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Training Manual Green Anode Plant

Vedanta - Jharsuguda

138-02-043
Group 431/432 F
DE-060300

13

PROCESS GROUP 431/432 F - BALL MILL SYSTEM-

13
13.1
13.1.1
13.1.2
13.1.3
13.2
13.2.1
13.2.2
13.3
13.3.1
13.3.2
13.3.3
13.3.4
13.3.5
13.3.6
13.3.7
13.3.8
13.3.9
13.3.10

Process Group 431/432 F - Ball Mill System-..............................................................................1


Process .......................................................................................................................................1
Process Flow Sheets...................................................................................................................1
Brief Process Description ............................................................................................................2
Main Process Data & Process Highlights ....................................................................................3
Process Control.........................................................................................................................10
P&Id`s, Operator Screen Images ..............................................................................................10
Control Logic Description ..........................................................................................................11
Main Equipment ........................................................................................................................12
Belt Weigh Feeder 431/432 F 010 ............................................................................................12
Double Pendulum Flap 431/432 F 025......................................................................................12
Ball Mill 431/432 F 100..............................................................................................................12
Dynamic Classifier 431/432 F 210 ............................................................................................12
Cyclone 431/432 F 215 .............................................................................................................12
Throttle Flap (motorized) 431/432 F 240 ...................................................................................12
Circulation Fan 431/432 F 245 ..................................................................................................12
Drum-Type Magnetic Separator 431/432 F 265 ........................................................................12
Impact Flow Meter 431/432 F 275.............................................................................................12
Automatic Sampler (pneumatic) 431/432 F 310 ........................................................................12

13.1

Process

13.1.1

Process Flow Sheets


(Work Copy)

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Training Manual Green Anode Plant


Vedanta - Jharsuguda
13.1.2

138-02-043
Group 431/432 F
DE-060300

Brief Process Description


(Work Copy)

Outokumpu Technology GmbH


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CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070

1 (2)

Rev. 00

Brief Process Description


of
Process Group 431-F
- Ball Mill System Reference:
Process Flow Sheet

132-01-082 UB

P+I Diagrams

168-01-062 UB, sheets 1-3

The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This Process Group is required to produce a very fine petroleum coke fraction (grain size 003mm with max. 75% <0.074mm) called Ball Mill Fraction which is used as filler material of
the dry mix to be blend in Group 431 H. This very fine material is ground by a ball mill (431 F
100) of the air-swepped type working in a closed conveying air circuit.
The feed material is continuously withdrawn from the storage bin (431 A 320) by means of
belt-weigh-feeder (431 F 010). The flat slide gate (431 F 005) under the storage bin is always
open except if maintenance has to be done on the weigh-feeder underneath.
The material is continuously fed to the ball mill passing a reversing flap (431 F 015), a screw
conveyor (431 F 022) and a double-pendulum flap (431 F 025). The double pendulum flap is
required because the ball mill air circuit and thus the ball mill are working under negative
pressure. If the weigh-feeder has to be calibrated, the material can be directed into a bulker
bag by manually tilting the reversing flap (431 F 015) for a certain time and weighing the bag
later on a platform scale (431 H 096).
In the ball mill (431 F 100) the feed material is ground by steel balls while the coke is slowly
passing the ball mill tube. The mill is capable to achieve a product grain size of about 0-2mm
containing a large portion of 0- 0.074mm size (- 200 mesh).
The circulating air flow, generated by a fan (431 F 245), is passing the mill tube and carries the
ground material via a vertical duct into the airflow classifier (431 F 210) where oversized
material (> 0.3mm) is separated, which is recycled to the ball mill and via rotary lock (431 F
260) and impact flow meter (431 F 275).
A drum magnet (431 F 265) with permanent magnet is removing fine ground iron (abration
loss of the grinding balls) and also small iron particles coming with the raw material, coke.
The air flow classifier is equipped with a number of adjustable baffles, concentrically located
around a motor driven cage wheel. Both baffles and cage wheel are making the air flow
rotating so that coarse particles are separated at the inner wall and in the separator center by
centrifugal force while the finer product is leaving the classifier through the top outlet. The
cutpoint of the classifier is adjustable by a variable speed drive for the cage wheel and by
adjusting the baffles.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070

2 (2)

Rev. 00

Material of required grain size (0-0.3mm) is transported by air flow to the cyclone (431 F 215)
where the fine ground coke is separated from the carrying air flow. Via a rotary lock (431 F
305) the fine ground material is discharged from the cyclone, is then passing an automatic
sampler (431 F 310) and is finally falling either into the fines bin (431 F 400). If the reversing
flap (431 F 325) is switched to the other way, the material is fed to the screw conveyors (431 F
330 / 335) it is conveyed into the Fresh Adsorbent bin (431 F 450). Between automatic
sampler (431 F 310) and reversing flap (431 F 325) is another reversing flap, for fed the
ground material in the first 10 minutes after starting the Ball Mill System via screw conveyor
(431 F 323) in the Filter Dust Bin (431 C 100). The reason for this procedure is the unsteady
quality of the ground material during the start phase of the ball mill.
The air flow leaving the cyclone (431 F 215) is passing the fan (431 F 245) via a motorized
throttle flap (431 F 240), which is closing before start up of the fan and is then opened to a
preset angle to adjust the flow rate.
The throttle flaps (431 F 250 / 255) downstream the fan are used to split the air flow to be send
through the mill and through the mill bypass duct.
A part of the circulation air is withdrawn by a dust collector fan (431 F 230) via a throttle flap
(431 F 225) and through a dust collector (431 F 220) in order to reduce the dust content in the
circulating air and to keep the circulation air system at negative pressure in order to avoid dust
leaks.
Dust separated by the dust collector (431 F 220) is discharged via a rotary lock (431 F 315)
and a screw conveyor (431 F 320) into either the Ball Mill Fraction bin (431 F 400) or into the
bin for Fresh Adsorbent (431 F 450).
With the ball mill operating, filter dust is continuously reclaimed from the Filter Dust bin (431
C 100) by means of the rotary lock (431 F 055), which is equipped with a variable speed drive
so that the feed rate is adjustable. An aeration unit (431 F 051) installed at the Filter Dust bin
bottom avoids bridging of material in the bin. The filter dust is added to the air flow which is
entering the air flow classifier (431 F 210). Filter Dust is only fed to the system when the Ball
Mill System is producing.
Loaded adsorbent from Group 431 G is continuously discharged from the Loaded Adsorbent
storage bin by means of the rotary lock (431 F 355), which is equipped with a variable speed
drive so that the feed rate is adjustable. An aeration unit (431 F 351) installed at the Loaded
Adsorbent bin bottom avoids bridging of material in the bin. The material is added to the chute
feeding the Ball Mill Fraction bin (431 F 400). Loaded Adsorbent is only then fed to the Ball Mill
Fraction bin as long as the bin is filled with fresh Ball Mill Product and is stopped when the
Fresh Adsorbent bin is filled.
For calibration of the rotary lock for Filter Dust (431 F 055) material is fed via the reversing flap
(431 F 060) into a bulker bag (431 F 285). The bulker bag has to be weighed on a platform
scale (431 H 096). Calibration of the impact flow meter (431 F 275) is via reversing flap (431 F
280). Only during automatic run of the complete Group it is possible to switch the reversing
flap (431 F 280) for a short while to the bulker bag.

Outokumpu Technology GmbH

Training Manual Green Anode Plant


Vedanta - Jharsuguda
13.1.3

138-02-043
Group 431/432 F
DE-060300

Main Process Data & Process Highlights


There are various ball mill systems working in green anode plants.
1) The simplest one, shown in figure 1, is an open system consisting of a ball mill and a
bucket elevator. The mill is continuously fed through the left trunnion bearing and is also
continuously discharged through the right bearing by simply overflowing into a bucket
elevator.

Advantages:
-

Lowest investment cost


Simple to operate
Low maintenance costs

Disadvantages:
-

Relatively large mill because of low specific production rate.


Significant part of fines over-ground (high super fines content)
High specific energy consumption because of over-grinding
Relatively high jamming (overflowing) risk
Product size controlled by feed rate only, not by grain size
Environment problems with dust (ball mill, bucket elevator)

The main disadvantage is uncontrolled over-grinding of fines. Fines, which is produced in


the first third of the grinding path, has particles already acceptable in size. The material is
forced to be transported through the next two thirds of the grinding path of the mill before
it is discharged. It is most likely that already fine grains are milled to finer size as required.
For the process of anode making this requires more pitch because of the larger surface
area.
Over-grinding is in principle due for all overflow ball mills.

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Training Manual Green Anode Plant


Vedanta - Jharsuguda

138-02-043
Group 431/432 F
DE-060300

2) Figure 2 is showing a more advanced closed system with overflow ball mill, bucket
elevator and dynamic classifier. Oversize material is separated by the classifier and
returned to the mill.

