Training Manual Green Anode Plant Vedanta - Jharsuguda: File: 138-02-043 - 08 - 0.doc, Codeword: Vedanta

Training Manual Green Anode Plant
Vedanta - Jharsuguda
138-02-043
Group 410 C
DE-060300
PROCESS GROUP 410 C - LIQUID PITCH STIRRING -
8
8.1
8.1.1
8.1.2
8.1.3
8.2
8.2.1
8.2.2
8.3
8.3.1
8.3.2
Process Group 410 C - Liquid Pitch Stirring -..............................................................................1

Process .......................................................................................................................................1
Process Flow Sheets...................................................................................................................1
Brief Process Description ............................................................................................................2
Main Process Data & Process Highlights ....................................................................................3
Process Control...........................................................................................................................5
P&Id`s, Material Route Diagrams, Operator Screen Images.......................................................5
Control Logic Description ............................................................................................................6
Main Equipment ..........................................................................................................................7
Basket Filter 410 C 015...............................................................................................................7
Positive Displacement Pump 410 C 030 .....................................................................................7
8.1
Process
8.1.1
Process Flow Sheets

(Work Copy)
Outokumpu Technology GmbH

file: 138-02-043_08_0.doc, Codeword: Vedanta
Revision: 0
Date: 29.09.2006
Page 1 of 7

8.1.2
138-02-043
Group 410 C
DE-060300
Brief Process Description

(Work Copy)

Page 2 of 7
Revision: 0
Date: 29.09.2006
CONTROL PHILOSOPHY
05.10.2006
Vedanta Alumina Ltd.
Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-063
1 (2)
Rev. 00
Brief Process Description

of
Process Group 410 C
- Liquid Pitch Stirring Reference:
Process Flow Sheet:
132-01-075 UB
P&I Diagram:
168-01-046 UB sheet 4, 168-01-047 UB sheet 1
Material Route Diagram:
133-50-064 UB sheet 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12
The Liquid Pitch Stirring Process Group 410 C stirs liquid pitch in tank 1 (410 A 200) and /or in
Tank 2 (410 A 300) and/or in tank 3 (410 A 400) or transfers liquid pitch between tank 1, tank
2 and tank 3.
Group 410 C consists of a set of three pitch pumps and three basket filters. Each pump is
connected to a tank discharge nozzle. Pitch is stirred in one tank or transferred to another tank
using one pump. This operation is only possible if the basket filter upstream the pump is
available and is not plugged. The differential pressure across the basket filters is monitored
continuously.
Pitch pump (410 C 030) keeps the pitch in tank 1 homogenous by circulation and thereby
stirring the pitch in tank 1 or transfers the pitch to tank 2 or tank 3. Pitch pump (410 C 130)
keeps the pitch in tank 2 homogenous by circulation and thereby stirring the pitch in tank 2 or
transfers the pitch to tank 1 or tank 3. Pitch pump (410 C 230) keeps the pitch in tank 3
homogenous by circulation and thereby stirring the pitch in tank 3 or transfers the pitch to tank
1 or tank 2. For operation in automatic mode, however only the main combinations are
foreseen, which results in 12 different routes that can be selected by the operator in the central
control room. Pitch pump (410C 030) is connected to the bottom suction nozzle of tank 1 via
basket filter (410 C 015). Pitch pump (410 C 030) circulates pitch within tank 1 via the stirring
nozzles (410 C 041, 042, 043, 044) or via nozzle (410 C 055) or to tank 2 via nozzle (410 C
155) or to tank 3 via nozzle (410 C 255). Four route selections Route 51,52,53,54 can be
made for pitch pump (410 C 030), which are described in detail under chapter 2.2.2. Pitch
pump (410C 130) is connected to the bottom suction nozzle of tank 2 via basket filter (410 C
115). Pitch pump (410 C 130) circulates pitch within tank 2 via the stirring nozzles (410 C 141,
142, 143, 144) or via nozzle (410 C 155) or to tank 1 via nozzle (410 C 055) or to tank 3 via
nozzle (410 C 255). Four route selections Route 61,62,63,64 can be made for pitch pump
(410 C 130), which are described in detail under chapter 2.2.3. Pitch pump (410C 230) is
connected to the bottom suction nozzle of tank 3 via basket filter (410 C 215). Pitch pump (410
C 230) circulates pitch within tank 3 via the stirring nozzles (410 C 241, 242, 243, 244) or via
nozzle (410 C 255) or to tank 1 via nozzle (410 C 055) or to tank 2 via nozzle (410 C 155).
Four route selections Route 71,72,73,74 can be made for pitch pump (410 C 230), which
are described in detail under chapter 2.2.4.
The selections of simultaneous routes are described under chapter 2.2.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
2 (2)
Rev. 00
The local operator has to open and close the corresponding pitch valves required for the
selected route. With valves in the correct position the control room operator receives the
confirmation by a signal on the operator display. Simultaneously the local operator receives
the confirmation for the corresponding pump by a pilot light on the local panel [410 LOP-B2].
He has to start the pump from the local panel. The local operator should always start the pump
at slow speed by pushing the "START SLOW" pushbutton. In this case the pump will only run
at slow speed. Slow speed is used to flush the piping system from possible obstructions
caused by cold spots. Slow speed should also be used as long as the pitch temperature is low
(160C). If the operator pushes the START FAST pushbutton the pump speed is controlled in
auto mode. In this case the pump will start at slow speed and will change to fast speed after a
pre-set time delay (setting in PLC: 4 minutes) if the pitch temperature in the tank where the
pump is sucking from has a level above 160C. According to the route selection the level of
the corresponding tank where the pitch is directed to has to be below maximum.
Should the pitch temperature drop below 160C during circulation the pump speed is changed
automatically back to slow speed.
If pitch shall be pumped from one tank to another with route 52/53/62/63/72/73 selected the
corresponding pump can only be started if the tank is not full, which the pitch is directed to.
The actual tank level is displayed on the local control panel.

