410B

Training Manual Green Anode Plant
Vedanta - Jharsuguda
138-02-043
Group 410 B
DE-060300
PROCESS GROUP 410 B - LIQUID PITCH TRANSFER -
7
7.1
7.1.1
7.1.2
7.1.3
7.2
7.2.1
7.2.2
7.3
7.3.1
7.3.2
7.3.3
7.3.4
Process Group 410 B - Liquid Pitch Transfer -............................................................................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 B 050 ...............................................................................................................7
Positive Displacement Pump 410 B 065 .....................................................................................7
Liquid pitch Heat Exchanger 410 B 215 ......................................................................................7
Pressure Holding Valve 410 B 235 .............................................................................................7
7.1
Process
7.1.1
Process Flow Sheets

(Work Copy)
Outokumpu Technology GmbH

file: 138-02-043_07_0.doc, Codeword: Vedanta
Revision: 0
Date: 29.09.2006
Page 1 of 7

7.1.2
138-02-043
Group 410 B
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.:
133-50-050
1 (3)
Rev. 00
Brief Process Description

of
Process Group 410 B
- Liquid Pitch Transfer Reference:
Process Flow Sheet:
132-01-074 UB
P&I Diagram:
168-01-046 UB sheet 1, 2, 3, 4
Material Route Diagram:
133-50-051 UB sheet 1 & 2 / 133-50-052 UB sheet 1 & 2 /

133-50-053 UB sheet 1 & 2 / 133-50-054 UB sheet 1 & 2 /
133-50-055 UB sheet 1 & 2 / 133 50-056 UB sheet 1 & 2 /
133-50-057 UB sheet 1 & 2 / 133-50-058 UB sheet 1 & 2 /
133-50-059 UB sheet 1 & 2 / 133-50-060 UB sheet 1 & 2 /
133-50-061 UB sheet 1 & 2 / 133-50-062 UB sheet 1 & 2
The Liquid Pitch Transfer Process Group 410 B reclaims liquid pitch from tank 1, tank 2 or
tank 3 to Process Group 431 H Proportioning via Pitch/HTM heat exchanger (410 B 215) and
/or to Process Group 432 H Proportioning via Pitch/HTM heat exchanger (410 B 315) and
back to tank 1, tank 2 or tank 3.
Group 410 B consists of a set of three pitch pumps and three basket filters connected to the
suction nozzles of all three tanks and to the feed and return line to the Green Anode Plant Line
1 (431) and /or to the Green Anode Plant Line 2 (432). This operation is only possible if the
basket filters are available and are not plugged. For this reason the differential pressure
across the basket filters has to be observed regularly.
Pitch pump (410 B 065) is foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the
Proportioning Group 431 H in the Green Anode Plant Line 1. Pitch pump (410 B 125) is
foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the Proportioning Group 432 H in
the Green Anode Plant Line 2. Pitch pump (410 B 165) can be used as stand-by to pump (410
B 065) or to pump (410 B 125). The arrangement of the pitch piping system allows for
numerous combinations of tank suction nozzles and pitch pumps. 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.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
2 (3)
Rev. 00
Pitch pumps (410 B 065) and pitch pump (410 B 125) can be connected to the bottom suction
nozzle of tank 1, tank 2 or tank 3. Pitch Pump (410 B 065) is operated in line with basket filter
(410 B 050) and pitch pump (410 B 125) with basket filter (410 B 110). In case that these
filters are plugged, an emergency transfer operation with stand-by pitch pump (410 B 165) via
basket filter (410 B 150) to Line 1(431) or to Line 2 (432) is possible. Pitch pump (410 B 065)
transfers pitch to Line 1 (431) via the liquid pitch heat exchanger (410 B 215) to the pressure
holding valve (410 B 235), where the amount of pitch required for anode production is
withdrawn by the pitch proportioning pump of Process Group 432 H. Pitch pump (410 B 125)
withdrawn by the pitch proportioning pump of Process Group 432 H. The operator has three
route selections for each transfer Pump, Route 11, 12, 13 for transfer pump (410 B 065) and
Route 31, 32, 33 for transfer pump (410 B 125). For stand-by pump (410 B 165) exists six
route selections, Route 21 26. The Route selections are described in detail under chapter
2.3.2 2.3.4 The pneumatic pitch valve (410 B 080) for Line 1 (431) and the pneumatic pitch
valve (410 B 140) for Line 2 (432) are always closed when the transfer pumps are not in
operation in order to shut off the long transfer line to the Green Anode Plant 1 and 2 keeping
the line full of pitch. In this way, air or vapour, which may affect the correct operation of the
Coriolis flow meters in Process Group 431 H and 432 H cannot enter the ring line. After longterm interruptions of the transfer operation, the transfer lines have to be vented by the manual
vent valves (410 B 230) for Line 1 (431) and (410 B 330) for Line 2 (432).
The liquid pitch heat exchangers are used to adjust the pitch temperature by heating prior to
transfer to the Proportioning Groups 431 H, 432 H.
The setpoint of the liquid pitch temperature after the heat exchangers (410 B 215) and (410 B
315) can be adjusted by the operator or the standard setpoint can be activated which is set to
180C. The setpoint of the liquid pitch temperature controller is transferred to the HTM
systems of Line 1 (431) and Line 2 (432) where it is connected in cascade to the
corresponding enabled HTM temperature controller to regulate the temperature in HTM
secondary circuit 3 of Line 1 (431) and the temperature in HTM secondary circuit 3 of Line 2
(432).
The selections of simultaneous routes are described under chapter 2.2.
The local operator has to open and close the corresponding pitch valves 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-B1]. 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. 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. 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) for Routes 11/12/13
or Routes 21/22/23/24/25/26 or Routes 31/32/33 if the pitch temperature in the tank where the
pumps sucking from has a level above 160C.
Transfer to the Green Anode Plant with routes 11/12/13 21/22/23/24/25/26 31/32/33 is
possible with slow speed and fast speed of the pump (410 B 065), pump (410 B 125) and/or
pump (410 B 165).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
3 (3)
Rev. 00
Should the pitch temperature drop below 160C during transfer with routes 11/12/13, routes
21/22/23/24/25/26 and routes 31/32/33 the pump speed is changed back to slow speed.

