Level 1 CDCP PDF

OPERATION MANUAL (LEVEL 1)
IISCO STEEL PLANT, INDIA
COKE DRY COOLING PLANT

Contents
1 GENERAL ................................................................................................................................ 1-1
1.1 User Interface ..................................................................................................................... 1-3
1.2 Button Area (keysets) ......................................................................................................... 1-4
1.3 Login to the Runtime System ............................................................................................. 1-5
1.4 Message Screens ................................................................................................................ 1-5
1.5 Screen symbols and Faceplates .......................................................................................... 1-8
1.5.1 Motors of Pumps/Blowers ............................................................................................... 1-11
1.5.2 Valves............................................................................................................................... 1-13
1.5.3 Measurements .................................................................................................................. 1-15
1.5.4 PID-Controllers ................................................................................................................ 1-16
1.5.5 Trends............................................................................................................................... 1-17
1.6 Graphics displays / Control philosophy ........................................................................... 1-19
1.6.1 Chamber ........................................................................................................................... 1-19
1.6.2 Boiler ................................................................................................................................ 1-23
1.6.3 Lifter ................................................................................................................................. 1-26
1.6.4 Boiler , Feed Water System.............................................................................................. 1-27
1.6.5 Service Water ................................................................................................................... 1-30
1.6.6 Discharging Devices , Conveyor Tunnel ......................................................................... 1-34
1.6.7 Dust Cleaning System ...................................................................................................... 1-36
1.6.8 Dust Pneumatic Transport System ................................................................................... 1-39
1.6.9 Pressure Pneumatic Transport System ............................................................................. 1-43
1.6.10 Auxliary System ............................................................................................................... 1-46
1.6.11 Discharging Hydraulic ..................................................................................................... 1-48
1.6.12 Air Comperssors .............................................................................................................. 1-50
1.6.13 Utilities ............................................................................................................................. 1-51
© VAI Finland ISP-CUI/SOY-III-003-020-58-DE-20211-Operation Manual

File: DE-20211 Level-1 Operation_manual - Rev 2 , 04 Date: 17 June, 2010 Rev. : 1 / Page: i
Feb 2013 4.6.2012
This document must not be copied without our written permission and the contents thereof must not be imparted to a third party or be
used for any unauthorized purpose. Contravention will be prosecuted.
1 GENERAL
This Operation Manual consists of general operation instructions and drafts of

screens of Siemens PCS7 Process Control & Monitoring System (HMI)
Process conditions like measurements, control loops, status of pumps and fans,
position of valves, alarms , interlocks, trends etc. are monitored and controlled via the
Siemens SIMATIC PCS7 Process Control System.
The Level-1 Operation Interface (HMI) of the plant is implemented with client / server
architecture i.e. there are two (2) Operator Station Servers (located in Engineering Room) and
five (5) Operation Stations OS1…OS5 (located in Main Control Room). Two (2)
Engineering Stations are included for creating HW configuration, application software and
graphical process displays.
The following functions are carried out by means of the Process Control and
Monitoring system (Siemens PCS7):
- Visualization of the process

- Control and monitoring of process activities
- Editing of actual process values
- Editing of process parameters e.g settings of control loops, settings of alarm ,
limits of measurements etc.
- Alarm and message processing
- Control and monitoring of sequential process functions
- Data collection and storage in the data archive of automation system
- Processing and analyzing of collected data history e.g. by trends
Operation Modes:
LOCAL MODE
Motors / motor Valves can be operated from LCP (Local Control Station) by selecting
LOCAL MODE at LCP. LOCAL PERMISSION shall be granted by Control Room
Operator to able operate devices in Local Mode.
LOCAL PERMISSION button is visible close to motor/motor valve symbol on HMI.
By pressing the button Control Room Operator may select LOCAL PERMISSION
On/Off.
- RED color , LOCAL PERMISSION OFF
- GREEN COLOR , LOCAL PERMISSION ON
On REMOTE MODE local permission button is not visible.
REMOTE MODE - MANUAL

REMOTE MODE shall be selected at LCP Panel. In Remote Mode – Manual control
room operator can operate individual devices i.e. start/stop , open/ close.
REMOTE MODE – AUTO

