FUD East Bunati Rev120318

BUNATI-CPP STOCKPILE & PORT Dir.
Ref: BIB-LDP-I-E-001
PLANT CONTROL SYSTEM Date : 22-12-2017
CONTROL PHILOSOPHY
CONTENTS
1.1 PLC Hardware General ........................................................................................ 17
1.2 PLC Communication Hardware General ............................................................. 18
1.3 SCADA Hardware General .................................................................................. 20
1.4 SCADA Software General ................................................................................... 21
1.5 Coal Preparation Plant (CPP) PLC ...................................................................... 21
1.5.1 CPP PLC Communications ........................................................................... 22
1.6 CPP Operation Philosophy .................................................................................. 23
1.6.1 Synchronizing Generator ............................................................................. 23
1.6.2 DSE 8610 Synchronous Module................................................................... 24
1.7 1500 TPH Dump Hopper ...................................................................................... 25
1.8 Low Level Switch ................................................................................................ 25
1.9 Chain Feeder ........................................................................................................ 26
1.9.1 Chain Feeder VVVF and Motor .................................................................... 26
1.9.2 Variable Speed Drive ..................................................................................... 26
1.9.3 Hardwire Emergency Stop ............................................................................ 27
1.9.4 Motor temperature .................................................................................... 28
1.10 Chain Feeder Indication & Operation .............. Error! Bookmark not defined.
1.9.5.1 Motor Faceplate Indications ....................... Error! Bookmark not defined.
1.9.5.2 Motor Faceplate Operations........................ Error! Bookmark not defined.
1.9.5.3 Motor Faceplate Statistics Information’s .. Error! Bookmark not defined.
1.9.5.4 Chain Feeder Safety Devices & Faults ....... Error! Bookmark not defined.
1.9.5.5 Local Control Station .................................. Error! Bookmark not defined.
1.9.5.6 Startup Warning Horn ................................. Error! Bookmark not defined.
1.9.5.7 MCCB Main Circuit Breaker Status ......... Error! Bookmark not defined.
1.9.5.8 Chain Feeder Start Permissive .................... Error! Bookmark not defined.
1.9.5.9 Chain Feeder Process Interlocks ................. Error! Bookmark not defined.
1.9.5.10 Chain Feeder Operation ............................ Error! Bookmark not defined.
1.9.5.11 Divergator ................................................................................................. 28
1.9.5.12 Primary Crusher ........................................................................................ 28
1.9.5.13 Primary Crusher SS and Motor ................................................................. 28
1.9.5.14 Primary Crusher Indication & Operation.................................................. 30
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BUNATI-CPP STOCKPILE & PORT Dir. Ref: BIB-LDP-I-E-001
CONTROL PHILOSOPHY
1.9.5.15 Primary Crusher Safety Devices & Faults ................................................ 32

1.9.5.16 Primary Crusher Start Permissive ............................................................. 34
1.9.5.17 Primary Crusher Process Interlocks .......................................................... 35
1.9.5.18 Primary Crusher Operation ....................................................................... 36
2.0 Transfer Conveyor CV-109 .................................................................................. 38
2.1 Transfer Conveyor VVVF and Motor .............................................................. 38
2.1.1 Hardwire Emergency Stop ............................................................................. 39
2.1.2 Motor temperature ......................................................................................... 40
2.2 Transfer Conveyor CV-109 Indication & Operation ........................................ 40
2.2.1 Motor Faceplate Indications .......................................................................... 40
2.2.2 Motor Faceplate Operations........................................................................... 41
2.2.3 Motor Faceplate Statistics information .......................................................... 42
2.3 Transfer Conveyor CV-109 Safety Devices & Faults ...................................... 44
2.3.1 Local Control Station ..................................................................................... 44
2.3.2 Pull Wire Switches (PWS) ............................................................................. 45
2.3.3 Belt Drift Switches (BDS) ............................................................................. 46
2.3.4 Blocked Chute Switches (BCS) ..................................................................... 47
2.3.5 Belt Rip Switch (BRS) ................................................................................... 48
2.3.6 Take-Up Switches .......................................................................................... 49
2.3.7 Under speeds Sensor (USS) ........................................................................... 50
2.3.8 Metal Detector (MD CV 101) ........................................................................ 51
2.3.9 Startup Warning Horn .................................................................................... 52
2.3.10 MCCB Main Circuit Breaker Status ............................................................ 52
2.4 Transfer Conveyor CV-109 Start Permissive ................................................... 52
2.5 Transfer Conveyor CV-109 Process Interlocks ................................................ 53
2.6 Transfer Conveyor CV-109 Operation ............................................................. 54
2.6.1 Operation Local Mode ................................................................................... 54
2.6.2 Operation Remote Mode ................................................................................ 55
2.7 Magnet Separator (MS CV-109) ...................... Error! Bookmark not defined.
2.7.1 MCCB – MCC Main Circuit Breaker Status . Error! Bookmark not defined.
2.7.2 Magnet Indications & Operation ................... Error! Bookmark not defined.
2.7.3 Magnet Faceplate Indications ........................ Error! Bookmark not defined.
2.7.4 Magnet Faceplate Operation .......................... Error! Bookmark not defined.
2.7.5 Magnet Statistic Information ......................... Error! Bookmark not defined.
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2.8 Magnet Safety Device & Faults ....................... Error! Bookmark not defined.
2.8.1 Emergency Stop ............................................. Error! Bookmark not defined.
2.8.2 Main Switch ................................................... Error! Bookmark not defined.
2.8.3 Magnet Energized .......................................... Error! Bookmark not defined.
2.8.4 Magnetic Running Feedback Failed .............. Error! Bookmark not defined.
2.8.5 Magnet Start Permissive ................................ Error! Bookmark not defined.
2.8.6 Magnet Process Interlocks ............................. Error! Bookmark not defined.
2.8.7 Magnet Operation .......................................... Error! Bookmark not defined.
2.8.7.1 Magnet Operation Local Mode ................... Error! Bookmark not defined.
2.8.7.2 Magnet Operation Remote Mode ............... Error! Bookmark not defined.
2.8.8 Magnet Cleaning ............................................ Error! Bookmark not defined.
2.9 Secondary Crusher ................................................ Error! Bookmark not defined.
2.9.1 Soft Starter ..................................................... Error! Bookmark not defined.
2.9.2 Hardwire Emergency Stop ............................. Error! Bookmark not defined.
2.9.3 Motor temperature ......................................... Error! Bookmark not defined.
2.9.4 Motor Faceplate Indications .......................... Error! Bookmark not defined.
2.9.5 Motor Faceplate Operations........................... Error! Bookmark not defined.
2.9.6 Motor Faceplate Statistics information .......... Error! Bookmark not defined.
2.10 Secondary Crusher Safety Devices & Faults Error! Bookmark not defined.
2.10.1 Local Control Station ................................... Error! Bookmark not defined.
2.10.2 MCCB Main Circuit Breaker Status ............ Error! Bookmark not defined.
2.10.3 Secondary Crusher Start Permissive ............ Error! Bookmark not defined.
2.10.4 Secondary Crusher Process Interlocks ......... Error! Bookmark not defined.
2.10.5 Secondary Crusher Operation ...................... Error! Bookmark not defined.
2.10.6 Operation Local Mode ................................. Error! Bookmark not defined.
2.10.7 Operation Remote Mode .............................. Error! Bookmark not defined.
3.2 Hardwire Emergency Stop .................................................................................... 77
3.3 Motor temperature ............................................................................................ 77
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3.5.2 Pull Wire Switches (PWS) ............................................................................. 83
3.5.3 Belt Drift Switches (BDS) ............................................................................. 84
3.5.4 Blocked Chute Switches (BCS) ..................................................................... 85
3.5.5 Belt Rip Switch (BRS) ................................................................................... 86
3.5.6 Take-Up Switch (TUS) .................................................................................. 87
3.5.7 Under speeds Sensor (USS) ........................................................................... 88
3.5.8 Startup Warning Horn .................................................................................... 89
3.5.9 MCCB Main Circuit Breaker Status .............................................................. 89
3.6 Transfer Conveyor CV-110 Start Permissive ................................................... 90
3.7 Transfer Conveyor CV-110 Process Interlocks ................................................ 90
3.7.1 Transfer Conveyor CV-110 Operation ........................................................... 91
3.7.2 Operation Local Mode ................................................................................... 91
3.7.3 Operation Remote Mode ................................................................................ 92
4.0 Belt Plough 1 ....................................................... Error! Bookmark not defined.
4.1 Belt Plough MCC and Motor ........................... Error! Bookmark not defined.
4.1.1 Motor Control Centre..................................... Error! Bookmark not defined.
4.1.2 Hardwired Circuit .......................................... Error! Bookmark not defined.
4.1.3 Hardwire Healthy ........................................... Error! Bookmark not defined.
4.1.4 Running .......................................................... Error! Bookmark not defined.
4.1.5 Motor Overload.............................................. Error! Bookmark not defined.
4.1.6 Earth Leakage ................................................ Error! Bookmark not defined.
4.1.7 MCC Main Circuit Breaker Status ................. Error! Bookmark not defined.
4.2 Belt Plough 1 Indication & Operation ............ Error! Bookmark not defined.
4.3 Belt Plough 1 Safety Devices & Faults ................ Error! Bookmark not defined.
4.3.1 Local Control Station ..................................... Error! Bookmark not defined.
4.3.2 MCCB Main Circuit Breaker Status .............. Error! Bookmark not defined.
4.3.3 Stockpile Limit Switch (SLS) ........................ Error! Bookmark not defined.
4.3.4 Low Level Switch .......................................... Error! Bookmark not defined.
4.4 The Belt Plough 1 Start Permissive ................. Error! Bookmark not defined.
4.5 The Belt Plough 1 Process Interlocks .............. Error! Bookmark not defined.
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4.6 The Belt Plough 1 Operation............................ Error! Bookmark not defined.

4.6.1 Operation Local Mode ................................... Error! Bookmark not defined.
4.6.2 Operation Remote Mode ................................ Error! Bookmark not defined.
4.2 Hardwire Emergency Stop ............................................................................... 94
4.3 Motor temperature ............................................................................................ 94
4.5.2 Pull Wire Switches (PWS) ........................................................................... 100
4.5.3 Belt Drift Switches (BDS) ........................................................................... 101
4.5.4 Belt Rip Switch (BRS) ................................................................................. 102
4.5.5 Take-Up Switch (TUS) ................................................................................ 103
4.5.6 Startup Warning Horn .................................................................................. 103
4.5.7 MCCB Main Circuit Breaker Status ............................................................ 104
4.6 Transfer Conveyor CV-111 Start Permissive ................................................. 104
4.7 Transfer Conveyor CV-111 Process Interlocks ................................................... 105
4.8 Transfer Conveyor CV-111 Operation ................................................................ 106
4.8.1 Operation Local Mode ................................................................................. 106
4.8.2 Operation Remote Mode .............................................................................. 107
6.2 Belt Plough 2 Indication & Operation ............. Error! Bookmark not defined.
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6.3 Belt Plough 2 Safety Devices & Faults ............ Error! Bookmark not defined.
6.4 The Belt Plough 2 Start Permissive.................. Error! Bookmark not defined.
7.1 Belt Plough MCC and Motor ................................ Error! Bookmark not defined.
7.2 Belt Plough 3 Indication & Operation .................. Error! Bookmark not defined.
7.4 The Belt Plough 3 Start Permissive.................. Error! Bookmark not defined.
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8.2 Belt Plough 4 Indication & Operation .................. Error! Bookmark not defined.
8.3 Belt Plough 4 Safety Devices & Faults ................ Error! Bookmark not defined.
8.4 The Belt Plough 4 Start Permissive ...................... Error! Bookmark not defined.
9.2 Belt Plough 5 Indication & Operation ............. Error! Bookmark not defined.
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9.4 The Belt Plough 5 Start Permissive ...................... Error! Bookmark not defined.
10.0 Transfer Conveyor CV-104 .............................. Error! Bookmark not defined.
10.1 Transfer Conveyor VVVF and Motor .......... Error! Bookmark not defined.
10.2 Hardwire Emergency Stop .................................. Error! Bookmark not defined.
10.3 Motor temperature .............................................. Error! Bookmark not defined.
10.4 Transfer Conveyor CV-104 Indication & Operation ......... Error! Bookmark not
defined.
10.4.1 Motor Faceplate Indications ........................ Error! Bookmark not defined.
10.4.2 Motor Faceplate Operations......................... Error! Bookmark not defined.
10.4.3 Motor Faceplate Statistics information ........ Error! Bookmark not defined.
10.5 Transfer Conveyor CV-104 Safety Devices & Faults . Error! Bookmark not
defined.
10.5.2 Pull Wire Switches (PWS) ........................... Error! Bookmark not defined.
10.5.3 Belt Drift Switches (BDS) ........................... Error! Bookmark not defined.
10.5.4 Belt Rip Switch (BRS) ................................. Error! Bookmark not defined.
10.5.5 Take-Up Switch (TUS) ................................ Error! Bookmark not defined.
10.5.6 Under speeds Sensor (USS) ......................... Error! Bookmark not defined.
10.5.7 Startup Warning Horn .................................. Error! Bookmark not defined.
10.6 Transfer Conveyor CV-104 Start Permissive Error! Bookmark not defined.
10.7 Transfer Conveyor CV-104 Process Interlocks ........... Error! Bookmark not
defined.
10.8 Transfer Conveyor CV-104 Operation ......... Error! Bookmark not defined.
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11.0 Belt Plough 6 .................................................... Error! Bookmark not defined.

