Instrumentation & control of typical material handling of FGD Plant

SANJIB KUMAR PATRA
06/05/2017
Instrumentation & Control of Typical Material
Handling for FGD Plant
KOLKATA

• Process and Instrumentation
• Control Philosophy
• Frequency of switching between Operating and Standby
• Shutdown Sequence
• Annunciation and Alarm List
• Start Up Sequence
Topic
• Changeover Sequence

Process and Instrumentation- Flow Diagram
• Process Flow Diagram: Lime Stone Handling System

Process and Instrumentation-Flow Diagram
• Process Flow Diagram: Gypsum Handling System

Process and Instrumentation
• Mounted on Tail Pulley /Snub Pulley
• Application: This device actuates relay contacts
at preset speed. Using these contacts desired
control action such as zero speed protection/
under speed protection can be achieved.
• Installed in Conveyor, Crusher, Bucket Elevator
and other rotating equipment.
• Mounted in Chute
• Application: This device actuates relay
contacts where chute is blocked due to
material Jamming
Zero Speed Switch
Chute Block Switch

• Mounted on Both Side of Conveyor
• Application: protective switch for detecting
the meandering (sway or deviation) of belt
conveyors, and sends out an alarm signal
• Detection & Monitoring Through Belt
Watch Panel
• Mounted on Both Side of Conveyor
• Application: Pull cord switch is used as
a safety switch to stop the conveyor
belt in case of an emergency
• Detection & Monitoring Through Belt
Watch Panel
Belt Sway Switch:
Pull Chord Switch:

• Belt Watch Panel1 for Lime Stone Handling System for
11 Nos. Belt conveyor & Belt Watch Panel2 for Lime
Stone Handling System for 3 Nos. Belt Watch Panel
• Each Belt Watch Panel having nos. of Belt Watch Controller
and each module connected to corresponding conveyor’s Belt
Sway Switch and Pull Chord Switch.
• 1) Master Cum Display Unit
• 2) Signal Module
• 3)Termination Module
• 4) Control Panel:
• Key Component of Belt Watch Panel.

Belt Watch Panel Loop Connection

Vibration Monitoring for Crusher 1 & 2
to determine the problem
• Unbalance
• Misalignment
• Mechanical Looseness
• Antifriction / Sleeve Bearing Defects
• Gear Defects
• Belt Defects
• Hammer Defects
• Bent Shaft
• Electrical Problems
• Resonance
Permissible Vibration Level:4.5mm/sec

Digital Vibration Indicator
Forbes Marshal 901P
PLC
4-20mA
PLC OUTPUT
Vibration Monitoring System
time waveform
DE-X & Y AXIS
NDE-X & Y AXIS
Shinkawa- CBT-420

Temperature Monitoring for Crusher Bearing(DE/NDE):
RTD –PT-100
Transmitter: E&H: TM-
112
PLC
4-20mA/Hart
• For Bearing Temperature Monitoring .
• Key Indicator of Bearing Health.
• Installed at Driving & Non Driving End – Bearing of Crusher 1 & 2

Silo Level Monitoring (Ultrasonic Level Measurement):
• For Silo Level Monitoring .
• Installed at Bin Top (SB1)
PLC
4-20mA/Hart
Level Sensor–Siemens:
Ecomax -XPS
Transmitter: LUT400

Belt Scale:
• Material Flow Measurement(t/h) & Totalized Output.
• Installed on BC-1 & BC-2
PLC
4-20mA (Flow Rate)
Totalized PulseOutput
KG/M
4 Nos.
IPA

The whole Limestone Handling System can be divided in two
independent handling systems as listed below. Each
system can operate either independently or as both.
Control Philosophy-Lime Stone Handling
• Path – IA through BF-1, BF-2, BC-1, CR-1, BF-5, BE-1A and BF-7
• Path – IB through BF-1, BF-2, BC-1, CR-1, BF-6, BE-1B and BF-7
• Path – IIA through BF-3, BF-4, BC-2, CR-2, BF-5, BE-1A and BF-
• Path – IIB through BF-3, BF-4, BC-2, CR-2, BF-6, BE-1B and BF-7
System-2- Handling systemfromLSStorageBin SB-1up toDayBin Silos DBS-1/2througheitherof
the followingpaths–
• Path – III through RF-1, BF-8 and BE-2A
• Path – IV through RF-2, BF-9 and BE-2B
System-1 - Handling system from Underground Tunnel up to LS Storage Bin SB-1 through
either of the following paths –

