Operation Manual CS4 Stock House

OPERATION MANUAL(CS4)

IISCO PROJECT PLANT BLAST FURNACE

FOR IISCO B.F PLANT

2011.02

BLAST FURNACE COMPLEX

APPD.

CHKD

SUB TITLE OPERATION MANUAL(CS4)MAIN TITLE AUTOMATION SYSTEM

0SUB CONTRACTOR DRG. NO.

LDH

Appr'dHJY HJY HJY

Drawn Che'd Rev'd

SHEET NO.PROJECT DRG. NO. ISP-POSCO E&C- V-007-780-58-DOC-0114

SCALE REVCONTRACTOR DRG. NO. BF780-EJ178-0114

DATE

DESGN

INFORMATION REFERANCE

CONTRACTOR'S

IISCO STEEL PLANT,BURNPUR,WEST BENGAL2.5 MTPA NEW STREAM EXPANSION

RECORD CONSTRUCTIONCATEGORY OF

DRG. APPROVAL

MECON LIMITED

No.2011.02.28

ITEM SIGN

DRAWN0 FOR INFORMATION

Revision & DescriptionDate

Rev. No. : 0Page : 45 including cover

LIST OF CONTENTS

1. Operation for Bunker Filling group2. Operation for Coke Discharge group3. Operation for Small sinter group4. Operation for Nut coke receiving group5. Operation for Ferrous discharge group6. Operation for small sinter receiving group7. Operation for Coke Matrix8. Operation for Ferrous Matrix10. Dedusting system11. Stock House ESP system12. Hydraulic system for Stock house(HU-601)13. Hydraulic system for Transfer house(HU-602)14. Check-weighing system15. Main charging BC

Stock House System Operation ManualDoc. No. : ISP-POSCO E&C- V-007-780-58-DOC-0114

POSCO ICT

2/45Rev. No. : 0Page :

1. Operation for Bunker Filling group

※ Please refer to CI No. 14.6 & 14.7 motor in "HMI Operation Manual" document about the Direct and Reversing Motor.※ Please refer to CI No. 14.12 Binary value monitoring in "HMI Operation Manual" document about Level Switchs.

< Figure.1 >

Doc. No. : ISP-POSCO E&C- V-007-780-58-DOC-0114

Stock House System Operation Manual

Belt conveyor motor

Brake motor

Bin Level Switch

BC Level Switch

A

B

C

D

POSCO ICT




1.1 Additive & Ore Group-. Material Selection

(Kinds of texts: Iron Ore, Lime Stone, Manganese, Dolomite, Quaritze)

Operator must check kind of materials before starting filling sequence.If the selected material is different from IISCO selection, the filling sequence can not be started at semi-auto mode.

1.1.1 Operation ModeOperator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI-. Operation mode selection button There are two kinds of operation modes for Additive & ore group. If you select a mode, the color of the selected button will be changed to 'RED'.

(1) SEMI-AUTO modeIf operator wants to operate '#1~4 Add. Bin' button in 'ADDITIVE FILLING' sub window or '#1~2 Ore Bin' button in 'ORE FILLING' sub window, you should select this When operator selects #1 Add. Bin, the filling sequence for No.1 Additive bin will be started.All other operation will be performed automatically. When the selected bin level is high, the filling sequence will be stopped automatically.(All filling sequence can be started one by one by operator.)

(This window will be shown when part 'B' (figure.1) is clicked.)(This window will be shown when part 'A' (figure.1) is clicked.)

(2) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC. POSCO ICT




Basic interlocks are applied equally with SEMI-AUTO mode.Even if change to manual mode during SEMI-AUTO progress, the sequence will be not stopped until the sequence is completed or some equipments are stopped forcibly by operator.

(3) TOTAL SYSTEM RESET button

If faults are happened during sequence, click this button or each reset button which is composed on each equipment sub windows after solved causal factors.Although the reason is removed, the sequence will be not started until this button or each reset button which is composed on each equipment sub windows is clicked by operator.All of equipments which are contained in this system are affected by this button.

(4) Emergency stop button

All of equipments which are contained in this system are stopped at the same time by "Emergency stop" switch.

1.2 Sinter GroupOperator can select which bin will be used to filling sequence .

(Display in each bin)

(This window will be shown when 'C' part(figure.1) is clicked.)

A : This means that the bins will be used to filling sequence in Auto mode.B : This means that the bins will be not used to filling sequence in Auto mode.

