SALT HANDLING SYSTEM SEQUENCE OPERATION

START SEQ STOP SEQ PATH-IA PATH-IB PATH-IIA PATH-IIB PATH-IIIA PATH-IIIB PATH-IIIC
9 1 TT-1(01H04C) TT-1(01H04C) TT-1(01H04C) TT-1(01H04C) TT-1(01H04C) TT-1(01H04C) TT-1(01H04C)
8 2 BC(01H09) BC(01H09) BC(01H09) BC(01H09) BC(01H09) BC(01H09) BC(01H09)
7 3 BELT SCALE(01W01) BELT SCALE(01W01) BELT SCALE(01W01) BELT SCALE(01W01) BELT SCALE(01W01) BELT SCALE(01W01) BELT SCALE(01W01)
6 4 BC(01H10) BC(01H10) BC(01H10) BC(01H10) BC(01H10) BC(01H10) BC(01H10)
5 5 DG(01G09)FWD DG(01G09)REV DG(01G09)FWD DG(01G09)REV DG(01G09)FWD DG(01G09)REV DG(01G09)MIDD
4 6 VF(01H11C) VF(01H11D) VF(01H11C) VF(01H11D) VF(01H11C) VF(01H11D) VF(01H11C/D)
3 7 BE(01H05D) BE(01H05E) BE(01H05D) BE(01H05E) BE(01H05D) BE(01H05E) BE(01H05D/E)
2 8 DG(01G12)(REV) DG(01G12)(REV) DG(01G12)(REV) DG(01G12)(REV) DG(01G12)(FWD) DG(01G12)(FWD) DG(01G12)(FWD)
1 9 DG(01G13)(FWD) DG(01G13)(FWD) DG(01G13)(REV) DG(01G13)(REV) (TPC)01H03B (TPC)01H03B (TPC)01H03B
SATURATOR(02D01D) SATURATOR(02D01D) EXS SATURATOR(02D01B) EXS SATURATOR(02D01B) EXISTING SALT STORAGE EXISTING SALT STORAGE EXISTING SALT STORAGE

NOTE : THIS DOCUMENT SHALL BE READ IN CONJUCTION WITH FLOW DIAGRAM

 OPERATION AND CONTROL PHILOSOPHY

SALT HANDLING SYSTEM

The Salt Handling System can be divided in Three Path as under:
PATH-I - Feed System 1 - SATURATOR (02D01D)
PATH-II - Feed System 2 – EXS SATURATOR (02D01B)
PATH-III - Feed System 3 - EXISTING SALT STORAGE

Operation at Automatic Sequentially Interlocked Condition

PATH-I - Feed System 1 – SATURATOR (02D01D)
Path –IA
a) Belt conveyor will operate if their respective overload relay, pull chord switch and belt sway switch are healthy
and run if respective zero speed switch is not operated.
b) Motor drive will operate only if respective overload relay is not energised /activated

The system will work as under –

Select PATH IA START ----˃ Hooter will buzz ----˃ Hooter will STOP after time delay of 30 sec --- ˃ Diverter Gate
(01G13)(FWD) ----˃ Diverter Gate (01G12)(REV) ----˃ Bucket Elevator(01H05D)----˃ Vibrating Feeder(01H11C)---- ˃
Diverter Gate (01G09)(FWD)----˃ Belt Conveyor (01H10) ----˃ Belt scale (01W01) ----˃ Belt Conveyor ((01H09) --- ˃
Truck Tippler -1 (01H04C)

The system STOP PATH is in Reverse chronological order of above

Path –IB
a) Belt conveyor will operate if their respective overload relay, pull chord switch and belt sway switch are healthy
and run if respective zero speed switch is not operated.
b) Motor drive will operate only if respective overload relay is not energised /activated

The system will work as under –

Select PATH IB START ----˃ Hooter will buzz ----˃ Hooter will STOP after time delay of 30 sec --- ˃ Diverter Gate
(01G13)(FWD) ----˃ Diverter Gate (01G12)(REV) ----˃ Bucket Elevator(01H05E)----˃ Vibrating Feeder(01H11D) ---- ˃
Diverter Gate (01G09)(REV)----˃ Belt Conveyor (01H10) ----˃ Belt scale (01W01) ----˃ Belt Conveyor ((01H09)---- ˃
Truck Tippler -1 (01H04C)