11.1 Belt Plough MCC and Motor ....................... Error! Bookmark not defined.
11.1.1 Motor Control Centre ................................... Error! Bookmark not defined.
11.1.2 Hardwired Circuit ........................................ Error! Bookmark not defined.
11.1.3 Hardwire Healthy ......................................... Error! Bookmark not defined.
11.1.4 Running ........................................................ Error! Bookmark not defined.
11.1.5 Motor Overload ............................................ Error! Bookmark not defined.
11.1.6 Earth Leakage .............................................. Error! Bookmark not defined.
11.1.7 MCC Main Circuit Breaker Status ............... Error! Bookmark not defined.
11.2 Belt Plough 6 Indication & Operation ............ Error! Bookmark not defined.
11.2.2 Motor Faceplate Operations ......................... Error! Bookmark not defined.
11.3 Belt Plough 6 Safety Devices & Faults ........ Error! Bookmark not defined.
11.3.3 Stockpile Limit Switch (SLS) ...................... Error! Bookmark not defined.
11.3.4 Low Level Switch ........................................ Error! Bookmark not defined.
11.4 The Belt Plough 6 Start Permissive .............. Error! Bookmark not defined.
11.5 The Belt Plough 6 Process Interlocks ........... Error! Bookmark not defined.
11.6 The Belt Plough 6 Operation ........................ Error! Bookmark not defined.
12.1.1 Motor Control Centre................................... Error! Bookmark not defined.
12.1.5 Motor Overload............................................ Error! Bookmark not defined.
12.2 Belt Plough 7 Indication & Operation .......... Error! Bookmark not defined.
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12.5 The Belt Plough 7 Process Interlocks ................. Error! Bookmark not defined.
12.6 The Belt Plough 7 Operation .............................. Error! Bookmark not defined.
13.2 Belt Plough 8 Indication & Operation ................ Error! Bookmark not defined.
14.1 Belt Plough MCC and Motor .............................. Error! Bookmark not defined.
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14.2 Belt Plough 9 Indication & Operation .......... Error! Bookmark not defined.
15.0 Drawdown Hopper 1 ........................................ Error! Bookmark not defined.
15.1 Vibrator Bin 1 ............................................... Error! Bookmark not defined.
15.1.1 Vibrator Bin MCC and Motor ...................... Error! Bookmark not defined.
15.1.2 Vibrator Bin 1 Indication & Operation ........ Error! Bookmark not defined.
15.1.3 Vibrator Bin 1 Safety Devices & Faults ...... Error! Bookmark not defined.
15.1.4 The Vibrator Bin 1 Start Permissive ............ Error! Bookmark not defined.
15.1.5 The Vibrator Bin 1 Process Interlocks ......... Error! Bookmark not defined.
15.1.6 The Vibrator Bin 1 Operation ...................... Error! Bookmark not defined.
15.2 Slide gate 1 ................................................... Error! Bookmark not defined.
15.2.1 Slide gate MCC and Motor .......................... Error! Bookmark not defined.
15.2.2 Slide gate 1 Indication & Operation ............ Error! Bookmark not defined.
15.2.3 Slide gate 1 Safety Devices & Faults........... Error! Bookmark not defined.
15.2.4 Slide gate 1 Start Permissive........................ Error! Bookmark not defined.
15.2.5 The Slide gate 1 Process Interlocks ............. Error! Bookmark not defined.
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15.2.6 The Slide gate 1 Operation .......................... Error! Bookmark not defined.
16.2.4 The Slide gate 2 Start Permissive ................ Error! Bookmark not defined.
17.2 Slide Gate 3 .................................................. Error! Bookmark not defined.
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19.0 Reclaimer Conveyor CV-105 ........................... Error! Bookmark not defined.
19.1 Reclaimer Conveyor VVVF and Motor ....... Error! Bookmark not defined.
19.2 Hardwire Emergency Stop............................ Error! Bookmark not defined.
19.3 Motor temperature ........................................ Error! Bookmark not defined.
19.4 Reclaimer Conveyor CV-105 Indication & Operation Error! Bookmark not
defined.
19.5 Motor Faceplate Statistics information......... Error! Bookmark not defined.
19.6 Reclaimer Conveyor CV-105 Safety Devices & Faults ..... Error! Bookmark
not defined.
19.6.4 Blocked Chute Switches (BCS) ................... Error! Bookmark not defined.
19.6.8 Start Up Warning Horn ................................ Error! Bookmark not defined.
19.7 Reclaimer Conveyor CV-105 Start Permissive .......... Error! Bookmark not
defined.
19.8 Reclaimer Conveyor CV-105 Process Interlocks ........ Error! Bookmark not
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defined.
19.9 Reclaimer Conveyor CV-105 Operation ...... Error! Bookmark not defined.
19.10 Conveyor Coal Flow Monitoring ................. Error! Bookmark not defined.
20.0 Reclaimer Conveyor CV-106 ........................... Error! Bookmark not defined.
20.1 Reclaimer Conveyor VVVF and Motor ....... Error! Bookmark not defined.
20.4 Reclaimer Conveyor CV-106 Indication & Operation Error! Bookmark not
defined.
20.6 Reclaimer Conveyor CV-106 Safety Devices & Faults ..... Error! Bookmark
not defined.
20.6.8 Start Up Warning Horn ................................ Error! Bookmark not defined.
20.7 Reclaimer Conveyor CV-106 Start Permissive ........... Error! Bookmark not
defined.
20.8 Reclaimer Conveyor CV-106 Process Interlocks ........ Error! Bookmark not
defined.
20.9 Reclaimer Conveyor CV-106 Operation ...... Error! Bookmark not defined.
20.9.1 Operation Local Mode ..................................... Error! Bookmark not defined.
20.10 Conveyor Coal Flow Monitoring ................. Error! Bookmark not defined.
21.0 Bypass Conveyor CV-107 ............................... Error! Bookmark not defined.
21.1 Bypass Conveyor VVVF and Motor ............ Error! Bookmark not defined.
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CONTROL PHILOSOPHY

21.4 Bypass Conveyor CV-107 Indication & Operation ..... Error! Bookmark not
defined.
21.6 Bypass Conveyor CV-107 Safety Devices & Faults ... Error! Bookmark not
defined.
21.6.6 Take-Up Switches ........................................ Error! Bookmark not defined.
21.6.8 Metal Detector (MD CV-107) ...................................................................... 63
21.6.9 Start up Warning Horn ................................. Error! Bookmark not defined.
21.6.10 MCCB Main Circuit Breaker Status .......... Error! Bookmark not defined.
21.7 Bypass Conveyor CV-107 Start Permissive . Error! Bookmark not defined.
21.8 Bypass Conveyor CV-107 Process Interlocks ............ Error! Bookmark not
defined.
21.9 Bypass Conveyor CV-107 Operation ........... Error! Bookmark not defined.
21.10 Magnet Separator (MS CV-107) ....................... Error! Bookmark not defined.
21.11 MCCB – MCC Main Circuit Breaker Status .... Error! Bookmark not defined.
21.12 Magnet Indications & Operation ...................... Error! Bookmark not defined.
21.13 Magnet Faceplate Indications ........................... Error! Bookmark not defined.
21.14 Magnet Faceplate Operation ............................. Error! Bookmark not defined.
21.15 Magnet Statistic Information ............................ Error! Bookmark not defined.
21.16 Magnet Safety Device & Faults ........................ Error! Bookmark not defined.
21.16.1 Emergency Stop ......................................... Error! Bookmark not defined.
21.6.2 Main Switch ................................................. Error! Bookmark not defined.
21.17 Magnet Energized ............................................. Error! Bookmark not defined.
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CONTROL PHILOSOPHY
21.18 Magnetic Running Feedback Failed ................. Error! Bookmark not defined.
21.19 Magnet Start Permissive ................................... Error! Bookmark not defined.
21.20 Magnet Process Interlocks ................................ Error! Bookmark not defined.
21.21 Magnet Operation ............................................. Error! Bookmark not defined.
21.21.1 Magnet Operation Local Mode .................. Error! Bookmark not defined.
21.21.2 Magnet Operation Remote Mode .............. Error! Bookmark not defined.
21.22 Magnet Cleaning ............................................... Error! Bookmark not defined.
22.0 Diverter Gate CV-107 .................................................................................... 108
22.1 Diverter Gate MCC and Motor................................................................... 108
22.1.1 Motor Control Centre................................................................................. 108
22.1.2 Hardwired Circuit ...................................................................................... 108
22.1.3 Hardwire Healthy ....................................................................................... 108
22.1.4 Running ...................................................................................................... 109
22.1.5 Motor Overload.......................................................................................... 109
22.1.6 Earth Leakage ............................................................................................ 109
22.1.7 MCC Main Circuit Breaker Status ............................................................. 110
22.2 Diverter Gate CV-107 Indication & Operation .......................................... 111
22.2.1 Motor Faceplate Indications ...................................................................... 111
22.2.2 Motor Faceplate Operations....................................................................... 111
22.4 Diverter Gate CV-107 Safety Devices & Faults ......................................... 112
22.4.1 Local Control Station ................................................................................. 112
22.4.2 MCCB Main Circuit Breaker Status .......................................................... 113
22.4.3 Position Switch .......................................................................................... 114
22.5 The Diverter Gate CV-107 Start Permissive .............................................. 114
22.6 The Diverter Gate CV-107 Process Interlocks ........................................... 115
22.7 The Diverter Gate CV-107 Operation ........................................................ 115
22.7.1 Operation Local Mode ............................................................................... 115
22.7.2 Operation Remote Mode ............................................................................ 116
22.7.3 Auto Coal Sampler ....................................... Error! Bookmark not defined.
22.8 Sample Plant Operation ................................ Error! Bookmark not defined.
22.8.1 Sample Plant Auto Mode (Remote) ............. Error! Bookmark not defined.
22.8.2 Sample Plant Local Mode ............................ Error! Bookmark not defined.
22.8.3 Sample Plant Manual Mode ......................... Error! Bookmark not defined.
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CONTROL PHILOSOPHY
22.8.4 Sample Plant off (Local or Remote) ............ Error! Bookmark not defined.
22.8.5 Sample Plant Auto (Local) ........................... Error! Bookmark not defined.
22.8.6 Sample Plant Auto Start ............................... Error! Bookmark not defined.
22.8.7 Sample Plant Auto Stop ............................... Error! Bookmark not defined.
22.8.8 Sample Plant Communications .................... Error! Bookmark not defined.
22.8.9 Sampler Process Interlocks .......................... Error! Bookmark not defined.
22.9 Dust Suppression .......................................... Error! Bookmark not defined.
22.10 Solenoid Faceplate Indication ........................... Error! Bookmark not defined.
22.11 Solenoid Faceplate Operations ......................... Error! Bookmark not defined.
23.0 Vvvf Warning & Fault Codes......................................................................... 117
1.0 General System Configuration
The entire plant Control System Consists of Siemens S7-1500 PLC
Hardware controlled With SIMATIC WinCC Professional Siemens offers a SCADA
system which is perfectly integrated in the WinCC Professional Siemens and with
which you are optimally prepared today for the requirements of the increasing
digitalization of production processes.
SIMATIC WinCC Runtime Professional is a PC-based operator control and
monitoring system for visualization and operator control of processes, production flows,
machines and plants in all sectors – from the simple single-user station through to
distributed multi-user systems and cross-location solutions with web clients.
1.1 PLC Hardware General
All PLC Hardware used for the Coal Preparation Plant (CPP) East Bunati
Project will be Siemens S7-1500 Modular type with details as follows,
Power Supply – 1 ea. - Simatic S7-1500, System Power Supply Ps 60w 120/230v
Ac/Dc, Supplies the Operating Voltage for the S7-1500 via the Backplane Bus.
(6ES7507-0RA00-0AB0).
Simatic S7-1500 – 1 ea. CPU 1516-3 PN/DP, Central Processing Unit With working,
Memory 1 Mb For Program And 5 Mb For Data, 1. Interface: Profinet Irt with 2 Port
Switch, 2. Interface: Profinet RT, 3. Interface: PROFIBUS, 10 Ns Bit-Performance,
Simatic Memory Card Necessary. (6ES7516-3AN01-0AB0).
Simatic S7, Memory Card – 1 ea. For S7-1500 CPU/SINAMICS, 3.3 V Flash, 4
17
CONTROL PHILOSOPHY
MByte. (6ES7954-8LC02-0AA0).
Communication Module – 1 ea. – Simatic S7-1500, Cm PTP RS422/485 HF
Communication Module For Serial Connection Rs 422, Rs 485, Freeport, 3964(R), Uss,
Modbus Rtu Master, Slave,- 1 ea. 115200 Kbit/S, 15-Pin Sub-D Female Connector
(6ES7541-1AB00-0AB0).
Digital Input Modules - 21 ea – Simatic S7-1500, Digital Input Module Di 32xdc 24v
Hf, 32 Channels In Groups Of 16; Input Delay 0.05, 20 Ms; Input Type 3 (IEC 61131);
diagnosis, Process alarms. (6ES7521-1BL00-0AB0).
Digital Output Modules – 4 ea – Simatic S7-1500, Digital Output Module Dq 32 X
24v Dc/0.5a Hf; 32 Channels In Groups Of 8, 4 A Per Group; Single-Channel
Diagnosis; Substitute Value.(6ES7522-1BL01-0AB0).
Analogue Input Modules – 2 ea – Simatic S7-1500, Analog Input Module Ai 8 X U/I
Hs, 16 Bits Of Resolution, Accuracy 0.3 %; 8 Channels In Groups Of 8; Common Mode
Voltage Appr. 10v; Diagnosis, Process alarms; 8 Channels in 0.0625 Ms
Oversampling Incl. Infeed Element, Shield Clamp and Shield Terminal. (6ES7531-
7NF10-0AB0).
Analogue Output Modules – 2 ea – Simatic S7-1500, Analog Output Module Aq 8 X
U/I Hs 16 Bits Of Resolution, Accuracy 0.3 %, 8channels In Groups Of 8, Diagnosis,
Substitute Value 8 Channels In 0.125 Ms Incl. Infeed Element, Oversampling Shield
Clamp And Shield Terminal.(6ES7532-5HF00-0AB0).
Simatic S7-1500, MOUNTING RAIL – 1 ea - 830 Mm (APPR. 32,7 Inch); Incl.
Grounding Element, Integrated Din Rail For Mounting Of Small Components Such As
Clamps, Fuses Or Relays.(6ES7590-1AJ30-0AA0).
Simatic S7-1500 - 18 ea - FRONT CONNECTOR SCREW-TYPE, 40pin, For 35mm
Wide Modules, Incl. 4 Jumpers, And Cable Strap( 6ES7592-1AM00-0XB0 ).
1.2 PLC Communication Hardware General
Siemens PROFIBUS DP, Siemens Modbus RTU Master-Slave and Siemens

Profinet (Ethernet) use Scalance X204-2LD, are the communication protocols used
for communications of the plant control system devices.
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CONTROL PHILOSOPHY
Picture 1. Configuration Fiber Optik to PLC Master

PLC Processor, communication module and I/O module one (1) mounting
rails/Racks system.
PLC Processor to Siemens Variable Speed Drives, Soft starters and SENTRON
3WL air circuit breaker System communications will be PROFIBUS DP both Copper
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CONTROL PHILOSOPHY
Cabled and com sampler for CV-107 with auto sampler.