Advantages:
-

Relatively low investment cost


Still simple to operate
Good control of product grain size (dynamic classifier and feed rate)
Higher specific production rate as open systems
Lower specific energy consumption as open systems

Disadvantages:
-

Part of fines over-ground (significant uncontrolled super fines content)


Higher maintenance costs (mill, bucket elevator, classifier
High specific energy consumption because of over-grinding
Relatively high jamming (overflowing) risk
Product size controlled by feed rate and re-circulation only, not by grain size
Environmental problems with dust (ball mill, bucket elevator, classifier)

3) Figure 3 is showing an often used closed system with overflow ball mill, static or
dynamic air flow classifier, a dust collector and a fan working as an air lift.

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Training Manual Green Anode Plant


Vedanta - Jharsuguda

138-02-043
Group 431/432 F
DE-060300

Advantages:
-

Still simple to operate


Good control of product grain size (static / dynamic classifier and feed rate)
Higher specific production rate
Lower specific energy consumption

Disadvantages:
-

Relatively high investment cost


Part of fines over-ground (significant uncontrolled super fines content)
Higher maintenance costs (mill, classifier, dust collector, fan)
Environmental problems with dust (ball mill)

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Training Manual Green Anode Plant


Vedanta - Jharsuguda

138-02-043
Group 431/432 F
DE-060300

4) Figure 4 is showing a typical closed air swept system with air swept ball mill, static or
dynamic air flow classifier, circulation fan, cyclone and dust collector / fan unit as installed
at VEDANTA. This is the most advanced ball mill system nowadays. The airflow through
the mill is adjustable. Grain of the desired product size, wherever generated is
immediately carried off the mill body by air stream. There is no over-grinding. Product
fineness below 200mesh can be in a certain range controlled by air velocity in the mill
body.

Advantages:
-

Simple to operate but relatively difficult to adjust


Good control of product grain size (static / dynamic classifier and feed rate)
Highest specific production rate
Lowest specific energy consumption
No over-grinding of mill product because air stream through mill body carries
already ground material continuously out.
No environmental problems with dust because whole system is at under-pressure.

Disadvantages:
Higher investment cost (additional cyclone, fan and air ducts)
Higher maintenance costs (mill, classifier, cyclone, dust collector, two fans, air
flaps)
The process group is designed for a maximum Fines production rate of 12 t/hour.
At worst operating condition (No Butts) the Ball Mill Fraction requirement is 8.9 t/h.
At this worst condition it was assumed that no recycled butts are available so that
petroleum coke has to be used instead
At operating condition Nominal Butts AA the Ball Mill Fraction requirement is 7.9 t/h
only.
-

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Training Manual Green Anode Plant


Vedanta - Jharsuguda

138-02-043
Group 431/432 F
DE-060300

During commissioning VEDANTA operating personnel has to decide at what capacity


and product grain size the mill system should operate. If for instance the capacity shall
be 10.0 t/hour at a product grain size of 75% < 200mesh then the mill body is filled
with the ball charge but not to the maximum of 29% of the mill volume, equal to 36
tons of balls as possible. The first filling would be 70% of 29% = 20.3 % of mill volume
only and then the system is started feeding only 8 t/hour of fresh coke to the mill.
Then samples are taken from the cyclone product and if the product size is too fine,
as expected, the feed rate is increased step by step until the product becomes too
coarse. Now the next charge of balls is added to the mill in the same distribution as
before until 80% of the maximum ball charge is reached followed by similar test runs.
This will be repeated until the required capacity and product size is reached.
From this moment the ball mill system should always be operated at the same feed
rate. If it runs at a significant lower feed rate the fines content increases and if it runs
at a significant higher feed rate the fines content decreases.
If it is decided to run the mill system at a higher capacity but with the same fineness of
the product, more balls have to be added but never more as 29% of the mill volume or
36 tons of balls in total.
Feed material is petroleum coke of 32 46 Hardgrove
A Hardgrove index of 32 is not very likely when running the mill with calcined
petroleum coke only. It is just a design figure for sizing the ball mill. The lower the
index the harder is it to grind and the more grinding energy is required. Calcined
petroleum coke mainly have Hardgrove indexes of 40 and higher.

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138-02-043
Group 431/432 F
DE-060300

Training Manual Green Anode Plant


Vedanta - Jharsuguda
Feed material comes from:
Ball Mill Feed bin

0-6mm

1.5 15 t/h

Feed rate can be controlled by belt weigh feeder, electronic ear and impact flow meter
for recycled material from air flow classifier.
Ball Mill Product size (into fines fraction bin):

Design
Normal
Total range adjustable

< 0.075mm
75 +/-2 %
< 0.075mm 65 to 70 +/-2 %
< 0.075mm
55-75 +/-2 %

The product size is mainly determined by:


1. Cut point of the air flow classifier
2. Retention time of material in the mill tube (depends on: feed rate, re-circulation rate
of oversize)
3. Air velocity through mill tube
4. Grinding ball charge (total weight and size distribution of balls)
5. Feed material size distribution
The finer the ball mill product shall be milled the more specific grinding work is
required as the following equation shows:

W = 1 / D 80 out 1 / D 80 in
W = specific grinding work
D80out = product grain size at 80% passing
D80in = feed grain size at 80% passing
Because each ball mill is designed for a maximum specific grinding work and product
fineness there is a capacity limit.
If finer product is required it can be achieved by readjusting the cut point of the airflow
classifier and by reducing the feed rate of fresh material at the same time.
If only the cut point of the classifier is changed to a smaller size without reducing the
feed rate then the amount of oversize returned to the mill is increasing. This would
only raise with each air cycle more and more the material level in the mill until the
material overflows the mill at the discharge end.
During automatic operation of the mill level control system overflowing of the mill
should be impossible because the flow meter and the sonic ear control the feed rate
automatically.

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Training Manual Green Anode Plant


Vedanta - Jharsuguda

138-02-043
Group 431/432 F
DE-060300

The feed size has also a significant impact on the product size of a ball mill system. It
would be ideal to feed continuously the same rate of coke to the mill but this cannot
be achieved all time. If the feed rate of one fraction has to be changed because there
is a lack or a surplus of material in the Ball Mill Feed bin the change should be
moderate. If a lot filter dust has been added to the Ball Mill Feed bin the product grain
size is shifted to a finer size immediately because filter dust is much finer as ball mill
dust and so is taken directly by the air stream out of the mill body. If much Fine Coke
(3-6 mm) has been fed to the Ball Mill Feed bin then the ball mill product is finally
coarser than usual.
Ball mill:
Manufacturer:
McNally Bharat Engineering Co. Limited
Size:
2.60m dia x 5.75m long
Dynamic Air Flow Classifier:
Manufacturer:
Type:
cut point:

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HUMBOLDT WEDAG INDIA PVT. LTD.


SKS-L 1300
adjustable by cage wheel speed and baffle adjustment

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Training Manual Green Anode Plant


Vedanta - Jharsuguda

13.2

Process Control

13.2.1

P&Id`s, Operator Screen Images

138-02-043
Group 431/432 F
DE-060300

(work copies)

Outokumpu Technology GmbH


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file: 138-02-043_13_0.doc, Codeword: Vedanta

Training Manual Green Anode Plant


Vedanta - Jharsuguda
13.2.2

138-02-043
Group 431/432 F
DE-060300

Control Logic Description


(Work Copy)

Outokumpu Technology GmbH


file: 138-02-043_13_0.doc, Codeword: Vedanta

Revision: 0
Date: 29.09.2006
Page 11 of 12

CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070

1 (28)

Rev. 00

Control Philosophy
of
Process Group 431-F
- Ball Mill System Reference:
Process Flow Sheet

132-01-082 UB

P+I Diagrams

168-01-062 UB, sheets 1-3

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

2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.5
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.7
2.8

Control Logic Description ............................................................................................................ 3


Special Terminology for this Group............................................................................................. 3
Process Groups Linked with this Group...................................................................................... 3
Selection ..................................................................................................................................... 4
Operation Mode of the Group (SE 1) .......................................................................................... 4
Material Route (SE 2).................................................................................................................. 4
Autosampler 431 F 310 (SE 3).................................................................................................... 4
Filter Dust (SE 4)......................................................................................................................... 5
Ball Mill Level (SE 5) ................................................................................................................... 5
Throttle Flap 431 F 240 (SE 6).................................................................................................... 7
Reversing Flap 431 F 322 (stable operation of ball mill system) (SE 7) ..................................... 7
Group Start ................................................................................................................................. 7
Selections Prior to Start .............................................................................................................. 7
Start Preconditions...................................................................................................................... 7
Setpoints Prior to Group Start ..................................................................................................... 9
Group Start Sequence .............................................................................................................. 11
Restarting the Group................................................................................................................. 13
Normal Operation...................................................................................................................... 13
Group Shut Down ..................................................................................................................... 17
Normal Shut Down .................................................................................................................... 17
Shut Down by Other Groups ..................................................................................................... 18
Fast Shut Down......................................................................................................................... 18
Trip in Case of Faults ................................................................................................................ 19
Shut Down by Full Bins ............................................................................................................. 26
Local Operation of Special Equipment...................................................................................... 27
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 28

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
1

2 (28)

