Specification: Department: Control Systems Document No: I010S

Page 1 of 34
SPECIFICATION
Department: Control Systems
Document No: I010S
Document Title: FUNCTIONAL DESCIPTION
28 Nov 2012
PO!ECT EFEENCE
2
Pro"ect No#: TS1$0100
Pro"ect Location: %ar&il' O(is)a' In(ia#
Pro"ect Title: Iron Ore Pelleti*in+ Plant II
Client: !in(al Steel an( Po,er Lt(#
P- Aut)orisation: Date:
Client Aut)orisation: Date:
APPO.ALS
e/ Issue Date e/ision Description Prepare( C)ec0e( Disp#App Pro"# App
0 16 Oct 2012 Issued for Design JR RC RC TC
1 20 Nov 2012 Issued for Design T RC RC TC
$ 28 Nov 2012 Issued for Design T RC RC TC

!ntire Docu"ent DOC#$!NT I%%#!D &OR'
Issued t(is Revision In)(ouse Revie* Purc(ase
Revised Pages On+, C+ient -..rova+ Construction
Issued t(is Revision !n/uir, Tender
Co.,rig(t0 2010 1, Jaco1s !ngineering 2rou. Inc3 -++ rig(ts reserved3 T(e contents of t(is docu"ent are .ro.rietar, and .roduced for t(e e4c+usive 1enefit of Jaco1s
!ngineering 2rou.s Inc3 and its affi+iated co".anies3 No .art of t(is docu"ent "a, 1e re.roduced5 stored in a retrieva+ s,ste"5 or trans"itted5 in an, for" or 1, an,
"eans5 e+ectronic5 "ec(anica+5 .(otoco.,ing5 recording or ot(er*ise5 *it(out t(e .rior *ritten a..rova+ of Jaco1s !ngineering 2rou. Inc3
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T-89! O& CONT!NT%
130 &#NCTION-9 D!%CRIPTION
230 IND#R-TIN2 D!T-I9%
330 CONTRO9 %:%T!$ O;!R;I!<
430 PO99#TION CONTRO9
=30 %!R;IC! %:%T!$%
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130 &#NCTION-9 D!%CRIPTION
T(is docu"ent descri1es t(e contro+ s,ste" for an iron ore .e++eti>ing faci+it,5
1ased on t(e Dravo Trave+ing 2rate Process5 +ocated at t(e site of Jinda+ %tee+
and Po*er 9i"ited ?J%P9@ in 8ar1i+5 Odis(a5 India3 T(is .+ant is designated as
J%P9 P+ant 2 and is +ocated ne4t to t(e e4isting J%P9 P+ant 13
131 T(e .e++et .+ant is conceived as a versati+e o.eration ca.a1+e of .roducing a
variet, of .roduct t,.es5 as .redicated 1, t(e ore su..+, andAor t(e consu"er
de"and3 T(us5 fro" ti"e to ti"e5 ca".aigns "a, 1e run to .roduce varieties
ranging fro" acid .e++ets to f+u4ed .e++ets3
13131 T(e .e++et .+ant conve,ors and (ard*are *i++ 1e "ec(anica++, designed to (and+e
45=005000 direct reduction grade ?DR)grade@ ore .e++ets .er ,ear in 330 da,s of
o.eration ?65720 sc(edu+ed (ours .er ,ear of o.eration@5 taBing into account a++
design safet, factors3 -ctua+ indurating ca.acit, is de.endent u.on t(e s.ecific
ore 1eing uti+i>ed5 t(e t,.e of .e++ets 1eing .roduced5 and /ua+it, s.ecifications of
t(e user3
Tota+ .+ant avai+a1i+it, is de.endent u.on t(e s.ecific o.erating and "aintenance
.ractice e".+o,ed at t(e site3 J%P9Cs target .roduction is 450005000 tonnes .er
annu" of fired .e++ets3
132 8a++ $i++s) -rea 1
8+ended Iron ore is de+ivered via o*nerCs 1+ended ore conve,or direct+, into t(e 1a++
"i++ feed 1in D1 ?843=10)1@ or onto t(e Ore Concentrate Conve,or O&)1
?843001-@3
13231 T(e Ore Concentrate s(utt+e conve,or O&)1 ?8430018@ feeds t(e 8a++ $i++ &eed
8in D2 ?843=10)2@ *(en .ositioned under t(e disc(arge of o*ner 1+ended ore
conve,or3
13232 T(e Ore concentrate conve,or O&)1 ?843001-@ runs on+, to fi++ 8in D23 8,
signa+ing t(e fi++ e/ui."ent o.erators *it( a signa+ +ig(t5 t(e 8+ended Ore Conve,or
*i++ 1e e".t, +ong enoug( for O&)1 conve,or to re.osition3 T(e o.erator can fi++ t(e
8a++ $i++ &eed 8ins "anua++,5 if desired3
13233 T(ere are 2 8a++ $i++ &eed Conve,ors 8$&)1 and 8$&)2 ?843002)152@ *it( 8e+t
%ca+es ?8==201)152@ ?<IC)0180106 E <IC)0180116@ +ocated under t(e
a..ro.riate 8a++ $i++ &eed 8ins3 T(e feed rate set.oint to t(e 8a++ $i++ &eeders is
fro" t(e 8a++ $i++ %.ecific !nerg, Rate ?JIC)01802065 JIC)0180=06@3
%ee .aragra.( 13238
13234 !ac( 8a++ $i++ is e/ui..ed *it( a Disc(arge %u". ?83=101)152 @ and a .air of
Disc(arge Pu".s ?841101)15 841101)2@5 and ?841101)35 841101)4@3 T(e +eve+
?9IC)01803065 9IC)018060=@ in t(e 8a++ $i++ Disc(arge %u".s is contro++ed 1,
t(e 8a++ $i++ Disc(arge Pu".s varia1+e s.eed drives3
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1323= In order to o.erate t(e 8a++ $i++s5 t(e o.erator "ust enter t(e desired s+urr,
densit, at densit, contro++er DIC)018030=5 DIC)018060=3
T(e O.erator enters +a1 data as fo++o*s'
9a1 Data'
13 F "oisture in feed ore e4a".+e 8F *ater
23 B<(A( for 1a++ "i++ grinding e4a".+e 1333
33 c,c+one underf+o* circu+ating +oad e4a".+e 430 ratio to ne* feed
43 s.ecific gravit, of disc(arge su". e4a".+e 137
13236 8a++ $i++ Disc(arge %u".s feed C+assif,ing C,c+ones ?84=801)1 t(roug( 4
de.ending on ;endor@ and ?84=802)1 t(roug( 4@3 C,c+one in+et va+ves ?G;)
01804015 25 35 4 and G;)01806015 25 35 4@ are contro++ed "anua++, 1, t(e
o.erator for .ro.er .ressure dro.3 T(e c,c+one 1anB consists of a radia+
distri1utor *it( re"ote contro++ed in+et va+ves to four ?4@ insta++ed c,c+ones on
eac( of t(e t*o "i++ +ines3 It is antici.ated t(at t(ere *i++ nor"a++, 1e t(ree
o.erating c,c+ones3 8ecause of t(e coarse si>e distri1ution of t(e ore ?10F
H="" fraction@5 *et sing+e)co".art"ent 1a++ "i++ grinding is e4.ected to resu+t in
re+ative+, (ig( circu+ating +oadsI and t(erefore t(e need to add t(e Jf+oatingK
c,c+ones *(en .u". vo+u"es increase3

13236 8a++ $i++ Disc(arge %u". "aBeu. *ater is added according to t(e desired s+urr,
densit,3 ?DT)018030= and DT)018060=@3 T(e set.oint of t(e +eve+ contro+ is
fro" t(e densit, contro++er ?DIC)018030= and DIC)018060=@3
- Do..+er f+o* trans"itter ?&T)01803025 &T)0180602 @ a+so "easures s+urr, f+o*
in "
3
A( at t(is +ocation3 Percent so+ids can 1e ca+cu+ated fro" t(e %.ecific 2ravit,3
T(e desired s.ecific gravit, of t(e 8a++ $i++ Disc(arge Pu".s is a..ro4i"ate+,
1373 T(e "aBeu. contro++er uses a 137 s.ecific gravit, set.oint 3 %u". +eve+
contro++er ?9IC)0180306 and 9IC)0180606@ sends a .u". s.eed signa+ to 8a++
$i++ disc(arge .u".s ?841101)15 2 or 841101)35 4@3
9i"its "ust 1e i".osed on t(e densit, contro++ers3 If 1ot( disc(arge .u".s
?841101)15 25 or 841101)35 4@ are sto..ed5 t(en "aBeu. *ater is a+so sto..ed3
If t(e +eve+ at t(e 8a++ $i++ Disc(arge %u". is too (ig(5 t(en *ater f+o* is sto..ed
unti+ t(e 8a++ $i++ Disc(arge %u". +eve+ dro.s3 If t(e 8a++ $i++ Disc(arge %u". is
too +o*5 t(en *ater f+o* "aBeu. *i++ increase unti+ t(e +eve+ rises3
If eit(er densit, instru"ent or f+o* "eter s(ou+d fai+5 t(e *ater "aBeu. f+o* can
1e set "anua++,3
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13238 T(e $i++s (ave Inc(ing $otors ?846201-5 2-@ and $ain $otors ?84620185 28@3
T(e Inc(ing $otor can 1e used to .osition t(e $i++ for c(arging ne* 1a++s as *e++
as s+o* rotation during do*nti"e3 T(e "ain "otor is used for grinding3 T(e
Inc(ing "otor (as on+, +oca+ contro+ *(i+e t(e $ain $otor (as 1ot( +oca+ and DC%
contro+s3 T(e 8a++ $i++ Bi+o*att "eters ?JIC)0180206 and JIC)0180=06@ feed
.o*er data to t(e DC% for ca+cu+ations and "onitoring3 - Profi1us +inB interfaces
t(e $i++ $otor to t(e DC% for additiona+ a+ar"s3 T(e Profi1us is a co""unications
+inB used to transfer +arge a"ounts of infor"ation in a defined for"at3
T(e B<(At is a va+ue given 1, t(e .+ant .rocess engineer and is a1out 1333 B<(At3
-verage "i++ B< over +ast (our A B<(At feed set .oint L tA( dr, feed
needed
!4a".+e 3312 B<(A( A 1333 B<(At L 247 tA( dr, feed
T(e 3312 B<(A( is t(e tota+ .o*er for 1ot( "ain drive "otors3
Dr, tA( "i++ feed A ?100)F "oisture in "i++ feed @ A100 L *et feed tA( set.oint
!4a".+e ' 247 dr, tA( A ?100) 8 @ A100 L 261 *et tA( set.oint to feeder