The system STOP PATH is in Reverse chronological order of above

PATH-II - Feed System 2 - EXS SATURATOR (02D01B)

Path –IIA
a) Belt conveyor will operate if their respective overload relay, pull chord switch and belt sway switch are healthy
and run if respective zero speed switch is not operated.
b) Motor drive will operate only if respective overload relay is not energised /activated

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The system will work as under –

Select PATH IIA START ----˃ Hooter will buzz ----˃ Hooter will STOP after time delay of 30 sec --- ˃ Diverter Gate
(01G13)(REV) ----˃ Diverter Gate (01G12)(REV) ----˃ Bucket Elevator(01H05D)----˃ Vibrating Feeder(01H11C) ---- ˃
Diverter Gate (01G09)(FWD)----˃ Belt Conveyor (01H10) ----˃ Belt scale (01W01) ----˃ Belt Conveyor ((01H09) --- ˃
Truck Tippler -1 (01H04C)

The system STOP PATH is in Reverse chronological order of above

Path –IIB
a) Belt conveyor will operate if their respective overload relay, pull chord switch and belt sway switch are healthy
and run if respective zero speed switch is not operated.
b) Motor drive will operate only if respective overload relay is not energised /activated

The system will work as under –

Select PATH IIB START ----˃ Hooter will buzz ----˃ Hooter will STOP after time delay of 30 sec --- ˃ Diverter Gate
(01G13)(REV) ----˃ Diverter Gate (01G12)(REV) ----˃ Bucket Elevator(01H05E)----˃ Vibrating Feeder(01H11D) ---- ˃
Diverter Gate (01G09)(REV)----˃ Belt Conveyor (01H10) ----˃ Belt scale (01W01) ----˃ Belt Conveyor ((01H09)---- ˃
Truck Tippler -1 (01H04C)

The system STOP PATH is in Reverse chronological order of above

PATH-III - Feed System 3 - EXISTING SALT STORAGE

Path – IIIA
a) Belt conveyor will operate if their respective overload relay, pull chord switch and belt sway switch are healthy
and run if respective zero speed switch is not operated.
b) Motor drive will operate only if respective overload relay is not energised /activated

The system will work as under –

Select PATH IIIA START ----˃ Hooter will buzz ----˃ Hooter will STOP after time delay of 30 sec----˃ Tripper
Conveyor(01H03B)----˃ Diverter Gate (01G12)(FWD) ----˃ Bucket Elevator(01H05D)----˃ Vibrating Feeder(01H11C) ----
> Diverter Gate (01G09)(FWD) ----˃ Belt Conveyor (01H10) ----˃ Belt scale (01W01) ----˃ Belt Conveyor ((01H09) --- ˃
Truck Tippler -1 (01H04C)

The system STOP PATH is in Reverse chronological order of above

Path – IIIB
a) Belt conveyor will operate if their respective overload relay, pull chord switch and belt sway switch are healthy
and run if respective zero speed switch is not operated.
b) Motor drive will operate only if respective overload relay is not energised /activated

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The system will work as under –

Select PATH IIIB START ----˃ Hooter will buzz ----˃ Hooter will STOP after time delay of 30 sec --- ˃ Tripper
Conveyor(01H03B)----˃ Diverter Gate (01G12)(FWD) ----˃ Bucket Elevator(01H05E) --- ˃ Vibrating Feeder(01H11D)
----˃ Diverter Gate (01G09)(REV) ----˃ Belt Conveyor (01H10) ----˃ Belt scale (01W01) ----˃ Belt Conveyor ((01H09) ----
> Truck Tippler -1 (01H04C)

The system STOP PATH is in Reverse chronological order of above

Path – IIIC
a) Belt conveyor will operate if their respective overload relay, pull chord switch and belt sway switch are healthy
and run if respective zero speed switch is not operated.
b) Motor drive will operate only if respective overload relay is not energised /activated