7.1.3
138-02-043
Group 410 B
DE-060300
Main Process Data & Process Highlights

The process group is used to supply liquid pitch to Group 431/432 H (Proportioning)
- Pitch supply rate is 5m3/hour (6 t/hour) pump runs at slow speed
- Pitch supply rate is 10 m3 / hour (12 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.
Pump 410 B 065 is foreseen for transfer liquid pitch to Group 431 H (Proportioning).
Pump 410 B 125 is foreseen for transfer liquid pitch to Group 432 H (Proportioning).
Pump 410 B 165 can be used as stand-by pump to pump (410 B 065) or to pump
(410 B 165).
From one tank only pitch can be taken at a time. Pitch reclaimed should be pumped
into the same tank
Pitch reclaimed can be heated up through a heat exchanger 410 B 215/315. The
heating capacity is 125 kW, what is sufficient to heat up a flow of 10 m3/hour by 20C.
It is most important that the pitch temperature is constant when metered to the mixer
of Group 431/432 H. It shall not vary more than +/-1C.
Pitch is reclaimed from 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 5m3/hour (6 t/hour). At high speed the capacity is 10m3/hour (12 t/hour).
Irregular pump noise may be caused by cavitation. Cavitation may occur 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 while one of
the tanks is 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 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 heat exchanger (410 B 215/315) can be bypassed for cleaning or other
maintenance purposes. The bypass route is via open pitch valve (410 B 225/325).

Revision: 0
Date: 29.09.2006
Page 3 of 7

138-02-043
Group 410 B
DE-060300
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 transfer allow the
manipulation of manual valves, normally during interruptions in production.
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
reclaiming. In order to do so, the proportioning and mixing group 431/432 J has to be
run empty (e.g. by a quick stop) and this Group 410 B has to be stopped. The route
with the stand-by basket filter and pump has then to be selected and this Group can
be started again. The anode production with Group 431/432 J can be resumed a few
minutes after restart of this Group.
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
Revision: 0
Date: 29.09.2006

7.2
Process Control
7.2.1
P&Id`s, Material Route Diagrams, Operator Screen Images
138-02-043
Group 410 B
DE-060300
(work copies)

Revision: 0
Date: 29.09.2006
Page 5 of 7

7.2.2
138-02-043
Group 410 B
DE-060300
Control Logic Description

(Work Copy)

Page 6 of 7
Revision: 0
Date: 29.09.2006
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
1 (31)
Rev. 00
Control Philosophy
of
Process Group 410 B
- Liquid Pitch Transfer Reference:
Process Flow Sheet:
132-01-074 UB
P&I Diagram:
168-01-046 UB sheet 1, 2, 3, 4
Material Route Diagram:
133-50-051 UB sheet 1 & 2 / 133-50-052 UB sheet 1 & 2 /