13237 T(e T(icBener ?84=601@ receives s+urr, fro" "an, sources3 T(e 8a++ $i++ %u".
Pu".s and &i+ter -rea su". .u".s go to t(e %ieve 8end ?84=4=1@ to se.arate
tras( and oversi>e "ateria+3 T(e T(icBener (as a raBe t(at rotates *it( t*o
(,drau+ic .o*er .acBs3 T(e raBe a+so (as a (,drau+ic c,+inder to raise and +o*er
t(e raBe3 Densit, and f+o* "eters ?DT)0180820@5 ?DT)0180830@ and ?&T)
0180821@5 ?&T)0180831@ "easure t(e T(icBener #nderf+o* Pu".s ?841101)
15253@ disc(arge3 T(ere are t*o underf+o* .u".s running *it( one s.are3
T(icBener s+urr, densit, is "aintained at a s.ecific gravit, of a..ro4i"ate+, 23133
T(ere are t*o densit, contro++ers t(at contro+ t(e disc(arge eit(er to t(e s+urr,
distri1uter or to t(e t(icBener3 #nderf+o* trave+s to t(e %+urr, Distri1utor ?848201@
and is directed 1, t(e t*o Dart ;a+ves ?848201)152@ to t(e %+urr, Mo+ding TanBs
? 836101)152@3 -n overf+o* at t(e Distri1utor returns s+urr, to t(e t(icBener3 T(e
t(ird dart va+ve is future3 T(e t(ree T(icBener #nderf+o* Pu".s (ave individua+
Mand %.eed Contro++ers at t(e DC%3
T(e t(icBener underf+o* rate *i++ 1e contro++ed to "aintain an e/ui+i1riu" 1et*een
t(e so+ids going into t(e t(icBener fro" a++ sources and t(e so+ids .u".ed as
underf+o* at t(e .ro.er densit, to t(e s+urr, (o+ding tanBs3 One indication t(at t(e
t(icBener is not in e/ui+i1riu" is t(at t(e +eve+ in t(e s+urr, tanB *i++ 1egin
dro..ing3 -not(er indication is t(e tor/ue "easured fro" t(e t(icBener raBe *i++
increase as a resu+t of e4cessive so+ids 1ui+ding3 T(e underf+o* .u". rate "a,
t(en 1e adNusted 1, t(e o.erator to reesta1+is( t(e so+ids 1a+ance3 T(e varia1+e
s.eed contro+ *i++ on+, 1e used for s"a++ adNust"ents3 T(e o.erator "a, a+so
increase t(e so+ids f+o* to t(e u.strea" 1a++ "i++s to 1a+ance t(e so+ids into and
out of t(e t(icBener3
If t(ere are +arge c(anges in t(e f+o* of so+ids to t(e t(icBener5 t(en t(e t(icBener
underf+o* *i++ 1e rec,c+ed unti+ t(e desired densit, (as 1een reesta1+is(ed3 One
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of t(e t(icBener underf+o* .u".s "a, 1e s(utdo*n if t(e one of t(e u.strea" 1a++
"i++s is s(utdo*n3
T(e f+o* and densit, instru"ents on t(e t(icBener underf+o* .u".s a++o*
o.erators to co".ute t(e "ass f+o* fro" t(e t(icBener3 Once e/ui+i1riu" is
reac(ed in t(e t(icBener5 t(e underf+o* .u". s.eed "a, 1e adNusted to ,ie+d t(e
sa"e "ass f+o* to t(e distri1utor as t(e ne* so+ids feeding t(e t(icBener3 T(e
.ri"ar, source of ne* so+ids enters t(e t(icBener fro" t(e c,c+one overf+o*3 T(e
c,c+one overf+o* so+ids *i++ 1e t(e sa"e as t(e feed to t(e u.strea" 1a++ "i++s3
T(e *eig( feeders under t(e "i++ feed 1ins *i++ a++o* t(e o.erator to deter"ine
t(e ne* feed so+ids to t(e 1a++ "i++ s,ste"3

133 Overf+o* fro" t(e t(icBener goes to 3 Process <ater .u".s ?84110=)15 25 3@3
T(ere are t*o .u".s o.erating and 1 .u". stand1,3 T(e su". +eve+ contro+
?9IC)0180804@ *i++ contro+ "aBeu. *ater t(roug( 9;)0180804- or divert *ater to
8+o*do*n t(roug( 9;)018080483
134 T(ree %+urr, Dart ;a+ves ?848201)15 2@ direct t(e f+o* "anua++,3 Nor"a++, t(e
o.erator *i++ a++o* t(e Dart va+ves to fi++ one %+urr, Mo+ding TanB at a ti"e3 $anua+
va+ves a++o* t(e &i+ter Press Pu".s ?841103)15 25 3@ to 1e fed fro" eit(er %+urr,
Mo+ding TanB3 -gitators ?837102)15 2@ are fitted to Bee. t(e s+urr, in sus.ension
in t(e %+urr, Mo+ding TanBs3 %+urr, +eve+ ?9IT)0181304 and 9IT)018130=@ s(ou+d
1e "aintained to Bee. t(e agitator 1e+o* s+urr, +eve+3 If 1ot( %+urr, Mo+ding tanBs
are e".t,5 t(en a++ t(ree &i+ter Press &eed .u".s ?841103)15 25 3@ sto.3 T(e
&i+ter Press &eed Pu".s are designed for one .u". for ?2@ &i+ter Presses3 T(e
+ogic *i++ a++o* t(e .u". to fi++ on+, one fi+ter .ress at a ti"e3
&i+tration ste.s are ' &i++ing 5 $e"1rane Co".ression 5 CaBe -ir Dr,ing5 CaBe
Disc(arge5 and C+ot( <as(ing3
&i+ter caBe is e4.ected to 1e a1out 10F "oisture3
13431 T(e fi+ter .resses *orB in a c,c+e to re"ove *ater fro" t(e s+urr,3 Co""ands
fro" eac( fi+ter .ress *i++ signa+ t(e DC% to su..+, (ig( .ressure s+urr,3 <(en not
fi++ing5 t(e &i+ter Press &eed Pu".s rec,c+e s+urr, to t(e %+urr, Distri1utor
?848201@3
T(ere are si4 ?6@ &i+ter Presses ?84=1015 25 35 45 =5 and 6@3 T(ese .resses *orB
on a c,c+e t(at is .art of t(e ;endor su..+ied P9C s,ste" *it( Profi1us +inB to t(e
DC%3 If %+urr, is not needed at a fi+ter .ress5 t(e s+urr, is rec,c+ed 1acB to t(e
%+urr, Distri1utor ?848201@3 Pu".ing .ressure and co".ressed air are used to
se.arate so+ids and *ater3 Mig( Pressure *ater s.ra,s are a+so used to c+ean t(e
c+ot( *(en t(e fi+ter fra"es are o.ened3 T(ere are 4 air co".ressors feeding 6
&i+ter Presses3 T(e &i+ter CaBe dro.s on t(e &i+ter CaBe Conve,or ?&C)
15253545=56@ ?843010)15253545=56@ and is trans.orted to co""on conve,or &C)8
?84301=@3
&ro" (ere t(e fi+ter caBe *i++ trave+ over conve,ors &C)75 105 115125133
13432 T(e &i+trate and <as( <ater TanB ?83=104@ (as t*o varia1+e s.eed .u".s
?841104)152@ to "ove t(e s+urr, 1acB to t(e T(icBener3 If t(e &i+trate and %+urr,
+eve+ gets 1e+o* t(e set.oint of ?9IT)0181801-@5 t(en "aBeu. *ater enters fro"
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?9;)01-81801@3 9eve+ contro++er 9IC)01818018@ contro+s t(e s.eed of t(e &i+trate
Pu".s ?841104)15 2@3
T(e set.oint of +eve+ contro++er ?9IC)0181801-@ is set at a1out 2= F *(i+e +eve+
contro++er ?9IC)01818018@ is set to 60 F 3
13= -dditive 2rinding )-rea 2
- .e++eti>ing feed 1+end reci.e is .re.ared in t(e DC%3
-dditive &eed can trave+ to 9ine 1 or 9ine 23 <(en directed to +ine 25 t(e "ateria+
trave+s fro" reversing s(utt+e conve,or -&)4 ?843120@ to -dditive &eed Conve,or
-&)= ?843110@ to reversing s(utt+e -&)6 ?84311=@3 8entonite su..+, is se.arate
and (as its o*n 8entonite %torage ?843=04@3
136 <(en t(e +i"estone 1in ?816206@ and coa+ 1in ?81620=@ reac(es t(e &#99 +eve+
?9-M)0282212 and 9-M)0282213@ a +ig(t *i++ i++u"inate at t(e fi++ing +ocation to
*arn o.erators t(at t(e 1in is near+, fu++3 If t(e +eve+ s(ou+d continue to rise to
Mig(5 Mig(5 t(e feed 1e+t or feed conve,or *i++ sto.3
136 T(e Coa+A9i"estone $i++ re/uires an air (eater and ot(er anci++ar, e/ui."ent3 -ir
Meaters are fired 1, fue+ oi+ *it( 9P2 .i+ots and *i++ dr, t(e Coa+A+i"estone "i4 to
1F "oisture3 T(e $i++ (as t(e fo++o*ing e/ui."ent3
138 Coa+A9i"estone $i++
-ir C+assifier -ir %+ide 8+o*er
Product C,c+one -ir+ocB
Product -ir %+ide 8+o*er
-dditive 2rinding 8ag(ouse and fan
-dditive 2rinding %cre* Conve,or
-dditive 2rinding %,ste" &an
$i++ 9ift %,ste"
CO2 %afet, %,ste"
137 %tartu. and o.eration of t(e -dditive 2rinding $i++s are descri1ed as .art of t(e ;endor
?OE$@ O.erating $anua+3
1310 T(e -dditive 2rinding $i++ "ust 1e running and (ave a va+id feed rate set.oint
1efore starting t(e a..ro.riate -dditive &eed Conve,or3 - Pneu"atic Transfer
%,ste" *it( &eed Mo..er and Pneu"atic 8+o* TanB ?843303 and 843714-@5
"oves t(e ground coa+A9i"estone to t(e Coa+ 9i"estone %torage 8in ?843=01@ 3
1311 %e.arate 1ins (o+d t(e as)received 1entonite ?843=04@5 Coa+A9i"estone ?843=015
and Organic 8inder ?843=0=@3
13123 Organic 8inder 8in is fi++ed 1, t(e Organic 8inder Pneu"atic Trans.ort s,ste"
fro" Organic 8inder 8ags3
1313 $IGIN2 O-rea 3
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T(e fi++ing of t(e Ore to t(e Iron Ore &i+ter CaBe %torage 8ins ?843=02)15 2@ is a
se.arate o.eration3 T(e -uto $ode &i++ing *i++ fi++ t(e Iron Ore &i+ter CaBe %torage
8in *it( t(e +o*est +eve+3 T(e "ateria+ can a+so 1e fed "anua++,3
T(e Dr, Ore %torage 8in ?843=06@ a+so can disc(arge t(roug( Rotar, <eig(
&eeder ?8==00=@ to t(e $i4er &eed Conve,or $&)1 ?843026@3 T(is 1in is fi++ed
fro" a Pneu"atic Transfer %,ste" ?1, ot(ers@3
T(e c(e"ica+ co".osition of t(e fired .e++ets is contro++ed 1, .ro.er .ro.ortioning
of t(e ore and additives3 &i+ter caBe is fed onto a $i4er &eed Conve,or $&)1
?843026@ 1, t*o varia1+e s.eed 1e+t conve,ors ?843086)15)2@ *it( *eig( sca+es
?<IC)0383111 and <IC)0383112@ and Rotar, <eig( &eeder ?8==00=@3 -dditives5
Coa+A9i"estone5 8entonite5 and Organic 8inder are "etered 1, +oss)in)*eig(t
feeders ?8==0015 8==0035 8==004@ onto t(e $i4er &eed Conve,or $&)1
?843026@5 *(ic( *i++ disc(arge into a vertica+ "i4er ?84=110@3
131331 $i4ing !/ui."ent
T(e "i4ed .e++et feed fro" t(e "i4er3?84=110@ is conve,ed to t(e 1a++ing feed
1ins3
T(e $i4er (as t(e fo++o*ing drives
$i4ing .an 2 4 22 B<
Rotor 1 160 B<
Rotor 2 132 B<
Disc(arge disBAga. adNust"ent 63= B<
Coo+ing fan of (,drau+ic unit 036= B<
Oi+ coo+er of rotor gear 1 03== B<
Oi+ +u1rication of rotor gear 1 036= B<
$otor +u1rication 1 0318 B<
$otor +u1rication 2 0318 B<
;i1ration "otor 1 0326 B<
;i1ration "otor 2 0326 B<
131332 $i4er &unction
$i4ing .an rotates *it( eccentrica++, .ositioned rotating "i4ing too+s ?rotors@
and fi4ed "u+ti).ur.ose too+ as f+o* def+ector3 T(e "u+ti).ur.ose too+ divides and
deviates t(e "ateria+ strea"3 %.+it "ateria+ strea"s are created and .roduce a
"acro"i4ing effect3 T(e rotor acts u.on t(e circu+ating "ateria+ strea" *(ic( is
caused 1, "i4ing .an and f+o* def+ector and .roduces a "icro"i4ing effect3
T(e 2reen &ines Return conve,or ?2&R)2@ ?843042@ de.osits fines returns
a+ong *it( "i4er disc(arge to t(e $i4ed Ore Conve,or $O)2 ?843026@3 T(e $O)
1 ?843026@ conve,or transfers "ateria+ to $O)2 ?843026@ and $O)3 ?843032@3
-t t(is .oint5 t(e a..ro.riate 1e+t .+o* *i++ du". to 8a++ing Disc &eed 8ins
?81621=)15 253545=5@ or direct+, to 8a++ing Disc &eed 8in 6 ?81621=)6@3
T(e DC% o.erator can s.ecif, *(ic( 8a++ing Disc &eed 8ins are to 1e fi++ed5 or
use t(e auto"atic "ode3 In auto"atic5 t(e "ateria+ *i++ fi++ one 8a++ing Disc &eed
8in at a ti"e5 de.ending on t(e 1in t(at (as t(e +o*est +eve+3
1314 8a++ing) -rea 4
2436627773doc
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T(ere are si4 ?6@ 63=" dia"eter 1a++ing discs3 T(e discs co"1ine s.ra, *ater
and t(e "i4ed ore feed to for" green .e++ets3
8a++ing discs (ave varia1+e s.eed drives *it( individua+ s.eed contro+s3
In order to .rocess different ore t,.es5 1a++ing disc s.eed5 scra.er .osition5 *ater
s.ra,s5 disc ang+e5 and feed .oint *i++ 1e adNusta1+e3 Nor"a++,5 on+, "inor
adNust"ents to *ater addition and disc s.eed *i++ 1e needed to .roduce good
/ua+it, green .e++ets3 &o++o*ing t(e initia+ setu. for t(e disc5 t(e ot(er
adNust"ents *i++ 1e necessar, on+, *(en t(ere is a significant c(ange in t(e ore
c(aracteristics3 %.eed is adNusted 1, fie+d o.erator3
Ot(er adNust"ents are "anua+ 3
131431 Co".ressed -ir and grease are directed to eac( disc via t(e 2ear 9u1rication
%,ste"s ?84600=-)152@3 Co".ressed air is used to .rovide t(e grease to disc
drives3
131= Indurating) -rea =
2reen .e++ets fro" t(e 1a++ing discs *i++ dro. onto green .e++et conve,ors 2P)1-
t(ru 2P)18 *(ic( in turn feed onto green .e++et conve,or 2P)2 ?843034@3 2P)2
conve,or (as a reci.rocating (ead ?843034-@ du".ing onto t(e <ide 8e+t
Conve,or ?843036@3 Pe++ets are distri1uted across a *ide 1e+t conve,or ?843036@
1, a reci.rocating Mead .u++e, "ec(anis"3 T(e .e++ets are screened and
conve,ed to t(e .e++et induration "ac(ine 1, a dou1+e decB ro++er screen ?DDR%@3
T(e off)si>e .e++ets are screened 1, t(e DDR% a(ead of t(e indurating "ac(ine
and rec,c+ed 1acB to t(e 1a++ing circuit3 Oversi>e .e++ets trave+ t(roug( 2reen
Oversi>e Return Con,e,or ?843036-@ to t(e Oversi>e Pe++et %(redder ?843036D@
onto 2reen &ines Return &ines Conve,ors 2&R)1525 ?843036C5843042@ to $O)2
?843026@3 T(e green .e++et conve,ors and DDR% reNect conve,ors are si>ed for a
reNection rate of 40 .ercent5 a+t(oug( rec,c+e rates of 2=F or +ess are antici.ated3
131=31 T(e design for t(e trave+ing grate iron ore .e++et .+ant *i++ incor.orate t(e Dravo
Process3 In t(is .rocess5 t(e unfired green .e++ets are dried5 .re(eated5
indurated5 and coo+ed on a continuous trave+ing grate5 *it(out inter"ediate
transfers3 Process air introduced for .e++et coo+ing is circu+ated fro" t(e coo+ing
>one of t(e grate in a "u+ti).ass "anner to t(e ot(er .rocess >ones to o1tain
t(er"a+ efficienc,3 On+, re+ative+, coo+5 "oisture +aden gases are disc(arged to
.rocess gas c+eaning and t(en to t(e at"os.(ere3
131=32 During nor"a+ o.eration5 t(e 6= "" to 100 "" t(icB 1ed of (eart( +a,er *i++
.erfor" t(ree i".ortant functions3
-3 It *i++ create a te".erature gradient 1et*een t(e 1otto" of t(e ne* 1ed and
t(e "eta+ grate co".onents5 so t(at t(e grate co".onents are e4.osed to gases
coo+er t(an t(e roug(+, 1300 C at t(e 1otto" of t(e ne* 1ed3
83 T(e (ig( +eve+ (eat5 *(ic( is stored in t(e (eart( +a,er5 is efficient+, returned to
t(e .rocess during u.draft coo+ing3
C3 It *i++ diffuse t(e gas f+o* .assing t(roug( t(e re+ative+, s"a++ fraction of o.en
grate area5 t(us ensuring unifor" gas f+o* t(roug( t(e ne* 1ed3
2436627773doc
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131=33 T(e (eart( +a,er t(icBness is adNusta1+e 1, t(e o.erator to a "a4i"u" (eig(t of
300""3
T(is feature *i++ a+so .er"it Jid+ingK t(e "ac(ine 1, re)circu+ating fu++ de.t( (eart(
+a,er5 *(i+e "aintaining t(e gas te".eratures in a++ >ones5 and to gradua++,
increase t(e green .e++et feed rate fro" >ero *it(out .roducing an, off)
s.ecification .roduct3 During interru.tions in green .e++et feed5 t(e (eart( +a,er
gate is raised to cover t(e grate and to "aintain grate s.eed3
131=34 %ide +a,er c(utes ?8400011@ are used to .rotect side .+ates fro" (ig(
te".eratures and to "aintain .e++et /ua+it,3
131=3= Pe++et induration *i++ occur on t(e 430 " *ide trave+ing grate3 T(e antici.ated tota+
1ed (eig(t of (eart( +a,er .+us green .e++ets *i++ 1e constant u. to a..ro4i"ate+,
=00 ""3 T(e s.eed of t(e trave+ing grate is varia1+e and auto"atica++, contro++ed
to "aintain a constant 1ed (eig(t3
131=36 T(e indurating "ac(ine ?840001@ *i++ (ave five furnace .rocessing >ones5 u.draft
dr,ing5 do*ndraft dr,ing5 .re(eating5 firing and coo+ing3 In t(e u.draft dr,ing
>one5 gas f+o* *i++ re"ove free *ater fro" t(e +o*er .ortion of t(e .e++et 1ed *(i+e
(eating t(at +a,er to a te".erature at *(ic( condensation *i++ not for" *(en t(e
gas f+o* reverses in do*ndraft dr,ing3 T(e u.draft dr,ing off)gas is e4(austed to
at"os.(ere fo++o*ing dust re"ova+3 T(e (eat for u.draft dr,ing is recovered fro"
t(e second section of t(e coo+ing >one3
131=36 T(e ne4t .rocess >one is do*ndraft dr,ing *(ere free *ater is re"oved fro" t(e
u..er .ortion of t(e .e++et 1ed3 T(e (eat for do*ndraft dr,ing is su..+ied fro" t(e
firing >one *ind1o4es3 2ases fro" t(e do*ndraft *ind1o4es are discarded via t(e
*ind1o4 e4(aust fan unti+ t(e off)gas reac(es sufficient te".erature for use in
do*ndraft dr,ing3 T(e air for t(e re"ainder of t(e (eating c,c+e co"es fro" t(e
first coo+ing >one via t(e direct recu.eration duct3
131=38 T(e .e++ets are .re(eated to inter"ediate te".eratures in t(e t(ird .rocessing
>one3 Provision is "ade to te".er t(e initia+ stages of .re(eat *it( coo+er air to
a++o* 1etter contro+ of t(e (eat)u. rate of t(e .e++ets3 T(e s+o* te".erature ra".