From device faceplate Control Room Operator can select AUTO MODE.
In Auto mode device is operated automatically based on process requirements,
interlocking etc.
1.1 User Interface
Selection of process screen Alarm & Message line, shows the latest occurred alarm or message Date and time
Overview area
Selection of sub screen Screen hardcopy
Name of current user
Workspace area
Button area
Horn acknowledgement
Alarm & message acknowledgement

The screen area is divided into three areas:
• Overview area
- Provides access to all process screens of the process.
• Workspace area
- The selected process screen of the the process is presented.
• Button area
- The buttons which triggers the desired function e.g special screen, report
or data handling tool of the process control and monitoring system.
1.2 Button Area (keysets)

Picture selection
Keyset change Reports via process tag Picture navigation
Message system Trend system Picture via name
Previous picture Store picture System configuration Picture info
Change language Lock messages User authorization
Call SFC Exit runtime

1.3 Login to the Runtime System
1. Click on the ”Log In” button and the following input possibilities are displayed
2. Enter your Username (Login) and the Password

3. Click ”OK” or press ENTER key
After completing ”LOG IN” successfully, the User is able to operate the Runtime
system.
The username (login) is displayed near the right- hand top corner of the screen area
(just below the system time).
1.4 Message Screens

Following message screens (Alarm & Message Lists) are available:
”Incoming Alarm List”

All occurred alarms and messages which have not been acknowledged
”Acknowledged Alarm List”

All acknowledged alarms and messages which still have not disappeared
”Outgoing Alarm List”

All alarms and messages which have already disappeared
”Process Alarms”
All process control system alarms and messages like internal process control
system alarms and messages (faults of cards, channels of IO-cards, faults of
communication etc.), external field device faults (cable and wire failures, field
device failures etc.)
”Operation List”
All operator input messages (list of controls, parameter changings etc. operations
which have been done by operator)
”History list”
All alarms and messages
“Hidden list”
All messages which were hidden manually or automatically
“List of messagesto be hidden”

All messages that are to be hidden while pending
Following background colors are used for messages:
Alarm Red Urgent proceedings, operators must react

immediately
Warning Yellow Operators must react immediately or soon
Message Violet Information for operators, reaction if necessary

System alarm Black Operators must react immediately , for
instance some measurement is out of order and
therefore process information is not available.
All alarms and messages are displayed on every Operation stations.

Message lists can be printed out for archiving and for closer studies by the hardcopy printer of the
Main Control Room.Click on the ”Alarm Logging” button on the Button area and the following
screen “Incoming Alarm List” appears on the monitor.
Name of the message list The latest occurred message

Acknowledge individual message
Acnowledge all visible messages
Autoscroll ON/OFF
Manual scroll buttons (4) Information message - Violet
Warning message - Yellow
Alarm message - Red
Back to the last process screen System alarm - Black
Horn/Buzzer acknowledgement
Selection of desired message list

Message screens are easily editable to a desired format by Alarm Logging Wizard
program of PCS7 system. There is more detailed information available in the helps of
the Alarm Logging Wizard.
1.5 Screen symbols and Faceplates

Below is a status bar of a faceplate, (except SIMOCODE), that provides the most important
information relating to the block status.
Instance name Lock/unlock alarms Supress alarms
Group display Views of the block
Acknowledge alarms Worst signal status
Worst signal status
Local functional check / simulation
Bad, device related
Bad, process related
Unknown, device related
Unknown, process related
Maintenance request
Good
Views of the block
Standard view
“Alarm view”
Shows all the alarms generated by the block
“Limits view”
Several values can be set here, for example, process value limits
“Trend view”
Displays all the trends of the current block
“Ramp view”
Possibility to set different ramp functions
“Parameter view”
Displays parameter adjustments for theblock
“Preview”
Displays the parameters that the operator can operate in the block
“Memo view”
Possibilty to leave messages for the operators. If message has been left, it will show in
the status bar of the block.
“Batch view”
Not used in this project
Simocode Motor/Pump
Motor/pump position
By clicking the block icon of Simocode Motor/pump opens the faceplate of

that motor/pump.
Auto/manual mode
Control in manual mode

On/off
Current display and current

alarm limits and bar range Alarm list
Trend view
Motor/pump position
By clicking the block icon opens the standard view faceplate of motor/pump. The view can be
changed from the view buttons as described in earlier chapter. This is an example of Motor with
frequency control
State presentation
Views of the block
Mode/command Area
Additional information
Bar graphs
External setpoint
Simocode valve
Motor/pump position
Auto/manual mode
Control in manual mode