133-50-053 UB sheet 1 & 2 / 133-50-054 UB sheet 1 & 2 /
133-50-055 UB sheet 1 & 2 / 133 50-056 UB sheet 1 & 2 /
133-50-057 UB sheet 1 & 2 / 133-50-058 UB sheet 1 & 2 /
133-50-059 UB sheet 1 & 2 / 133-50-060 UB sheet 1 & 2 /
133-50-061 UB sheet 1 & 2 / 133-50-062 UB sheet 1 & 2
Brief Process Description............................................................................................................ 2
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
2.5.3
2.5.4
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 Transfer Pump 410 B 065 (SE 2).................................................... 5
Selection of Material Route Stand-By Pump 410 B 165 (SE 3) .................................................. 9
Selection of Material Route Transfer Pump 410 B 125 (SE 4).................................................. 17
Group Start ............................................................................................................................... 20
Selections Prior to Start ............................................................................................................ 20
Start Preconditions.................................................................................................................... 20
Setpoints Prior to Group Start ................................................................................................... 20
Group Start Sequence .............................................................................................................. 22
Normal Operation...................................................................................................................... 23
Pitch Temperature Storage Tank .............................................................................................. 23
Pitch Temperature Liquid Pitch Heat Exchanger (410 B 215) (410 B 315)............................... 23
Vent valve (410 B 230).............................................................................................................. 24
Vent valve (410 B 330).............................................................................................................. 24
Shut Down ................................................................................................................................ 24
Normal Shut Down .................................................................................................................... 24
Shut Down by other Groups...................................................................................................... 24
Fast Shut Down......................................................................................................................... 24
Trip in Case of Faults ................................................................................................................ 25
Local Operation of Special Equipment...................................................................................... 30
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 31
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
2 (31)
Rev. 00
BRIEF PROCESS DESCRIPTION

The Liquid Pitch Transfer Process Group 410 B reclaims liquid pitch from tank 1, tank 2 or
tank 3 to Process Group 431 H Proportioning via Pitch/HTM heat exchanger (410 B 215) and
/or to Process Group 432 H Proportioning via Pitch/HTM heat exchanger (410 B 315) and
back to tank 1, tank 2 or tank 3.
Group 410 B consists of a set of three pitch pumps and three basket filters connected to the
suction nozzles of all three tanks and to the feed and return line to the Green Anode Plant Line
1 (431) and /or to the Green Anode Plant Line 2 (432). This operation is only possible if the
basket filters are available and are not plugged. For this reason the differential pressure
across the basket filters has to be observed regularly.
Pitch pump (410 B 065) is foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the
Proportioning Group 431 H in the Green Anode Plant Line 1. Pitch pump (410 B 125) is
foreseen for transfer of pitch from tank 1, tank 2 or tank 3 to the Proportioning Group 432 H in
the Green Anode Plant Line 2. Pitch pump (410 B 165) can be used as stand-by to pump (410
B 065) or to pump (410 B 125). The arrangement of the pitch piping system allows for
numerous combinations of tank suction nozzles and pitch pumps. 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 pumps (410 B 065) and pitch pump (410 B 125) can be connected to the bottom suction
nozzle of tank 1, tank 2 or tank 3. Pitch Pump (410 B 065) is operated in line with basket filter
(410 B 050) and pitch pump (410 B 125) with basket filter (410 B 110). In case that these
filters are plugged, an emergency transfer operation with stand-by pitch pump (410 B 165) via
basket filter (410 B 150) to Line 1(431) or to Line 2 (432) is possible. Pitch pump (410 B 065)
withdrawn by the pitch proportioning pump of Process Group 432 H. Pitch pump (410 B 125)
withdrawn by the pitch proportioning pump of Process Group 432 H. The operator has three
route selections for each transfer Pump, Route 11, 12, 13 for transfer pump (410 B 065) and
Route 31, 32, 33 for transfer pump (410 B 125). For stand-by pump (410 B 165) exists six
route selections, Route 21 26. The Route selections are described in detail under chapter
2.3.2 2.3.4 The pneumatic pitch valve (410 B 080) for Line 1 (431) and the pneumatic pitch
valve (410 B 140) for Line 2 (432) are always closed when the transfer pumps are not in
operation in order to shut off the long transfer line to the Green Anode Plant 1 and 2 keeping
the line full of pitch. In this way, air or vapour, which may affect the correct operation of the
Coriolis flow meters in Process Group 431 H and 432 H cannot enter the ring line. After longterm interruptions of the transfer operation, the transfer lines have to be vented by the manual
vent valves (410 B 230) for Line 1 (431) and (410 B 330) for Line 2 (432).
The liquid pitch heat exchangers are used to adjust the pitch temperature by heating prior to
transfer to the Proportioning Groups 431 H, 432 H.
CONTROL PHILOSOPHY
05.10.2006
3 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
The setpoint of the liquid pitch temperature after the heat exchangers (410 B 215) and (410 B
315) can be adjusted by the operator or the standard setpoint can be activated which is set to
180C. The setpoint of the liquid pitch temperature controller is transferred to the HTM
systems of Line 1 (431) and Line 2 (432) where it is connected in cascade to the
corresponding enabled HTM temperature controller to regulate the temperature in HTM
secondary circuit 3 of Line 1 (431) and the temperature in HTM secondary circuit 3 of Line 2
(432).
The selections of simultaneous routes are described under chapter 2.2.
The local operator has to open and close the corresponding pitch valves 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-B1]. 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. 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. 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) for Routes 11/12/13
or Routes 21/22/23/24/25/26 or Routes 31/32/33 if the pitch temperature in the tank where the
pumps sucking from has a level above 160C.
Transfer to the Green Anode Plant with routes 11/12/13 21/22/23/24/25/26 31/32/33 is
possible with slow speed and fast speed of the pump (410 B 065), pump (410 B 125) and/or
pump (410 B 165).
Should the pitch temperature drop below 160C during transfer with routes 11/12/13, routes
21/22/23/24/25/26 and routes 31/32/33 the pump speed is changed back to slow speed.
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 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 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.:
133-50-050
MAINTENANCE
4 (31)
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
*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
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
2.2
5 (31)
Rev. 00
Linked Process Groups

