410A

138-02-043
Group 410 A
DE-060300
Training Manual Green Anode Plant

Vedanta - Jharsuguda
PROCESS GROUP 410 A - LIQUID PITCH UNLOADING & STORAGE -
6
6.1
6.1.1
6.1.2
6.1.3
6.2
6.2.1
6.2.2
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
Process Group 410 A - Liquid Pitch Unloading & Storage - ........................................................1

Process .......................................................................................................................................1
Process Flow Sheets (Work Copy) .............................................................................................1
Brief Process Description (Work Copy) .......................................................................................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
Plug Valve (pneumatic) 410 A 010 ..............................................................................................7
Basket Filter 410 A 015 ...............................................................................................................7
Positive Displacement Pump 410 A 055 .....................................................................................7
Three Way Plug Valve (manual) 410 A 060 ................................................................................7
Pitch Storage Tank 410 A 200 ....................................................................................................7
6.1
Process
6.1.1
Process Flow Sheets (Work Copy)
Outokumpu Technology GmbH

file: 138-02-043_06_0.doc, Codeword: Vedanta
Revision: 0
Date: 29.09.2006
Page 1 of 7

6.1.2
138-02-043
Group 410 A
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.:
133-50-048
1 (1)
Rev. 00
Brief Process Description

of
Process Group 410 A
- Liquid Pitch Unloading & Storage Reference:
Process Flow Sheet:
132-01-073 UB
P&I Diagram:
168-01-045 UB sheet 1 & 2
Material Route Diagram:
133-50-049 UB sheet 1, 2, 3, 4, 5, 6
Process Group 431 A receives liquid pitch from tanker trucks.

The Group consist of three liquid pitch tanks and two unloading facilities with each unloading
facility having one pitch pump and one filter.
The three pitch tanks (410 A 200, 410 A 300 and 410 A 400) can be filled individually from
either unloading stations or simultaneously from both unloading stations. The operator in the
central control room (CCR) can select 6 different routes for the filling of one or two tanks.
Two trucks can be unloaded simultaneously, each one connected to a separate unloading
facility. The truck nozzle is connected to a hose by a flange connection. The truck unloading
process is manually controlled from local pushbutton stations [410 LOP-A1] and [410 LOP-A2].
The central control room operator determines which tank is to be filled from the unloading
pump (410 A 055) or (410 A 070) respectively. He selects Route 1, 2 or 3 for pump (410 A
050) and/or route 4, route 5 or route 6 for pump (410 A 070).
The local operator has to open and close the corresponding manual pitch valves as required
for the selected route. With the valves in the correct position for the selected route the local
operator receives the confirmation by a pilot light on the local panel of the corresponding
unloading pump [410 LOP-A1] and [410 LOP-A2] respectively. Prior to connecting the hose
between the truck discharge nozzle and the unloading station the tanker vents are opened,
only then can the truck discharge valve be opened and the unloading can commence. He then
has to push the "Start SLOW" pushbutton for pump (410 A 055) or pump (410 A 070)
respectively. The pneumatic valve at the suction side (410 A 010) for pump (410 A 055) or
valve (410 A 030) for pump (410 A 070) is opened and the corresponding pump starts at slow
speed. At slow speed the pump suction side is flushed and any obstruction particles are
caught in the filter. During the flushing time (2 minutes adjusted in the PLC) the local operator
has to observe the operation and watch for unusual noise or cavitation. He can then switch the
corresponding pump to high speed if the pitch temperature is high enough (> 160C) and if the
pump is operating smoothly. In case that the pitch temperature is too low or if the filter is close
to get plugged he has to leave the pump operating on slow speed.
The corresponding pump can only be started if the selected tank is not full i.e. under 95% of its
filling capacity. The actual tank level is displayed on the local control panel.