Close / Stop / Open
Alarm list
Trend view
Other valve
Valve position
By clicking the block icon opens the standard view faceplate of valve. The view can be changed
from the block view butons as described in earlier chapter.
State presentation
Mode/command Area
1.5.3 Measurements
There are many kind of measured variables from the process, like levels of the tanks and vessels,
flows of the liquids/steams/gases, pressures, temperatures etc. By clicking the tag number field of
the measurement the following faceplate appears on the screen.
Block icon of measurement
Operating mode
Bar graphs,
Process value/gradient
Reset peak values

of gradient
1.5.4 PID-Controllers
PID-controllers (including measurements and control loops) are used to control the
control valves.
A-letter on the right-hand top corner of the symbol means that the controller is in the automatic-
control mode, comparable M-letter means manual-control mode.
By clicking the PID-control loop block icon the following faceplate appears
on the screen:
Block icon of PID
Mode/command Area
Bar graphs,
Process value/setpoint
High/low scale range

for processs value
High/low scale range

for setpoint
Bar graphs,
Manipulated variable/
position feedback
1.5.5 Trends
Trend window is opened from the faceplate of measurement or from the faceplate of
PID-Controller or through the online-trend button or through the specially made trend
buttons on the screen (see for example buttons on the CDQ1 screen).
Trend screen
Buttons of trend window Name of the trend
Size of the trend window can be changed by using normal drag and drop function.
Buttons of the Trend Window are described as follows:
Previous/Next data record Zoom Original size Start/stop Statistical tools Archive data
Time range Move trend/axis range Ruler Relative axis Print

1.6 Graphics displays / Control philosophy
1.6.1 Chamber
Operation Modes:
Local, Remote – Manual & Auto
LOCAL , REMOTE-MANUAL OPERATED DEVICES
Shut-off valve of Circulation gas before Main Mill Fan, x-M-351

Local and Remote-Manual
Main Mill Fan, x-M-355

Interlockings;
- Drum level LL (LIT 544.4), delay 10s
- Drum Level HH ( LIT 544.4)-, delay 10s
- Temperature of circulation gas before boiler (TIT-502) too high, delay...
- Both RC - water pumps are stopped (M-566 & M-576)
- Flow of RC-water is too low (FI-585)
File: DE-20211 Level-1 Operation_manual - Rev 2 , 04 Date: 17 June, 2010 Rev. : 2 Page: 19of 53
Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
SAIL, IISCO STEEL PLANT, INDIA 17 June, 2010
CDCP AUTOMATION
- Feed Water Pressure LL (PIT-594), delay 10s

- Feed Water Pressure HH (PIT-594), delay 10s
- Shut-off valve before Main mill fan opened
- Shut-off valve before Aux mill fan closed
- Bearing temperatures (TI-356 & TI-357) , Direct HT-Feeder interlocking
- Winding temperatures (TI-358.1-.6),Direct HT-Feeder interlocking
- Vibration monitors of fan and motor (VIA-359 & VIA-360)
NOTE !
Guide Vane M-354 shall be closed when starting Main Mill Fan
Above interlocks are valid also in LOCAL MODE, but however following interlocks can be
by-passed with BOILER GUARD switch (located at Emergency Stop Pulpit in Control
Room:
- Temperature of circulation gas before boiler (TIT-502) too high, delay 10s
- Both RC - water pumps are stopped (M-566 & M-576)
- Feed Water Pressure LL (PIT-594), delay 10s
- Feed Water Pressure HH (PIT-594), delay 10s
Shut-off valve of Circulation gas before Auxiliary Mill Fan, x-M-361