Rev. 00

BRIEF PROCESS DESCRIPTION


The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This Process Group is required to produce a very fine petroleum coke fraction (grain size 003mm with max. 75% <0.074mm) called Ball Mill Fraction which is used as filler material of
the dry mix to be blend in Group 431 H. This very fine material is ground by a ball mill (431 F
100) of the air-swepped type working in a closed conveying air circuit.
The feed material is continuously withdrawn from the storage bin (431 A 320) by means of
belt-weigh-feeder (431 F 010). The flat slide gate (431 F 005) under the storage bin is always
open except if maintenance has to be done on the weigh-feeder underneath.
The material is continuously fed to the ball mill passing a reversing flap (431 F 015), a screw
conveyor (431 F 022) and a double-pendulum flap (431 F 025). The double pendulum flap is
required because the ball mill air circuit and thus the ball mill are working under negative
pressure. If the weigh-feeder has to be calibrated, the material can be directed into a bulker
bag by manually tilting the reversing flap (431 F 015) for a certain time and weighing the bag
later on a platform scale (431 H 096).
In the ball mill (431 F 100) the feed material is ground by steel balls while the coke is slowly
passing the ball mill tube. The mill is capable to achieve a product grain size of about 0-2mm
containing a large portion of 0- 0.074mm size (- 200 mesh).
The circulating air flow, generated by a fan (431 F 245), is passing the mill tube and carries the
ground material via a vertical duct into the airflow classifier (431 F 210) where oversized
material (> 0.3mm) is separated, which is recycled to the ball mill and via rotary lock (431 F
260) and impact flow meter (431 F 275).
A drum magnet (431 F 265) with permanent magnet is removing fine ground iron (abration
loss of the grinding balls) and also small iron particles coming with the raw material, coke.
The air flow classifier is equipped with a number of adjustable baffles, concentrically located
around a motor driven cage wheel. Both baffles and cage wheel are making the air flow
rotating so that coarse particles are separated at the inner wall and in the separator center by
centrifugal force while the finer product is leaving the classifier through the top outlet. The
cutpoint of the classifier is adjustable by a variable speed drive for the cage wheel and by
adjusting the baffles.
Material of required grain size (0-0.3mm) is transported by air flow to the cyclone (431 F 215)
where the fine ground coke is separated from the carrying air flow. Via a rotary lock (431 F
305) the fine ground material is discharged from the cyclone, is then passing an automatic
sampler (431 F 310) and is finally falling either into the fines bin (431 F 400). If the reversing
flap (431 F 325) is switched to the other way, the material is fed to the screw conveyors (431 F
330 / 335) it is conveyed into the Fresh Adsorbent bin (431 F 450). Between automatic
sampler (431 F 310) and reversing flap (431 F 325) is another reversing flap, for fed the
ground material in the first 10 minutes after starting the Ball Mill System via screw conveyor
(431 F 323) in the Filter Dust Bin (431 C 100). The reason for this procedure is the unsteady
quality of the ground material during the start phase of the ball mill.
The air flow leaving the cyclone (431 F 215) is passing the fan (431 F 245) via a motorized
throttle flap (431 F 240), which is closing before start up of the fan and is then opened to a
preset angle to adjust the flow rate.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070

3 (28)

Rev. 00

The throttle flaps (431 F 250 / 255) downstream the fan are used to split the air flow to be send
through the mill and through the mill bypass duct.
A part of the circulation air is withdrawn by a dust collector fan (431 F 230) via a throttle flap
(431 F 225) and through a dust collector (431 F 220) in order to reduce the dust content in the
circulating air and to keep the circulation air system at negative pressure in order to avoid dust
leaks.
Dust separated by the dust collector (431 F 220) is discharged via a rotary lock (431 F 315)
and a screw conveyor (431 F 320) into either the Ball Mill Fraction bin (431 F 400) or into the
bin for Fresh Adsorbent (431 F 450).
With the ball mill operating, filter dust is continuously reclaimed from the Filter Dust bin (431
C 100) by means of the rotary lock (431 F 055), which is equipped with a variable speed drive
so that the feed rate is adjustable. An aeration unit (431 F 051) installed at the Filter Dust bin
bottom avoids bridging of material in the bin. The filter dust is added to the air flow which is
entering the air flow classifier (431 F 210). Filter Dust is only fed to the system when the Ball
Mill System is producing.
Loaded adsorbent from Group 431 G is continuously discharged from the Loaded Adsorbent
storage bin by means of the rotary lock (431 F 355), which is equipped with a variable speed
drive so that the feed rate is adjustable. An aeration unit (431 F 351) installed at the Loaded
Adsorbent bin bottom avoids bridging of material in the bin. The material is added to the chute
feeding the Ball Mill Fraction bin (431 F 400). Loaded Adsorbent is only then fed to the Ball Mill
Fraction bin as long as the bin is filled with fresh Ball Mill Product and is stopped when the
Fresh Adsorbent bin is filled.
For calibration of the rotary lock for Filter Dust (431 F 055) material is fed via the reversing flap
(431 F 060) into a bulker bag (431 F 285). The bulker bag has to be weighed on a platform
scale (431 H 096). Calibration of the impact flow meter (431 F 275) is via reversing flap (431 F
280). Only during automatic run of the complete Group it is possible to switch the reversing
flap (431 F 280) for a short while to the bulker bag.
2

CONTROL LOGIC DESCRIPTION

2.1

Special Terminology for this Group


There is no special terminology for this group.

2.2

Process Groups Linked with this Group


The following Process Groups are linked with this Group 431 F:

Main Dust Treatment 431 C

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

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006

4 (28)

Rev. 00

Vedanta Alumina Ltd.


Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
2.3

Selection

2.3.1

Operation Mode of the Group (SE 1)


The operator has two options:
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.

2.3.2

CENTRAL operation mode

After this selection this Group is ready to start in CENTRAL


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

LOCAL operation mode

(details please see under 2.7 below)

Material Route (SE 2)


The operator has two options:
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 and can be changed any time.
SE 2-1 - Ball Mill Fraction Bin
This is the selection used most of the time.
At this selection Ball Mill Product will be fed to the Ball Mill Fraction bin (431 F 400).
SE 2-2 - Fresh Adsorbent Bin
This selection is used only if the Fresh Adsorbent bin (431 F 450) has to be refilled.
At this selection Ball Mill Product will be fed to the Fresh Adsorbent bin.
SE 2-3 - Auto Select
This selection enables automatic selection of the Ball Mill Feed bin and of the Fresh Adsorbent
bin.
The selection depends on the actual material level in the bins.
SE 2-4 - Manual Select
This selection disables automatic selection of the Ball Mill Feed bin and of the Fresh
Adsorbent bin.

2.3.3

Autosampler 431 F 310 (SE 3)


The operator may initiate taking a sample 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 3-1 - Auto Sample
This selection enables automatic sampling of the ball mill product.
Sampling is controlled by a software timer.
SE 3-2 - Manual Sample
This selection disables automatic sampling of the ball mill product.
Sampling is controlled by the operator. Clicking the Sample button on SCADA will initiate one
sampling cycle.

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Rev. 00

SE 3-3 - Sample
If SE 3-2 is selected and the operator is clicking on the Sample button (SE 3-3) on SCADA a
single sample is taken.
2.3.4

Filter Dust (SE 4)


The operator two options:
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 Add Filter Dust
The operator may select Add Filter Dust at any time as long as CENTRAL operation mode is
selected and if the reversing flap (431 F 060) is in correct position [limit switch 431 F 060-ZH
activated] so that Filter Dust will be fed to ball mill system air circuit.
SE 4-2 Filter Dust LOCAL
The operator may select Filter Dust Local at any time. Straight with the selection the rotary
lock (431 F 055) stops feeding. Starting the rotary lock requires the reversing flap limit switch
[431 F 060-ZL] to be initiated (flap to calibration). On the Local Operator Panel [431 F 060LOP1] the pilot light [431 F 055-H2] indicates the rotary lock is stopped and thus the LOCAL
operating mode is released (at Add Filter Dust selection all pilot lights on the local panel are
off) and so are the push buttons on this local panel.
SE 4-3 No Filter Dust
The operator may select No Filter Dust at any time as long as CENTRAL operation mode is
selected so that no Filter Dust will be fed to ball mill system air circuit.

2.3.5

Ball Mill Level (SE 5)


The actual level of coke in the mill body is measured by a sonic level measuring system
(electronic ear) [431 F 100-LY].
The material level in the ball mill can be either controlled automatically or manually by the
operator.
The material level in the mill is a function of:

the fresh coke feed rate provided by the belt weigh feeder (431 F 010)
the recycling rate of oversize material coming back from the air flow classifier (431 F 210)
the feed size of fresh coke and recycled coke
the grindability of the feed material (coke)
the mill size (grinding capacity) of the ball mill.