6.1.3
138-02-043
Group 410 A
DE-060300
Main Process Data & Process Highlights

The process group is designed for a maximum truck unloading rate of 30 m3 / hour
corresponding 36 tonnes / hour of liquid pitch, supposed pitch temperature is not
below 170C.
Three pitch tanks of 1000 tonnes (833m3) capacity each are installed.
The tank may receive pitch from tanker trucks until the high level in the corresponding
tank is reached. This "high" level will be adjusted during the commissioning to approx.
95%. In order to increase the effective storage capacity the high high level will be
adjusted at approx. 2% above the high level. With this adjustment one tanker truck of
20 tonnes capacity may still be safely unloaded into the corresponding tank if "high
level" is reached during the unloading procedure.
Pitch is unloaded from tanker trucks by positive displacement pumps. Two tanker
trucks can be unloaded in parallel. Irregular pump noise may be caused by cavitation.
Cavitation may be caused by plugged nozzle at the tanker truck, plugged basket filter
or because the pitch temperature in the tanker truck 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, if the
tanker truck must be unloaded because the pitch in the tanker would froze, to keep
the pump running under strict observation. If the pitch temperature in the truck is low
(< 160C) the pump should only be used at low speed, what reduces the unloading
rate to 15 m3 / hour.
The operator has to make sure that the tanker truck is in good condition and ready to
be unloaded e.g. pitch at a temperature level high enough for unloading (min.
160C) and discharge nozzle not frozen prior to connect the hose with the coupling.
The tanker truck has to have an operable air inlet (vacuum breaker).
Normally, pitch from different sources or of different qualities will not be mixed when
filling to the tanks with the unloading pumps.
In case that a basket filter is plugged indicated by alarm signal or in case that
cavitation noise indicates that the filter is close to getting plugged, the filter has to be
inspected and cleaned instantaneously in order to keep the full flexibility for unloading.
The flexible hose and the coupling have to be kept clean. Pitch spillage has to be
removed immediately in order to avoid damage to the hose and coupling due to
frozen pitch.
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.
The seal pot for the tanks has to be inspected frequently at least once per day for
correct level of seal oil. Accumulated condensate has to be drained. Missing oil has to
be refilled.
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.) spoil 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.

Revision: 0
Date: 29.09.2006
Page 3 of 7

Smoking and open fire is strictly prohibited in the pitch unloading area 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 A
DE-060300
Revision: 0
Date: 29.09.2006

6.2
Process Control
6.2.1
P&Id`s, Material Route Diagrams, Operator Screen Images
138-02-043
Group 410 A
DE-060300
(work copies)

Revision: 0
Date: 29.09.2006
Page 5 of 7

6.2.2
138-02-043
Group 410 A
DE-060300
Control Logic Description

(Work Copy)

Page 6 of 7
Revision: 0
Date: 29.09.2006
CONTROL PHILOSOPHY
05.10.2006
1 (16)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
Control Philosophy
of
Process Group 410 A
- Liquid Pitch Unloading & Storage Reference:
Process Flow Sheet:
132-01-073 UB
P&I Diagram:
168-01-045 UB sheet 1 & 2
Material Route Diagram:
133-50-049 UB sheet 1, 2, 3, 4, 5, 6
Brief Process Description............................................................................................................ 1
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.5
2.5.1
2.5.2
2.5.3
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.7
2.7.1
2.8
Control Logic Description ............................................................................................................ 2

