Setpoint.

2.6.1 Normal Shut Down

To initiate this sort of shut down the operator uses the RESTOP button on the SCADA

system.

The operator stops this Group using the RESTOP push button on SCADA.

Vibrating trough feeder (422 A 031) stops if it is selected and running



All actual setpoints of this Group are memorized as Actual Setpoint

Delay of 7 minutes (run-empty time)

All equipment of this Group stops.

The whole group is stopped.

2.6.2 Shut Down by Other Groups

If this Group 422 A is running in CENTRAL mode it requires the following other Groups alsorunning in CENTRAL operation mode:

432 C Main Dust Treatment only if SE 2-2 or 2-3 or 3-2 or 3-3 is selected

431 B Butts Crushing & Screening only if SE 2-1 or 2-3 or 3-1 or 3-3 is selected

432 B Butts Crushing & Screening only if SE 2-2 or 2-3 or 3-2 or 3-3 is selected

2.6.2.1 Group 432 C Main Dust Treatment

If SE 2-2 or 2-3 or 3-2 or 3-3 is selected (Because belt conveyor (422 A 135) and buttsfeed bin (422 A 300) of this Group 422 A is connected to the Main Dust Treatment) it is

essential that Group 432 C is running in CENTRAL control mode and is not in a STARTor STOP sequence.

If SE 2-2 or 3-2 is selected and if Group 432 C is not running anymore in CENTRALmode because it has been stopped by a Normal Shut Down (RESTOP), by a Fast ShutDown (FASTOP) or is tripped through a fault

- alarm is generated

- Normal Shut Down (see 2.6.1 above) will be initiated automatically

If SE 2-3 is selected and if Group 432 C is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down(FASTOP) or is tripped through a fault and if splitter gate (422 A 130) is after a travel time

of 90 seconds not at 100% material flow to butts feed bin (422 A 200) [limit switch 422 A130-ZH is not actuated] or if the butts feed bin (422 A 200) is full (bin level is >/= 95% [422A 200-LAH2] and/or >/= 100% [422 A 200-LAHH])



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If SE 3-3 is selected and if Group 432 C is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down(FASTOP) or is tripped through a fault, and if splitter gate (422 A 130) is after a travel timeof 90 seconds not at 100% material flow to reversing flap (422 A 132) [limit switch 422 A130-ZH is not actuated] or if Group 432 B is not running anymore in CENTRAL mode



2.6.2.2 Group 431 B Butts Crushing And Screening

If SE 2-1 is selected and if Group 431 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down(FASTOP) or is tripped through a fault


- Normal Shut Down (see 2.6.1 above) will be initiated automatically.

If SE 2-3 is selected and if Group 431 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down(FASTOP) or is tripped through a fault, and if splitter gate (422 A 130) is after a travel timeof 90 seconds not at 100% material flow to belt conveyor (422 A 135) [limit switch 422 A130-ZL not actuated] or if the butts feed bin (422 A 300) is full (bin level is >/= 95% [422 A300-LAH2] and/or >/= 100% [422 A 300-LAHH])

- an alarm is created

- Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically.

If SE 3-1 is selected and if Group 431 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP)



If SE 3-1 is selected and if Group 431 B is not running anymore in CENTRAL modebecause it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a fault


- Fast Shut Down (see 2.6.3 below) will be initiated automatically

If SE 3-3 is selected and if Group 431 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP) and if splitter gate (422A 130) is after a travel time of 90 seconds not at 100% material flow to belt conveyor (422A 135) [limit switch 422 A 130-ZL is not actuated] or if Group 432 B is not runninganymore in CENTRAL mode



If SE 3-3 is selected and if Group 431 B is not running anymore in CENTRAL modebecause it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a faultand if splitter gate (422 A 130) is after a travel time of 90 seconds not at 100% materialflow to belt conveyor (422 A 135) [limit switch 422 A 130-ZL is not actuated] or if Group432 B is not running anymore in CENTRAL mode



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2.6.2.3 Group 432 B Butts Crushing And Screening

If SE 2-2 is selected and if Group 432 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down(FASTOP) or is tripped through a fault



If SE 2-3 is selected and if Group 432 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP), by a Fast Shut Down

(FASTOP) or is tripped through a fault, and if splitter gate (422 A 130) is after a travel timeof 90 seconds not at 100% material flow to butts feed bin (422 A 200) [limit switch 422 A130-ZH not actuated] or if the butts feed bin (422 A 200) is full (bin level is >/= 95% [422 A200-LAH2] and/or >/= 100% [422 A 200-LAHH])