The Limestone & Gypsum Handling System will be
controlled and monitored from WFGD PLC
Three position Mode Selector Switch (MSS) on OWS -
Mode – I – Operation at automatic sequentially interlocked condition
Off
Mode – II- Operation at manual sequentially interlocked condition
Control Philosophy-Lime Stone & Gypsum Handling
System
Maintenance Bypass Selector Switch (MSS) on OWS
ON – Operation at Manual De-interlocked Condition during
Maintenance
Off

 One Emergency Stop Button to stop the operation of the system in case of Emergency,
irrespective of positions Path Selector Switch and Mode Selector Switch .
 HMI On Screen Image with Running / Position / On (Red) Indication, as applicable, for
each Motors / ILMS-1 / ILMS-2/ MD-1/ MD-2/ SM-1/ SM-2/ BW-1/ BW-2/ LSU/ FG-1/
FG-2/LSU.
 HMI of Gypsum Handling System On Screen Image with Running / Position / On (Red)
Indication, as applicable, for each drives / Tripper-1/ Tripper-2/ FG-1/ FG-2
 One no. Position (Green) Indication for the following items –
Control Philosophy-Lime Stone & Gypsum Handling
System
All positions for Path Selector Switch
All positions for Mode Selector Switch
All positions for Maintenance Bypass Switch
Provision tin OWS / HMI

Local Panels for SM-1, SM-2, BW-1, BW-2, ILMS-1, ILMS-2, MD-1, MD-2 shall
have Local/ Remote Mode Selector for Operation. All Operations of such
panels shall be done and monitored from either Locally or WFGD PLC as per
mode selected.
Local Control Panels for DE-1, DE-2 shall be controlled locally. Remote
feedback regarding trip and on status shall be taken to WFGD PLC, and run
permissive shall be obtained from WFGD PLC.
VS, FS shall be have all Motor and the system will be controlled from PLC.
Motors, Flap Gates, Rack & Pinion Gate, Motorised Butterfly Valves shall be
operated through WFGD PLC.
Local Panels

Local Push Button station.
Local push Button station with One Emergency Stop
Push Button for drive for Emergency operation
Hooter
One common Hooter will be located in suitable location of the
plant area. This hooter will be activated before starting of the
operation under any path.

This system is an Individual System and it operates separately.
It is operated from the Local Control Panel
The LSU can be started, if the conveyor BC-1 or BC-2 is running and the running permissive received from WFGD
PLC.
On starting of the system knife gate position is decided as per running status of BF-5 & BF-6.The
Knife Gate is closed in event of BF-05 in running mode, where the material will be fed to the
conveyor. The Knife Gate is energized and charged in event of BF-06 in running mode, where the
material will then be fed to BF-06.
Consequently the Screw Conveyor starts after the preset time and conveys the material.
At the system will check whether bottle sample collector is in proper position for sample collection. If it is not in
the position then it will rotate for proper position. After one hour it will rotate next bottle position for sample
filling.
After the preset time the Sample divider will start to rotate and which feed sample material to bottle collector
and also feed reject material to screw conveyor as per requirement..
Lime Sampling Unit

Damper
Damper Operation – As per selected path
S
VD
P
LocalControlPanel.
Sequential
Timer Panel
WFGDPLC
Dust
Extraction
System
1 for Under
Ground
Hopper area
2 for
Crusher House
Area