Special Terminology for this Group............................................................................................. 2
Linked Process Groups............................................................................................................... 4
Selections ................................................................................................................................... 4
Selection of Operation Modes (SE 1).......................................................................................... 4
Selection of Material Route Unloading Pump 431 A 055 (SE 2)................................................. 5
Selection of Material Route Unloading Pump 410 A 070 (SE 3)................................................. 6
Group Start ................................................................................................................................. 8
Selections Prior to Start .............................................................................................................. 8
Start Preconditions...................................................................................................................... 8
Setpoints Prior to Group Start ..................................................................................................... 9
Group Start Sequence ................................................................................................................ 9
Normal Operation...................................................................................................................... 10
Tank High Level ........................................................................................................................ 10
Pitch Filter Low Differential Pressure........................................................................................ 10
Pitch Filter High Differential Pressure ....................................................................................... 10
Shut Down ................................................................................................................................ 10
Normal Shut Down .................................................................................................................... 10
Shut Down by other Groups...................................................................................................... 11
Fast Shut Down......................................................................................................................... 11
Trip in Case of Faults ................................................................................................................ 11
Local Operation of Special Equipment...................................................................................... 14
Pitch Sampling .......................................................................................................................... 14
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 15
BRIEF PROCESS DESCRIPTION

Process Group 431 A receives liquid pitch from tanker trucks.
The Group consist of three liquid pitch tanks and two unloading facilities with each unloading
facility having one pitch pump and one filter.
CONTROL PHILOSOPHY
05.10.2006
2 (16)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
The three pitch tanks (410 A 200, 410 A 300 and 410 A 400) can be filled individually from
either unloading stations or simultaneously from both unloading stations. The operator in the
central control room (CCR) can select 6 different routes for the filling of one or two tanks.
Two trucks can be unloaded simultaneously, each one connected to a separate unloading
facility. The truck nozzle is connected to a hose by a flange connection. The truck unloading
process is manually controlled from local pushbutton stations [410 LOP-A1] and [410 LOP-A2].
The central control room operator determines which tank is to be filled from the unloading
pump (410 A 055) or (410 A 070) respectively. He selects Route 1, 2 or 3 for pump (410 A
050) and/or route 4, route 5 or route 6 for pump (410 A 070).
The local operator has to open and close the corresponding manual pitch valves as required
for the selected route. With the valves in the correct position for the selected route the local
operator receives the confirmation by a pilot light on the local panel of the corresponding
unloading pump [410 LOP-A1] and [410 LOP-A2] respectively. Prior to connecting the hose
between the truck discharge nozzle and the unloading station the tanker vents are opened,
only then can the truck discharge valve be opened and the unloading can commence. He then
has to push the "Start SLOW" pushbutton for pump (410 A 055) or pump (410 A 070)
respectively. The pneumatic valve at the suction side (410 A 010) for pump (410 A 055) or
valve (410 A 030) for pump (410 A 070) is opened and the corresponding pump starts at slow
speed. At slow speed the pump suction side is flushed and any obstruction particles are
caught in the filter. During the flushing time (2 minutes adjusted in the PLC) the local operator
has to observe the operation and watch for unusual noise or cavitation. He can then switch the
corresponding pump to high speed if the pitch temperature is high enough (> 160C) and if the
pump is operating smoothly. In case that the pitch temperature is too low or if the filter is close
to get plugged he has to leave the pump operating on slow speed.
The corresponding pump can only be started if the selected tank is not full i.e. under 95% of its
filling capacity. The actual tank level is displayed on the local control panel.
2
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 Group is started and stopped locally only.
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 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.
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
MAINTENANCE
3 (16)
For this process groups, 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 Panels

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
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
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
2.2
4 (16)
Rev. 00
Linked Process Groups

The following Process Groups are linked with this Group 410 A:
Liquid Pitch Transfer 410 B

Liquid Pitch Transfer 410 C
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 selector switch at the local control panel [410 LOP-A1 ]
to run the unloading pump (410 A 055) or by selector switch at the local control panel [410
LOP-A2 ] to run the unloading pump (410 A 070) in Automatic or Maintenance mode. The
central control room operator has to confirm the selection on the Operator Station in the CCR.
If the selector switch at [410 LOP-A1] is moved during automatic operation, the drive of pump
(410 A 055) is stopped immediately. If the selector switch at [410 LOP-A2] is moved during
automatic operation, the drive of pump (410 A 070) is stopped immediately.
AUTOMATIC operation mode After this selection the pump could start if all start
preconditions are met.
MANTENANCE operation mode
(details please see under 2.6 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)
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
2.3.2
5 (16)
Selection of Material Route Unloading Pump 431 A 055 (SE 2)