If SE 3-2 is selected and if Group 432 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP)



If SE 3-2 is selected and if Group 432 B is not running anymore in CENTRAL modebecause it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a fault



If SE 3-3 is selected and if Group 432 B is not running anymore in CENTRAL modebecause it has been stopped by a Normal Shut Down (RESTOP) and if splitter gate (422A 130) is after a travel time of 90 seconds not at 100% material flow to reversing flap (422A 132) [limit switch 422 A 130-ZH is not actuated] or if Group 431 B is not runninganymore in CENTRAL mode



If SE 3-3 is selected and if Group 432 B is not running anymore in CENTRAL modebecause it has been stopped by a Fast Shut Down (FASTOP) or is tripped through a faultand if splitter gate (422 A 130) is after a travel time of 90 seconds not at 100% materialflow to reversing flap (422 A 132) [limit switch 422 A 130-ZH is not actuated] or if Group432 B is not running anymore in CENTRAL mode



2.6.3 Fast Shut Down (FASTOP)

If this Group 422 A is running in CENTRAL mode and an operator has detected a seriousfault, which did not automatically trip this Group the operator is able to stop this Group as Fast

Shut Down (FASTOP).

The operator may initiate the Fast Shut Down of this Group at any time on the SCADAsystem actuating the FASTOP button.


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All equipment of this Group stops instantly

All actual setpoints of this Group are memorized as Actual Setpoint

The whole Group is stopped now with full load of material on conveyors.

2.6.4 Trip in Case of Faults

If this Group 422 A is running in CENTRAL mode and equipment or an instrument of thisGroup fails this may cause an Alarm only and, if the fault is of the serious sort, this wholeGroup or a part of this Group is stopped. Different faults may cause different stop sequences,depending on the equipment and on the impact of this fault on the whole process of thisGroup. In some cases a Normal Shut Down (RESTOP) will commence, in other cases a Fast

Shut Down (FASTOP) is the safer way and in few cases a special stop sequence may berequired.

After a shut down of the Group or of a part of the Group all actual setpoints of this Group arememorized as Actual Setpoint.

Note: All instruments mounted on equipment or located somewhere in the field or anywhereelse are to be wired fail-safe.

2.6.4.1 Vibrating Trough Feeders for Butts 422 A 031, 422 A 041

If one of these two feeders, which is selected and which is running, trips

- an alarm is generated only

The faulty feeder can be deselected and the other feeder can be selected and thisGroup can be restarted.

[422 A 031/041-VFD] If there is a fault detected in the frequency controller

- cause an alarm

- motor(s) stops

[422 A 031/041] If there is a fault detected in the MCC

- cause an alarm

- pertinent VFD-unit is shut off

2.6.4.2 Vibrating Trough Feeder for Green Scrap 422 A 051

If the feeder is selected and is running, trips

- an alarm is generated

- if after a delay time of 10 minutes this feeder is still faulty and could not be restarted, aNormal Shut Down (see 2.6.1 above) will be initiated automatically

[422 A 051-VFD] If there is a fault detected in the frequency controller

- cause an alarm

- motor stops

[422 A 051] If there is a fault detected in the MCC

- cause an alarm- pertinent VFD-unit is shut off


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2.6.4.3 Magnet 422 A 055

[422 A 055-SAL] The conveyor is equipped with a proximity type low-speed detectormeasuring the frequency of a target rotating with the rotor. If the frequency of the rotor is toolow or the switch fails

- cause an alarm

- equipment trips

- Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.

[422 A 055M1] If there is a fault detected in the electric motor or in the MCC of this motor

- cause an alarm- equipment trips



[422 A 060-SAL] The conveyor is equipped with a proximity type low-speed detectormeasuring the frequency of a target rotating with the tail pulley. If the frequency of the tailpulley is too low or the switch fails

- cause an alarm

- equipment trips

[422 A 060M1] If there is a fault detected in the electric motor or in the MCC of this motor- cause an alarm

- equipment trips

[422 A 060-ZXA1 to ZXA4] The conveyor is equipped with 4 side travel switches, two installedclose to the drive pulley and another two close to the tail pulley. If a side travel switch isshowing the belt is off-track for more than 2 seconds or if a switch fails

- causes an alarm

- equipment trips

[422 A 060-HSSA] The conveyor is equipped with 2 pull cord switches (This safety switch ishard-wired to the MCC), one at each conveyor side. If a pull cord is drawn or if a switch fails