8.1.3
138-02-043
Group 410 C
DE-060300
Main Process Data & Process Highlights

The process group is used to stir pitch stored in the pitch tanks.
- Pitch stirring rate is 10m3/hour (12 t/hour) pump runs at slow speed
- Pitch stirring rate is 20 m3 / hour (24 t/hour) pump runs at high speed
The control room operator has to communicate with the local operator for selection of
the desired pump and pipe route. The local operator is then responsible for the
opening and closing of the corresponding valves. Whenever a route is selected that
has not been used for some time, the local operator has to make sure that the
temperature of the heating jacket is sufficiently high by checking the HTM temperature
in the return spool of the corresponding pitch lines.
Each pitch tank can be stirred individually.
Two pitch tanks can be stirred while from the third tank pitch can be pumped to Group
431/432 H or circulated to the same tank.
Pitch is stirred in the storage tanks by positive displacement pumps. Pitch pumps are
equipped with two speed motors to run at low or high capacity. At slow speed the
capacity is 10m3/hour (12 t/hour). At high speed the capacity is 20m3/hour (24 t/hour).
Irregular pump noise may be caused by cavitation. Cavitation may occure by plugged
nozzle in the tank, plugged basket filter or because the pitch temperature in the tanks
is too low. In all cases the operator has to switch the pump drive to low speed (if the
pump is running at high speed) in order to reduce the pitch flow rate. If the pump runs
already at low speed, the operator has to decide either to stop the pump to prevent it
from damage or to keep the pump running under strict observation.
Normally, the pitch in two of the three tanks is stirred for homogenisation, at the same
time these tanks could filled by group 410 A also. The third tank is only used to feed
pitch to Group 431/432 H. If the feeding tank gets empty it is possible to use the
stirring pumps to fill the tank in charge from the other tanks, which has been stirred in
order not to interrupt the anode production. During this transfer period, stirring in the
corresponding tank has to be interrupted.
The pitch temperature in the tank not in charge for anode production should be
maintained as low as possible to minimise aging of pitch. The lower the pitch
temperature the lower is the aging rate but the higher is the viscosity. At the same
time pitch has to be stirred continuously to reduce settling of fine grainy pitch matters
at the tank bottom but stirring requires a viscosity convenient for pumping. Depending
on the pitch quality for each new delivery of pitch a compromise has to be found
between aging and pumping requirements. The third factor is the wetting ability of
pitch on the coke grain surface during mixing of anode paste. The higher the coke
temperature and the higher the pitch temperature the better is the ability of pitch to
wet the grain surface. According to actual knowledge 190 - 200C pitch temperature
gives the best results when using pitch of about 110 R+B softening point.
If 200C has been chosen to be the best pitch temperature for making anode paste
the temperature of pitch in the tank in charge must be not less than 180C because of
the limited heating capacity of the liquid pitch heat exchanger, which can heat up 12 t
/ hour pitch by 20C maximum.
The pitch in the tank not actually in charge should be lower in temperature. If the
temperature has dropped under 170C pumping becomes difficult (cavitation) so that
the pitch has to be heated up by means of HTM heated coils installed at the pitch
tanks bottom until pumping without cavitation noise is possible again. Heating is also
supported by the immersion heaters, which are part of tanks heating system.