The operator has three options:
The selection is made on the Operator Station located in the Central Control Room (CCR).
The state of selection is on the Operation Station (OS) indicated. A Route o.k. light on the
local operator panel [410 LOP-A1] 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 1: Unloading Pump 410 A 055 to pitch storage tank 410 A 200
This material route can be selected simultaneous with following Routes:
Route 4 (Selection SE 3-1) or Route 5 (Selection SE 3-2) or Route 6 (Selection SE 3-3).
The local operator has to verify this Route Selection by manual control of the following valve
positions:
OPEN:
(410 A 050)
CLOSE:
(410 A 230)
(410 A 025)
THREE WAY VALVE:
(410 A 060) open in direction to tank 1 (410 A 200)

indicated by limit switch [410 A 060-ZH].
The pitch sample valve (410 A 080) has to be closed during the start of pitch pump (410 A
055) but may be opened after the start for minimum periods for sampling (time adjusted in
PLC: 60 seconds).
This Route Selection cannot be made if:
pump (410 A 055) is in operation with a different route (Route 2 Selection SE 2-2 or Route
3 Selection SE 2-3).
With the verification of the above valve positions this route is set in the PLC.
SE 2-2:
positions:
OPEN:
(410 A 050)
CLOSE:
(410 A 330)
(410 A 025)
THREE WAY VALVE:
(410 A 060) open in direction to tanks (431 A 300 and 410 A

400) indicated by limit switch [410 A 060-ZL]
CONTROL PHILOSOPHY
05.10.2006
6 (16)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
(410 A 062) open in direction to tank (431 A 300) indicated by

limit switch [410 A 062-ZL].
PLC: 60 seconds).
SE 2-3:
positions:
OPEN:
(410 A 050)
CLOSE:
(410 A 430)
(410 A 025)
THREE WAY VALVE:

400) indicated by limit switch [410 A 060-ZL]
limit switch [410 A 062-ZH].
PLC: 60 seconds).
2.3.3
Selection of Material Route Unloading Pump 410 A 070 (SE 3)

The operator has three options:
The selection is made on the Operator Station located in the Central Control Room (CCR).
The state of selection is on the Operation Station (OS) indicated. A Route o.k. light on the
local operator panel [410 LOP-A2] 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 3-1:
CONTROL PHILOSOPHY
05.10.2006
7 (16)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
positions:
OPEN:
(410 A 065)
CLOSE:
(410 A 230)
(410 A 045)
THREE WAY VALVE:

300) indicated by limit switch [410 A 075-ZH]
limit switch [410 A 077-ZL]
PLC: 60 seconds).
6 Selection SE 3-3 ).
SE 3-2:
positions:
OPEN:
(410 A 065)
CLOSE:
(410 A 330)
(410 A 045)
THREE WAY VALVE:
(410 A 075) open in direction to tank (410 A 200 and 410 A

300) indicated by limit switch [410 A 075-ZH]
limit switch [410 A 077-ZH]
PLC: 60 seconds).
6 Selection SE 3-3 ).
CONTROL PHILOSOPHY
05.10.2006
8 (16)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
SE 3-3:
positions:
OPEN:
(410 A 065)
CLOSE:
(410 A 430)
(410 A 045)
THREE WAY VALVE:

limit switch [410 A 075-ZL].
PLC: 60 seconds).
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 1 and 4 directed to this storage tank cannot be selected.
Storage Tank 2 [431 A 300-LSHH] indicates
Storage Tank 3 [431 A 400-LSHH] indicates high-high level
2.4.2.3 Seal pot
Seal pot of tank 1 [410 A 210-LSHH] indicates high-high level
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
9 (16)
Rev. 00