Guide Vane of Auxiliary Mill Fan , x-M-364

Local & Remote-Manual
Auxiliary Mill Fan, x-M-355

Interlockings;
- Bearing temperatures (TI-366 & TI-367), Direct HT-Feeder Interlocking
- Winding temperatures (TI-368.1-.6), Direct HT-Feeder Interlocking
- Vibration monitors of fan and motor (VIA-369 & VIA-370)
NOTE !
Guide Vane M-364 shall be closed when starting Main Mill Fan
Above interlocks are valid also in LOCAL MODE, but however following interlocks can be
Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
by-passed with BOILER GUARD switch (located at Emergency Stop Pulpit in Control
Room:
AUTO OPERATED DEVICES
Chamber Hatch Lid, x-M-210

Opened / closed during Lifter AUTO sequency
Interlockings : Chamber HH Limit
Charging Device , dust free charging gate valves x-M-261 & x-M-271
Opened during charging sequency and closed after charging is over.
Interlockings : One if the IF fans must run
Pressure Control of Cooling Chamber, PIC-321

Pressure control based on measurement PIT-321.
During Charging PID control is freezed. After 5 minutes control back to AUTO.
Circulation Gas Pressure Control in Discharging Device , x-PIC-322

Pressure control based on measurement PIT-322.
Valve for Reburning, x-HV-328

Opened when CO-value (AIT-342) more than 12 %
Opned when H2-value (AIT-344 or AIT-383) more than 5 %
Closed when CO-value less than 12 % and H2-value less than 5 %.
Shut-off valve for discharge of circulation gas at boiler stopping, x-M-349

Opened during Boiler Emergency Stoppage, see separate Interlocking Diagram
Guide Vane of Main Mill Fan , x-M-354

Opening / Closing based on Temperature Measurement TIT-502, PID-Control
In Auto mode opening / closing is restricted to 30…70%.
Shut-off Valve of Nitrogen Supply to Main Mill Fan , x-M-375

Opened durig Boiler Emergency Stoppage, see separate interlocking diagram
Shut-off Valve of Nitrogen Supply to Aux Mill Fan , x-M-376


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Shut-off Valve of Nitrogen Supply to discharging Device , x-M-386

OTHER
Discharging Device , see 1.6.6

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.2 Boiler
Operation Modes:
Shut-off valve for Superheated Steam into Collector , x-M-522.1 & x-M-522.2
Interlockings:
Ref. Thermax Dwg 58-DE-22015 Interlocking diagram (Only to M-522.1)
Shut-off Valve of Steam Superheater Purging , x-M-524

Interlockings:

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Shut-off Valve for continous Purging , x-M-548

Shut-off Valve for continous Purging , x-M-550

Shut-off Valve before Circulation Pump No.1 , x-M-564

Shut-off Valve before Circulation Pump No.2 , x-M-574

Shut-off Valve 1 for Boiler Feeding Unit , x-M-591



Shut-off Valve of Nitrogen Supply to Boiler , x-M-512

Superheated Steam Temperature Control , x-TIC-521

-Ref. Thermax (TBW) Dwg. No. D13-WH-CS-43030 and D13-3WH-2495E
Level Control of Boiler Drum , x-LIC-555 / FIC-544

Circulation Water Emergency by-pass , x-X-562

Interlocked to OPEN if both circulation pumps are not running
Circulation Pump No. 1 , x-M-566

AUTO start if Circulation Pump No. 2 trips
Interlockings;
- Drum Level low, LIT-544.4, delay…
- Differential Pressure across strainer , PDI-565
- Bearing Temperature of Pump , TI567.1 & .2

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
- Vibration monitoring of pump, VI-572

- Circulation water flow, FI-585, delay…
- Shut-off valve after circulation pump not opened, M-570, , delay…..
Shut-off Valve aftere Circulation Pump No.1 , x-M-570

Opened when circulation pump 1 starts, delay….
Closed if circulation pump 1 trip/stop
Circulation Pump No. 2 , x-M-576

AUTO start if Circulation Pump No. 1 trips
Interlockings;
- Drum Level low, LIT-544.4, delay…
- Bearing Temperature of Pump , TI577.1 & .2
- Circulation water flow, FI-585, delay…
- Shut-off valve after circulation pump not opened, M-570, , delay…..
Shut-off Valve aftere Circulation Pump No.1 , x-M-580


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.3 Lifter
See separater finctional description for Lifter.