Revision: 0
Date: 29.09.2006
Page 3 of 7

All liquid pitch valves (with exception to the tank drain valves) have to be operated at
regular intervals by the local operator in agreement with the central control room
operator. This has to be done when the corresponding routes for unloading allow the
manipulation of manual valves, normally during interruptions in production.
Frequent cleaning is absolutely necessary for a safe and healthy operation. The
operators and maintenance people have to make sure that no foreign material (e.g.
bags, tools, debris, rags, petrol coke dust, etc.) spoils the area of the liquid pitch
unloading, the pitch pumps and liquid pitch tanks and other floors where heated
equipment is located. In case of a leakage foreign material may get soaked with oil,
which increases a hazard of a fire and may hinder the access to the equipment,
especially in case of emergency.
The tank drain valves are only opened for maintenance of an empty tank or in case
that samples for testing purpose have to be drawn from the tank. These valves should
be tagged and locked for unintentional operation. In case that these valves have to be
opened for maintaining the empty tank the other valves on the pipe connections to
this tank have to be safely locked in order to avoid unintended re-filling.
Smoking and open fire is strictly prohibited in the pitch unloading area and on and
around the pitch storage tanks.
In case that maintenance work like grinding, burning or welding has to be done,
special rules have to be established by VEDANTA that have to be strictly obeyed.
The operators have to be aware that the facility includes heated equipment avoid
burns on hot machine parts, tanks, valves, pipes, etc.

Page 4 of 7
138-02-043
Group 410 C
DE-060300
Revision: 0
Date: 29.09.2006

8.2
Process Control
8.2.1
P&Id`s, Material Route Diagrams, Operator Screen Images
138-02-043
Group 410 C
DE-060300
(work copies)

Revision: 0
Date: 29.09.2006
Page 5 of 7

8.2.2
138-02-043
Group 410 C
DE-060300
Control Logic Description

(Work Copy)

Page 6 of 7
Revision: 0
Date: 29.09.2006
CONTROL PHILOSOPHY
05.10.2006
1 (23)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-063
Control Philosophy
of
Process Group 410 C
- Liquid Pitch Stirring Reference:
Process Flow Sheet:
132-01-075 UB
P&I Diagram:
168-01-046 UB sheet 4, 168-01-047 UB sheet 1
Material Route Diagram:
133-50-064 UB sheet 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12
Brief Process Description............................................................................................................ 1
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.5
2.5.1
2.5.2
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.7
2.8
Control Logic Description ............................................................................................................ 3

Special Terminology for this Group............................................................................................. 3
Linked Process Groups............................................................................................................... 5
Selections ................................................................................................................................... 5
Selection of Operation Modes (SE 1) ......................................................................................... 5
Selection of Material Route Stirring Pump 410 C 030 (SE 2) ..................................................... 5
Selection of Material Route Stirring Pump 410 C 130 (SE 3) ..................................................... 9
Selection of Material Route Stirring Pump 410 C 230 (SE 4) ................................................... 12
Group Start ............................................................................................................................... 15
Selections Prior to Start ............................................................................................................ 15
Start Preconditions.................................................................................................................... 15
Setpoints Prior to Group Start ................................................................................................... 16
Group Start Sequence .............................................................................................................. 16
Normal Operation...................................................................................................................... 17
High Level Storage Tank........................................................................................................... 17
Pitch Temperature Storage Tank .............................................................................................. 17
Shut Down ................................................................................................................................ 17
Normal Shut Down .................................................................................................................... 17
Shut Down by other Groups...................................................................................................... 17
Fast Shut Down......................................................................................................................... 18
Trip in Case of Faults................................................................................................................ 18
Local Operation of Special Equipment...................................................................................... 22
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 23
BRIEF PROCESS DESCRIPTION