-
2.4.2.4 Route Settings

Start pitch pump (431 A 055): Route 1, Route 2 or Route 3 has to be set.
Start pitch pump (431 A 070): Route 4, Route 5 or Route 6 has to be set.
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.
2.4.2.7 Compressed Air Pressure 410 A 009
Compressed air pressure in Group 410 A [410 A 009-PAL] shall be higher than 6 bar (P>6
bar).
2.4.3
Setpoints Prior to Group Start

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

In case that a tanker truck has to be unloaded the operator has to connect the hose with the
truck nozzle and open the truck discharge valve.
The operator starts both pitch pumps (410 A 055) and (410 A 070) individually from the
corresponding local control panel [410 LOP-A1] and [410 LOP-A2]. A start is only initiated if
the operator pushes the "SLOW" Start pushbutton of the corresponding pump.
2.4.4.1 Start Unloading Pump (431 A 055)

The Operator actuates "SLOW" start pushbutton for pitch pump (410 A 055). Flashing light
indicates that start up sequence is initiated.
Pneumatic pitch valve (410 A 010) is opened. If the valve does not reach open position
after opening is initiated for 10 seconds, limit switch [410 A 010-ZSH] is not actuated, an
excess runtime alarm is initiated and the corresponding pitch pump is not started.
Pitch pump (410 A 055) is started at slow speed.
Condition:
- pitch valve (410 A 010) open indicated by limit switch [410 A 010-ZSH]
After 2 minutes observation during operation at slow speed the local operator can switch
the pump to high speed by actuating "FAST" pushbutton for pitch pump (410 A 055).
Condition:
- pitch temperature at pump above low level (160C) [410 A 050-TL]
- differential pressure at pitch filter between low level 0,5 mbar [410 A 015-PDSL] and high
level 10 mbar [410 A 015-PDSH]
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
10 (16)
Rev. 00
2.4.4.2 Start Unloading Pump (431 A 070)

The Operator actuates "SLOW" start pushbutton for pitch pump (410 A 070). Flashing light
indicates that start up sequence is initiated.
Pneumatic pitch valve (410 A 030) is opened. If the valve does not reach open position
after opening is initiated for 10 seconds, limit switch [410 A 030-ZSH] is not actuated, an
excess runtime alarm is initiated and the corresponding pitch pump is not started.
Pitch pump (410 A 070) is started at slow speed.
Condition:
- pitch valve (410 A 030) open indicated by limit switch [410 A 030-ZSH]
After 2 minutes observation during operation at slow speed the local operator can switch
the pump to high speed by actuating "FAST" pushbutton for pitch pump (410 A 070).
Condition:
- pitch temperature at pump above low level (160C) [410 A 065-TL]
- differential pressure at pitch filter between low level 0,5 mbar [410 A 035-PDSL] and high
level 10 mbar [410 A 035-PDSH]
2.5
Normal Operation
2.5.1
Tank High Level

The operator is warned by an acoustic signal and a pilot light in the local panel when the high
level in storage tank 1 [410 A 200-LAH], in storage tank 2 [410 A 300-LAH] or in storage tank 3
[410 A 400-LAH] is reached. He has then 30 minutes left if the pump is operating at fast speed
or 60 minutes left if the pump is operating at slow speed to empty the connected tanker truck.
2.5.2
Pitch Filter Low Differential Pressure

The operator is warned by an acoustic signal and a pilot light in the local panel when the
differential pressure at the filter is too low <0,5 mbar " LOW PITCH FLOW" [410 A 015-PDSL]
for pump (410 A 055) or [410 A 035-PDSL] for pump (410 A 070). He has then 3 minutes time
to find the reason for that alarm (e.g. tanker truck empty or truck nozzle plugged, manual
butterfly valve at hose end not open). In case that the operator cannot eliminate the reason for
the alarm he has to stop the corresponding pump. If operating at fast speed the corresponding
pump is automatically stopped after 3 minutes delay time.
2.5.3
Pitch Filter High Differential Pressure

