CUSTOMER: Codelco Chuquicamata, Chile KUMERA TECHNOLOGY CENTER

CONTRACT: 4501679027 435106 01

KUMERA STEAM DRYER
I/O LIST - STEAM DRYER Project: 2191
REV. DATE DRAWN CHANGE
J 8.9.2017 MSR
K 19.9.2017 MSR
L 3.10.2017 MSR
M 27.10.2017 MSR
(1) Signals to plant control system PDCS
(2) Safety relay by others

SLOT FUSE CARD SHEET ADDR ID ID DEVICE SERVICE REV.

I/O (Electric) (PID)
NO

KUMERA CUSTOMER /
SUB CONTRACTOR

A.CPU - CENTRAL PROCESSING UNIT

A.CPU1 - Central processing unit
00.0 F.CPU1 -A.CPU1 20 Central processing unit
00.1 -A.CPU1.COM communication module ethernet to DCS

A.CPU2 - Central processing unit

01.0 F.CPU2 -A.CPU2 20 Central processing unit
01.1 -A.CPU2.COM communication module ethernet to DCS

A.DIO0 - DISTRIBUTED IO-UNIT IN DRYER CONTROL ROOM

Distributed IO-unit in field, -A.DIO0 - Communication modules
10.0 F.DIO2 -A.DIO0.IM1 23 interface module ethernet

Distributed IO-unit in control room, -A.DIO0 - Digital inputs

10.1 F.I1001 -A.DIO0.I1001 40 I10.01.00 PDCS XY-03.04.01 (1) plant system digital output permission from plant system for dry material output
Dig. Inp. I10.01.01 PDCS XY-03.04.02 (1) plant system digital output permission from plant system for reject material output
16*120Vac I10.01.02 -KES1 (2) safety relay safety relay status, 1= ok
I10.01.03 MCC G-29.01.01 (1) plant system digital output dryer electric supply status, 1= supply normal J
I10.01.04 MCC G-29.01.02 (1) plant system digital output dryer electric supply status, 1= reserve supply on to dryer J
I10.01.05
I10.01.06
I10.01.07
41 I10.01.08
I10.01.09
I10.01.10
I10.01.11
I10.01.12
I10.01.13
I10.01.14
I10.01.15

Distributed IO-unit in control room, -A.DIO0 - Digital outputs

10.2 F.Q1002 -A.DIO0.Q1002 60 Q10.02.00 PDCS XY-02.00.02 (1) plant system digital input permission to plant system to feed wet material
Dig. Out. Q10.02.01
8*relay Q10.02.02
Q10.02.03
Q10.02.04
Q10.02.05
Q10.02.06
Q10.02.07

Distributed IO-unit in control room, -A.DIO0 - Analog inputs

10.3 F.AI1003 A.DIO0.AI1003 88 IW10.03.00 PDCS FT-2.0.01 (1) plant system analog output material feedrate from plant system
Analog input IW10.03.01 PDCS LT-8.11.01 (1) plant system analog output condensate tank level (option) L
8* 4…20mA IW10.03.02
IW10.03.03
IW10.03.04
IW10.03.05
IW10.03.06
IW10.03.07

1/8 27.11.2017
SLOT FUSE CARD SHEET ADDR ID ID DEVICE SERVICE REV.
I/O (Electric) (PID)
NO

A.DIO2 - DISTRIBUTED IO-UNIT NEAR STEAM DRYER

Distributed IO-unit in field, -A.DIO2 - Communication modules
20.0 F.DIO2 -A.DIO2.IM1 23 Eth ? interface module ethernet
20.1 -A.DIO2.OT optical tranceiver ethernet, copper / fibre optics

Distributed IO-unit in field, -A.DIO2 - Digital inputs

20.8 F.I2008 -A.DIO2.I2008 42 I20.08.00 K
Dig. Inp. I20.08.01 S121C02 M-1.2.1 push button speed adjusting of main drive, 1 pulse = speed up
16*120Vdc I20.08.02 S121C03 M-1.2.1 push button speed adjusting of main drive, 1 pulse = speed down
I20.08.03 S121C04 M-1.2.1 push button start drum forward, 1 pulse = start
I20.08.04 S121C05 M-1.2.1 push button start drum reverse, 1 pulse = start reverse
I20.08.05 S121C06 M-1.2.1 push button stop drum, 0 pulse = stop
I20.08.06 S121C09 push button system reset, 1 = reset
I20.08.07 B.LS08106 LS-8.1.6 level switch flash tank level, 0= high-high
43 I20.08.08 B.LS020104 LS-2.1.4 level switch level of dry material hopper, 0=low I
I20.08.09 B.LS030106 LS-03.01.06 level switch level of concentrate in discharge end, 0=high-high
I20.08.10 B.LS030112 LS-03.01.12 level switch level of concentrate in discharge end, 0=high-high
I20.08.11 B.LS030110 LS-03.01.10 level switch level of reject hopper, 0=high-high
I20.08.12 A1.3 A-1.3-XI fault alarm lubrication unit of girth gear, 0 = alarm
I20.08.13 B.XS01205 XS-1.2.5 limit switch, brake 1 status of brake, 1=open
I20.08.14 B.XS01215 XS-1.2.15 limit switch, brake 2 status of brake, 1=open
I20.08.15 B.LS060101 LS-06.01.01 LSH-1100 level switch dust level in bag filter, highhigh, 0=above limit, hopper 1
20.9 F.I2009 -A.DIO2.I2009 44 I20.09.00 B.LS060102 LS-06.01.02 LSH-1200 level switch dust level in bag filter, highhigh, 0=above limit, hopper 2
Dig. Inp. I20.09.01 B.LS060103 LS-06.01.03 LSH-1300 level switch dust level in bag filter, highhigh, 0=above limit, hopper 3
16*120Vdc I20.09.02 B.LS060104 LS-06.01.04 LSH-1400 level switch dust level in bag filter, highhigh, 0=above limit, hopper 4
I20.09.03 A.060311XI1 A-06.03.11-XI1 KC-1104 cleaning control unit status, 1= last pulse active, chamber 1 F
I20.09.04 A.060311XI2 A-06.03.11-XI2 KY-1104 cleaning control unit mode, 1=forced cleaning on, chamber 1 F
I20.09.05 A.060311XI3 A-06.03.11-XI3 PSL-1104 cleaning control unit cleaning pressure detection, 1= ok in chamber 1 F
I20.09.06 A.060312XI1 A-06.03.12-XI1 KC-1204 cleaning control unit status, 1= last pulse active, chamber 2 F
I20.09.07 A.060312XI2 A-06.03.12-XI2 KY-1204 cleaning control unit mode, 1=forced cleaning on, chamber 2 F
45 I20.09.08 A.060312XI3 A-06.03.12-XI3 PSL-1204 cleaning control unit cleaning pressure detection, 1= ok in chamber 2 F
I20.09.09 A.060313XI1 A-06.03.13-XI1 KC-1304 cleaning control unit status, 1= last pulse active, chamber 3 F
I20.09.10 A.060313XI2 A-06.03.13-XI2 KY-1304 cleaning control unit mode, 1=forced cleaning on, chamber 3 F
I20.09.11 A.060313XI3 A-06.03.13-XI3 PSL-1304 cleaning control unit cleaning pressure detection, 1= ok in chamber 3 F
I20.09.12 A.060314XI1 A-06.03.14-XI1 KC-1404 cleaning control unit status, 1= last pulse active, chamber 4 F
I20.09.13 A.060314XI2 A-06.03.14-XI2 KY-1404 cleaning control unit mode, 1=forced cleaning on, chamber 4 F
I20.09.14 A.060314XI3 A-06.03.14-XI3 PSL-1404 cleaning control unit cleaning pressure detection, 1= ok in chamber 4 F
I20.09.15 H
20.1 F.I2010 -A.DIO2.I2010 46 I20.10.00 H
0 Dig. Inp. I20.10.01 H
16*120Vdc I20.10.02 H
I20.10.03 B.SS060501 SS-06.05.01 SSL-1102 speed switch bag filter airlock feeder, pulses= rotation, chamber 1 I
I20.10.04 B.SS060502 SS-06.05.02 SSL-1202 speed switch bag filter airlock feeder, pulses= rotation, chamber 2 I
I20.10.05 B.SS060503 SS-06.05.03 SSL-1302 speed switch bag filter airlock feeder, pulses= rotation, chamber 3 I
I20.10.06 B.SS060504 SS-06.05.04 SSL-1402 speed switch bag filter airlock feeder, pulses= rotation, chamber 4 I
I20.10.07 B.XV060701XI1 XV-06.07.01-XI1 ZSO-1100 limit switch bag filter inlet valve position, 1=open, chamber 1
47 I20.10.08 B.XV060701XI2 XV-06.07.01-XI2 ZSC-1100 limit switch bag filter inlet valve position, 1=closed, chamber 1
I20.10.09 B.XV060702XI1 XV-06.07.02-XI1 ZSO-1200 limit switch bag filter inlet valve position, 1=open, chamber 2
I20.10.10 B.XV0607012I2 XV-06.07.02-XI2 ZSC-1200 limit switch bag filter inlet valve position, 1=closed, chamber 2
I20.10.11 B.XV060703XI1 XV-06.07.03-XI1 ZSO-1300 limit switch bag filter inlet valve position, 1=open, chamber 3
I20.10.12 B.XV060703XI2 XV-06.07.03-XI2 ZSC-1300 limit switch bag filter inlet valve position, 1=closed, chamber 3
I20.10.13 B.XV060704XI1 XV-06.07.04-XI1 ZSO-1400 limit switch bag filter inlet valve position, 1=open, chamber 4
I20.10.14 B.XV060704XI2 XV-06.07.04-XI2 ZSC-1400 limit switch bag filter inlet valve position, 1=closed, chamber 4
I20.10.15
20.1 F.I2011 -A.DIO2.I2011 48 I20.11.00 B.XV060711XI1 XV-06.07.11-XI1 ZSO-1108 limit switch bag filter outlet valve position, 1=open, chamber 1
1 Dig. Inp. I20.11.01 B.XV060711XI2 XV-06.07.11-XI2 ZSC-1108 limit switch bag filter outlet valve position, 1=closed, chamber 1
16*120Vdc I20.11.02 B.XV060712XI1 XV-06.07.12-XI1 ZSO-1208 limit switch bag filter outlet valve position, 1=open, chamber 2
I20.11.03 B.XV060712XI2 XV-06.07.12-XI2 ZSC-1208 limit switch bag filter outlet valve position, 1=closed, chamber 2
I20.11.04 B.XV060713XI1 XV-06.07.13-XI1 ZSO-1308 limit switch bag filter outlet valve position, 1=open, chamber 3
I20.11.05 B.XV060713XI2 XV-06.07.13-XI2 ZSC-1308 limit switch bag filter outlet valve position, 1=closed, chamber 3
I20.11.06 B.XV060714XI1 XV-06.07.14-XI1 ZSO-1408 limit switch bag filter outlet valve position, 1=open, chamber 4
I20.11.07 B.XV060714XI2 XV-06.07.14-XI2 ZSC-1408 limit switch bag filter outlet valve position, 1=closed, chamber 4
49 I20.11.08
I20.11.09
I20.11.10
I20.11.11
I20.11.12
I20.11.13
I20.11.14
I20.11.15

21.0 F.I2100 -A.DIO2.I2100 50 I21.0.00 B.XS01501/02 XS-1.5.01/.02 inductive sensor jump preventor status, support roller 1, 0= alarm
Dig. Inp. I21.0.01 B.XS01503/04 XS-1.5.03/.04 inductive sensor jump preventor status, support roller 2, 0= alarm
16*120Vdc I21.0.02 B.XS01505/06 XS-1.5.05/.06 inductive sensor jump preventor status, support roller 3, 0= alarm
I21.0.03 B.XS01507/08 XS-1.5.07/.08 inductive sensor jump preventor status, support roller 4, 0= alarm
I21.0.04 B.SS030302 SS-03.03.02 speed switch reject airlock feeder, 1= rotation H
I21.0.05
I21.0.06 (condensate flow switches connection to customer system) M
I21.0.07 (condensate flow switches connection to customer system) M
51 I21.0.08
I21.0.09
I21.0.10
I21.0.11
I21.0.12
I21.0.13
I21.0.14
I21.0.15

Distributed IO-unit in filed, -A.DIO2 - Digital outputs

2/8 27.11.2017
SLOT FUSE CARD SHEET ADDR ID ID DEVICE SERVICE REV.
I/O (Electric) (PID)
NO

21.1 F.Q2101 -A.DIO2.Q2101 61 Q21.01.00 A.060311XS1 A-06.03.11-XS1 KY-1104 cleaning control unit bag filter, forced cleaning, 1= command on, chamber 1
Dig. Outp. Q21.01.01 A.060312XS1 A-06.03.12-XS1 KY-1204 cleaning control unit bag filter, forced cleaning, 1= command on, chamber 2
8xrelay Q21.01.02 A.060313XS1 A-06.03.13-XS1 KY-1304 cleaning control unit bag filter, forced cleaning, 1= command on, chamber 3
Q21.01.03 A.060314XS1 A-06.03.14-XS1 KY-1404 cleaning control unit bag filter, forced cleaning, 1= command on, chamber 4
Q21.01.04 Y.XV060701 XV-06.07.01 FV-1100 shut-off valve bag filter inlet valve, 1=open command, chamber 1
Q21.01.05 Y.XV060702 XV-06.07.02 FV-1200 shut-off valve bag filter inlet valve, 1=open command, chamber 2
Q21.01.06 Y.XV060703 XV-06.07.03 FV-1300 shut-off valve bag filter inlet valve, 1=open command, chamber 3
Q21.01.07 Y.XV060704 XV-06.07.04 FV-1400 shut-off valve bag filter inlet valve, 1=open command, chamber 4
21.2 -A.DIO2.Q2102 62 Q21.02.00 Y.XV060711 XV-06.07.11 FV-1108 shut-off valve bag filter outlet valve, 1=open command, chamber 1
Dig. Outp. Q21.02.01 Y.XV060712 XV-06.07.12 FV-1208 shut-off valve bag filter outlet valve, 1=open command, chamber 2
8xrelay Q21.02.02 Y.XV060713 XV-06.07.13 FV-1308 shut-off valve bag filter outlet valve, 1=open command, chamber 3
Q21.02.03 Y.XV060714 XV-06.07.14 FV-1408 shut-off valve bag filter outlet valve, 1=open command, chamber 4
Q21.02.04
Q21.02.05 Y.061001 Y-06.10.01 VBR-1102 vibrator filter hopper pneumatic vibrator, 1=virbation on, chamber 1
Q21.02.06 Y.061002 Y-06.10.02 VBR-1202 vibrator filter hopper pneumatic vibrator, 1=virbation on, chamber 2
Q21.02.07 Y.061003 Y-06.10.03 VBR-1302 vibrator filter hopper pneumatic vibrator, 1=virbation on, chamber 3
21.3 F.Q2103 -A.DIO2.Q2103 63 Q21.03.00 Y.061004 Y-06.10.04 VBR-1402 vibrator filter hopper pneumatic vibrator, 1=virbation on, chamber 4
Dig. Outp. Q21.03.01
8xrelay Q21.03.02 H121C01 A-1.2 signal light drive alarm, 1 = alarm
Q21.03.03 A01220 A-1.2.20 alarm horn alarm horn, warning signal from equipment starting, 1= start
Q21.03.04 A01220 A-1.2.20 alarm light alarm light, 1=start
Q21.03.05
Q21.03.06 A1.3 A-1.3-XS lubrication unit lubrication unit start command, 1 = lubrication on
Q21.03.07
21.4 -A.DIO2.Q2104 64 Q21.04.00
Dig. Outp. Q21.04.01
8xrelay Q21.04.02
Q21.04.03
Q21.04.04
Q21.04.05
Q21.04.06
Q21.04.07

Distributed IO-unit in field, -A.DIO2 - Analog inputs

20.2 F.AI2002 A.DIO2.AI2002 81 IW20.02.00 B.PT08101 PT-8.1.1 pressure sensor flash tank pressure
IW20.02.01 B.LT08102 LT-8.1.2 pressure sensor flash tank level measurement
Analog input IW20.02.02 B.PDIT060301 PDIT-6.3.1 PDIT-1002 filter cleaning unit pressure difference accross the filter
8* 4…20mA IW20.02.03 B.XT070501 XT-7.5.01 dust monitor off gas dust content after bag filter
IW20.02.04 B.TE01203 TE-1.2.3 temperature sensor gearbox oil temperature, drive 1
IW20.02.05 B.TE01203 TE-1.2.13 temperature sensor gearbox oil temperature, drive 2
IW20.02.06 B.FT04101 FT-4.1.1 flow transmitter steam flow to dryer
IW20.02.07 B.PT04101 PT-4.1.1 pressure sensor supply steam pressure, high pressure side
20.3 A.DIO2.AI2003 82 IW20.03.00 B.TE04101 TE-4.1.1 temperature sensor steam temperature, high pressure side
IW20.03.01 B.PT04201 PT-4.2.1 pressure sensor steam pressure to pressure, low pressure side
Analog input IW20.03.02 B.TE04301 TE-4.3.1 temperature sensor steam temperature, low pressure side
8* 4…20mA IW20.03.03 B.TE07203 TE-7.2.3 temperature sensor temperature after bag filter
IW20.03.04 B.TE03102 TE-3.1.2 temperature sensor output material temperature
IW20.03.05 B.TE03103 TE-3.1.3 temperature sensor output material temperature
IW20.03.06 B.PT03101 PT-3.1.1 pressure sensor pressure inside the discharge end chamber
IW20.03.07 B.TE03104 TE-3.1.4 temperature sensor off gas temperature
20.4 F.AI2004 A.DIO2.AI2004 83 IW20.04.00 B.TE05101 TE-5.1.1 temperature sensor concdensate temperature before steam trap
IW20.04.01 B.TE05201 TE-5.2.1 temperature sensor concdensate temperature after steam trap
Analog input IW20.04.02 B.PT05102 PT-5.1.2 pressure sensor concdensate pressure before steam trap
8* 4…20mA IW20.04.03 B.PT05202 PT-5.2.2 pressure sensor concdensate pressure after steam trap
IW20.04.04 B.FT07201 FT-7.2.1 flow sensor off gas flow measurement
IW20.04.05 B.TE060730 TE-6.7.30 TE-1000 temperature sensor bag filter input
IW20.04.06 B.TE060732 TE-6.7.32 TE-1004 temperature sensor bag filter output
IW20.04.07 B.TE073012 M-7.3.01-TE2 TE-1716 temperature sensor offgas fan motor D-bearing temperature, fan 1
20.5 A.DIO2.AI2005 84 IW20.05.00 B.TE073013 M-7.3.01-TE3 TE-1718 temperature sensor offgas fan motor N-bearing temperature, fan 1
IW20.05.01 B.TE073112 M-7.3.11-TE2 TE-1816 temperature sensor offgas fan motor D-bearing temperature, fan 2
Analog input IW20.05.02 B.TE073113 M-7.3.11-TE3 TE-1818 temperature sensor offgas fan motor N-bearing temperature, fan 2
8* 4…20mA IW20.05.03 B.PV040201XI PV-4.2.1-XI control valve input steam valve position feedback
IW20.05.04 B.TE070401 TE-7.4.01 TE-1700 temperature sensor offgas fan inboard bearing, fan 1
IW20.05.05 B.TE070402 TE-7.4.02 TE-1702 temperature sensor offgas fan outboard bearing, fan 1
IW20.05.06 B.TE070411 TE-7.4.11 TE-1800 temperature sensor offgas fan inboard bearing, fan 2
IW20.05.07 B.TE070412 TE-7.4.12 TE-1802 temperature sensor offgas fan outboard bearing, fan 2
20.6 F.AI2006 A.DIO2.AI2006 85 IW20.06.00 B.XT070403 XT-7.4.03 VT-1700 vibration sensor offgas fan inboard bearing, fan 1
IW20.06.01 B.XT070404 XT-7.4.04 VT-1702 vibration sensor offgas fan outboard bearing, fan 1
Analog input IW20.06.02 B.XT070413 XT-7.4.13 VT-1800 vibration sensor offgas fan inboard bearing, fan 2
8* 4…20mA IW20.06.03 B.XT070414 XT-7.4.14 VT-1802 vibration sensor offgas fan outboard bearing, fan 2
IW20.06.04 B.QT070501 QT-5.3.01 conductivity sensor leak detection, condensate water conductivity I
IW20.06.05 B.PV080501XI PV-8.5.1-XI control valve flash steam valve position feedback I
IW20.06.06
IW20.06.07
20.7 A.DIO2.AI2007 86 IW20.07.00 B.TE060201 TE-6.2.01 TE1100 temperature sensor bag filter wall temperature, hopper 1
IW20.07.01 B.TE060202 TE-6.2.02 TE1200 temperature sensor bag filter wall temperature, hopper 2
Analog input IW20.07.02 B.TE060203 TE-6.2.03 TE1300 temperature sensor bag filter wall temperature, hopper 3
8* 4…20mA IW20.07.03 B.TE060204 TE-6.2.04 TE1400 temperature sensor bag filter wall temperature, hopper 4
IW20.07.04 B.TE060211 TE-6.2.11 TE1102 temperature sensor bag filter wall temperature, upper chamber 1
IW20.07.05 B.TE060212 TE-6.2.12 TE1202 temperature sensor bag filter wall temperature, upper chamber 2
IW20.07.06 B.TE060213 TE-6.2.13 TE1302 temperature sensor bag filter wall temperature, upper chamber 3
IW20.07.07 B.TE060214 TE-6.2.14 TE1402 temperature sensor bag filter wall temperature, upper chamber 4