1.2.1 Operation ModeOperator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI-. Operation mode selection button

A B

POSCO ICT




There are two kinds of operation modes for Sinter group . If you select a mode, the color of the selected button will be changed to 'RED'.

(1) AUTO modeAll monitoring and control functions will be performed automatically via PLC(Programmable Logic Controller) and HMI.

At 'AUTO' mode, sinter filling sequence will be operated automatically by bin levelA "Stop" switch is used to do stop all related conveyors sequentially.

(2) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Basic interlocks are applied equally with AUTO mode.Even if change to manual mode during AUTO progress, the sequence will be not stopped until the sequence is completed or some equipments are stopped forcibly by operator.





POSCO ICT




1.3 Coke-1 Group(Using KC-1A)-. Equipments: CRC-1, CRSC-1, CRSC-2Operator can select which bin will be used to filling sequence .

(Display in each bin)

(This window will be shown when 'D' part(figure.1) is clicked.)Operator can select only one button among three.(Using KC-1A or Using KC-2A or Out of Service)The bins which are selected as 'out of service' will be excepted from coke filling sequence.

1.3.1 Operation ModeOperator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI-. Operation mode selection button There are two kinds of operation modes for Coke group. If you select a mode, the color of the selected button will be changed to 'RED'.


At 'AUTO' mode, sinter filling sequence will be operated automatically by bin levelA "Stop" switch is used to do stop all related conveyors sequentially.

(2) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Basic interlocks are applied equally with semi-auto mode.

POSCO ICT

Mr. R. P. Mondal

Sticky Note

How 60-80mm coke will be selected & filled?




Even if change to manual mode during progress of sequence at semi-auto mode, the sequence will be not stopped-until the sequence is completed or some equipments are stopped forcibly by operator.





1.3 Coke-2 Group(Using KC-2A)Please refer to 1.2 Coke-1 Group(Using KC-1A)-. Equipments: CRC-2, CRSC-3, CRSC-4

POSCO ICT




2. Operation for Coke Discharge group

※ Please refer to CI No. 14.6 & 14.7 motor in "HMI Operation Manual" document about the Direct and Reversing Motor.※ Level Switch: No. 14.12, VFD: No. 14.5, Valve: No. 14.9 &14.10

< Figure.2 >

B C

A

Coke Group

Small sinter Group

Nut CokeGroup

D

POSCO ICT




2.1 Operation ModeOperator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI2.1.1 Operation mode selection button There are four kinds of operation modes for Coke System. If you select a mode,the color of the selected button will be changed to 'RED'.

(1)

(2)

(3)

(4)


`

When operators push the "START" button, the coke batch sequence will be started automatically by MATRIX selection.A "Stop" switch is used to do stop all related screens, VFD, conveyors sequentially.

(2) SEMI-AUTO modeOperator can control some parts of equipments by using Fill Start or Discharge Start in 'CSH CONTROL' or 'CWH CONTROL' sub window.If operator wants to operate 'FILL START' or 'DISCHARGE START' button in 'CSH CONTROL' sub window, you should select this mode.All other operation will be performed automatically.The biggest difference of Auto mode and Semi-auto mode is that Auto mode controls all equipments continually automatically, otherwise Semi-auto mode controls some part of equipments automatically during 1 batch.

CSH Control

POSCO ICT

10/45Rev. No. : 0Page :



Before click 'Fill start' S/W in 'CSH CONTROL' sub window, you should select CWH which will be used in this sequence at 'CWH CONTROL'.

(3)AUTO O/R mode(Auto override mode)Auto override mode can be used during Auto or Semi-auto mode operation.During auto sequence, although AUTO O/R mode is selected, Auto and Semi-auto mode operation will go on.and it gives operator the ability to command forcibly "Full", "Empty" signals to coke weighing and surge hopper.

(4) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Operator can drive all equipments which are selected remote regardless of the matrix line, and matrix doesn't progress at this mode.Basic interlocks are applied equally with AUTO and SEMI-AUTO mode.Even if change to manual mode during AUTO or SEMI-AUTO progress, the sequence will be not stopped-until the sequence is completed or some equipments are stopped forcibly by operator.



CWH Control

POSCO ICT

11/45Rev. No. : 0Page :




All equipments are stopped at the same time by "Emergency stop" switch.

2.2 Sub window 2.2.1 CWH CONTROL

(1)

(2)

*SV: Target value(ton) PV: Weighing result value(ton)

(3)

(This window will be shown when 'A' part(figure.2) is clicked.)