The operator is warned by an acoustic signal and a pilot light in the local panel when the
differential pressure at the filter is too high >10 mbar "FILTER PLUGGED" [410 A 015-PDSH]
for pump (410 A 055) or [410 A 035-PDSH] for pump (410 A 070). The reason for this alarm
may be too high pitch viscosity normally together with too low pitch temperature or a dirty filter.
In case that the reason for the alarm is prevailing for 3 minutes the corresponding pump is
automatically stopped if operating at fast speed.
2.6
Shut Down
2.6.1
Normal Shut Down

The equipment of this Group is only started and stopped from the local operating panels [410
LOP-A1] or [410 LOP-A2] respectively.
There is no Normal Shut Down (Run Empty) from the SCADA in the Central Control Room
(CCR).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
2.6.2
11 (16)
Rev. 00
Shut Down by other Groups

This Group is not shut down by other Groups.
2.6.3
Fast Shut Down

The equipment of this Group is stopped from the local operating panels [410 LOP-A1] and
[410 LOP-A2].
2.6.3.1 Fast Shut Down by the Operator from local operating panel [410 LOP-A1]
The operator initiates the STOP pushbutton for unloading pump (410 A 055).
Pump (410 A 055) is stopped immediately.
Pneumatic Pitch Valve (410 A 010) is closed
The operator closes the truck valve and disconnects the hose from the tanker truck nozzle.
In case that no additional truck has to be unloaded within the next hour the pitch in the
hose has to be drained in order to avoid freezing of pitch in the hose.
2.6.3.2 Fast Shut Down by the Operator from local operating panel [410 LOP-A2]
The operator initiates the STOP pushbutton for unloading pump (410 A 070).
Pump (410 A 070) is stopped immediately.
Pneumatic Pitch Valve (410 A 030) is closed
The operator closes the truck valve and disconnects the hose from the tanker truck
nozzle.
In case that no additional truck has to be unloaded within the next hour the pitch in the
hose has to be drained in order to avoid freezing of pitch in the hose.
2.6.4
Trip in Case of Faults

If this Group 410 A 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 Unloading Pump (410 A 055)

MCC: [410 A 055] 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.
2.6.4.2 Pitch Unloading Pump (410 A 070)
MCC: [410 A 070] fault
alarm is initiated
drive is stopped
Fast Shut Down of this part of the group (see 2.6.3.2 above) will be initiated.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
12 (16)
Rev. 00
2.6.4.3 Pitch Valve (410 A 010)

limit switch [410 A 010-ZSL] actuated
alarm is initiated
pitch pump (410 A 055) stops
limit switch [410 A 010-ZSL] and [410 A 010-ZSH] actuated simultaneously
alarm is initiated
limit switch [410 A 010-ZSH] lost
alarm is initiated
2.6.4.4 Pitch Valve (431 A 030)
limit switch [410 A 030-ZSL] actuated
alarm is initiated
limit switch [410 A 030-ZSL] and [410 A 030-ZSH] actuated
alarm is initiated
limit switch [410 A 030 ZSH] lost
alarm is initiated
2.6.4.5 Route Selection SE2
In case that a valve is moved during operation and the valve position required for the
selected route is lost
alarm is initiated
pitch valve (410 A 010) is closed
2.6.4.6 Route Selection SE3
In case that a valve is moved during operation and the valve position required for the
selected route is lost
alarm is initiated
2.6.4.7 Pitch Valve (410 A 080)
sampling valve is kept open for more than 60 seconds
alarm is initiated
"Route selection o.k." symbol starts flashing
pump (410 A 055) stops
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
Rev. 00
2.6.4.8 Pitch Valve (410 A 085)

sampling valve is kept open for more than 60 seconds
alarm is initiated
"Route selection o.k." symbol starts flashing
2.6.4.9 Tank 1 High-High Level
[410 A 200-LSHH] indicates High-high level
operating with Route 1