*i++ .revent t(er"a+ s(ocB and avoid da"age fro" ra.id+, evo+ving stea" or
gases resu+ting fro" cr,sta++ine *ater in t(e ore5 ca+cination of t(e f+u45 and
co"1ustion of t(e coa+3
131=37 -fter .re(eating5 t(e .e++ets are fired at (ig( te".erature3 T(e (ood te".erature
in t(e +atter .art of t(e firing >one is s+ig(t+, +o*er as t(e residua+ (eat in t(e u..er
.ortion of t(e .e++et 1ed is dra*n do*n to t(e 1otto" +a,er to ensure unifor"
.roduct /ua+it,3 <ind1o4es 13 t(roug( 22 are used for firing3
131=310 Coo+ing of t(e .e++ets is acco".+is(ed *it( an u.draft f+o* of air to +o*er t(e
te".erature of t(e grate co".onents /uicB+, and to recu.erate t(e sensi1+e (eat
fro" t(e .e++et 1ed at t(e (ig(est .ossi1+e te".erature3
131=311 T(e gas f+o* sc(e"e is designed to recu.erate a significant a"ount of sensi1+e
(eat fro" t(e .rocess gas strea"s3 Mig( +eve+ (eat is recu.erated direct+, fro"
t(e first coo+ing >one5 *(i+e +o* +eve+ (eat is recu.erated fro" t(e second coo+ing
2436627773doc
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>one for dr,ing at te".eratures5 *(ic( avoid t(e use of e4otic "ateria+s of
construction for t(e u.draft dr,ing fan3 Process .ara"eters "a, 1e reset to
o.ti"i>e t(e induration .attern as ca".aigns of different t,.es of .e++ets are run3
131=312 -dditiona+ (eat for indurating is su..+ied 1, 1urners firing eit(er fue+ oi+ or fue+
gas3 Oi+ (eaters5 .i.e insu+ation5 and e+ectric (eat tracing of oi+ +ines are
incor.orated into t(e .+ant design3
131=313 Meart( 9a,er 8in
131=31331 9oad ce++s sense t(e *eig(t of fired .e++ets in t(e (eart( +a,er 1in ?8=4013@3 -
+eve+ trans"itter ?9T)0=80206@ sends t(e signa+ to t(e DC% *(ic( co".ares t(e
signa+ *it( t(e 1in +eve+ set.oint and according+, regu+ates t(e varia1+e s.eed
drive on M9)1 conve,or ?843061@3
Meart( +a,er 1in +eve+ is "aintained at a..ro4i"ate+, 8=F fu++3 -1nor"a+ 1in +eve+
a+ar"s are .rovided on t(e M$I for (ig( +eve+ ?7=F fu++@ and +o* +eve+ ?=0F fu++@3
Meart( +a,er 1in set.oint is entered via t(e M$I3
1316 Product %creening O-rea 6
131631 Product screen feed 1in ?843611@ is used to distri1ute fired .roduct .e++ets to t(e
.roduct screens ?843=22)152@3 T(is se.aration occurs as .e++ets .ass t(roug( t(e
screens3 Product .e++ets go to t(e P)2 ?843046@ Product Conve,or3 Meart( +a,er
c(ute .e++ets ?123= 417""@ go to M9)1 ?843061@ (eart( +a,er conve,or *(ic(
feeds M9)25 M9)3 to t(e Meart( 9a,er 8in ?8=4013@3
131632 T(e e"ergenc, .roduct vi1rating feeder is .rogra""ed to o.erate 1ased on t(e
.roduct screen feed 1in +eve+ or t(e (eart( +a,er 1in +eve+3 If t(e .roduct screens
are do*n5 t(e feed to t(e screens is sto..ed 1, c+osing t(e screen feed gates3
T(e e"ergenc, gate to feed .e++ets to t(e M9)2 ?843666@ is o.ened3 - soft*are
s*itc( no* a++o*s t(e e"ergenc, .roduct feeder run at 1ased on (eart( +a,er 1in
+eve+3
131633 -n e"ergenc, (eart( +a,er (o..er is fed 1, "o1i+e e/ui."ent3 T(e rec+ai"ed
"ateria+ trave+s to t(e Meart( 9a,er 8in ?8=4013@3
131634 Product .e++ets on P)2 ?843046@ are "easured 1, 1e+t sca+e ?8==221@ ?<IT)
0680122@ and su..+, t(e J%P9 Product Conve,or3
%creened %inter &ines trave+ to %&)15%&)2 to t(e %inter &ines 9oading 8in
?843=20@3 - sinter fines sa".+ing s,ste" ?8==402@ e4tracts .e++ets .eriodica++,3
T(e .e++ets are recovered in a container and taBen to a +a1 for ana+,sis of .(,sica+
and c(e"ica+ .ro.erties3 - Product %creening 8ag(ouse ?8=0006@ co++ects tra".
dust fro" screening3
13163= T(e Product %creening 8ag(ouse ?8=0006@ receives dust fro" t(e Meart( 9a,er
%e.aration .icBu. .oints3 3 Process <ater is used to s+urr, t(e 1ag(ouse dust into
t(e 1ag(ouse su". ?83=010@3 T(e .roduct screening 1ag(ouse su". .u".s
?841026)152@ .u". t(e s+urr, to t(e t(icBener for 9ine 13
1316 #TI9ITI!% O -rea 8
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131631 &ue+ Oi+ is un+oaded 1, J%P9 to t(e e4isting &ue+ Oi+ %torage TanBs D1 and D23
Ne* fue+ oi+ e4.ansion tanBs ?83=6015 2@ s(a++ su..+, fue+ oi+ to t(e indurating fue+
oi+ circu+ation .u".s ?841002)152@ and to t(e additive fue+ oi+ circu+ation .u".s
?841003)152@3
!ac( set of .u".s are one o.erating and one stand 1,3 !ac( circu+ation +oo.
.rovides (eater contro+s ?848002)152@ for .u".s ?841002)152@ and ?848003)152@
for .u".s ?841003)152@3 Oi+ (eaters (eat oi+ to 12= degrees C and decrease oi+
viscosit, to "eet 1urner ato"i>ing re/uire"ents3
Pri"ar, .ressure contro+ for indurating "ac(ine circu+ating .u".s ?841002)152@ is
1e acco".+is(ed uti+i>ing ?PIC)0880242@ *it( a secondar, .ressure +oo. ?PIC)
0880246@3 Pri"ar, .ressure contro+ additive fue+ oi+ circu+ation .u".s ?841003)
152@ is acco".+is(ed uti+i>ing ?PIC)08802=2@ *it( a secondar, +oo. ?PIC)
08802=3@ 3
230 IND#R-TIN2 D!T-I9%
231 Indurating $ac(ine Pe++et 8ed De.t( ?Pri"ar, %,ste"@
23131 T(e .ri"ar, .e++et 1ed de.t( contro+ s,ste" uses t(ree ?3@ u+trasonic +eve+ .ro1es
to "onitor tota+ 1ed de.t( and one ?1@ u+trasonic +eve+ .ro1e to "onitor t(e (eart(
+a,er 1ed de.t(3 T(e difference 1et*een t(e average tota+ 1ed de.t( and t(e
(eart( +a,er de.t( e/ua+s t(e green 1ed de.t(3 Tota+ 1ed de.t( is contro++ed 1,
"eans of "ac(ine s.eed "odu+ation via t(e 1ed de.t( contro++er on t(e M$I3
Meart( +a,er de.t( is fi4ed 1, setting t(e .osition of t(e (eart( +a,er gate3 -++
t(ree ?3@ signa+s5 tota+ 1ed de.t(5 green 1ed de.t( and (eart( +a,er 1ed de.t( are
dis.+a,ed on t(e M$I3 - DC% se+ector s*itc( is used to c(oose t(e active +eve+
instru"ent' -verage5 !ast5 Center5 or <est3 T(e (eart( +a,er is "easured 1, t(e
(eart( +a,er trans"itter ?9IT)0=80210@
232 Indurating $ac(ine Pe++et 8ed De.t( ?-+ternate %,ste"@
23231 T(e a+ternate s,ste" of 1ed de.t( contro+ is .rovided for 1acBu. contro+3 Its t(ree
?3@ signa+sI ca+cu+ated green 1ed de.t(5 (eart( +a,er gate .osition and t(e su" of
t(e t*o ?2@ for a tota+ 1ed de.t( are a+so dis.+a,ed on t(e M$I for co".arison3
23232 T(e 1e+t sca+e on conve,or 2P)2 ?843034@ sends a signa+ .ro.ortiona+ to t(e
*eig(t rate of "ateria+ across t(e sca+e to t(e DC%3 T(is signa+ is de+a,ed to
a++o* for t(e ti"e it taBes t(e green .e++ets to trave+ fro" t(e sca+e to t(e
indurating "ac(ine3 T(e 1e+t sca+e on conve,or 2&R)2 ?843042@ ?<IT)0=80126@
a+so sends a signa+ .ro.ortiona+ to t(e *eig(t of t(e "ateria+ reNected to t(e DC%3
T(e DC% ca+cu+ates a difference 1et*een t(e *eig(t of "ateria+ on conve,ors
2P)2 and 2&R)2 3 T(e .osition of t(e (eart( +a,er gate is sensed and
trans"itted to t(e DC%3 T(e 1u+B densit, of t(e green .e++ets is in.ut "anua++, to
t(e DC% 1, *a, of t(e M$I3 T(e s.eed of t(e trave+ing grate is sensed and
trans"itted to t(e DC%3 8ased on t(ese in.uts t(e DC% varies t(e "ac(ine
s.eed to "aintain a constant tota+ 1ed de.t( on t(e grate3
23233 Derivation of t(e contro+ a+gorit(" is s(o*n 1e+o*3
9
T
L 9
M9
H 9
2P

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<(ere'
9
T
L Tota+ 8ed De.t(
9
M9
L 9eve+ of Meart( 9a,er ?"anua++, set5 does not var, *it( "ac(ine
s.eed@
-1out 100 "" nor"a+
9
2P
L 9eve+ of green .e++ets *(ic( is ca+cu+ated 1ased on area as
fo++o*s'
?9
2P
4 2
<
@ 4 % 4 D L < or %o+ving for 9
2P
'
9
2P
L <A2
<
%D
<(ere'
2
<
L 2rate *idt( ?fi4ed@ +ess *idt( of side +a,er ?"ade u. of fired .e++ets@
% L 2rate %.eed
D L 2reen Pe++ets densit, ?"anua+ set@
< L <eig(t rate of green .e++ets feed to "ac(ine ?"easured tota+ +ess
green fines return@
%u1stituting to so+ve for Tota+ 8ed De.t(5 9
T
9
T
L 9
M9
H <A2
<
%D a1out 400) 4=0 ""
#sing %I units of "easure"ent ?C2% s,ste"@
9 L $i++i"eters ?""@
< L $etric TonsAMr ?tA(@
2 L $ ?$eters@
% L $A"in
D L $TA"eter
3
L a1out 234
9
T
L 9
M9
H
1
<
2
*
%D <(ere
1
is a constant of di"ension J""K
;a+ue of
1
'

1
L 1000 ""A$ or
1
L 163666
PPPP60 "in 3
Mr
T(en co"1ine di"ensiona+ constant
1
*it( 2
*
for a di"ension+ess constant
2
2
L
1

2
*
&or t(is "ac(ine'
2rate <idt( L 4 "eters
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%ide 9a,er L =0 "" .er side
2
*
L 4000 ) ?2 4 =0@ L 3700 ""L 337 $
2
L 163664 L 43263
337
9
T
L 9
M9
H ?43263@ <
%D
Or
9
T
L 9
M9
H <
%D Q?03234@
450005000 "t., and 6720 (rsA,r
!4a".+e at =0= tA( %.eed %L 3300 $A"in
23234 T(e DC% co".ares t(e 1ed de.t( *it( its set.oint 1ed de.t( and "odifies t(e
grate s.eed according+, t(roug( t(e varia1+e fre/uenc, drive3 -s green .e++et
feed rate is increased5 t(e ca+cu+ated tota+ 1ed de.t( *i++ e4ceed t(e set.oint and
t(e grate s.eed is increased .ro.ortiona++,3
2323= Converse+,5 for a decrease in green .e++et feed rate5 t(e ca+cu+ated tota+ 1ed de.t(
is +ess t(an t(e set.oint and t(e grate s.eed is decreased .ro.ortiona++,3 T(e
"ac(ine s.eed varies continuous+, to "aintain t(e set.oint 1ed de.t(3
23236 In t(e event of a +oss of green .e++et feed5 t(e o.erator "ust taBe action3 T(e
course of action taBen 1, t(e o.erator *i++ de.end on t(e cause of t(e +oss of
green .e++et feed5 as *e++ as t(e overa++ needs of t(e .+ant3 T(is area is covered
t(oroug(+, during t(e training .(ase of .+ant start)u.3 -n a+ar"5 differentiated
fro" ot(er a+ar"s 1, tone and vo+u"e5 indicates +oss of feed to t(e "ac(ine3
233 Process &an Protection
23331 T(e five ?=@ .rocess fans'
<ind1o4 Recu. &an ?84200=@
#.draft Dr,ing &an ? 842006@
Coo+ing -ir &an ?842004@
<ind1o4 !4(aust &an ?842006@
Mood !4(aust &an ?842008@
2333131 Te".erature e+e"ents +ocated on 1ot( "otor 1earings and fan 1earings are *ired
to t(e fan "onitoring s,ste" ?&$%@5 *(ic( t(en sends a+ar"s to t(e M$I *(en a
(ig( or (ig()(ig( te".erature e4ists in an, 1earing3 Mig()Mig( te".erature in a
"otor 1earing or fan 1earing is a fan s(utdo*n3
T(e "otor current is indicated on t(e M$I3
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&an and "otor vi1ration is a+so "onitored 1, t(e fan "onitoring s,ste" at t(e
in1oard and out1oard 1earings3 -n a+ar" is activated to t(e M$I at (ig( and at
(ig()(ig( vi1ration for an, 1earing3 T(e fan *i++ s(ut do*n at a (ig()(ig(
condition3
!ac( fan (as an in+et da".er c+osed start .er"issive inter+ocB3
!ac( fan +u1e s,ste" "easures5 a+ar"s5 or acts u.on certain conditions
according to t(e fo++o*ing'
9o* oi+ +eve+ ) ?not@ .er"its start5 t(en a+ar" on+,
Mig( oi+ te".erature ) ?not@ .er"its start5 t(en a+ar" on+,
-t +east 1 oi+ .u". running O .er"its start
9o* oi+ .ressure O ?not@ .er"its start
9o* oi+ .ressure O after s(ort de+a,5 start stand1, oi+ .u".