(1) FILL START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and coke weighing hopper is empty, operator can use the 'fill start' switch. All other related equipments will be performed automatically

(2) FILL STOP ON/OFF SELECTIONOperator can select filling hopper by using 'fill stop' ON, OFF selection.If operator selects "fill stop ON" during auto sequence progress, the sequence will be stopped after the sequence is completed.And next fill sequence for the hopper may not progress until 'fill stop ON' is changed to 'fill stop OFF'.

POSCO ICT

12/45Rev. No. : 0Page :



(3) OVERRIDE Full/Empty S/W This is only for AUTO override mode.

When operator selects AUTO O/R mode, it gives operator the ability to command forcibly "Full", "Empty" signals to coke weighing hopper(CWH).This only means 'full' or 'empty' within the framework of software, it doesn't mean that a state of hopper is full or empty.

2.2.2 CSH CONTROL

(1)

(2)

(3)

(4)*PV: Weighing result value(ton)

(5) MO: Moisture rate(%)

(6)

(7)(This window will be shown when 'B' part(figure.2) is clicked.)

(1) MATRIX STEP UP S/WCoke weighing hopper used in every batch will be selected in coke matrix on HMI. In the situation that all coke surge hoppers are selected fill stop "ON", operator can forcibly progress one coke batch line with using 'matrix step up' S/W.

(2) HOPPER SELECTION S/WCoke surge hopper will be selected by using hopper selection S/W during Auto and Semi-auto mode.If "1" is selected by operator, No.2 hopper will be not processed coke fill and discharge sequence in auto and semi-auto mode,and "NOT SERVICE" is showed above No.2 hopper on HMI.

(3) FILL START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and coke surge hopper is empty, operator can use the 'fill start' switch. All other related equipments will be performed automatically

POSCO ICT

13/45Rev. No. : 0Page :



(4) FILL STOP ON/OFF SELECTIONOperator can select filling hopper by using 'fill stop' ON, OFF selection, without changing of hopper selection.If operator selects "fill stop ON" during auto sequence progress, the sequence will be stopped after the sequence is completed.And next fill sequence for the hopper may not progress until 'fill stop ON' is changed to 'fill stop OFF'.


When operator selects AUTO O/R mode, it gives operator the ability to command forcibly "Full", "Empty" signals to coke surge hopper(CSH).This only means 'full' or 'empty' within the framework of software, it doesn't mean that a state of hopper is full or empty.

(6) DISCHARGE START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and coke surge hopper is full, operator can use the 'discharge start' switch. All other related equipments will be performed automatically

(7) DISCHARGE STOP ON/OFF SELECTIONOperator can select discharge hopper by using 'discharge stop' ON, OFF selection, without changing of hopper selection.If operator selects discharge stop "ON" S/W during auto sequence progress, the sequence will be stopped after the sequence is completed. And next discharge sequence for the hopper may not progress until 'discharge stop ON' is changed to 'discharge stop OFF'.

2.3 Belt conveyor main motor selection

Operator can select which motor is used main or stand-by for BFC-1 BCIf main selection motor has fault during operation, the main motor selection will be changed to another motor automatically.

2.4 Coke Fne Bin selection

*Direct CFB: Direct coke fine bin, CFB: Coke Fine BinBefore started coke sequence, operator must select using coke fine binIf selected bin has fault by level High during operation, the selected bin will be changed to another bin automatically.

POSCO ICT

14/45Rev. No. : 0Page :



3. Operation for Small sinter group(*Refer to Figure.2)3.1 Operation Mode

Operator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI3.1.1 Operation mode selection button There are four kinds of operation modes for small sinter group. If you select a mode,the color of the selected button will be changed to 'RED'.

(1)

(2)

(3)

(4)


When operators push the "START" button, the small sinter sequence will be started automatically.SSWH must be empty to start auto sequence.A "STOP" switch is used to do stop all related VFD, conveyors sequentially.

(2) SEMI-AUTO modeOperator can control some parts of equipments by using Fill Start or Discharge Start in 'SSWH CONTROL' sub window.If operator wants to operate 'FILL START' or 'DISCHARGE START' button in 'SSWH CONTROL' sub window, you should select this mode.All other operation will be performed automatically.The biggest difference of Auto mode and Semi-auto mode is that Auto mode controls all equipments continually automatically, otherwise Semi-auto mode controls some part of equipments automatically during 1 batch.