21.6 F.AQ2105 A.DIO2.AI2106 87 IW20.07.00 B.TE010111 TE-1.1.11 temperature sensor Input gas temperature to drum K
IW20.07.01 B.PDT010110 PDT-1.1.10 differential pressure sensor Pressure in the input end of the drum K
Analog input IW20.07.02
8* 4…20mA IW20.07.03
IW20.07.04
IW20.07.05
IW20.07.06
IW20.07.07

Distributed IO-unit in field, -A.DIO2 - Analog outputs

3/8 27.11.2017
SLOT FUSE CARD SHEET ADDR ID ID DEVICE SERVICE REV.
I/O (Electric) (PID)
NO

21.5 F.AQ2105 A.DIO2.AQ2105 88 PQW21.05.0 Y.PV421 PV-4.2.1 control valve actuator control of main steam control valve
Analog output PQW21.05.1 Y.PV851 PV-8.5.1 control valve actuator control of flash tank presssure
4…20mA PQW21.05.2 Y.LV8101A LV-8.10.01A LV-8102A control valve actuator control of flash tank condensate level M
PQW21.05.3 Y.LV8101B LV-8.10.01B LV-8102B control valve actuator control of flash tank condensate level M

WIRELESS TEMPERATURE MEASUREMENT

(Modbus TCP)
SLOT FUSE CARD SHEET ADDR ID (elec.) ID (PID) DEVICE SERVICE REV.
I/O
NO

X1 Periphery devices Wireless receiver

B.TE01101 TE-1.1.01 temperature sensor material temperature in drum, feed end, zone 1
B.TE01102 TE-1.1.02 temperature sensor material temperature in drum, middle part, zone 2
B.TE01103 TE-1.1.03 temperature sensor material temperature in drum, middle part, zone 3
B.TE01104 TE-1.1.04 temperature sensor material temperature in drum, discharge end, zone 4

A.PRM - DEVICES WITH BUS INTERFACE

Profibus DP
Frequency converters
DP 10 G.M01201 M-1.2.01 frequency converter (PPO4)

PQW500 frequency converter main drive frequency converter, master drive, command word
PQW502 main drive frequency converter, master drive, reference
PQW504 PZD3
PQW506 PZD4
PQW508 PZD5
PQW510 PZD6
PIW500 frequency converter main drive frequency converter, master drive, status word
PIW502 main drive frequency converter, master drive, actual value
PIW504 torque
PIW506 current
PIW508 motor winding temperature
PIW510 PZD6

DP 11 G.M01211 M-1.2.11 frequency converter (PPO4)

PQW512 frequency converter main drive frequency converter, follower drive, command word
PQW514 main drive frequency converter, follower drive, reference
PQW516 PZD3
PQW518 PZD4
PQW520 PZD5
PQW522 PZD6
PIW512 frequency converter main drive frequency converter, follower drive, status word
PIW514 main drive frequency converter, follower drive, actual value
PIW516 torque
PIW518 current
PIW520 motor winding temperature
PIW522 PZD6

DP 12 G..M07301 M-7.3.01 frequency converter (PPO4)

PQW524 frequency converter offgas fan 1, command word

PQW526 offgas fan 1, reference
PQW528 PZD3
PQW530 PZD4
PQW532 PZD5
PQW534 PZD6
PIW524 frequency converter offgas fan 1, status word 1
PIW526 offgas fan 1, actual value
PIW528 torque
PIW530 current
PIW532 motor winding temperature
PIW534 PZD6
DP 13 G..M07302 M-7.3.02 frequency converter (PPO4)

PQW536 frequency converter offgas fan 2, command word

PQW538 offgas fan 2, reference
PQW540 PZD3
PQW542 PZD4
PQW544 PZD5
PQW546 PZD6
PIW536 frequency converter offgas fan 2, status word 1
PIW538 offgas fan 2, actual value
PIW540 torque
PIW542 current
PIW544 motor winding temperature
PIW546 PZD6
DP 14 G.M081001 M-8.10.01 frequency converter
PQW548 frequency converter condensate pump 1, command word
PQW550 condensate pump, reference
PQW552 PZD3
PQW554 PZD4
PQW556 PZD5
PQW558 PZD6
PIW548 frequency converter condensate pump 1, status word
PIW550 condensate pump 1, speed
PIW552 torque
PIW554 current
PIW556 PZD5

4/8 27.11.2017
SLOT FUSE CARD SHEET ADDR ID ID DEVICE SERVICE REV.
I/O (Electric) (PID)
NO

PIW558 PZD6
DP 15 G.M081002 M-8.10.02 frequency converter
PQW560 frequency converter condensate pump 2, command word
PQW562 condensate pump 2, reference
PQW564 PZD3
PQW566 PZD4
PQW568 PZD5
PQW570 PZD6
PIW560 frequency converter condensate pump 2, status word
PIW562 condensate pump 2, speed
PIW564 torque
PIW566 current
PIW568 PZD5
PIW570 PZD6
DP 16 G.M07105 M-7.1.05 frequency converter
PQW572 frequency converter reject dust fan, command word
PQW574 reject dust fan, reference
PQW576 PZD3
PQW578 PZD4
PQW580 PZD5
PQW582 PZD6
PIW572 frequency converter reject dust fan, status word
PIW574 reject dust fan, speed
PIW576 torque
PIW578 current
PIW580 PZD5
PIW582 PZD6

Direct-on-line starters
DP 20 A.M01202 M-1.2.02 DOL starter main motor 1 fan
PQW600 DOL starter command word
PQW602 analog output
PQW604 logic output command register
PIW600 DOL starter main motor 1 fan, status word
PIW602 average current
PIW604 inputs status
PIW606 outputs status
PIW608 status

DP 21 A.M01212 M-1.2.12 DOL starter main motor 2 fan

PQW620 DOL starter command word
PQW622 analog output
PQW624 logic output command register
PIW620 DOL starter main motor 1 fan, status word
PIW622 average current
PIW624 inputs status
PIW626 outputs status
PIW628 status

DP 22 A.M01205 M-1.2.05 DOL starter main drive 1 brake

PQW640 DOL starter command word
PQW642 analog output
PQW644 logic output command register
PIW640 DOL starter main motor 1 fan, status word
PIW642 average current
PIW644 inputs status
PIW646 outputs status
PIW648 status

DP 23 A.M01215 M-1.2.15 DOL starter main drive 2 brake

PQW660 DOL starter command word
PQW662 analog output
PQW664 logic output command register
PIW660 DOL starter main motor 1 fan, status word
PIW662 average current
PIW664 inputs status
PIW666 outputs status
PIW668 status

DP 24 A.M02101 M-2.1.01 DOL starter input feeder vibra motor

PQW680 DOL starter command word
PQW682 analog output
PQW684 logic output command register
PIW680 DOL starter main motor 1 fan, status word
PIW682 average current
PIW684 inputs status
PIW686 outputs status
PIW688 status

DP 25 A.M03301 M-3.3.01 DOL starter reject screw feeder motor

PQW670 DOL starter command word
PQW672 analog output
PQW674 logic output command register
PIW670 DOL starter main motor 1 fan, status word
PIW672 average current
PIW674 inputs status
PIW676 outputs status
PIW678 status

DP 26 A.M03302 M-3.3.02 DOL starter reject air lock feeder motor

PQW680 DOL starter command word
PQW682 analog output
PQW684 logic output command register
PIW680 DOL starter main motor 1 fan, status word
PIW682 average current

5/8 27.11.2017
SLOT FUSE CARD SHEET ADDR ID ID DEVICE SERVICE REV.
I/O (Electric) (PID)
NO

PIW684 inputs status

PIW686 outputs status
PIW688 status

DP 27 A.M06501 M-6.5.01 DOL starter airlock motor of bag filter chamber 1

PQW690 DOL starter command word
PQW692 analog output
PQW694 logic output command register
PIW690 DOL starter main motor 1 fan, status word
PIW692 average current
PIW694 inputs status
PIW696 outputs status
PIW698 status

DP 28 A.M06502 M-6.5.02 DOL starter airlock motor of bag filter chamber 2

PQW700 DOL starter command word
PQW702 analog output
PQW704 logic output command register
PIW700 DOL starter main motor 1 fan, status word
PIW702 average current
PIW704 inputs status
PIW706 outputs status
PIW708 status

DP 29 A.M06503 M-6.5.03 DOL starter airlock motor of bag filter chamber 3

PQW710 DOL starter command word
PQW712 analog output
PQW714 logic output command register
PIW710 DOL starter main motor 1 fan, status word
PIW712 average current
PIW714 inputs status
PIW716 outputs status
PIW718 status

DP 30 A.M06504 M-6.5.04 DOL starter airlock motor of bag filter chamber 4

PQW720 DOL starter command word
PQW722 analog output
PQW724 logic output command register
PIW720 DOL starter main motor 1 fan, status word
PIW722 average current
PIW724 inputs status
PIW726 outputs status
PIW728 status

DP 31 A.M06601 M-6.6.01 DOL starter screw feeder motor of bag filter chamber 1 and 2
PQW730 DOL starter command word

PQW732 analog output

PQW734 logic output command register
PIW730 DOL starter main motor 1 fan, status word
PIW732 average current
PIW734 inputs status
PIW736 outputs status
PIW738 status

DP 32 A.M06602 M-6.6.02 DOL starter screw feeder motor of bag filter chamber 3 and 4
PQW740 DOL starter command word

PQW742 analog output

PQW744 logic output command register
PIW740 DOL starter main motor 1 fan, status word
PIW742 average current
PIW744 inputs status
PIW746 outputs status
PIW748 status

DP 33 A.M06603 M-6.6.03 DOL starter screw feeder motor, material out from bag filters
PQW750 DOL starter command word

PQW752 analog output

PQW754 logic output command register
PIW750 DOL starter main motor 1 fan, status word
PIW752 average current
PIW754 inputs status
PIW756 outputs status
PIW758 status

DP 34 A.M06901 M-6.9.01 MY1810 DOL starter Penthouse vent fan 1

PQW760 DOL starter command word
PQW762 analog output
PQW764 logic output command register
PIW760 DOL starter main motor 1 fan, status word
PIW762 average current
PIW764 inputs status
PIW766 outputs status
PIW768 status

DP 35 A.M06902 M-6.9.02 MY-1812 DOL starter Penthouse vent fan 2

PQW770 DOL starter command word
PQW772 analog output
PQW774 logic output command register
PIW770 DOL starter main motor 1 fan, status word
PIW772 average current
PIW774 inputs status
PIW776 outputs status
PIW778 status

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SLOT FUSE CARD SHEET ADDR ID ID DEVICE SERVICE REV.
I/O (Electric) (PID)
NO

DP 44 A.M07106 M-7.1.06 DOL starter Dust removal airlock feeder J

PQW770 DOL starter command word
PQW772 analog output
PQW774 logic output command register
PIW770 DOL starter main motor 1 fan, status word
PIW772 average current
PIW774 inputs status
PIW776 outputs status
PIW778 status

DP 36 A.E060201 DOL starter bag filter heater, module 1 hopper

DP 37 A.E060202 DOL starter bag filter heater, module 2 hopper

DP 38 A.E060203 DOL starter bag filter heater, module 3 hopper

DOL starter bag filter heater, module 4 hopper

DP 39 A.E060204

DP 40 A.E060211 DOL starter bag filter heater, module 1 chamber

DP 41 A.E060212 DOL starter bag filter heater, module 2 chamber

DP 42 A.E060213 DOL starter bag filter heater, module 3 chamber

DP 43 A.E060214 DOL starter bag filter heater, module 4 chamber

DP 45 A.E01203 E-1.2.03 DOL starter gearbox heater L

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I/O (Electric) (PID)
NO

DP 46 A.E01213 E-1.2.13 DOL starter gearbox heater L

8/8 27.11.2017
KUMERA TECHNOLOGY CENTER doc. 435111 01 1/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

Rev. Date Written Approved

A 31.3.17 MSR
B 6.7.17 MSR
C 22.9.17 MSR
D 11.10.17 MSR, HVM

CONTROL SYSTEM DESCRIPTION

KUMERA STEAM DRYER

0 GENERAL
0.1 Component and signal naming convention
The tag numbers refer to P&I diagram 435110 /01, /02.
NNN-xxxx

NNN : customer's function code of signal or instrument

xx : customer's identification code

Some of the documents are common for Kumera’s different projects, and therefore in
those documents the standard Kumera ID is used, which is as follows:

NNN-y.x.z
Where:
NNN : is the function code of signal or instrument according to ISO 3511 standard
y.x.z : number code taking into account part of the process and device, where the
component is located. Basically as follows:
y : plant unit or area
x : device
z : device related instrument, running number

For example PT-4.2.1 means the pressure (P) transmitter (T) in the valve assembly in the
pressure regulating unit (4.2) and it is in the first measurement loop (1).
In the following text Kumera's standard ID is in brackets ().
Please note, that in some documents a zero can precede numbers y, x or z. It is used for
making automatic alphabetical order possible in the lists.

Special identification
KUMERA TECHNOLOGY CENTER doc. 435111 01 2/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

To identify signals more accurately in the logic and circuit diagrams and in instrument list
a more specific identification is used. This is because in the same measurement loop
there can be several inputs and outputs. The identification is made by extending the tag
number with 2 or 3 characters as follows:

NNN-y.x.z-ab
Where:
a: signal type (S=switch, I=indication,...), 1 or 2 characters
b: running number, if needed (1, 2,…)

When programmed to DCS (PLC) the different signals in same signal loop can be
specified (in the variable names) with the extension. For example the control signal to the
regulating valve PV-4.2.1 is PV-4.2.1-XS1 (XS = special switching function, 1 = running
number).

0.2 Terminology
Following abbreviations are used for defining signals.
NV: Normal value
SP: Set point
LL: Low Low alarm
L: Low alarm
H: High alarm
HH: High High alarm
-: not applicable, not used
PFC: potential free contact
24IO: 24Vdc IO signal
120IO 120Vac IO signal
PS: Power supply

Normal value (NV) is the expected process value.

LL and HH alarms should in most cases cause stopping of equipment.
In normal conditions process value shall stay between values L and H values.
Set point SP is normal set point value of controller.
Loop powered instrument gets its power from signal circuit (4...20 mA) and does not need
separate power supply.

0.3 Operator interface

The steam dryer line is controlled with PLC system. Generally operator controls the
steam dryer system from operation station screen. It is called in this text Dryer operation
station and its identification in electrical documents is –A.HMI. It consists of touch screen
panel PC and it is installed in the cabinet (+CA0) door.
A second control place, the supervisory control system (SV) of the plant, is connected via
Ethernet Modbus TCP to PLC.
From the plant system SV can be done most control and monitoring operations, which
are available from HMI station. Many of basic configurations, especially the hardware
related ones, are available only from the dryer HMI panel.

Following short terms are used about control equipment:

KUMERA TECHNOLOGY CENTER doc. 435111 01 3/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

PLC: The dryer control PLC running the main control code of the system.
HMI: The operation station of the dryer installed near the dryer. It has complete user
interface of the dryer PLC.
SV: The plant DCS, which is a supervisory system. It has user interface only to part of
the dryer PLC data and functions.
The term DCS is used for referring generally to both HMI and SV.
Local control panel (A-1.2) is situated on a maintenance platform near the dryer and has
following control elements:
- Start/reverse/stop buttons of dryer drum rotation
- Speed adjusting buttons of rotation speed
- Emergency stop button
The remote IO unit (-A.DIO2) for field instrument connections is installed inside the local
panel (A-1.2).
Local panels of other motors are not in Kumera’s delivery.
For manual steam controlling at dryer start there are mechanical steam pressure meters
in the pressure regulating unit and in steam trap unit

0.4 Data logging

All signals, which are measured by the PLC, are logged to the database of the dryer
operation station HMI. These include, among other things, the steam, material and off
gas temperatures, pressures, flows, dryer drive rotation speed and power demand and
the concentrate feed rate.
From software controllers the set points, actual values and controller output values are
logged.
The logging interval of measurement points in data file can be for example 1 minute.
Every row in the data log file has a time stamp, which includes the date and time.
Logged data can be exported from the HMI to standard files (such as .csv) for process
data analysis purposes.
The logged data can be read from the hard disk of HMI via an additional Ethernet port of
HMI. For the safety reasons direct connection to the Ethernet network between PLC and
HMI is not allowed from outside.
Alarm list system displays all the LL, L, H and HH alarms of the analog measurements
and alarms based on discrete input signals as well as alarms made in program code by
combining several signals. All the alarms are saved to mass storage system of HMI, even
though they are not particularly specified in following description.
Alarms from the all motor starters (DOL and frequency converter) are displayed and
saved, even though they are not explicitly specified in the text.

0.5 Scope of delivery

In this text is described the equipment necessary for steam dryer operation. Note, that
Kumera does not deliver all of these devices. The delivery scope is defined in Annex of
the Contract.

0.6 Interfacing of dryer control system to plant systems

0.6.1 Interface to plant control system

Databus interface
Databus to plant supervisory system (SV)
KUMERA TECHNOLOGY CENTER doc. 435111 01 4/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

- Modbus TCP connection between dryer PLC and SV

- Optical/copper converter shall be used at longer distance. Their delivery is not,
however, in Kumera's scope.

- Direct connection from office network or internet to the dryer control system is not
allowed.

Traditional IO interface
Following signals are coming from plant system to dryer PLC
- Material federate, 4…20 mA
- Dry material conveying system fault, PFC
Signals from dryer PLC to plant system
- Material feeding allowed to dryer, PFC

0.6.2 Interface between dryer PLC and motor control center

- Profibus DP connection to individual motor starters in MCC
- DOL starters and frequency converters operate as slaves in bus
- For reducing the Profibus segment size, bus is divided to separate segments by a
repeaters to be installed in MCC room. Repeaters by others.