PLC Processor (via communication module) to DEEP SEA Synchronizing auto
start load share control module, Siemens SENTRON Power Monitoring PAC3200 and
Caterpillar generator set controller System communications will be Modbus RTU both
Copper Cabled.
PLC Processor and PLC Network to SIMATIC WinCC SCADA
communications will be Profinet (Ethernet) both Copper.
PLC Processor communication The Existing PLC Schneider for control BLC
CV-14 and CV-22 communications will be Fiber Cabled depending on the transmission
distance.
Industrial Ethernet switches equipment will be use Siemens Scalance X204-
2LD, managed IE Switch, 4x10/100 Mbit/s RJ45 Ports, 2x100.
1.3 SCADA Hardware General
The Coal Preparation Plant (CPP) East Bunati Project SCADA system will be a
server and client system for monitoring and operation of the East Bunati Plant.
A new full sized IT Cabinet will be installed in the Coal Preparation Plant (CPP)
Control Room which will house rack mounted hardware as follows,
Description for server computer is listed below:
Dell Power Edge R530 Server
 Intel Xeon E5-2620v4 2.1GHz 20M Cache.
 Redundant Power Supply 750W hot plug.
 8GB+16GB RDIMM 2400MT/s.
 DVD+/-RW.
 Hardisk 3.5” Rack is available up to 8 Slot.
 1Gigabit Ethernet 2 Port Tower x 2 Port Rack.
Description for client computer is listed below:
Dell OptiPlex 5050
 Intel Core i5-7500TM 3.4GHz 4 core 6MB Smart Cache.
 8+8GB Ram DDR4 2400 MHz
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CONTROL PHILOSOPHY
 DVD+/-RW.
 Integrated Gigabit Ethernet Speaker.
 Dell E2417H Wide Screen LED Monitor 24” Monitor.
The Operator will be facilitated with 24” Wide Screen Samsung Monitors,
keyboards, and mouse which will be connected to the Display Client Computers
installed in the Coal Preparation Plant (CPP) Control Room.
A Hewlett Packard A4 Color Laser printer will be installed on the CPP Control
Room and connected to the USB port in the PC Operator Workstation.
1.4 SCADA Software General

SCADA system Client-Server with SIMATIC WinCC Runtime Professional
visualization software Servers will have the following Operating System & SCADA
Software installed,
For server side will be installed software in listed below:
 Windows 10 Pro X64 ENG System Operation.
 WinCC system software v7.4 SP1, RC 8192 Power Tags.
Simatic Step 7 Professional V15 Floating License.
For client side will be installed software in listed below:
 Windows 10 Pro X64 System.
 WinCC system software V7.4 SP1, RT 128 Power Tags, runtime software.
 WinCC User Archives V7.4, Option for WinCC V7.4, runtime software.
 Simatic WinCC/Server V7.4, Option for WinCC V7.4, runtime software.
1.5 Coal Preparation Plant (CPP) PLC

A new free standing PLC enclosure consisting of S7-1500 1516-3 PN/DP
Processor, communication module and I/O module one (1) mounting rails/Racks will be
installed into the CPP Panel Room. This PLC will be referred to as “CPP PLC”.
The CPP PLC handles all indications and control functions for the following
equipment:
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CONTROL PHILOSOPHY
00. Genset.
00. Dump Hopper
Sensor Low Level Dump Hopper when the level of BB at DH < 10%, then
chain feeder will die and will run auto when BB level at DH reach > 35%.
1. Chain Feeder DH-108.
2. Diverter Gate DH-108.
2. Primary Crusher.
3. Transfer Conveyor CV-109.
4. Magnet Separator CV-109.
5. Belt Scale CV-109.
5. Metal Detector CV-109.
7. Diverter Gate CV-110.
8. Secondary Crusher.
30. Dust Suppression – Dust Suppression Solenoid Valves at the head end of
conveyor.
31. Communications PLC with Plant Existing.
1.5.1 CPP PLC Communications
CPP PLC/SCADA Communications are detailed on PLC Architecture

Block Diagram BIB-E-01-1001 ARC BIB.
PLC to PLC communications will be monitored continuously. In the event that a
communication failure occurs all plant will be crash stopped and the
communication error will appear on CPP SCADA alarms.
1.5.1.1 PROFIBUS DP
Siemens PROFIBUS DP communications is used for PLC to Remote
or monitoring Device Communications. PROFIBUS DP communications
of the CPP PLC S7-1500 1516-3 PN/DP CPU is connected to CPP MCC
all VSD, All Soft start, and Coal Sampler.
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CONTROL PHILOSOPHY
All read and write information and commands between PLC and all
VSD, All Soft start, Coal Sampler will be over the PROFIBUS DP
network.
1.5.1.2 Profinet (ETHERNET)

Siemens Profinet communications is used for CPP PLC to SCADA
communications. Profinet communications of the CPP PLC S7-1500
1516-3 PN/DP CPU is connected to Siemens Scalance X204-2LD,
managed IE Switch, 4x10/100 Mbit/sRJ45 Ports,2x100. Siemens
Scalance X204-2LD switch fiber port for communications to the Existing
PLC Schneider (BLC CV-14 and CV- 22) connected to a fiber
optic cable for communication to the Existing PLC Schneider and
SCADA network.
1.5.1.3 Modbus RTU Master-Slave

Siemens Modbus RTU communecation is used for PLC to Remote or
monitoring Device Communication. Modbus RTU communication of the
CPP PLC S7-1500 1516-3 PN/DP CPU (via communication module) is
connected to CPP LVMDP device DEEP SEA Synchronizing auto start
load share control module, Siemens SENTRON Power Monitoring
PAC3200, all ACB 3WL air circuit breaker and CPP generator local
control panel Caterpillar.
1.6 CPP Operation Philosophy
1.6.1 Synchronizing Generator
Synchronizing generator is parallelizing the work of two or more

generators to get the power of the amount of the generator with the condition
that has been determined.
The basic terms of the parallel generator are as follows:
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CONTROL PHILOSOPHY
1. Has the same working voltage.
2. Have the same phase sequence.
3. Having the same working frequency.
4. Has the same phase angle.
1.6.2 DSE 8610 Synchronous Module
The DSE8610 is an easy to use Synchronizing Auto Start Control

Module suitable for use in a multi-generator load share system, designed to
synchronize up to 32 generators including electronic and non-electronic
engines. The DSE8610 monitors the generator and indicates operational
status and fault conditions, automatically starting or stopping the engine on
load demand or fault condition. System alarms are annunciated on the
LCD screen (multiple language options available), illuminated LED and
audible sounder. The event log will record 250 events to facilitate easy
maintenance. An extensive number of fixed and flexible monitoring,
metering and protection features are included as well as comprehensive
communication and system expansion options. Using the DSE PC
Configuration Suite Software allows easy alteration of the operational
sequences, timers and alarms. With all communication ports capable of
being active at the same time, the DSE8610 is ideal for a wide variety of
demanding load share applications.
KEY FEATURES • Comprehensive synchronizing & load sharing

capabilities • Built-in governor and AVR control • Base load (kW export)
functionality • Positive & negative kVAR export control • Mains (utility)
de-coupling protection • Generator power (kW, kVAR, kV A & pf)
monitoring • Overload (kW & kVAR) protection • Reverse power (kW &
kVar) protection • Unbalanced load protection • Independent earth fault
protection • Advanced integral PLC editor • 11 Configurable inputs • 8
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CONTROL PHILOSOPHY
Configurable outputs • Configurable flexible sensor inputs • DSENet®

expansion compatibility • User configurable RS232, RS485 and Ethernet
communications • Remote SCADA monitoring via various DSE software
applications • MODBUS RTU & TCP support • User configurable
MODBUS pages • Advanced SMS control and fault messaging (additional
GSM modem required) • Easy access diagnostic pages including modem
diagnostic pages • Data logging and trending • CAN, MPU and Frequency
speed sensing • Tier 4 CAN engine support • “Protections disabled” feature
• Front panel editing with PIN protection • Fully configurable using DSE
Configuration Suite PC software via USB • 4 Line back-lit LCD text
display • LED and LCD alarm indication • Configurable display languages
• USB connectivity • Customizable status screens • Five key menu
navigation • 3 Configurable maintenance alarms • Multiple date and time
run scheduler • Manual fuel pump control • Fuel usage monitor and low
fuel level protection • Charge alternator failure protection • Load switching
(load shedding and dummy load control) • Configurable event log (250) •
Backed up real time clock.
KEY BENEFITS • Compatible in load share systems containing

DSE5500, DSE7500 and DSE8600 series. Contact DSE for further details
• 132 x 64 pixel ratio display for clarity • Real-time clock provides
accurate event logging • Ethernet communication, provides built in
advanced remote monitoring. • Can be integrated into building
management systems (BMS) and programmable logic control (PLC) •
Increased input and output expansion capability via DSENet ® • License-
free PC software • IP65 rating (with supplied gasket) offers increased
resistance to water ingress • Advanced Internal PLC editor allows user
configurable functions to meet specific application requirements.
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CONTROL PHILOSOPHY
2.0 1500 TPH Dump Hopper
Hopper to receive the discharge from the coal handling Trucks with Capacity
1500 tph.
2.1 Low Level Switch

Low Level Switch (Level tech tilt Switch) in this will be put in the chute before
the Chain Feeder this equipment is used to detect the Coal in the Hopper is available. In
the PLC Low Level Ready = 1. Low Level Not Ready = 0. This part is important in the
plant because if this work will first part to start the sequence of all process, This Will Be
displayed in the PLC. When the material is present then the chain feeder runs and will
run until the level at 10% (for detect level 10% can use sensor level or set the placement
of this tilt switch). And when more than 10% or 35%, then the chain feeder will
automatically run according to the previous set point.
3.0 Chain Feeder DH-108
Chain Feeder is used to transport coal from the Dump Hopper to the Divergator
and Chain Feeder is controlled by Siemens SINAMICS G120 VVVF Drive. The VVVF
will control the speed of the Chain Feeder as selected by the CPP Control Room
Operator which will regulate the Coal transport onto the Divergator.
3.1 Chain Feeder VVVF and Motor
3.2 Variable Speed Drive
The SINAMICS G120 VVVF Drive is connected to the MCC Material

Handling PLC PROFIBUS Network. All status information, start/stop
commands and speed adjustments will be displayed and executed to CPP
WinCC over this PROFIBUS Network.
Status Information from the VVVF to the PLC will consist of the
following;
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CONTROL PHILOSOPHY
 Chain Feeder VVVF Fault Code. This will contain all available VVVF
fault information. (VVVF Fault codes will be described in more detail
later in this document).
 Chain Feeder VVVF Warning Code. This will contain all the available
VVVF warning information. (VVVF Warning codes will be described in
more detail later in this document).
 Chain Feeder VVVF Running Status.
 Chain Feeder Actual Motor Current.
A VVVF Warning will not prevent the drive from starting, nor stop the
drive when running. The warning is for Operator Information and
investigation.
A VVVF Fault will prevent the drive from starting and will stop the drive
if it is running. Commands from the CPP Control System to the VVVF
will consist of the following;
 Chain Feeder VVVF Start / Stop commands.
 Chain Feeder VVVF Speed Adjustment, control speed chain feeder for
remote mode: speed VSD will reduce to 0% if hopper level sensor shows
value <10%. And when the hopper level > 35% then the VSD speed will
return to normal like the previous set point speed. This control functions
as a protection chain feeder so as not to fall directly to the coal.
 Chain Feeder VVVF Fault Reset.
3.3 Hardwire Emergency Stop
A Hardwired Safety circuit consisting of an Emergency Stop in field

must still work in the Local Control Station (LCS) / Remote. This function
includes voltage disconnection of the converter, bypassing the
microprocessor controller by means of a safety combination in accordance
with EN 60204-1. The motor coasts to a stop with the process.
Regardless of the Hard Wired Emergency Stop Circuit or the operating

mode when any Chain Feeder Hardwire Healthy input is de-energized the
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CONTROL PHILOSOPHY
following action will occur;
 Chain Feeder Run Command via the PROFIBUS network to the VVVF
drive is removed.
 Chain Feeder fault condition shall be displayed and alarmed on the CPP
SCADA system.
3.4 Motor temperature
The Chain Feeder Motor is equipped with two Motor Thermistors, one
for motor high temperature alarm, and the other for motor over
temperature trip. The Thermistors are connected to the VVVF which will
control motor over temperature protection. Motor Temperature alarm and
trip information is relayed to the CPP SCADA system over the PROFIBUS
network. VVVF Drive Fault and Warning codes will be described in more
detail later in this document.
4.0 Divergator DH-108

Divergator work in mechanically, it used to Diver the Small Coal and
Big Coal, the Small Coal will be drop down to the Transfer Conveyor CV-
109 and Big Coal will be transport down to the Primary Crusher.
5.0 Primary Crusher

Primary Crusher is used to crush the Coal to small pieces Coal. Primary
Crusher is controlled by Siemens Soft start Drive. The Soft Start will
control the start of the Primary Crusher as selected by the CPP Control
Room Operator.
5.1 Primary Crusher SS and Motor

5.1.1 Soft Starter
The Soft Start Drive is connected to the MCC Material Handling PLC
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CONTROL PHILOSOPHY
PROFIBUS Network. All status information, start/stop commands will

be displayed and executed to CPP WinCC over this PROFIBUS
Network.
Status Information from the Soft start to the PLC will consist of the
following;
 Primary Crusher SOFTSTART Fault Code. This will contain all
available SOFTSTART fault information. (SOFTSTART Fault codes
will be described in more detail later in this document).
 Primary Crusher SOFTSTART Warning Code. This will contain all
the available SOFTSTART warning information. (SOFTSTART
Warning codes will be described in more detail later in this document).
 Primary Crusher SOFTSTART Running Status.
 Primary Crusher Actual Motor Current.
A SOFTSTART Warning will not prevent the drive from starting, nor
stop the drive when running. The warning is for Operator Information
and investigation.
A SOFTSTART Fault will prevent the drive from starting and will stop
the drive if it is running. Commands from the CPP Control System to the
SOFTSTART will consist of the following;
 Primary Crusher SOFTSTART Start / Stop commands.
 Secondary Crusher SOFTSTART Forward Commands for remote,
reverse motor crusher only use can do if in mode Local (maintenance)
and Running from LCS.
 Primary Crusher SOFTSTART Fault Reset.
5.1.2 Hardwire Emergency Stop

A Hardwired Safety circuit consisting of an Emergency Stop Push
Button on the Local Control Station (LCS) This function includes
voltage disconnection of the converter, bypassing the microprocessor
controller by means of a safety combination in accordance with EN
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CONTROL PHILOSOPHY
60204-1. The motor coasts to a stop with the process.

mode when any Primary Crusher Hardwire Healthy input is de-energized
the following action will occur;
 Primary Crusher Run Command via the PROFIBUS network to the

Soft start drive is removed.
 Primary Crusher fault condition shall be displayed and alarmed on the

CPP SCADA system.
5.1.3 Motor temperature

The Primary Crusher Motor is equipped with two Motor Thermistors,
one for motor high temperature alarm, and the other for motor over
temperature trip. The Thermistors are connected to the Soft start which
will control motor over temperature protection. Motor Temperature
alarm and trip information is relayed to the CPP SCADA system over the
PROFIBUS network. Soft start Drive Fault and Warning codes will be
described in more detail later in this document.
5.2 Primary Crusher Indication & Operation

5.2.1 Motor Faceplate Indications
The Motor Faceplate will present the SCADA user with the following
status indications, all alarms, events, warnings from plant equipment
must be logged on WinCC;
 Primary Crusher Interlock Ready Status. Ready (Green Text) / Not

Ready (Red Text) indicates if all the drive Interlocks are Ready.
 Primary Crusher Drive Status. Drive Stopped (Green Text) / Drive

Running (Red Text) indicates if the equipment is running or stopped,
Drive Fault (Yellow Text) Indicates that the Drive has a Fault
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CONTROL PHILOSOPHY
Condition.
 Primary Crusher Operating Mode Status. Drive Local (White Text)

/Drive Remote (Cyan Text) – Indicates the selected operating mode.
 Primary Crusher Soft start Fault Code. Soft start No Fault (White Text)
/ cult Code (White Alpha Numeric Code) – Indicates when there is an
active fault code from the Soft start.
 Primary Crusher Soft start Warning Code. Soft start No Warning

(White) / soft start Warning Code (White Alpha Numeric Code) –
Indicates when there is an active warning code from the Soft start.
 Primary Crusher Actual Motor Current Shown in real time displayed in

Amps (Yellow Numeric).
 Crusher Actual Belt Speed – Shown in real time displayed in Meters /

Second (Yellow Numeric).
 Primary Crusher Control Mode Status. Manual Selected (White Text)

/Automatic Selected (Cyan Text) – Indicates the selected control mode.
5.2.2 Motor Faceplate Operations