POSCO ICT

15/45Rev. No. : 0Page :



(3)AUTO O/R modeAuto override mode can be used during Auto or Semi-auto mode operation.During auto sequence, although AUTO O/R mode is selected, Auto and Semi-auto mode operation will go on.and it gives operator the ability to command forcibly "Full", "Empty" signals to small sinter weighing hopper.

(4) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Basic interlocks are applied equally with AUTO and SEMI-AUTO mode.Even if change to manual mode during AUTO or SEMI-AUTO progress, the sequence will be not stopped-until the sequence is completed or some equipments are stopped forcibly by operator.





POSCO ICT

16/45Rev. No. : 0Page :



3.2 Sub window 3.2.1 SSWH CONTROL

(1)

(2)

(3)

(4)*SV: Target value(ton)

(5) PV: Weighing result value(ton)

(6)

(This window will be shown when 'C' part(figure.2) is clicked.)(1) VFD SELECTION S/W

Using VFD will be selected by VFDselection S/W during Auto and Semi-auto mode.If "1" is selected by operator, No.2 VFD will be not used for small sinter fill sequence in auto and semi-auto mode.If "1+2" is selected, two VFDs will be run at the same time.*"1": No.1 Small sinter VFD(VFD631)*"2": No.2 Small sinter VFD(VFD632)

(2) FILL START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and small sinter weighing hopper is empty, operator can use the 'fill start' switch. All other related equipments will be performed automatically


POSCO ICT

17/45Rev. No. : 0Page :




When operator selects AUTO O/R mode, it gives operator the ability to command forcibly "Full", "Empty" signals to small sinter weighing hopper(SSWH).This only means 'full' or 'empty' within the framework of software, it doesn't mean that a state of hopper is full or empty.

(6) DISCHARGE START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and SSWH is full, operator can use the 'discharge start' switch. All other related equipments will be performed automatically

(7) DISCHARGE STOP ON/OFF SELECTIONOperator can select discharge hopper by using of 'discharge stop' ON, OFF selection.If operator selects discharge stop "ON" S/W during auto sequence progress, the sequence will be stopped after the sequence is completed. And next discharge sequence for the hopper may not progress until 'discharge stop ON' is changed to 'discharge stop OFF'.

3.3 Belt conveyor main motor selection

Operator can select which motor is used main or stand-by for BFC-3 BCIf main selection motor has fault during operation, the main motor selection will be changed to another motor automatically.

4. Operation for Nut coke receiving group(*Refer to Figure.2)4.1 Operation Mode

Operator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI4.1.1 Operation mode selection button There are two operation modes for nut coke receiving System. If you select a mode,the color of the selected button will be changed to 'RED'.

(1)

(2)


POSCO ICT

18/45Rev. No. : 0Page :



When operators push the "START" button, the nut coke sequence will be started automatically.Nut coke bin must be not level high to start auto sequence.A "STOP" switch is used to do stop all related VFD and screen, conveyors sequentially.PLC operates all the equipments automatically.

(2) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Basic interlocks are applied equally with AUTO mode.Even if change to manual mode during AUTO progress, the sequence will be not stopped until the sequence is completed or some equipments are stopped forcibly by operator.





POSCO ICT

19/45Rev. No. : 0Page :



4.2 Sub window 4.2.1 FCC-3 BC Request "start" or "stop"(TO IISCO).

(This window will be shown when 'D' part(figure.2) is clicked.)*VFD-629(Direct coke fine bin VFD) has only manual mode. This equipment is unrelated to nut coke group.

POSCO ICT

20/45Rev. No. : 0Page :



5. Operation for Ferrous discharge group

※ Please refer to CI No. 14.6 & 14.7 motor in "HMI Operation Manual" document about the Direct and Reversing Motor.※ Level Switch: No. 14.12, VFD: No. 14.5, Valve: No. 14.9 &14.10

< Figure.3 >

A

Ferrous Group

Small sinter Rec.Group

BD

C

POSCO ICT

21/45Rev. No. : 0Page :



5.1 Operation ModeOperator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI

5.1.1 Operation mode selection button There are four operation modes for Ferrous System. If you select a mode,the color of the selected button will be changed to 'RED'.

(1)

(2)

(3)

(4)


`

When operators push the "START" button, the coke batch sequence will be started automatically by MATRIX selection.A "Stop" switch is used to do stop all related screens, VFD, conveyors sequentially.