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.4 Boiler , Feed Water System
Operation Modes:
Shut-off valve of demineralized water pipeline 1 , 0-M-201

Shut-off valve of demineralized water pipeline 2 , 0-M-211


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
LP Dosing Pump 1 , 0-M-311

interlocking:
Low-low level in reagent solution service tank, LALL-319
Pressure after LP Dosing pump 1, PI-312

interlocking:
Mixer of LP Dosing Tank , 0-M-316

Water Level Control in deaerator tank 1 & 2, 0-LIC-221

Pressure Control in deaerator tank 1 & 2, 0-PIC-222

Feed Water Pump 1 , 0-M-231

If server as stand-by pump , AUTO start in case operating pump trips
Interlockings;
- Inlet pressure low
- Bearing Temperature of Motor , TI232.1 & .2 (Directly to HT-Feeder)
- Winding temperature of Motor, TISA-239 (Directly to HT-Feeder)
- Vibration monitoring of Motor, VI-236
- Low level of deaerator tank 1 and tank 2, LIAS-220
- Feed Water pressure in feedwater line 1 and 2, PI-267 or PI-269
- Cooling water pressure to feedwater pumps, PI-270
Shut-off Valve after Feed Water Pump 1, 0-M-233


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION

Interlockings;


Interlockings;


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.5 Service Water
Operation Modes:
Fan of Service Water Cooling Tower , 0-M-421 and 0-M-421


interlocking:
Mixer of LP Dosing Tank , 0-M-316


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Hot Water Pump 1 , 0-M-403

If server as reserve pump , AUTO start in case operating pump trips
Acts according to Hot Water Tank level, LISA-400
- If HH - level reached, start if reserve pump
- if H - level reached, start if master pump
- if L - level reached, stop pump
Interlockings;
- Shut-off valve M-405 shall be closed during start-up
- Pump operation to closed shut-off valve (M-405) shall not be more the 2 minutes
- If pressure(0311-0-PISA-404) in head pipe line is not available for one minute, shut
down pump
- Water level in heated water collecting tank (LISA-400 LL)
Shut-off valve of Hot Water Pump 1 , 0-M-405

Start of pump 0311-0-M-403 - slide valve is opening (if pressure (PISA-404) is OK)
Stop of pump 0311-0-M-403 - slide valve is closing.
Hot Water Pump 2 , 0-M-413

Acts according to Hot Water Tank level, LISA-400
Interlockings;
down pump
- Water level in heated water collecting tank (LISA-400 LL)
Shut-off valve of Hot Water Pump 1 , 0-M-415

Start of pump 0311-0-M-413 - slide valve is opening (if pressure (PISA-414) is OK)
Water Level Control in Service Water Cooling Tower , 0-LIC-422 and 0-LIC-424
Valve is opened when elevation of water level in basin is +1.000
Valve is closed when water level at elevation is +1.1.00
Cooling Water Pump 1 , 0-M-433

Interlockings;

Feb 2013 15.1.2013
DETAIL ENGINEERING
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CDCP AUTOMATION

down pump
- Water level in Cooling Water Tower (LISA-422 LL)
Shut-off valve of cooling Water Pump 1 , 0-M-435

Start of pump 0311-0-M-433 - slide valve is opening
Cooling Water Pump 2 , 0-M-443

Interlockings;
down pump
- Water level in Cooling Water Tower (LISA-424 LL)
Shut-off valve of cooling Water Pump 2 , 0-M-445

Start of pump 0311-0-M-443 - slide valve is opening
Sump Pumps 1 & 2 , 0-M-451, 0-M-453

Acts according to Sump Water tank level, LISA-450
Water Level Control in Production Water Tank , 0-LIC-460

Valve is opened when elevation of water level in basin is +2,9 m
Valve is closed when water level at elevation is +3,0 m
Production Water Pump 1 , 0-M-462