 Auto Mode Select Button. The Auto Mode Button will switch the
Primary Crusher Control to Automatic and the start the motor will be
controlled by the PLC Control can only be De-selected from
Automatize the SCADA user is logged in as engineer.
 Manual Mode Select Button. The Manual Mode Select Button will
switch the Primary Crusher Control to manual start made by the
SCADA user. The Primary Crusher control can only be selected to
Manual Mode with this push button which will allow operation of the
Primary Crusher from the Local Control Station Start push button.
Local Mode Select push button will become disabled when the
31
CONTROL PHILOSOPHY
equipment is running.
 Remote Mode Select Button. When the remote operating mode is

selected it shall not be possible to start the Primary Crusher from the
Local Control Station. Starting Primary Crusher will now be possible
from the Start Button provided on the faceplate.
 Start push button. The Primary Crusher can be started with this button
providing the drive is selected to Remote Operating Mode and the
Drive is ready.
 Stop push button. The Primary Crusher can be stopped at any time with
this button regardless of operating mode.
 Reset push button. Used to reset The Primary Crusher Faults, Soft start
Faults and Warnings. The Reset function will be held on within the
PLC Code for two seconds.
 More Button. Pressing the Status Display Button will expand the
Motor Faceplate and present the operator with Fault, Warning,
Interlock and Drive Statistic information about the Primary Crusher.
1.9.5.15 Primary Crusher Safety Devices & Faults

A Fault condition will prevent the plant equipment from starting and
will stop the plant equipment when running. The Primary Crusher is
equipped with the following field devices;
1.9.5.15.1 Local Control Station

The Local Control Station is equipped with a Mushroom Head latching
Emergency Stop push button. The bush button is equipped with two
normally closed contacts. One contact is used in the hardwired circuit
explained previously; the other is connected to a Material Handling
MCC PLC input and is used for display and alarming on the control
32
CONTROL PHILOSOPHY
room SCADA.

mode when Primary Crusher Emergency Stop - LCS PLC input is de-
energized the following action will occur;
 The Primary Crusher Run Command via the PROFIBUS network to

the soft starter drive is removed.
 The Primary Crusher Fault a MATERIAL HANDLING MCC PLC

Output shall be de-energized.
 The Primary Crusher fault condition shall be displayed and alarmed on

the CPP SCADA system.
The Local Control Station is equipped with a Start push button. The
push button is activated when pressed and deactivated (spring return) on
release. The push button is equipped with a normally open contact which
relays the local start request to a Material Handling MCC PLC input.
1.9.5.15.2 Block Chute Switch

Blocked Chute Switches are installed in the discharge chute. There is
one switch and these are installed in positions within the chute to detect
coal build-up within the chute originating from the bottom of the chute
upwards in the chute.
Each Blocked Chute switch is connected individually to Material

Handling MCC PLC inputs as follows,
 Primary Blocked Chute Switch (Upper) When the either of the

normally closed contacts of the Blocked Chute switches (Level Tilt
Switch) is broken for more than two seconds continuously when
running in remote operating mode, the following action will take
place;
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CONTROL PHILOSOPHY
 Which need to be turned off is the chain feeder, crusher still running
only when tilt switch is active. Because when the crusher died then it
was built up in divergator.
 Primary Crusher Fault Material Handling MCC PLC Output shall be

de-energized.

CPP SCADA system. Fault will be displayed in both local and remote
operating modes.
If the Blocked Chute input returns to its healthy state before two
seconds has expired, no action will be taken.
A blocked Chute Switch will not return to its healthy state until the
blockage has been cleared.
1.9.5.15.3 MCCB Main Circuit Breaker Status

An auxiliary contact from the MCC main circuit breaker is connected
to a Material Handling MCC PLC Input. The PLC input is energized
when the MCCB is closed and the Primary Crusher is ready for use.
Even though it is obvious that the Primary Crusher will stop if the
MCC MCCB trips or is isolated, if the PLC input is de-energized in any
operating mode the following actions occur;
 Primary Crusher Run Command via the PROFIBUS network to the

 Primary Crusher Fault a Material Handling MCC PLC Output shall be

de-energized.

CPP SCADA system. The MCC Circuit Breaker Position will be
displayed in the fault message.
34
CONTROL PHILOSOPHY
1.9.5.16 Primary Crusher Start Permissive

A Start Permissive is a condition that must be met before the equipment
can be started and will stop the equipment when running.
The Primary Crusher requires the following start permissive to be

healthy to permit start of the equipment remotely from the CPP WinCC
SCADA;
 Primary Crusher can start in remote mode if all safety device and
emergency stop de -energize. (Status Healthy and ready). Equipment in
front of is running CV-109.
 Transfer Conveyor CV-109 Running.
Start Permissive are required to start Primary Crusher in Remote

Operating Mode. When a Permissive condition becomes unhealthy while
Primary Crusher is running the Primary Crusher will be stopped
immediately in the same manner as a fault condition.
When the equipment is started in Local Operating Mode in shall be the

responsibility of the Operations Personnel to ensure it is safe to do so.
1.9.5.17 Primary Crusher Process Interlocks

A Process Interlock is a condition that is not required to start the
equipment but will stop the equipment after it is running. Primary Crusher
has the following process interlocks;
 Primary Crusher loss of running feedback.
Process Interlocks are required to keep the Primary Crusher running in

Remote Operating Mode. When a Process Interlock becomes unhealthy
while the Primary Crusher is running the will be stopped immediately in
the same manner as a fault condition.
35
CONTROL PHILOSOPHY
When a process interlock fault occurs stopping the equipment, the fault
will be matched by the PLC, recorded in the WinCC Alarm Log and will
be reset again automatically whenever the equipment is started again in
any mode.

1.9.5.18 Primary Crusher Operation

The Primary Crusher feeds coal onto the Transfer Conveyor. The
Primary Crusher is operated from the CPP Control Room WinCC.
The operator will use the indications and controls explained previously to
monitor and operate the Primary Crusher as follows;
1.9.5.18.1 Operation Local Mode

The Primary Crusher can be operated in Local mode with the following
sequence;
 The Primary Crusher must be selected to Local Operation Mode on the

WinCC SCADA Faceplate.
 For all equipment requiring local mode operation, local operation can
only be done when SCADA is localized.
 When LOCAL mode, then equipment can only be start from LCS in
field. LCS→ Start Button : Active
Stop Button : Active
(E-stop remains active)
SCADA→ Start Button : Active
Stop button : Active
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CONTROL PHILOSOPHY
 When REMOTE mode, then equipment can only be start from SCADA
in field. LCS → Start Button : Not Active
Stop Button : Not Active
SCADA→ Start Button: Active
All events & alarms are logged in SCADA.
 All hardwired Interlocks must be healthy.
 All horn warning must stay alive during starting motor, either local
mode or remote mode.
 The Local Start push button on the Local Control Station is activated.
 The Primary Crusher will start at the Local Speed Set point as selected
on the SCADA screen when logged in as Engineer.
 The Primary Crusher can be stopped by any hardwired interlock or the

Stop Button on the CPP WinCC Primary Crusher Faceplate.
The local operator must monitor the equipment.
It shall be possible to switch plant equipment from Local to Remote

Operating mode without the need for stopping the plant item. If any
faults, start permissive or process interlock conditions are unhealthy
when switched to Remote Operating mode the plant item will be tripped
in the same manner as previously described. It shall not be possible to
switch a plant item from Remote Operating Mode to Local Operating
Mode at any time after a Start has been initiated in remote operating
mode, this shall include the start-up warning time period.
1.9.5.18.2 Operation Remote Mode

When the equipment is running in remote mode, then the selector on
37
CONTROL PHILOSOPHY
SCADA cannot be switched to local mode. But if the equipment has been
left in local mode, then the SCADA selectors can be switched to remote
mode (with attention to permissive start and interlocking it;
 The Primary Crusher must be selected to Remote Operation Mode on

the WinCC SCADA Faceplate.
 All fault conditions must be healthy.
 The WinCC SCADA operator will start the using the Start Button on
the CPP WinCC Primary Crusher Faceplate.
 The Star-Up Warning Horn will sound for twenty seconds.
 Primary Crusher will start and the speed will be controlled to maintain
the production set point as set on the Face Plate. The Automatic
operation of CPP Primary Crusher will be described in more detail later
in this document.
 The can be stopped by any hardwired interlock, any Safety Device, any
Start Permissive, any Process Interlock, any Sequential Stop or the
Stop Button on the CPP WinCC Primary Crusher Faceplate.
6.0 Transfer Conveyor CV-109
Transfer Conveyor CV-109 is used to transport the Coal from Primary Crusher
On to Secondary Crusher this Conveyor is controlled by Siemens SINAMICS G120
VVVF Drive. The VVVF will control the speed of the Conveyor as selected by the CPP
Control Room Operator.
6.1 Transfer Conveyor VVVF and Motor
38
CONTROL PHILOSOPHY

following;
 Transfer Conveyor CV-109 VVVF Fault Code. This will contain all
available VVVF fault information. (VVVF Fault codes will be described
in more detail later in this document).
 Transfer Conveyor CV-109 VVVF Warning Code. This will contain all
the available VVVF warning information. (VVVF Warning codes will be
described in more detail later in this document).
 Transfer Conveyor CV-109 VVVF Running Status.
 Transfer Conveyor CV-109 Actual Motor Current.
drive when running. The warning is for Operator Information and investigation.
if it is running. Commands from the CPP Control System to the VVVF will
consist of the following;
 Transfer Conveyor CV-109 VVVF Start / Stop commands.
 Transfer Conveyor CV-109 VVVF Speed Adjustment.
 Transfer Conveyor CV-109 VVVF Fault Reset.
A Hardwired Safety circuit consisting of an Emergency Stop Push Button

on the Local Control Station (LCS) This function includes voltage
disconnection of the converter, by passing the microprocessor controller by
means of a safety combination in accordance with EN 60204-1.
The motor coasts to a stop with the process.
39
CONTROL PHILOSOPHY
mode when any Transfer Conveyor CV-109 Hardwire Healthy input is de-
 Transfer Conveyor CV-109 Run Command via the PROFIBUS network

to the VVVF drive is removed.
 Transfer Conveyor CV-109 fault condition shall be displayed and

alarmed on the CPP SCADA system.
The Transfer Conveyor CV-109 Motor is equipped with two Motor

Thermistors, one for motor high temperature alarm, and the other for
motor over temperature trip. The Thermistors are connected to the VVVF
which will control motor over temperature protection. Motor Temperature
alarm and trip information is relayed to the CPP SCADA system over the
PROFIBUS network. VVVF Drive Fault and Warning codes will be
6.2 Transfer Conveyor CV-109 Indication & Operation
status indications, all alarms, events, warnings from plant equipment must
be logged on WinCC;
 Transfer Conveyor CV-109 Interlock Ready Status. Ready (Green Text) /

Not Ready (Red Text) indicates if all the drive Interlocks are Ready.
 Transfer Conveyor CV-109 Drive Status. Drive Stopped (Green Text) /

Drive Running (Red Text) – Indicates if the equipment is running or
stopped, Drive Fault (Yellow Text) – Indicates that the Drive has a Fault
Condition.
40
CONTROL PHILOSOPHY
 Transfer Conveyor CV-109 Operating Mode Status. Drive Local (White

Text) / Drive Remote (Cyan Text) – Indicates the selected operating
mode.
 Transfer Conveyor CV-109 VVVF Fault Code. VVVF No Fault (White

Text) / VVVF Fault Code (White Alpha Numeric Code) – Indicates when
there is an active fault code from the VVVF.
 Transfer Conveyor CV-109 VVVF Warning Code. VVVF No Warning

(White) / VVVF Warning Code (White Alpha Numeric Code) – Indicates
when there is an active warning code from the VVVF.
 Transfer Conveyor CV-109 Actual Motor Current Shown in real time

displayed in Amps (Yellow Numeric).
 Transfer Conveyor CV-109 Actual Belt Speed – Shown in real time

displayed in Meters / Second (Yellow Numeric).
 Transfer Conveyor CV-109Control Mode Status. Manual Selected

(White Text) / Automatic Selected (Cyan Text) – Indicates the selected
control mode.
Transfer Conveyor CV-109 Control to Automatic and the speed will be
controlled by the PLC Chain Control can only be de-selected from
Automatic Mode when the SCADA user is logged in as engineer.
switch the Transfer Conveyor CV-109 Control to manual speed control
with speed adjustments made by the SCADA user. The Transfer
Conveyor CV-109 Control can only be selected to Manual Mode when
the SCADA user is logged in as engineer.
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CONTROL PHILOSOPHY
 Manual Speed Adjust. A Bar Controller and a text box are provided to
the SCADA user for the purpose of speed adjustment of Transfer
Conveyor CV-109in manual mode. The user can adjust the slide bar from
left to right for 0-100% speed adjustment. A numeric display of the speed
adjustment will also be provided which will display the requested speed
from 0-100%. It will only be possible for the SCADA user to manually
adjust Transfer Conveyor CV-109 speed using the slide bar or input a
numeric value with a keyboard when the SCADA user is logged in as
engineer.
 Local Mode Select Button. The operator can select Local Mode with this
push button which will allow operation of the Transfer Conveyor CV-109
from the Local Control Station Start push button. Local Mode Select
push button will become disabled when the equipment is running.

selected it shall not be possible to start the Transfer Conveyor CV-109
from the Local Control Station. Starting Transfer Conveyor CV-109 will
now be possible from the Start Button provided on the faceplate.
 Start push button. The Transfer Conveyor CV-109 can be started with
this button providing the drive is selected to Remote Operating Mode
and the Drive is ready.
 Stop push button. The Transfer Conveyor CV-109can is stopped at any

time with this button regardless of operating mode.
 Reset push button. Used to reset The Transfer Conveyor CV-109 Faults,
VVVF Faults and Warnings. The Reset function will be held on within
the PLC Code for two seconds.
 More Button. Pressing the Status Display Button will expand the Motor
Faceplate and present the operator with Fault, Warning, Interlock and
42
CONTROL PHILOSOPHY
Drive Statistic information about the Transfer Conveyor CV-109.
6.2.3 Motor Faceplate Statistics information
The Motor Faceplate will display Statistical Information regarding The