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

Liquid Pitch Stirring 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 individual selector switch for each pump at the local
control panel [410 LOP-B1] to run the transfer pumps 410 B 065 and/or 410 B 125 and/or 410
B 165 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-B1] 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 Transfer Pump 410 B 065 (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-B1] 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 11: Transfer Pump 410 B 065 from tank 410 A 200 to tank 410 A 200
This material route can be selected simultaneous with following Routes:
Route 31 (SE 4-1) or Route 24 (SE 3-4)
CONTROL PHILOSOPHY
05.10.2006
6 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
The local operator has to verify this Route Selection by manual control of the following valve
positions:
OPEN:
(410 B 010)
(410 B 017)
(410 B 040)
(410 B 045)
(410 B 060)
(410 B 070)
(410 B 100)
(410 B 210)
(410 B 220)
(410 B 240)
(410 B 250)
CLOSE:
(410 A 230)
(410 B 005)
(410 B 015)
(410 B 025)
(410 B 027)
(410 B 037)
(410 B 055)
(410 B 075)
(410 B 105) if Route 31 is not selected
(410 B 205)
(410 B 225)
(410 B 305)
(410 B 340) if Route 31 or Route 24 is not selected
(410 C 010)
THREE WAY VALVE:
(410 B 255) has to be open in direction from tank 2 to tank 3

(closed position) indicated by limit switch [410B255-ZX].
The pitch vent valve (410 B 230) has to be closed during the start of pitch pump (410 B 065)
but may be opened after the start for minimum periods for venting (time adjusted in PLC: 40
seconds).
This Route Selection cannot be made if:
pump (410 B 065) is in operation with a different route (Route 12/13, SE 2-2/2-3)
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
7 (31)
Rev. 00
pump (410 C 030) is in operation with route 51, 52, 53, 54 (SE 2-1/2-2/2-3/2-4)
With the verification of the above valve positions and the presence of signal Group 431 S in
Operation this route is set in the PLC.
SE 2-2:
positions:
OPEN:
(410 B 020)
(410 B 027)
(410 B 040)
(410 B 045)
(410 B 060)
(410 B 070)
(410 B 100)
(410 B 210)
(410 B 220)
(410 B 240)
CLOSE:
(410 A 330)
(410 B 005)
(410 B 015)
(410 B 017)
(410 B 025)
(410 B 037)
(410 B 055)
(410 B 075)
(410 B 205)
(410 B 225)
(410 B 250)
(410 B 305)
CONTROL PHILOSOPHY
05.10.2006
8 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
(410 C 110)
THREE WAY VALVE:

indicated by limit switch [410B255-ZL].
seconds).
pump (410 B 065) is in operation with a different route (Route 11/13 SE 2-1/2-3)
SE 2-3
positions:
OPEN:
(410 B 030)
(410 B 037)
(410 B 040)
(410 B 045)
(410 B 060)
(410 B 070)
(410 B 100)
(410 B 210)
(410 B 220)
(410 B 240)
CLOSE:
(410 A 430)
(410 B 005)
(410 B 015)
(410 B 017)
(410 B 025)
(410 B 027)
(410 B 055)
(410 B 075)
CONTROL PHILOSOPHY
05.10.2006
9 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050

(410 B 205)
(410 B 225)
(410 B 250)
(410 B 305)
(410 C 210)
THREE WAY VALVE:

indicated by limit switch [410B255-ZH].
seconds).
2.3.3
Selection of Material Route Stand-By Pump 410 B 165 (SE 3)