Acts according to Production Water Tank level, LISA-460
Interlockings;
down pump

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
- Water level in Production Water tank (LISA-460 LL)
Production Water Pump 2 , 0-M-466

Acts according to Production Water Tank level, LISA-400
Interlockings;
down pump
- Water level in Production Water tank (LISA-460 LL)

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.6 Discharging Devices , Conveyor Tunnel
Operation Modes:
Rotary Feeder of Discharging Device, x-M-410

Speed of Discharging Device can be adjusted manually by changing the capacity value of
discharging rate 0 … 60 t/h
Interlockings:
TISA-314, TISA-315, TISA-316, TISA-317, TISA-318 or TISA-319 reaches high limit
if LSA-303 reaches low limit
Y-451 or Y-461 open and respective conveyor running
Repair valve 1-Y-441 opened
In stoppage of Main Mill Fan and Auxiliary Mill Fan
Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
In stoppage of hydraulic system (pump 1 & 2)

In stoppage of ventilation system (ID fans + M-491)
Sector Gates, x-Y-421, x-Y-431

Local, Remote – Manual
NOTE!
Sector Gates may work also in AUTO mode i.e. following sequency,
open sector gate 1
wait time x
close sector gate 1
open sector gate 2
wait time x
close sector gate 2
Wait time x can be adjusted from HMI.
Repair Valve, x-Y-441

Only LOCAL mode with Local Permission feature.
Shut-off valve to Coveyors 1 & 2Valve, x-Y-451, x-Y-461

Local, Remote – Manual
Emergency Quenching to Conveyors 1 & 2, , TISA-041…TISA-047

Emeregency Water valve opens in case corresponding temperature measurement exceeds
Rotary Feeder of Discharging Device, x-M-410

Speed of Discharging Device can be adjusted manually by changing the capacity value of
discharging rate 0 … 60 t/h

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.7 Dust Cleaning System
Operation Modes:
Shut-off Valve before bag filter, line 1, 0-M-534

Shut-off Valve before bag filter, line 1, 0-M-539

Shut-off Valve after bag filter, line 1, 0-M-552


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Shut-off Valve after bag filter, line 2, 0-M-554

Shut-off Valve before IF Fan 1, 0-M-561

Shut-off Valve before IF Fan 2, 0-M-571

Charging Device , dust free charging gate valves x-M-261 & x-M-271
Opened during charging sequency and closed after charging is over.
Interlockings : One if the IF fans must run
Dust Free Charging, Main Gate Valve 0–M-514
Dust Free Discharging gate valve , x-M-491

Opened / closed based on operation of discharging device.
Interlockings : One if the ID fans must run
Guiding Device for ID Fan , 0-M–562 , 0-M-572

Delayed opening after ID fan started.
Closed when ID Fan Stops.
ID Fan , 0-M–563 , 0-M-573

AUTO start if other ID Fan trips.
Interlockings :
- Hydrogen content excess in Circulation Gas System
- Bearing temperatures of Motor (connected to HD-Feeder)
- Bearing temperatures of Fan
- Motor Winding temperatures (connected to HD-Feeder)
- Vibration monitoring of Fan
- Stop bin case of fire (Fire alarm system)
- High Level in bag filter bunker 1 more than two hours (LSA-543)
- High Level in bag filter bunker 1 more than two hours (LSA-548)
- High Level in Dust Cyclone 1 more than two hours (LSA-692)
- High Level in Dust Cyclone 2 more than two hours (LSA-693)
- Flow of Cooling Water (FS-555 & FS-556)

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
NOTE!
There is separate conrol system for Bag Filter Cleaning System. Control Room operator can
start/stop Cleaning System as REMOTE-MANUAL mode.