The Liquid Pitch Stirring Process Group 410 C stirs liquid pitch in tank 1 (410 A 200) and /or in
Tank 2 (410 A 300) and/or in tank 3 (410 A 400) or transfers liquid pitch between tank 1, tank
2 and tank 3.
Group 410 C consists of a set of three pitch pumps and three basket filters. Each pump is
connected to a tank discharge nozzle. Pitch is stirred in one tank or transferred to another tank
using one pump. This operation is only possible if the basket filter upstream the pump is
available and is not plugged. The differential pressure across the basket filters is monitored
continuously.
CONTROL PHILOSOPHY
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OTK ref.:
DE-060300
Doc. No.:
133-50-063
2 (23)
Rev. 00
Pitch pump (410 C 030) keeps the pitch in tank 1 homogenous by circulation and thereby
stirring the pitch in tank 1 or transfers the pitch to tank 2 or tank 3. Pitch pump (410 C 130)
keeps the pitch in tank 2 homogenous by circulation and thereby stirring the pitch in tank 2 or
transfers the pitch to tank 1 or tank 3. Pitch pump (410 C 230) keeps the pitch in tank 3
homogenous by circulation and thereby stirring the pitch in tank 3 or transfers the pitch to tank
1 or tank 2. For operation in automatic mode, however only the main combinations are
foreseen, which results in 12 different routes that can be selected by the operator in the central
control room. Pitch pump (410C 030) is connected to the bottom suction nozzle of tank 1 via
basket filter (410 C 015). Pitch pump (410 C 030) circulates pitch within tank 1 via the stirring
nozzles (410 C 041, 042, 043, 044) or via nozzle (410 C 055) or to tank 2 via nozzle (410 C
155) or to tank 3 via nozzle (410 C 255). Four route selections Route 51,52,53,54 can be
made for pitch pump (410 C 030), which are described in detail under chapter 2.2.2. Pitch
pump (410C 130) is connected to the bottom suction nozzle of tank 2 via basket filter (410 C
115). Pitch pump (410 C 130) circulates pitch within tank 2 via the stirring nozzles (410 C 141,
142, 143, 144) or via nozzle (410 C 155) or to tank 1 via nozzle (410 C 055) or to tank 3 via
nozzle (410 C 255). Four route selections Route 61,62,63,64 can be made for pitch pump
(410 C 130), which are described in detail under chapter 2.2.3. Pitch pump (410C 230) is
connected to the bottom suction nozzle of tank 3 via basket filter (410 C 215). Pitch pump (410
C 230) circulates pitch within tank 3 via the stirring nozzles (410 C 241, 242, 243, 244) or via
nozzle (410 C 255) or to tank 1 via nozzle (410 C 055) or to tank 2 via nozzle (410 C 155).
Four route selections Route 71,72,73,74 can be made for pitch pump (410 C 230), which
are described in detail under chapter 2.2.4.
The selections of simultaneous routes are described under chapter 2.2.
The local operator has to open and close the corresponding pitch valves required for the
selected route. With valves in the correct position the control room operator receives the
confirmation by a signal on the operator display. Simultaneously the local operator receives
the confirmation for the corresponding pump by a pilot light on the local panel [410 LOP-B2].
He has to start the pump from the local panel. The local operator should always start the pump
at slow speed by pushing the "START SLOW" pushbutton. In this case the pump will only run
at slow speed. Slow speed is used to flush the piping system from possible obstructions
caused by cold spots. Slow speed should also be used as long as the pitch temperature is low
(160C). If the operator pushes the START FAST pushbutton the pump speed is controlled in
auto mode. In this case the pump will start at slow speed and will change to fast speed after a
pre-set time delay (setting in PLC: 4 minutes) if the pitch temperature in the tank where the
pump is sucking from has a level above 160C. According to the route selection the level of
the corresponding tank where the pitch is directed to has to be below maximum.
Should the pitch temperature drop below 160C during circulation the pump speed is changed
automatically back to slow speed.
If pitch shall be pumped from one tank to another with route 52/53/62/63/72/73 selected the
corresponding pump can only be started if the tank is not full, which the pitch is directed to.
The actual tank level is displayed on the local control panel.
CONTROL PHILOSOPHY
05.10.2006
3 (23)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-063
CONTROL LOGIC DESCRIPTION
2.1
Special Terminology for this Group

Operation Modes to be selected at the Central Control Room
CENTRAL
There is no CENTRAL mode foreseen for this Process Group.

Equipment of this exceptional Group is started and stopped
locally only for observing leakages, noise etc.
AUTOMATIC
For this process group, AUTOMATIC mode is available from

the corresponding Local Operator Panels. For this process
group, equipment is started and stopped in AUTOMATIC
mode from a Local Operator Panel when both the Central
Control Room operator and the local operator have selected
AUTOMATIC mode for this group. Details are explained in the
description for this individual process group. In AUTOMATIC
mode all equipment related devices and safety devices are
interlocked. Alarms are always indicated on SCADA,
independent of the operation mode.
MAINTENANCE
For this process group, MAINTENANCE mode is available

from the corresponding Local Control Switches when both the
Central Control Room operator and the local operator have
selected MAINTENANCE mode for this group. Maintenance
mode allows running equipment in jogging operation without
any process and equipment related interlocks foreseen in
AUTOMATIC mode. Alarms are always indicated on SCADA,
independent of the operation mode.
Operation Modes to be selected on Local Operator Panels (LOP)

AUTOMATIC
For this process group, AUTOMATIC mode is available from

the corresponding Local Operator Panels, if AUTOMATIC
mode is both selected on the corresponding LOP and on an
Operator Station in the Central Control Room.
MAINTENANCE
For this process group, MAINTENANCE mode is available

from the corresponding Local Control Switches, if
MAINTENANCE mode is both selected on the corresponding
LOP and on an Operator Station in the Central Control Room.
Pushbuttons and lights on Local Operator Panel