(2) SEMI-AUTO modeOperator can control some parts of equipments by using Fill Start or Discharge Start in 'FSH CONTROL' or 'FWH CONTROL' sub window.If operator wants to operate 'FILL START' or 'DISCHARGE START' button in 'FSH CONTROL' sub window, you should select this mode.All other operation will be performed automatically.The biggest difference of Auto mode and Semi-auto mode is that Auto mode controls all equipments continually automatically, otherwise Semi-auto mode controls some part of equipments automatically during 1 batch.

FSH Control

POSCO ICT

22/45Rev. No. : 0Page :



Before click S/W 'Fill start' in 'FSH CONTROL' sub window, you should select FWH which will be used in this sequence at 'FWH CONTROL'.

(FWH Control)

(3)AUTO O/R modeAuto override mode can be used during Auto or Semi-auto mode operation.During auto sequence, although AUTO O/R mode is selected, Auto and Semi-auto mode operation will go on.and it gives operator the ability to command forcibly "Full", "Empty" signals to ferrous weighing and surge hopper.

(4) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Operator can drive all equipments which are selected remote regardless of the matrix line, and matrix doesn't progress at this mode.Basic interlocks are applied equally with AUTO and SEMI-AUTO mode.Even if change to manual mode during AUTO or SEMI-AUTO progress, the sequence will be not stopped-until the sequence is completed or some equipments are stopped forcibly by operator.



POSCO ICT

23/45Rev. No. : 0Page :





5.2 Sub window 5.2.1 FWH CONTROL

(1)

(2)

*SV: Target value(ton)PV: Weighing result value(ton)

(3)

(This window will be shown when 'A' part(figure.3) is clicked.)

(1) FILL START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and ferrous weighing hopper is empty, operator can use the 'fill start' switch. All other related equipments will be performed automaticallyYou can start fill sequence for sinter, additive, ore and nut coek in "FWH CONTROL" sub window. (A = Additive, O = Ore, S = Sinter, NC = Nut Coke)


POSCO ICT

24/45Rev. No. : 0Page :




When operator selects AUTO O/R mode, it gives operator the ability to command forcibly "Full", "Empty" signals to ferrous weighing hopper(FWH).This only means 'full' or 'empty' within the framework of software, it doesn't mean that a state of hopper is full or empty.

5.2.2 FSH CONTROL

(1)

(2)

(3)

(4)*PV: Weighing result value(ton)

(5)

(6)

(7)(This window will be shown when 'B' part(figure.3) is clicked.)

(1) MATRIX STEP UP S/WFerrous weighing hopper used in every batch will be selected on ferrous matrix in HMI. In the situation that all ferrous surge hoppers are selected fill stop "ON", operator can forcibly progress one ferrous batch line with using 'matrix step up' S/W.

(2) HOPPER SELECTION S/WFerrous surge hopper will be selected by using hopper selection S/W during Auto and Semi-auto mode.If "1" is selected by operator, No.2 hopper will be not processed ferrous fill and discharge sequence in auto and semi-auto mode,and "NOT SERVICE" is shown above No.2 hopper on HMI.

(3) FILL START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and ferrous surge hopper is empty, operator can use the 'fill start' switch. All other related equipments will be performed automatically

POSCO ICT

25/45Rev. No. : 0Page :



(4) FILL STOP ON/OFF SELECTIONOperator can select filling hopper by using 'fill stop' ON, OFF selection, without changing of hopper selection.If operator selects "fill stop ON" during auto sequence progress, the sequence will be stopped after the sequence is completed.And next fill sequence for the hopper may not progress until 'fill stop ON' is changed to 'fill stop OFF'.


When operator selects AUTO O/R mode, it gives operator the ability to command forcibly "Full", "Empty" signals to ferrous surge hopper(FSH).This only means 'full' or 'empty' within the framework of software, it doesn't mean that a state of hopper is full or empty.

(6) DISCHARGE START S/WThis is only for Semi-auto mode.If operation mode is selected as 'semi-auto' and ferrous surge hopper is full, operator can use the 'discharge start' switch. All other related equipments will be performed automatically

(7) DISCHARGE STOP ON/OFF SELECTIONOperator can select discharge hopper by using 'discharge stop' ON, OFF selection, without changing of hopper selection.If operator selects discharge stop "ON" S/W during auto sequence progress, the sequence will be stopped after the sequence is completed. And next discharge sequence for the hopper may not progress until 'discharge stop ON' is changed to 'discharge stop OFF'.

