OWNER

ONGC PETRO EIL JOB No.: 6987

additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 1 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

CHECKED DATE
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INITIALS SIGNATURE
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ACCEPTED AS
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ACCEPTED
ACCEPTED SMP 18.08.12
7(&1,0217¶6$&&(37$1&(2)7+,6
DOCUMENT DOES IN NO WAY RELIEVE THE
SUPPLIER OF HIS CONTRACTUAL
OBLIGATIONS. (TM 061)

1 LEGEND
H Hold Point (perform activity / test) S Subvendor of K-Tron
W Witness Point V Vendor (K-Tron, Manufacturer)
SW Spot Witness (%) TCM Tecnimont
R Review of Document TPIA Appointed Third Party Inspection
Agency
NCR Non Conformity PMC Project Management Consultant
(EIL)

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 2 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

Content:

1 Definitions .......................................................................................................................... 3
1.1 Introduction ................................................................................................................. 3
1.2 Definition summary ..................................................................................................... 3
2 SFM Control Theory .......................................................................................................... 4
2.1 Introduction ................................................................................................................. 4
2.2 Basics of SFM control ................................................................................................. 4
3 SFM Control Algorithm ..................................................................................................... 7
3.1 Introduction ................................................................................................................. 7
3.2 Massflow computation from the SFM ......................................................................... 7
4 Pellet Massflow Meter, YF-810 ....................................................................................... 11

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 3 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

1 Definitions

1.1 Introduction

The following is a list of terms and definitions used in this chapter.

1.2 Definition summary

Term Definition

Diverting Channel The vertical chute in which material flow out

of the
flowmeter.
Mass or gravimetric mode In this mode of operation, any change in belt
loading causes a change in output drive
command
from the controller.
Chute The angled channel into which material first
flows
in the flowmeter.
Volumetric mode In this mode of operation the speed of the
control
device is fixed but still dependent on the
Setpoint.

4008.3
Smart Flow Meter Control Basics

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 4 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

2 SFM Control Theory

2.1 Introduction

This section explains the theory of operation of the K-Tron SFM control system. The SFM
produces a Massflow signal that represents the actual Massflow of the bulk solids
passing through the meter. It is similar to what a coriolis liquid Massflow meter does to
meter liquids but it works on a different principle for bulk solids.

2.2 Basics of SFM control

It is easiest to draw an analogy about this feeding system if we look at a liquid feeding
system with control. Here is a block diagram.

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 5 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

FC12 is the flow controller which receives a Setpoint for some value of liquid flow. Motor
#02 runs the pump which transports liquid flow to the turbine meter FE80. The meter
provides a flow signal back to FC12.
The output of FC12 provides the Setpoint for the motor controller MC02. We have a
cascade control loop now shown. To stabilize the motor, if DC, a velocity sensor VS09
sends a feedback signal of motor velocity to MC02. If the loop is correctly tuned, the SP
value is delivered by the pump system to the downstream process. We will now show
the SFM system as the same. The analogy is even more close if we replace the turbine
meter which measures only volumetric flow with a coriolis liquid flow meter which
measures liquid Massflow rate. The following diagram mimics the liquid system. The
BC02 belt conveyor is the pump, the Smart Flow Meter SM03 is the turbine meter. The
other components are very much the same.

However, there is one important conceptual difference. In the liquid system, the flow
meter can be either up-stream or down-stream of the pump. With the SFM, the flow
controlling device, whether it is a screw

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 6 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

feeder, belt conveyor or rotary valve, the SFM must be downstream but tightly coupled
to the flow controlling device. It is important for best operation to minimize the time
lags between flow controlling device and the SFM.
Now let us look at the block diagram of the actual system. The SFM controller is really a
specialized PID controller designed to accept and calibrate the special parameters of the
SFM. It behaves as a continuous flow control system. The SFM produces a massflow
signal that represents the actual massflow of the bulk solids passing through the meter.
Here is a sample block diagram.

Wiring will be similar to other K-Tron products that have a control system with SFTs.
The SFM controller is an KCM controller where the drive may be separate or builtin.

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 7 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

3 SFM Control Algorithm

3.1 Introduction

This section details the calculations used to compute Massflow from the SFM.

3.2 Massflow computation from the SFM

To compute Massflow from the flowmeter, two SFTs under weighing channels are
provided. One is vertical, the other is at an angle to the vertical. The vertical channel is
called the diverting channel. The angled channel is called the chute. The normal
component of force measured by the chute is defined as FR. The diverting channel forces
that are normal to the flow channel is defined as FP. The measurement is only of the
horizontal forces of the material flow striking the diverting channel. See the graphic
below to see how the forces are exerted on the two measurement regions.

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 8 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

03 ISSUED AS FINAL SHA TCO PGU 15-06-12

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 9 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

It is important to recognize that forces on the chute SFT (FR) place the chute SFT in
compression. The forces operating on diverting channel SFT (FP) are causing the SFT to
operate also in compression due to its placement in the weigh bridge. A spring is used to
pre-load the SFT. Force FP additionally loads the diverting channel SFT as impacting
forces strike the channel cover. Note the direction of force. We will need to use some
formulas to determine how this device works.