The operator has six options:
The state of selection is on the Operation Station (OS) indicated. A Route o.k. light on the
position.
SE 3-1
Route 21: Stand-By Pump 410 B 165 from tank 410 A 200 via Line 1 (431) to tank 410 A
200
Route 31 (SE 4-1)
positions:
OPEN:
(410 B 010)
(410 B 017)
(410 B 075)
(410 B 100)
(410 B 145)
(410 B 160)
CONTROL PHILOSOPHY
05.10.2006
10 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
(410 B 170)
(410 B 210)
(410 B 220)
(410 B 240)
(410 B 250)
CLOSE:
(410 A 230)
(410 B 027)
(410 B 037)
(410 B 040)
(410 B 070)
(410 B 135)
(410 B 155)
(410 B 205)
(410 B 225)
(410 B 305)
(410 C 010)
THREE WAY VALVE:

seconds).
pump (410 B 165) is in operation with a different route (Route 22/23/24/25/26 SE 3-2/33/3-4/3-5/3-6)
SE 3-2
300
Route 32 (SE 4-2)
positions:
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
OPEN:
11 (31)
(410 B 020)
(410 B 027)
(410 B 075)
(410 B 100)
(410 B 145)
(410 B 160)
(410 B 170)
(410 B 210)
(410 B 220)
(410 B 240)
CLOSE:
(410 A 330)
(410 B 017)
(410 B 037)
(410 B 040)
(410 B 070)
(410 B 135)
(410 B 155)
(410 B 205)
(410 B 225)
(410 B 250)
(410 B 305)
(410 B 340) if Route 32 is not selected)
(410 C 110)
THREE WAY VALVE:

seconds).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
12 (31)
Rev. 00
SE 3-3
400
Route 33 (SE 4-3)
positions:
OPEN:
(410 B 030)
(410 B 037)
(410 B 075)
(410 B 100)
(410 B 145)
(410 B 160)
(410 B 170)
(410 B 210)
(410 B 220)
(410 B 240)
CLOSE:
(410 A 430)
(410 B 017)
(410 B 027)
(410 B 040)
(410 B 070)
(410 B 135)
(410 B 155)
(410 B 205)
(410 B 225)
(410 B 250)
(410 B 305)
(410 B 340) if Route 33 is not selected)
(410 C 210)
THREE WAY VALVE:

CONTROL PHILOSOPHY
05.10.2006
13 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
seconds).
pump (410 C 230) is in operation with route 71/72/73/74 (SE 4-1/4-2/4-3/4-4)
SE 3-4
200
Route 11 (SE 2-1)
positions:
OPEN:
(410 B 010)
(410 B 017)
(410 B 100)
(410 B 135)
(410 B 145)
(410 B 160)
(410 B 170)
(410 B 250)
(410 B 310)
(410 B 320)
(410 B 340)
CLOSE:
(410 A 230)
(410 B 027)
(410 B 037)
(410 B 075)
(410 B 105 and/or 410 B 130)
(410 B 155)
(410 B 205)
( 410 B 240) if Route 11 is not selected
CONTROL PHILOSOPHY
05.10.2006
14 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
(410 B 305)
(410 B 325)
(410 C 010)
THREE WAY VALVE:

but may be opened after the start for minimum periods for venting (time adjusted in PLC 40
seconds).
SE 3-5:
300
Route 12 (SE 2-2)
positions:
OPEN:
(410 B 020)
(410 B 027)
(410 B 100)
(410 B 135)
(410 B 145)
(410 B 160)
(410 B 170)
(410 B 310)
(410 B 320)
(410 B 340)
CLOSE:
(410 A 330)
(410 B 017)
(410 B 037)
(410 B 075)
CONTROL PHILOSOPHY
05.10.2006
15 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
(410 B 105 and/or 410 B 130)

(410 B 155)
(410 B 205)
(410 B 250)
(410 B 305)
(410 B 325)
(410 C 110)
THREE WAY VALVE:

seconds).
SE 3-6
400
Route 13 (SE 2-3)
positions:
OPEN:
(410 B 030)
(410 B 037)
(410 B 100)
(410 B 135)
(410 B 145)
(410 B 160)
(410 B 170)
(410 B 310)
(410 B 320)
(410 B 340)
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
CLOSE:
16 (31)
(410 A 430)
(410 B 017)
(410 B 027)
(410 B 075)
(410 B 105 and /or 410 B 130)
(410 B 155)
(410 B 205)
(410 B 250)
(410 B 305)
(410 B 325)
(410 C 210)
THREE WAY VALVE:

seconds).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
2.3.4
17 (31)
Rev. 00
Selection of Material Route Transfer Pump 410 B 125 (SE 4)