The grindability varies with the source of coke but is more or less fix for short term (hours /
days) and the feed size (fresh and oversize) should be kept in a small range but still is a
variable. The mill size is a design figure and is another fix value.
Thus for short term operation mainly the feed rate of fresh coke and oversize coke from the
classifier have the main impact on the material level in the ball mill. The rate of oversize coke
is a function of the feed size, the grindability and other impacts like the stability of the
circulating air flow and therefore is not fix

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Rev. 00

The higher the total feed rate is the higher is the mill level and the shorter is the retention time
of material passing the mill body. A typical retention time is 15 minutes.
At low retention time (high feed rate) the chance of a coke grain to be ground to fine mill dust
is relatively low while at a higher retention time (lower feed rate) the chance is much higher.
However the level control system must be able to balance the rate of fresh coke and recycled
coke from the air flow classifier in order to attain the required fineness of the ball mill product.
SE 5-1 Auto Level
The operator may select Auto Level at any time as long as CENTRAL operation mode is
selected.
At this selection the material level in the mill is controlled automatically by variation of the feed
rate of belt weigh feeder (431 F 010) using the following command variables:

electronic ear [431 F 100-LY] material level impact flow meter [431 F 275-FY] recycled material -

Both are input variables for a software-type PID Controller, which delivers the control value
[431 F 010-FY] for the belt weigh feeder (431 F 010).
SE 5-2 Auto Electronic Ear
The operator may select Auto Electronic Ear at any time as long as CENTRAL operation
mode is selected.
At this selection the material level in the mill is controlled automatically by variation of the belt
weigh feeder (431 F 010) feed rate using the following command variable:

electronic ear [431 F 100-LY] material level -

At this selection this is the only input variable for a software-type PID Controller, which delivers
the control value [431 F 010-FY] for the belt weigh feeder (431 F 010). In this case the impact
flow meter is just used for display of the recycled material flow rate.
SE 5-3 Auto Flow Meter
The operator may select Auto Flow Meter at any time as long as CENTRAL operation mode
is selected.
At this selection the total feed rate, fresh feed from the belt weigh feeder plus recycled material
from the air flow classifier shall be kept constant automatically while the material level in the
mill is only displayed but not controlled. The command variable in this case is:

impact flow meter [431 F 275-FY] recycled material -

In this case the electronic ear is just used for display of the material level in the mill but shuts
off the belt weigh feeder, if the level increases too much or gives alarm, if the level is too low.
SE 5-4 Manual Level
The operator may select Manual Level at any time as long as CENTRAL operation mode is
selected.

At this selection the material level in the mill is controlled manually by the operator using
the Operator Station in the Central Control Room.

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Rev. 00

In this case the electronic ear is just used for display of the material level in the mill but shuts
off the belt weigh feeder when the level increases too much and for display of the flow of
recycled material the impact flow meter is used.
Note: This selection shall be used for each start of this Group and shall be kept at
minimum for a time of 20 minutes after the start of the ball mill (431 F 100) until the ball
mill system is in stable operation.
2.3.6

Throttle Flap 431 F 240 (SE 6)


The opening of the throttle flap is determining the flow rate through the air circulation system.
SE 6-1 Manual Control
The operator may select Manual Control at any time as long as CENTRAL operation mode is
selected. At this selection the operator controls the position of the flap and thus the circulating
air flow.
SE 6-2 Auto Control
The operator may select Auto Control at any time as long as CENTRAL operation mode is
selected. At this selection the position of the flap is controlled automatically by the PLC using
the actual power consumption of the fan (431 F 245) motor as command variable.

2.3.7

Reversing Flap 431 F 322 (stable operation of ball mill system) (SE 7)
This selection shall be used for each start of this Group and shall be kept at minimum for a
time of 10 minutes after the start of the ball mill (431 F 100) until the ball mill product has a
steady quality.
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:
SE 7-1 - Auto Select
At this selection the ground material is fed to the filter dust bin (431 C 100) during the start
phase of the ball mill (first approach for Standard Setpoint SP 7 is 10 minutes). After the start
phase the ground material is fed to the ball mill fraction bin (431 F 400) or fresh adsorbent bin
(431 F 450).
SE 7-2 - Manual Select
At this selection the operator controls manually the fed of the ground material to the filter dust
bin (431 C 100) or in direction to the ball mill fraction bin (431 F 400) or fresh adsorbent bin
(431 F 450).

2.4

Group Start

2.4.1

Selections Prior to Start

2.4.2

Start Preconditions
CENTRAL operation mode must be selected.

2.4.2.1 Process Group 431 C - Main Dust Treatment

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The Group Main Dust Treatment must be running in CENTRAL operation mode prior to
start of this Group. It must not be tripped and not be in a stop (RESTOP or FASTOP)
sequence.

2.4.2.2 Ball Mill Sub-Group 431 F 100


If there is no Ball Mill Sub-Group Ready signal this Group 431 F does not start.
Note: This is a collective signal indicating that the main drive of the mill, the trunnion bearing
lubrication units, the gear lube unit and the bearing jacking pumps are healthy and the inching
drive is not engaged. For details please refer to the equipment documentation of the ball mill
prepared by MBE.
2.4.2.3 Belt Weigh Feeder 431 F 010
If there is no Belt Weigh Feeder Ready signal this Group 431 F does not start.
Note: This is a collective signal indicating the belt weigh feeder is healthy and has a sufficient
material layer on the belt. For details please refer to the equipment documentation of the
weigh feeder prepared by TRANSWEIGH.
2.4.2.4 Reversing Flap 431 F 015
If the flap is not in position to feed the screw conveyor (431 F 022) and thus limit switch
[431 F 015-ZH] is not activated, this Group does not start.
2.4.2.5 Reversing Flap 431 F 280
If the flap is not in position to feed the ball mill (431 F 100) and thus limit switch [431 F
280-ZL] is not activated, this Group does not start.
2.4.2.6 Reversing Flap 431 F 060
If Ball Mill Feed (SE-2-1) is selected and if then the flap is not in position to feed the air
circulation pipe to the air-flow separator (431 F 210) and thus limit switch [431 F 060-ZH]
is not activated, this Group does not start.
If Filter Dust Local (SE-2-2) is selected and if then the flap is not in position to feed the
bulker bag (431 F 285) and thus limit switch [431 F 060-ZL] is not activated, this Group
does not start.
2.4.2.7 Ball Mill Fraction Bin 431 F 400
If the bin (431 F 400) is full [431 F 400-LAH2 or 431 F 400-LAHH is indicating very high-or
high-high level] and if the Fresh Adsorbent bin (431 F 450) is also full [431 F 450-LAH2 or
431 F 450-LAHH is indicating very high-or high-high level] this Group does not start.
2.4.2.8 Fresh Adsorbent Bin 431 F 450
If the bin (431 F 450) is full [431 F 450-LAH2 or 431 F 450-LAHH is indicating very high-or
high-high level] and if the Ball Mill Fraction bin (431 F 400) is also full [431 F 400-LAH2 or
431 F 400-LAHH is indicating very high-or high-high level] this Group does not start.
2.4.2.9 Emergency stops
If the Emergency Stop of the Group has been activated it has to be RESET.
2.4.2.10 Alarms
If an Alarm of this Group has been activated it has to be RESET.

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Rev. 00

2.4.2.11 MCC`s of this Group


The MCCs signal of this group must be OK.
2.4.2.12 FASTOP Signal
If a FASTOP signal is valid this Group does not start.
2.4.2.13 RESTOP Signal
If a RESTOP signal is valid this Group can be restarted by overriding the RESTOP signal
by the Group Start signal.
2.4.2.14 Local Control Stations
Equipment selected to run the ON switches must be activated.
2.4.2.15 Vibrating Screen Feeder 431 A 140 -plugged chute switch
If the plugged chute switch [431 A 140-LAH] is indicating Plugged Chute in the chute
above the screen feeder (431 A 140), this Group does not start.
2.4.2.16 Compressed Air Pressure 431 G 120
Compressed air pressure in Group G [431 G 120-PAL] shall be higher than 6 bar (P>6
bar).
2.4.2.17 Medium Voltage for Ball Mill Main Drive Motor 431 F 100-M1
If medium voltage (6.6 kV) signal is not available this Group does not start.
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 as


Actual Setpoint The Actual Setpoint is automatically used
for the next start after the Group has been stopped or for a
restart after the Group has tripped. The Actual Setpoint is
displayed on SCADA.

New Setpoint

The operator has the opportunity to override the actual


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

Previous Setpoint

Did the operator change an Actual Setpoint while the Group is


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

Standard Setpoint

The operator may also override the actual setpoint by the


Standard Setpoint any time. Selection of the Standard
Setpoint is on SCADA. The Standard Setpoint can be edited
on the SCADA system any time but by a Shift Leader only,
after using his Password.

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Rev. 00

2.4.3.1 Throttle Flap 431 F 240 (Circulating Air Flow)

(Setpoints SP 1-1 to 1-2)

This throttle flap is equipped with a servo drive for remote adjustment of the flap position.