1 STEAM DRYER LOOPS

1.1 Material temperature inside steam dryer TE-1101 ... 1104 (TE-1.1.01 … 1.1.04), TE-1101 ...
1104 (TT-1.1.01 … 1.1.04)
Tag: TE-1101 ... 1104 (TE-1.1.01 … 1.1.04),
TE-1101 ... 1104 (TT-1.1.01 … 1.1.04)
Service: Temperature measurement of material inside drum.
Display: HMI and SV screen, unit °C
Signal type: 4…20 mA, Wireless HART, battery power
Compensation: -
Scaling: 0…150°C
Values, limits
TE-1.1.1 °C NV 40, L 10, HH 130
TE-1.1.2 °C NV 60, L 30, HH 130
TE-1.1.3 °C NV 80, L 50, HH 130
TE-1.1.4 °C NV 100, L 70, HH 130
Alarms: L and HH alarms to alarm list
Interlocks: -

The rotating dryer drum has 4 temperature sensors. The sensors TE-1101 ... 1104 (TE-
1.1.1 … 1.1.4) are installed on the wall of the drum in one of the 5 pipe sections and
axially in 4 points. Sensor TE-1101 (TE-1.1.1) is installed in the feed end to measure the
input material temperature little after feeding point. Sensor TE-1104 (TE-1.1.2) is axially
in next zone and after them is sensor TE-1103 (TE-1.1.3). In the last measuring zone
there is sensor TE-1104 (TE-1.1.4).
The temperatures can be observed from HMI/SV screen scaled as 0…150 °C.
KUMERA TECHNOLOGY CENTER doc. 435111 01 5/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

The temperature readings give necessary information to the operator during starting and
stopping of the dryer for selecting appropriate operation actions.
Measured temperatures are also used in the control of the steam as described in point "
Operating modes / Temperature measurement inside drum ".
Because the sensors are in the rotating part, the signals are transmitted wirelessly TE-
1101 ... 1104 (TT-1.1.1 … 1.1.4) from the dryer drum. The radio signals are received with
receiver (TR-1.1), which is connected with Ethernet and Profibus DP communication to
the PLC.

1.2 Main drive control, speed indication and control 5121-SVP-2001M1 (M-1.2.01), 5121-SVP-
2001M2 (M-1.2.11)
Tag: 5121-SVP-2001M1 (M-1.2.01), 5121-SVP-2001M2 (M-1.2.11),
SI-1201 (M-1.2.01/.11-SI)
SI-1211 (M-1.2.01/.11-XI)
Service: Dryer drum rotating drives
Control signal: Profibus DP
Scaling: Speed 0…100 %/ 0… 2 rpm
Torque 0...200 %/ 0 ... 2060 Nm (2 x Tn)
Feedback signal Profibus DP
Operation modes:
Local: Starting and speed control from local panel.
Frequency converter control is via PLC.
Manual: Starting and speed control from HMI/SV screen
From SV screen control of individual motors and brakes not
possible
Auto: Speed control from program based on material feed rate.

Values, limits Reverse rotation speed always limited to 0.3 rpm.

Local: Speed range 0.3 … 1.0 rpm
Manual: Speed range 0.3 … 2.0 rpm
Auto: Speed range 0.3 … 2.0 rpm
Alarms: Low speed monitoring, SI-1201/1211 (M-1.2.01/11-SI.LL), 0.1
rpm
Frequency converter fault
Interlocks: Stopping of drive at event:
- Emergency shutdown
- Emergency stop system activated
- Dry material conveyor fault
- Drive system internal fault, instant stop
* motor fault
* frequency converter fault
* brake fault
- Drive system internal fault, delayed stop
* drive motor fan fault
* girth gear lubrication fault
- Steam flow stopped FIT-4101 (FT-4.1.01.LL), delayed stop
KUMERA TECHNOLOGY CENTER doc. 435111 01 6/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

The main rotating drive motors 5121-SVP-2001M1 (M-1.2.01) and 5121-SVP-2001M2

(M-1.2.11) of dryer drum are supplied with a frequency converters for enabling variable
rotation speed of the drum. The drum is started and stopped using control elements at
the HMI screen.
The rotation speed can also be adjusted from the screen. Commands (on/off/reverse)
and speed reference signal 0…2.0 rpm (drum speed) are signaled to the frequency
converter via Profibus DP from the control PLC.
The rotation speed is normally kept constant, when the material flow is constant.
Guidelines for the rotation speed in different process situations will be defined on the
basis of experience gathered during the start-up and commissioning.
The rotation speed can also be controlled automatically based on material feed rate,
when auto speed control mode is selected. Then speed follows the feed rate in steps.
When feed rate has stayed in a preset time delay inside certain range, the speed
reference is changed to the corresponding speed value. Idea is that speed stay normally
always in constant value. The whole speed range is divided in 7 steps. The speed is
changed slowly (in some minutes) from step to another using ramp function.

Torques of the main motors NI-1201 (M-1.2.01-XI) and NI-1211 (M-1.2.11-XI) measured
by the frequency converter are displayed at HMI screen scaled as 0...200% (100% =
motor nominal 1030 Nm). Main motors rotation speeds SI-1201/1211 (M-1.2.01/11-SI)
are measured and shown on the HMI screen as motor speed (0…2000 rpm) and as drum
speed (0…2.0 rpm).

1.3 Main drive control with 2 motors

The dryer drum is driven with 2 induction motors supplied by frequency converters.
The load shall be shared equally to both motors. The sharing method depends is Master-
Follower system of the ABB ACS880 series.
The speed reference is transferred only to the master frequency converter via Profibus
DP. It gives torque reference to the follower unit via master/follower link, which is a fiber
optic cable. Follower gives back its status word.
When there is failure in one frequency converter, both motors shall be stopped.

1.4 Dryer local panel controls (A-1.2)

A local control panel is installed on the service platform near the steam dryer. The
selection between local and remote mode is done from HMI screen. In local mode the
drum can be started and stopped by switches and the drum rotation speed may be
adjusted with buttons. Start and stop switches are connected to digital inputs of the PLC.
PLC program processes the signals, after which the required control signals are
transmitted to frequency converter, and starters of the brakes and fan motors via Profibus
DP bus. (More detailed description of the different controls is in the in PLC program
documentation.)

1.5 Temperature measurement of main motor winding TE-1201 (M-1.2.1-TE1), TE-1211 (M-
1.2.11-TE1)
Tag: TE-1201 (M-1.2.1-TE2), TE-1211 (M-1.2.11-TE2)
Service: Motor winding high temperature
Display: HMI screen, unit °C
Signal type: PT100, resistance
Compensation: -
Scaling: -
Values, limits HH 150 °C
KUMERA TECHNOLOGY CENTER doc. 435111 01 7/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

Alarms: HH alarm to alarm list

Interlocks: Activation causes alarm to HMI screen
Motor winding temperature is measured with PT100 temperature sensors, which are
connected to analog input card of the frequency converter. The winding temperature
transferred via Profibus DP to dryer PLC and is displayed at HMI screen.

1.6 Gear box oil temperature TE-1203 (TE/TT-1.2.3), (TE/TT-1.2.13), (E-1.2.03), (E-1.2.13)
Tag: drive 1 (TE/TT-1.2.3), (E-1.2.03A/B)
drive 2 (TE/TT-1.2.13), (E-1.2.13A/B),
Service: Gearbox oil heating and temperature measurement
Control signal: Profibus DP to starter
Display: HMI screen, °C
Signal type: 4…20 mA, loop powered
Feedback signal Profibus DP, motor starter.
Operation modes:
Local: -
Manual: -
Auto: Control according to oil temperature
Scaling: -10 ..120 °C
Values, limits °C, L -5, H 90
SP
Alarms: L and H alarms to alarm list
Interlocks: -

A temperature sensors measures the temperatures of the main gearboxes oil and gives it
as 4...20mA signal to DCS. Temperatures are displayed in HMI screen scaled as -10 ...
120 ºC. Heater (E-1.2.03/13) is on, when temperature is below set point, typically 15°C.
In gearbox there are needed 2 heating resistors because of the gearbox mechanics. The
heaters of one gearbox are controlled with one common motor starter unit in MCC.

1.7 Main drive brakes 5121-SVP-2001M5 (M-1.2.5), 5121-SVP-2001M6 (M-1.2.15)

Tag: thruster motor 5121-SVP-2001M5 (M-1.2.5),
5121-SVP-2001M6 (M-1.2.15)
limit switch ZS-1205 (M-1.2.5-ZS), ZS-1215 (M-1.2.15-ZS),

Service: Drum drive brake thrustors and position limit switches

Control signal: Profibus DP to starter
Scaling: -
Feedback signal From limit switch, PFC.
Operation modes:
Local: -
Manual: Control from HMI screen
Both brakes controlled with same command
Auto: Control from drive control code
Values, limits -
KUMERA TECHNOLOGY CENTER doc. 435111 01 8/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

Alarms: - Mismatching position feedback stop via drive control

- Starter fault
Interlocks Emergency shutdown
- Brake closes delayed via drive control
Emergency stop activation
- Brake closes short delay, hardwired

The status of the main brakes 5121-SVP-2001M5/M6 (M-1.2.5/.15) are detected with a
limit switch ZS-1205/1215 (M-1.2.5/15-ZS) attached to the brake. A closed contact
provides a logic ‘1’ signal to DCS digital input in case the brake is open. The status limit
switch signal is used for diagnosing the condition of brake. This feedback signal shall
match the command (open/close) given to the brake. If the feedback differs from the
command and this state lasts longer than the preset delay (preliminary 1 s), the motors
are stopped.
Emergency stop relay shall be equipped with delayed contacts (0...4 s), which interlock
brake supply. Purpose is to not stop with brake from full speed.

1.8 Lubrication control (A-1.3)

Tag: (A-1.3), (A-1.3-XS), XA-1230 (A-1.3-XI)
Service: Girth gear lubricator
Control signal: PFC, at closed contact is lubrication enabled

Scaling: -
Feedback signal PFC, lubricator fault, 0 = alarm
Operation modes:
Local: From lubricator panel
Manual: Starting control from DCS screen
Auto: From drive control code: on, when drive running
Values, limits -
Alarms: Fault including running out of grease
Fault alarm at HMI screen
Interlocks: Stopping of drive, when:
- Lubricator fault lasted over set time period, 8 h

Dryer has automatic lubricator for the girth gear (A-1.3). The lubrication sequence is on
when the start command (A-1.3-XS) active. This means that DCS gives a closed contact
to lubricator unit input. Opening the contact stops the lubrication sequence. DCS shall
normally keep the command active when the dryer drive is running.
Lubrication control unit gives an alarm XA-1230 (A-1.3-XI), when there is a malfunction in
the system. Alarm signal is connected to DCS digital input.
A normally closed contact opens in case there is a fault in the lubricator. In the lubricator
there are timers and sensors for sequencing the lubricate pumping. If control unit detects
a fault in the lubrication, for example due to component malfunction or extinction of
lubricant, the pump stops and a fault signal activates in the lubricator unit. Also the alarm
contact opens and initiates an alarm to PLC. Signal '0' means the alarm has initiated and
it is displayed in the HMI screen.
The alarm must be reset locally from the lubrication unit button to enable the lubrication
unit to function again.
KUMERA TECHNOLOGY CENTER doc. 435111 01 9/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

If the alarm is active longer than a predefined period, preliminary 8 h, the steam dryer
rotation is automatically stopped. The error message can be read from the lubricator
display.

1.9 Drive component fault situation

If there is fault in some motor, in frequency converter or in brake, special measures has
to be taken, if operation is wanted to be continued before the faulty component is
repaired.
Instructions for rotating the dryer drum with one drive unit are given in separate
document.

1.10 Jump preventor ZSH-1501...1508 (XS-1.5.01,..., 08)

Tag: ZSH-1501...1508 (XS-1.5.01,..., 08)
Service: Earth quake detection
Display: -
Signal type: Inductive sensor, output 120IO
Compensation: -
Scaling: -
Values, limits
Alarms: L and H alarms to alarm list
Interlocks: -

At the each support rollers is installed a construction for keeping drum in place during
earthquake. Jump preventor contains inductive proximity sensors for detecting its
displacement. When the preventor position changes, alarm is activated and main drive is
stopped.

2 STEAM DRYER FEED SYSTEM LOOPS

2.1 Feeding conveyor 5121-AVB-2001M (M-2.1.1)

Tag: 5121-AVB-2001M (M-2.1.1)
Service: Input feed chute vibration motor
Control signal: Profibus DP to motor starter
Scaling: -
Feedback signal From motor starter via Profibus DP
run, fault, mode (remote/ local)
Operation modes:
Local: From local panel (by others), including local/remote switch
Hardwired to motor starter
Manual: Starting control from screen
Auto: Starting control from line control code

Values, limits -
Alarms: Motor starter alarm
KUMERA TECHNOLOGY CENTER doc. 435111 01 10/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

Interlocks: Stop when:

- Emergency shutdown
Start for short run when:
- Chute level switch LSH-2104 (LS-2.1.4) activates

The concentrate is fed to the steam dryer with chute feeder.

The chute is vibrated by electric motor driven vibrator. Motor has constant speed and is
running always intermittently when material feed is on to the steam dryer. The interval
and the running time can be adjusted from DCS screen. Preliminary values are for
interval 2 minutes and for running time 5 seconds.
The vibration motor is also started for one 5 seconds cycle, when level switch LSH-2104
(LS-2.1.4)
activates for longer than 1 second.
Status of feeding (running/stop/fault) vibrator is detected from the motor starter and
displayed in the HMI screen.

2.2 Level switch of input hopper LSH-2104 (LS-2.1.4)

Tag: LSH-2104 (LS-2.1.4)
Service: Input feed chute too high level (HH)
Display: -
Signal type: PFC
Compensation: -
Scaling: -
Values, limits -
Alarms: Level HH alarm to alarm list
Long activation shall stop upstream conveyors, time setting 5 s.
Interlocks: -

In upper part of input feeder is vibration type level switch for detecting clogging of the
input feeder. It gives potential free contact signal "0", when material rises at the sensor
level. Activation shall stop the upstream conveyors.
It is not necessary to stop the upstream conveyors from the fault of vibration motor 5121-
AVB-2001M (M-2.1.1), if the level switch does not give alarm.

2.3 Material feed rate WT-2075 (FT-2.0.01)

Tag: WT-2075 (FT-2.0.1)
Service: Incoming material feed rate
Display: HMI screen, unit t/h
Signal type: 4…20 mA
Compensation: -
Scaling: 0…? 240 t/h
Values, limits t/h NV 230 L 20, HH 237
Alarms: L and HH alarms (duration >5 s) to alarm list
Interlocks:
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CONTROL SYSTEM DESCRIPTION

Material feed rate signal is sent from plant control system to dryer PLC analog input.
Feed rate is displayed at the HMI screen, scaled from 0 to 240 tons/h. Feed rate signal is
used for calculating minimum pressure in discharge chamber.

2.4 Permission for material input to dryer (XY-2.0.02)

Tag: (XY-2.0.02)
Service: Signal to plant system SV for allowing input of wet material
Control signal: PFC from PLC output to SV system, 1= input allowed

Scaling: -
Feedback signal -
Operation modes:
Local: -
Manual: -
Auto: From line control code

Values, limits -
Alarms: -
Interlocks: Permission denied at:
- Emergency stop activation
- Emergency shutdown
- Dryer under pressure too low PT-3101 (PT-3.1.1.HH)

3 DISCHARGE SYSTEM LOOPS

3.1 Steam Dryer Discharge End Pressure PT-3101 (PT-3.1.1)
Tag: PT-3101 (PT-3.1.1)
Service: Pressure inside discharge chamber
Display: HMI, SV screen, unit kPa(g)
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…-0.5 kPa(g)
Values, limits kPa(g) ) NV -0.1, L -0.4, H -0.01, HH -0.005
Alarms: L and H and HH alarms to alarm list
HH, too low under pressure to stop the feed
Interlocks: -

The negative pressure relative to the ambient pressure in the discharge end chamber of
the steam dryer is measured with pressure transmitter PT-3101 (PT-3.1.01). It provides
the pressure measurement to PLC as a 4…20 mA signal. The pressure is sensed from
the discharge end chamber with impulse pipe, which goes approximately 50 mm inside
the chamber.
Pressure PT-3101 (PI-3.1.01) is displayed at the HMI and SV screen, scaled to 0...-0.5
kPa(g).
The normal operation point is approximate -0.1 kPa(g). An alarm is initiated above value -
0.01 kPa(g) or below -0.4 kPa(g).
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CONTROL SYSTEM DESCRIPTION

To prevent dust coming out from drum, feed is stopped, if under pressure less than LL.
The pressure signal is used as one basis in controlling the offgas gas fan.

3.2 Control concept for air flow through the dryer TIC-3104 (TIC-3.1.04), (XY-3.1.01)
The off gas consists of the evaporated water from the material and of the air coming from
the feed end into the dryer. In addition there can be nitrogen, which is used to reduce the
ignition risk of the concentrate dust.
To keep the process in good state, the water content in the exhaust gas should be in
certain limits. Therefore basically the air flow and thus the exhaust gas flow should be in
relation to the concentrate feed rate. Exhaust gas flow is determined by adjusting the off-
gas fan M-1700/1800 (M-7.3.01/02) speed.

3.2.1 Exhaust gas flow control principle

Off gas flow is controlled according to under pressure inside the discharge chamber PT-
3101 (PT-3.1.01). The set point for the pressure is calculated form the input material flow

p sp = Ka * Qmat + Kb

where :
p sp vacuum pressure set point [kPa] (absolute value in relation to atmosphere)
Ka capacity factor [kPa*h/ton]
Kb pressure factor [kPa]
Qmat material flow [ton/h]. This signal can be made for example from the material
input feeder capacity set point (0...100 %), scaled by a calculation element (XY-
3.1.01).

The pressure factor shall be big enough to maintain always negative pressure inside
discharge chamber.
The factors Ka and Kb shall be adjustable by operator, so that input material moisture
variations can be compensated manually.
Settings Ka = 0.0006 kPa*h/ton and Kb = 0.04 kPa can be used as preliminary values.
Using the above-mentioned values for instance for a material flow of 80 ton/h, a pressure
set point (p sp) can be calculated as follows:

p sp = 80 ton/h * 0.0006 kPa*h/ton + 0.04 kPa = 0.088 kPa

When under pressure decreases, fan speed is increased and vice versa.

The off gas temperature is controlled with software controller TIC-3104 (TIC-3.1.04). It
also affects to the off gas fan speed.
Normally temperature controller TIC-3104 (TIC-3.1.04) shall not interfere the under
pressure controller (PIC-3.1.01). Only if the temperature TE-3104 (TE-3.1.04) exceeds
limit, the low limit of pressure controller shall be increased.
If this low limit goes now over the normal output value of the pressure controller (PIC-
3.1.01), which is based on the material flow, output is increased. Then fan speed is
increased and so the off gas temperature will decrease.
Operator shall give set point for the temperature controller TIC-3104 (TIC-3.1.04), which
is functioning as the high limit for xs-the off gas temperature. Note, that in normal process
conditions this set point is not reached.
The airflow is measured with flow sensor FE-7201 (FE-7.2.01).
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CONTROL SYSTEM DESCRIPTION

3.2.2 Maintaining negative pressure in the system

There should be a minimum limit for fan speed, because the under pressure in dryer shall
be guaranteed all the time. Also alarm is activated if pressure goes below limit L-limit of
PI-3101 (PT-3.1.01.L).
The minimum limit of the useful speed range of the fan depends on the feed rate and can
be changed automatically.
The minimum value of the negative pressure is determined according to linear formula:

pmin = Ka * Qmat + Kb

where :
pmin vacuum pressure set point [kPa] (absolute value of vacuum in relation to
atmosphere)
Ka capacity factor [kPa*h/ton]
Kb pressure factor [kPa]
Qmat material flow [ton/h]. This signal can be made for example from the material
input feeder capacity set point (0...100 %), scaled by a calculation element
(XY-3.1.01).

The factors Ka and Kb shall be adjustable by operator, so that input material moisture
variations can be compensated manually.
Settings Ka = 0.001 kPa*h/ton and Kb = 0.01 kPa can be used as preliminary values.
Using the above-mentioned values for instance for a material flow of 35 ton/h, a pressure
set point (psp) can be calculated as follows:

pmin = 35 ton/h * 0.001 kPa*h/ton + 0.01 kPa = 0.045 kPa

Controller TIC-3104 (TIC-3.1.04) controls the fan speed. In case the discharge end
pressure (PT-3.1.1) goes under the limit pmin, fan speed is not decreased anymore. Pmin
is set to minimum value of the controller TIC-3104 (TIC-3.1.04).
The airflow is measured with flow sensor FE-7201 (FE-7.2.01).