The operator has three options:
The state of selection is on the Operation Sation (OS) indicated. A Route o.k. light on the
position.
SE 4-1
positions:
OPEN:
(410 B 010)
(410 B 017)
(410 B 105)
(410 B 120)
(410 B 130)
(410 B 250)
(410 B 310)
(410 B 320)
(410 B 340)
CLOSE:
(410 A 230)
(410 B 027)
(410 B 037)
(410 B 115)
(410 B 135)
(410 B 205)
(410 B 305)
(410 B 325)
(410 B 330)
(410 C 010)
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
THREE WAY VALVE:
18 (31)

seconds).
SE 4-2:
positions:
OPEN:
(410 B 020)
(410 B 027)
(410 B 105)
(410 B 120)
(410 B 130)
(410 B 310)
(410 B 320)
(410 B 340)
CLOSE:
(410 A 330)
(410 B 017)
(410 B 037)
(410 B 115)
(410 B 135)
(410 B 205)
(410 B 250)
(410 B 305)
(410 B 325)
(410 B 330)
CONTROL PHILOSOPHY
05.10.2006
19 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
(410 C 110)
THREE WAY VALVE:

seconds).
SE 4-3
Route 13 (SE 2-3) and/or Route 23 (SE 3-3)
positions:
OPEN:
(410 B 030)
(410 B 037)
(410 B 105)
(410 B 120)
(410 B 130)
(410 B 310)
(410 B 320)
(410 B 340)
CLOSE:
(410 A 430)
(410 B 017)
(410 B 027)
(410 B 115)
(410 B 135)
(410 B 205)
(410 B 250)
(410 B 305)
(410 B 325)
CONTROL PHILOSOPHY
05.10.2006
20 (31)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
(410 B 330)
(410 C 210)
THREE WAY VALVE:

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 431 S / 410 S and 432 S / 410 S
2.4.2.2 Route Settings
Start pitch pump (410 B 065): Route 11, 12 or 13 have to be set.
Start pitch pump (410 B 165): Route 21, 22, 23, 24, 25 or 26 have to be set.
Start pitch pump (410 C 125): Route 31, 32 or 33 have to be set.
2.4.2.3 Emergency stops
If the Emergency Stop of the Group has been activated it has to be RESET.
2.4.2.4 Alarms
If an Alarm of this Group has been activated it has to be RESET.
2.4.2.5 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

It makes sense to check and, if required, to readjust setpoints prior to a start of this Group.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
21 (31)
Rev. 00
Actual Setpoint
The PLC program is storing all actually used setpoints as

Actual Setpoint. The Actual Setpoint is automatically used
for the next start after the Group has been stopped or for a
restart after the Group has tripped. The Actual Setpoint is
displayed on SCADA.
New Setpoint
The operator has the opportunity to override the actual

setpoint by the New Setpoint any time. Changing of setpoint
is on SCADA.
Previous Setpoint
Did the operator change an Actual Setpoint the previous one

is also stored in the PLC as Previous Setpoint for possible
later use. The operator may override the actual setpoint by the
Previous Setpoint at any time. Selection of the Previous
Setpoint is on SCADA.
Standard Setpoint
The operator may also override the actual setpoint by the

Standard Setpoint any time. Selection of the Standard
Setpoint is on SCADA. The Standard Setpoint can be edited
on the SCADA system any time but by a Shift Leader only,
after using his Password.
2.4.3.1 SP 1 Pitch Temperature Storage Tank 1 (410 A 200)

The operator in the CCR may determine the setpoint of the liquid pitch temperature in the
tank. Any value between 160C and 200C is accepted. If the "standard setpoint" is
activated, the controller uses a fix value, which has been proven to cover most of the
operating conditions for liquid pitch set value is 180C. If the "New setpoint is not
accepted, the "actual setpoint" remains activated.
The liquid pitch temperature controller [TY-410 A 200] for storage tank 1 sends the
setpoint to the HTM temperature controller in secondary circuit 5 [TY-410 S 541].
The signal superimposes the HTM temperature controller in a cascade.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
22 (31)
Rev. 00
2.4.3.4 SP 4 Pitch Temperature downstream LP Heat Exchanger (410 B 215 and 410 B 315)
The operator in the CCR may determine the setpoint of the liquid pitch temperature
downstream the liquid pitch heat exchanger (410 B 215 and 410 B 315). Any value
between 160C and 200C is accepted. If the "standard setpoint" is activated, the
controller uses a fix value, which has been proven to cover most of the operating
conditions for liquid pitch set value is 180C. If the "New setpoint is not accepted, the
"actual setpoint" remains activated.
setpoint to the HTM temperature controller in secondary circuit 3 Line 1 (431) [TY-431 S
330] and in secondary circuit 3 Line 2 (432) [TY-432 S 330].
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 B 065), (410 B 125) and (410 B 165) individually
from the local control panel [410 LOP-B1]. A start is only initiated if the operator pushes the
"SLOW" Start pushbutton of the corresponding pump.
2.4.4.1 Start Transfer Pump (410 B 065)