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.8 Dust Pneumatic Transport System
Operation Modes:
Shut-off valve of Steam Supply , 0-M-605

Interlocks:
- Steam supply to ejectors 1-4 closed (M-611, M-615, M-621, M-625)
- Pressure PIT-602 OK
- Temperature TIT-604 OK
Shut-off valve of Steam Supply to Ejector 1 , 0-M-611

Interlocks:
- Steam shut-off opened (M-605)
Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
- Vacuum release M-614 closed

- Settling chamber 1 gate closed (M-633)
Shut-off valve of Vacuum blowndown line 1 , 0-M-614


Interlocks:

Interlocks:
Shut-off valve of Vacuum blowndown line 1 , 0-M-624


Interlocks:
Discharge gate valve of Settling chamber 1 , 0-M-633

Interlocks:
- Chamber 1 not in low level (LS-632)
- Steam ejectors 1 & 2 closed (M-611 & M-615))
Discharge gate valve of Settling chamber 2 , 0-M-637

Interlocks:
- Chamber 1 not in low level (LS-636)
- Steam ejectors 1 & 2 closed (M-621 & M-625))

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Valve for unloading , 0-M-649

ONLY Local mode
Shut-off valve for air supply to Vacuum line 1 , 0-M-661

Interlocks:
- M-662... M-673 closed or maintanance
- M-633 settling gate valve closed
- PIT-613 or PIT-617 vacuum pressure ok
Shut-off valve for Dust Transmitting , Vacuum Line 1, 0-M-662 …0-M-673

Interlocks:
Shut-off valve for air supply to Vacuum Line 2 line, 0-M-691

Interlocks:
Shut-off valve for Dust Transmitting , Vacuum Line 2, 0-M-692 & 0-M-693
Interlocks:
AUTO SEQUENCIES
AUTO SEQUENCY for Dust Transmitting, Vacuum Line 1 & 2

see separate sequency chart
By clicling the SEQ CONTROL button Operator can select following:
- Control of Sequency START / ABORT
- Start transmitting
- Stop transmitting
- Select transmitter to Maintenance mode ( i.e. not included in interlocking)
- Select TIMER MODE i.e. opening time of shut-off valve

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
- Select max opening time for shut-off valve

Transmitting can be started from Control Room or from Local Control box
NOTE! Only one transmitter can operate at one time
AUTO SEQUENCY for PURGE, Vacuum Line 1 & 2

- Start PURGE
- SET Purge time
Transmitting can be started from Control Room
AUTO SEQUENCY for VACUUM CREATION, Vacuum Line 1 & 2

- Start VACUUM CREATION
- SET Pressure delay time
Sequency can be started from Control Room
NOTE! Not in use
AUTO SEQUENCY for DISCHARGE, Vacuum Line 1 & 2

- Start /Stop DISCHARGE
- SET Discharge time
Sequency can be started from Control Room
NOTE! Not in use

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.9 Pressure Pneumatic Transport System
Operation Modes:
Screw Conveyor of dust filter bunker , 0-M-544 & 0-M-549

Interlockings Remote-Manual :
Rotary Air Lock Valve 0-M-545 / 0-M-550 must Run
Rotary Air Lock Valve of dust filter bunker , 0-M-545 & 0-M-550
none

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Rotary Air Lock Valve RAL-300 in Storage Hopper , 0-M-545A & 0-M-550A
none
Slide gate vlave in Storage Hopper , 0-XC-579 & 0-M-580

Remote-Manual
none
Shut-off valve of dust collecting bunker , 0-M-643 & 0-M-646

ONLY Local
Wetting screwfor discharge from dust collecting bunker , 0-M-644 & 0-M-647
ONLY Local
Shut-off valve for unloading , 0-M-648

ONLY Local
Pump for contaminated condensate water , 0-M-652 & 0-M-654

Local & Remote Manual & Auto
Interlockings:
Low level of water tank (LIT-651)
Auto control:
- Starts when wetting screw M-644 or M-647 is running
Aspiration System of dust transporting , 0-M/XC-676

Local & Remote Manual & Auto
Interlockings:
PIRA-675 in auto sequency
Valve for dust transmitting from collection bunker 1 of bag filter , 0-XC-682.1 & -2 & .3
Remote – Manual & Auto
Valve for dust transmitting from collection bunker 2 of bag filter , 0-XC-686.1 & -2 & .3
Remote – Manual & Auto
AUTO SEQUENCIES
AUTO SEQUENCY for Dust Transmitting, Line 1 & 2


Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION

- Start transmitting
- Stop transmitting
- Select TIMER MODE i.e. opening time of shut-off valve
Transmitting can be started from Control Room or from Local Control box