Transfer Conveyor CV-109 as follows;
 Motor Run Hours this Shift. Shows current accumulated Run Hours
(White Numeric) in Hours and Minutes for The Transfer Conveyor
CV-109this shift.
 Motor Run Hours last Shift. Shows total accumulated Run Hours
(White Numeric) in Hours and Minutes for The Transfer Conveyor CV-
101 for the previous shift.
 Motor Run Hours Total. Shows total accumulated Run Hours (White
Numeric) in Hours and Minutes for The Transfer Conveyor CV-109since
reset. A reset button will be provided to users with Engineer Login and
above.
 Utilized Run Hours this Shift. This will show an accumulation of

productive run hours where the plant item has been operating above 5%
of design capacity for this shift.
 Utilized Run Hours last Shift. This will show accumulation of

productive run hours where the plant item was operating above 5% of
design capacity for the previous shift.
 Idle Run Hour this Shift. This will show an accumulation of

unproductive run hours where the plant item has been operating below
5% of design capacity for this shift.
 Idle Run Hour last Shift. This will show an accumulation of

unproductive run hours where the plant item was operating below 5% of
43
CONTROL PHILOSOPHY
 Average Flow Rate (Gross) this Shift. This will indicate the average
gross flow rate for the current shift. This will be calculated as follows,
Gross Average Flow Rate = Current Production Tones / Current time
expired from the shift period.
 Average Flow Rate (Gross) last Shift. This will indicate the average
gross flow rate for the previous shift. This will be calculated as follows,
Gross Average Flow Rate = Total Production Tones last Shift / Total Shift
period last shift.
 Average Flow Rate (Net) this Shift. This will indicate the average net
flow rate for the current shift. This will be calculated as follows, Net
Average Flow Rate = Current Production Tones / Current Utilized Run
Hours expired from the shift period.
 Average Flow Rate (Net) last Shift. This will indicate the average net
flow rate for the previous shift. This will be calculated as follows, Net
Average Flow Rate = Total Production Tones last shift / Total Utilized
Run Hours from the previous shift.
 Motor speed Transfer Conveyor CV-109 3.3 m/s; motor speed Transfer
Conveyor CV-110 3.3 m/s; motor speed Transfer Conveyor CV-111 3.3
m/s.
6.3 Transfer Conveyor CV-109 Safety Devices & Faults
A Fault condition will prevent the plant equipment from starting and will
stop the plant equipment when running. The Transfer Conveyor CV-109 is
44
CONTROL PHILOSOPHY
6.3.1 Local Control Station

explained previously; the other is connected to Material Handling MCC
PLC input and is used for display and alarming on the control room
SCADA.

mode when Transfer Conveyor CV-109 Emergency stop - LCS PLC input
is de-energized the following action will occur;
 The Transfer Conveyor CV-109 Run Command via the PROFIBUS

network to the VVVF drive is removed.
 The Transfer Conveyor CV-109 Fault MCC Material Handling PLC

 The Transfer Conveyor CV-109 fault condition shall be displayed and

The Local Control Station is equipped with a Start push button. The push
button is activated when pressed and deactivated (spring return) on release.
The push button is equipped with a normally open contact which relays the
local start request to a MCC PLC input.
6.3.2 Pull Wire Switches (PWS)
A Pull wire Switch is still works in mode local remote, installed on either
side of the Transfer Conveyor CV-109 Each Pull wire Switch is equipped
with two normally closed contacts and one normally open contact. One of
the normally closed contacts are used in the hardwired circuit explained
previously, the other normally closed contacts are used for display and
45
CONTROL PHILOSOPHY
alarming on the control room SCADA. These are connected to Material

Handling MCC PLC inputs as follows;
 Transfer Conveyor CV-109 Pull wire Switch #1 (Left).
 Transfer Conveyor CV-109 Pull wire Switch #2 (Right).

mode when any Transfer Conveyor CV-109 Pull wire Switch input is de-

 Transfer Conveyor CV-109 Conveyor Fault Material Handling MCC

PLC Output shall be de-energized.

The normally open contact of the pull wire switches will close when in
its tripped state and will energize an indicating strobe light. The strobe will
extinguish when the pull wire is reset.
6.3.3 Belt Drift Switches (BDS)
Belt Drift Switches are installed in carry return conveyor head tail. So
every conveyor there is 8 BDS. The Belt Drift switches are sprung loaded
roller arms that will be activated when the conveyor belt misaligns. Each
Belt Drift Switch is equipped with a normally closed contact connected
individually to Material Handling MCC PLC inputs as follows,
 Transfer Conveyor CV-109 Belt Drift Head End (Left).
 Transfer Conveyor CV-109 Belt Drift Head End (Right).
46
CONTROL PHILOSOPHY
 Transfer Conveyor CV-109 Belt Drift Tail End (Left).
 Transfer Conveyor CV-109 Belt Drift Tail End (Right).
When any Transfer Conveyor CV-109 Belt Drift Switch PLC input is
de-energized for more than five seconds continuously when the Transfer
Conveyor CV-109 is running in remote operating mode, the following
action will take place, to belt drive, please add warning before BDS text
conveyor, because in the BDS there are 2 contacts, 1 for Warning, 1 Her To
Trip;



Fault will be displayed in both local and remote operating modes.
If the Belt Drift Switch input returns to its healthy state before five
If the equipment has stopped with the Belt Misaligned and the Belt Drift
switch still activated, the equipment must be placed into Local Operating
Mode and the Belt started from the Local Control Station. Once the belt
has run back into position, Remote operation from the CPP WinCC
SCADA may be restored.
6.3.4 Blocked Chute Switches (BCS)
Blocked Chute Switches are installed in the Transfer Conveyor CV-109

discharge chute. There are two switches and these are installed in different
47
CONTROL PHILOSOPHY
positions within the chute to detect coal build-up within the chute
originating from the bottom of the chute upwards and originating midway
in the chute. Each Blocked Chute switch is connected individually to
Material Handling MCPPLC inputs as follows,
 Transfer Conveyor CV-109 Blocked Chute Switch (Lower).
When the either of the normally closed contacts of the Blocked Chute
switches (Level tech Tilt Switch) is broken for more than two seconds
continuously when running in remote operating mode, the following action
will take place;


PLC Output shall be de-energized. Transfer Conveyor CV-109 fault
condition shall be displayed and alarmed on the CPP SCADA system.
If the Blocked Chute input returns to its healthy state before two seconds
has expired, no action will be taken.
6.3.5 Belt Rip Switch (BRS)
A Belt Rip Switch is installed at the tail end of the Transfer Conveyor
CV-109 and is installed to monitor the condition of the underside of the
carry belt. The Belt Rip Switch has a tensioned lanyard monitoring line
installed under the carry side of the belt which follows the contour of the
48
CONTROL PHILOSOPHY
belt profile. When the Lanyard is connected to the switch body the internal
contact becomes healthy (closed). If running in Remote Operating Mode,
when a foreign object pierces the belt and hits the Belt Rip Lanyard it is
disconnects from the switch body. The switch contact connected to
Material Handling MCC PLC Input de-energized and the following actions
occur immediately;



alarmed on the CPP SCADA system. Fault will be displayed in both
local and remote operating modes.
The Belt Rip input will not become healthy again until the Belt Rip
Switch lanyard is again securely attached to the Belt Rip switch body.
6.3.6 Take-Up Switches
Take-Up Switches are installed on the Conveyor Take-Up Trolley Travel

and. The Take-Up Switches are connected to PLC Inputs as follows;
 Take-Up Limit switch (upper).
 Take-Up Switches (lower).
The Trolley Upper & Lower Ultimate Limit Switches are mechanically
operated switches with a level arm that is activated when in contact with
the take-up trolley. When either Take-Up Ultimate upper or lower Limit
Input is de-energized with the Transfer Conveyor CV-109 running in
remote operating mode, the following action will take place;
49
CONTROL PHILOSOPHY
 Run Command via the PROFIBUS network to the VVVF Drive #1 is

removed.
 Conveyor Fault PLC Output shall remain energized to prevent an E-Stop

condition. The VVVF will initiate a ramp stop over approximately 100 -
300 seconds.
 Fault condition shall be displayed and alarmed on the Terminal SCADA

system.
6.3.7 Under speeds Sensor (USS)
A Proximity Sensor is installed to monitor the Transfer Conveyor CV-

109 Tail Pulley Speed. The tail pulley is equipped metal flags installed
around the tail pulley circumference which are counted by the proximity
sensor connected Material Handling MCC PLC Input.
The PLC will calculate the tail pulley speed which will be displayed on
the CPP WinCC SCADA in meters/second.
The PLC will compare the measured tail pulley speed against the
requested speed command to the Transfer Conveyor CV-109. When
running in Remote Operating Mode, and the requested speed and actual
speed differ more than 15% for a continuous period greater than five
second the following actions will occur;



50
CONTROL PHILOSOPHY
The under speed trip fault will be matched by the PLC and will be reset
by pressing the reset button provided on the faceplate.
The PLC will ignore the Tail Pulley Speed for a period of ten seconds
during start-up allowing the equipment time to reach full speed.
If the speed difference falls below 15% before the five second delay has
expired, no action will be taken.
6.3.8 Metal Detector (MD CV 101)
The Transfer Conveyor CV-109 is equipped with a DETEC Metal

Detector. The Metal detector will detect tramp metal in the coal on the
conveyor belt and activate a relay output which is connected to CPP
Substation PLC Input. Conveyor remains fault as long as it has not been
reset in win cc and it’s LCS MD.
When metal is detected and PLC Input becomes de-energized the

following will occur;
 CPP Substation PLC Output to Start/Stop Drive #1 will be de-energized.
 Conveyor fault condition shall be displayed and alarmed on the CPP

SCADA system. Fault will be displayed in both local and remote
operating modes.
Using the pulse signal to the PLC from the under speed sensor connected
to the CPP Substation PLC, the PLC will calculate the distance that the
belt travelled after the Metal Detector Trip was activated. The result of the
calculation will be displayed on the SCADA screen “Metal 1” in Meters to
assist the operations personnel to locate the tramp metal on the conveyor.
A Metal Detector Count signal is connected to CPP Substation PLC
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CONTROL PHILOSOPHY
Input. This signal will pulse if a second or third foreign metal object is
detected after the initial Metal Detected Output has been driven as
described above. The PLC will also calculate and display “Metal 2” and
“Metal 3” distance in meters that belt has travelled after each count pulse
was detected.
6.3.9 Startup Warning Horn
A Start-up Warning Horn & Beacon is installed at the Transfer Conveyor

CV-109 to alert personnel near the equipment that it is about to start. Once
a start command to the is activated by a local start request, a start request
from the CPP WinCC SCADA or a sequential start request a Material
Handling MCC PLC Output will energize the Warning Horn via a control
relay for a period of twenty second. Once the twenty second period has
expired the PLC will continue the start of the CV-109.
6.3.10 MCCB Main Circuit Breaker Status
An auxiliary contact from the MCC main circuit breaker is connected to

a Material Handling MCC PLC Input. The PLC input is energized when
the MCCB is closed and the Transfer is ready for use.
Even though it is obvious that the Transfer Conveyor CV-109will stop if

the MCC MCCB trips or is isolated, if the PLC input is de-energized in
any operating mode the following actions occur;

 Transfer Conveyor CV-109 Fault a Material Handling MCC PLC


alarmed on the CPP SCADA system. The MCC Circuit Breaker Position
52
CONTROL PHILOSOPHY
will be displayed in the fault message.
6.4 Transfer Conveyor CV-109 Start Permissive

can be started and will stop the equipment when running. For all existing
conveyor magnetic separator, please enter the Magnet Separator into the
conveyor ready condition. So the conveyor can start after the Magnet Separator
is running.
The Transfer Conveyor CV-109 requires the following start permissive to

be healthy to permit start of the equipment remotely from the CPP WinCC
SCADA;
 Blocked Chute Switch on Secondary Crusher de-Energized, CV-109 can

start if all safety device healthy and secondary crusher and CV-110
running.
Start Permissive are required to start Transfer Conveyor CV-109 in

Remote Operating Mode. When a Permissive condition becomes unhealthy
while Transfer Conveyor CV-109 is running the Conveyor will be stopped

6.5 Transfer Conveyor CV-109 Process Interlocks

equipment but will stop the equipment after it is running. Transfer Conveyor
CV-109 has the following process interlocks;
 Transfer Conveyor CV-109 loss of running feedback.
Process Interlocks are required to keep the Transfer Conveyor CV-109
53
CONTROL PHILOSOPHY
running in Remote Operating Mode. When a Process Interlock becomes

unhealthy while the Transfer Conveyor CV-109 is running the will be stopped
When a process interlock alarm fault from VSD, display description of

the alarm in SCADA (not the general alarm that appears in scada), recorded in
the WinCC Alarm Log and will be reset again automatically whenever the
equipment is started again in any mode.

6.6 Transfer Conveyor CV-109 Operation
The Transfer Conveyor CV-109feeds coal onto the Divergator. The

Transfer Conveyor CV-109 is operated from the CPP Control Room WinCC.
monitor and operate the Transfer Conveyor CV-109 as follows;
6.6.1 Operation Local Mode
The Transfer Conveyor CV-109 can be operated in Local mode with the
following sequence;
 The must be selected to Local Operation Mode on the WinCC SCADA

Faceplate.
 All Fault Conditions must be healthy.
54
CONTROL PHILOSOPHY
 The Transfer Conveyor CV-109 will start at the Local Speed Set point as
selected on the SCADA screen when logged in as Engineer.
 The Transfer Conveyor CV-109 can be stopped by any hardwired

interlock or the Stop Button on the CPP WinCC Transfer Conveyor CV-
101 Faceplate.
field. LCS →Start Button: Active
Stop Button: Active
SCADA → Start Button: Not Active
Stop Button: Active
the local operator must monitor the equipment.

Operating mode without the need for stopping the plant item. If any faults,
start permissive or process interlock conditions are unhealthy when
switched to Remote Operating mode the plant item will be tripped in the
same manner as previously described. It shall not be possible to switch a
plant item from Remote Operating Mode to Local Operating Mode at any
time after a Start has been initiated in remote operating mode, this shall
include the start-up warning time period.
6.6.2 Operation Remote Mode
The Transfer Conveyor CV-109can be operated in Remote mode with the

following sequence;
 The Transfer Conveyor CV-109must be selected to Remote Operation
55
CONTROL PHILOSOPHY
Mode on the WinCC SCADA Faceplate.
 The WinCC SCADA operator will start the using the Start Button on the
CPP WinCC Transfer Conveyor CV-109Faceplate.
 Transfer Conveyor CV-109will Start and the speed will be controlled to

maintain the production set point as set on the Face Plate. The Automatic
operation of CPP Transfer Conveyor CV-109 will be described in more
Start Permissive, any Process Interlock, any Sequential Stop or the Stop
Button on the CPP WinCC Transfer Conveyor CV-109 Faceplate.
 When REMOTE mode, then equipment can only be start from

SCADA. LCS → Start Button: Not active
Stop Button: Not active
(E-stop stay active)
SCADA → Start button: Active
7.0 Magnet Separator (MS CV-109)

The Transfer Conveyor CV-101 has a Tramp Metal Magnet installed. The
Magnet will remove any metal from the coal flow with the Magnetic Separator.
The Magnet is a self-contained Vendor Package requiring only a power feed
from Material Handling MCC. Magnet Starter and Control Circuits are installed
in the Vendor Control Panel.
56
CONTROL PHILOSOPHY
The Magnet also has a Motorized Trolley that enables the magnet to be
auto self-cleaning and dump the collected tramp metal. Motor Starter and
Controls for the Motorized Trolley are installed in the Vendor Control Panel.
7.1 MCCB – MCC Main Circuit Breaker Status

Material Handling PLC Input. The PLC input is energized when the
MCCB is closed indicating that the Power Supply to Magnet is on.
Even though it is obvious that the Magnet will stop if the MCC MCCB
trips or is isolated, if the PLC input is de-energized in any operating mode
the following actions occur;
 Material Handling PLC Output to Start/Stop Magnet will be de-

energized if active.
 Material Handling PLC Output to Start/Stop Magnet Separator

Movement will be de-energized if active.
 Magnet fault condition shall be displayed and alarmed on the Terminal