3.3 Dried material temperature TE-3102 (TE-3.1.02), TE-3103 (TE-3.1.03), TIC-3102 (TIC-3.1.02)
Tag: TE/TT-3102 (TE/TT-3.1.02),
TE/TT-3102 (TE/TT-3.1.03)
Service: Dry material temperature measurement
Display: HMI, SV screen, unit °C
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…150 °C
Values, limits °C NV 115, L 95, H 125, HH 135
Alarms: L and H alarms to alarm list
Activation of HH shall cause emergency shutdown
Interlocks: -
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CONTROL SYSTEM DESCRIPTION

Temperature sensors are installed in the discharge end hopper for measuring the
material temperature at the point where the material drops from the dryer drum to the
discharge end hopper. The sensor signals are displayed at the DCS, tagged TT-3102
(TT-3.1.02) and TT-3103 (TT-3.1.03), and scaled to 0…150°C. The normal operating
point is 115 °C. An alarm is initiated at the DCS when the temperature exceeds 125 °C or
falls below 95 °C. These are preliminary values, which shall be confirmed during
commissioning.
The output material temperature is used in auto mode to control the input steam pressure
with controller TIC-3102 (TIC-3.1.02). For details, see chapter “Automatic mode, material
temperature feedback, TIC-3102 (TIC-3.1.02)”.

3.4 Steam Dryer offgas temperature TE-3104 (TE-3.1.04)

Tag: TE/TT-3104 (TE/TT-3.1.04)
Service: Dry material temperature measurement
Display: HMI, SV screen, unit °C
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…200 °C
Values, limits °C NV 125, LL 90, L 100, H 135, HH 140
Alarms: L and H alarms to alarm list
Activation of HH shall cause emergency shutdown
Activation of LL shall cause stopping of material feeding
Interlocks: -

Temperature sensor TE-3104 (TE-3.1.04) is installed in the exhaust gas duct for
measuring the air temperature. The signal is displayed in the HMI screen TI-3104 (TI-
3.1.04) scaled to 0…200 °C. The normal operating point is 125 °C as preliminary value.
Alarm is initiated when the temperature exceeds 135 °C (H) or falls below 100 °C (L).
Feed shutdown limit can be set as the temperature 90 °C (LL) and steam shutdown limit
set as 140°C (HH). The used (HH) value depends on the chosen filter material.
The sensor (TE-3.1.04) is in a dusty gas stream, which is very abrasive. The sensor
element is equipped with a thick metallic protection tube.

Ignitation preventing
When temperature of the concentrate goes higher, the risk of the ignition of the dust
rises. Therefore emergency shutdown is activated, if temperature TE-3104 (TE-3.1.04)
rises too high (over HH limit). In emergency shutdown, steam supply is closed.

3.5 Dried material level switches LSH-3106 (LS-3.1.06), LSH-3110 (LS-3.1.10), LSH-3112 (LS-
3.1.12)
Tag: LSH-3106 (LS-3.1.06), HH level in discharge hopper
LSH-3112 (LS-3.1.12), HH level in discharge hopper
LSH-3110 (LS-3.1.10), HH limit in reject hopper
Service: Level detections in discharge chamber
Display: HMI, SV screen animation
Signal type: PFC
Compensation: -
Scaling: -
Values, limits -
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CONTROL SYSTEM DESCRIPTION

Alarms: HH alarms to stop drum and material feeding

Interlocks: -

In the dryer discharge end hopper and reject hopper there are a vibration type level
switches. Level switches LSH-3106 (LS-3.1.06.HH) and LSH-3112 (LS-3.1.12.HH) are
installed in the material hopper for initiating a HighHigh alarms at the PLC. The sensor
LSH-3110 (LS-3.1.10.HH) is in reject hopper respectively initiates HighHigh alarm. The
sensors are equipped with cover which is installed approximately 100 mm above the
sensing element for avoiding false alarms from falling material.
Each sensor has an output relay with one changeover contact. The relay is connected to
PLC digital input, so that when level is under the switch, the signal is a logical ‘1’ (contact
closed). When material level rises to the switch level, the signal is a logical ‘0’, (contact
open).
The HighHigh level switch is used to interlock the drum and material feed to the dryer. If
the sensor is activated for a certain time (nominal 3 s), the drum and upstream material
feed is stopped.
The operator can start the drum or material feed manually only after the material level in
the discharge end has lowered to an acceptable level, meaning alarms HighHigh de-
activated.

3.6 Airlock feeder (M-3.3.02), (SS-3.3.02)

Tag: (M-3.3.02)
(SS-3.3.02)
Service: Airlock in reject outlet
Control signal: Profibus DP to starter
Start
Scaling: -
Feedback signal Profibus DP,
Run, fault, remote control from starter
Operation modes:
Local: From local panel (by others), including local/remote switch
Hardwired to motor starter
Manual: From screen
Auto: From line control code
Values, limits -
Alarms: Speed detector signal does not match to command
Interlocks: Stop at:
- Signal from plant system “stop reject” (XY-3.4.02).
- Emergency stop activation
- Emergency shutdown
- Screw conveyor (M-3.3.01) stop

Reject airlock feeder will be stopped, if plant system cannot take material (XY-3.4.02).
Condition of the feeder is monitored with speed detector. If the signal of the sensor ("1"=
rotates) does not match to the given command in specified time (1 s), motor is stopped
and an alarm is activated.

3.7 Screw conveyor 5121-TRS-3001M (M-3.3.01)

Tag: 5121-TRS-3001M (M-3.3.01)
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CONTROL SYSTEM DESCRIPTION

Service: crew conveyor for reject

Control signal: Profibus DP to starter
Start
Scaling: -
Feedback signal Profibus DP
Run, fault, remote control from starter
Operation modes:
Local: From local panel (by others), including local/remote switch
Hardwired to motor starter
Manual: From screen
Auto: From line control code
Values, limits -
Alarms: -
Interlocks: Stop at:
- Signal from plant system “stop reject” (XY-3.4.02).
- Emergency stop activation
- Emergency shutdown

Reject screw feeder will be stopped, if plant system cannot take material (XY-3.4.02).
Screw feeder is delivered by others.

3.8 Output material sample (XV-3.1.07)

At the bottom of the discharge end hoppers there are sample hole for taking manually
samples for dryness measurements.

3.9 Gate valves (V-3.2.1), (V-3.2.11), (V-3.2.21)

Below hoppers there are manually operated gate valves (V3.2.1), (V3.2.11) and (V3.2.21)
for shutting off the dry material to pneumatic conveyor system. They are not in Kumera's
scope and not connected to PLC.

4 STEAM PRESSURE REGULATING SYSTEM LOOPS

4.1 Steam Dryer Incoming Steam Flow Indication FIT-4101 (FIT-4.1.01)
Tag: FIT-4101 (FIT-4.1.01)
Service: Steam flow measurement
Display: HMI, SV screen, unit t/h
As auxiliary information at screen also raw signal m3/h
Signal type: 4…20 mA, HART, loop powered
Compensation: According to temperature and pressure
Scaling: Sensor gives volume flow m3/h
After compensation 0… 50 t/h
Values, limits t/h NV 44.7, L 1, HH 48
Alarms: L and HH alarms to alarm list
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CONTROL SYSTEM DESCRIPTION

Interlocks: -

The incoming steam flow to the dryer is measured using Vortex type flow sensor FIT-
4101 (FIT-4.1.1). Sensor gives measuring result as volume flow.
The whole steam flow measurement system consists of the flow sensor FIT-4101 (FIT-
4.1.1) and flow conditioner (V-4.1.05), which is in upstream pipe. This arrangement
reduces the needed straight lengths for the accurate measurement. The sensor and flow
conditioner are assembled in flow measurement unit (4.1), which is delivered as one
separate part. This unit can be mounted to suitable place. Piping between steam flow unit
and pressure regulation unit (4.) is not in Kumera's scope.
The signals from the sensors TE-4101 (TE-4.1.01) and PT-4101 (PT-4.1.01) are used to
calculate steam density in the actual process condition from temperature and pressure.
For the operator steam mass flow is calculated using density and it displayed on HMI and
SV screen scaled as 0... 50.00 t/h.

Below is the formula for the steam mass flow calculation:

F 2 = F1 * ρ 2 < Formula 0 >

Where:
F1 : Flow signal from the flow transmitter [m3/h]. It is directly proportional to
volume flow.
T2 : Actual steam temperature [K] TE-4101 (TE-4.1.01).
p2 : Actual steam pressure ps [Pa(a)] (signal PI-4101 (PI-4.1.01) + 101.325 kPa )
ρ2 : Actual steam density [kg/m3] of the sensor. It is calculated using <Formula 2
>.

Specific volume of steam in condition (T, p) can be calculated with following formula
(Mollier's formula):

3.1 2 6 13,5
v = (461.11*T/p - 1.45 / ((T/100) ) - 0.603096 *p /(10 *(T/100) )) [m3/kg]

< Formula 1 >

It is valid for saturated and superheated steam with reasonable accuracy.

In the formula temperature T shall be expressed in [K] and pressure p in [Pa].

Steam density is:

ρ = 1 / v [kg/m ]
3
< Formula 2 >

Calculating of the mass flow value can be done as follows:

1. First to get specific volume is assigned in < Formula 1 > :
T2  T [K],
p2  p [Pa (abs)]
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CONTROL SYSTEM DESCRIPTION

2. Then ρ2 is calculated using < Formula 2 >.

3. The mass flow is then calculated with < Formula 0 >.

Alternative
If available, the steam measurement can also be corrected using the standard flow
measurement correction software module of the DCS system.

4.2 Incoming Steam to pressure regulating unit Pressure indication PT-4101 (PT-4.1.01)
Tag: PT-4101 (PT-4.1.01)
Service: Supply steam pressure measurement
Display: HMI screen, unit kPa(g)
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…2500 kPa(g)
Values, limits kPa(g) NV 2200, L 50, H 2250, HH 2280
Alarms: L and H alarms to alarm list
HH to activate emergency shutdown
Interlocks: -

Pressure of the steam supply before the pressure regulating unit is measured and
displayed at HMI screen PI-4101 (PI-4.1.01). The nominal supply pressure is 2200
kPa(g).
The pressure is displayed in DCS screen scaled 0…2500 kPa(g).
Alarm is given from high and low pressures. Exceeding of HH limit shall activate
emergency shutdown of the dryer system.
Incoming pressure to the pressure regulating unit shall be constant, the pressure shall not
normally vary more than 200 kPa.

4.3 Incoming steam to pressure regulating unit temperature (TE-4.1.01)

Tag: (TE-4.1.01)
Service: Supply steam temperature measurement
Display: HMI screen, °C
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…250 °C
Values, limits °C NV 220, HH 240
Alarms: HH alarm to alarm list
Interlocks: -

The steam temperature is measured upstream side of the pressure regulating unit with
PT100 type temperature sensor TE-4101 (TE-4.1.01), equipped with transmitter
4…20mA. Temperature is displayed at the DCS screen scaled 0…250 ºC.

4.4 Steam Dryer Incoming Steam Pressure PIC-4201 (PIC-4.2.1), PT-4201 (PT-4.2.1)
Tag: PT-4201 (PT-4.2.1)
PIC-4201 (PIC-4.2.1)
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CONTROL SYSTEM DESCRIPTION

Service: Dryer steam pressure measurement and control

Display: HMI, SV screen, unit kPa(g)
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…2500 kPa(g)
Values, limits kPa(g) NV 2000, LL 50, L variable, H var., HH 2100
Alarms: L and H alarms to alarm list
HH to activate emergency shutdown
Interlocks: -

The inlet pressure to steam dryer PT-4201 (PT-4.2.01) is measured by a pressure

transmitter, and signaled in kPa(g). The pressure signal initiates at the PLC:
- Pressure indication PI-4201 (PI-4.2.01), scaled 0 to 2500 kPa(g) at the screen.
- Pressure alarm function PT-4201 (PT-4.2.01.L) and PT-4201 (PT-4.2.1.H)
- Emergency shut down at HH value PT-4201 (PT-4.2.01.HH)
Pressure alarm function PT-4201 (PT-4.2.01.L) to warn the operator of too low steam
pressure at the steam input for the dryer.

The L and H pressure alarms of PT-4201 (PT-4.2.01.L) and PT-4201 (PT-4.2.01.H) are to
warn the operator about abnormal values.
The limits for their activation are calculated automatically from the current set point of the
controller PIC-4201 (PIC-4.2.01).
L limit is Set point – tolerance and
H limit is Set point + tolerance.
Preliminary the tolerance (allowed deviation from set point) is 50 kPa.
The expected operating point for output side is at 300 …2000 kPa(g).

4.4.1 Steam control valve PV-4201 (PV-4.2.01)

Tag: PV-4201 (PV-4.2.01)
Service: Steam pressure control valve
Control signal: 4…20 mA, HART, power
Fail to close.
Scaling: 4…20mA /0…100%.
Feedback signal -
Operation modes:
Local: -
Manual: From HMI screen 0…100%
Auto: From pressure controller PIC-4.2.01
Values, limits -
Alarms: -
Interlocks: Closing at:
- Emergency shutdown
- Emergency stop activation
- Flash tank HH-level LIC-8102 (LIC-8.1.02.HH) is exceeded
- Flash tank HH-pressure PT-8101 (PT-8.1.01.HH) is exceeded
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CONTROL SYSTEM DESCRIPTION

The output material dryness is correlated to its temperature. The primary control for
material dryness is performed by adjusting the steam pressure and thus the temperature
of the heating elements inside the dryer.
The control valve PV-4201 (PV-4.2.01) controls the steam pressure to the dryer. The
pressure, which is measured with transmitter PT-4201 (PT-4.2.01), is used as regulating
variable and controlled with a PID type software controller PIC-4201 (PIC-4.2.01).
Flash tank HH-level and HH-pressure interlocks are automatically reset, when process
value returns below the limit.
The maximum opening of control valve PV-4201 (PV-4.2.01) is limited with stop screws in
the actuator to limit the needed discharge capacity of safety valve PSV-4.2.01.

4.4.2 Operating Modes

The steam dryer operating modes are described below. In the operation instructions of
the steam dryer control system is described, how the modes are changed.

Manual mode
Manual mode is available from the HMI panel, which is located dryer control room.
In manual mode, the operator controls the steam temperature manually by adjusting the
steam pressure set point (MAN SP), 0…2000 kPa(g) of the controller function PIC-4201
(PIC-4.2.01). The pressure controller controls the opening (0…100 %) of the control (PV-
4.2.01) so that the desired pressure PI-4201 (PI-4.2.01) is achieved.
At the screen the operator can observe the pressure, temperature and flow, which
change as the opening of the valve changes.
The primary regulated variable is the material dryness, which the operator monitors via
material temperature TE-3102 (TE-3.1.02) / TE-3103 (TE-3.1.03) and output air
temperature TE-3104 (TE-3.1.4) measurements. The changes in the material
temperature shall be studied after a delay, approximately 5…30 minutes, so that the
whole effect of the control action is visible.

Automatic mode, material temperature feedback TIC-3102 (TIC-3.1.02)

In automatic mode the input steam pressure is controlled using a temperature feedback
from the measured material temperature TE-3102 (TE-3.1.02) / TE-3103 (TE-3.1.03).
Other possibility is to use the off-gas air temperature (TE-3.1.04) as feedback signal.
A software based PID controller TIC-3102 (TIC-3.1.02) takes the material temperature
TE-3102 (TE-3.1.2) as the actual value. The other sensor TE-3103 (TE-3.1.03) is on
standby and can be taken into use (by software switch from screen) in case there is a
problem with the primary sensor.
The controller TIC-3102 (TIC-3.1.02) output controls the set point (AUTO SP) of the
steam input pressure controller PIC-4201 (PIC-4.2.01).
For establishing a correlation between material temperature and dryness, the logged data
of the drying operation shall be studied. Based on this data the temperature set point can
be selected for getting the desired dryness.

Temperature measurement inside drum

Variation of the moisture content of the feed material has delayed effect on the output
material temperature. The controller response can be made faster by introducing also
material temperature inside the drum, TI-1101...1104 (TI-1.1.01,... ,0.4) into the control
loop.
The axial temperature profile of the material inside the dryer from feed end to discharge
end is measured as follows:
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Tzone1 = temperature in zone 1, TI-1101 (TI-1.1.01)

Tzone2 = temperature in zone 2, TI-1102 (TI-1.1.02)
Tzone3 = temperature in zone 3, TI-1103 (TI-1.1.03)
Tzone4 = temperature in zone 4, TI-1104 (TI-1.1.04)
The effect of the temperatures can be taken into control in following way.
For each zone is given reference temperature value, which corresponds the "ideal" drying
of the material. The difference of actual temperature of the zone Tzonei from its reference
value TSPí is made to contribute to a term, which is added to the steam pressure
reference for the pressure controller PIC-4201 (PIC-4.2.01). This is a feed forward control
addition (XY-1.1.01) to the temperature control loop TIC-3102 (TIC-3.1.02), which should
reduce the disturbances caused by variations input material moisture.
The material flow is also taken in account to get faster response to the temperature
control. Average of the signal WT-2075 (FT-2.0.01) is calculated from certain time. It is
used as one factor for the correction to the pressure controller.
Qave = average of material flow WT-2075 (FT-2.0.01) [t/h]
Qmat = (Qave - Qmin) / 100,
where
Qmin = 0 t/h (preliminary)
Average is calculated from last 10 minutes (preliminary).

The correction for the pressure reference can be calculated as follows:

pSPcorr = k * ( k1 * (TSP1 - Tzone1) + k2 * (TSP2 - Tzone2)

+ k3 * (TSP3 - Tzone3) + k4 * (TSP4 - Tzone4) + k5 * Qmat )

This correction is added to the pressure reference, which is coming from the output of
controller TIC-3102 (TIC-3.1.02). When process is running in steady state and each
actual value is near its set point, the correction needed for the pressure is near zero.
The reference temperature TSPí and the coefficient ki are adjustable parameters for each
zone. The temperature reference of the zone can be established on the logged data from
the drying process.
The coefficients k1, k2, k3 and k4 give the weight of each zone to the control. Their sum
shall be one.
The coefficient for the material flow k5 coefficient can in range 0 ... 20, preliminary value
k5 = 2.
The whole effect of the material temperature in drum and material flow to the steam
pressure set point PIC-4201 (PIC-4.2.01) is determined by setting the amplifying factor k
Alternatively the feed forward signal can be programmed to controller module of the used
software, if this feature is there available.
The value of correction pSPcorr shall be limited to -1000 ... +1000 kPa. In addition there
shall be locking, that the set point of PIC-4201 (PIC-4.2.1) is always over 300 kPa(g).

4.4.3 Protection of steam pipes

For reducing risk of damages in possible leaks in the steam pipes some measures shall
be made in the control system. Most vulnerable are the flexible pipes between pressure
regulating unit and steam dryer. The hot steam leaks are risk for work safety.
Pressure drop
A leak can be detected from sudden drop of pressure at the output side of the control
valve PV-4201 (PV-4.2.01). In the DCS program there should be monitoring for the rate
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of change of the pressure (ZY-4.2.01). If the derivative (change speed) of the pressure
exceeds a pre-defined value, it is considered as possible leak and a shut-down of the
control valve PV-4201 (PV-4.2.01) is performed. Also steam supply to the dryer system
should be shut down.
Abnormal pressure
The actual steam pressure PT-4201 (PT-4.2.01) shall be monitored and if it the pressure
is outside of the allowed pressure window around the set point PIC-4201 (PIC-4.2.01.L ...
PIC-4.2.01.H) for certain period, shut-down shall be performed. The window limits can be
preliminary 100 kPa down and up from the current pressure set point. The delay before
shut-down can be some seconds.
Excess flow
As third method should be used the HH-limit of the steam flow FI-4101 (FI-4.1.01). If the
flow is over the extreme high limit, steam shall be shut-down.