Term Definition

FR Normal force as measured at the Chute

FP Normal force as measured at the Diverting
Channel.
M Amount of bulk material on the chute
Vo Initial flow material velocity
μ Angle of flow in the chute to the horizontal.
g gravity
Ɋ flow rate of material
Td mean dwell time of material on the chute
L Length of chute
Ve Chute exit velocity
e Vo/Ve

The force FR = M*g*cos μ .

If the length of the chute is L, and the average dwell time of material on the chute is Td
ƒ†–Š‡ˆŽ‘™”ƒ–‡‹•Ɋǡ–Š‡

αɊȗ†

The length - time relationship on the chute can be calculated by

L= [(Vo + Ve)/2 ] * Td

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 10 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

When the bulk material contacts the diverting channel, the force of the impact can be
computed by formulas which result in

’αɊȗ‡ȗ…‘•μ

Doing the substitution,

Ɋ αȏȏȋ ȗ ȌȋͳΪ‡ȌȐȀʹȗ‰ȗȗ…‘•μȐͳȀʹ

where e = Vo/Ve

Or one can look upon the operation more simply as follows:

The chute computes the mass/length value of the product in a form such as Kg/M. The
diverting channel by impact determines the velocity of the material in a form such as
M/min. If these values are multiplied together, they define massflow in Kg/minute.

Mass Flow = (Kg/M )*(M/min) = Kg/min

Fortunately, the computation is executed by the controller and we don't have to worry
about it. The measured SFT outputs are defined by the geometry of the unit and the flow
of the bulk solid. The SFT signals are transmitted on the Weight Channel to the KCM
controller.

Important Note:
The chute SFT must be set to address 1 on the weight channel and the diverting channel
SFT must be set to address 2.

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 11 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

4 Pellet Massflow Meter, 33-YF-401

Smart Flow Meter (SFM)

Pellet material is falling by gravity from the Pellet classifier 33-GN-408 to and through the
SFM. The SFM is connected to a KCM. The KCM measures the material flow and sends the
Massflow in kg/h (33-FQIC-40401) permanently to the DCS. If material flows trough the
SFM, the KCM measures the Massflow and indicates run status.
Switch 33-ZSC-40450 detects that the maintenance door on the SFM is closed and signal is
reported to the DCS.
The SFM itself is a measuring device, which is comprised of two material guide chutes that
are weighed using SFT load cells. The two resulting weight measurements are combined
mathematically in the KCM to determine the material flow through the SFM as mentioned
above. Build up of material on the chutes or bridging of the gaps between the chutes can
result in measurement errors. Periodically the unit will go through an automatic tare and
cleaning cycle. The interval for this bypass function can be set on the KCM. During this cycle
the KCM is in Volumetric Mode, the Massflow value is frozen.The Diverter valve 33-XV-
40450 inside the SFM will divert material flow away from the weighed chute and divert
channel and an instrument air blow-off (33-XV-40452) will clean the gap between the chute
and the inlet. After this the weight of the chute and divert channel will be determined to
establish a new zero point. At the end of the tare cycle the diverter valve will return to its
normal position and the Massflow is measured. The tare cycle is managed and controlled by
the KCM. Status of the tare cycle and position of the diverter valve is available to the DCS
system.
Since the material temperature will be elevated, the SFM will be equipped for high
temperature operation. This includes enclosing the SFT load cells in insulated cooling boxes
and monitoring the temperature of the SFT. The cooling medium in this case is instrument air
through Vortex coolers, which are then piped into the SFT enclosures. Thermal sensing for
High Temperature (>50°C) TAH-40450 and TAH-40451as well as High High Temperature
(>55°C) TAHH - 40450 and TAHH-40451will be provided. Signals for these alarms are
available to the DCS for monitoring. The High High Temperature condition will also be wired
locally to remove the power from the SFT load cells to avoid any hazardous situation. If
power is removed from the load cells the control will go to Volumetric Mode and an alarm

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OWNER
ONGC PETRO EIL JOB No.: 6987
additions LTD
(OPaL) Package Control Philosophy EIL /OWNER ID. CODE

EPCC2-3670-GP-VD-
P.O.: 7500030547 026_0547_ZSG_401050
PMC
ENGINEERS 3670-GP-MR-026 CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
INDIA
LIMITED 3670-GP-VD-
026_0547_ZSG_401050
CONTRACTOR
PROJECT: DAHEJ
UNIT: LLDPE / HDPE LOCATION: DAHEJ,
PETROCHEMICAL
Swing (2x360 KTPA) INDIA Sheet 12 of 12 REV 03
COMPLEX

K-Tron (Switzerland) LLC K-Tron project No:

Lenzhardweg 43/45 1115821
CH -5702 Niederlenz

from the KCM will be generated. The Massflow value is 0 kg/h. Operator will have to decide
whether or not to shut down the system.

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