alarm is initiated
alarm is initiated


alarm is initiated
alarm is initiated


alarm is initiated
alarm is initiated
13 (16)
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
14 (16)
Rev. 00
2.6.4.12 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
2.7
Local Operation of Special Equipment
2.7.1
Pitch Sampling
The operator may take samples from the incoming pitch by opening the corresponding
sample valve (410 A 080) or (410 A 085) for maximum periods of 60 seconds, see also
(2.6.4.7 and 2.6.4.8).
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-048
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 A
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
Compressed air pressure above 6
bar (no low-pressure indicated by
410 A 009-PE1)
Pitch Valve 410 A 230 closed
DRAIN TANK 1 CLOSED
DRAIN TANK 2 CLOSED
DRAIN TANK 3 CLOSED
Actual level [410 A 200-LI] in tank 1
LEVEL TANK 1
LEVEL TANK 2
LEVEL TANK 3
DRAIN TANK 1 CLOSED
DRAIN TANK 2 CLOSED
DRAIN TANK 3 CLOSED
LEVEL TANK 1
LEVEL TANK 2
LEVEL TANK 3
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 A
from Group 410 A to Group 410 B

from Group 410 A to Group 410 C
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
15 (16)
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-048
Rev. 00
High-high level [410 A 200-LSHH] in

tank 1 HIGH-HIGH LEVEL TANK 1
seal pot tank 1 OVERFLOW TANK
1
2
3
High level [410 A 200-LSH] in tank 1
HIGH LEVEL TANK 1
HIGH LEVEL TANK 2
HIGH LEVEL TANK 3

16 (16)

6.3
Main Equipment
6.3.1
Plug Valve (pneumatic) 410 A 010
6.3.2
Basket Filter 410 A 015
6.3.3
Positive Displacement Pump 410 A 055
6.3.4
Three Way Plug Valve (manual) 410 A 060
6.3.5
Pitch Storage Tank 410 A 200

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

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138-02-043

Training Manual Green Anode Plant

PROCESS GROUP 410 A - LIQUID PITCH UNLOADING & STORAGE -

Process Group 410 A - Liquid Pitch Unloading & Storage - ........................................................1

Process Flow Sheets (Work Copy)

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Brief Process Description (Work Copy)

Outokumpu Technology GmbH

Brief Process Description

168-01-045 UB sheet 1 & 2

Material Route Diagram:

Process Group 431 A receives liquid pitch from tanker trucks.

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Main Process Data & Process Highlights

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Outokumpu Technology GmbH

Training Manual Green Anode Plant

P&Id`s, Material Route Diagrams, Operator Screen Images

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Control Logic Description

Outokumpu Technology GmbH

Vedanta Alumina Ltd.

168-01-045 UB sheet 1 & 2

Material Route Diagram:

Brief Process Description............................................................................................................ 1

Control Logic Description ............................................................................................................ 2

BRIEF PROCESS DESCRIPTION

Outokumpu Technology GmbH

Vedanta Alumina Ltd.

CONTROL LOGIC DESCRIPTION

Special Terminology for this Group

There is no CENTRAL mode foreseen for this Process Group.

For this process group, AUTOMATIC mode is available from

Outokumpu Technology GmbH

Vedanta Alumina Ltd.

For this process groups, MAINTENANCE mode is available

Operation Modes to be selected on Local Operator Panels (LOP)

For this process group, AUTOMATIC mode is available from

For this process group, MAINTENANCE mode is available

Pushbuttons and lights on Local Operator Panels

Mushroom PB stops equipment instantly

PB resets horn sounding

PB powers all lights in LOP

Selector switch for operation mode

PUMP START SLOW

PB initiates start sequence of this pump

PUMP START FAST

PB allows fast start sequence of this pump

PB initiates stop sequence of this pump

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