4.4.4 Protection of pressurized pipes at low temperatures

To avoid damages during start-up, steam pressure should be kept under 1000 kPa(g),
when temperature of the heating elements is below 20°C.
An interlocking shall be made in the DCS program as follows. When the off-gas
temperature (TE-3.1.04) is below 20°C, maximum set point of steam pressure (PIC-4.2.1)
shall be limited to 1000 kPa(g).
Also an alarm shall be activated, when temperature (TE-3.1.04) is below 20°C and
pressure (PT-4.2.01) is over 1000 kPa(g). This is for reminding the operator of not
allowed process state, when he is adjusting pressure using the manual valve (CV-4.2.01).

4.4.5 Limiting temperatures temperature, when drum stopped

Because of the self-ignition possibility of the material, the temperature of the steam piping
shall be limited, when process is not on. The maximum pressure set point is forced under
300 kpa(g), when drum is not rotating. Then pipe temperature stays under 150°C.

4.5 Steam Dryer Incoming Steam Pressure Relief Valve PSV-4201 (PSV-4.2.01)
A pressure relief valve PSV-4201 (PSV-4.2.01) is installed at the low-pressure side of the
pressure regulation unit for over pressure protection of the steam dryer devices. Its
activation value is 2300 kPa(g).
The pressure at the supply point to the steam dryer system shall be kept in all times
under 2500 kPa(g).

4.6 Manual control valve for incoming steam (CV-4.2.01)

A manually operated control valve (CV-4.2.1) is installed as by-pass for the main control
valve (PV-4.2.01). It is used when starting up cold steam dryer. The valve has only a local
function and cannot be operated from the DCS screen. The starting up value and desired
maximum feed rate to be used during main control valve failure shall be taken into
account when selecting the capacity for the valve. The capacity is preliminarily estimated
as 4000 kg/h.
Note: There shall be a shut-off valve for the supply steam before the pressure regulating
unit to ensure work safety in maintenance of the components. This valve is not in
Kumera's scope.

4.7 Steam Dryer Incoming Steam Pressure Indication (PI-4.2.02)

A mechanical pressure meter PI-4202 (PI-4.2.02) is installed at the pressure regulating
unit for displaying the steam pressure at dryer side of the control valve. It can be used at
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starting up of the dryer, when steam is carefully supplied to the cold dryer using the
manual valve (CV-4.2.01). This indication is only local.

4.8 Steam Dryer Incoming Steam Temperature Indication TE-4301 (TE-4.3.01)

Tag: TE-4301 (TE-4.3.1)
Service: Dryer steam temperature measurement
Display: HMI(, SV) screen, unit °C
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…250 °C
Values, limits °C NV 144...215, HH 240
Alarms: HH alarms to alarm list
Interlocks: -

The steam temperature is measured at the input of the dryer with PT100 type
temperature sensor TE-4301 (TE-4.3.01). The temperature is displayed at the DCS
screen, tagged TI-4301 (TI-4.3.01) scaled as 0…250 °C.

4.9 Shut-off valve for pipe connection (V-4.3.02)

In the low pressure side there is pipe inlet, which is equipped with shut-off valve (V-4.3.2)
and blind flange. During the starting-up phase of the steam dryer this inlet can be used to
lubricate the rotary joint with water, when steam is not available.
The flange can be opened only with tools, which minimize the risk of unintentional steam
outbreak.

5 STEAM TRAP UNIT LOOPS

5.1 Steam trap unit (XV-5.1.01), (XV-5.1.02), (XV-5.1.03), PT-5102 (PT-5.1.02), PT-5202 (PT-
5.2.02),
Tag: PT-5102 (PT-5.1.02),
PT-5202 (PT-5.2.02),
PI-5104 (PI-5.1.04) mechanical,
PI-5205 (PI-5.2.05) mechanical
Service: Pressure in steam trap unit
Display: HMI screen, unit kPa(g)
Signal type: 4…20 mA, loop powered
Compensation: -
Scaling: 0…2500 kPa(g)
Values, limits kPa(g) )
PT-5102 (PT-5.1.02) NV 500…2000, L 50, HH 2100
PT-5202 (PT-5.2.02) NV 300, L 50, HH 500

Alarms: L and HH alarms to alarm list

Interlocks: -
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CONTROL SYSTEM DESCRIPTION

A steam trap unit is installed near to the steam dryer for removing the condensate water
from the dryer’s condensate pipe. The steam trap unit consists of three steam traps (XV-
5.1.01), (XV-5.1.02) and (XV-5.1.03), which are installed in different pipe branches.
All steam traps are expansion chamber type.
No-return valves V-5.2.01, V-5.2.02 and V-5.2.03 are installed for preventing backwards
flow.
Before and after the steam traps there are pressure transmitters PT-5102 (PT-5.1.02)
and PT-5202 (PT5.2.02) for monitoring the condition of the steam traps.
Mechanical pressure meters PI-5104 (PI-5.1.04) and PI-5205(PI-5.2.05) are installed for
indicating the pressures before and after the steam traps. They can be used for
monitoring the function and condition of the steam traps. The meters are not connected to
DCS.

5.2 Steam trap unit temperatures TE-5101 (TE-5.1.01), TE-5201 (TE-5.2.01)

Tag: TE/TT-5101 (TE/TT-5.1.01),
TE/TT-5201 (TE/TT-5.2.01)
Service: Temperature measurement in steam trap unit
Display: HMI screen, unit °C
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…250 °C
Values, limits °C
TE-5101 (TE-5.1.1) NV 150…215, L 100, HH 220
TE-5201 (TE-5.2.1) NV 130…150, L 90, HH 160
Alarms: L and HH alarms to alarm list

Interlocks: -

Before and after the steam traps there are temperature sensors TE-5101 (TE-5.1.1) and
TE-5201 (TE-5.2.1) for monitoring the condition of the steam traps.

5.3 Condensate handling system

The condensate from dryer is collected into a flash tank 5123-EST-2001. Flash tank
pressure and level is controlled according to following descriptions. From flash tank, the
condensate is lead to a condensate tank. Steam and condensate is cooled before
transferring to a condensate tank 5123-EST-2002.
The transferring of condensate water via the control valve from tank 5123-EST-2001 to
tank 5123-EST-2002 is based on pressure difference between the tanks.
It shall be noted that in special situations the pressure of tank flash 5123-EST-2001 can
be low. For example, when dryer is stopped for short period and kept warm, the pressure
is low, but after all water is coming from the dryer to the flash tank. Measures shall be
taken to ensure water removing from the tank to prevent overfilling of it.

5.3.1 Flash tank Level control LV-8102A (LV-8.10.01A), LV-8102B (LV-8.10.01B), PT-8101 (PT-
8.1.01), LT-8102 (LT-8.1.02), LIC-8102 (LIC-8.1.02), XY-8102 (XY-8.1.02)
Tag: LV-8102A (LV-8.10.01A)
LV-8102B (LV-8.10.01B)
PT-8101 (PT-8.1.01)
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CONTROL SYSTEM DESCRIPTION

LT-8102 (LT-8.1.02)
Service: Pressure and level in flash tank
Display: HMI screen, unit kPa(g)
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: PT-8101 (PT-8.1.01), 0…600 kPa(g)
LT-8102 (LT-8.1.02), 0...3 m, level from pressure difference
LV-8102A/B (FV-8.10.01A/B), 0...100%, 4...20mA
Values, limits Pressure, kPa(g)
PT-8101 (PT-8.1.1) NV 300, LL 30, L var., H var., HH 480
LT-8102 (LT-8.1.2) NV 300, LL 30, HH 480
Level, m
LIC-8102 (LIC-8.1.2) NV 1.5, LL 0.2, L var., H var., HH 2.8
Alarms: LL, L and H alarms to alarm list
PT-8101 (PT-8.1.01.HH) to interlock steam control valve (PV-4.2.01)
LIC-8102 (LIC-8.1.02.HH) to interlock steam control valve (PV-4.2.01)
Interlocks: -
Level of the flash tank is controlled by letting out condensate via control valve LV-8102A
or B (LV-8.10.01A or B). Condensate from the flash tank is going to the condensate tank
5123-EST-2002 via condensate cooler 5123-ENF-3002.
The valve LV-8102B (LV-8.10.01B) works as stand-by unit for the LV-8102A (LV-
8.10.01A). It can be taken in operation with software switch at DCS screen.
The water level in the tank is measured with a pressure transmitter located above the
water level PT-8101 (PT-8.1.01) and one transmitter LT-8102 (LT-8.1.02) in the bottom
part of the tank. These provide pressure as 0…600 kPa(g), signaled via 4…20mA to
DCS. By calculating the difference between the pressures (XY-8.1.2), the water level is
determined. Normal value is approximately 1.5 m water above the lower sensor. It means
hydrostatic differential pressure 15 kPa. This is changed to level height (meters) in
calculating program module (XY-8.1.02). This value is displayed in unit meters at DCS
display (0.00 … 3.00 m).
The water level in the flash tank is controlled with software based PID-type controller LIC-
8102 (LIC-8.1.02). When level exceeds the set point, the flow valve LV-8102A or B (LV-
8.10.01A or B) is opened so that water flow out of the tank increases. When the level falls
below the set point value, the valve opening is decreased.
Alarm is activated for the operator, when pressure in the tank PT-8101 (PT-8.1.01)
exceeds H-value. If the pressure exceeds the HH-value (480 kPa(g)), steam supply to
dryer shall be closed, reference to steam control valve PV-4201 (PV-4.2.01) is set to
minimum.
The activation limits of the L and H values of the surface level are calculated
automatically from the set point of LIC-8102 (LIC-8.1.02).
L limit is set point - tolerance.
H limit is set point + tolerance.
The preliminary value for tolerance is 0.5 m.
When the water level LIC-8102 (LIC-8.1.02) in the tank exceeds the HH-value, steam
control valve (PV-4.2.1) is shut off.

The activation limits of the L and H values of the tank pressure are calculated
automatically from the set point of PIC-8101 (PIC-8.1.01).
L limit is set point - tolerance.
H limit is set point + tolerance.
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CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

The preliminary value for tolerance is 30 kPa.

5.3.2 Pressure control of flash tank PV-8501 (PV-8.5.01), PIC-8101 (PIC-8.1.01),

Tag: PV-8501 (PV-8.5.1)
ZT-8501 (PV-8.5.1-XI) position feedback
PIC-8101 (PIC-8.1.1)
Service: Flash tank pressure control
Control signal: 4…20 mA, HART, loop powered
4…20mA / 0…100%, fail to open.
Scaling: 0…100 %
Feedback signal 4...20mA
Operation modes: Valve position control
Local: -
Manual: From HMI screen 0…100%
Auto: From pressure controller PIC-8101 (PIC-8.1.01)
Values, limits Maximum set point 350 kPa(g)
Alarms: see PT-8.1.01
Interlocks: Valve open at:
- Emergency shutdown
Pressure set point maximum 350 kPa(g)

Pressure of the flash tank 5123-EST-2001 is controlled by letting out steam via control
valve PV-8501 (PV-8.5.01). Steam from the flash tank is going to the condensate tank via
steam cooler.
Valve has pneumatic actuator, which is opened by springs if control signal or instrument
air fails. In fault situation (for example earth quake) valve opens and pressure is released
from the tank via normal route.
Pressure controller PIC-8101 (PIC-8.1.01) measures tank pressure with the pressure
transmitter PT-8101 (PT-8.1.01) and opens and closes valve accordingly. Normal set
point is 300 kPa(g).
Nominal steam flow is 7 t/h. The nominal pressure across the control valve is 50 kPa(g).
The set point of the tank pressure controller shall be kept under value 350 kPa(g) to keep
the condensate water temperature under the allowed limit of the condensate pump
(150°C).

5.3.3 Starting and stopping of flash tank operation

When the steam supply to dryer is started, the level / pressure controller LIC-812 / PIC-
8101 (LIC-8.1.2 / PIC-8.1.01) shall be active and level / pressure is controlled by letting
out steam /condensate trough control valve FV81001 / PV-8501 (FV-8.10.01 / PV-8.5.01).
Both valves shall be in automatic mode to enable the operation automatically.

5.3.4 Pressure safety valve for flash tank PSV-8103 (PSV-8.1.03)

In the flash tank a mechanical safety valves are installed for overpressure protection.
Operation point of valve PSV-8103 (PSV-8.1.03) is 600 kPa(g). Safety valves are not
connected to dryer PLC.
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CONTROL SYSTEM DESCRIPTION

5.3.5 Flash tank over level switch LSH-8106 (LS-8.1.06)

Tag: LSH-8106 (LS-8.1.6)
Service: Flash tank overfill detection
Display: animation in DCS screen
Signal type: PFC, sensor power 24Vdc
Compensation: -
Scaling: -
Values, limits -
Alarms: HH alarms to alarm list
Activation shall activate emergency shutdown
Interlocks: -

In the upper part of the tank there is a level switch, which operates as back-up safety
device in case the water level in tank goes too high. When the level switch activates
(=signal 0) more than 2 s, the steam supply to the dryer shall be stopped by closing the
control valve PV-4201 (PV-4.2.01) and emergency shutdown of the system is started.

5.3.6 Condensate pumping from condensate tank (5123-EST-2002), (M-8.3.01), (M-8.3.02), FS-
8311 (FS-8.3.11), FS-8321 (FS-8.3.21), PI-8330 (PI-8.3.30)
Tag: (M-8.3.01), (M-8.3.02)
FS-8311 (FS-8.3.11),
FS-8321 (FS-8.3.21),
PI-8330 (PI-8.3.30)
Service: Condensate pumping from condensate tank
Control signal: To be defined by customer
Scaling: To be defined by customer
Feedback signal Frequency converters, Profibus DP.
Flow detection sensors (FS-8.3.11/21), PFC.
Operation modes:
Local: To be defined by customer
Frequency converter control is via PLC.
Manual: Starting and speed control from screen
Auto: Starting and speed control from program based on tank
surface.
Values, limits min speed ?1200 rpm
Alarms: Frequency converter faults
No flow at active pump
Interlocks: Stop at:
- Emergency shutdown
- Tank level LL limit LT-8102 (LT8.1.2.LL)
- Flow alarm at duty pump FS-8311 (FS-8.3.11),
FS-8321 (FS-8.3.21)

Note!
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CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

The control of the pumps M-8.3.01 and M-8.3.02 is

not made in the dryer control system. Pumps shall
be controlled by customer's control system.

Pumping unit including the pumps M8.3.01/.02 tranfers the condensate water from tank
5123-EST-2002 to tank 5126-EST2003.
The water level in the condensate tank is controlled with software based PID-type
controller LIC-8111 (LIC-8.11.01). When level exceeds the set point, the condensate
pump (M-8.3.01) speed is increased so that water flow out of the tank increases. When
the level falls below the set point value, the pump speed is decreased.
If the required pump speed decreases below the minimum available speed of the pump
(preliminary 1200 rpm), the pump is stopped. It is re-started when condensate level is
above the set point of controller LIC-81101 (LIC-8.11.01).
One of the pumps (M-8.3.01) and (M-8.3.02) is a duty pump and the other is a standby
pump. The shut-off valves of the pumps are normally open and the non-return valves
prevent backwards flow in stopped pump.
If duty pump fails, alarm is activated in HMI screen and the stand-by pump is started
automatically. Failure is detected from too high water level LIC-81101 (LIC-8.11.01.H)
and frequency converter faults.
DCS allocates duty pump status to this now operating pump. A function shall be
programmed so that the duty pump status is changed between the pumps so that both
pumps are used alike. This can be based on running hours or by simply starting pumps in
turns. In this way the possible failures in pumps can be detected sooner.

In the inlet lines of the condensate pumps are installed flow switches for detecting low
flow FS-8311/8321 (FS-8.3.11/21). The switch of the duty pump is monitored always,
when pump is running. If then no flow is detected in preset time, alarm is activated.
Reason for low flow can be a closed valve in line or in fault situation empty condensate
tank or faulty sensor.
A pressure gauge PI-8330 (PI-8.3.30) is installed for monitoring the pressure in the output
pipe.
To ensure safe operation of the pumps, they must be located well beneath of the level of
the condensate tank (see NPSH of pump).
The draining shut-off valves of the pumps can be used to empty the tank.
During production stoppage, the condensate pump is stopped. The pump motor is started
automatically, when level in the tank exceeds a starting level, which can be the same as
the set point of the level. Then the pump motor speed will follow the output of the level
controller LIC-81101 (LIC-8.11.01).
When dryer is stopped, condensate flow will go down. The condensate pump can be
stopped manually to keep the water level in the tank.
If the level goes under LL value of LT-81101 (LT-8.11.01), pump shall be stopped
automatically, preliminary 0.2 m.

5.4 Condensate conductivity measurement (QT-5.3.01)

Tag: QT-5301 (QT-5.3.01)
Service: Monitoring of conductivity of condensate
Display: HMI, SV screen, unit %
Signal type: 4…20mA, PS 120Vac
Compensation: -
Scaling: 0...1000 μS/cm
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CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

Values, limits Conductivity, μS/cm

NV < 10, H 20, HH 100
Alarms: H and HH alarms to alarm list
Interlocks: -

For detecting leaks in the steam piping of the steam dryer a conductivity sensor (QT-
5.3.01) is installed in steam trap unit. Water from the input side of the unit is lead via
cooler to the conductivity sensor element.
Maximum allowed temperature for the element is 120°C. The water flow to the element is
adjusted with the manual control valve V5.3.02 so that temperature measured by
mechanical temperature (TI-5.3.03) meter is below 80°C in all operation points.
The expected water flow is 6 kg/h.
If conductivity of the condensate water increases above the H or HH limit, alarm is given
to operator.

6 BAG FILTER LOOPS

6.1 Shut-off valves of bag filter FV-1100...1400 (XV-6.7.01...6.7.04), FV-1108...1408 (XV-

6.7.11...6.7.14)
Tag: valves FV-1100 (XV-6.7.01), FV-1200 (XV-6.7.02),
FV-1300 (XV-6.7.03), FV-1400 (XV-6.7.04),
FV-1108 (XV-6.7.11), FV-1208 (XV-6.7.12),
FV-1308 (XV-6.7.13), FV-1408 (XV-6.7.14),
limit switches ZSO/ZSC-1100 (XV-6.7.01-XI1/XI2),
ZSO/ZSC-1200 (XV-6.7.02-XI1/XI2),
ZSO/ZSC-1300 (XV-6.7.03-XI1/XI2),
ZSO/ZSC-1400 (XV-6.7.04-XI1/XI2)
ZSO/ZSC-1108 (XV-6.7.11-XI1/XI2),
ZSO/ZSC-1208 (XV-6.7.12-XI1/XI2),
ZSO/ZSC-1308 (XV-6.7.13-XI1/XI2),
ZSO/ZSC-1408 (XV-6.7.14-XI1/XI2)

Service: Bag filter shutoff valves

Control signal: PFC, 24Vdc
Valve opens, when activated.
Scaling: -
Feedback signal Open (-XI1) and close (-XI2) position limit switches
Operation modes:
Local: -
Manual: From HMI screen open and close
Auto: From HMI screen open and close
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CONTROL SYSTEM DESCRIPTION

Values, limits -
Alarms: Error, when feedback does not match to command
Interlocks: Closing at:
- Emergency shutdown

In the input sides of the bag filter there are pneumatically controlled shut-off valves FV-
1100 (XV-6.7.01), FV-1200 (XV-6.7.02), FV-1300 (XV-6.7.03) and FV-1400 (XV-6.7.04).
At output side FV-1108 (XV-6.7.11), FV-1208 (XV-6.7.12), FV-1308 (XV-6.7.13), FV-1408
(XV-6.7.14),They can be controlled from HMI screen manually.
Actuators of the valves are controlled with pneumatic magnet valves coil voltage 24 Vdc.
Digital outputs PLC remote IO unit control the pneumatic valves.
In the actuators there are limit switches for open positions ZSO (-XI1) of valves, for
example ZSO-1100 (XV-6.7.01-XI1). For closed positions are the limit switches ZSC (-
XI2), for example ZSC-1408 (XV-6.7.14-X2).
The potential free contacted are connected to digital inputs of the PLC.