5.2.3 FOC-3 BC Request "start" or "stop"(TO IISCO).

(This window will be shown when 'C' part(figure.3) is clicked.)Operator can select which motor is used main or stand-by for BFC-1 BCIf main selection motor has fault during operation, the main motor selection will be changed to another motor automatically.

5.3 Sinter fine bin selection

*Direct SFB: Direct Sinter Fine Bin, SFB: Sinter Fine BinBefore started ferrous sequence, operator must select using sinter fine binIf selected bin has fault by level High during operation, the selected bin will be changed to another bin automatically.

POSCO ICT

26/45Rev. No. : 0Page :



5.4 Ore gathering BC main selection

*Main selection signal is from Local. Operator can not select main motor.

6. Operation for small sinter receiving group(*Refer to Figure.3)6.1 Operation Mode

Operator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI6.1.1 Operation mode selection button There are two operation modes for small sinter receiving System. If you select a mode, the color of the selected button will be changed to 'RED'.

(1)

(2)


When operators push the "START" button, the small sinter receiving group sequence will be started automatically.The selected fine bin must be not level high to start auto sequence.A "STOP" switch is used to do stop all related VFD and screen, conveyors sequentially.PLC operates all the equipments automatically.

(2) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Basic interlocks are applied equally with AUTO mode.

POSCO ICT

27/45Rev. No. : 0Page :



Even if change to manual mode during AUTO progress, the sequence will be not stopped until the sequence is completed or some equipments are stopped forcibly by operator.





6.2 Sub window 6.2.1 FSC-3 BC Request "start" or "stop"(TO IISCO).

(This window will be shown when 'D' part(figure.3) is clicked.)*VFD-614(Direct sinter fine bin VFD) has only manual mode. This equipment is unrelated to small sinter receiving group.

6.3 Small sinter bin selection

*#1 BIN: No.1 small sinter bin, #2 BIN: No.2 small sinter binBefore started ferrous sequence, operator must select using small sinter binIf selected bin has fault by level High during operation, the selected bin will be changed to another bin automatically.

POSCO ICT

28/45Rev. No. : 0Page :



7. Operation for Coke Matrix

< Figure. 4 >

Only for C3

POSCO ICT

29/45Rev. No. : 0Page :



7.1 Screen selection (in "1~6 CWH")Matrix consists of 12 batch lines and coke screen to be used in each batch will be selected by mouse clicking on HMI.The color of screen which is selected will be changed to "Red".

7.2 Batch No.Now coke batch number display with red colour.

7.3 GO TOOperator can set the number between 0 and 12.If filling sequence is completed in the concerned batch line and GOTO number is 0(zero), the matrix number will be step up to next line.In this time, if GO TO number is not 0, matrix may progress accoding to GO TO number.When all screens stopped, operator can forcibly progress the batch line using 'matrix step up' S/W in CSH CONTORL sub window.For example, the batch sequence at above picture(Figure.4) is 1-->2-->5-->1-->2-->5-->1-->…….(If start batch No. is 1):

7.4 Batch line for C3No.5 Batch line is only for C3 mode.When present batch line is No.5, the filling sequence is called C3 set value

POSCO ICT

30/45Rev. No. : 0Page :



8. Operation for Ferrous Matrix

< Figure. 5 >POSCO ICT

31/45Rev. No. : 0Page :



8.1 Screen or VFD selectionMatrix consists of 12 batch lines and the sinter, ore and additive screen to be used in each batch will be selected by mouse clicking on HMI.The color of screen which is selected will be changed to "Red".*AWH-1,2: For Additive OWH-1,2: For Ore SWH-1~6: For Sinter NCWH: For Nut coke

8.2 Batch No.Now coke batch number display with red colour.

8.3 GO TOOperator can set the number between 0 and 12.If filling sequence is completed in the concerned batch line and GOTO number is 0(zero), the matrix number will be step up to next line.In this moment, matrix will go to the batch line of GOTO number previously set if set GOTO number is not 0(zero).When all screens stop, operator can forcibly progress the batch line using 'matrix step up' S/W in CSH CONTORL sub window.For example, the batch sequence at above picture(Figure.5) is 1-->2-->3-->1-->2-->3-->1-->…….(If start batch No. is 1)

POSCO ICT

32/45Rev. No. : 0Page :



9. Weighing control data for stock house system

※ Please refer to CI No. 14.2 Analogue value monitoring in "HMI Operation Manual" document about Analogue value.< Figure. 6 >

POSCO ICT

33/45Rev. No. : 0Page :



9.1 Set value & Present value(The colour of character)Characters which can set by operator have 'GREEN' colour. If it has 'BLUE' colour, it means that operator can't change the data.