The Operator actuates "SLOW" start pushbutton for pitch pump (410 B 065). Flashing light
indicates that start up sequence is initiated.
Pneumatic Valve (410 B 080) is opened.
Pitch pump (410 B 065) is started at slow speed.
Condition:
- Route 11/12/13 selected and verified
The local operator can switch the pump to high speed by actuating "FAST" pushbutton for
pitch pump (410 B 065) 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 B 045-TL] when operating with
route 11/12/13
- differential pressure at pitch filter between low level 0,5 mbar [410 B 050-PDSL] and high
level 10 mbar [410 B 050-PDSH] when operating with route 11/12/13/14.
2.4.4.2 Start Transfer Pump (410 B 125)
Condition:
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
23 (31)
Rev. 00
Condition:
route 61/62/63/64
- differential pressure at pitch filter between low level 0,5 mbar [410 C 115-PDSL] and high
level 10 mbar [410 C 115-PDSH] when operating with route 61/62/63/64
2.4.4.3 Start Stand-By Pump (410 B 165)

Route 21/22/23 for pump (410 B 165) is set:

Condition:
Route 24/25/26 for pump (410 B 165) is set:

Condition:
Any route 21/22/23/242/25/26 for pump (410 B 165) is set:
Condition:
route 21/22/23/24/25/26
- differential pressure at pitch filter between low level 0,5 mbar [410 B 150-PDSL] and high
level 10 mbar [410 B 150-PDSH] when operating with route 21/22/23/24/25/26
2.5
Normal Operation
2.5.1
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.
2.5.2
Pitch Temperature Liquid Pitch Heat Exchanger (410 B 215) (410 B 315)
The operator may vary the set value for the liquid pitch temperature [410 B 215-TIC], [410 B
315-TIC] during operation. Normally, a variation of the pitch temperature setpoint during
operation is only necessary when pitch with a different softening point was received from a
different source and requires a different temperature level for mixing.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
2.5.3
24 (31)
Rev. 00
Vent valve (410 B 230)

When operating pump (410 B 065) with Route 11/12/13 or pump (410 B 165) with Route
21/22/23, the local operator may open the vent valve (410 B 230) for maximum periods of 40
seconds in order to remove air from the pitch pipeline.
2.5.4
Vent valve (410 B 330)

When operating pump (410 B 125) with Route 31/32/33 or pump (410 B 165) with Route
24/25/26, the local operator may open the vent valve (410 B 330) for maximum periods of 40
seconds in order to remove air from the pitch pipeline.
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-B1] 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.
2.6.3
Fast Shut Down

The equipment of this Group is stopped from the local operating panel [410 LOP-B1].
2.6.3.1 Fast Shut Down of pump (410 B 065) from local operating panel [410 LOP-B1]
The operator actuates the STOP pushbutton for transfer pump (410 B 065).
-
Pump (410 B 065) is stopped immediately

Pneumatic Valve (410 B 080) is closed
The operator actuates the STOP pushbutton for transfer pump (410 B 125).
-

The operator actuates the STOP pushbutton for Stand-by pump (410 B 165).
Pump (410 B 165) is operating with Route 21/22/23
-

Pump (410 B 165) is operating with Route 24/25/26

-

CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
2.6.4
25 (31)
Rev. 00
Trip in Case of Faults

If this Group 410 B 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 Transfer Pump (410 B 065)

MCC: [410 B 065] 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 Transfer Pump (410 B 125)

-
alarm is initiated
drive is stopped
2.6.4.3 Stand-By Pump (410 B 165)

-
alarm is initiated
drive is stopped
2.6.4.4 Pitch Valve (410 B 080)

If both limit switches [410 B 080-ZSL] and [410 B 080-ZSH] of the pitch valve are actuated or if
limit switch [410 B 080 ZSH] is lost an alarm is initiated and when operating with Route
11/12/13 pitch pump (410 B 065) is stopped, when operating with Route 21/22/23 pitch pump
(410 B 165) is stopped.
2.6.4.5 Pitch Valve (410 B 140)
If both limit switches [410 B 140-ZSL] and [410 B 140-ZSH] of the pitch valve are actuated or if
limit switch [410 B 140 ZSH] is lost an alarm is initiated and when operating with Route
31/32/33 pitch pump (410 B 125) is stopped, when operating with Route 24/25/26 pitch pump
(410 B 165) is stopped.
2.6.4.6 Route Selection SE 2-1/2-2/2-3
In case that a valve is moved during operation and the valve position required for the selected
route 11/12/13 is lost
-
alarm is initiated
"Route selection o.k." symbol starts flashing
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
-
26 (31)
Rev. 00

Pneumatic valve (410 B 080) is closed
2.6.4.7 Route Selection SE 3-1/3-2/3-3/3-4/3-5/3-6

route 21/22/23/24/25/26 is lost
-
alarm is initiated
Pneumatic valve (410 B 080) is closed when operated with route 21/22/23
Pneumatic valve (410 B 140) is closed when operated with route 24/25/26
2.6.4.8 Route Selection SE 4-1/4-2/4-3

route 31/32/33 is lost
-
alarm is initiated
2.6.4.9 Pitch Valve (410 B 230)