At Selection SE 6-1 Manual Control - (Setpoint SP 1-1)


At this selection the flap position is set by the operator.
The operator may set the flap position at any time in a range of 0% to 100% [0% = limit
switch position 431 F 240-ZL]. Setting and display of the actual position is on SCADA. On
SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint all overriding the actual setpoint.
At Selection SE 6-2 Auto Control - (Setpoint SP 1-2)
At this selection the flap position is controlled by the actual power consumption of the fan
motor [431 F 245-M1].
The operator may set the power consumption of the fan at any time in a range of (??? kW
to be elaborated during commissioning -). Setting and display of the actual power is on
SCADA. On SCADA 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 Air Flow Classifier 431 F 210- (Setpoint SP 2)


The airflow classifier is equipped with a variable speed drive. Setting the speed of the
dynamic classifier can be done at any time but requires a password of a shift leader.
The cage wheel speed can be varied between 20 % and 100 %.
20 %
83 RPM
100 %
416 RPM
It is critical to play with the cage rotor speed because this has great influence
Note:
on the ball mill product grain size.
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 36%)
all overriding the actual setpoint.
2.4.3.3 Rotary Lock 431 F 055 (Floor Dust)

(Setpoint SP 3)

This rotary lock is equipped with a variable speed drive.

The speed can be varied between 20 % and 100 %.corresponding a feed rate between
0.2 and 2.0 tons/hour. If Add Floor Dust (SE 2-1) is selected, this feed rate can be
varied any time.
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.

2.4.3.4 Rotary Lock 431 F 355 (Loaded Adsorbent) (Setpoint SP 4)


This rotary lock is equipped with a variable speed drive.

The speed can be varied between 20 % and 100 %.corresponding a feed rate between
0.5 and 2.5 tons/hour. Setting and display of the actual position is on SCADA at any time.
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.

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Rev. 00

2.4.3.5 Ball Mill Level Control System 431 F 275 (Setpoints SP 5-1 to 5-3)
The actual level of coke in the mill body is measured by a sonic level measuring system
(electronic ear) [431 F 100-LY].

At Selection SE 5-1 Auto Level - (Setpoint SP 5-1)


The target value at this selection is the material level in the ball mill tube, measured by the
electronic ear [431 F 100-LY]. {Setpoint : 80%}
The PLC to accept input values from the operator only between 70% and 90% (final
setting during commissioning).
Only the shift leader may change this setpoint by using his password.
At Selection SE 5-2 Auto Electronic Ear - (Setpoint SP 5-2)
The target value at this selection is the material level in the ball mill tube, measured by the
electronic ear [431 F 100-LY]. {Setpoint : 80%}
The PLC to accept input values from the operator only between 70% and 90% (final
setting during commissioning).
Only the shift leader may change this setpoint by using his pass word.
At Selection SE 5-3 Auto Flow Meter - (Setpoint SP 5-3)
The target value at this selection is the total feed rate to the ball mill (431 F 100) what is
the sum of fresh feed from the belt weigh feeder plus recycled material from the air flow
classifier. {Setpoint : 13 tons/hour 1st approach}
At Selection SE 5-4 Manual Level - (Setpoint SP 5-4)
At this selection the feed rate of the belt weigh feeder (431 F 010) is set by the operator.
The operator may set the feed rate at any time in a range of 1.5 to 15.0 tons/hour. Setting
and display of the actual position is on SCADA. On SCADA the operator has the choice to
select one of three options, New setpoint, Previous setpoint and Standard setpoint all
overriding the actual setpoint.

2.4.3.6 Automatic Sampler 431 F 310 Sampler Waiting Time - (Setpoint SP 6)


The waiting time (SWT) between two samples can be set any time.
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 4
hours) all overriding the actual setpoint.
2.4.3.7 Reversing Flap (431 F 322) start phase ball mill system (Setpoint SP 7)
The time for the start phase of the ball mill system can be varied between 5 minutes and
20 minutes. Setting the time can be done at any time.
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 10
minutes) all overriding the actual setpoint.
2.4.4

Group Start Sequence


The operator is enabling this Group 431 F to start and to run the selected equipment. To
initiate the start he is using the SCADA system on the Operator Station in the Central
Control Room.
Signal from Group 431 C (Main Dust Treatment) is required (Group is running in
CENTRAL mode and is not in Group Start (START) or any Group Stop sequence
(RESTOP or FASTOP)).

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Rev. 00

Signal from Sub-Group 431 F 100 required, indicating the equipment and controls of this
Sub-Group is healthy. (Details please refer to machine documentation of the ball mill (431
F 100) prepared by MBE)
The horn starts to sound permanently for 15 seconds prior to start of the first equipment,
then it sounds intermittently until the last drive is running.
Screw conveyor (431 F 335) starts.
Screw conveyor (431 F 330) starts.
Reversing flap (431 F 325) is enabled.
Screw conveyor (431 F 320) starts
Rotary lock (431 F 315) starts.
Jet cleaning of dust collector (431 F 220) is enabled.
Fan (431 F 230) starts.
Delay of 20 seconds for fan impeller run-up.
Screw conveyor (431 F 323) starts.
Reversing flap (431 F 322) is enabled.
Automatic sampler (431 F 310) is tilting to limit switch [431 F 310-ZH].
Rotary lock (431 F 305) starts after limit switch [431 F 310-ZH] is activated.
Drum magnet (431 F 265) starts.
Rotary lock (431 F 260) starts.
Impact flow meter (431 F 275) is enabled.
Air flow separator cage rotor (431 F 210) starts.
Throttle flap (431 F 240) closes until limit switch [431 F 240-ZL] is activated.
Delay of 20 seconds for cage rotor run-up.
Fan (431 F 245) starts, if limit switch [431 F 240-ZL] is indicating the throttle flap is closed.
Delay of 30 seconds for fan impeller run-up.
Throttle flap (431 F 240) opens until setpoint (SP 1-1 or SP 1-2 see 3.3.3 above) is
reached.
Sub-Group 431 F 100 -Ball mill is initiated to start
Note: Start details to be described by MBE
Sub-Group 431 F 100 completely started (ball mill 431 F 100 runs).
Screw conveyor (431 F 022) starts.
Belt weigh feeder (431 F 010) starts.
Rotary lock (431 F 055) starts if SE 4-1 is selected.
Rotary lock (431 F 355) starts.
Aeration unit (431 F 351) is enabled.
Aeration unit (431 F 051) is enabled if rotary lock (431 F 055) runs.
Group 431 F is running completely in CENTRAL mode.

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2.4.5

13 (28)

Rev. 00

Restarting the Group


If the Group is in a run-empty stop sequence, (after Normal Shut Down (RESTOP has been
initiated by the operator or the Group has been tripped after of an equipment fault) and a part
of the Group is still running, it is possible to restart this Group by activating the START
button. Restarting is only possible after all faults have been eliminated and reset. The Restart
follows the same sequence like the normal Group Start including the horn sequence as
described above.

2.5

Normal Operation

2.5.1

Belt Weigh Feeder 431 F 010 If the weigh feeder is not tripped this Group is in normal operation.
If SE 5-1 (Auto Level) is selected, the feed rate of the belt weigh feeder (431 F 010) is
automatically controlled by the electronic ear [431 F 100-LY] (ball mill material level) and
by the impact flow meter [431 F 275-FY] (recycled material from the air flow classifier).
The operator may select Auto Level at any time as long as CENTRAL operation mode is
selected.
If SE 5-2 (Auto Electronic Ear) is selected, the feed rate of the belt weigh feeder (431 F
010) is automatically controlled by the electronic ear [431 F 100-LY] (ball mill material
level) only. - The operator may select Auto Electronic Ear at any time as long as
CENTRAL operation mode is selected.
If SE 5-3 (Auto Flow Meter) is selected, the feed rate of the belt weigh feeder (431 F 010)
is automatically controlled by the impact flow meter [431 F 275-FY] (recycled material from
air flow classifier) only.
The operator may select Auto Flow Meter at any time as long as CENTRAL operation
mode is selected.
If SE 5-4 (Manual Level) has been selected the feed rate of the belt weigh feeder is set by
the operator.
The operator may set the feed rate at any time in a range of 1.5 to 15.0 tons/hour. Setting
and display of the actual position is on SCADA. On SCADA the operator has the choice to
select one of three options, New setpoint, Previous setpoint and Standard setpoint all
overriding the actual setpoint.
The operator may select Manual Level at any time as long as CENTRAL operation mode
is selected.

2.5.2

Reversing Flap 431 F 015


If the reversing flap is not tripped this Group is in normal operation
If the reversing flap is positioned correctly so that limit switch [431 F 015-ZH] is activated
(flow to screw conveyor 431 F 022)), this Group is in normal operation.

2.5.3

Screw Conveyor 431 F 022


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

2.5.4

Rotary Lock 431 F 055


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

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Rev. 00

This rotary lock is equipped with a variable speed drive. The speed can be varied between
20 % and 100 % corresponding a feed rate between 0.2 and 2.0 tons/hour. If Add Floor
Dust (SE 2-1) is selected, this feed rate can be varied any time.
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.

2.5.5

Reversing Flap 431 F 060


If the reversing flap is not tripped this Group is in normal operation
If SE 4-1 Add Filter Dust is selected and if the reversing flap is positioned correctly so
that limit switch [431 F 060-ZH] is activated (flow to ball mill system air circuit), this Group
is in normal operation.
If SE 4-2 Filter Dust Local is selected and if the reversing flap is positioned correctly so
that limit switch [431 F 060-ZL] is activated (flow to bulker bag), this Group is in normal
operation.