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.10 Auxliary System
Operation Modes:
Phosphate solution pump 0-M-300, 0-M-301

LL level of phosphate solution tank (LALL-338)
HP Dosing pump , 0-M-303, 0-M-305, , 0-M-307, 0-M-309

LL level of HP Dosing Service tank (LALL-337)
Pressure after respective HP Dosing pump shall be more than pressure in Drum
(PI-304, PI-306, PI-308 , PI-310)
Mixer of HP dosing service tank , 0-M-316

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Shut-off valve of Main Steam Line , 0-M-3541.&2 , 0-M-364.1&.2

PRDS-1 , Temperature & Pressure Control , TIC-382 & PIC-381

Ref. Thermax documents D13-WH-CS-43030 and D13-3WH-2495E
PRDS-2 , Temperature & Pressure Control , TIC-373 & PIC-371

Drainage Expander Level Control , LIC-274

CBD Tank Level Control , LIC-279

Drain Tank Temperature Control , TIC-276 & TIC-280

Drainage Pump, 0-M-264 , 0-M-265

LL level in drain Tank (LI-263)

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.11 Discharging Hydraulic
Operation Modes:
Hydraulic pump 0-M-711 & x-M-721

Stand-by pump will start in case other pump trips.
Interlockings :
Oil Temperature HH limit
Oil level Low limit
Circulation pump , 0-M-731

Auto start when one of the hydraulic pumps starts.

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
Cooling Fan , 0-M-741

Auto start when one of the hydraulic pumps starts.
Pressure Relief Valve , 0-Y-708 & 0-Y-709

Opened when respective pumps is started and closed after 10 s delay.

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.12 Air Comperssors
Operation Modes:
Air Compressor 0-M-501 & 0-M-503

In case compressor is stand-by one in AUTO-mode it will starts automatically if other
Compressor stops.
Interlockings :

Feb 2013 15.1.2013
DETAIL ENGINEERING
Date:
CDCP AUTOMATION
1.6.13 Utilities
Operation Modes:
Local & Remote – Manual for Boiler Drum Wash Water Pump 0-M-321

Feb 2013 15.1.2013

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OPERATION MANUAL (LEVEL 1)

IISCO STEEL PLANT, INDIA

COKE DRY COOLING PLANT

© VAI Finland ISP-CUI/SOY-III-003-020-58-DE-20211-Operation Manual

This Operation Manual consists of general operation instructions and drafts of

- Visualization of the process

REMOTE MODE - MANUAL

REMOTE MODE – AUTO

Selection of sub screen Screen hardcopy

Name of current user

Alarm & message acknowledgement

1.2 Button Area (keysets)

Message system Trend system Picture via name

Previous picture Store picture System configuration Picture info

Change language Lock messages User authorization

Call SFC Exit runtime

2. Enter your Username (Login) and the Password

1.4 Message Screens

”Incoming Alarm List”

”Acknowledged Alarm List”

”Outgoing Alarm List”

“List of messagesto be hidden”

Following background colors are used for messages:

Alarm Red Urgent proceedings, operators must react

Warning Yellow Operators must react immediately or soon

Message Violet Information for operators, reaction if necessary

All alarms and messages are displayed on every Operation stations.

Name of the message list The latest occurred message

Acnowledge all visible messages

Manual scroll buttons (4) Information message - Violet

Warning message - Yellow

Alarm message - Red

Back to the last process screen System alarm - Black

Selection of desired message list

1.5 Screen symbols and Faceplates

Instance name Lock/unlock alarms Supress alarms

Group display Views of the block

Acknowledge alarms Worst signal status

Worst signal status

Local functional check / simulation

Bad, device related

Bad, process related

Unknown, device related

Unknown, process related

By clicking the block icon of Simocode Motor/pump opens the faceplate of

Control in manual mode

Current display and current

Control in manual mode

Block icon of measurement

Reset peak values

Block icon of PID

High/low scale range

High/low scale range

Time range Move trend/axis range Ruler Relative axis Print

LOCAL , REMOTE-MANUAL OPERATED DEVICES