- causes an alarm

- equipment trips

[422 A 060-ZAL and ZAH] The conveyor is equipped with 2 take-up switches, one detectinglow take-up pulley position and another detecting high take-up pulley position. If one of theswitches is detecting an excessive position of the take-up pulley for more than 2 seconds or ifa switch fails

- causes an alarm

- equipment trips

If the belt conveyor trips


- all vibrating feeders (422 A 031, 422 A 041, 422 A 051), which are selected and whichare running are stopped instantly


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- rotary lock (422 A 065) is stopped instantly

- if after a delay time of 20 minutes this conveyor is still faulty and could not berestarted, a Normal Shut Down (see 2.6.1 above) will be initiated automatically

2.6.4.5 Rotary Lock 422 A 065


- cause an alarm

- equipment trips


- if after a delay of 30 minutes this rotary lock is still faulty and could not be restarted, aNormal Shut Down (see 2.6.1 above) will be initiated automatically.


- cause an alarm

- equipment trips


[422 A 070-LCP1] If the bag cleaning device trips

- alarm is generated- but this Group is kept running until the differential pressure across the bags reaches

high-high differential pressure

[422 A 070-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or ifthe switch fails for more than 5 seconds

- cause an alarm

- Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.NOTE: During Start or Restart of this Group there is an override of this function of 20seconds to allow the fan to run up.

[422 A 070-PDAH] {> 13mbar} If high differential pressure is detected across the filter bags or

if the switch fails for more than 5 seconds- cause an alarm only

[422 A 070-PDAHH] {> 15mbar} If high-high differential pressure is detected across the filterbags or if the switch fails for more than 5 seconds

- cause an alarm

- Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.

2.6.4.7 Fan 422 A 080


- cause an alarm

- equipment trips


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[422 A 065-SAL] The fan is equipped with a proximity type low-speed switch measuring thefrequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low orthe switch fails

- cause an alarm

- equipment trips

If the fan trips


- all vibrating feeders (422 A 031, 422 A 041, 422 A 051), which are selected and whichare running, stopped instantly

- rotary lock (422 A 065) stops instantly

- belt conveyor (422 A 060) stops instantly

- The rest of equipment of this Group is kept running.

2.6.4.8 Belt Scale 422 A 062

If a collective alarm of the scale is detected


[422 A 062-FAL] {< 3 t/h} If low feed rate is detected for more than 60 seconds

- cause an alarm. This alarm is suspended during a run empty cycle.

[422 A 062-FAH] {> 44 t/h} If SE 2-3 or 3-3 is selected and high feed rate is detected for morethan 20 seconds

- cause an alarm

[422 A 062-FAH] {> 22 t/h} If SE 2-1 or 2-2 or 3-1 or 3-2 is selected and high feed rate isdetected for more than 20 seconds

- cause an alarm

[422 A 062-FAHH] {> 48 t/h} If SE 2-3 or 3-3 is selected and high-high feed rate is detected formore than 5 seconds

- cause an alarm.

- This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating troughfeeders 422 A 031, 422 A 041) and the setpoint SP 3 (Setpoint for the vibratingtrough feeder 422 A 051) by multiplying the actual setpoint with a factor of 0.85 inorder to reduce the feed rate automatically and if after another 60 seconds the fault isstill detected

- Normal Shut Down of this Group (see 2.6.1 above) is initiated automatically

[422 A 062-FAHH] {> 24 t/h} If SE 2-1 or 2-2 or 3-2 or 3-2 is selected and high-high feed rateis detected for more than 5 seconds

- cause an alarm.

- This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating trough

feeders 422 A 031, 422 A 041) and the setpoint SP 3 (Setpoint for the vibratingtrough feeder 422 A 051) by multiplying the actual setpoint with a factor of 0.85 inorder to reduce the feed rate automatically and if after another 60 seconds the fault isstill detected


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2.6.4.9 Rotary Lock 422 A 100


- cause an alarm

- equipment trips


- if after a delay of 30 minutes this rotary lock is still faulty and could not be restarted, aNormal Shut Down (see 2.6.1 above) will be initiated automatically.


- cause an alarm

- equipment trips


[422 A 105-LCP1] If the bag cleaning device trips


- but this Group is kept running until the differential pressure across the bags reaches

high-high differential pressure[422 A 105-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or ifthe switch fails for more than 5 seconds

- cause an alarm

- Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.NOTE: During Start or Restart of this Group there is an override of this function of 20seconds to allow the fan to run up.