9o* oi+ .ressure continues O after +onger de+a,5 tri. fan
9o* oi+ f+o* return fro" fan 1earings O a+ar" on+,I no tri.#
Coo+ing *ater to t(e fans (as a +o* f+o* O a+ar" on+,
T(ree ?3@ RTDRs5 one on eac( *inding of t(e .rocess fan "otor5 are *ired direct+,
to t(e s*itc(gear for t(at .rocess fan "otor5 and t(e s*itc(gear *i++ s(utdo*n t(e
fan on (ig( "otor *indings te".erature3

-fter sto..ing a .rocess fan "otor5 t(e "otor "ust re"ain off for t(e .eriod
reco""ended 1, t(e "otor vendor5 1ased u.on t(e nu"1er and duration of its
.rior runs5 1efore a restart can 1e atte".ted3 <(en an, of t(e = .rocess fans are
sto..ed5 t(e DC% o.erator "ust c+ose t(e in+et da".ers "anua++,3
234 #.draft Dr,ing Sone Mood Pressure
23431 - .ressure trans"itter ?PT)0=80401@ in t(e u.draft dr,ing >one (ood .rovides t(e
signa+ for t(e DC% contro++er t(at regu+ates t(e fan s.eed of t(e (ood e4(aust fan3
- s+ig(t+, negative .ressure of a1out )1 to )2 "" *ater co+u"n is nor"a++,
"aintained3
23432 T(is .ressure ?P%9)0=80401@ "ust 1e negative as a .er"issive to +ig(t t(e
1urners and after +ig(t off if a .ositive .ressure occurs t(e DC% *i++ force t(e
1urners to +o* fire after a ti"e de+a,3 T(e 1urners *i++ go to +o* fire *(en t(e
.ressure at t(e coo+ing air duct is +o* ?P%9)0=8133=@ 3 %ettings *i++ 1e
deter"ined in t(e fie+d3 T(e DC% *i++ J+ocB inK t(e +o* fire condition unti+ reset at
t(e M$I3 - J9o* &ire 8,.assK s*itc( is .rovided in t(e M$I to a++o* "odu+ation of
1urners a1ove +o* fire during startu.3
23433 T(e fan in+et da".er .osition and "otor s.eed are indicated on t(e M$I and can
1e "anua++, adNusted fro" t(e screen3 &an a".s are a+so indicated on t(e M$I
screen3
23434 T(e .ressure set.oint for ?PIC)0=80401@ is entered via t(e M$I3
2343= On an out of to+erance .ressure condition5 an a+ar" is dis.+a,ed on t(e M$I3
2436627773doc
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23= Do*ndraft Dr,ing Sone Mood Pressure
23=31 - .ressure trans"itter ?PT)0=80403@ in t(e do*ndraft dr,ing >one (ood .rovides
t(e .ri"ar, signa+ t(at is trans"itted to t(e DC%3 %(ou+d t(e .ressure in t(e
do*ndraft dr,ing >one increase5 a da".er ?8=4810@ *i++ o.en to disc(arge
e4cess gas to t(e u.draft dr,ing (ood3 If t(e do*ndraft dr,ing (ood .ressure
continues a1ove t(e desired set.oint5 t(e Do*ndraft dr,ing 1+eedoff da".er
8=4807@ *i++ o.en to 1+eed gas to t(e Mood !4(aust !%P3
23=32 %et.oint .ressure is nor"a++, "aintained at a s+ig(t+, negative va+ue of a1out )3
"" *ater co+u"n3
23=33 T(e .ressure set.oint is entered via t(e M$I3
23=34 On an out of to+erance .ressure condition5 an a+ar" is dis.+a,ed on t(e M$I3
236 Do*ndraft Sone Mood Pressure
23631 - .ressure trans"itter in t(e firing >one (ood ?PT)0=8181=@ sends a signa+ to t(e
DC%5 *(ic( co".ares t(e signa+ *it( t(e set.oint and according+, regu+ates t(e
coo+ing air fan s.eed3 &an "otor current *i++ 1e dis.+a,ed to t(e o.erator3 T(e
set.oint of t(e contro++er is nor"a++, set at a s+ig(t+, negative va+ue of a1out )4
"" *ater co+u"n3 T(e .ressure is not "uc( 1e+o* at"os.(eric ot(er*ise
+eaBage of co+d air into t(e furnace cou+d cause inco".+ete 1urnt(roug( a+ong t(e
sides of t(e "ac(ine3 T(e .osition of t(e fan in+et da".ers and "otor s.eed can
1e adNusted "anua++, fro" t(e M$I3
23632 T(e set.oint for t(e .ressure is entered via t(e M$I3
23633 On an out of to+erance .ressure condition5 an a+ar" *i++ 1e dis.+a,ed on t(e M$I3
23634 In case of fai+ure of .ressure trans"itter5 ?PT)0=8181=@5 a s*itc( is .rovided on
t(e M$I to a++o* t(e o.erator to "anua++, s*itc( t(e 1acBu. firing >one .ressure
trans"itter5 ?PT)0=80732@5 into t(e coo+ing air fan s.eed contro+ +oo. unti+ t(e ?PT)
0=8181=@ signa+ is restored3
236 %econd Coo+ing Sone Mood Pressure and #.draft Dr,ing ?#DD@ &an Mig(
Te".erature Protection
23631 - .ressure trans"itter ?PT)0=80602@ in t(e second coo+ing >one (ood sends a
signa+ to t(e DC%5 *(ic( co".ares t(e signa+ *it( t(e set.oint and according+,
regu+ates t(e u.draft dr,ing fan s.eed3 Nor"a+ set.oint .ressure for t(e second
coo+ing >one is )4 to )7 "" *ater co+u"n3
23632 T(e fan in+et da".er .osition can 1e "anua++, adNusted fro" t(e M$I3
23633 T(e set.oint .ressure is entered via t(e M$I3
23634 In t(e event of an out of to+erance .ressure condition5 an a+ar" is dis.+a,ed on
t(e M$I3
2436627773doc
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2363= -s +ong as t(e "easured te".erature at t(e u.draft dr,ing gas (eader ?T!)
0=80406@ does not e4ceed t(e set.oint for fan .rotection .ur.oses ?t(e set.oint
te".erature is 1e+o* "a4i"u" fan structura+ te".erature@5 t(e second coo+ing
iso+ation da".er ?8=4828@ re"ains in t(e o.en .osition and t(e u.draft dr,ing
1+eed)in da".er ?8=4806@ *i++ "odu+ate as needed3 If t(e gas te".erature
continues to rise after t(e .ri"ar, 1+eed)in da".er is fu++, o.en5 t(e DC% *i++ t(en
start c+osing t(e iso+ation da".er ?8=4828@ to reduce t(e f+o* of (ot gas "i4ing
*it( t(e a"1ient 1+eed)in air3
%et.oint te".erature for fan .rotection is a1out 260TC3 T(e fan s.eed and
.osition of t(e 1+eed)in da".er5 t(e duct da".er and t(e #DD fan in+et da".er
are s(o*n on t(e M$I3 $otor a".s are a+so dis.+a,ed on t(e M$I3
23636 T(e set.oint te".erature for fan .rotection is entered via t(e M$I3
23636 In t(e event of an out of to+erance te".erature condition5 an a+ar" is dis.+a,ed on
t(e M$I3
238 Do*ndraft Sone <ind1o4 Pressure
23831 T(e .ressure in t(e firing >one *ind1o4es is deter"ined 1, t(e 1urnt(roug(
te".erature contro+ and is not direct+, contro++ed3
23832 <ind1o4 e4(aust duct .ressure contro+ ?PIC)0=81821@ is .rovided 3 T(ere is an
o.tion for ratio contro+ set.oint to ?PIC)0=81821@ 1, *a, of a M$I se+ector ?M%)
0=81821@3
T(e out.ut of t(e contro++er ?PIC)0=81821@ "odifies t(e s.eed of t(e <ind1o4
!4(aust &an3 -n increased s.eed *i++ +o*er t(e *ind1o4 e4(aust duct .ressure5
reduced s.eed *i++ increase t(e .ressure in t(e duct3
23833 Nor"a+ .ressure for t(e *ind1o4 e4(aust duct is a1out )=00 "" *ater co+u"n3
23834 If t(e o.erator c(ooses5 t(e *ind1o4 e4(aust (eader .ressure can 1e "aintained
at a s.ecific va+ue 1, .+acing t(e DC% contro++er in UDIR!CT CONTRO9U instead
of UR-TIO CONTRO9U3 T(e *ind1o4 e4(aust duct .ressure can t(en 1e direct+,
contro++ed 1, entering t(e desired .ressure set.oint on t(e M$I3 T(e ratio is a
nu"1er fro" 0 to 2303 <(en R-TIO is active5 t(e set.oint of t(e <ind1o4
!4(aust Meader ?PIC)0=81821@ is set to t(e ratio ti"es t(e *ind1o4 recu.eration
(eader .ressure ?PT)0=80=01@3
2383= T(e ratio set.oint for t(e *ind1o4 e4(aust (eader .ressure is entered via t(e M$I
at ?M%)0=81821@3
t(e M$I3
23836 T(e .osition of t(e *ind1o4 e4(aust fan in+et da".ers and "otor s.eed can 1e
"anua++, adNusted fro" t(e M$I3
T(e "otor a".s are dis.+a,ed on t(e M$I3
2436627773doc
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237 #.draft Dr,ing Sone <ind1o4 Pressure
23731 - .ressure trans"itter ?PT)0=8040=@ in t(e u.draft dr,ing duct sends a signa+ to
t(e DC%5 *(ic( co".ares t(e signa+ *it( t(e set.oint and according+, regu+ates
t(e u.draft dr,ing 1+eed)off da".er ?8=4806@3 T(e da".er o.ens to re+ieve
e4cess .ressure under t(e grate to .revent an, distur1ances of t(e 1ed due to
e4cessive undergrate .ressure3 Nor"a+ set.oint .ressure is a1out =00 "" *ater
co+u"n3
23732 T(e set.oint for t(e .ressure is entered via t(e M$I3
t(e M$I3
23734 T(e .osition of t(e 1+eed off da".er is s(o*n on t(e M$I3
2310 <ind1o4 Recu.eration &an Te".erature
231031 - t(er"ocou.+e ?T!)0=8123=@ +ocated on t(e do*nstrea" side of t(e *ind1o4
recu.eration fan sends a signa+ to t(e DC%5 *(ic( co".ares t(e signa+ *it( t(e
set.oint and according+, regu+ates t(e t*o 1+eed)in da".ers ?8=4808)15 2@3
T(e da".ers a++o* ingress of a"1ient air at t(e in+et side of t(e *ind1o4
recu.eration fan if t(e te".erature rises a1ove t(e set.oint te".erature3 T(e
.osition of t(e 1+eed)in da".ers is indicated on t(e M$I3
231032 T(e te".erature set.oint for ?TIC)0=8123=@ is entered via t(e M$I3
231033 On an out of to+erance te".erature condition5 an a+ar" is dis.+a,ed on t(e M$I3
2311 8urnt(roug( Te".erature
231131 T*o t(er"ocou.+es are +ocated in *ind1o4 22 ?T!)0=80631@ ?T!)0=80632@3 T(e
te".eratures are trans"itted to t(e DC% *(ere t(e te".eratures are averaged
and co".ared *it( t(e set.oint3 T(e DC% t(en regu+ates t(e *ind1o4
recu.eration fan s.eed5 increasing fan s.eed as necessar, to contro+ t(e f+o* of
(ot gases t(roug( t(e 1ed and contro+ t(e te".erature in t(e *ind1o4es as
necessar,3 %et.oint te".erature is a..ro4i"ate+, ==0TC ?setting "a, 1e
adNusted to "aintain .e++et /ua+it,@3 T(e "otor s.eed can 1e "anua++, adNusted
fro" t(e M$I3
231132 T(e te".erature set.oint ?TIC)0=80634@ is entered via t(e M$I3 T(e .osition of
t(e da".ers5 "otor s.eed and "otor a".s are dis.+a,ed on t(e M$I3
231133 On an out of to+erance te".erature condition5 an a+ar" is dis.+a,ed on t(e M$I3
2312 <ind1o4 ;ent Doors
231231 T(e *ind1o4 vent doors5 one in t(e *ind1o4 e4(aust (eader ?8=4001@ and one in
t(e *ind1o4 recu.eration (eader ?8=4002@5 are e/ui..ed *it( e+ectric "otor
o.erators3 T(e vent doors are to 1e o.ened *(en a sto. grate (o+d is initiated3
T(e vent doors are o.ened "anua++, fro" t(e DC% or a +oca+ contro+ station3
2436627773doc
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2313 Pre(eat and &iring Sone Mood Te".erature
231331 T(e DC% "anages t(e co"1ustion and regu+ator, contro+ of t(e co"1ustion
s,ste"3 - 1urner "anage"ent s,ste" .rovided *it( t(e 1urners ?8$%@
su.ervises t(e f+a"e safet, re/uire"ents for t(e indurating 1urners ?.i+ots @3 T(e
1urner contro+ a+so inc+udes one $aster and one %+ave .ane+ +ocated on t(e
1urner .+atfor"3
231332 T(e DC% sends t(e "aster 1urner .er"issive5 read, for .urge5 and at .urge f+o*
signa+s to t(e $ain Pane+3 Detai+s of t(ese signa+s can 1e found in t(e 8urner
O.eration section of t(e O.erating $anua+ and t(e vendorCs 1urner o.eration
"anua+3
231333 -++ do*nco"er te".eratures are "onitored for eac( 1urner3 T(ese sa"e
te".eratures are avai+a1+e at t(e DC%3
- .urge and 1urner restart "ust t(en 1e co".+eted if te".eratures are 1e+o* t(e
auto)ignition te".erature at an, 1urner or >one3