9.2 ACC. ERROR-. Accumulator error = Weighing result value - Target value

9.3 ERROR MAX-. Limit value of Acc. Error(maximum and minimum)If Error max. value is 3, error value ==> -3≤ACC. ERROR≤+3

9.4 TARGET VALUE-. SV-Acc.error+Net weight at fill sequence start

9.5 WEIGHING RESULT VALUE-. Net weight(screen stopped and after 5seconds)

9.6 TOTAL WEIGHT-. Local raw data

9.7 TARE WEIGHT-. Set value by operator

9.8 NET WEIGHT-. Total weight - Tare weight

9.9 OVERWEIGHT-. When Total weight is over this value, Screen and VFD will be stopped and then Hopper will be FULL.

9.10 EMPTY JUDGEMENT-. When Net weight is under this value, Hopper will be EMPTY.

9.11 DISCHARGE TIME-. After gate opens, time that take to empty

9.12 C3 SET VALUE(Only for cokes)-. Set value for C3 Sequence.

9.13 Moisture mode selectPOSCO ICT

34/45Rev. No. : 0Page :



There are two operation modes for moisture compensation of Coke-System. If you select a mode, the color of the selected button will be changed to 'RED'.

(1) AUTO mode-Each coke surge hopper contains a moisture detector probe that is used to measure moisture content in the coke.-Moisture(AUTO) : When operators select 'AUTO' mode, the moisture compensation rate is calculated with this value.-The value is affected by 'HIGH LIMIT' and 'LOW LIMIT'.

(2) MANUAL mode-Moisture(MANUAL) : When operators select 'MANUAL' mode, the moisture compensation rate is calculated with set value by operator on HMI.

POSCO ICT

35/45Rev. No. : 0Page :



10. Dedusting system

※ Please refer to CI No. 14.10 Open/Close valve(double) in "HMI Operation Manual" document about Double valves.< Figure. 7 >

A

POSCO ICT

36/45Rev. No. : 0Page :



10.1 Operation ModeOperator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI-. Operation mode selection button There are two kinds of operation modes for Additive group. If you select a mode, the color of the selected button will be changed to 'RED'.

Although the group mode is selected as 'AUTO', Operators can change mode to 'MANUAL' by using each damper faceplate.

10.1.1 Auto mode A damper will open or close automatically when related equipments are run or open in Auto mode.

10.1.2 Manual modeOperator can operate each damper without any interlock.

POSCO ICT

37/45Rev. No. : 0Page :



11. Stock House ESP system

※ Please refer to CI No. 14.6 & 14.7 motor in "HMI Operation Manual" document about the Direct and Reversing Motor.※ Please refer to CI No. 14.12 Binary value monitoring in "HMI Operation Manual" document about Level Switchs.

< Figure. 8 >

Only Localoperation

POSCO ICT

38/45Rev. No. : 0Page :



11.1 Operation ModeOperator can select two operation modes except "local mode" by using "mode selection button" which is composed on HMI

11.1.1 Operation mode selection button There are two kinds of operation modes for ESP System. If you select a mode, the color of the selected button will be changed to 'RED'.


At 'AUTO' mode, ESP sequence will be operated automatically by dust silo bin level except ID Fan & Damper & Hyd. Pump.A "Stop" switch is used to do stop all related equipments sequentially.

(2) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Basic interlocks are applied equally with automatic mode.==> Dust silo handling system sequence can be operated only at local. Operator can't any operation action on HMI.




All of equipments which are contained in this system are stopped at the same time by "Emergency stop" switch except ID Fan, Hyd. Pump and damper.POSCO ICT

39/45Rev. No. : 0Page :



11.2 ID Fan & Damper & Hyd. Pump-. These equipments are not included in the ESP group mode. ID Fan and Hyd. Pump has its own distinct mode from other ESP group.