SCADA system. The MCC Circuit Breaker Position will be displayed
in the fault message.
Loss of the MCCB Closed signal will prevent the equipment from
starting and stop the equipment if running.
7.2 Magnet Indications & Operation
Whenever the WinCC SCADA operator clicks on the graphic

representation of Transfer Conveyor CV-101 Magnet Separator, the user
will be presented with the Magnet Control and Status faceplate.
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CONTROL PHILOSOPHY
7.3 Magnet Faceplate Indications
The Magnet Faceplate will present the SCADA user with the following
status indications;
 Magnet Interlock Ready Status. Ready (Green Text) / Not Ready (Red
Text) indicates if all the Magnet Interlocks are Ready.
 Magnet Status. Magnet off (Green Text) / Magnet On (Red Text) –

Indicates if the equipment is running or stopped, Magnet Fault (Yellow
Text) – Indicates that the Magnet has a Fault Condition.
 Magnet Separator Interlock Ready Status. Ready (Green Text) / Not

Ready (Red Text) indicates if all the Magnet Interlocks are Ready.
 Magnet Operating Mode Status. Magnet Local (White Text) / Magnet

Remote (Cyan Text) – Indicates the selected operating mode.
7.4 Magnet Faceplate Operation
The Magnet Faceplate will present the SCADA user with the following
status indications;
 Local push button. This will de-energize Material Handling PLC Output
and allow Magnet Operation from the Vendor Local Panel. Local Mode
Select push button will become disabled when the equipment is running.
 Remote push button. This will energize Material Handling PLC Output
and allow Magnet Operation from the Terminal SCADA.
 Magnet Start push button. The Magnet can be energized with this button
providing the magnet is selected to Remote Operating Mode and the
Magnet is ready.
 Magnet Stop push button. The Magnet can be de-energized with this
58
CONTROL PHILOSOPHY
button providing the drive is selected to Remote Operating Mode.
 Status Display Button. Pressing the Status Display Button will expand
the Magnet Faceplate and present the operator with Fault, Warning,
Interlock and Magnet Statistic information about the Magnet.
7.5 Magnet Statistic Information
The Magnet Faceplate will display Statistical Information regarding

Magnet as follows;
 Magnet Run Hours this Shift. Shows current accumulated Energized

Hours (White Numeric) in Hours and Minutes for the Magnet for the
current shift.
 Magnet Run Hours last Shift. Shows current accumulated Energized

Hours (White Numeric) in Hours and Minutes for the Magnet for the
previous shift.
 Magnet Run Hours Total. Shows total accumulated Energized Hours

(White Numeric) in Hours and Minutes for the Magnet since reset. A
reset button will be provided to users with Engineer Login and above.
7.6 Magnet Safety Device & Faults

All fault and status of MS LCS are drawn to PLC, for example: magnetic
fault, belt fault, magnet ready, and belt ready. The Magnet is equipped with the
following safety devices, applies to all MS.
7.6.1 Emergency Stop

The Magnet Control Panel is equipped with and Emergency Stop push
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CONTROL PHILOSOPHY
button which when pressed will stop the operation of the Magnet and
Trolley with a Hardwired Circuit in the Vendor Local Panel. An additional
Contact from the Emergency Stop push button is also connected to MCC
Material Handling PLC Input and is used for display and alarming on the
control room SCADA.

mode when Magnet Emergency Stop PLC input is de-energized the
 MCC Material Handling PLC Output to Start/Stop Magnet will be de-


SCADA system.
7.6.2 Main Switch

An auxiliary contact from the Local Vendor Panel main Isolator is
connected to Material Handling PLC Input. The PLC input is energized
when the Switch is closed indicating that the Main Power Switch in the
Field to Magnet is on. Even though it is obvious that the Magnet will stop
if the Main Switch is isolated, if the PLC input is de-energized in any
 Material Handling PLC Output to Start/Stop Magnet will be de-energized

if active.

SCADA system.
Loss of the Main Switch signal will prevent the equipment from starting
and stop the equipment if running.
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CONTROL PHILOSOPHY
7.6.3 Magnet Energized

The Magnet Separator Local Panel will provide Magnet. Magnet
Energized Feedback to Material Handling PLC Input. Whist the running
feedback is not a fault condition; it serves to indicate to the Terminal
WinCC SCADA operator the running status of the Magnetic Separator.
7.6.4 Magnetic Running Feedback Failed

When a Magnet Energize request is initiated when selected to remote
operating mode, the PLC will expect to receive running confirmation
within a few seconds. If Magnet On feedback PLC input is not received
when operating in Remote Operating Mode within the required time the
 Material Handling PLC Output to Start/Stop Magnet will be de-


SCADA system.
A Running Feedback Failed fault will be matched by the PLC recorded

in the WinCC SCADA alarm log and will be reset by pressing the reset
button provided on the faceplate.
7.6.5 Magnet Start Permissive

can be started and will stop the equipment when running. The Magnet has
no start permissive.
7.6.6 Magnet Process Interlocks

equipment but will stop the equipment after it is running. The Magnet has
the following process interlocks;
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CONTROL PHILOSOPHY
 Magnet loss of Magnet On feedback.
Process Interlocks are required to keep the Magnet running in Remote

Operating Mode. When a Process Interlock becomes unhealthy while the
Magnet is running the Magnet will be stopped immediately in the same
manner as a fault condition.
be reset by pressing the reset button provided on the faceplate.

7.6.7 Magnet Operation

The Transfer Conveyor CV-101 Magnet Separator is operated from the
East Bunati Control Room. The operator will use the indications and
controls explained previously to monitor and operate the Magnet as
follows;
7.6.7.1 Magnet Operation Local Mode

The Transfer Conveyor CV-101 Magnet Separator can be operated in
Local mode with the following sequence;
 The Magnet must be selected to Local Operation Mode on the

WinCC Magnet SCADA Faceplate.
 The required Local Start push button on the Local Vendor Panel is
activated.
 Magnet will be started as required.
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CONTROL PHILOSOPHY
 The Magnet can be stopped by any hardwired interlock or the Stop

Button on the Vendor Local Panel.
7.6.7.2 Magnet Operation Remote Mode

The Magnet can be operated in Remote mode with the following
sequence;
 The Magnet must be selected to Remote Operation Mode on the

WinCC Magnet SCADA Faceplate.
 All hardwired interlocks must be healthy.
 WinCC Operator Can now Start the Magnet using the Magnet Start
Button on the WinCC Magnet Faceplate.
 The above starting of the Belt Conveyor and Magnetic Separator can
also be started as part of Transfer Conveyor starting sequence.
 The Magnet can be stopped by any hardwired interlock, any Magnet

Safety Device, any Start Permissive, any Process Interlock, any
Sequential Stop or the Stop Button on the Coal Terminal WinCC
Magnet Faceplate.
7.6.8 Magnet Cleaning

The Magnet shall continue self-clean continuously not waiting the Transfer Conveyor
CV-101 are stopped.
8.0 Belt Scale (BS CV-109)

Bypass Conveyor CV-107 is equipped with a DETEC Metal Detector.
The Metal detector will detect tramp metal in the coal on the conveyor belt
and activate a relay output which is connected to CPP Substation PLC
63
CONTROL PHILOSOPHY
Input. Conveyor remains fault as long as it has not been reset in WIN CC
and its LCS MD, reset can be done from local reset panel push button,
reset which is remotely done via SCADA WinCC.


SCADA system.
A Metal Detector Count signal is connected to CPP Substation PLC Input. This signal
will pulse if a second or third foreign metal object is detected after the initial Metal
Detected Output has been driven as described above. The PLC will also calculate and
display “Metal 2” and “Metal 3” distance in meters that belt has travelled after each
count pulse was detected.
9.0 Metal Detector (MD CV-109)

Bypass Conveyor CV-107 is equipped with a DETEC Metal Detector.
The Metal detector will detect tramp metal in the coal on the conveyor belt
and activate a relay output which is connected to CPP Substation PLC
Input. Conveyor remains fault as long as it has not been reset in WIN CC
and its LCS MD, reset can be done from local reset panel push button,
reset which is remotely done via SCADA WinCC.
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CONTROL PHILOSOPHY

SCADA system.
A Metal Detector Count signal is connected to CPP Substation PLC Input. This signal
will pulse if a second or third foreign metal object is detected after the initial Metal
Detected Output has been driven as described above. The PLC will also calculate and
display “Metal 2” and “Metal 3” distance in meters that belt has travelled after each
count pulse was detected.
10.0 Divergator CV-109

Divergator work in mechanically, it used to Diver the Small Coal and Big Coal, the
Small Coal will be drop down to the Transfer Conveyor CV-109 and Big Coal will
be transport down to the Primary Crusher.
11.0 Secondary Crusher

Secondary Crusher is used to crush the Coal to small pieces Coal.
Secondary Crusher is controlled by Siemens Soft start Drive. The Soft
Start will control the start of the Secondary Crusher as selected by the CPP
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CONTROL PHILOSOPHY
11.1 Secondary Crusher SS and Motor

11.1.1 Soft Starter
The Soft Start Drive is connected to the MCC Material Handling PLC
PROFIBUS Network. All status information, start/stop commands will
be displayed and executed to CPP WinCC over this PROFIBUS
Network.
Status Information from the Soft start to the PLC will consist of the
following;
 Secondary Crusher SOFTSTART Fault Code. This will contain all
available SOFTSTART fault information. (SOFTSTART Fault codes
will be described in more detail later in this document).
 Secondary Crusher SOFTSTART Warning Code. This will contain
all the available SOFTSTART warning information.
(SOFTSTART Warning codes will be described in more detail
later in this document).
 Secondary Crusher SOFTSTART Running Status.
 Secondary Crusher Actual Motor Current.
A SOFTSTART Warning will not prevent the drive from starting, nor
stop the drive when running. The warning is for Operator Information
and investigation.
A SOFTSTART Fault will prevent the drive from starting and will stop
the drive if it is running. Commands from the CPP Control System to the
SOFTSTART will consist of the following;
 Secondary Crusher SOFTSTART Start / Stop commands.
 Secondary Crusher SOFTSTART Forward Commands for remote,
reverse motor crusher only use can do if in mode Local (maintenance)
and Running from LCS.
 Secondary Crusher SOFTSTART Fault Reset.
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CONTROL PHILOSOPHY

A Hardwired Safety circuit consisting of an Emergency Stop Push
Button on the Local Control Station (LCS) This function includes
voltage disconnection of the converter, bypassing the microprocessor
controller by means of a safety combination in accordance with EN
60204-1. The motor coasts to a stop with the process.

mode when any Secondary Crusher Hardwire Healthy input is de-
 Secondary Crusher Run Command via the PROFIBUS network to the

 Secondary Crusher fault condition shall be displayed and alarmed on

the CPP SCADA system.

The Secondary Crusher Motor is equipped with two Motor
Thermistors, one for motor high temperature alarm, and the other for
motor over temperature trip. The Thermistors are connected to the Soft
start which will control motor over temperature protection. Motor
Temperature alarm and trip information is relayed to the CPP SCADA
system over the PROFIBUS network. Soft start Drive Fault and Warning
codes will be described in more detail later in this document.
11.2 Secondary Crusher Indication & Operation

status indications, all alarms, events, warnings from plant equipment
must be logged on WinCC;
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CONTROL PHILOSOPHY
 Secondary Crusher Interlock Ready Status. Ready (Green Text) / Not

 Secondary Crusher Drive Status. Drive Stopped (Green Text) / Drive

Running (Red Text) indicates if the equipment is running or stopped,
Drive Fault (Yellow Text) Indicates that the Drive has a Fault
Condition.
 Secondary Crusher Operating Mode Status. Drive Local (White Text)

/Drive Remote (Cyan Text) – Indicates the selected operating mode.
 Secondary Crusher Soft start Fault Code. Soft start No Fault (White
Text) / cult Code (White Alpha Numeric Code) – Indicates when there
is an active fault code from the Soft start.
 Secondary Crusher Soft start Warning Code. Soft start No Warning

(White) / soft start Warning Code (White Alpha Numeric Code) –
Indicates when there is an active warning code from the Soft start.
 Secondary Crusher Actual Motor Current Shown in real time displayed

in Amps (Yellow Numeric).
 Crusher Actual Belt Speed – Shown in real time displayed in Meters /

Second (Yellow Numeric).
 Secondary Crusher Control Mode Status. Manual Selected (White

Text) /Automatic Selected (Cyan Text) – Indicates the selected control
mode.

Secondary Crusher Control to Automatic and the start the motor will be
68
CONTROL PHILOSOPHY
controlled by the PLC Control can only be De-selected from

Automatize the SCADA user is logged in as engineer.
switch the Secondary Crusher Control to manual start made by the
SCADA user. The Secondary Crusher control can only be selected
to Manual Mode with this push button which will allow operation of
the Secondary Crusher from the Local Control Station Start push
button. Local Mode Select push button will become disabled when the
equipment is running.

selected it shall not be possible to start the Secondary Crusher from the
Local Control Station. Starting Secondary Crusher will now be
possible from the Start Button provided on the faceplate.
 Start push button. The Secondary Crusher can be started with this
button providing the drive is selected to Remote Operating Mode and
the Drive is ready.
 Stop push button. The Secondary Crusher can be stopped at any time
with this button regardless of operating mode.
 Reset push button. Used to reset The Secondary Crusher Faults, Soft
start Faults and Warnings. The Reset function will be held on within
 More Button. Pressing the Status Display Button will expand the
Motor Faceplate and present the operator with Fault, Warning,
Interlock and Drive Statistic information about the Secondary Crusher.
11.3 Secondary Crusher Safety Devices & Faults

A Fault condition will prevent the plant equipment from starting and
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CONTROL PHILOSOPHY
will stop the plant equipment when running. The Secondary Crusher is

explained previously; the other is connected to a Material Handling
MCC PLC input and is used for display and alarming on the control
room SCADA.

mode when Secondary Crusher Emergency Stop - LCS PLC input is de-
 The Secondary Crusher Run Command via the PROFIBUS network to

the soft starter drive is removed.
 The Secondary Crusher Fault a MATERIAL HANDLING MCC PLC

 The Secondary Crusher fault condition shall be displayed and alarmed

on the CPP SCADA system.
The Local Control Station is equipped with a Start push button. The
push button is activated when pressed and deactivated (spring return) on
release. The push button is equipped with a normally open contact which
relays the local start request to a Material Handling MCC PLC input.
11.3.2 Block Chute Switch

Blocked Chute Switches are installed in the discharge chute. There is
one switch and these are installed in positions within the chute to detect
coal build-up within the chute originating from the bottom of the chute
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CONTROL PHILOSOPHY
upwards in the chute.
Each Blocked Chute switch is connected individually to Material

Handling MCC PLC inputs as follows,
 Secondary Blocked Chute Switch (Upper) When the either of the

normally closed contacts of the Blocked Chute switches (Level Tilt
Switch) is broken for more than two seconds continuously when
running in remote operating mode, the following action will take
place;
 Which need to be turned off is the chain feeder, crusher still running
only when tilt switch is active. Because when the crusher died then it
was built up in divergator.
 Secondary Crusher Fault Material Handling MCC PLC Output shall be

de-energized.

the CPP SCADA system. Fault will be displayed in both local and
remote operating modes.
If the Blocked Chute input returns to its healthy state before two

to a Material Handling MCC PLC Input. The PLC input is energized
when the MCCB is closed and the Secondary Crusher is ready for use.
Even though it is obvious that the Secondary Crusher will stop if the
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CONTROL PHILOSOPHY
 Secondary Crusher Run Command via the PROFIBUS network to the

 Secondary Crusher Fault a Material Handling MCC PLC Output shall

be de-energized.

the CPP SCADA system. The MCC Circuit Breaker Position will be
11.4 Secondary Crusher Start Permissive

The Secondary Crusher requires the following start permissive to be

SCADA;
 Secondary Crusher can start in remote mode if all safety device and
emergency stop de -energize. (Status Healthy and ready).
Equipment in front of is running CV-109.
 Transfer Conveyor CV-109 Running.
Start Permissive are required to start Secondary Crusher in Remote

Operating Mode. When a Permissive condition becomes unhealthy while
Secondary Crusher is running the Secondary Crusher will be stopped

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CONTROL PHILOSOPHY
11.5 Secondary Crusher Process Interlocks

equipment but will stop the equipment after it is running. Secondary
Crusher has the following process interlocks;
 Secondary Crusher loss of running feedback.
Process Interlocks are required to keep the Secondary Crusher running in

Remote Operating Mode. When a Process Interlock becomes unhealthy
while the Secondary Crusher is running the will be stopped immediately in
be reset again automatically whenever the equipment is started again in
any mode.