The system will work as under –

Select PATH IIIC START ----˃ Hooter will buzz ----˃ Hooter will STOP after time delay of 30 sec --- ˃ Tripper
Conveyor(01H03B)----˃ Diverter Gate (01G12)(FWD) ----˃ Bucket Elevator(01H05D/E) --- ˃ Vibrating
Feeder(01H11C/D) ----˃ Diverter Gate (01G09)(MIDDLE) ----˃ Belt Conveyor (01H10) ----˃ Belt scale (01W01)---- ˃ Belt
Conveyor ((01H09) --- ˃ Truck Tippler -1 (01H04C)

The system STOP PATH is in Reverse chronological order of above

Manual/Local Mode Operation of Equipment

Every equipment can be START individually during maintenance time or during belt changing time from PLC to START
the individual equipment, LOCAL selection shall be selected and START the equipment.
for conveyor local START permissive
Motor Trip Feedback
Emergency Stop
Pull Cord Switch Healthy
Motor will be started after checking of above mentioned 3 permissive conditions and RUN feedback signal indicated
in PLC. Others interlock shall be de-energised during Local Mode Operation.
For Others Equipment except Belt Conveyor,
Motor Trip Feedback
Emergency Stop
Motor will be started after checking of above mentioned 2 permissive conditions and RUN feedback signal comes in
PLC. Others interlock shall be de-energised during Local Mode Operation.
Path will be started in this above mentioned process. If any fault is occurring in stream or instrument of a definite Path,
fault signal will be transferred to PLC and in parallel manner, system will be stopped.

Auto mode:
In the “AUTO” mode, the conveyors and related equipment will START sequentially when the “SYSTEM START” is
activated. During Stopping, when the “SYSTEM STOP” is activated, all conveyors will also STOP sequentially (in the
reverse order) allowing time delays for clearing the belts.

Local Control Panels for following equipment’s shall be provided

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(a) Travelling Tripper (Not in ICPL SCOPE)
(b) Belt weigher (ICPL SCOPE)

All the above local control panels shall be accessible and Belt weigher located in control room and shall be complete
with all the required controls, interlocks,

Conveyor System:
Each conveyor shall be protected against damage to the edge of the belt due to excessive side ways movement by
providing an adequate number of belt sway switches. In addition, each conveyor shall be provided with one (1) No.
speed detection device (zero speed switch). The zero speed switches shall be designed to sense belt speed. In case of
speed of belt goes below 90% of rated speed, it shall trip the conveyor.

The following are the various safety interlocks for the conveyors and other equipment. This list is indicative the
contractor shall develop a comprehensive interlocking scheme.

a) Pull - Chord switch - not operated

b) Belt sway switch - not operated
c) Zero speed switch - closed at 90% speed of the conveyor within designed accelerating time.
d) Motor protection - not tripped
e) Local STOP PB – reset
f) Trip circuits healthy.

Existing Tripper Conveyor:

Mobile tripper unit shall be locally controlled from the operating platform suitably located with the unit as per
instructions given from control room.
After starting conveyor Travelling Tripper shall be started

Following Signal required for Interlock

1) Motor ON
2) Motor TRIP

Saturator:
Following Signal required for Interlock

1) EXISTING BRINE SATURATOR (012D01B) LEVEL HIGH

2) BRINE SATURATOR (012D01D) LEVEL HIGH

Details of START/STOP & TRIP signal kindly refer IO List.

STOP/Tripping Procedure
Above mentioned condition will be treated as permissive for Starting and tripping or Stopping. If above mentioned
conditions are changed from healthy to Fault, the system will be tripped/STOP.
The Salt Handling System will be controlled and monitored from PLC located in the Control Room.

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Two position Mode Selector Switch (MSS) on Operator Work Station (OWS) with following positions
Mode – I –Automatic operation sequentially interlocked condition
Mode – II- Manual operation sequentially interlocked condition
Annunciation shall be provided for the following:-
a) Overload relay operated for Motor Drives
b) Pull Chord Switch operated for Belt Conveyors as applicable
c) Belt Sway Switch operated for Belt Conveyors as applicable
d) Zero Speed Switch operated for Belt Conveyors as applicable
e) Emergency STOP Push Button pressed
Local Push Button station.
Local push Button station for all drives shall have One Emergency STOP Push Button, START Push Button and Auto
manual selector switch

Hooter
Hooters will be located in suitable location of the plant area. One Hooter are considered DO for each drive
And this hooter will be buzz 10 sec before Starting of the conveyor

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