6.2 Trace heating of bag filter (A-6.2)

Tag: Heaters, hoppers HTR-1100 (E-6.2.01), HTR-1200 (E-6.2.02),
HTR-1300 (E-6.2.03), HTR-1400 (E-6.2.04)
walls HTR-1102 (E-6.2.11), HTR-1202 (E-6.2.12),
HTR-1302 (E-6.2.13), HTR-1402 (E-6.2.14)
Sensors TE-1100 (TE/TT-6.2.01), TE-1200 (TE/TT -6.2.02),
TE-1300 (TE/TT -6.2.03), TE-1400 (TE/TT -6.2.04)
TE-1102 (TE/TT -6.2.11), TE-1202 (TE/TT -6.2.12),
TE-1302 (TE/TT -6.2.13), TE-1402 (TE/TT -6.2.14)
Service: Bag filter trace heating
Signal type: J-type thermocouple, 4...20 mA
Display HMI screen, °C
Control signal: Profibus DP to starter
Scaling: 0...200°C
Operation modes:
Local: -
Manual: Heating enabling from HMI screen
Auto: Heating enabling from HMI screen
Values, limits °C NV 110, LL 90, L 100, H 130, HH 140
Alarms: Heater alarm to alarm list
Interlocks: Heating stopping at:
- Emergency shutdown

For bag filter walls there is an electrical trace heating system. It includes the heating
elements and temperature sensors on the walls. Heating is divided to 8 groups, 4
hoppers and 4 upper parts of the of the bag filter chambers.
Heating element are supplied from starters in the electrical room. They are control via
Profibus DP similarly as the motor starters.
PLC program switch off heating, when wall temperature set point is reached. If
temperature falls below "set value" - "hysteresis", heater is switched on again.
Hysteresis value is preliminary 3°C. For example, if set point is 105°C, power is switched
off at it and switched on again at 102°C.
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CONTROL SYSTEM DESCRIPTION

There are two set points, one for the hoppers and and one for the walls. The hysteresis is
common for all 8 heating groups.
When wall temperature is over the L limit, the drying process is allowed to start.
For overheating protection in case for example sensor failure a time based power
limitation is made. Power to heating element is switch off for certain time, even if
temperature control requires heating. The forced off-time period is preliminary 2 minutes
in a ten minute period.

6.3 Bag cleaning system of bag filter (A-6.3)

Tag: Devices KY-1104 (A-6.3.11), KY-1204 (A-6.3.12),
KY-1304 (A-6.3.13), KY-1404 (A-6.3.14)
Feedback signals
PDT-1002 (PDT-6.3.01)
KY-1104 (A-6.3.11-XI1), KC-1104 (A-6.3.11-XI2),
PSL-1104 (A-6.3.11-XI3),
KY-1204 (A-6.3.12-XI1), KC-1104 (A-6.3.12-XI2),
PSL-1204 (A-6.3.12-XI3),
KY-1304 (A-6.3.13-XI1), KC-1304 (A-6.3.13-XI2),
PSL-1304 (A-6.3.13-XI3),
KY-1404 (A-6.3.14-XI1), KC-1404 (A-6.3.14-XI2),
PSL-1404 (A-6.3.14-XI3),
Control signals
KY-1104 (A-6.3.11-XS1), KY-1204 (A-6.3.12-XS1),
KY-1304 (A-6.3.13-XS1), KY-1404 (A-6.3.14-XS1),

Service: Cleaning of bag filter bags

Signal type:
PDT-1002 (PDT-6.3.01) 4…20 mA, own power
Feedback PFC
Control PFC
Scaling: 4…20mA/ 0…4 kPa
Operation modes:
Local: Additional cleaning with local switch
Manual: -
Auto: From HMI screen additional cleaning

Values, limits PDT-1002 (PDT-6.3.01)

kPa HH 3
Alarms: HH alarm to alarm list
Interlocks: Cleaning disabling at:
- Emergency shutdown

Bag filter bags are cleaned by pressure air pulses. System is controlled automatically by
its own control unit. The cleaning is done periodically and also based on the pressure
difference across the bags. Refer to bag filter supplier manual.
Each of the 4 chambers has ITS own cleaning control unit.
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The pressure difference across the filters PDT-1002 (PDT-6.3.01) is displayed at HMI
screen.

6.4 Dust conveying system of bag filter M-1102...1402 (M-6.5.01...6.5.04), SSL-1102...1402

(SS-6.5.01...6.5.04), LSH-1100...1400 (LS-6.1.01...6.1.04),
Tag: airlock feeders M-1102 (M-6.5.01), M-1202 (M-6.5.02),
M-1302 (M-6.5.03), M-1402 (M-6.5.04),
speed switches SSL-1102 (SS-6.5.01), SSL-1202 (SS-6.5.02)
SSL-1302 (SS-6.5.03), SSL-1402 (SS-6.5.04)
level switches LSH-1100 (LS-6.1.01), LSH-1200 (LS-6.1.02),
LSH-1300 (LS-6.1.03), LSH-1400 (LS-6.1.04),

Service: Dust removing from bag filter chambers

Control signal: Profibus DP to starter
Scaling: -
Feedback signal Profibus DP from motor starters
PFC from level switches
Operation modes:
Local: From local panel (by others), including local/remote switch
Hardwired to motor starter
Manual: From HMI screen
Auto: From line control code

Values, limits -
Alarms: Dust level alarm in HMI screen
Motor starter alarms
Interlocks:
- Airlock feeders stop, when corresponding screw (M-6.6.01 or
.02) or the common screw (M-6.6.03) stops.
- Emergency shutdown

Dust from the bag filter chambers is conveyed trough airlock feeders M-1102...1402 (M-
6.5.01/02/03/04) and screw conveyors (M-6.6.01/02) to screw conveyor (M-6.6.03), which
takes the dust to dry material output of the discharge chamber of the steam dryer.
If bag filter level switches activate, alarm is given to operator at HMI screen, who shall
manually clear the situation.

6.5 Vibrators of bag filter VBR-1100...1400 (Y-6.10.01...6.10.04)

Tag: VBR-1100 (Y-6.10.01), VBR-1200 (Y-6.10.02),
VBR-1300 (Y-6.10.03), VBR-1400 (Y-6.10.04)
Service: Vibrating of bag filter hoppers
Control signal: PLC output
Scaling: -
Feedback signal -
Operation modes:
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Local: -
Manual: Additional vibration cycle from HMI screen
Auto: Periodic cycles from line control code
Values, limits -
Alarms: -
Interlocks: Stop at emergency shutdown

In the lower parts of the bag filter chambers are installed pneumatically operated vibrators
to prevent sticking of concentrate dust to back filter walls. They are started periodically.
Preliminary: 5 seconds run with 2 minutes interval.

6.6 Dust conveying system of bag filter (M-6.6.01/02/03)

Tag: (M-6.6.01), (M-6.6.02), (M-6.6.03)
Service: Dust conveying
Control signal: Profibus DP to starter
Scaling: -
Feedback signal Profibus DP from starter
Operation modes:
Local: From local panel (by others), including local/remote switch
Hardwired to motor starter
Manual: From HMI screen
Auto: From line control code
Values, limits -
Alarms: Starter fault
Interlocks: Stop at emergency shutdown

Dust conveying from filter to discharge end. Delivery by others.

6.7 Ventilation fans MY-1810 (M-6.9.01), MY-1812 (M-6.9.02)

Description to be added.

7 EXHAUST GAS SYSTEM LOOPS

7.1 Exhaust gas flow (FE-7.2.1)

7.1.1 Flow measurement

Tag: (FE-7.2.01), flow sensor
(TE-7.2.03), temperatue sensor
Service: Offgas flow measurement
Display: HMI, SV screen, flow unit Nm3/h
Additional display in unit m3/h can be activated separately
Signal type: Ultrasonic sensor
4…20 mA, PS 120 (220)Vac
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Compensation: According to temperature

Scaling: 0…90000 Nm3/h
Values, limits Nm3/h NV 70265, LL 5000, HH 85000
Alarms: LL and HH alarms to alarm list
Low flow value LL shall interlock nitrogen supply to dryer
Interlocks: -

The off gas flow through the system is measured from the duct after the filter. It is
displayed in the DCS screen scaled as 0…90000 Nm3/h.
The sensor gives the actual flow F1 [m3/h].
The flow value shall be compensated for displaying the flow in standard state (0 °C,
101.325 kPa(g)) as normal cubic meters [Nm3/h],.

F2 = F1 * ( p2 + 101.325 ) / ( p1 + 101.325 ) * ( T1 + 273.15 ) / ( T2 + 273.15 )

T1 : Standard gas temperature, 0 °C.

p1 : Standard gas pressure [kPa(g)], 101.325 kPa(g)
F2 : Flow [Nm3/h], in standard state.
T2 : Actual air temperature at sensor [°C ] (TT-7.2.03).
p2 : Actual gas pressure [kPa(g)], near atmosphere pressure 72 kPa(g).
If not measured, constant value can be inputted to formula.

Correction software module of DCS can be used for compensation, if it is available.

7.1.2 Flow sensor mounting

In addition adequate straight lengths are needed before and after the sensor. The needed
straight lengths are less, when smaller duct diameter is used.

7.2 Steam Dryer exhaust gas temperature TE-7203 (TE-7.2.03)

Tag: TE/TT-7203 (TE/TT-7.2.03)
Service: Offgas after bag filter temperature measurement
Display: HMI, SV screen, unit °C
Signal type: 4…20 mA, HART, loop powered
Compensation: -
Scaling: 0…200 °C
Values, limits °C NV 125, LL 90, L 100, H 135, HH 140
Alarms: L and H alarms to alarm list
Activation of HH shall cause emergency shutdown
Interlocks: -

Temperature sensor TE-7203 (TE-7.2.03) is installed in the exhaust gas duct for
measuring the air temperature. The signal is displayed in the HMI screen scaled to
0…200 °C. The normal operating point is 125 °C as preliminary value.
Alarm is initiated when the temperature exceeds H limit (135 °C). Steam shutdown limit
set as 140°C (HH).
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7.3 Offgas fan M-1700 (M-7.3.01), M-1800 (M-7.3.02)

Tag: Motor M-1700 (M-7.3.01), M-1800 (M-7.3.02)
Winding temperature
TE-1700ABC (M-07.03.01-TE1)
TE-1800ABC (M-07.03.02-TE1
Motor bearing temperature
TE-1716 (M-07.03.01-TE2), D-end
TE-1718 (M-07.03.01-TE3), N-end
TE-1816 (M-07.03.02-TE2)
TE-1818 (M-07.03.02-TE3)
Fan bearing temperature
TE-1700 (TE-07.04.01), inboard
TE-1702 (TE-07.04.02), outboard
TE-1800 (TE-07.04.11)
TE-1802 (TE-07.04.12)
Fan bearing vibration
VT-1700 (XT-07.04.03), inboard
VT-1702 (XT-07.04.04), outboard
VT-1800 (XT-07.04.13)
VT-1802 (XT-07.04.14)
Service: Offgas fan
Control signal: Profibus DP
Scaling: 0…100 %
Feedback signal Profibus DP
Operation modes:
Local: To be defined by customer
Manual: Starting and speed control from HMI screen
Auto: Starting from line control, speed from controller (TIC-3.1.4)
Values, limits Temperatures, °C
Motor winding H 140, HH 155
Motor bearing H 80, HH 100
Fan bearing H 70, HH 90
Vibration, mm/s
H 1.0, HH 4.0
Alarms: Starter fault
Interlocks: Stop at:
- Emergency shutdown

There are two parallel off gas fans after the bag filter, which blow the gas from dryer to
common stack.
Off gas fans are supplied with frequency converters. Fans are started simultaneously and
have same speed reference. Speed is controlled with (PIC-3.1.01) in auto mode, see
chapter "Exhaust gas flow control principle".
The motor winding temperature sensors are connected directly to frequency converters.
They shall be parametrized to trip motor, when temperature rises over insulation class
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limit (F class 155°C). Winding temperature is transferred via bus to PLC and displayed in
HMI screen.

7.4 Dust removal fan from reject (M-7.1.05)

Tag: (M-7.1.05)
Service: Dust removal from the reject chute to offgas line
Control signal: Profibus DP
Scaling: 0…100 %
Feedback signal Profibus DP
Operation modes:
Local: To be defined by customer
Manual: Starting and speed control from HMI, SV screen
Auto: Starting from line control,
Speed follows the main fan
Values, limits NV 500...1000 m3/h
pressure rise approximately 2 kPa
Alarms: Starter fault
Interlocks: Stop at:
- Emergency shutdown

The dust from the reject chute is removed with fan M-7.1.05, which is supplied with
frequency converter. Before the fan there is a cyclone, which removes excess dust, which
is lead out via airlock feeder M-7.1.06.
In auto mode starting and speed reference shall follow the control of the offgas fan.
In plant starting up phase the speed scale is defined so, that the suction is adequate in all
process situations.

7.5 Airlock feeder of dust removal cyclone (M-7.1.06)

Tag: (M-7.1.06)
Service: Material removing from the cyclone of dust removal system
Control signal: Profibus DP
Scaling: -
Feedback signal Profibus DP
Operation modes:
Local: To be defined by customer
Manual: Starting and speed control from HMI, SV screen
Auto: Starting from line control
Values, limits NV 1000 kg/h
Alarms: Starter fault
Interlocks: Stop at:
- Emergency shutdown

The material from the cyclone of the reject dust removal system is moved with airlock
feeder M-7.1.06. Motor has constant speed and started to both directions with DOL-R
starter.
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Airlock feeder is running always, when fan M-7.1.06 is running.

7.6 Dust monitoring sensor XT-7501 (XT-7.5.01)

Tag: XT-7501 (XT-7.5.1)
Service: Monitoring of dust content after bag filter
Display: HMI, SV screen, unit %
Signal type: 4…20mA, PS 24Vdc
Inductive electrification principle
Compensation: -
Scaling: -
Values, limits Shall be set, when process is running
Alarms: HH alarms to alarm list
Interlocks:

The dust content of offgas after bag filter is measured using dust monitor sensor XT-7501
(XT-7.5.1). When output signal of the sensor exceeds the set limit, alarm is given to
operator.
The setting of the alarm limit is done first finding out the normal dust flow in the pipe
during the process. The alarm limit can be set for example to be 2...4 times bigger than
the normal value.
If possible, the sensor should be calibrated with dust measuring system to the get relation
between the sensor output and real dust content [g/Nm3].

8 STEAM DRYER ROTATION CONTROL AND INTERLOCKING

8.1 Dryer Drum Drive

8.1.1 Equipment numbers:

5121-SVP-2001M1 (M-1.2.01), 5121-SVP-2001M2 (M-1.2.11), Main motor
5121-SVP-2001M3 (M-1.2.02), 5121-SVP-2001M4 (M-1.2.12), Main motor fan
5121-SVP-2001M5 (M-1.2.05), 5121-SVP-2001M6 (M-1.2.15), Brake thruster motor
Local control panel (A-1.2)

8.1.2 Drive electric motors

Drum rotation motor is driven with frequency converters for adjusting the rotation speed
of the dryer. The motors 5121-SVP-2001M1 (M-1.2.01) and 5121-SVP-2001M2 (M-
1.2.11) are equipped with a separate cooling fans 5121-SVP-2001M3 (M-1.2.02), 5121-
SVP-2001M4 (M-1.2.12) to secure a sufficient cooling at low speeds.
Because of high frequency stray currents, which are present in frequency converter
operation, the drive motor shall be equipped with insulated N-end bearing. This is to
prevent possible bearing problems.

8.1.3 Drum drive control description

Dryer drive consists of several pieces of equipment, which can be controlled in local
manual mode via PLC. Local panel (A-1.2) controls are connected to PLC, which takes
care of the proper sequencing of the motor and the brake.
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The local control panel (A-1.2) for the dryer operation is installed near the dryer drum. It
includes start, reverse and stop buttons, buttons for adjusting speed reference and an
emergency stop push button.
The software mode selector switch at the HMI/SV screens determines the control place.
When selector is in ‘local’, control is from the local panel buttons and when selector is in
position ’remote’, control is from HMI.
The rotation speeds and their limitations in different situations are described in chapter
“Main drive control, speed indication and control (M-1.2.01), (M-1.2.11)”.

Main drive torque limitation

Acceleration ramp time for steam dryer can be set to value 30 s. This leads to moderate
torque for drive mechanics in start.
In emergency stop dryer drum shall be stopped quickly. This is done by stopping motor
without ramp and closing mechanical brake with short delay. To limit the peak torque in
emergency stop, torque setting of brake shall not be bigger than 1000 Nm (total 2000
Nm).
For further decrease the stress to drive mechanics, the mechanical brake is closed after
delay. Then drum decelerates first by the load before mechanical brake stop the rotation.
This function can be made by using safety relay, which is equipped with delayed contacts
for the brake. Proper delay is 1...2 seconds.

8.1.4 Automatic line control mode

Rotation start sequence
Start signal is initiated, which causes the following:
- Checking, that the motor is not rotating. Waiting for brake close signal, before
continuing start sequence.
- Start signal for alarm device (A-1.2.20) (sound and light) for warning about
movement, relay output in remote IO unit +DIO2. The beacon device is not in
Kumera's scope.
- Brakes are opened by starting thruster motors 5121-SVP-2001M5/M6 (M-1.2.5/15)
after adjustable delay 0...1 s
- Motors 5121-SVP-2001M1/M11 (M-1.2.1/11) are started after adjustable delay
0...1 s. When start signal is in frequency converter input, it starts using ramp
adjusted in frequency converter. The running speed will be the one adjusted from
DCS screen.
- Fan motor 5121-SVP-2001M3/M4 (M-1.2.2/12) is started.

Rotation stop sequence

Start signals is reset, subsequently:
- Motor 5121-SVP-2001M1/M11 (M-1.2.01/11) powers are switched off. Motor stop
due to friction and drum unbalance.
- Fan motor 5121-SVP-2001M3/M4 (M-1.2.02/12) is stopped
- Brake 5121-SVP-2001M5/M6 (M-1.2.05/15) is closed after a delay (45 s) so that
drum has time to rotate back to a balanced position due to unbalanced material at
the drum wall.
When delay is running, starting of motor is prevented.
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The adjustable delays in starting enable the adjusting of the proper starting sequence at
site, so that the mechanical and electrical delays of brake and motor drive can be
compensated. The fan motor is set to run always when the main motor is running.

8.1.5 Manual control mode

Rotation start sequence
Manual starting of the dryer drum rotation is identical to the starting from the HMI. The
only difference is that the initial command comes from the local panel instead of the HMI
screen. The speed is controlled by using the push buttons (increase/decrease) in the
local panel. When for example the speed-up button is pressed, the speed reference is
stepped up as long as the button is pressed. Sequential steps are for example 3 times a
second when button is pressed. The basic step increment can be 1% of the whole range
0…1 rpm.

Rotation stop sequence

Stopping the dryer drum manually differs from the auto mode stop of the drum rotation.
The manual mode stopping is designed for maintenance work purpose and it stops the
drive and holds the drum with the brake immediately, when stop button is pressed.
Dryer drum rotation is stopped in manual mode as follows:
Start signals is reset, which causes the following:
- Motor 5121-SVP-2001M1/M11 (M-1.2.01/11) powers are switched off, frequency
converter stops without ramp.
- Brakes 5121-SVP-2001M5/M6 (M-1.2.05/15) are closed without delay, when the
main motor is switched off. This way the drum can be positioned accurately for
maintenance work.
- There shall be a delay (2 s) after brake close signal before re-starting of motor.
- Fan 5121-SVP-2001M3/M4 (M-1.2.2/12) motor is stopped

8.2 Interlocks for dryer drive

Dryer drum rotating is internally interlocked to:
- Emergency stop relay position
- Safety switch position
- Lubricator status signal
- Steam pressure indication
- Downstream equipment running status
- Level switches in discharge chamber
A fault alarm from the lubricator is indicated to the operator on the HMI screen. A stop of
is activated when alarm has been on a certain time, preliminary value 4 hours.
An alarm shall be given to operator, in case the drum motor is running for a certain time
(default 15 min / 0.1 MPa) without steam pressure PT-4201 (PT-4.2.1) in dryer feed line.
This is because the rotary joint of steam needs water lubrication and cannot stand
rotation without steam.
The drum rotation is interlocked externally to the downstream equipment. If pneumatic
conveyor is stopped, the drum will be locked.
More detailed control description is expressed in PLC program.
The emergency stop system is hard-wired. The e-stop buttons and safety relays shall be
selected and the connections shall be made so that the installation fulfills the local safety
standards. Status of the safety relay is connected to PLC input.
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8.3 Work safety aspects

Generally, most dangerous moving parts of the dryer are protected with separate shields,
and the shields can be opened only with tools.
However, there are some points that pose a potential danger if not taken into
consideration if personnel are allowed to work at dryer area during running of the
equipment.
The wireless temperature sensors are sticking out from the drum surface level, and when
drum is rotating can hit persons moving or things left in the vicinity of the dryer.
The steam- and condensate system arrangement at the discharge end of the drum is
very dangerous during running of the dryer, if not properly and adequately shielded from
approaching of personnel.
It shall be protected with mechanical shield or a cabin structure as shown in main
assembly drawing xto prevent people to enter the dangerous area when the dryer is
rotating. Note, that the shield is not included in Kumera’s delivery but must be built locally
by Client.
The shield structure shall be made so that entering the area accidentally is not possible. If
access doors are used, those must be interlocked to the control system to stop the drum
when accessed. This can be based for example on limit switches installed at shields or
doors, which can be opened manually without using tools.
Otherwise the access openings must be such that those cannot be opened manually
without using tools.