In case that the vent valve is kept open for more than 40 seconds
operating with Route 11/12/13
alarm is initiated
operating with Route21/22/23
alarm is initiated
2.6.4.10 Pitch Valve (410 B 330)
In case that the vent valve is kept open for more than 40 seconds
alarm is initiated
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
-
27 (31)
Rev. 00
alarm is initiated
2.6.4.11 Pitch Temperature Valve (410 B 045) low

[410 B 045-TY] pitch temperature is lower than 160 C
alarm is initiated
"Pitch Temperature Filter 410 B 050 low" symbol starts flashing
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 actuate the "SLOW" start pushbutton for pitch pump (410 B 065) or he has to
stop the pump (410 B 065). If operating at fast speed pump (410 B 065) is
automatically stopped after 3 minutes delay time and pneumatic valve (410 B 080) is
closed.
alarm is initiated
closed.
alarm is initiated
closed.
alarm is initiated
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
-
28 (31)
Rev. 00
closed.
2.6.4.14 Pitch Filter 410 B 050 Low Differential Pressure [410 B 050-PDSL]
[410 B 050-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 B 050-PDSL]
closed.
closed.
closed.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
29 (31)
Rev. 00
closed.
2.6.4.17 Pitch Filter (410 B 050) High Differential Pressure [410 B 050-PDSH]
[410 B 050-PDSH] differential pressure at the filter is too high >10 mbar
pilot light in the local panel when the "FILTER PLUGGED" [410 B 050-PDSH]
In case that the reason for the alarm is prevailing for 3 minutes pump (410 B 065) is
automatically stopped if operating at fast speed and pneumatic valve (410 B 080) is
closed.
The reason for this alarm may be too high pitch viscosity normally together with too low pitch
temperature or a dirty filter.
closed.
operating with Route 21/22/23/
closed.
operating with Route 24/25/26/
closed.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-050
30 (31)
Rev. 00
2.7
Local Operation of Special Equipment

Not applicable
CONTROL PHILOSOPHY
05.10.2006
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-050
2.8
Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal
Description
Sort of Signal
from Group 431 S to Group 410 B
GROUP 431 S IN OPERATION

Group 431 S is running in
AUTOMATIC mode, minimum 2
primary pumps in operation, minmum
1 pump of secondary 1 & 2 & 3 & 4 in
operation, no Heater Common Fault
GROUP 432 S IN OPERATION
Group 432 S is running in
AUTOMATIC mode, minimum 2
primary pumps in operation, minmum
1 pump of secondary 1 & 2 & 3 & 4 in
operation, no Heater Common Fault
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)
Pump 410 B 065 operating with route
11-13 or pump 410 B 165 operating
with route 21-23 PITCH AVAILABLE
FOR PROPORTIONING
Pump 410 B 125 operating with route
31-33 or pump 410 B 165 operating
with route 24-26 PITCH AVAILABLE
FOR PROPORTIONING
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
Pitch Valve 410 C 010 closed
Pitch Valve 410 B 010 open
Pitch Valve 410 B 017 closed
Digital signal from PLC Number

431 PLC 11 410 PLC 01
from Group 432 S to Group 410 B
from Group 431 S / 410 S to

Group 410 B
from Group 431 S / 410 S to

Group 410 B
from Group 410 A to Group 410 B

from Group 410 B to Group 431 H
from Group 410 B to Group 432 H

from Group 410 C to Group 410 B
from Group 410 B to Group 410 C
Digital signal from PLC Number

432 PLC 22 to 410 PLC 01
Digital signal from 431 PLC 11 to

410 PLC 01 and
within PLC Number 410 PLC 01

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

431 PLC 15
432 PLC 25
Analogue signal within 410 PLC 01
31 (31)

7.3
Main Equipment
7.3.1
Basket Filter 410 B 050
7.3.2
Positive Displacement Pump 410 B 065
7.3.3
Liquid pitch Heat Exchanger 410 B 215
7.3.4
Pressure Holding Valve 410 B 235

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

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Training Manual Green Anode Plant

PROCESS GROUP 410 B - LIQUID PITCH TRANSFER -

Process Group 410 B - Liquid Pitch Transfer -............................................................................1

Process Flow Sheets

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Brief Process Description

Outokumpu Technology GmbH

Brief Process Description

Material Route Diagram:

133-50-051 UB sheet 1 & 2 / 133-50-052 UB sheet 1 & 2 /

Outokumpu Technology GmbH

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

Material Route Diagram:

133-50-051 UB sheet 1 & 2 / 133-50-052 UB sheet 1 & 2 /

Brief Process Description............................................................................................................ 2

Control Logic Description ............................................................................................................ 3

Outokumpu Technology GmbH

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 group, 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 Panel

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

Light indicates high differential pressure at filter