2.5.6

Ball Mill Sub-Group 431 F 100


If the ball mill sub-group (ball mill with all auxiliary equipment) is not tripped this Group is in
normal operation.
(Details to be prepared by MBE)

2.5.7

Air Flow Classifier 431 F 210


If the classifier is not tripped this Group is in normal operation.
The airflow classifier is equipped with a variable speed drive. Setting the speed of the
dynamic classifier can be done at any time but requires a password of a shift leader.
The cage wheel speed can be varied between 20 % and 100 %.
20 %
83 RPM
100 %
416 RPM
Note:
It is critical to play with the cage rotor speed because this has great influence
on the ball mill product grain size.
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 36%)
all overriding the actual setpoint.

2.5.8

Dust Collector 431 F 220


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

2.5.9

Fan 431 F 230


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

2.5.10

Fan 431 F 245


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

2.5.11

Rotary Lock 431 F 260


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

2.5.12

Drum-type Magnet 431 F 265


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

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CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
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15 (28)

Rev. 00

2.5.13

Impact Flow Meter 431 F 275


If the flow meter is not tripped this Group is in normal operation

2.5.14

Reversing Flap 431 F 280


If the reversing flap is not tripped this Group is in normal operation
If the reversing flap is positioned correctly so that limit switch [431 F 280-ZL] is activated
(flow to double pendulum flap), this Group is in normal operation.

2.5.15

Automatic Sampler 431 F 310


If the sampler is not tripped this Group is in normal operation
If SE 3-1 - Auto Sample is selected on SCADA automatic sampling of the ball mill
product is enabled.
Sampling is controlled by a software timer. All (SWT see 3.3.3 above, SP 6) hours a
sample is be taken. The sampling pelican is tilting from the parking position at side A to
side B or vice versa, where ever the pelican sampler is actually located. If the sampling
pelican does move from limit switch to limit switch [431 F 310-ZL to 431 F 310-ZH or vice
versa] within a time limit of 10 seconds this Group is in normal operation.
If SE 3-2 - Manual Sample is selected and the operator has initiated taking a sample and
the sampling pelican moves from parking position A to B or vice versa within a time limit of
10 seconds, this Group is in normal operation.
If SE 3-2 is selected and the operator is clicking on the Sample button (SE 3-3) on
SCADA a single sample is taken. If the sampling pelican moves from parking position A to
B or vice versa within a time limit of 10 seconds, this Group is in normal operation.

2.5.16

Reversing Flap 431 F 322


If the reversing flap is not tripped this Group is in normal operation
If Auto Select SE 7-1 is selected and if the Filter Dust Bin (431 C 100) is full [431 C 100LAH2 is indicating very high level] and this reversing flap is adjusted at 100% material flow
to screw conveyor (431 F 323) [limit switch 431 F 322-ZL is actuated], the flap tilts to limit
switch [431 F 322-ZH] automatically

2.5.17

Screw Conveyor 431 F 323


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

2.5.18

Rotary Lock 431 F 315


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

2.5.19

Screw Conveyor 431 F 320


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

2.5.20

Reversing Flap 431 F 325


If the reversing flap is not tripped this Group is in normal operation
If Auto Select SE 2-3 is selected and if the Ball Mill Fraction bin (431 F 400) is full [431
F 400-LAH2 is indicating very high level] and this reversing flap (431 F 325) is not
adjusted at 100% material flow to screw conveyor (431 F 330) [limit switch 431 F 325-ZL
is not actuated] and the Fresh Adsorbent bin (431 F 450) is not full the flap tilts to limit
switch [431 F 325-ZL] automatically.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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Vedanta Alumina Ltd.
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Client ref.: VJ/SML/PO/032/1
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Doc. No.:
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16 (28)

Rev. 00

If Auto Select SE 2-3 is selected and if the Fresh Adsorbent bin (431 F 450) is full [431
F 450-LAH2 is indicating very high level] and this reversing flap (431 F 325) is not
adjusted at 100% material flow to the Ball Mill Fraction bin (431 F 400) [limit switch 431 F
325-ZH is not actuated] and the Ball Mill Fraction bin (431 F 400) is not full the flap tilts to
limit switch [431 F 325-ZL] automatically.
If Auto Select SE 2-3 is selected and if the Ball Mill Fraction bin (431 F 400) is nearly
empty [431 F 400-LAL is indicating low level 10% of maximum level -] and this reversing
flap (431 F 325) is not adjusted at 100% material flow to the Ball Mill Fraction bin [limit
switch 431 F 325-ZH is not actuated] the flap tilts to limit switch [431 F 325-ZH]
automatically.
If Auto Select SE 2-3 is selected and if the Fresh Adsorbent bin (431 F 450) is nearly
empty [431 F 450-LAL is indicating low level 10% of maximum level -] and this reversing
flap (431 F 325) is not adjusted at 100% material flow to the Fresh Adsorbent bin [limit
switch 431 F 325-ZL is not actuated] the flap tilts to limit switch [431 F 325-ZL]
automatically but only if there is no low level at the Ball Mill fraction bin [431 F 400-LAL]
indicated.

2.5.21

Screw Conveyor 431 F 330


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

2.5.22

Screw Conveyor 431 F 335


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

2.5.23

Rotary Lock 431 F 355


If the rotary lock is not tripped this Group is in normal operation.
This rotary lock is equipped with a variable speed drive. The speed can be varied between
20 % and 100 % corresponding a feed rate between 0.5 and 2.5 tons/hour. Setting and
display of the actual position is on SCADA at any time.
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.

2.5.24

Fraction Bin 431 F 400 Ball Mill Fraction


If the fraction bin level measurement is not tripped this Group is in normal operation.
If Auto Select SE 2-3 is selected and if the fraction bin (431 F 400) is nearly empty [431 F
400-LAL is indicating low level 10% of maximum level -] there is an alarm and the
reversing flap (431 F 325) tilts to limit switch [431 F 325-ZH] automatically to refill the bin if
the gate is not already adjusted at 100% material flow to the Ball Mill Fraction bin [limit
switch 431 F 325-ZH is actuated].
If the fraction bin is not full (bin level is not >/= 95% [431 F 400-LAH2] and/or not >/=
100% [431 F 400-LAHH]) this Group is in normal operation.
If Auto Select SE 2-3 is selected and if the fraction bin is full (bin level is >/= 95% [431 F
400-LAH2] and/or >/= 100% [431 F 400-LAHH]) and the flap of reversing flap (431 F 325)
is after a travel time of 90 seconds at 100% material flow to screw conveyor 431 F 330
[limit switch 431 F 325-ZL actuated] this Group is in normal operation.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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Vedanta Alumina Ltd.
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Client ref.: VJ/SML/PO/032/1
OTK ref.:
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Doc. No.:
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17 (28)

Rev. 00

2.5.25

Fresh Adsorbent Bin 431 F 450


If the fraction bin level measurement is not tripped this Group is in normal operation.
If Auto Select SE 2-3 is selected and if the bin (431 F 450) is nearly empty [431 F 450LAL is indicating low level 10% of maximum level -] there is an alarm and the reversing
flap (431 F 325) tilts to limit switch [431 F 325-ZL] automatically to refill the bin if the gate
is not already adjusted at 100% material flow to screw conveyor (431 F 330) [limit switch
431 F 325-ZL is actuated].
If the bin is not full (bin level is not >/= 95% [431 F 450-LAH2] and/or not >/= 100% [431 F
450-LAHH]) this Group is in normal operation.
If Auto Select SE 2-3 is selected and if the bin is full (bin level is >/= 95% [431 F 450LAH2] and/or >/= 100% [431 F 450-LAHH]) and the flap of reversing flap (431 F 325) is
after a travel time of 90 seconds at 100% material flow to the Ball Mill Feed bin (431 F
400) [limit switch 431 F 325-ZH actuated] this Group is in normal operation.

2.5.26

Throttle Flap 431 F 240


If the throttle flap is not tripped this Group is in normal operation.
The operator may set the flap position at any time in a range of 0% to 100% [0% = limit
switch position 431 F 240-ZL]. Setting and display of the actual position is on SCADA. On
SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint all overriding the actual setpoint (Standard
setpoint: 80% open).
Note: Changing of this set point requires the shift leaders password. If the flap is closed
too much the mill could overflow!

2.6

Group Shut Down

2.6.1

Normal Shut Down


To initiate this sort of shut down the operator uses the RESTOP button on the SCADA
system.
After a shut down of the Group or of a part of the Group all actual setpoints of this Group are
memorized as Actual Setpoint.

The operator stops this Group using the RESTOP push button on SCADA.
Ball mill Sub-Group (431 F 100) stop sequence is initiated. (Details of the stop sequence
of this Sub-Group to be prepared by MBE)
Rotary lock (431 F 055) stops.
Rotary lock (431 F 355) stops.
Aeration unit (431 F 051) cycle is disabled and solenoid [431 F 051-ZY1] closes.
Aeration unit (431 F 351) cycle is disabled and solenoid [431 F 351-ZY1] closes.
Screw conveyor (431 F 022) stops.
Delay of 2 minutes (run-empty time for circulation air pipework)
Circulation fan (431 F 245) stops.
Delay of 5 minutes (run-empty time for rest of equipment)

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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OTK ref.:
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18 (28)

Rev. 00

All equipment of this Group stops or is disabled. Equipment perhaps in motion like the
automatic sampler (431 F 310) or the reversing flap (431 F 325) is finishing the actual
operation step first.