9 NITROGEN SYSTEM LOOPS

Not used.

10 OPERATION OF STEAM DRYER

.

10.1 Starting sequence of steam dryer

Dryer starting is a part of the drying line control. Here is explained only the part that is in
Kumera delivery.
General preparing work needed before the starting of the dryer is explained in the
document xxxx "Test-run and start-up instructions". The operator shall do the start-up
preparation manually.
The operator can activate the line start command after the preliminary conditions are
ready.

10.1.1 Preliminary work (manually by operator):

See doc. xxxx “Operation Instructions”
- Start of offgas system
- Start of the steam supply to dryer and condensate water system
- Start of the dryer rotation

10.1.2 The line start command from HMI (dryer is rotating and heating with steam is on)
- Start of dry material equipment downstream after discharge chamber (automatic)
- Start of airlock feeder (M-3.3.02) (automatic)
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- Start of concentrate feeding chute conveyor vibrator 5121-AVB-2001M (M-2.1.01)

(automatic)
- Start of the equipment upstream before the conveyor (automatic)

10.2 Stopping sequence of steam dryer

10.2.1 Normal line stop

Stop command from HMI by the operator:
- Stopping of concentrate feed by stopping the feed to the line (automatic)
- Stopping up stream equipment including feed conveyor 5121-AVB-2001M (M-
2.1.01) with delay to enable emptying the line. (delayed, automatic)
- Adjusting the steam pressure to lower level (waiting mode) automatically
- Stopping of rotary feeders (M-3.3.02) (delayed for emptying the line, automatic)
- Stopping of downstream equipment (delayed, automatic)
- Stopping of the steam dryer rotation (delayed, automatic)
- Stopping the steam supply (delayed, automatic)
- Stopping of nitrogen supply (delayed, automatic)
- Stopping of off gas fan (delayed, automatic)

10.2.2 Emergency stop

When emergency stop button of steam dryer is pressed:
- Steam dryer rotation and air lock feeder are stopped
- The upstream conveyor equipment are stopped
- Steam supply to dryer is shut off, and the control valve PV-4201 (PV-4.2.01) is
adjusted to a minimum position.

11 TRACE HEATING
Trace heating is highly recommended for preventing sticking of material to the inner
surfaces of dryer line equipment. The purpose of trace heating is to keep the surface
always in high enough temperature, so that condensation of water will not happen.
The walls of discharge chamber (E-3.1.08), dry material conveyors and the offgas duct
(E-7.1.01) shall be trace heated. The control of heating should be based on measured
temperature of the walls.
The detailed control of heaters is not in the scope of this description.

12 ELECTRICAL SYSTEM

12.1 Control power

The control power (120V 50Hz 1 phase) for the PLC, IO-units and operation unit is
supplied and backed up with central UPS of the plant. The IO voltage of PLC is 120 Vac.

12.2 Reserve power

Following loads of the steam dryer process can be supplied from the reserve power, see
single line diagram 434114 /01:
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- Main motors 5121-SVP-2001M1 (M-01.2.01), 5121-SVP-2001M2 (M-01.2.11) and their

fan motors 5121-SVP-2001M3 (M-01.1.02), 5121-SVP-2001M4 (M-01.1.12),
- Brakes 5121-SVP-2001M5 (M01.2.05), 5121-SVP-2001M6 (M-01.2.15)
- Off gas fan M-1700 (M-07.3.01)
The reserve power can be used during power failure to rotate the dryer drum to reduce
the risk of agglomeration of concentrate to the inner parts of the dryer.

12.2.1 Procedure at power failure situation

When power failure at plant stops the dryer line, basically there is some time before there
is increased risk for sticking of material to the interior of dryer.
All the needed operations can be done manually and the rotation is recommended to be
started in 10 minutes.
Here is assumed that the power to the control system is available (UPS).
The supply to the backed-up equipment shall be switched to be taken from the reserve
power. The electric power system design is by others and the details are not discussed
here.

12.2.2 Control system functions for power failure handling

Interface to plant system concerning the electrical supply status is via 2 digital inputs to
the dryer PLC.
"Electrical system status" signal (G-29.1.01) is "1", when electrical supply system is
working in normal connection. Signal goes down, when there is power failure.
Signal "reserve power" (G-29.1.02) is "1", when the reserve power is connected to feed
the backed-up loads of the dryer system.
When the reserve power signal is on, there will come automatically some changes in the
dryer PLC function. After operator has also selected "Power failure mode", the PLC takes
off the interlock from the dry material conveyors thus enabling the starting of the dryer
drum rotation. Also the speed limits of the rotating drive and off gas fan are forced down,
so that only low speeds are available.

During mains power failure the dryer line devices shall be changed to manual mode, so
that they can be controlled individually from the HMI/SV screens. The whole drive system
consisting of the two motors, their fans and brakes are controlled as one unit both in
remote and local mode.

12.2.3 Dryer running during power failure

During the power failure the dryer rotating drive shall be run at minimum speed (0.3 rpm).
Also the the fan (M-07.3.01) speed shall be adjusted to low value.
Steam should be supplied to dryer, if it is available and the control power is healthy
enabling the 4...20 mA signal to valve PV-4201 (PV-4.2.01). Also the instrument air shall
be available for the control valve. If the valve PV-4201 (PV-4.2.01) cannot be used,
steam can be supplied to the dryer using the manual by-pass valve (CV-4.2.01).
Steam pressure PT-4201 (PT-4.2.01) can be adjusted and monitored from the screen
and should be controlled to a low value.
Rotation shall be continued approximately 4...6 hours when there is steam available and
the material is drying. After that the dryer can be stopped. Then it can be started for short
periods in some hour interval.
If the steam is not available the rotation shall be continued longer.
The material dryness can be monitored using the material sample hole (XV-3.1.07), when
there is enough material still falling out from the drum. The material temperature sensors
in drum give also clue about the dryness.
KUMERA TECHNOLOGY CENTER doc. 435111 01 43/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

12.2.4 Things to be considered

Even though new material is not introduced into the dryer, dry material will come out to
the discharge chamber. Therefore there shall be enough space where the dry material is
lead into, so that the discharge chamber will not be full.
It shall be noted that the seals of steam rotary joint of the dryer need lubrication. Normally
the steam works as lubricant. If the steam is not available during the power failure, the
rotation shall be stopped.
The rotary joint can also be lubricated with water, which can be entered via the valve
V4.3.02. One should be careful when using this option and shall remember to close the
valve and reinstall the blind flange, before again supplying the steam into the system.

12.3 Motor control

12.3.1 Communication
Communication between dryer PLC and the motor starters and the frequency converters
in the motor control center (MCC) is made with Profibus DP network.
The direct on line starters (DOL) have Schneider Tesys (model ??) starter device.

12.3.2 Data to dryer PLC

From each motor starter following data is transferred:
- motor current
- voltage
- power
- motor power factor
- temperature (thermal status calculated by the starter device)

From motor with frequency converter torque is available and it is transferred to PLC.
From motors, where there are installed analog temperature sensors in the winding, the
actual winding temperature is transferred.

12.3.3 Data displaying on operator screens

On the process window for the operator is displayed:
- motor torque, % of nominal torque
- motor power, % of nominal power (if torque is not displayed)
- motor temperature, °C (motors with sensors in winding)

On the maintenance window is displayed:

- motor torque, Nm and %
- motor power, kW and %
- motor current, A and %
- voltage, V
- motor power factor, cosfii
- thermal status, %
- motor winding (and bearing) temperature, °C
(motors with sensors in winding or bearings)
This same data is also displayed in starting dialog windows of individual motors. It is then
available easily by clicking motor symbol also for normal operators, when needed.
KUMERA TECHNOLOGY CENTER doc. 435111 01 44/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

13 MISCELLANEOUS
13.1 Emergency shutdown
The steam dryer system is shut down automatically in following situations
- Mains power failure
- Flash tank is full detected by level switch (LS-8.1.06)
- Operator activates emergency stop from HMI or SV screen

Mains power failure stops normally most of conveyors depending on the electric supply
connections. When the mains power detection relay indicates power failure the whole line
is stopped. This includes also shutting down the steam supply to dryer by closing the
control valve (PV-4.2.01)

In emergency shutdown following actions are made:

- Steam supply to dryer is stopped by closing the control valve PV-4201 (PV-4.2.01)
- Stopping of material feed to system (not in Kumera's scope)
- Stopping dryer drum using normal procedure, electric supply to drive motors 5121-
SVP-2001M1/M2 (M-1.2.01/11) is cut off from frequency converters (coasting
stop).
Brakes 5121-SVP-2001M5/M6 (M-1.2.05/15) are closed after delay to enable drum
to fall back to balanced position. Motor fan 5121-SVP-2001M5/M6 (M-1.2.02/12)
are stopped.
- Vibration feeder 5121-AVB-2001M (M-2.1.01) is stopped.
- Off gas fan M-1700/1800 (M-7.3.01/02) are stopped
- The valves FV-1100...1408 (XV-6.7.01....14) off gas ducts before and after bag
filter are closed
- Dust conveyors M-1102/1202/1302/1402 (M-6.5.01/02/03/04), (M-6.6.01/02/03) are
stopped
- Airlock feeder (M-3.3.02) and screw 5121-TRS-3001M (M-3.3.01) are stopped

13.2 Ignition risk in exhaust gas line

High temperature of the concentrate and its dust in off gas increases risk of the ignition of
material. Therefore the temperatures of offgas gas and dried concentrate are monitored
and, emergency shutdown is activated, if gas temperature or dried concentrate
temperature rise too high (HH limit). This kind of situation can happen for example, when
material feed is stopped while high temperature steam is still supplied.
In emergency shutdown steam supply is closed and material feed and the whole
conveying line is stopped.
During normal operation the oxygen level in dryer is low, because in offgas there is water
vapour. In special situations, such as shut-downs, when no new material is supplied into
the drum, water vapour content decreases and oxygen level goes near the normal air
value. This increases risk of ignition of copper concentrate, because temperature can
also go up at the same time.
As rule for design of off gas line including selection of bag filter and conveyors, no dried
concentrate should be accumulated anywhere in the line. The accumulated concentrate
is a possible source of fire.
KUMERA TECHNOLOGY CENTER doc. 435111 01 45/ 46
CUSTOMER: Codelco Chuquicamata, Chile
CONTRACT: 4501679027
CONTROL SYSTEM DESCRIPTION

0 GENERAL .........................................................................................................................................................................1
0.1 Component and signal naming convention ...................................................................................................................1
0.2 Terminology .................................................................................................................................................................2
0.3 Operator interface ........................................................................................................................................................2
0.4 Data logging .................................................................................................................................................................3
0.5 Scope of delivery..........................................................................................................................................................3
0.6 Interfacing of dryer control system to plant systems .....................................................................................................3
0.6.1 Interface to plant control system ........................................................................................................................3
0.6.2 Interface between dryer PLC and motor control center ......................................................................................4
1 STEAM DRYER LOOPS ...................................................................................................................................................4
1.1 Material temperature inside steam dryer TE-1101 ... 1104 (TE-1.1.01 … 1.1.04), TE-1101 ... 1104 (TT-1.1.01 …
1.1.04) ....................................................................................................................................................................................4
1.2 Main drive control, speed indication and control 5121-SVP-2001M1 (M-1.2.01), 5121-SVP-2001M2 (M-1.2.11) ..........5
1.3 Main drive control with 2 motors ...................................................................................................................................6
1.4 Dryer local panel controls (A-1.2) .................................................................................................................................6
1.5 Temperature measurement of main motor winding TE-1201 (M-1.2.1-TE1), TE-1211 (M-1.2.11-TE1) .........................6
1.6 Gear box oil temperature TE-1203 (TE/TT-1.2.3), (TE/TT-1.2.13), (E-1.2.03), (E-1.2.13) ............................................7
1.7 Main drive brakes 5121-SVP-2001M5 (M-1.2.5), 5121-SVP-2001M6 (M-1.2.15) ..........................................................7
1.8 Lubrication control (A-1.3) ............................................................................................................................................8
1.9 Drive component fault situation ....................................................................................................................................9
1.10 Jump preventor ZSH-1501...1508 (XS-1.5.01,..., 08) ..............................................................................................9
2 STEAM DRYER FEED SYSTEM LOOPS..........................................................................................................................9
2.1 Feeding conveyor 5121-AVB-2001M (M-2.1.1) ............................................................................................................9
2.2 Level switch of input hopper LSH-2104 (LS-2.1.4)......................................................................................................10
2.3 Material feed rate WT-2075 (FT-2.0.01) .....................................................................................................................10
2.4 Permission for material input to dryer (XY-2.0.02) ......................................................................................................11
3 DISCHARGE SYSTEM LOOPS ......................................................................................................................................11
3.1 Steam Dryer Discharge End Pressure PT-3101 (PT-3.1.1).........................................................................................11
3.2 Control concept for air flow through the dryer TIC-3104 (TIC-3.1.04), (XY-3.1.01)......................................................12
3.2.1 Exhaust gas flow control principle ....................................................................................................................12
3.2.2 Maintaining negative pressure in the system ...................................................................................................13
3.3 Dried material temperature TE-3102 (TE-3.1.02), TE-3103 (TE-3.1.03), TIC-3102 (TIC-3.1.02) .................................13
3.4 Steam Dryer offgas temperature TE-3104 (TE-3.1.04) ...............................................................................................14
3.5 Dried material level switches LSH-3106 (LS-3.1.06), LSH-3110 (LS-3.1.10), LSH-3112 (LS-3.1.12) ..........................14
3.6 Airlock feeder (M-3.3.02), (SS-3.3.02) ........................................................................................................................15
3.7 Screw conveyor 5121-TRS-3001M (M-3.3.01) ...........................................................................................................15
3.8 Output material sample (XV-3.1.07) ...........................................................................................................................16
3.9 Gate valves (V-3.2.1), (V-3.2.11), (V-3.2.21) ..............................................................................................................16
4 STEAM PRESSURE REGULATING SYSTEM LOOPS ...................................................................................................16
4.1 Steam Dryer Incoming Steam Flow Indication FIT-4101 (FIT-4.1.01) .........................................................................16
4.2 Incoming Steam to pressure regulating unit Pressure indication PT-4101 (PT-4.1.01)................................................ 18
4.3 Incoming steam to pressure regulating unit temperature (TE-4.1.01)..........................................................................18
4.4 Steam Dryer Incoming Steam Pressure PIC-4201 (PIC-4.2.1), PT-4201 (PT-4.2.1) ...................................................18
4.4.1 Steam control valve PV-4201 (PV-4.2.01)........................................................................................................19
4.4.2 Operating Modes .............................................................................................................................................20
4.4.3 Protection of steam pipes ................................................................................................................................21
4.4.4 Protection of pressurized pipes at low temperatures ........................................................................................22
4.4.5 Limiting temperatures temperature, when drum stopped .................................................................................22
4.5 Steam Dryer Incoming Steam Pressure Relief Valve PSV-4201 (PSV-4.2.01) ...........................................................22
4.6 Manual control valve for incoming steam (CV-4.2.01) ................................................................................................22
4.7 Steam Dryer Incoming Steam Pressure Indication (PI-4.2.02) ....................................................................................22
4.8 Steam Dryer Incoming Steam Temperature Indication TE-4301 (TE-4.3.01) ..............................................................23
4.9 Shut-off valve for pipe connection (V-4.3.02) ..............................................................................................................23
5 STEAM TRAP UNIT LOOPS ...........................................................................................................................................23
5.1 Steam trap unit (XV-5.1.01), (XV-5.1.02), (XV-5.1.03), PT-5102 (PT-5.1.02), PT-5202 (PT-5.2.02), ...........................23
5.2 Steam trap unit temperatures TE-5101 (TE-5.1.01), TE-5201 (TE-5.2.01) .................................................................. 24
5.3 Condensate handling system .....................................................................................................................................24
5.3.1 Flash tank Level control LV-8102A (LV-8.10.01A), LV-8102B (LV-8.10.01B), PT-8101 (PT-8.1.01), LT-8102
(LT-8.1.02), LIC-8102 (LIC-8.1.02), XY-8102 (XY-8.1.02) ................................................................................................24
5.3.2 Pressure control of flash tank PV-8501 (PV-8.5.01), PIC-8101 (PIC-8.1.01), ................................................... 26
5.3.3 Starting and stopping of flash tank operation ...................................................................................................26
5.3.4 Pressure safety valve for flash tank PSV-8103 (PSV-8.1.03) ...........................................................................26
5.3.5 Flash tank over level switch LSH-8106 (LS-8.1.06)..........................................................................................27
5.3.6 Condensate pumping from condensate tank (5123-EST-2002), (M-8.3.01), (M-8.3.02), FS-8311 (FS-8.3.11),
FS-8321 (FS-8.3.21), PI-8330 (PI-8.3.30) ........................................................................................................................27
5.4 Condensate conductivity measurement (QT-5.3.01)...................................................................................................28
6 BAG FILTER LOOPS ......................................................................................................................................................29
6.1 Shut-off valves of bag filter FV-1100...1400 (XV-6.7.01...6.7.04), FV-1108...1408 (XV-6.7.11...6.7.14) ......................29
6.2 Trace heating of bag filter (A-6.2) ...............................................................................................................................30
6.3 Bag cleaning system of bag filter (A-6.3) ....................................................................................................................31
 6.4 Dust conveying system of bag filter M-1102...1402 (M-6.5.01...6.5.04), SSL-1102...1402 (SS-6.5.01...6.5.04), LSH-
1100...1400 (LS-6.1.01...6.1.04), ..........................................................................................................................................32
6.5 Vibrators of bag filter VBR-1100...1400 (Y-6.10.01...6.10.04) .....................................................................................32
6.6 Dust conveying system of bag filter (M-6.6.01/02/03) .................................................................................................33
6.7 Ventilation fans MY-1810 (M-6.9.01), MY-1812 (M-6.9.02) .........................................................................................33
7 EXHAUST GAS SYSTEM LOOPS ..................................................................................................................................33
7.1 Exhaust gas flow (FE-7.2.1) .......................................................................................................................................33
7.1.1 Flow measurement ..........................................................................................................................................33
7.1.2 Flow sensor mounting......................................................................................................................................34
7.2 Steam Dryer exhaust gas temperature TE-7203 (TE-7.2.03) ......................................................................................34
7.3 Offgas fan M-1700 (M-7.3.01), M-1800 (M-7.3.02) .....................................................................................................35
7.4 Dust removal fan from reject (M-7.1.05) .....................................................................................................................36
7.5 Airlock feeder of dust removal cyclone (M-7.1.06) ......................................................................................................36
7.6 Dust monitoring sensor XT-7501 (XT-7.5.01) .............................................................................................................37
8 STEAM DRYER ROTATION CONTROL AND INTERLOCKING .....................................................................................37
8.1 Dryer Drum Drive .......................................................................................................................................................37
8.1.1 Equipment numbers:........................................................................................................................................37
8.1.2 Drive electric motors ........................................................................................................................................37
8.1.3 Drum drive control description .........................................................................................................................37
8.1.4 Automatic line control mode.............................................................................................................................38
8.1.5 Manual control mode .......................................................................................................................................39
8.2 Interlocks for dryer drive .............................................................................................................................................39
8.3 Work safety aspects ...................................................................................................................................................40
9 NITROGEN SYSTEM LOOPS .........................................................................................................................................40
10 OPERATION OF STEAM DRYER ...................................................................................................................................40
10.1 Starting sequence of steam dryer .........................................................................................................................40
10.1.1 Preliminary work (manually by operator): .........................................................................................................40
10.1.2 The line start command from HMI (dryer is rotating and heating with steam is on) ...........................................40
10.2 Stopping sequence of steam dryer ........................................................................................................................41
10.2.1 Normal line stop...............................................................................................................................................41
10.2.2 Emergency stop...............................................................................................................................................41
11 TRACE HEATING ...........................................................................................................................................................41
12 ELECTRICAL SYSTEM...................................................................................................................................................41
12.1 Control power .......................................................................................................................................................41
12.2 Reserve power......................................................................................................................................................41
12.2.1 Procedure at power failure situation .................................................................................................................42
12.2.2 Control system functions for power failure handling .........................................................................................42
12.2.3 Dryer running during power failure ...................................................................................................................42
12.2.4 Things to be considered ..................................................................................................................................43
12.3 Motor control .........................................................................................................................................................43
12.3.1 Communication................................................................................................................................................43
12.3.2 Data to dryer PLC ............................................................................................................................................43
12.3.3 Data displaying on operator screens ................................................................................................................43
13 MISCELLANEOUS ..........................................................................................................................................................44
13.1 Emergency shutdown ...........................................................................................................................................44
13.2 Ignition risk in exhaust gas line .............................................................................................................................44
CUSTOMER: Codelco Chuquicamata, Chile KUMERA TECHNOLOGY CENTER
CONTRACT: 4501679027 Project 2191
KUMERA STEAM DRYER Doc. 435113 01
Starter type: DOL: direct on line starter, DOLR: direct on line, reversible Starter design: WiDr : withdrawable compartment
Electric consumer list
Rev. Drawn Date Change DOL-2W : direct on line, 2 speed/2 winding Fix : fixed compartment