[422 A 105-PDAH] {> 13mbar} If high differential pressure is detected across the filter bags orif the switch fails for more than 5 seconds

- cause an alarm only

[422 A 105-PDAHH] {> 15mbar} If high-high differential pressure is detected across the filterbags or if the switch fails for more than 5 seconds

- cause an alarm


2.6.4.11 Fan 422 A 115


- cause an alarm

- equipment trips

[422 A 115-SAL] The fan is equipped with a proximity type low-speed switch measuring thefrequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low orthe switch fails


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- cause an alarm

- equipment trips

If the fan trips



2.6.4.12 Splitter gate with servo drive 422 A 130

[422 A 130-ZL / ZH] The splitter gate is equipped with two limit switches, incorporated in acontrol box fitted to the drive unit. If a limit switch fails

- causes an alarm

- equipment trips

[422 A 130-XAL / XAH] The splitter gate is equipped with two torque switches, incorporated ina control box fitted to the drive unit. If a switch is actuated or a switch fails

- causes an alarm

- equipment trips


- cause an alarm

- equipment trips

The maximum time required between start and stop of the actuator drive, which is tilting theblade of a splitter gate, shall not be more than 90 seconds. If after 90 seconds the motor hasnot been stopped automatically because the target position has not been reached


- equipment trips

If the splitter gate trips




[422 A 135-SAL] The conveyor is equipped with a proximity type low-speed detectormeasuring the frequency of a target rotating with the tail pulley. If the frequency of the tailpulley is too low or the switch fails

- cause an alarm

- equipment trips


- cause an alarm

- equipment trips

[422 A 135-ZXA1 to ZXA 4] The conveyor is equipped with 4 side travel switches, two installed

close to the drive pulley and another two close to the tail pulley. If a side travel switch isshowing the belt is off-track for more than 2 seconds or if a switch fails

- causes an alarm


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- equipment trips

[422 A 135-HSSA] The conveyor is equipped with 2 pull cord switches (This safety switch ishard-wired to the MCC), one at each conveyor side. If a pull cord is drawn or if a switch fails

- causes an alarm

- equipment trips

[422 A 135-ZAL and ZAH] The conveyor is equipped with 2 take-up switches, one detectinglow take-up pulley position and another detecting high take-up pulley position. If one of theswitches is detecting an excessive position of the take-up pulley for more than 2 seconds or ifa switch fails

- causes an alarm

- equipment trips

If SE 2-2 or 3-2 is selected and the belt conveyor trips



If SE 2-3 or 3-3 is selected and the belt conveyor trips


- splitter gate (422 A 130) tilts at 100% material flow to reversing flap 422 A 132 [limitswitch 422 A 135-ZH actuated]

- This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating troughfeeders 422 A 031, 422 A 041) and the setpoint SP 3 (Setpoint for the vibratingtrough feeder 422 A 051) by multiplying the actual setpoints with a factor of 0.5 inorder to reduce the feed rate automatically.


[422 A 132 ZSL / ZSH] The reversing flap is equipped with two limit switches. If after actuationand start signal the limit switch for the selected position is not reached within 10 seconds, themaximum operation time is exceeded (runtime supervision)

- causes an alarm

- equipment trips

If the limit switch indication is not in agreement with the selected position (limit switch lost) or ifZSL and ZSH are indicated simultaneously

- causes an alarm

- equipment trips

If the reversing flap trips

- cause an alarm

- Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically


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[422 A 140 ZSL / ZSH] The reversing flap is equipped with two limit switches. If after actuationand start signal the limit switch for the selected position is not reached within 10 seconds, themaximum operation time is exceeded (runtime supervision)

- causes an alarm

- equipment trips

If the limit switch indication is not in agreement with the selected position (limit switch lost) or ifZSL and ZSH are indicated simultaneously

- causes an alarm- equipment trips

If the reversing flap trips

- cause an alarm

Fast Shut Down of this Group (see 2.6.3 above) is initiated automatically

2.6.4.16 Butts Feed Bin 422 A 200

If SE 2-1 is selected

[422 A 200-LY] The bin is equipped with a continuous level measurement (load cell system). Ifthe level measurement fails

- cause an alarm


[422 A 200-LAHH] The bin is equipped with a level probe. If the level measurement fails

- cause an alarm




- cause an alarm- splitter gate (422 A 130) tiltis at 100% material flow to belt conveyor 422 A 135 [limit

switch 422 A 135-ZL actuated]