231334 T(e firing >one is (eated *it( 38 1urners3 !ac( 1urner can 1e contro++ed
individua++,3 T(e o.erator can se+ect oi+ or gas firing5 *it( se.arate se+ector
s*itc(es avai+a1+e on t(e "ain 1urner .ane+3
23133431 In "ini"u" f+o* .osition5 t(e 1urner +ig(t)off is a++o*ed as +ong as .er"issives
are satisfied3 T(e +o* fire indicating .osition is avai+a1+e to t(e DC%3 Nor"a++, t(e
furnace is started *it( oi+ and s*itc(ed over to gas once contro+ te".eratures are
"aintained3
23133432 Dou1+e 1+ocB va+ves are used for 1ot( oi+ and gas for 1urner "anage"ent3 Refer
to t(e vendorCs o.eration "anua+ for s.ecifics of t(is contro+ and inter+ocBing3
23133433 T(e co"1ustion s,ste" uses co"1ustion air5 a"1ient coo+ing .i+ot air5 and
ato"i>ing air3
23133434 T(e 1urners turn do*n 1, reducing fue+ f+o* and run e4cess air o.eration3
2313343= Coo+ing -ir is "aintained to t(e 1urners at a++ ti"es5 *(et(er t(e 1urners are firing
or in stand1,3
23133436 T(e .ressure 1ot( (ig( and +o* are "onitored 1, t(e 1urner "anage"ent
s,ste"3 Refer to t(e vendorCs o.eration "anua+ for s.ecifics of t(is inter+ocBing3
23133436 T(e s,ste" run .er"it is re"oved if '
!"ergenc, %to. is .ressed5 Co"1ustion -ir 1+o*er is not running5 $ain
Co"1ustion -ir .ressure is +o*5 ato"i>ing air .ressure is +o*5 or .i+ot air .ressure
is +o* 5 fue+ .ressure is +o* or an, safet, fau+t e4ists3
23133438 T(e furnace re/uires a fu++ .urge for initia+ start3 - fu++ .urge is ti"ed for four
vo+u"etric air c(anges3 If fu++ .urge is re/uired5 it is initiated at t(e $ain Pane+3
2436627773doc
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23133437 &or a fu++ .urge5 t(e s,ste" run .er"it "ust 1e on and t(e .urge conditions
satisfied3 T(e $ain Pane+ verifies t(e "ain 1urner gas safet, s(utoff va+ves are
c+osed 5 a++ 1urner .ri"ar, fue+ va+ves c+osed 5 a++ fue+ va+ves c+osed5 a++ secondar,
u.strea" and do*nstrea" fue+ va+ves are c+osed3 T(e fu++ .urge "ust 1e
co".+eted 1efore an, 1urners are +it3 <(en t(e .urge is co".+ete5 a++ fue+ contro+
va+ves go to +o* fire +ig(toff .osition3
231334310 T(ere is a 1urner run .er"issive for eac( 1urner3 If f+a"eout occurs5 t(e DC% *i++
auto"atica++, turn off t(e .er"issives to t(e fai+ed 1urner >one3 - reset is
re/uired fro" 1ot( t(e DC% and f+a"e safet, for re+ig(t3
231334311 8urner start se/uence inc+udes t(e fo++o*ing ste.s' .rove va+ves at +o* fire5
ignition transfor"er on5 f+a"e .roven5 ignition off5 "ain fue+ va+ves o.en3 <it( a++
t(ese ste.s co".+eted5 t(e 1urner is "odu+ated as needed to "aintain desired
te".eratures3
231334312 &or >one contro+5 eac( >one (as its o*n te".erature contro+3 8, soft*are5 t(e
individua+ 1urners can 1e directed to fo++o* t(e >one te".erature se+ected3
231334313 T(e $ain Pane+ transfers 8$% data to t(e DC% via (ard*ire3 - +isting of inter+ocBs
and ot(er functions are inc+uded in t(e ;endor $anua+ 3
2314 9inte+ Coo+ing %urge TanB 9eve+
231431 - +eve+ trans"itter ?9IT)0=82601@ sends a signa+ to t(e DC%5 *(ic( co".ares t(e
signa+ *it( its set.oint and according+, regu+ates t(e t(rott+ing va+ve ?9;)0=82601@
for "aBe)u. *ater3 &or nor"a+ o.eration on+, a re+ative+, s"a++ /uantit, of "aBe)
u. soft *ater addition is re/uired3
231432 T(e 9inte+ Coo+ing TanB +eve+ set.oint is entered via t(e DC% M$I3
231433 9inte+ Coo+ing Pu".s ?841101)152@ su..+, +inte+ *ater t(roug( t(e t*o 9inte+
Coo+ing <ater Meat !4c(angers ?831201)152@ to t(e furnace +inte+s5 1aff+es and
(ood sea+s3 T(e te".erature of t(e +inte+ *ater is "onitored and a+ar"ed3 ?T!)
0=82607@
231434 In t(e event of an e"ergenc, condition *(ere t(e *ater te".erature ?T!)
0=82604@ fro" t(e furnace +inte+s is too (ig(5 t(e DC% *i++ o.en a va+ve ?T;)
0=82604@ to introduce e"ergenc, "aBe)u. *ater fro" t(e e"ergenc, (ead tanB
into t(e furnace +inte+ coo+ing *ater su..+, (eader3 <(en t(e e"ergenc, *ater
va+ve is o.en t(e +inte+ coo+ing *ater storage tanB cou+d overfi++ and t(e *ater "a,
te".orari+, overf+o* to drain3 It s(ou+d 1e an o.erator action to c+ose t(is
e"ergenc, va+ve *(en it (as o.ened for an, reason3 Coo+ing *ater distri1ution
"ust 1e 1a+anced using "anua+ va+ves and o1serving t(e co++ection 1o4es3
T(e e"ergenc, (ead tanB is on+, used unti+ t(e e"ergenc, stand1, generator
can 1e started to run t(e +inte+ coo+ing *ater .u".s3
231= $ac(ine Disc(arge Mo..er 9eve+
231=31 9oad ce++s sense t(e *eig(t ?9IT)0=8030=@ of fired .e++ets in t(e disc(arge
(o..er3 - +eve+ trans"itter sends t(e +oad ce++ signa+s to t(e DC%5 *(ic(
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co".ares t(e signa+ *it( t(e set.oint and varies t(e s.eed of feeders ?8==016)
152@3
T(is contro+ need not 1e over+, tig(tI t(e 1in +eve+ s(ou+d 1e a++o*ed to f+oat u. or
do*n3 - .ro.ortiona+ or ga. contro+ sc(e"e s(ou+d 1e used for t(is contro++er3
231=32 T(e set.oint is entered via t(e M$I3
231=33 T(e ?9IC)0=8030=@ out.ut signa+ fro" t(e DC% ?9IT)0=8030=@ is co""on to 1ot(
vi1rating feeders3
231=34 In t(e event t(at t(e disc(arge +eve+ rises 1e,ond t(e set.oint5 nor"a++, =0F of
t(e fu++ 1in5 an a+ar" is activated at t(e M$I3 If t(e +eve+ continues to rise to t(e
second set.oint ?6=F@ an additiona+ a+ar" is activated at t(e M$I and t(e
"ac(ine drive *i++ 1e a+ar"ed for "anua+ s(utdo*n33 9o* +eve+ is usua++, set for
2=F3 T(e Indurating $ac(ine is not inter+ocBed to Disc(arge Mo..er 9eve+3 T(e
o.erator "ust taBe action to .revent overfi++ing of t(e Mo..er3
231=3= T(e +eve+ set.oint is entered via t(e M$I3
231=36 Product conve,or P)1 ?8430=0@ Te".erature Protection
231=3631 T(ere is a te".erature e+e"entAtrans"itter ?T!)0=80301@ +ocated in t(e second
coo+ing >one (ood at t(e end of t(e furnace *(ic( senses t(e te".erature a1ove
t(e fired .e++ets and trans"its it to t(e DC%3 9ogic in t(e DC% uses t(is
infor"ation to contro+ t(e disc(arge end (ood coo+ing *ater s.ra,s ?T;)0=80301
-585C@ to .revent (ot .e++ets fro" da"aging conve,or P)1 ?8430=0@ or an,
do*nstrea" conve,ors3 T(ere are t(ree sets of s.ra,s in t(e (ood3 T(e first set
co"es on at 42=TC5 t(e second set at 480TC5 and t(e t(ird set at =40TC3 T(e
set.oints "a, need to 1e reset during startu.3
231=3632 Do*nstrea" of t(e "ac(ine disc(arge c(utes t(ere are t*o sets of 1e+t *ater
s.ra,s a1ove t(e P)1 ?8430=0@ .roduct conve,or to .rotect t(e 1e+t fro" (ig(
te".erature .roduct5 disc(arging fro" t(e indurating "ac(ine3 - te".erature
trans"itter ?TT)0=80316@ "onitors t(e disc(arge (ood3 T(e DC% *i++ turn on t(e
first set of s.ra,s ?.rocess *ater s,ste"@ ?G;)0=80314@ at 100TC and t(e second
set ?fire*ater s,ste"@ ?T;)0=8031=@ at 1=0TC3 T(e set.oints "a, need to 1e
reset during startu.3
231=3633 -++ of t(e a1ove "entioned auto"atic s.ra, *ater te".erature contro+s s(ou+d
(ave so"e a"ount of dead1and .rogra""ed into t(e set.oints to "ini"i>e
c,c+ing t(e va+ves3
231=3634 -dditiona++, t(ere is a .air of infrared te".erature detectors ?T!)0=8031=@ for
1e+t fire .rotection a1ove t(e 1e+t itse+f do*nstrea" of t(e disc(arge c(ute *(ic(
send .e++etA1e+t te".erature readings to t(e DC%3 T(ese signa+s s(ou+d drive
+ogic *(ic( *i++ turn on t(e second set of 1e+t s.ra,s ?fire*ater s,ste"@ ?T;)
0=8031=@ to .rovide /uenc( *ater *(en (ig( te".eratures are detected3
T(e te".erature set.oint for t(e .e++etA1e+t te".erature contro+ is de.endent on
t(e +i"its of t(e se+ected 1e+t "ateria+3 - s.ecific a+ar" s(ou+d dis.+a, on t(e M$I
to indicate a (ig( te".erature (as 1een detected on t(e 1e+t 1, t(ese sensors
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and t(at t(e s.ra, va+ve is o.en3 Once o.ened 1, t(ese sensors5 it s(ou+d
re/uire o.erator action to c+ose t(e s.ra, va+ve and reset t(e s,ste"3
2316 Indurating $ac(ine Drive Contro+
231631 - vendor su..+ied contro+ s,ste" interfaces t(e DC% and t(e "ac(ine drives3
%igna+s are sent 1et*een t(ese s,ste"s to ac(ieve contro+ and "onitoring3 T(e
indurating "ac(ine drive can 1e contro++ed fro" four +ocations5 *it( on+, one
+ocation in contro+ at an, one ti"e3 -n indicator +ig(t on eac( of t(e "ac(ine
1ridge5 .a++et c(ange and drive station indicates *(en t(at station (as contro+ of
t(e grate3
23163131 Contro+ fro" t(e Contro+ Roo"
T(e DC% .rovides startAsto. contro+ t(roug( M$I screens3 T(e DC% .rovides a
s.eed reference signa+ to t(e varia1+e fre/uenc, drive fro" t(e "ac(ine
s.eedA1ed de.t( contro++er3
23163132 Contro+ fro" t(e $ac(ine 8ridge Contro+ %tation
T(e "ac(ine o.erator re/uests t(e DC% o.erator to give t(e 1ridge o.erator
contro+ of t(e "ac(ineCs s.eed3 T(e DC% o.erator gives s.eed contro+ to t(e
1ridge 1, c+icBing on t(e a..ro.riate contro+ area on t(e M$I3 T(e +oca+ s*itc( at
t(e 1ridge station can no* 1e turned JONK5 giving contro+ of t(e "ac(ine s.eed to
t(e 1ridge station3 T(e $ac(ine Contro+ s(ou+d indicate t(at t(e 1ridge (as contro+
1, +ig(ting a .i+ot +ig(t on t(e 1ridge contro+ station3 T(e varia1+e fre/uenc, unit
sets t(e s.eed reference circuit to acce.t t(e s.eed reference signa+ fro" t(e
s.eed contro+ .us(1uttons ?Increase and Decrease@ +ocated on t(e 1ridge contro+
station3 <(en t(e 1ridge o.erator (as co".+eted (is o.erating tasB5 (e ca++s t(e
DC% o.erator and infor"s (i"5 and t(en returns s.eed contro+ to t(e DC% 1,
turning off t(e s*itc( on t(e 1ridge contro+ .ane+3
) T(e varia1+e fre/uenc, unit resets t(e s.eed contro+ circuits to receive s.eed
contro+ fro" t(e DC%5 and t(e "ac(ine continues to run5 at t(e .revious s.eed
sent out 1, t(e DC%3 T(e !)sto. functions fro" 1ot( t(e DC% and t(e 1ridge
contro+ stations are active *(en eit(er t(e contro+ roo" is in contro+ or t(e 1ridge
is in contro+3
) T(e +oca+ V$ac(ine startK and VNor"a+ sto.C on t(e 1ridge .ane+ are active on+,
*(en t(e 1ridge .ane+ is ena1+ed 1, t(e DC% and t(e s*itc( on t(e +oca+ .ane+3
23163133 Contro+ fro" t(e Pa++et C(ange %tation
T(is is a J+ogic s,ste"K5 not a true grou.)starting situation3 It is o.erated fro" its
o*n +oca+ .ane+5 *it( .us(1uttons and data entr,Adis.+a, screen3
T(e .a++et c(ange station o.erator re/uests t(e DC% o.erator to give t(e .a++et
c(ange station contro+ of t(e "ac(ine3
T(e DC% o.erator gives contro+ to t(e .a++et c(ange station 1, c+icBing on t(e
a..ro.riate contro+ area of t(e M$I screen3 T(e DC% sends a signa+ to t(e .a++et