• The DE system shall be controlled from LCP through start command
and feedback from WFGD PLC.
• In local mode the there also have provision for manual operation
through start/stop button from local starter panel where as motorized
actuator will be operated from in-built starter panel.
• Selected Path Feedback to be obtained from WFGD PLC
• System ON command shall be given to the DE Panel from WFGD PLC.
• The motorized valves for different paths shall be energized according
to the path selection from PLC
Dust Extraction System

Damper Operation of Dust Extraction Crusher House area
BC01 MBV101 PATH-IA/IB
BC02 MBV102 PATH-IIA/IIB
BF05 MBV103 PATH-IA/IIA
BF06 MBV104 PATH-IB/IIB
BE1A INLET MBV105A PATH-IA/IIA
BE1B INLET MBV105B PATH-IB/IIB
BF-08 MBV106A PATH-III
BF-09 MBV106B PATH-IV
BE-2A(OUTLET) MBV108A PATH-III
BE-2B(OUTLET) MBV108B PATH-IV
BE-1A MBV109A PATH-IA/IIA
BE-1B MBV109B PATH-IB/IIB
BE-2A-INLET MBV111A PATH-III
BE-2B-INLET MBV111B PATH-IV
Damper Operation of Under Ground Hopper Area
BC01-BF-01-BF-02 MBV101B PATH-IA/IB
BC02-BF-03- BF04 MBV101A PATH-IIA/IIB

Silo Fluidization System
LocalControlPanel.
WFGDPLC
Sequential
Timer Panel
SV
Compressor With
Inbuilt Starter

Silo Fluidization System
• Fluidising system consist compressor and
Sequential Timer Panel for Bin aeration.
• Each compressor having inbuilt starter and
local operation facility.
• The Fluidising System can be controlled from
the LHP Control Room.

Flap Gate (FG):
All Flap Gates shall be motorized actuator type, with power supply feeder in respective Panels. It shall be operated
From WFGD PLC.
• Feedback (F/b) & Output from WFGD PLC
• Indication on Local Panel
Rack and Pinion Gate (RPG):
Feedback (F/b) & Output from WFGD PLC
Indication on Local Panel
All Rack and Pinion Gates shall be motorized actuator type, with power supply feeder
in respective Panels. It shall be operated From WFGD PLC.

The whole Gypsum Handling System can be operated through
either of the following paths –
Control Philosophy-Gypsum Handling System
• Path – I through FG-01, BC-1A and Tripper-1
• Path – II through FG-01, BC-1B and Tripper-2
• Path – III through FG-02, BC-1B and Tripper-2
• Path – IV through FG-02, BC-1B and Tripper-1

Provision to be kept in OWS for Gypsum Handling System (contd)
a) One Emergency Stop (Red) Button to stop the operation of the system in case of
Emergency, irrespective of positions Path Selector Switch and Mode Selector Switch .
b) HMI On Screen Image with Running / Position / On (Red) Indication, as applicable, for
each drives / Tripper-1/ Tripper-2/ FG-1/ FG-2
c) One no. Position (Green) Indication for the following items –
 All positions for Path Selector Switch
 All positions for Mode Selector Switch
 All positions for Maintenance Bypass Switch

Operation Philosophy –Gypsum
Handling System
Local Push Button station.
Local push Button station for all drives have One Emergency Stop Push Button
Local Panel:
• All Motor of local Panels shall have a Local /Remote Mode Selector.
• Motors shall be in Remote mode for operation through WFGD PLC and in Local mode for
operation from Local Panels. However, there are some panels which will have only
Operation Permissive in Remote Mode, but Operation shall be done locally.
• Local Emergency Stop from LPBS can be operated provided beside each local drive
irrespective of Local / Remote Mode Selection
Hooter
One common Hooter will be located in suitable location of the plant area. This hooter will
be activated before starting of the operation under any path

Control Philosophy for Tripper panel
• Tripper Panel will be mounted on Tripper car. In Local mode same can be operated
from local panel.
• Two nos. emergency stop button is considered. One will be provided on Tripper Panel
and another will be provided fixed platform to stop the machine at any position from
Tripper panel and also from fixed platform.
• The tripper brakes and rail clamps shall be energised (and released) when the tripper
motors are ON and the brakes will be applied when the travel motors are OFF.
• Two travel limit switches (TLS & OTLS) shall be provided at either end of tripper
carriage for limiting the travel drive between two ends of the track. The first one shall
be normal limit and the second one for over travel limit.
• In addition to above, 2 Nos. position indication Limit switch for position of tripper will
be provided in Main control room.
Handling System