11.2.1 ID FanID Fan has only manual mode. Operator cannot change to auto mode.

11.2.2 ID Fan Damper controlIf you want open damper, first of all ID Fan and a hyd. Pump must be running.

(1)

(2)

(1) PV : present value from local

(2) SV : set by operator(0~100%)

11.2.3 Hydraulic pumpHydraulic pump has only manual mode. Operator cannot change to auto mode.This pump is constantly running irrespective of requirement of movement of actuator or not.Only at the time of maintenanc & shut down motor is switched off.

POSCO ICT

40/45Rev. No. : 0Page :



12. Hydraulic system for Stock house(HU-601)

※ Please refer to CI No. 14.15 Group Start in "HMI Operation Manual" document about the Pumps.※ Level Switch: No. 14.12, Valve: No. 14.9 &14.10

< Figure. 9 >

A B

C

Main Hyd. Pump groupCirculation Pump

group

POSCO ICT

41/45Rev. No. : 0Page :



12.1 Main hydraulic pump groupOperator can select two operation modes except "local mode" by using "mode selection button" which is composed on HMI

12.1.1 Operation Mode(Refer to "A" part) There are two kinds of operation modes for Hyd. Pump group. If you select a mode, the color of the selected button will be changed to 'RED'.

(1)AUTO modeThe Working and stand-by selections of hydraulic pumps are composed on HMI.(1 Working, 1 Stand-by)In case of initial start, the working pump is started by group start button and stand-by pump will be driven automatically by PLC at the oil pressure low.All monitoring and control functions will be performed via PLC(Programmable Logic controller) and HMI.


12.2 Circulation pump groupOperator can select two operation modes except "local mode" by using "mode selection button" which is composed on HMI

12.2.1 Operation Mode(Refer to "B" part) There are two kinds of operation modes for Cir. Pump group. If you select a mode, the color of the selected button will be changed to 'RED'.

(1)AUTO modeThe Working and stand-by selections of hydraulic pumps are composed on HMI.(1 Working, 1 Stand-by)In case of initial start, the working pump is started by group start button and stand-by pump will be driven automatically by PLC at the oil pressure low.All monitoring and control functions will be performed via PLC(Programmable Logic controller) and HMI.


12.3 Grease unit(Refer to part 'C' of figure.9)It is only display. Operators can't any operation action on HMI.

13. Hydraulic system for Transfer house(HU-602)*Philosophy of Hydraulic system for transfer house is exactly same with stock house hydraulic system.

POSCO ICT

42/45Rev. No. : 0Page :



14. Check-weighing system

※ Please refer to CI No. 14.9 & 14.10 open/close valve in "HMI Operation Manual" document about the Single and the Double valves.※ Please refer to CI No. 14.3 PID Control in "HMI Operation Manual" document about Control valves.

< Figure. 10 >

SHS Group

TFS Group

POSCO ICT

43/45Rev. No. : 0Page :



14.1 Operation ModeOperator can select all kinds of operation modes except "local mode" by using "mode selection button" which is composed on HMI

14.1.1 Operation mode selection button There are two kinds of operation modes for Sinter group . If you select a mode, the color of the selected button will be changed to 'RED'.

(1) Semi-AUTO modeAll monitoring and control functions will be performed automatically via PLC(Programmable Logic Controller) and HMI.The buttons which are located above each bin are used for Semi-auto mode.When operator selects #1 AWH, the check-weighing sequence for No.1 AWH will be started.(All check-weighing sequence can be started by one hopper at a time by operator.)

(2) MANUAL modeAll control operations will be performed step by step by operator.Operator can operate related equipments by using sub-window of each equipments which are composed on HMI,All controls are performed by PLC.Basic interlocks are applied equally with SEMI-AUTO mode



14.2 Explain each item-. CHECK W. SV: Set value by operator-. CHECK W. PV: Check weighing load cell value-. WEIGHING PV: Hopper weighing load cell value-. DIFFERENCE: CHECK W. PV - WEIGHING PV

POSCO ICT

44/45Rev. No. : 0Page :



15. Main charging BC

※ Please refer to CI No. 14.5 motor in "HMI Operation Manual" document about the VFD Motor.< Figure.11 >

Display (Alarm hornfeedback signal)

Only alarmmessage

POSCO ICT

45/45Rev. No. : 0Page :



15.1 The BF Charging BC has only group start & stop. It is impossible to start individually in manual mode.

15.2 Operator can change VFD speed only in CFC chart of PLC program.

POSCO ICT

Operation Manual CS4 Stock House

Documents

Transcript of Operation Manual CS4 Stock House