Note: MBE to add stop philosophy of Sub-Group 431 F 100.

2.6.2

The whole Group is stopped.

Shut Down by Other Groups


If this Group 431 F is running in CENTRAL mode it requires the following other Groups also
running in CENTRAL operation mode:

431 C Main Dust Treatment

After a shut down of the Group or of a part of the Group all actual setpoints of this Group are
memorized as Actual Setpoint.
2.6.2.1 Group 431 C Main Dust Treatment
Because a mayor part of equipment of this Group 431 F is connected to the Main Dust
Treatment it is essential that Group 431 C is running in CENTRAL control mode and is not
in a START or STOP sequence.
If Group 431 C is not running anymore in CENTRAL mode because it has been stopped
by a Normal Shut Down (RESTOP), by a Fast Shut Down (FASTOP) or is tripped through
a fault a Fast Shut Down (see 2.6.3 below) is initiated.
2.6.3

Fast Shut Down


If this Group 431 F is running in CENTRAL mode and an operator has detected a serious fault,
which did not automatically trip this Group the operator is able to stop this Group as Fast Shut
Down (FASTOP).
After a shut down of the Group or of a part of the Group all actual setpoints of this Group are
memorized as Actual Setpoint.

2.6.3.1 Fast Shut Down by the Operator (FASTOP)


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

All equipment of this Group stops instantly except of the ball mill Sub-Group 431 F 100,
which stops according to the normal stop sequence as described above.
All actual setpoints of this Group are memorized as Actual Setpoint
Reversing flap (431 F 325) is finishing the operating step, if this step has been started
prior to the FASTOP signal and stops, when the target position is reached.
Automatic sampler (431 F 310) is finishing the operating step, if this step has been started
prior to the FASTOP signal and stops, when the target position is reached.
The whole Group is stopped now with full load of material in conveyors.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
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Doc. No.:
133-50-070
2.6.4

19 (28)

Rev. 00

Trip in Case of Faults


If this Group 431 F is running in CENTRAL mode and an equipment or an instrument of this
Group fails this may cause an Alarm only and, if the fault is of the serious sort, this whole
Group or a part of this Group is stopped. Different faults may cause different stop sequences,
depending on the equipment and on the impact of this fault on the whole process of this
Group. In some cases a Normal Shut Down (RESTOP) will commence, in other cases a Fast
Shut Down (FASTOP) is the safer way and in few cases a special stop sequence may be
required.
After a shut down of the Group or of a part of the Group all actual setpoints of this Group are
memorized as Actual Setpoint.
Note: All instruments mounted on equipment or located somewhere in the field or
anywhere else are to be wired fail-safe.

2.6.4.1 Belt Weighfeeder 431 F 010


A collective fault signal
-

causes an alarm
drive stops
This is causing a Normal Shut Down as described above (see 2.6.1).

2.6.4.2 Reversing Flap 431 F 015


[431 F 105-ZH] If the limit switch fails
-

causes an alarm
Normal Shut Down as described above (see 2.6.1).

2.6.4.3 Screw Conveyor 431 F 022


[431 F 022-SAL] The screw conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the screw. If the frequency of the screw is too
low or the switch fails
-

cause an alarm
equipment trips

[431 F 022M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an alarm
equipment trips

If the conveyor trips


-

alarm is generated
Normal Shut Down as described above (see 2.6.1).

2.6.4.4 Rotary Lock 431 F 055


[431 F 055-SAL] The rotary lock is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-

cause an alarm

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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Vedanta Alumina Ltd.
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Client ref.: VJ/SML/PO/032/1
OTK ref.:
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-

20 (28)

Rev. 00

equipment trips

[431 F 055M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an alarm
equipment trips

If the rotary lock trips


-

alarm is generated.

2.6.4.5 Ball Mill Sub-Group 431 F 100


MBE to describe all faults of this Sub-Group.
If the Sub-Group trips
-

alarm is generated
Normal Shut Down (see 2.6.1 above) of this Group 431 F is executed.

2.6.4.6 Air Flow Classifier 431 F 210


[431 F 210-SAL] {50 1/min} The airflow classifier is equipped with a low speed switch, which
gives a trip signal if the speed is below the minimum setting. If the speed is too low or the
switch fails
-

cause an alarm
shut down of this equipment.

[431 F 210-TAHH1/TAHH2] {>90C} The airflow classifier is equipped with 2 bearing


temperature measurements. If one of the bearing temperatures is too high or the measuring
equipment fails
-

cause an alarm
shut down of this equipment.

If there is a failure detected in the motor control system


-

cause an alarm
shut down of this equipment.

If the equipment trips


-

alarm is generated
Normal Shut Down (see 2.6.1 above) of this Group 431 F is executed.

2.6.4.7 Dust Collector 431 F 220


[431 F 220-LOP1] If the bag cleaning device trips
-

an alarm is generated
Normal Shut Down (see 2.6.1 above) will be initiated automatically.

[431 F 220-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or if
the switch fails for more than 5 seconds
-

cause an alarm followed

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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21 (28)

Rev. 00

Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.
NOTE: During Start or Restart of this Group there is an override of this function of 20
seconds to allow the fan to run up.

[431 F 220-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

[431 F 220-PDAHH] {> 15mbar} If high-high differential pressure is detected across the filter
bags or if the switch fails for more than 5 seconds
-

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

2.6.4.8 Fan 431 F 230


[431 F 230M1] If there is a fault detected in the electric motor or in the MCC of this motor
cause an alarm
equipment trips.
[431 F 230-SAL] The fan is equipped with a proximity type low-speed switch measuring the
frequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low or
the switch fails
-

cause an alarm followed


equipment trips

If the fan trips


-

an alarm is generated
fan (431 F 230) is shut down instantly
cause an alarm
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.

2.6.4.9 Throttle Flap with Servo Drive 431 F 240


[431 F 240-ZL / ZH] The throttle flap is equipped with two limit switches, incorporated in a
control box fitted to the drive unit. If a limit switch fails
-

causes an alarm
equipment trips

[431 F 240-XAL / XAH] The throttle flap is equipped with two torque switches, incorporated in
a control box fitted to the drive unit. If a switch is actuated or a electric motor: [431 F 240M1]
If there is a fault detected in the motor or in the MCC of this motor
-

cause an alarm
equipment trips

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

cause an alarm
equipment trips.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006
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22 (28)

Rev. 00

If the throttle flap trips


-

alarm is generated
flap (431 F 240) is shut down instantly
This will cause an alarm
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.

2.6.4.10 Fan 431 F 245 Circulation Fan [431 F 245M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an
equipment trips

[431 F 245-SAL] The fan is equipped with a proximity type low-speed switch measuring the
frequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low or
the switch fails
-

cause an alarm
equipment trips

[431 F 245-VAH] The fan is equipped with a vibration switch. If vibration is too high
-

fan trips

If the fan trips


-

alarm is generated
fan (431 F 245) is shut down instantly
This will cause an
Fast Shut Down of this Group (see 2.6.3 above), which is initiated automatically.

2.6.4.11 Rotary Lock 431 F 260


[431 F 260-SAL] The rotary lock is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-

cause an alarm
equipment trips

[431 F 260M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an alarm
equipment trips

If the rotary lock trips


-

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

2.6.4.12 Drum-Type Magnetic Separator 431 F 265


[431 F 265-M1] If there is a fault detected in the electric motor or in the MCC of the motor
-

cause an alarm
equipment trips

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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23 (28)

Rev. 00

[431 F 265-SAL] The magnetic separator is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the magnetic drum. If the frequency of the
drum is too low or the switch fails
-

cause an alarm
equipment trips

If the magnet drive trips


-

alarm is generated
Fast Shut Down (see 2.6.3 above) of this Group 431 F is executed.

2.6.4.13 Impact Flow Meter 431 F 275


A collective fault signal is causing an alarm and disables the flow meter.

If SE 5-1 (Auto Level) is selected


causing Normal Shut Down as described above (see 2.6.1).
If SE 5-3 (Auto Flow Meter) is selected
causing a Normal Shut Down as described above (see 2.6.1).

2.6.4.14 Reversing Flap 431 F 280


[431 F 280-ZH] The reversing flap is equipped with a limit switch. If the limit switch fails
-

causes an alarm
Fast Shut Down as described above (see 2.6.3).