Tripper Control Panel
Handling System
Following individual indications shall be provided on local control panel
1) Motor ON/OFF/TRIP
2) Brakes applied
3) Rail clamps applied
4) Flap gate position
Indication of tripper flap gate positions shall be given in the main LHP control room.
Chute blockage switch shall be provided at each leg of chute and shall trip the tripper
conveyor in case of blockage.

Handling System
Belt Watch Panel (BWP):
Feedback (F/b) & Output from WFGD PLC
• PCS Operated for Each Conveyors & Belt Feeders
• BSS Operated for Each Conveyors & Belt Feeders
Indication on Local Panel
• Identification of PCS and BSS Operated.
• Mode of communication with WFGD PLC through Analog Signal Cable and
Digital Signal Cable
Flap Gates (FG-1, FG-2, 3WFG-1, 3WFG-2, 3WFG-3, 3WFG-4)
• Feedback (F/b) & Output from WFGD PLC
• All Flap Gates shall be motorized actuator type, with power supply feeder in
respective Panels. It shall be operated From WFGD PLC.

Handling System
Dust Suppression System.
• The dust suppression system mainly consists of a solenoid valve, with water pipe line
throughout the gypsum storage shade.
• The Water Pipe lines are equipped with nozzles at different strategic positions.
• The water will be available from customer’s end up to the solenoid valve at desired
pressure.
• The Solenoid Valve shall be operated from the WFGD PLC Control Room and are
included within the System operation sequence.

Control Philosophy – Start Up, Shut down &
Interlocking – Lime Stone Handling System
PATH-Selector
Switch (PSS)
PATH-IA PATH-IB PATH-IIA PATH-IIB
Operation at Automatic Sequentially Interlocked Condition
Mode Selector Switch: MSS in Mode-I (Automatic Sequentially Operation)
Maintenance Bypass Switch (MBS) on HMI Screen is kept ‘Off’ position
All respective Flap Gates (FG) on HMI Screen are kept in required position.
Level of LS Storage Bin SB-1(LI) is not high.
Start Ventilation System (VS)
All Drives and Local Panels shall be in remote mode Selected Position
PCS – not operated for the selected Path
BSS – not operated for the selected Path
Emergency Stop– not operated for the selected Path
VMS for Crusher – Not High
Temperature for Crusher – not high.
Chute Block switch not operated
Motor Protection for respective Feeders not tripped
Interlocking.

Additional
Interlocking for
Magnetic
Separators,
Suspended
Magnets, and
Metal detector
and Flap Gate
O/L Fault Relay – Not Tripped.
All Stop PB – Reset.
Metal Detector – Reset
FG – End of Travel Limit Switch – Reset
FG – Thrust Limit Switch – Reset.

Path – IA – START UP
STOP
Button
RPG1&2
Belt
Feeder1&2
Other drive Opposite
to Start Seq.
Ventilation
Fan
Path – IA – STOP
System will trip if Interlocking condition fail

Path – IB – START UP
STOP
Button
RPG1&2
Belt
Feeder1&2
to Start Seq.
Ventilation
Fan
Path – IB – STOP

Path – IIA – START UP
STOP
Button
RPG3&4
Belt
Feeder3&4
to Start Seq.
Ventilation
Fan
Path – IIA – STOP

Path – IIB – START UP
STOP
Button
RPG3&4
Belt
Feeder3&4
to Start Seq.
Ventilation
Fan
Path – IIB – STOP

PATH-Selector Switch
(PSS)
PATH-III PATH-IV
Fluidizing System shall be in ‘ON’ condition.
Level of LS Storage Bin SB-1(LI) is not LOW.
Interlocking.