E_STOP
Mushroom PB stops equipment instantly
HORN OFF
PB resets horn sounding
ALARM ACKNOWLEDGEMENT
PB resets alarm
LAMP TEST
PB powers all lights in LOP
*AUTOMATIC / MAINTENANCE
Selector switch for operation mode
*PUMP START SLOW
PB initiates start sequence of this pump
CONTROL PHILOSOPHY
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Rev. 00
*PUMP START FAST
PB allows fast start sequence of this pump
*PUMP STOP
PB initiates stop sequence of this pump
*ROUTE OK
Light indicates correct route selection
FAULT HTM CIRCUIT
Light indicates fault of HTM circuit
*PUMP RUNNING SLOW
Light indicates pump operates in low speed
*PUMP RUNNING FAST
Light indicates pump operates in fast speed
**PITCH TEMP. LOW
Light indicates low level of pitch temperature
**LOW PITCH FLOW
Light indicates low differential pressure at filter
**FILTER PLUGGED
Light indicates high differential pressure at filter
LI-410 A 200
Digital indication (0-100%) of tank 1 level
LI-410 A 300
LI-410 A 400

* one individual Pushbutton / Light for each pump
** one individual Light for each basket filter
4 (23)
CONTROL PHILOSOPHY
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Doc. No.:
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2.2
5 (23)
Rev. 00
Linked Process Groups

The following Process Groups are linked with this Group 410 C:
Liquid Pitch Unloading & Storage 410 A

Liquid Pitch Transfer 410 B
HTM System 431 S / 432 S
The exchange of control signals is described in the following chapters and especially under 2.8
below.
2.3
Selections
2.3.1
Selection of Operation Modes (SE 1)

The local operator shall determine by individual selector switch for each pump at the local
control panel [410 LOP-B2] to run the stirring pumps 410 C 030 and/or 410 C 130 and/or 410
C 230 in Automatic or Maintenance mode. The central control room operator has to confirm
the selection on the Operator Station in the CCR for the corresponding pump individually. If a
selector switch at [410 LOP-B2] is moved during automatic operation, the drive of the
corresponding pump is stopped immediately.
2.3.2
AUTOMATIC operation mode
After this selection the pumps could start if all start

preconditions are met.
MANTENANCE operation mode
(details please see under 2.7 below). Operation mode to

start equipment strictly for maintenance, particularly from
their individual local switches if installed. Functional
machine interlocks such as overload relays and selfevident safety circuits are still active. Sequence and
logic interlocks for automatic operation and interlocks
from related Process Groups are not active. This
operation mode allows field adjustments but requires
local operator survey in case that material is conveyed.
(For geared pitch pumps only very short running
intervals are allowed without pitch)
Selection of Material Route Stirring Pump 410 C 030 (SE 2)

The operator has four options:
The selection is made on the Operator Station located in the Central Control Room (CCR).
The state of selection is on the Operation Sation (OS) indicated. A Route o.k. light on the
local operator panel [410 LOP-B2] indicates the correct position of the manual pitch valves for
the selected route. If the correct valve position for the selected route is not confirmed by
Route o.k. indication, the local operator has to verify the correct open or closed valve
position.
SE 2-1:
Route 51: Stirring Pump 410 C 030 from tank 410 A 200 to tank 410 A 200 via stirring
nozzles
This material route can be selected simultaneous with following Routes:
Route 71 (SE 4-1) and/or Route 61/62/63/64 (SE 3-1/3-2/3-3/3-4)
CONTROL PHILOSOPHY
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or Route 61 (SE 3-1) and/or Route 72/73/74 (SE 4-2/4-3/4-4)

The local operator has to verify this Route Selection by manual control of the following valve
positions:
OPEN:
(410 B 010)
(410 C 010)
(410 C 025)
(410 C 035)
(410 C 040)
a minimum of two of the following valves (410 C 041), (410 C
042), (410 C 043), (410 C 044)
CLOSE:
(410 A 230)
(410 B 017)
(410 C 020)
(410 C 050)
This Route Selection cannot be made if:
pump (410 C 030) is in operation with a different route (Route 52/53/54 SE 2-2/2-3/2-4)
pump (410 B 065) is in operation with route 11 (SE 2-1)
pump (410 B 165) is in operation with route 21 (SE 3-1) or 24 (SE 3-4)
With the verification of the above valve positions this route is set in the PLC.
SE 2-2:
Route 52: Stirring Pump 410 C 030 from tank 410 A 200 to tank 410 A 300
Route 71 (SE 4-1) and/or Route 61 (SE 3-1)
positions:
OPEN:
(410 B 010)
(410 C 010)
(410 C 025)
(410 C 035)
(410 C050)
(410 C 155)
CLOSE:
(410 A 330)
(410 B 017)
(410 C 020)
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(410 C 040)
(410 C 055)
(410 C 150)
(410 C 250)
(410 C 255)
This Route Selection cannot be made:
SE 2-3:
positions:
OPEN:
(410 B 010)
(410 C 010)
(410 C 025)
(410 C 035)
(410 C 050)
(410 C 255)
CLOSE:
(410 A 430)
(410 B 017)
(410 C 020)
(410 C 040)
(410 C 055)
(410 C 150)
(410 C 155)
(410 C 250)
CONTROL PHILOSOPHY
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Rev. 00