2436627773doc
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Error: Reference
source not found
c(ange contro+ s,ste" signif,ing to t(e varia1+e fre/uenc, unit t(at t(e .a++et
c(ange station can taBe contro+3
T(e .a++et c(ange station o.erator taBes contro+ *(en t(e JContro+ -ctiveK 9ig(t is
on3 T(e varia1+e fre/uenc, unit a+so sets t(e ;& contro+ signa+ circuits to acce.t
Nog for*ard and Nog reverse signa+s fro" t(e .a++et c(ange station contro+ .ane+3
T(e s.eed of t(e "ac(ine is contro++ed 1, a .reset s.eed signa+ in t(e varia1+e
fre/uenc, unit3
C(ange)Out $ode'
T(e o.erator *i++ use t(e M$I JC(ange)Out $odeK se+ector to c(oose JRe.+ace5
Re"ove5 9oad or ;ie*K after turning t(e Pa++et JOn)OffK se+ector to JOnK ) Pa++et
C(ange %tation contro+3
Re.+ace $ode'
T(e o.erator is .ro".ted to J!nter Pa++et ID to 1e insertedK and t(e o.erator
.resses J!NT!RU after Be,ing in t(e ID nu"1er3
&or Re"ove $ode'
Re"ove "u+ti.+e .a++ets fro" t(e "ac(ine after first ID nu"1er is entered3
&or 9oad $ode'
T(e .a++et ID "ust 1e entered 1, t(e o.erator3 -fter t(e first .a++et is +oaded5 t(e
o.erator can +oad ot(er .a++ets in se/uence3
;ie* $ode'
T(e o.erator vie*s t(e .a++et stacB3 Data dis.+a,ed is Position D5 Pa++et D5 and t(e
va+ue of %ag3
<(en t(e .a++et c(ange station o.erator (as co".+eted (is o.erating tasB5 (e
ca++s t(e DC% o.erator and infor"s (i"5 and t(en turns t(e Pa++et JOn)OffK
se+ector to JOffK3
<(en t(e se+ector s*itc( is s*itc(ed to DC% contro+5 t(e varia1+e fre/uenc, unit
resets t(e s.eed signa+ circuits and contro+ circuits to receive t(e DC% signa+s3
23163134 Contro+ fro" t(e $ac(ine Drive %tation
T(e "ac(ine drive station o.erator re/uests t(e DC% o.erator to give t(e
"ac(ine drive station contro+ of t(e "ac(ine3 T(e DC% o.erator gives contro+ to
t(e "ac(ine drive station 1, c+icBing on t(e a..ro.riate contro+ area of t(e M$I
screen3 T(e DC% sends a signa+ to t(e varia1+e fre/uenc, unit t(at t(e "ac(ine
drive station can taBe contro+3 T(e "ac(ine drive station o.erator taBes contro+ 1,
acBno*+edging acce.tance of t(e contro+ t(roug( a se+ection s*itc(3
T(e DC% receives t(e taBe contro+ signa+ and indicates t(e "ac(ine drive station
(as contro+ 1, +ig(ting a .i+ot +ig(t on t(e "ac(ine drive station contro+ .ane+3
T(e varia1+e fre/uenc, ?;&@ unit a+so sets t(e ;& contro+ signa+ circuits to acce.t
Nog for*ard and Nog reverse signa+s fro" t(e "ac(ine drive station contro+ .ane+3
T(e s.eed of t(e "ac(ine is contro++ed 1, a .reset s.eed signa+ in t(e varia1+e
2436627773doc
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fre/uenc, unit3 <(en t(e "ac(ine drive station o.erator (as co".+eted (is
"aintenance tasB5 (e ca++s t(e DC% o.erator and infor"s (i"5 and t(en turns t(e
se+ector s*itc( to t(e DC% contro+ .osition3
<(en t(e se+ector s*itc( is s*itc(ed to DC% contro+5 t(e varia1+e fre/uenc, unit
resets t(e s.eed signa+ circuits and contro+ circuits to receive t(e DC% signa+s3
231632 Pa++et %ag $easure"ent
23163231 T(e .a++et sag "easure"ent is recorded as it .asses t(e %ag $onitor +aser
distance detector3 T(e sag "easure"ent is recorded in t(e Indurating $ac(ine
P9C and is ta1u+ated for eac( of t(e res.ective .a++et .ositions3 T(e data is
avai+a1+e on t(e +oca+ Touc(screen #nit3 %agging .a++ets are disasse"1+ed3 T(e
center casting is reversed3 T(e .a++et is t(en reasse"1+ed3
T(e o.erator "ust .eriodica++, re.+ace .a++ets t(at (ave defor"ed 1e,ond design
+i"its3
2316 Mood %ea+ &+o*
231631 T(e (ood sea+ f+o* is auto"atica++, contro++ed *it( t(e fan in+et da".er3
T(ere is a cross tie to t(e co"1ustion air fans *it( crossover da".ers ?8=4812@3
T(ese da".ers on+, o.en *(en t(e co"1ustion air 1+o*ers fai+3 Nor"a++, t(ese
da".ers are c+osed3
T(e da".ers o.en to Bee. air going to t(e 1urners *(en t(ere is a co"1ustion
air fai+ure3
Mood sea+ f+o* contro+ is designed to Bee. a +o* differentia+ .ressure 1et*een t(e
(ood sea+ .ressure ?PT)0=80601@ and t(e furnace .ressure ?PT)0=80610@3
Mood %ea+ &an f+o* contro++er ?&IC)0=8611@ is +i"ited to 30F "ini"u" to
"aintain t(e sea+ under a++ conditions3 &or added .rotection5 t(e (ood sea+ fan
(as e"ergenc, .o*er avai+a1+e3
330 CONTRO9 %:%T!$ O;!R;I!<
331 T(e contro+ s,ste" s(a++ consist of a distri1uted contro+ s,ste" ?DC%@ *(ic(
interfaces *it( ana+og and discrete fie+d signa+s3 It is referred to generica++, as a
DC% 1ut "a, in fact a+so incor.orate andAor interface one or "ore .rogra""a1+e
+ogic contro++er ?P9C@ s,ste"s for discrete +ogic functions and contro+ of t(ird .art,
e/ui."ent3
T(ere is a +inB fro" t(e DC% to eac( $CC for "otor contro+3
33131 T(e contro+ s,ste" s(a++ 1e .rogra""ed to "onitor andAor contro+ a++ e/ui."ent
associated *it( t(e .e++eti>ing .+ant5 fro" t(e DC% Mu"an $ac(ine Interface
?M$I@ or +oca+ contro+ stations3
33132 ;endor .acBages are interfaced to t(e DC%3
332 Contro+ %,ste" Configuration
33231 T(e .rocess contro+ and auto"ation for t(e .e++et .+ant5 feed .re.aration and
.roduct +oadout areas is a DC% s,ste"3 T(e o.erator functions at eac( M$I
station *i++ inc+ude a+ar" (and+ing and contro++er "ani.u+ation5 i3e3 set.oint
c(ange and "anua+ contro+3
2436627773doc
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33232 Printed docu"ents avai+a1+e at o.erator co""and *i++ inc+ude o.erating re.orts
and a+ar" +ogs3 T(e for"at of t(e re.orts is configura1+e and set during design
configuration of t(e DC% s,ste"3 -+ar" re.orting .rints out a +ist of t(e a+ar"s5
inc+uding t(e date and ti"e of t(e a+ar"5 t(e a+ar" descri.tion5 t(e ti"e t(e a+ar"
*as acBno*+edged and t(e ti"e at *(ic( t(e a+ar" c+eared3 - .rintout of t(e
contro++er configurations and co.ies of t(e .rocess screens can 1e "ade via t(e
co+or gra.(ics .rinter3 M$I is in %I units of "easure3
33233 -na+og in.uts into t(e DC% s,ste" are .rovided 1, fie+d instru"entation5
inc+uding s"art trans"itters for re+a,ing f+o*5 .ressure and te".erature signa+s
fro" t(e .rocess3 -+ternate+,5 devices +iBe "otor contro+ centers5 *eig( s,ste"s5
1in +eve+ s,ste"s5 t(ird).art, contro+ s,ste"s and varia1+e s.eed drives (ave t(e
ca.a1i+it, to co""unicate direct+, to t(e .+ant contro+ s,ste"5 "ini"i>ing *iring
and faci+itating startu.3 <(erever .ossi1+e5 OPC can 1e used to reduce CP#
+oading of DC%3
33234 Contro+ Roo" and Process Contro+
T(e .rocess contro+ and auto"ation for t(e .e++et .+ant and feed .re.aration
areas are a co"1ined s,ste"5 .+aced into a centra+ contro+ roo"3 Progra""a1+e
+ogic contro++ers ?P9Cs@ for "otor contro+ *i++ 1e integrated *it( a distri1uted
contro+ s,ste" ?DC%@ for .rocess contro+ and (u"anA"ac(ine interface ?M$I@3
T(e centra+ contro+ roo" is +ocated in t(e sa"e 1ui+ding as t(e indurating area
office faci+ities3
333 CONTRO9 PMI9O%OPM:
2 33331 T(e contro+ .(i+oso.(, fo++o*s t(e contro+ .(i+oso.(, of e4isting P+ant 13
33332 %creens s(o*ing inter+ocBs and .er"issives s(ou+d 1e .rovided for e/ui."ent as
re/uired to a++o* t(e o.erator to trou1+es(oot ite"s not satisfied3
33333 DC% set.oints are s*itc(ed fro" interna+ to e4terna+ o.eration as needed3 <(en
an e4terna+ set.oint is entered5 t(e s,ste" *i++ ignore t(e va+ue ca+cu+ated 1, t(e
contro+ a+gorit("3 T(ese "odes can 1e referred to as C-9C#9-T!D %P and
OP!R-TOR %P3 Transfer 1et*een "odes s(ou+d 1e 1u".+ess3
333 $otors5 Drives and ;a+ves'
2
3333131 T(e "otor contro+ .(i+oso.(, is 1ased on t(e referenced "otor contro+
sc(e"atics' R)00)1003 t(roug( R)00)10063 &or 9T "otors run co""and *i++ 1e
sing+e "aintained out.ut 1ut for MT "otors run co""and *i++ 1e a .u+se on+,3
3333132 - s*itc( at t(e "otor s(a++ 1e a1+e to se+ect Vre"oteC5 *(ic( ena1+es t(e DC%
soft*are to o.erate t(e "otor5 or V+oca+C *(ic( ena1+es t(e "otor to 1e started in
t(e fie+d 1, a .us(1utton3 9oca+ARe"ote se+ector s*itc( to 1e .rovided3 Off
.osition is not envisaged 3
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3333133 On a sto..age due to a "otor fau+t5 t(e e/ui."ent "ust 1e .ut into M$I "anua+
and sto. se+ected to c+ear t(e fau+t 1efore a restart can 1e initiated3 ?Reset P8 is
genera++, .rovided on t(e "otor face.+ate to reset fau+ts @
3333134 T(e +oca+ VstartC 1utton5 *(en .er"itted5 s(a++ run t(e "otor3 In case of
co""unication fai+ure5 start is in(i1ited3
333313= %afet, regu+ations re/uire t(at an, e"ergenc, sto. 1utton5 safet, .u++)ro.e5 or
ot(er si"i+ar device *i++ 1e (ard*ired direct+, to t(e "otor contro+ center ?$CC@
circuit5 so as to 1e a1+e to sto. t(e drive regard+ess of t(e o.erating conditions or
"ode3
333313631 T(e starter s(a++ re.ort 1acB to t(e DC% t(e "otor status avai+a1+e via soft*are
co""unications3
$ore co".+e4 drives "a, re.ort 1acB additiona+ status data as re/uired3
3333136 Dra*ings R)00)1003 t(roug( R)00)1006 detai+ t(e various t,.es of "otor contro+3
DC% soft*are s(a++ inc+ude a++ functiona+it, descri1ed for t(e various "otor t,.es3
33332 T(e M$I screen s(a++ dis.+a, one or "ore of t(e fo++o*ing Vo.eratorsC for individua+
"otors'
3333231 V-utoAOffA$anC s*itc(I VautoC signifies auto"atic "ode and *(en se+ected t(e
"otor res.onds to +ogica+ co""ands to run or starts as .art of a grou.)startI
V"anC indicates "anua+ "ode and t(e "otor can 1e contro++ed 1, t(e individua+
M$I V.us(1uttonsC
<(en a grou. of drives (ave 1een grou.)started in VautoC5 turning an, .articu+ar
drive in t(at grou. to V"anC *i++ not sto. t(at drive5 1ut *i++ on+, give t(e o.erator
access to sto. or restart t(at drive individua++,3
Mo*ever5 if t(at drive is inter+ocBed *it( ot(er drives ?usua++, to .revent t(e
u.strea" e/ui."ent fro" continuing to feed t(e sto..ed ite"@5 t(e inter+ocB *i++
sti++ 1e active5 and sto. t(e ot(er e/ui."ent u.strea"3
2 <(en in VautoC5 t(ere are t*o *a,s to sto. a grou. of drives ?usua++, conve,ors@3
!it(er or 1ot( of t(ese Vsto..ing "odesC can 1e .rogra""ed5 de.ending on t(e
situation3 VProgra""ed sto.C5 used to s(ut do*n a grou. of "ateria+ feeding
e/ui."ent in an order+, fas(ion and +eaving it e".t,3
In t(is "ode5 Vgrou. sto.C *i++ first s(ut do*n t(e feed to t(e first ite" in t(e grou.I
t(en *ait unti+ t(e ne4t ite" runs e".t,5 and sto. itI and so on do*n t(e +ine unti+
t(e entire grou. is sto..ed and +eft e".t,3 VI""ediate sto.C5 used to instant+, sto.