2.6.4.15 Rotary Lock 431 F 305


[431 F 305-SAL] The rotary lock is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-

cause an alarm
equipment trips

[431 F 305M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an alarm
equipment trips

If the rotary lock trips


-

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

2.6.4.16 Automatic Sampler 431 F 310 pneumatic [431 F 310-ZH / ZL] The sampler is equipped with two proximity type limit switches. If one of
the switches fails
-

cause an alarm
equipment trips

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
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Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
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OTK ref.:
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Doc. No.:
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24 (28)

Rev. 00

The maximum time required by the pneumatic drive for tilting the pelican type sampler from
one limit switch to the other one shall not be more than 10 seconds. If after 10 seconds the
limit switch is not reached
-

cause an alarm
equipment trips

If the sampler trips


-

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

2.6.4.17 Rotary Lock 431 F 315


[431 F 315-SAL] The rotary lock is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-

cause an alarm
equipment trips

[431 F 315M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an alarm
equipment trips

If the rotary lock trips


-

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

2.6.4.18 Screw Conveyor 431 F 320


[431 F 320-SAL] The screw conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the screw. If the frequency of the screw is too
low or the switch fails this
cause an alarm
equipment trips
[431 F 320M1] If there is a fault detected in the electric motor or in the MCC of this motor
cause an alarm
equipment trips
-

If the conveyor trips


-

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

2.6.4.19 Reversing Flap 431 F 325 pneumatic [431 F 325-ZH / ZL] The flap is equipped with two proximity type limit switches. If one of the
switches fails
-

causing an alarm
equipment trips

Outokumpu Technology GmbH

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25 (28)

Rev. 00

The maximum time required by the pneumatic drive for tilting the reversing blade from one
limit switch to the other one shall not be more than 10 seconds. If after 10 seconds the limit
switch is not reached
-

causing an alarm
equipment trips

If the flap trips


-

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

2.6.4.20 Screw Conveyor 431 F 330


[431 F 330-SAL] The screw conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the screw. If the frequency of the screw is too
low or the switch fails
-

cause an alarm
equipment trips

[431 F 330M1] If there is a fault detected in the motor or in the MCC of this electric motor
-

cause an alarm
equipment trips

If the conveyor trips


-

alarm is generated
if the reversing flap (431 F 325) is positioned to feed this screw conveyor [limit switch
431 F 325-ZL is activated] a Fast Shut Down for this Group (see 3.5.3 above) is
initiated automatically.

2.6.4.21 Screw Conveyor 431 F 335


[431 F 335-SAL] The screw conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the screw. If the frequency of the screw is too
low or the switch fails
-

cause an alarm
equipment trips

[431 F 335M1] If there is a fault detected in the electric motor or in the MCC of this motor
-

cause an alarm
equipment trips

If the conveyor trips


-

alarm is generated
if the reversing flap (431 F 325) is positioned to feed the screw conveyor (431 F 330)
[limit switch 431 F 325-ZL is activated] a Fast Shut Down for this Group (see 3.5.3
above) is initiated automatically.

Outokumpu Technology GmbH

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26 (28)

Rev. 00

2.6.4.22 Ball Mill Fraction Bin 431 F 400


[431 F 400-LY] The bin is equipped with a continuous level measurement (load cell system). If
the level measurement fails
-

cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZL is not
activated] to feed the screw conveyor (431 F 330) a Normal Shut Down of this Group
(see 2.6.1 above) is initiated automatically.

[431 F 400-LAHH] The bin is equipped with a level probe. If the level measurement fails
-

cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZL is not
activated] to feed the screw conveyor (431 F 330) a Fast Shut Down of this Group
(see 2.6.3 above) is initiated automatically.

2.6.4.23 Fresh Adsorbent Bin 431 F 450


[431 F 450-LY] The bin is equipped with a continuous level measurement (load cell system). If
the level measurement fails
-

cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZH is not
activated] to feed the Ball Mill Feed bin (431 F 400) a Normal Shut Down of this Group
(see 2.6.1 above) is initiated automatically.

[431 F 450-LAHH] The bin is equipped with a level probe. If the level measurement fails
-

cause an alarm
if the reversing flap (431 F 325) is not in position [limit switch 431 F 325-ZH is not
activated] to feed the Ball Mill Fraction bin (431 F 400) a Fast Shut Down of this Group
(see 3.5.3 above) is initiated automatically.

2.6.5

Shut Down by Full Bins

2.6.5.1

Ball Mill Fraction Bin 431 F 400


If Auto Select SE 2-3 is selected and if the fraction bin is full (bin level is >/= 95% [431 F 400LAH2]) and the flap of reversing flap (431 F 325) is not after a travel time of 90 seconds at
100% material flow to screw conveyor (431 F 330) [limit switch 431 F 325-ZL is not actuated]
-

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

If Manual Select SE 2-4 is selected and if the fraction bin is full (bin level is >/= 95% [431 F
400-LAH2]) and the flap of reversing flap (431 F 325) is not at 100% material flow to screw
conveyor (431 F 330) [limit switch 431 F 325-ZL is not actuated]
-

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

If the fraction bin is totally full (bin level >/= 100% [431 F 400-LAHH]) and the flap of reversing
flap (431 F 325) is not at 100% material flow to screw conveyor (431 F 330) [limit switch 431 F
325-ZL actuated]
-

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

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070

27 (28)

Rev. 00

If the fraction bin is full (bin level is >/= 95% [431 F 400-LAH2]) and if the Fresh Adsorbent bin
(431 F 450) is also full (bin level is >/= 95% [431 F 450-LAH2 and/or bin level >/= 100% [431 F
450-LAHH])
-

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

2.6.5.2 Fresh Adsorbent Bin 431 F 450


If Auto Select SE 2-3 is selected and if the bin is full (bin level is >/= 95% [431 F 450-LAH2])
and the flap of reversing flap (431 F 325) is not after a travel time of 90 seconds at 100%
material flow to the Ball Mill Feed bin (431 F 400) [limit switch 431 F 325-ZH is not actuated]
-

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

If Manual Select SE 2-4 is selected and if the bin is full (bin level is >/= 95% [431 F 450LAH2]) and the flap of reversing flap (431 F 325) is not at 100% material flow to the Ball Mill
Feed bin (431 F 400) [limit switch 431 F 325-ZH is not actuated]
-

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

If the bin is totally full (bin level >/= 100% [431 F 450-LAHH]) and the flap of reversing flap
(431 F 325) is not at 100% material flow to the Ball Mill Feed bin (431 F 330) [limit switch 431
F 325-ZH is not actuated]
-

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

If the bin is full (bin level is >/= 95% [431 F 450-LAH2]) and if the Ball Mill Feed bin (431 F
400) is also full (bin level is >/= 95% [431 F 400-LAH2 and/or bin level >/= 100% [431 F 400LAHH])
-

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

2.7

Local Operation of Special Equipment

2.7.1

Ball Mill Sub-Group 431 F 100


Local operation of the ball mill requires the lubrication units, jack pumps, grease spry unit,
inching drive to start and stop in certain sequence.
Note: This sequence has to be described by MBE.

Outokumpu Technology GmbH

CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-070
2.8

Rev. 00

Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal

Description

Sort of Signal

from Group 431 C to Group 431


F

Group 431 C is running in


CENTRAL mode and is not in any
Group START or STOP sequence
Floor Dust Bin is indicating very
high level [431 C 100-LAH2]
6.6 kV available

Digital signal within PLC Number


431 PLC 12

from Group 431 C to Group 431


F
from Medium Voltage Substation
to Group 431 F
from Group 431 F to Group 431
F 100
from Group 431 F to Group 431
F 100
from Sub-Group 431 F 100 to
Group 431 F
from Sub-Group 431 F 100 to
Group 431 F
from Sub-Group 431 F 100 to
Group 431 F
from Group 431 F to Group 431
F 100
from Sub-Group 431 F 100 to
Group 431 F

Outokumpu Technology GmbH

Start Sub-Group 431 F


Stop Sub-Group 431 F
Sub-Group 431 F 100 is running in
CENTRAL mode and is not in any
Group START or STOP sequence
and is not tripped
Sub-Group 431 F 100 is ready to
be started
Sub-Group 431 F 100 is
completely shut down
Further signals to be described by
MBE
Further signals to be described by
MBE

Digital signal within PLC Number


431 PLC 12
by VEDANTA
Digital signal within PLC Number
431 PLC 12
Digital signal within PLC Number
431 PLC 12
Digital signal within PLC Number
431 PLC 12
Digital signal within PLC Number
431 PLC 12
Digital signal within PLC Number
431 PLC 12
Digital signal within PLC Number
431 PLC 12
Digital signal within PLC Number
431 PLC 12

28 (28)

Training Manual Green Anode Plant


Vedanta - Jharsuguda

13.3

Main Equipment

13.3.1

Belt Weigh Feeder 431/432 F 010

13.3.2

Double Pendulum Flap 431/432 F 025

13.3.3

Ball Mill 431/432 F 100

13.3.4

Dynamic Classifier 431/432 F 210

13.3.5

Cyclone 431/432 F 215

13.3.6

Throttle Flap (motorized) 431/432 F 240

13.3.7

Circulation Fan 431/432 F 245

13.3.8

Drum-Type Magnetic Separator 431/432 F 265

13.3.9

Impact Flow Meter 431/432 F 275

138-02-043
Group 431/432 F
DE-060300

13.3.10 Automatic Sampler (pneumatic) 431/432 F 310

Outokumpu Technology GmbH


Page 12 of 12

Revision: 0
Date: 29.09.2006
file: 138-02-043_13_0.doc, Codeword: Vedanta