OTK ref.:
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Doc. No.:
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8 (23)
SE 2-4;
positions:
OPEN:
(410 B 010)
(410 C 010)
(410 C 025)
(410 C 035)
(410 C 050)
(410 C 055)
CLOSE:
(410 A 230)
(410 B 017)
(410 C 020)
(410 C 040)
(410 C 150)
(410 C 155)
(410 C 250)
(410 C 255)
CONTROL PHILOSOPHY
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Rev. 00

OTK ref.:
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Doc. No.:
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2.3.3
9 (23)

The state of selection is on the Operation Station (OS) indicated. A Route o.k. light on the
position.
SE 3-1:
Route 61: Stirring Pump 410 C 130 from tank 410 A 300 to tank 410 A 300 via stirring
nozzles
Route 71 (SE 4-1) and/or Route 51/52/53/54 (SE 2-1/2-2/2-3/2-4) or Route 51 (SE 2-1)
and/or Route 72/73/74 (SE 4-2/4-3/4-4)
positions:
OPEN:
(410 B 020)
(410 C 110)
(410 C 125)
(410 C 135)
(410 C 140)
142), (410 C 143), (410 C 144)
CLOSE:
(410 A 330)
(410 B 027)
(410 C 120)
(410 C 150)
SE 3-2:
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positions:
OPEN:
(410 B 020)
(410 C 055)
(410 C 110)
(410 C 125)
(410 C 135)
(410 C 150)
CLOSE:
(410 A 230)
(410 B 027)
(410 C 050)
(410 C 120)
(410 C 140)
(410 C 155)
(410 C 250)
(410 C 255)
SE 3-3:
positions:
OPEN:
(410 B 020)
(410 C 110)
(410 C 125)
(410 C 135)
(410 C 150)
(410 C 255)
CONTROL PHILOSOPHY
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CLOSE:
11 (23)
(410 A 430)
(410 B 027)
(410 C 050)
(410 C 055)
(410 C 120)
(410 C 140)
(410 C 155)
(410 C 250)
SE 3-4:
positions:
OPEN:
(410 B 020)
(410 C 110)
(410 C 125)
(410 C 135)
(410 C 150)
(410 C 155)
CLOSE:
(410 A 330)
(410 B 027)
(410 C 050)
(410 C 055)
(410 C 120)
(410 C 140)
(410 C 250)
(410 C 255)
CONTROL PHILOSOPHY
05.10.2006
12 (23)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-063
2.3.4

The state of selection is on the Operation Station (OS) indicated. A Route o.k. light on the
position.
SE 4-1:
Route 71: Stirring Pump 410 C 230 from tank 410 A 400 to tank 410 A 400 stirring
nozzles
Route 51 (SE 2-1) and/or Route 61/62/63/64 (SE 3-1/3-2/3-3/3-4) or Route 61 (SE 3-1)
and/or Route 52/53/54 (SE 2-2/2-3/2-4)
positions:
OPEN:
(410 B 030)
(410 C 210)
(410 C 225)
(410 C 235)
(410 C 240)
242), (410 C 243), (410 C 244)
CLOSE:
(410 A 430)
(410 B 037)
(410 C 220)
(410 C 250)
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-063
13 (23)
SE 4-2:
positions:
OPEN:
(410 B 030)
(410 C 055)
(410 C 210)
(410 C 225)
(410 C 235)
(410 C 250)
CLOSE:
(410 A 230)
(410 B 037)
(410 C 050)
(410 C 150)
(410 C 155)
(410 C 220)
(410 C 240)
(410 C 255)
SE 4-3:
positions:
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-063
OPEN:
14 (23)
(410 B 030)
(410 C 155)
(410 C 210)
(410 C 225)
(410 C 235)
(410 C 250)
CLOSE:
(410 A 330)
(410 B 037)
(410 C 050)
(410 C 055)
(410 C 150)
(410 C 220)
(410 C 240)
(410 C 255)
SE 4-4:
positions:
OPEN:
(410 B 030)
(410 C 210)
(410 C 225)
(410 C 235)
(410 C 250)
(410 C 255)
CLOSE:
(410 A 430)
(410 B 037)
CONTROL PHILOSOPHY
05.10.2006
15 (23)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-063
(410 C 050)
(410 C 055)
(410 C 150)
(410 C 155)
(410 C 220)
(410 C 240)
2.4
Group Start
2.4.1
Selections Prior to Start