- This signal is overriding the setpoint SP 2 (Master setpoint for the vibrating troughfeeders 422 A 031, 422 A 041) by multiplying the actual setpoint with a factor of 0.5 inorder to reduce the feed rate automatically


- cause an alarm

- splitter gate (422 A 130) tiltis at 100% material flow to belt conveyor 422 A 135 [limitswitch 422 A 135-ZL actuated]



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2.6.4.17 Butts Feed Bin 422 A 300



- cause an alarm



- cause an alarm




- cause an alarm

- splitter gate (422 A 130) tiltis at 100% material flow to reversing flap 422 A 132 [limitswitch 422 A 135-ZH actuated]



- cause an alarm

- splitter gate (422 A 130) tiltis at 100% material flow to reversing flap 422 A 132 [limitswitch 422 A 132-ZH actuated]


- belt conveyor 422 A 135 stops instantly

2.6.5 Shut Down by Full Bins

2.6.5.1 Butts Feed Bin (422 A 200)


If the butts feed bin is full (bin level is >/= 95% [422 A 200-LAH2])



If the butts feed bin is totally full (bin level >/= 100% [422 A 200-LAHH])

- cause an alarm

- Fast Shut Down (2.6.3 above) of this Group is initiated automatically.



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Rev. 00

If the butts feed bin is full (bin level is >/= 95% [422 A 200-LAH2]) and if splitter gate (422 A130) is after a travel time of 90 seconds not at 100% material flow to belt conveyor (422 A 135)[limit switch 422 A 130 ZL not actuated] or if the butts feed bin (422 A 300) is full (bin level is>/= 95% [422 A 300-LAH2] and/or >/= 100% [422 A 300-LAHH])



If the butts feed bin is totally full (bin level >/= 100% [422 A 200-LAHH]) and if splitter gate(422 A 135) is not at 100% material flow to belt conveyor 422 A 135 [limit switch 422 A 135-ZLactuated]

- cause an alarm- Fast Shut Down (2.6.3 above) of this Group is initiated automatically.

2.6.5.2 Butts Feed Bin (422 A 300)


If the butts feed bin is full (bin level is >/= 95% [422 A 300-LAH2])



If the butts feed bin is totally full (bin level >/= 100% [422 A 300-LAHH])

- cause an alarm- Fast Shut Down (2.6.3 above) of this Group is initiated automatically.


If the butts feed bin is full (bin level is >/= 95% [422 A 300-LAH2]) and if splitter gate (422 A130) is after a travel time of 90 seconds not at 100% material flow to reversing flap (422 A132) [limit switch 422 A 130 ZH not actuated] or if the butts feed bin (422 A 200) is full (binlevel is >/= 95% [422 A 200-LAH2] and/or >/= 100% [422 A 200-LAHH])



If the butts feed bin is totally full (bin level >/= 100% [422 A 300-LAHH]) and if splitter gate

(422 A 135) is not at 100% material flow to reversing flap 422 A 132 [limit switch 422 A 135-ZHactuated]

- cause an alarm

- Fast Shut Down (2.6.3 above) of this Group is initiated automatically.

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 Signalfrom Group 432 C toGroup 422 A

Group 432 C is running inCENTRAL mode and is notin any Group START orSTOP sequence

Digital signal fromPLC Number 432PLC 22 to PLCNumber 422 PLC 02

from Group 431 B toGroup 422 A

Group 431 B is running inCENTRAL mode and is notin any Group START orSTOP sequence


from Group 432 B toGroup 422 A

Group 432 B is running inCENTRAL mode and is notin any Group START orSTOP sequence


from Group 410 A toGroup 422 A

Compressed air pressureabove 6 bar (no low-pressure indicated by 410

A 009-PE1)

Digital signal fromPLC Number 410PLC 01 to 422 PLC02

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138-02-043Group 422 ADE-060300

5.3 Main Equipment

5.3.1 Flat Slide Gate (manual) 422 A 001

5.3.2 Vibrating Trough Feeder 422 A 031

5.3.3 Magnetic Separator, overhead 422 A 055

5.3.4 Belt Conveyor 422 A 060

5.3.5 Belt Scale 422 A 062

5.3.6 Rotary Lock 422 A 065

5.3.7 Bag Filter 422 A 070

5.3.8 Fan 422 A 080

5.3.9 Splitter Gate 422 A 130

5.3.10 Reversing

422a

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