"ateria+ de+iver, fro" t(e grou.3 In t(is "ode5 Vgrou. sto.C *i++ sto. a++ t(e ite"s in
t(e grou. si"u+taneous+,5 1ut +eaving t(e conve,ors in t(e grou. fu++ of "ateria+3
In t(is case5 t(e ne4t Vgrou. startC *i++ restart a++ t(e ite"s rig(t a*a, ?or as /uicB+,
as starting .o*er +oading *i++ a++o*@3 T(is "ode "ust 1e se+ected *it( care5 1eing
sure t(at a++ t(e "ateria+ (and+ing ite"s in t(e grou. are a1+e to restart under fu++
+oad3 I""ediate sto. can 1e o.erated 1ut i""ediate start "ode is not
reco""ended e4ce.t for e"ergenc,3
3333232 V%tartA%to.C DC% .us(1uttons or t(eir gra.(ic e/uiva+ent5 are used to o.erate t(e
"otor in t(e VDC%)"anC "ode3
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334 -uto"ated On)Off ;a+ves
33431 In genera+5 a++ auto"ated on)off contro+ va+ves are s(o*n sc(e"atica++, on t(e
M$I screens and e4ce.t *(ere e4.+icit+, noted *i++ 1ring u. a dis.+a, *(en
se+ected a++o*ing t(e o.erator to "anua++, contro+ t(e va+ve .osition3 2enera++,
"anua+ contro+ 1,.asses an, inter+ocBs3
33432 If feed1acB fro" .osition s*itc(es is avai+a1+e5 t(e va+ve .osition is indicated on
t(e gra.(ic 1ased on s*itc( status3 - va+ve .osition fau+t s(ou+d 1e generated if
t(e va+ve does not res.ond in a reasona1+e ti"e to a co""and to "ove or +oses
.osition feed1acB3
33433 If .osition feed1acB is not avai+a1+e5 t(e va+ve gra.(ic *i++ c(ange status 1ased
so+e+, on t(e out.ut +ogic state3
33434 %o"e va+ves re/uire a sing+e out.ut *(i+e ot(ers *i++ (ave t*o out.uts3 %o"e
va+ves *i++ re/uire an energi>ed out.ut to o.en5 so"e de)energi>ed3 T(e s.ecific
+ogic 1+ocBs for eac( t,.e of va+ve s(ou+d 1e deve+o.ed and a..+ied consistent+,3
3343= Regard+ess of t(e +ogic re/uired to o.erate a va+ve5 t(e M$I gra.(ic convention
and functiona+it, s(ou+d 1e consistent t(roug(out a++ screens3
33436 <(en -#TO "ode is se+ected t(e va+ve res.onds on+, to contro+ s,ste" +ogic3 In
cases *(ere t(e +ogic +atc(es t(e va+ve in .osition and an action is re/uired 1,
t(e o.erator to reset it5 .+acing t(e va+ve in $-N#-9 and se+ecting c+ose or o.en
can 1e one *a, to .rovide t(e +ogic reset3
33436 T(e a1ove sections a+so a..+, to s(utoff da".ers5 gates5 and vent doors
contro++ed 1, t(e DC%3
33= Process Pu".s
33=31 T(ese are .u".s *(ic( (and+e s+urr, or .rocess *ater in t(e s,ste"5 not su".
.u".s3
33=3131 -++ .rocess .u".s (ave t(e fo++o*ing +ogica+ attri1utes'
Pu".s are nor"a++, started fro" t(e M$I screen "anua++, as re/uiredI un+ess
ot(er*ise indicated 1e+o*5 .u".s are not .art of Ve/ui."ent starting grou.sC5 1ut
are started individua++, a(ead of ti"e as re/uired5 and nor"a++, +eft on3
-fter t(e .u". is started fro" t(e DC%I and after a ti"e de+a,5 if t(e drive
feed1acB indicates t(at t(e .u". (as 1een sto..ed ot(er t(an 1, t(e o.erator5 a
Vdrive fau+t a+ar"C sounds3
On a sto..age due to a drive fau+t5 t(e e/ui."ent "ust 1e .ut into M$I "anua+
and sto. se+ected to c+ear t(e fau+t 1efore a restart can 1e initiated3 If t(e vesse+5
*(ic( feeds t(e .u".5 reac(es +o*)+o* +eve+ ?1e+o* t(e .oint *(ere t(e +o*)+eve+
a+ar" sounds@5 t(e .u". *i++ s(ut do*n ?or can not 1e started@3
Mig()(ig( +eve+ fro" t(e vesse+ 1eing .u".ed into is not an inter+ocB to t(e
.u".s3 T(e (ig()+eve+ a+ar" in t(at vesse+ on+, *arns t(e o.erator of t(is
i".ending .ossi1i+it,3 !4ce.tions to t(is strateg, are noted on t(e PEIDs3
2436627773doc
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T(e accu"u+ated run ti"e for a++ .rocess and +u1e .u".s s(a++ 1e recorded in t(e
DC% ?and 1e a1+e to 1e dis.+a,ed@5 so t(at t(e o.erator5 if (e (as a c(oice5 ?or t(e
DC% +ogic5 if a1+e to "aBe t(e c(oice@ can start t(e one in an, grou. *it( t(e +east
service5 or .eriodica++, c(ange over to even+, distri1ute t(e *ear3
T(e tota+ accu"u+ated ti"e can 1e reset at t(e DC% screen3
33=32 Process Pu". Pairs *it( -uto"atic 8acBu. %tarts
33=3231 -++ .rocess .u".s in grou.s of t*o ?one nor"a++, o.erating and one stand1,@5
*(ic( .u". c+ear *ater or ot(er non)sett+ing .rocess f+uid *i++ (ave t(e non)
running5 1acBu. .u". tr, to start auto"atica++, if t(e initia++, started .u". (as a
drive fau+t a+ar" as descri1ed a1ove and t(e .u". is se+ected for DC% -#TO3
33=3232 Nor"a++, 1ot( suc( .u".s *i++ 1e va+ved o.en5 and non)return va+ves .rovided so
t(at no 1acBf+o* t(roug( t(e stand1, .u". can occur3
33=3233 %ee Dra*ing R)00)100= Detai+ 4 for Process Pu".s *it( -uto"atic 8acBu.3
33=33 Process Pu". Pairs *it( $anua+ 8acBu. %tarts
33=3331 -++ .rocess s+urr, .u".s in grou.s of t*o ?one nor"a++, o.erating and one
stand1,@5 *i++ (ave t(e non)running5 1acBu. .u". started "anua++, 1, t(e
o.erator on recei.t of a fau+t a+ar"3
33=3332 %+urr, .u". .airs re/uire "anua+ f+us(ing3 <(en a s*itc(over occurs5 t(e
o.erator "ust .ro".t+, attend to t(e va+ving and f+us(ing 1efore t(e s+urr,
re"aining in t(e sto..ed .u". sett+es out3
33=34 Oi+ and 9u1e Pu".s
33=3431 %ee Dra*ing R)00)100= Detai+ 4 for 9u1e Pu".s *it( -uto"atic 8acBu.3
33=3= Reci.rocating Conve,or Contro+
33=3=31 T(e reci.rocating conve,or and *ide 1e+t conve,or are su..+ied 1, $!T%O3 T(e
co".onents consist of a (,drau+ic .o*er unit5 reci.rocating conve,or *it( dua+
(,drau+ic c,+inders5 and *ide1e+t ?843036@3 T(e s,ste" inc+udes a +oca+ contro+
.ane+ used to .erfor" "aintenance as *e++ as s.eed contro+3
Inc+uded *it( t(e reci.rocating conve,or are 1ot( a (,drau+ic .u". and (,drau+ic
f+us(ing "otor drives3
33=3=32 Contro+ signa+s fro" t(e DC% inc+udesI
Inter+ocB)?Per"it to run@
Reci.rocating Run Co""and
2 Position t(e C,+inders Out.ut
Coo+ing &an Run
Meater Run
33=3=33 %tatus In.uts to t(e DC% inc+udeI
&+us( Pu". &i+ter O
Coo+ing <ater &i+ter O
2436627773doc
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$ain Pu". &i+ter O
33=3=34 9oca+ $aintenance In.uts to DC% fro" $onnet 9oca+ Pane+ inc+udeI
C,+inder &or*ard
C,+inder Reverse
C,+inder %to.
<ide 8e+t Run5 %to.
Pu".s %tart5 %to.
Re"ote5 $aintenance %*itc(
Reci.rocating Conve,or %tart 5 %to.
C,+inder %.eed %etting ?4)20 "-@
<ide 8e+t %.eed %etting ?4)20 "-@
Reci.rocating Conve,or %.eed %etting ? 4)20 "-@
33=3=3= %tart %e/uence'
%tart Dou1+e DecB Ro++er %creen ? 843036!5 843036& @
%tart <ide 8e+t ? $ac(ine is Running @
-ctive Morn = seconds
%tart M,drau+ic Pu".s
%tart Reci.rocating 8e+t and .rove at desired s.eed
%tart Reci.rocating C,+inder o.eration at desired s.eed3
-++o* -+ar"s to "onitor s.eed s*itc( and ot(er a+ar" actions3
2 33=3=36 Reci.rocating C,+inder O.eration'
T(e out.ut of t(e DC% Reci.rocating C,+inder contro++er is vendor defined3
T(e ti"e for t(e c,c+e is adNusted to "eet t(e reci.rocating conve,or s.eed3
T(e "a4i"u" reci.rocating ti"e *i++ e/ua+ t(e "a4i"u" reci.rocating
conve,or s.eed3

33=36 %u". Pu".s
33=3631 T(ese are .u".s *(ic( co++ect surface runoffs or ot(er "inor *aste +i/uids or
s+urries and are contro++ed as fo++o*s'
33=3632 - +eve+ s*itc( *it( a *ide 1and 1et*een Joff at +o* +eve+K and Jon at (ig( +eve+K is
connected to t(e .u". starter t(roug( t(e DC%3
T(is o.erates t(e .u". as re/uired5 *it(out an, intervention fro" t(e o.erator3
If t(is s*itc( indicates Vrun t(e su". .u".C and t(e .u". does not co"e on after
a ti"e5 a fau+t a+ar" is indicated on t(e M$I3
No +eve+ indication or a+ar"s ot(er t(an t(e a1ove are re/uired in t(e DC%3
33=36 Pu". %ea+ %,ste"
33=3631 !ac( .rocess s+urr, .u".s or dust co++ection s+urr, .u".s in -rea 1 5(as *ater
sea+s5 contro++ed as fo++o*s'
T(ere is a f+o* s*itc( in eac( sea+ *ater su..+,3 If t(e f+o* s*itc( does not
register "ini"u" f+o*5 an a+ar" is set3
T(is +o* f+o* a+ar" does not s(ut do*n t(e .u".5 1ut s(ou+d 1e .ro".t+,
attended to 1, t(e o.erator3
2436627773doc
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336 Conve,or %,ste"s
33631 %tandard %ing+e %.eed Conve,ors

3363131 %ing+e s.eed conve,ors are s(o*n on $otor Detai+ 1 on R)00)10033
3363132 2enera+ 9ogic &or Conve,ors
Conve,ors can 1e o.erated in -uto"atic or $anua+ "odes3
Conve,or o.eration is conditiona+ 1ased on t(e status of t(e start .er"issives and
run inter+ocBs3
Conve,or statuses ?Read,5 running5 etc3@ and a+ar"s ?>ero)s.eed5 1e+t side trave+5
fau+t5 .+ugged c(ute5 !)sto.@ are indicated on t(e M$I3
-++ side trave+ s*itc(es for a conve,or are *ired in series as a sing+e in.ut to t(e
contro+ s,ste"3
!)sto.s are (ard*ired into t(e "otor contro+ circuit *it( a .ara++e+ contact in.ut to
t(e contro+ s,ste" for "onitoring3
!ac( conve,or in a U2RO#PU is inter+ocBed to t(e conve,or .receding it3 Prior to
conve,or starting a *arning (orn is sounded3
Conve,or 2P)2 ?8==016@ @ and 2P)4 ?843036@ are varia1+e s.eed conve,orsI
(o*ever5 t(e s.eed is adNusted +oca++, to give .ro.er 1ed de.t(3 8ecause t(e
s.eed of 2P)2 and 2P)4 are adNusted "anua++,5 fro" a contro+ s,ste"
stand.oint5 t(eir o.eration is t(e sa"e as a standard conve,or3
On a sto..age due to a drive fau+t5 t(e e/ui."ent "ust 1e .ut into M$I "anua+
and sto. se+ected to c+ear t(e fau+t 1efore a restart can 1e initiated3
3363133 -uto"atic $ode
) <(en its +oca+ t(ree ?3@ .osition se+ector s*itc( is in t(e UR!$OT!U .osition5 eac(
conve,or is o.erated via t(e M$I3 Conve,ors are grou. started 1, c+icBing on t(e
U2RO#P %T-RTU co""and on t(e M$I and grou. sto..ed 1, .ressing t(e
U2RO#P %TOPU co""and on t(e M$I3
) &or eac( grou.5 it is desira1+e to (ave so"e eas, *a, to Bno* t(at a++ "e"1ers
of an, grou. are read,5 signified 1, a++ starters V$CC read,C5 a++ turned to VautoC5
and a++ individua+ inter+ocBs satisfied5 and t(at an, ot(er grou.s or ite"s *(ic(
need to 1e running as a .recondition are in fact running3 T(ere are severa+ *a,s
to do t(is5 de.ending on t(e M$I design3 One *a, is to (ave a++ t(e o1Nects in a
grou. s(o* u. on a sing+e overvie* gra.(ic fro" *(ic( t(e Vgrou.C co""ands
are given3 %uc( a gra.(ic cou+d 1e designed so t(at it s(o*s a unifor" +ooBing
Vgreen)1oardC *(en ever,t(ing is read, or5 converse+,5 (ig(+ig(ts an, unfu+fi++ed
.recondition in so"e visua++, o1vious "anner3 -not(er a..roac( is to (ave a .o.)