AUTOMATIC operation mode must be selected.
2.4.2
Start Preconditions
2.4.2.1 Process Group 410 S HTM System

HTM Secondary 5 in Operation signal shall be present
HTM Secondary 6 in Operation signal shall be present
for details see Group 410 S
2.4.2.2 Pitch Storage Tank
Storage Tank 1 [410 A 200-LSHH] indicates high-high level
Route 62, 72 directed to this storage tank cannot be selected.
2.4.2.3 Seal pot
Seal pot of tank 1 [410 A 210-LSHH] indicates high-high level
2.4.2.4 Route Settings
Start pitch pump (410 C 030): Route 51, 52, 53 or 54 have to be set.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
16 (23)
Rev. 00
2.4.2.5 Emergency stops

If the Emergency Stop of the Group has been activated it has to be RESET.
2.4.2.6 Alarms
If an Alarm of this Group has been activated it has to be RESET.
2.4.3
Setpoints Prior to Group Start

There are no setpoints in this group.
2.4.4
Group Start Sequence

The local operator has to get instructions from the Central Control Room operator which Route
will be determined for the corresponding pump.
The operator starts the pitch pumps (410 C 030), (410 C 130) and (410 C 230) individually
from the local control panel [410 LOP-B2]. A start is only initiated if the operator pushes the
"SLOW" Start pushbutton of the corresponding pump.
2.4.4.1 Start Stirring Pump (410 C 030)

The Operator actuates "SLOW" start pushbutton for pitch pump (410 C 030). Flashing light
indicates that start up sequence is initiated.
Pitch pump (410 C 030) is started at slow speed.
Condition:
Route 51/52/53/54 selected and verified
The local operator can switch the pump to high speed by actuating "FAST" pushbutton for
pitch pump (410 C 030) observing the pump operation at slow speed. The pump is then
switched to fast speed after 4 minutes operation at slow speed.
Condition:
- pitch temperature at pump above low level 160C [410 C 010-TL] when operating with
route 51/52/53/54
- differential pressure at pitch filter between low level 0,5 mbar [410 C 015-PDSL] and high
level 10 mbar [410 C 015-PDSH] when operating with route 51/52/53/54
Condition:
- Route 61/62/63/64 selected and verified
Condition:
route 61/62/63/64
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
17 (23)
Rev. 00

Condition:
- Route 71/72/73/74 selected and verified
Condition:
route 71/72/73/74
2.5
Normal Operation
2.5.1
High Level Storage Tank

Storage Tank 1 [410 A 200-LSH] indicates High Level
operating with Route 62 or 72
acoustic signal in the local panel
alarm on the operator station in the CCR
2.5.2
Pitch Temperature Storage Tank

The operator may vary the set value for the liquid pitch temperature [410 A 200-TIC], [410 A
300-TIC], [410 A 400-TIC] during operation. Normally, a variation of the pitch temperature
setpoint during operation is only necessary when pitch is stirred in the tanks and if liquid pitch
was received at a too low temperature.
2.6
Shut Down
2.6.1
Normal Shut Down

The equipment of this Group is only started and stopped from the local operating panel
[410 LOP-B2] respectively.
There is no Normal Shut Down from the SCADA in the Central Control Room (CCR).
2.6.2
Shut Down by other Groups

This Group is not shut down by other Groups.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
2.6.3
18 (23)
Rev. 00
Fast Shut Down

The equipment of this Group is stopped from the local operating panels [410 LOP-B2].
2.6.3.1 Fast Shut Down of pump (410 C 030) from local operating panel [410 LOP-B2]
The operator actuates the STOP pushbutton for stirring pump (410 C 030)
Pump (410 C 030) is stopped immediately.
The operator actuates the STOP pushbutton for stirring pump (410 C 130).
Pump (410 130) is stopped immediately.
The operator actuates the STOP pushbutton for stirring pump (410 C 230).
Pump (410 C 230) is stopped immediately.
2.6.4
Trip in Case of Faults

If this Group 410 C is running in AUTOMATIC mode and an equipment or an instrument of this
Group fails an Alarm is initiated and, if the fault is of the serious sort, the corresponding part of
this Group is stopped. All faults listed below will cause a Fast Shut Down of the respective part
of this Group.
An E-Stop will cause a Fast Shut Down of this Group.
Note: All instruments mounted on equipment or located somewhere in the field or
anywhere else are to be wired fail-safe.
2.6.4.1 Pitch Stirring Pump (410 C 030)

MCC: [410 C 030] fault
alarm is initiated
drive is stopped
Fast Shut Down of this part of the group (see 2.6.3.1 above) will be initiated.
alarm is initiated
drive is stopped
alarm is initiated
drive is stopped
2.6.4.4 Route Selection SE 2-1/2-2/2-3/2-4
In case that a valve is moved during operation and the valve position required for the
selected route 51/52/53/54 is lost,
alarm is initiated
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
-
19 (23)
Rev. 00
"Route selection o.k." symbol starts flashing

pump (410 C 030) is stopped immediately.