11.6 Secondary Crusher Operation

The Secondary Crusher feeds coal onto the Transfer Conveyor. The
Secondary Crusher is operated from the CPP Control Room WinCC.
monitor and operate the Secondary Crusher as follows;

The Secondary Crusher can be operated in Local mode with the
following sequence;
 The Secondary Crusher must be selected to Local Operation Mode on
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CONTROL PHILOSOPHY
the WinCC SCADA Faceplate.
field. LCS→ Start Button : Active
SCADA→ Start Button : Active
 When REMOTE mode, then equipment can only be start from SCADA
in field. LCS → Start Button : Not Active
Stop Button : Not Active
SCADA→ Start Button: Active
All events & alarms are logged in SCADA.
 All horn warning must stay alive during starting motor, either local
mode or remote mode.
 The Secondary Crusher will start at the Local Speed Set point as
 The Secondary Crusher can be stopped by any hardwired interlock or

the Stop Button on the CPP WinCC Secondary Crusher Faceplate.
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CONTROL PHILOSOPHY

Operating mode without the need for stopping the plant item. If any
faults, start permissive or process interlock conditions are unhealthy
when switched to Remote Operating mode the plant item will be tripped
in the same manner as previously described. It shall not be possible to
switch a plant item from Remote Operating Mode to Local Operating
Mode at any time after a Start has been initiated in remote operating
mode, this shall include the start-up warning time period.

When the equipment is running in remote mode, then the selector on
SCADA cannot be switched to local mode. But if the equipment has been
left in local mode, then the SCADA selectors can be switched to remote
mode (with attention to permissive start and interlocking it;
 The Secondary Crusher must be selected to Remote Operation Mode

on the WinCC SCADA Faceplate.
 The WinCC SCADA operator will start the using the Start Button on
the CPP WinCC Secondary Crusher Faceplate.
 Secondary Crusher will start and the speed will be controlled to

maintain the production set point as set on the Face Plate. The
Automatic operation of CPP Secondary Crusher will be described in
more detail later in this document.
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CONTROL PHILOSOPHY
The can be stopped by any hardwired interlock, any Safety Device, any Start
Permissive, any Process Interlock, any Sequential Stop or the Stop Button on the CPP
WinCC Secondary Crusher Faceplate
Transfer Conveyor CV-110 is used to transport the Coal from Secondary Crusher
onto Transfer Conveyor CV-111 and Transfer Conveyor CV-104 this Conveyor is
controlled by Siemens SINAMICS G120 VVVF Drive. The VVVF will control the
speed of the Conveyor as selected by the CPP Control Room Operator.
Transfer Conveyor CV-110 Upstream Equipment consists of secondary crusher

and transfer conveyor CV-109. Starting time motor works when the secondary crusher
and transfer conveyor CV-109 works.
Transfer Conveyor CV-110 Downstream Equipment consists of Transfer

conveyor CV-111 and Transfer conveyor CV-104. Stopping Time motor works in case
fault on Transfer conveyor CV-111 and Transfer conveyor CV-104.

following;
in more detail later in this document), starting time with full load will
work then the motor will die for a moment. Starting time with empty
load will works then the motor dead motor does not work, transfer
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CONTROL PHILOSOPHY
Conveyor Ready status. When the current reaches according to the

setting, the motor will stop for a moment until the load is reduced and
reset the breaker.
described in more detail later in this document)
 Transfer Conveyor CV-110 VVVF Running Status

on the Local Control Station (LCS) This function includes voltage
disconnection of the converter, by passing the microprocessor controller by
means of a safety combination in accordance with EN 60204-1.
The motor coasts to a stop with the process.

Transfer Conveyor CV-110 Run Command via the PROFIBUS network

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CONTROL PHILOSOPHY
Transfer Conveyor CV-110 fault condition shall be displayed and


Thermistors, one for motor high temperature alarm, and the other for motor over
temperature trip. The Thermistors are connected to the VVVF which will control
motor over temperature protection. Motor Temperature alarm and trip
information is relayed to the CPP SCADA system over the PROFIBUS network.
VVVF Drive Fault and Warning codes will be described in more detail later in
this document.
be logged on WinCC;


Condition.

mode.
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CONTROL PHILOSOPHY



 Transfer Conveyor CV-110 Control Mode Status. Manual Selected

(White Text) / Automatic Selected (Cyan Text) – Indicates the selected
control mode.
controlled by the PLC Chain Control can only be de-selected from
Automatic Mode when the SCADA user is logged in as engineer.
Conveyor CV-110Control can only be selected to Manual Mode when
 Manual Speed Adjust. A Slide Bar Controller and a text box are provided
to the SCADA user for the purpose of speed adjustment of Transfer
Conveyor CV-110in manual mode. The user can adjust the slide bar from
left to right for 0-100% speed adjustment. A numeric display of the speed
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CONTROL PHILOSOPHY
adjustment will also be provided which will display the requested speed
from 0-100%. It will only be possible for the SCADA user to manually
adjust Transfer Conveyor CV-110 speed using the slide bar or input a
numeric value with a keyboard when the SCADA user is logged in as
engineer.

 Start push button. The Transfer Conveyor CV-110 can be started with
this button providing the drive is selected to Remote Operating Mode
and the Drive is ready.
 Stop push button. The Transfer Conveyor CV-110 can be stopped at any
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CONTROL PHILOSOPHY
CV-110 this shift.
 Motor Run Hours last Shift. Shows total accumulated Run Hours (White
Numeric) in Hours and Minutes for The Transfer Conveyor CV-110for
the previous shift.
Numeric) in Hours and Minutes for The Transfer Conveyor CV-110since
above.




81
CONTROL PHILOSOPHY
period last shift.
m/s.

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CONTROL PHILOSOPHY

SCADA.




A Pull wire Switch is installed on either side of the Conveyor; Each Pull
wire Switch is equipped with two normally closed contacts and one
normally open contact. One of the normally closed contacts are used in the
hardwired circuit explained previously, the other normally closed contacts
are used for display and alarming on the control room SCADA.
These are connected to Material Handling MCC PLC inputs as follows;
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CONTROL PHILOSOPHY



PLC Output shall be De-energized.

 Transfer Conveyor CV-110 Belt Drift Tail End (Right),
When any Transfer Conveyor CV-110 Belt Drift Switch PLC input is de-
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CONTROL PHILOSOPHY
energized for more than five seconds continuously when the Transfer
conveyor. Because in the BDS there are 2 contacts, 1 for Warning, 1 her to
Trip;



local and remote operating modes. If the Belt Drift Switch input returns
to its healthy state before five seconds has expired, no action will be
taken.
Mode and the Belt started from the Local Control Station.
Once the belt has run back into position, Remote operation from the CPP
WinCC SCADA may be restored.
12.5.4 Blocked Chute Switches (BCS)
Blocked Chute Switches are installed in the Transfer Conveyor CV-110

discharge chute. There are two switches and these are installed in different
positions within the chute to detect coal build-up within the chute
originating from the bottom of the chute upwards and originating midway
in the chute. Each Blocked Chute switch is connected individually to
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CONTROL PHILOSOPHY
Material Handling MCP PLC inputs as follows, add BCS in tail CV-110 /
under secondary crusher. To anticipate the built-up material in the CV-110
tail;
 Transfer Conveyor CV-110 Blocked Chute Switch (Lower).
When the either of the normally closed contacts of the Blocked Chute
switches (Level tech Tilt Switch) is broken for more than two seconds
continuously when running in remote operating mode, the following action
will take place;



If the Blocked Chute input returns to its healthy state before two seconds
has expired, no action will be taken.
86
CONTROL PHILOSOPHY

disconnects from the switch body. The switch contact connected to
Material Handling MCC PLC Input de-energized and the following actions
occur immediately;



The Belt Rip input will not become healthy again until the Belt Rip
Switch lanyard is again securely attached to the Belt Rip switch body.
12.5.6 Take-Up Switch (TUS)

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CONTROL PHILOSOPHY
removed.

300 seconds.
 Fault condition shall be displayed and alarmed on the Terminal SCADA

system.
12.5.7 Under speeds Sensor (USS)
A Proximity Sensor is installed to monitor the Transfer Conveyor CV-

110 Tail Pulley Speed. The tail pulley is equipped metal flags installed
around the tail pulley circumference which are counted by the proximity
sensor connected Material Handling MCC PLC Input. The PLC will
calculate the tail pulley speed which will be displayed on the CPP WinCC
SCADA in meters/second.
The PLC will compare the measured tail pulley speed against the
requested speed command to the Transfer Conveyor CV-110. When
running in Remote Operating Mode, and the requested speed and actual
speed differ more than 15% for a continuous period greater than five
second the following actions will occur;



88
CONTROL PHILOSOPHY
The under speed trip fault will be matched by the PLC and will be reset
by pressing the reset button provided on the faceplate.
The PLC will ignore the Tail Pulley Speed for a period of ten seconds
during start-up allowing the equipment time to reach full speed.
If the speed difference falls below 15% before the five second delay has
expired, no action will be taken.

from the CPP WinCC SCADA or a sequential start request a Material
expired the PLC will continue the start of the Chain Feeder.

Even though it is obvious that the Transfer Conveyor CV-110will stop if


 Transfer Conveyor CV-110 Fault a Material Handling MCC PLC

89
CONTROL PHILOSOPHY



SCADA;
Start Permissive are required to start Transfer Conveyor CV-110in

while Transfer Conveyor CV-110 is running the will be stopped immediately in


equipment but will stop the equipment after it is running.
Transfer Conveyor CV-110 has the following process interlocks;
 Process Interlocks are required to keep the Transfer Conveyor CV- 102
unhealthy while the Transfer Conveyor CV-110is running the will be
stopped immediately in the same manner as a fault condition.
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CONTROL PHILOSOPHY
will be matched by the PLC, recorded in the WinCC Alarm Log and will be reset
again automatically whenever the equipment is started again in any mode.

12.7.1 Transfer Conveyor CV-110 Operation
The Transfer Conveyor CV-110 feeds coal onto CV-111 or CV-104. The
Transfer Conveyor CV-110 is operated from the CPP Control Room
WinCC. The operator will use the indications and controls explained
previously to monitor and operate the Transfer Conveyor CV-110 as
follows. If belt plow leads to CV-111 then make sure CV-111 running to
CV-110 ready to start. If belt plow leads to CV-104 then make sure CV-104
running to CV-110 is ready to start.
The Transfer Conveyor CV-110can be operated in Local mode with the

following sequence;

Faceplate.
 All Fault Conditions must be healthy.
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CONTROL PHILOSOPHY

interlock or the Stop Button on the CPP WinCC Transfer Conveyor
CV-110 Faceplate.

The Transfer Conveyor CV-110can be operated in Remote mode with the

following sequence;
 The Transfer Conveyor CV-110must be selected to Remote Operation

CPP WinCC Transfer Conveyor CV-110 Faceplate.
 Transfer Conveyor CV-110will Start and the speed will be controlled to

maintain the production set point as set on the Face Plate.
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CONTROL PHILOSOPHY
The Automatic operation of CPP Transfer Conveyor CV 102 will be

Start Permissive, any Process Interlock, any Sequential Stop or the Stop
Button on the CPP WinCC Transfer Conveyor CV-110 Faceplate.
Transfer Conveyor CV-111 is used to transport the Coal from Transfer Conveyor
onto Stockpile 1, this Conveyor is controlled by Siemens SINAMICS G120 VVVF
Drive. The VVVF will control the speed of the Conveyor as selected by the CPP

Status Information from the VVVF to the PLC will consist of the following;
in more detail later in this document).
described in more detail later in this document).
 Transfer Conveyor CV-111 VVVF Running Status.
93
CONTROL PHILOSOPHY

on the Local Control Station (LCS) This function includes voltage disconnection
of the converter, bypassing the microprocessor controller by means of a safety
combination in accordance with EN 60204-1. The motor coasts to a stop with
the process.


 Transfer Conveyor CV-111 fault conditions shall be displayed and


Thermistors, one for motor high temperature alarm, and the other for motor over
temperature trip. The Thermistors are connected to the VVVF which will control
94
CONTROL PHILOSOPHY
motor over temperature protection. Motor Temperature alarm and trip

information is relayed to the CPP SCADA system over the PROFIBUS network.
VVVF Drive Fault and Warning codes will be described in more detail later in
this document.
status indications;


Condition.

mode.


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CONTROL PHILOSOPHY

 Transfer Conveyor CV-111Control Mode Status. Manual Selected (White

Text) / Automatic Selected (Cyan Text) – Indicates the selected control
mode.
controlled by the PLC, Control can only be de-selected from Automatic
Mode when the SCADA user is logged in as engineer.
Conveyor CV-111Control can only be selected to Manual Mode when
 Manual Speed Adjust. A Slide Bar Controller and a text box are provided
to the SCADA user for the purpose of speed adjustment of Transfer
Conveyor CV-111 in manual mode. The user can adjust the slide bar
from left to right for 0-100% speed adjustment. A numeric display of the
speed adjustment will also be provided which will display the
requested speed from 0-100%. It will only be possible for the
SCADA user to manually adjust Transfer Conveyor CV-111 speed using
the slide bar or input a numeric value with a keyboard when the SCADA
user is logged in as engineer.
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CONTROL PHILOSOPHY

 Start push button. The Transfer Conveyor CV-111 can be started with this
button providing the drive is selected to Remote Operating Mode and the
Drive is ready.
 Stop push button. The Transfer Conveyor CV-111 can be stopped at any

CV-111 this shift.
 Motor Run Hours last Shift. Shows total accumulated Run Hours (White
97
CONTROL PHILOSOPHY
Numeric) in Hours and Minutes for The Transfer Conveyor CV-111 for
the previous shift.
Numeric) in Hours and Minutes for The Transfer Conveyor CV-111 since
above.