START
Button
DE-2 BE-2A BF-8 RF-1
Path – III – START UP
STOP Button RF-1 BF-8 BE-2A DE-2
Path – III – STOP

PATH-Selector
Switch (PSS)
PATH-I PATH-II PATH-III PATH-IV
Flap Gate in proper position.
Under speed switch – closed at 90% speed of the conveyor within designed accelerated time.
Interlocking.
Interlocking – Gypsum Handling System

START
Button
3WFG-1
& 2 -
OPEN
BC-1A DS-SV BF-1
Path – I – START UP
STOP Button
VACCUM
FILTER
DS-SV BC-1A
3WG-1&2
CLOSE
Path – I – STOP

START
Button
3WFG-3
& 4 -
OPEN
BC-1B DS-SV BF-2
Path – II – START UP
STOP Button
VACCUM
FILTER
DS-SV BC-1B
3WG-3&4
CLOSE
Path – II – STOP

START
Button
3WFG-3
& 4 -
OPEN
BC-1B DS-SV BF-2
Path – III – START UP
STOP Button
VACCUM
FILTER
DS-SV BC-1b
3WG-3&4
CLOSE
Path – III – STOP

START
Button
3WFG-
1 & 2
OPEN
BC-1A DS-SV RBF-1
Vaccum
Filter-2
Path – IV – START UP
STOP Button
VACCUM
FILTER-2
DS-SV BC-1A
3WG-1&2
CLOSE
Path – IV – STOP

Condition Status : Normal
Control Philosophy: Annunciation & Alarm
Annunciation System on HMI/OWS will be as follows:-
Annunciation Window on OWS Screens : Off
Status indication of Equipments/ Signals : Steady Glow.
Buzzer : Off
Condition Status : Fault
Annunciation Window on OWS Screens : Blinking
Status indication of Equipments/ Signals : Fast Blinking
Buzzer : Sounding

Press Accept Button
Control Philosophy: Annunciation & Alarm
Annunciation Window on OWS Screens : Steady Glow
Status indication of Equipments/ Signals : Fast Blinking.
Buzzer : Off
Press Reset after Fault Clearance
Annunciation Window on OWS Screens : OFF
Status indication of Equipments/ Signals : Steady Blinking
Buzzer : Off
Press Reset Before Fault Clearance
Annunciation Window on OWS Screens : Steady Glow
Status indication of Equipments/ Signals : Fast Blinking
Buzzer : Off

• Overload Relay operated for all Motor Drives
• Pull Chord Switch operated for all Belt Conveyors & Belt Feeders, as applicable
• Belt Sway Switch operated for all Belt Conveyors & Belt Feeders, as applicable
• Zero Speed Switch operated for all Belt Conveyors & Belt Feeders, as applicable
• Level High of LS Storage Bin SB-1
• Level High of Sump in Underground Hopper Area.
• Chute Blocked as applicable.
Annunciation & Alarm: Limestone Handling System
Annunciation in HMI:-

Magnetic separator fault and cleaning belt trip.
Metal detector fault.
Metal Detected.
Metal detector Not Reset.
Belt weigher fault.
Sampling System fault.
Dust Extraction system fault and trips.
Emergency Stop Push Button operated.
Annunciation & Alarm: Limestone Handling System

Overload Relay operated for all Motor Drives
Pull Chord Switch operated for all Belt Conveyors & Reversible Belt Feeder, as applicable
Belt Sway Switch operated for all Belt Conveyors & Reversible Belt Feeder, as applicable
Zero Speed Switch operated for all Belt Conveyors & Reversible Belt Feeders, as applicable
Chute Plugged as applicable.
Dust Suppression Pressure Switch Low.
Emergency Stop Push Button operated.
Annunciation & Alarm: Gypsum Handling System

Instrumentation & control of typical material handling of FGD Plant

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to Instrumentation & control of typical material handling of FGD Plant

Similar to Instrumentation & control of typical material handling of FGD Plant (20)

Recently uploaded

Recently uploaded (20)

Instrumentation & control of typical material handling of FGD Plant