alarm is initiated
alarm is initiated
2.6.4.7 Tank 1 High-High Level
[410 A 200-LSHH] indicates High-high level
operating with Route 62

alarm is initiated
Route Selection O.K. symbol starts flushing
pump (410 C 130) stops
operating with Route 72.
alarm is initiated


alarm is initiated
alarm is initiated


alarm is initiated
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
Rev. 00

alarm is initiated
-
2.6.4.10 Seal pot Tank 1 High-High Level


alarm is initiated
alarm is initiated


alarm is initiated
alarm is initiated


alarm is initiated
alarm is initiated
20 (23)
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
21 (23)
Rev. 00
2.6.4.13 Pitch Temperature Valve (410 C 010) low

[410 C 010-TY] pitch temperature is lower than 160 C
operating with Route 51/52/53/54

alarm is initiated
"Pitch Temperature Filter 410 C 015 low" symbol starts flashing
low temperature indication is prevailing for more than 3 minutes corresponding pump
(410 C 030) is stopped immediately if running fast.


alarm is initiated


alarm is initiated
2.6.4.16 Pitch Filter 410 C 015 Low Differential Pressure [410 C 015-PDSL]
[410 C 015-PDSL] differential pressure at the filter is too low <0,5 mbar

The operator is warned by an acoustic signal
pilot light in the local panel " LOW PITCH FLOW" [410 C 015-PDSL]
He has then 3 minutes time to find the reason for that alarm (e.g. bottom suction
nozzle too cold). In case that the operator cannot eliminate the reason for the alarm he
has to stop the corresponding pump (410 C 030). If operating at fast speed the
corresponding pump is automatically stopped after 3 minutes delay time.
-

CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-063
22 (23)
Rev. 00

-
2.6.4.19 Pitch Filter (410 C 015) High Differential Pressure [410 C 015-PDSH]
[410 C 015-PDSH] differential pressure at the filter is too high >10 mbar

pilot light in the local panel when the "FILTER PLUGGED" [410 C 015-PDSH]
In case that the reason for the alarm is prevailing for 3 minutes pump (410 C 030) is
automatically stopped if operating at fast speed.
The reason for this alarm may be too high pitch viscosity normally together with too low
pitch temperature or a dirty filter.

2.7

Local Operation of Special Equipment

Not applicable
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-063
2.8
Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal
Description
Sort of Signal
from Group 431 S / 410 S to

Group 410 B
HTM SECONDARY 5 IN
OPERATION Group 431 S / 410 S is
running in AUTOMATIC mode,
minimum 2 primary pumps in
operation, minimum 1 pump of
secondary 5 in operation, minimum 1
Heater no Common Fault
HTM SECONDARY 6 IN
OPERATION Group 431 S / 410 S is
running in AUTOMATIC mode,
minimum 2 primary pumps in
operation, minimum 1 pump of
secondary 6 in operation, minimum 1
Heater no Common Fault
Pitch Valve 410 A 230 closed
DRAIN TANK 1 CLOSED
DRAIN TANK 2 CLOSED
DRAIN TANK 3 CLOSED
High-high level [410 A 210-LSHH] in
Seal pot tank 1 OVERFLOW TANK
1
2
3
tank 1 HIGH-HIGH LEVEL TANK 1
High level [410 A 200-LSH] in tank 1
HIGH LEVEL TANK 1
HIGH LEVEL TANK 2
HIGH LEVEL TANK 3
Actual level [410 A 200-LI] in tank 1
LEVEL TANK 1
LEVEL TANK 2
LEVEL TANK 3
Pitch Valve 410 B 010 open
Pitch Valve 410 B 017 closed
Pitch Valve 410 C 010 closed
Digital signal from 431 PLC 11 to

410 PLC 01 and
within PLC Number 410 PLC 01
from Group 431 S / 410 S to

Group 410 B
from Group 410 A to Group 410 C

from Group 410 B to Group 410 C
from Group 410 C to Group 410 B
Digital signal from 431 PLC 11 to

410 PLC 01 and
within PLC Number 410 PLC 01
Digital signal within 410 PLC 01

Analogue signal within 410 PLC 01
23 (23)

8.3
Main Equipment
8.3.1
Basket Filter 410 C 015
8.3.2
Positive Displacement Pump 410 C 030

138-02-043
Group 410 C
DE-060300
Revision: 0
Date: 29.09.2006
Page 7 of 7

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PROCESS GROUP 410 C - LIQUID PITCH STIRRING -

Process Group 410 C - Liquid Pitch Stirring -..............................................................................1

Process Flow Sheets

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