98
CONTROL PHILOSOPHY
period last shift.
m/s.

SCADA.
99
CONTROL PHILOSOPHY



A Pull wire Switch is installed on either side of the Conveyor. Each Pull
wire Switch is equipped with two normally closed contacts and one
normally open contact. One of the normally closed contacts are used in the
hardwired circuit explained previously, the other normally closed contacts
are used for display and alarming on the control room SCADA.
These are connected to Material Handling MCC PLC inputs as follows.

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CONTROL PHILOSOPHY


PLC Output shall be De-energized.

 Transfer Conveyor CV-111 Belt Drift Tail End (Right).
When any Transfer Conveyor CV-111 Belt Drift Switch PLC input is
de-energized for more than five seconds continuously when the Transfer
conveyor. Because in the BDS there are 2 contacts, 1 for Warning, 1 her to
Trip;
101
CONTROL PHILOSOPHY



local and remote operating modes. If the Belt Drift Switch input returns
to its healthy state before five seconds has expired, no action will be
taken.
Mode and the Belt started from the Local Control Station. Once the belt
has run back into position, Remote operation from the CPP WinCC
SCADA may be restored.
disconnects from the switch body.
The switch contact connected to Material Handling MCC PLC Input de-
energized and the following actions occur immediately;

102
CONTROL PHILOSOPHY


local and remote operating modes. The Belt Rip input will not become
healthy again until the Belt Rip Switch lanyard is again securely attached
to the Belt Rip switch body.
13.5.5 Take-Up Switch (TUS)


removed.

300 seconds.
 Fault condition shall be displayed and alarmed on PLC.
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CONTROL PHILOSOPHY

from the CPP WinCC SCADA or a sequential start request A Material
expired the PLC will continue the start of the CV-111.

Even though it is obvious that the Transfer Conveyor CV-111 will stop if

 Transfer Conveyor CV-111 Fault a MATERIAL HANDLING MCC PLC



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CONTROL PHILOSOPHY

SCADA;
 Belt Plough 1 Energized.
 Belt Plough 1 Leads to CV-111.
 Also apply to CV-104, the running condition CV-104 is Belt Plough 1

leads to CV-104.
Start Permissive are required to start Transfer Conveyor CV-111 in

while Transfer Conveyor CV-111 is running the will be stopped immediately in


equipment but will stop the equipment after it is running. Transfer Conveyor
CV-111 has the following process interlocks;
Process Interlocks are required to keep the Transfer Conveyor CV-111

unhealthy while the Transfer Conveyor CV-111 is running the will be stopped
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CONTROL PHILOSOPHY

13.8 Transfer Conveyor CV-111 Operation
The Transfer Conveyor CV-111 feeds coal onto the stock pile. The
Transfer Conveyor CV-111 is operated from the CPP Control Room WinCC. The
operator will use the indications and controls explained previously to monitor
and operate the Transfer Conveyor CV-111 as follows;
The Transfer Conveyor CV-111 can be operated in Local mode with the
following sequence;

Faceplate.
 All Fault Conditions must be healthy

interlock or the Stop Button on the CPP WinCC Transfer Conveyor
CV-111 Faceplate.
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CONTROL PHILOSOPHY
The Transfer Conveyor CV-111 can be operated in Remote mode with

the following sequence;
 The Transfer Conveyor CV-111 must be selected to Remote Operation

CPP WinCC Transfer Conveyor CV-111 Faceplate.
 Transfer Conveyor CV-111 will start and the speed will be controlled to
maintain the production set point as set on the Face Plate. The Automatic
operation of CPP Transfer Conveyor CV-111 will be described in more
 The Conveyor can be stopped by any hardwired interlock, any Conveyor

Safety Device, any Start Permissive, any Process Interlock, any
Sequential Stop or the Stop Button on the CPP WinCC Transfer
Conveyor CV-111 Faceplate.
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CONTROL PHILOSOPHY
14.0 Diverter Gate CV-107
Diverter Gate CV-107 is used to transport the Coal from Bypass Conveyor CV-
107 onto Existing Conveyor CV-14 & CV-22 this Conveyor is controlled by Forward
Reverse Starter. The starter will control the movement of the Diverter Gate as selected
by the CPP Control Room Operator.
14.1 Diverter Gate MCC and Motor
14.1.1 Motor Control Centre
The Diverter Gate CV-107 is powered by 5 kW Forward Reverse Starter

in MCC Material Handling.
14.1.2 Hardwired Circuit
A hardwired safety circuit consisting of Motor Protection Thermal

Overload, earth Fault Protection Emergency Stop Push Button on the Local
Control Station. Activation of any of these faults will disconnect the main
contactor for stopping the motor.
14.1.3 Hardwire Healthy
When all Hard Wired protection conditions are healthy, Material

Handling PLC Inputs will be energized.

mode when Spillage Conveyor Hardwire Healthy PLC input is de-
energized the following action will occur for the corresponding motor;
 Material Handling PLC Output to Start/Stop Spillage Conveyor will be

de-energized.
 Diverter Gate fault condition shall be displayed and alarmed on the

SCADA system.
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CONTROL PHILOSOPHY
Loss of Diverter Gate Ready signal will prevent that equipment from
14.1.4 Running
A Drive Running Signal will originate from the MCC Motor Starter
module and connect to Material Handling PLC Input. The PLC must detect
the PLC Input is energized before it is confirmed that the Diverter Gate
motor is Running.
14.1.5 Motor Overload
A Motor Overload Trip Signal will originate from the MCC Motor
Starter module and connect to Material Handling PLC Input

mode when a Diverter Gate Overload PLC input is de-energized the
 Material Handling PLC Output to Start/Stop Diverter Gate will be de-

energized.
 Material Handling fault condition shall be displayed and alarmed on the

SCADA system.
A Motor Overload fault will prevent the equipment from starting and
stop the equipment if running.
14.1.6 Earth Leakage
An Earth Leakage Trip Signal will originate from the MCC Motor Starter
module and connect to Material Handling PLC Input.
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CONTROL PHILOSOPHY

mode when a Diverter Gate CV-107 Earth Leakage PLC input is de-
 Material Handling PLC Output to Start/Stop Diverter Gate CV-107 will

be de-energized.

SCADA system.
An Earth Leakage fault will prevent the equipment from starting and stop
the equipment if running.
14.1.7 MCC Main Circuit Breaker Status

Material Handling PLC Input.
Even though it is obvious that the Diverter Gate CV-107will stop if the
MCC MCCB trips or is isolated, however if the Diverter Gate MCCB
Closed PLC input is de-energized the following action will occur;
 Material Handling PLC Output to Start/Stop Diverter Gate will be de-

energized.

Terminal SCADA system. The MCC Circuit Breaker Position will be
Loss of the MCCB Closed signal will prevent the equipment from
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CONTROL PHILOSOPHY
14.2 Diverter Gate CV-107 Indication & Operation
be logged on WinCC;
 Diverter Gate CV-107 Interlock Ready Status. Ready (Green Text) / Not
 Diverter Gate CV-107 Drive Status. Drive Stopped (Green Text) / Drive
Running (Red Text) – Indicates if the equipment is running or stopped,
Drive Fault (Yellow Text) – Indicates that the Drive has a Fault
Condition.
 Diverter Gate CV-107 Operating Mode Status. Drive Local (White

mode.
 Diverter Gate CV-107 Actual Motor Current Shown in real time

control functions;
push button which will allow operation of the Diverter Gate CV-107
from the Local Control Station Start push button. Local Mode
Select push button will become disabled when the equipment is
running. It should be noted that all Diverter Gate and hardwired
Emergency stop circuit will be ignored in this operating mode.
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CONTROL PHILOSOPHY
It shall be the operations personnel responsibility to ensure the equipment

is safe to operate.

selected it shall not be possible to start Diverter Gate from the Local
Control Station. Starting Diverter Gate will now be possible from the
Start Button provided on the faceplate or will start as part of the PLC
start sequence.
 Start push button. Diverter Gate can be started with this button providing
the drive is selected to Remote Operating Mode and the Drive is ready.
 Stop push button. Diverter Gate can be stopped at any time with this
button regardless of operating mode. Status Display Button. Pressing the
Status Display Button will expand the Motor Faceplate and present the
operator with Fault, Warning, Interlock and Drive Statistic information
about the Diverter Gate Auto Mode Select Button.
14.4 Diverter Gate CV-107 Safety Devices & Faults
stop the plant equipment when running. The Diverter Gate CV-107 is equipped
with the following field devices;

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CONTROL PHILOSOPHY

SCADA.

mode when The Diverter Gate CV-107 Emergency stop - LCS PLC input
 The Diverter Gate CV-107 Fault MCC Material Handling PLC Output
shall be de-energized.
 The Diverter Gate CV-107 fault condition shall be displayed and alarmed
on the CPP SCADA system.

Even though it is obvious that the Diverter Gate CV-107 will stop if the
 The Diverter Gate CV-107 Fault a Material Handling MCC PLC

113
CONTROL PHILOSOPHY
 The Diverter Gate CV-107 fault condition shall be displayed and alarmed
on the CPP SCADA system. The MCC Circuit Breaker Position will be
14.4.3 Position Switch
The Diverter Gate CV-107 is equipped with 2 Position Switch Each

Discharge Chute this instrument input will be put in to PLC. PLC can
select which one that will be Chose Coal to transport from CV-107
 Position Switch 1 input existing CV-14.
 Position Switch 2 Input existing CV-14.
14.5 The Diverter Gate CV-107 Start Permissive

The Diverter Gate CV-107 requires the following start permissive to be

SCADA;
 Existing Conveyor CV-14 running.
 Existing Conveyor CV-22 running.
 Bypass Conveyor CV-107 running.
Start Permissive are required to start The Diverter Gate CV-107 Remote
Operating Mode. When a Permissive condition becomes unhealthy while The
Diverter Gate CV-107 is running the Diverter Gate CV-107 will be stopped
114
CONTROL PHILOSOPHY

14.6 The Diverter Gate CV-107 Process Interlocks

equipment but will stop the equipment after it is running. The Diverter Gate CV-
107 has the following process interlocks;
 The Diverter Gate CV-107 loss of running feedback.
Process Interlocks are required to keep the Diverter Gate CV-107

unhealthy while the Diverter Gate CV-107 is running the Diverter Gate CV-107
will be stopped immediately in the same manner as a fault condition.

14.7 The Diverter Gate CV-107 Operation
The Diverter Gate CV-107 Transport coal onto the Transfer CV-111. The
Diverter Gate CV-107 is operated from the CPP Control Room WinCC. The
operator will use the indications and controls explained previously to monitor
and operate The Diverter Gate CV-107 as follows;
The two Local Operation Mode on the WinCC SCADA Faceplate.
115
CONTROL PHILOSOPHY
 All Fault Conditions must be healthy
The Diverter Gate CV-107 can be stopped by any hardwired interlock or

the Stop Button on the CPP WinCC the Diverter Gate CV-107 Faceplate

The Diverter Gate CV-107 can be operated in Remote mode with the
following sequence;
 The Diverter Gate CV-107 must be selected to Remote Operation Mode

on the WinCC SCADA Faceplate.
CPP WinCC the Diverter Gate CV-107 Faceplate.
 The Diverter Gate CV-107 can be stopped by any hardwired interlock,

any The Diverter Gate CV-107 Safety Device, any Start Permissive, any
116
CONTROL PHILOSOPHY
Process Interlock, any Sequential Stop or the Stop Button on the CPP
WinCC The Diverter Gate CV-107 Faceplate.
15.0 VVVF Warning & Fault Codes
VVVF Warning and Fault Codes are relayed from the VVVF to the PLC over
the local PROFIBUS Link at each substation. The VVVF Warning and Fault codes have
a vast amount of information. These VVVF Warnings and Faults will be displayed on
the corresponding Motor Faceplates and will also be logged into the SCADA alarm
logs.
117

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BUNATI-CPP STOCKPILE & PORT Dir.

1.9.5.15 Primary Crusher Safety Devices & Faults ................................................ 32

3.5 Transfer Conveyor CV-110 Safety Devices & Faults ...................................... 82

4.6 The Belt Plough 1 Operation............................ Error! Bookmark not defined.

6.2.1 Motor Faceplate Indications .......................... Error! Bookmark not defined.

8.0 Belt Plough 4 ....................................................... Error! Bookmark not defined.

11.0 Belt Plough 6 .................................................... Error! Bookmark not defined.

14.1.1 Motor Control Centre................................... Error! Bookmark not defined.

21.2 Hardwire Emergency Stop............................ Error! Bookmark not defined.

1.1 PLC Hardware General

1.2 PLC Communication Hardware General

Siemens PROFIBUS DP, Siemens Modbus RTU Master-Slave and Siemens

Picture 1. Configuration Fiber Optik to PLC Master

Cabled and com sampler for CV-107 with auto sampler.

1.3 SCADA Hardware General

1.4 SCADA Software General

1.5 Coal Preparation Plant (CPP) PLC

1.5.1 CPP PLC Communications

CPP PLC/SCADA Communications are detailed on PLC Architecture

1.5.1.2 Profinet (ETHERNET)

1.5.1.3 Modbus RTU Master-Slave

1.6 CPP Operation Philosophy

1.6.1 Synchronizing Generator

Synchronizing generator is parallelizing the work of two or more

The basic terms of the parallel generator are as follows:

1. Has the same working voltage.

2. Have the same phase sequence.

3. Having the same working frequency.

4. Has the same phase angle.

1.6.2 DSE 8610 Synchronous Module

The DSE8610 is an easy to use Synchronizing Auto Start Control

KEY FEATURES • Comprehensive synchronizing & load sharing

Configurable outputs • Configurable flexible sensor inputs • DSENet®

KEY BENEFITS • Compatible in load share systems containing

2.0 1500 TPH Dump Hopper

2.1 Low Level Switch

3.0 Chain Feeder DH-108

3.1 Chain Feeder VVVF and Motor

3.2 Variable Speed Drive

The SINAMICS G120 VVVF Drive is connected to the MCC Material

3.3 Hardwire Emergency Stop

A Hardwired Safety circuit consisting of an Emergency Stop in field

Regardless of the Hard Wired Emergency Stop Circuit or the operating

following action will occur;

3.4 Motor temperature

4.0 Divergator DH-108

5.0 Primary Crusher

5.1 Primary Crusher SS and Motor

PROFIBUS Network. All status information, start/stop commands will

5.1.2 Hardwire Emergency Stop

60204-1. The motor coasts to a stop with the process.

Regardless of the Hard Wired Emergency Stop Circuit or the operating

 Primary Crusher Run Command via the PROFIBUS network to the

 Primary Crusher fault condition shall be displayed and alarmed on the

5.1.3 Motor temperature

5.2 Primary Crusher Indication & Operation

 Primary Crusher Interlock Ready Status. Ready (Green Text) / Not

 Primary Crusher Drive Status. Drive Stopped (Green Text) / Drive

 Primary Crusher Operating Mode Status. Drive Local (White Text)

 Primary Crusher Soft start Warning Code. Soft start No Warning

 Primary Crusher Actual Motor Current Shown in real time displayed in

 Crusher Actual Belt Speed – Shown in real time displayed in Meters /

 Primary Crusher Control Mode Status. Manual Selected (White Text)

5.2.2 Motor Faceplate Operations