2436627773doc
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u. +ist of a++ t(e grou.Cs .reconditions5 (ig(+ig(ting an, .recondition not "ade in a
distinctive co+or3
) %ervice ite"s +iBe +u1e s,ste"s5 .u".s35 etc3 *(ic( serve ite"s in an, grou. are
not .art of t(e se/uence)start order5 T(e, s(ou+d 1e started u. a(ead of ti"e5 and
1e running and read, to *orB 1efore t(e grou. is started3 <(ere a..ro.riate5 a
read, status *it( no critica+ a+ar" "a, 1e a +ogica+ /ua+ification to .er"it t(e
grou. to start3
3363134 !/ui."ent %tartsA%to.s3 O.erator *i++ start t(e s,ste" fro" t(e +ast conve,or5
1acB*ards t(roug( to t(e feed e/ui."ent3
%ee O.erating $anua+ for detai+s3
33632 <arning Morn %,ste"
3363231 Prior to t(e start of an, conve,or5 or an, ot(er "ac(iner, suc( as a screen t(at
can endanger .ersonne+ 1, sudden+, starting to "ove5 a *arning (orn or (orns
s(a++ sound for a .redeter"ined ti"e3
Morns are not necessari+, assigned to eac( individua+ .iece of "ac(iner,5 1ut
rat(er to areas of t(e .+ant suc( t(at t(e entire area near ever, .iece of
"ac(iner,5 or grou.s of "ac(iner, *(ic( "a, 1e started toget(er5 are covered 1,
t(e *arning sound3
T(erefore5 (orns are not driven direct+, 1, starter contacts in eac( drive5 1ut 1,
t(e DC%3 It is t(e res.onsi1i+it, of t(e detai+ engineering designer to +a, out t(e
(orns and assign t(e" to various devices or grou.s to insure .ro.er coverage3
T(e Indurating $ac(ine does not (ave a *arning (orn 1efore starting3
De.ending on t(e "ode of starting5 t(e (orn +ogic is as fo++o*s'
<(en an individua+ drive is co""anded to start fro" an i"age on t(e M$I5 t(e
associated (orn ?or (orns in t(e case of a +ong conve,or@ s(a++ 1+o* for a .eriod5
1efore t(e drive VrunC co""and is sent fro" t(e DC% to t(e $CC3
<(en a grou. is started fro" t(e M$I5 a++ t(e (orns covering t(e grou.Cs area
s(a++ 1+o* for a ti"e5 t(en t(e co".onents of t(e grou. s(a++ se/uentia++, start in
t(eir nor"a+ order3
It is not necessar, for eac( .iece in t(e grou. to (ave its o*n (orn 1+o* de+a,5
un+ess t(e start se/uence is interru.ted3
<(en an ite" is started fro" t(e fie+d in V+oca+C "ode5 t(ere is no *a, t(at t(e
DC% can Bno* t(at a (orn 1+o* is needed3 T(erefore5 a V*arning (ornC
.us(1utton5 connected to t(e DC% is .rovided at t(e +oca+ station for a++ suc(
e/ui."ent3
T(e +oca+ o.erator (as to 1+o* t(e (orn "anua++, 1efore starting t(e e/ui."ent3
430 PO99#TION CONTRO9
431 T(e .e++et .+ant *i++ convert (ig( grade iron ore into (eat (ardened .e++ets3 T(e
.rocess ste.s in t(e core .+ant *i++ consist of receiving iron ore5 Iron ore *et
2436627773doc
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Document Title# !rror' Reference source not found Pa+e 2$ o1 23
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grinding5 .re.aration of additives5 1+ending and "i4ing of ra* "ateria+s into a
.e++eti>ing "i45 green .e++et for"ation5 (eat (ardening of t(e .e++ets5 and
conve,ing of t(e fina+ .e++et .roduct3 Ra* "ateria+s *i++ inc+ude .redo"inant+,
iron ore *it( t(e fo++o*ing additives' coBeAcoa+5 1entonite5 organic 1inder and
+i"estone3 -dditives are "i4ed *it( t(e concentrate to faci+itate t(e .rocess and
to inf+uence t(e .roduct /ua+it,3 T(e 1urner fue+ for .e++eti>ing is fue+ oi+ or fue+
gas3 CoBeAcoa+ in t(e 1+end of .e++eti>ing feed *i++ su..+, a1out 2=F to 4=F of
t(e tota+ Indurating fue+ to t(e .rocess3
432 T(e .+ant is designed *it( e+ectrostatic .reci.itators ?!%Ps@ to re"ove .articu+ate
fro" t(e gas disc(arge'
43231 Mood !4(aust !%P ?8=002=@
T(is !%P is e/ui..ed *it( a Transfor"er and Ra..er contro+ .ane+3 T(e !%P
%ea+ -ir &ans ?8=002=$15$2@ are contro++ed and "onitored +oca++,3
Dou1+e Du". ;a+ves re"ove dust to drag conve,ors and feed t(e Mood !4(aust
%u". ?843134@3
43232 <ind1o4 !4(aust !%P ?8=0026@
T(is !%P is e/ui..ed *it( a Transfor"er and Ra..er contro+ .ane+3 T(e !%P
%ea+ -ir &ans ?8=0026$15253@ are contro++ed and "onitored +oca++,3
Dou1+e Du". ;a+ves re"ove dust to drag conve,ors and feed t(e <ind1o4
!4(aust %u". ?836006@
433 %+urr, su". .u".s disc(arge to t(e .+ant t(icBener3
434 MouseBee.ing scru11ers and a 1ag(ouse are used to co++ect fugitive dust'
43= %cru11ers
43=31 $ac(ine Disc(arge %cru11er ?8=000=@
T(is scru11er inc+udes a $ac(ine Disc(arge %cru11er &an5 and +oca+ *ater
s.ra,s3 T(e *ater va+ve ?G;)0686262@ *i++ o.en an, ti"e t(at t(e scru11er is in
o.eration3
43=32 Meart( 9a,er 8in %cru11er ?8=0006@
T(is scru11er inc+udes Meart( 9a,er !4(aust &an5 and +oca+ *ater s.ra,s 3 T(e
*ater va+ve ?G;)0686262@ *i++ o.en an, ti"e t(at t(e scru11er is in o.eration3

436 %i"i+ar to t(e !%Ps5 t(e *et disc(arge fro" t(ese scru11ers is co++ected in su".s
and .u".ed to t(e .+ant t(icBener3 T(e 1ag(ouse dust is s+urried and .u".ed to
t(e t(icBener3
436 Product %creening 8ag(ouse ?8=0006@ inc+udes a fan ?8=0006-@ and dust
(and+ing va+ves ? G;) 2626) 2626@3
438 2aseous !"issions
43831 Products of co"1ustion are disc(arged fro" t(e indurating *aste gas stacB3 T(e
indurating *aste gas stacB *i++ a+so contain CO2 ?car1on dio4ide@ resu+ting fro"
t(e ca+cination of car1onates in t(e additives or t(e ore and %O4 ?su+fur dio4ide@
2436627773doc
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fro" co"1ustion of t(e su+fur)containing co".ounds in t(e fue+3 Ot(er
co".ounds in t(e f+ue gases *i++ inc+ude +o* concentration nitrous o4ides5 car1on
"ono4ide5 and vo+ati+e organic co".ounds5 as *e++ as car1on dio4ide5 *ater
va.or5 nitrogen5 and o4,gen3 Jaco1sC sco.e of t(e .roNect does not inc+ude an,
a1ate"ent s,ste"s for gaseous e"issions3 Restrictions on t(e +eve+ of su+fur in
t(e fue+ and t(e (eig(t of t(e e4(aust stacBs "ust 1e deter"ined after .erfor"ing
at"os.(eric dis.ersion "ode+ing3
T(e dis.ersion "ode+ing is a+so not inc+uded in Jaco1sC sco.e3
=30 %!R;IC! %:%T!$%
=31 &i+ter .ress air co".ressors and dr,ers are su..+ied 1, &i+ter Press ;endor3
=32 Co".ressed P+ant air for genera+ .e++et .+ant use is su..+ied at 630 BgAc"2 3 P+ant
-ir is dried in Refrigerant Dr,ers ?8=2404)152@ to = degree C3
=33 Dr,5 oi+)free instru"ent air *i++ a+so 1e su..+ied at a .ressure of 730 BgAc"2 1, a
dedicated instru"ent air co".ressor and receiver s,ste"3 T(e air is treated and
dried at t(e Instru"ent -ir Dr,ers ?8460=1)152@ to )40 degree C3
=34 $aBe)u. <ater is .rovided 1, J%P9 to t(e T(icBener Overf+o* %u".3
=3= %tand1, Po*er is .rovided 1, t(e stand1, generator3
=36 Oi+ %u..+, to t(e Indurating furnace and -dditive 2rinders5 is fro" t(e fue+ oi+
tanBs3 Oi+ co".osition is given 1e+o*'
=3631 &ue+ Oi+ Pro.erties
Ta&le 5#4#1 Fuel Oil Composition
&urnace Oi+5 $;2
Co".osition5 *t3F
Ta&le 5#4#$ Fuel Oil Properties
C(aracteristics
1
2rade $;2 Re/uire"ents
Inorganic acidit, Ni+
-s(5 F *t3 $a4 031
2ross Ca+orific ;a+ue5 ca+Ag" 105000
Densit, at 1=TC -ssu"e 037=
&+as( Point TC3 $in 66
ine"atic ;iscosit,5 centistoBes W =0TC 12= ) 180
%edi"ent5 F *t 5 $a4 032=
%u+fur5 tota+ F *t3 $a4 430
<ater content5 F vAv5 $a4 130
Pour Point5 TC5 $a4 26
2436627773doc
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=36 Process <ater
=3631 Process <ater %u..+,
=363131 Process *ater to users is fro" t(e Process <ater Pu".s at t(e T(icBener
Overf+o*3
T(e Process <ater Pu".s (ave t*o .u".s o.erating and one .u". as 1acBu.3
T(e .+ant *ater 1a+ance is "aintained 1, eit(er "aBeu.5 or 1+o*do*n to 1atter,
+i"its5 fro" t(e T(icBener Overf+o* %u".3
=38 %oft <ater %u..+,
=3831 %oft *ater at 33= BgAc"2 is su..+ied 1, J%P9 for "isce++aneous users suc( as
+inte+ coo+ing "aBeu. *ater3
=37 2+and %ea+ <ater
=3731 Pu".s in t(e .+ant t(at (and+e (eav, iron ore s+urries (ave f+us(ed "ec(anica+
sea+s3 %ea+ *ater su..+, s,ste" for *et grinding inc+udes a 2+and %ea+ <ater
TanB ?834031@ and .u".s ?841034)152@ .roducing *ater at 630 BgAc"2 or
.ressure deter"ined 1, t(e su..+ier3 %ea+ *ater su..+, s,ste" for ot(er areas
inc+udes a 2+and %ea+ <ater TanB ?834030@ and .u".s ?841033)152@
=310 Pota1+e *ater for .+ant offices and associated areas is su..+ied 1, J%P93
=311 &ire .rotection *ater is su..+ied fro" J%P9Cs fire *ater su..+, s,ste"3 - se.arate
(eader s,ste" fro" t(e fire *ater su..+, is .rovided de.ending on t(e a..rova+
of +oca+ regu+ator, agencies3 Nor"a+ fire *ater +oo. .ressure is 630 BgAc"23
=312 &ue+ 2as
=31231 2as is avai+a1+e to t(e 1urners3 T(e 1urner s,ste" is se+ected for use on fue+ oi+
or fue+ gas 1ut not 1ot( at t(e sa"e ti"e3 %afet, s(utoff va+ves are connected to
t(e a..ro.riate 1urner "anage"ent s,ste"3 &ue+ gas is for use on+, *it( t(e
Indurating %,ste"3
=31232 &#!9 2-% PROP!RTI!% ?To 1e confir"ed 1, J%P9@
Ta&le 5#4#2 FUEL 9AS POPETIES
Compound Unit Value
CO %
Volume
25
CO
2
% Volume 6
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Ta&le 5#4#2 FUEL 9AS POPETIES
Compound Unit Value
M
2
% Volume 13
CM
4
% Volume 1.5
N
2
% Volume 53
C
2
M
% Volume 0
O
2
% Volume 0.6
M
2
%
% Volume 0.2
M
2
O $a4
% Volume 5
Dust "gAN"
3
5
Pressure BgAc"
2
0.97 minimum at
burner valve stand
Te".erature TC 50 a!imum
Meating ;a+ue Bca+AN"
3
1350 minimum
=31233 &ue+ gas .ressure and c+eanu. are 1, J%P93
T(e fue+ gas *i++ initia++, 1e at a +o*er C; va+ue ?13=0 Bca+AN"
3
@ 5 *it( future Cv
va+ue ?22=0 Bca+AN"
3
@3
=313 Coo+ing <ater
=31331 <et 2rinding Coo+ing <ater is su..+ied 1, coo+ing *ater .u".s ?841060@3 T(e coo+ing
*ater return goes to a coo+ing to*er *it( varia1+e s.eed fans3 $aBeu. *ater is su..+ied
1, J%P93
=31332 Coo+ing <ater is su..+ied 1, coo+ing *ater .u".s3 T(e coo+ing *ater return goes to a
coo+ing to*er *it( varia1+e s.eed fans3 $aBeu. *ater is su..+ied 1, J%P93 - c+osed +oo.
s,ste" for service *ater is used in area 1 as *e++ as in area 2 to 83
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