G MSR 18.8.2017 VSD: Variable speed drive, frequency converter S = signal only, I = device/instrument

H MSR 22.9.2017 Ctr: Contactor, Sw: Control switch, CB: circuit breaker or fuses Location: F = field, C = control room/system, L = local panel, D = DCS

I MSR 9.10.2017 Load type: CT: constant torque, FT: fan, NLS: no-load start, LS: loaded start Scope: K = Kumera, O = others

J MSR 14.11.2017 M-6.9.01/0.2 to 1x115V50Hz ND: normal duty, HD: heavy duty

Scope K/O
Comp. ID Equipment Installed power Motor Voltage Reserve Service Starter / Duty Load data Specification Model Manufacturer Remarks Deli Rev
speed power electr. class very
ns supply

Kumera Customer / Nominal Nominal ND Esimated load

(Subcontracto power, power /HD
r)
mech. electrical
(automatic column) Pn / kW Sn / kVA rpm V RP type Mech. Electr. Torque Operation time
kW kVA type

G -01.2.01 Frequency 177,0 3*460V 50Hz RP Frequency converter for main CB - 126 Frequency converter installed in K 2) sep
converter drive 1 cabinet NEMA 12 (IP54),
M -01.2.01 Electric motor 160,00 1500 3*460V 50Hz Main drive motor VSD ND 113 CT Always when dryer line is on NEMA mounting, foot, encl.IP55, K 2) dri
PT100, separate cooling fan,
insulated N-end bearing
M -01.2.02 Electric motor 0,75 1,1 1500 3*460V 50Hz RP Fan motor of main motor DOL - 0,75 1,1 FT Always when dryer line is on Integrated in main motor, IP55, ? A K dri

M -01.2.05 Electric motor 0,32 0,53 3000 3*460V 50Hz RP Main drive brake, drive 1 DOL - 0,32 0,53 - On, when main drive Electric motor, integrated in the brake K Galvi dri
running thrustor
G -01.2.11 Frequency 177,0 3*460V 50Hz RP Frequency converter for main CB - 126 Frequency converter installed in K 2) sep
converter drive 1 cabinet NEMA 12 (IP54),
M -01.2.11 Electric motor 160,00 1500 3*460V 50Hz Main drive motor VSD ND 113 CT Always when dryer line is on NEMA mounting, foot, encl.IP55, K 2) dri
PT100, separate cooling fan,
insulated N-end bearing
M -01.2.12 Electric motor 0,75 1,1 1500 3*460V 50Hz RP Fan motor of main motor DOL - 0,75 1,1 FT Always when dryer line is on Integrated in main motor, IP55, ? A K dri

M -01.2.15 Electric motor 0,32 0,53 3000 3*460V 50Hz RP Main drive brake, drive 1 DOL - 0,32 0,53 - Always when dryer line is on Integrated in main motor, IP55, ? A K Galvi dri

A -01.3. Lubricator 0,2 1*220V 50Hz Lubrication of girth gear and CB 0,2 Always when dryer line is on K sep
pinion
M -01.4.01 Electric motor 3*460V 50Hz Hoist for pipe elements CB In heating pipe maintenance O delivery by others, -
power to be confirmed
E -01.2.03 A Heater 0,5 1*220V 50Hz Gearbox oil heater DOL 0,5 Accoding to oil temperature K 4) dri I

E -01.2.03 B Heater 0,5 1*220V 50Hz Gearbox oil heater DOL 0,5 Accoding to oil temperature K 4) I

E -01.2.13 A Heater 0,5 1*220V 50Hz Gearbox oil heater DOL 0,5 Accoding to oil temperature K 4) dri I

E -01.2.13 B Heater 0,5 1*220V 50Hz Gearbox oil heater DOL 0,5 Accoding to oil temperature K 4) I

M -02.1.01 Electric motor 0,27 0,4 3000 3*460V 50Hz Input chute vibration motor DOL 0,27 0,36 Intermittent (approx 5%) K

M -03.3.02 Electric motor 2,20 3,2 1500 3*460V 50Hz Airlock feeder for reject DOL-R 1,8 2,6 Always when dryer line is on K sep E

E -06.2.01 (HTR- Heater 4,5 3*460V 50Hz Bag filter trace heater, hopper Ctr According to wall K bfi C
1100) 1 (DOL) temperatures
E -06.2.02 (HTR- Heater 4,5 3*460V 50Hz Bag filter trace heater, hopper Ctr According to wall K bfi C
1200) 2 (DOL) temperatures
E -06.2.03 (HTR- Heater 4,5 3*460V 50Hz Bag filter trace heater, hopper Ctr According to wall K bfi C
1300) 3 (DOL) temperatures
E -06.2.04 (HTR- Heater 4,5 3*460V 50Hz Bag filter trace heater, hopper Ctr According to wall K bfi C
1400) 4 (DOL) temperatures
E -06.2.11 (HTR- Heater 10,5 3*460V 50Hz Bag filter trace heater, straight Ctr According to wall K bfi C
1102) walls 1 (DOL) temperatures
E -06.2.12 (HTR- Heater 10,5 3*460V 50Hz Bag filter trace heater, straight Ctr According to wall K bfi C
1202) walls 2 (DOL) temperatures
E -06.2.13 (HTR- Heater 10,5 3*460V 50Hz Bag filter trace heater, straight Ctr According to wall K bfi C
1302) walls 3 (DOL) temperatures
E -06.2.14 (HTR- Heater 10,5 3*460V 50Hz Bag filter trace heater, straight Ctr According to wall K bfi C
1402) walls 4 (DOL) temperatures
A -06.3. Cleaning system 1,0 1*220V 50Hz Bag filter cleaning system Ctr? 1 Always on, when dryer line K bfi
CB? running
M -06.5.01 (MY-1102) Electric motor 0,75 1,2 ?1500 3*460V 50Hz Airlock feeder of bag filter DOLR ND 0,71 1,2 CT Always when dryer line is on K bfi
chamber 1

M -06.5.02 (MY-1202) Electric motor 0,75 1,2 ?1500 3*460V 50Hz Airlock feeder of bag filter DOLR ND 0,71 1,2 CT Always when dryer line is on K bfi
chamber 2
M -06.5.03 (MY-1302) Electric motor 0,75 1,2 ?1500 3*460V 50Hz Airlock feeder of bag filter DOLR ND 0,71 1,2 CT Always when dryer line is on K bfi
chamber 3

27.11.2017 1/2
 Scope K/O
Comp. ID Equipment Installed power Motor Voltage Reserve Service Starter / Duty Load data Specification Model Manufacturer Remarks Deli Rev
speed power electr. class very
ns supply

Kumera Customer / Nominal Nominal ND Esimated load

(Subcontracto power, power /HD
r)
mech. electrical
(automatic column) Pn / kW Sn / kVA rpm V RP type Mech. Electr. Torque Operation time
kW kVA type
M -06.5.04 (MY-1402) Electric motor 0,75 1,2 ?1500 3*460V 50Hz Airlock feeder of bag filter DOLR ND 0,71 1,2 CT Always when dryer line is on K bfi
chamber 4
A -06.8. Control unit Bagfilter control unit K bfi
M -06.9.01 (MY-1810) Electric motor 0,19 0,3 1800 1*120V 50Hz Penthouse vent fan DOL 0,186 0,33 K brushless DC motor bfi J

M -06.9.02 (MY-1812) Electric motor 0,19 0,3 1800 1*120V 50Hz Penthouse vent fan DOL 0,186 0,33 K brushless DC motor bfi J

M -07.1.05 Electric motor 5,50 6,1 3000 3*460V 50Hz Fan for reject dust removal VSD 4 4,4 FT Always when dryer line is on K sep

M -07.1.06 Electric motor 0,37 0,7 1500 3*460V 50Hz Airlock feeder of the dust DOL-R 0,37 0,71 CT Always when dryer line is on K sep I

removal cyclone
G -07.3.01 Frequency 166,0 3*460V 50Hz RP Frequency converter of of gas CB 145 O sep F

converter fan
M -07.3.01 (MY1700) Electric motor 150,0 1500 3*460V 50Hz Offgas fan motor VSD - 130,6 FT Always when dryer line is on NEMA mounting, foot, encl. IP55, K 2) bfi F

PT100, insulated N-end bearing

G -07.3.02 Frequency 166,0 3*460V 50Hz Frequency converter of of gas CB 145 O sep F

converter fan
M -07.3.02 (MY1000) Electric motor 150,0 1500 3*460V 50Hz Offgas fan motor VSD - 130,6 FT Always when dryer line is on NEMA mounting, foot, encl. IP55, K 2) bfi F

PT100, insulated N-end bearing

G -08.3.01 Frequency 20,5 3*460V 50Hz Frequency converter of CB 12,9 O -
converter condensate pump 1
M -08.3.01 Electric motor 18,5 3000 3*460V 50Hz Condensate pump 1 VSD - 11,6 FT One pump as duty pump K 2) chs
M -08.3.01 E Space heater 0,05 1*220V 50Hz Electric motor space heater Ctr 0,05 Always on, when pump not K chs
running
G -08.3.02 Frequency 20,5 3*460V 50Hz Frequency converter of CB 12,9 O -
converter condensate pump 2
M -08.3.02 Electric motor 18,5 3000 3*460V 50Hz Condensate pump 2 VSD - 11,6 FT One pump as duty pump K 2) chs
M -08.3.02 E Space heater 0,05 1*220V 50Hz Electric motor space heater Ctr 0,05 Always on, when pump not K chs
running
A -30.1.01 Control unit 1,0 1*120V 50Hz, Dryer PLC, +CA0 CB 1 K sep
UPS
A -30.1.02 Remote IO unit 0.5 1*120V 50Hz, Remote IO unit cabinet +A01.2 CB 0,5 K sep
UPS
A -30.2.01 Control unit 1,0 1*120V 50Hz, Dryer operation station, CB 0,5 K sep
UPS +A.HMI

Installed motor power (mech.) 671 kW 522,2 kW Mechanical power, estimated

Installed power (electr.) 811,4 kVA 589,9 kVA Electric power, estimated

Delivery code
sep = separately / integrated in : prs = pressure reducing station, sts = steam trap station, dri = dryer drive unit, sco = screw conveyor, alf =air lock feeder
mcc = motor control center, bfi = bag filter, cru = crusher, chs = condensate handling system

Notes: 1) Powers in table expressed in kW, motor rating may be in HP.

2) More details in field component list
3) In list basically only data of equipment in Kumera's delivery

27.11.2017 2/2
CUSTOMER: Codelco Chuquicamata, Chile KUMERA TECHNOLOGY CENTER
CONTRACT: 4501679027 Project 2191
KUMERA STEAM DRYER 435123 01
INSTRUMENT AND SIGNAL LIST

Rev. Date Change Drawn Abbreviations: Dryer areas (1. number of tag)

I 11.9.2017 MSR General: SP = setpoint, normal or nominal value, LL,L,H,HH = alarms Signal Connection: 1 = Steam Dryer 7 = Exhaust Gas System

J 27.9.2017 MSR IOBus = connection via system data bus (Profibus DP) DCS= Plant DCS, PLC= PLC of dryer, FC= frequency conv. 2 = Feed System 8=

K 10.10.02017 HVM FC=spring to close, FO=spring to open, FL=fail to latch PDCS= plant DCS, i = signals defined in other row of device 3 = Discarge System 9 = Nitrogen system

In component ID: i = input, o = output of DCS MS= motor starter unit, OD= other device 4 = Pressure Regulating Station

Notes: Data of each signal loop is written normally on sensor's row only. Type: SW = signal only, HW = device/instrument, - = mechnics 24IO = digital inputs/outputs 24Vdc, 24IOR = digital remote inputs/outputs 24Vdc 5 = Steam Trap Station

Device data is on the row of its main motor (generally). Scope: K = Kumera, O = others, - = only signal /part of component 120IO, 230IO = digital inputs/outputs 120Vac, 230Vac 6 = Bag Flter

Location: F = field, L = local panel, D = DCS program/screen, C = DCS wiring panel, M = MCC PFC = potential free contact, PFC-R = potential free contact in remote IO unit Barrier: marked if needed for hazardous environment
Environment: Altitude 2800 m, pressure 72 kPa(a), temperature -5 ... 30ºC
Kumera Customer Tag / Instrument /signal /device Service Measuring/ operation range Instrument data Process material Process pipe I/O for DCS (or PLC) Instrument/ Remark Rev
Tag (Subcontractor tag) signal
Information
Signal Connection Transmitte Material p T Type Loc. Scope

r,
(automatic 0% 100 % unit SP LL L H HH Sensor Class Type Connec- Power Type D L Approvals, Actuator nom. max nom. max max DN PN/ Dig in Dig out An in An out IO bus Barrier Cont
column) tion to supply (min) (min) instrum /materia CL roller
type material,
mm mm ATEX, IP ent l
kPa(g) kPa(g) °C °C °C
TE-01.01.01 TE-1101 Temperature sensor Material in drum, feed end 0 150 °C 40 130 PT100, 4- A Wireless PLC battery flange, 27 /18 310 ATEX II 3 D wireless, Cu-conc., -0.1 - - 1 HW F K I

wire HART, DN25 PN40 separate abrasive

2.4GHz
TI-01.01.01 TI-1101 Temperature indication Material temperature in drum i i SW D -

TT-01.01.01 TT-1101 Temperature transmitter Wireless transmitter i i HW F K

TE-01.01.02 TE-1102 Temperature sensor Material in drum, middle part 0 150 °C 60 130 PT100, 4- A Wireless PLC battery flange, 27 /18 225 ATEX II 3 D wireless, Cu-conc., -0.1 - - 1 HW F K

wire HART, DN25 PN40 separate abrasive

2.4GHz
TI-01.01.02 TI-1102 Temperature indication Material temperature in drum i i SW D -

TT-01.01.02 TT-1102 Temperature transmitter Wireless transmitter i i HW F K

TE-01.01.03 TE-1103 Temperature sensor Material in drum, middle part 0 150 °C 80 130 PT100, 4- A Wireless PLC battery flange, 27 /18 225 ATEX II 3 D wireless, Cu-conc., -0.1 - - 1 HW F K

wire HART, DN25 PN40 separate abrasive

2.4GHz
TI-01.01.03 TI-1103 Temperature indication Material temperature in drum i PLC SW D -

TT-01.01.03 TT-1103 Temperature transmitter Wireless transmitter i PLC HW F K

TE-01.01.04 TE-1104 Temperature sensor Material temperature in drum, discharge end 0 150 °C 100 130 PT100, 4- A Wireless PLC battery flange, 27 /18 225 ATEX II 3 D wireless, Cu-conc., -0.1 - - 1 HW F K

wire HART, DN25 PN40 separate abrasive

2.4GHz
TI-01.01.04 TI-1104 Temperature indication Material temperature in drum i i SW D -

TT-01.01.04 TT-1104 Temperature transmitter Wireless transmitter i i HW F K

PDT-01.01.10 PDT-1110 Pressure differential sensor Pressure in the input end of the drum -1 1 kPa(g) -0.1 -0.3 -0.01 -0.005 4...20mA DCS loop thread NPT Air (wet), -0.1 25 -5, - - 1 HW F K
HART (impulse 1/4-18 dust, +130
pipe)
V-01.01.10 Manifold Manifold for differential pressure sensor, 3-valve - - - thread NPT 1/2" air -0.1 40 HW F K
(impulse
pipe)
TE-01.01.11 TE-1111 Temperature sensor Input gas temperature to drum 0 150 °C 50 PT100, 4- A 4...20mA DCS loop ATEX II 3 D head- ambient air 0 25 -5, - - 1 HW F K

wire HART mounted +130

TT-01.01.11 TT-1111 Temperature transmitter Input gas temperature to drum i i HW F K

TR-01.01. TR-1100 Temperature receiver Wireless receiver Ethernet/ PLC 24Vdc 1 HW F K Signals from SD and
Profibus DP PD transmitters

G-01.02.01 Frequency converter Main drive frequency converter, drive 1 0 1500 Nm IObus PLC 1 HW M K

M-01.02.01 5121-SVP-2001M1 Electric motor Main drive motor 1 0 2 rpm i FC HW F K

M-01.02.01-SC SC-1201 Frequency converter Rotation speed reference to frequency 0 2 rpm i PLC 1 SW D -

converter.
M-01.02.01-SI SI-1201 Speed alarm and indication Dryer drum rotating speed, DCS display 0 2 rpm 0.05 2.05 i PLC 1 SW D -

M-01.02.01-TE1 TE-1201 Temperature sensor Main motor winding, PT100, motor 1 0 200 °C PT100 PT100 FC 1 HW F K

M-01.02.01-XI NI-1201 Torque display Main motor load torque signal from frequency 0 200 % 1025 Nm i PLC 1 SW D -

converter 1
M-01.02.02 5121-SVP-2001M3 Electric motor Main motor fan, motor 1. IOBus MS 1 HW F K

E-01.02.03 Space heater Gearbox space heater, drive 1 1

TE-01.02.03 TE-1203 Temperature sensor Gear oil temperature, drive 1. -10 120 °C 10 90 4…20mA PLC loop 1 HW F K sensor integrated in
gearbox

TI-01.02.03 TI-1203 Temperature indication i PLC SW D -

TT-01.02.03 TT-1203 Temperature transmitter i PLC HW F K

M-01.02.05 5121-SVP-2001M5 Brake thruster Main drive brake, electro-hydraulic thruster, drive 0 ? Nm IOBus MS 1 HW F K

1
M-01.02.05-ZS ZS-1205 Limit switch Status of brake, 1=open, drive 1 on off mech. PFC PLC 1 HW F K

G-01.02.11 Frequency converter Main drive frequency converter, drive 2 0 1500 Nm IObus PLC 1 HW M K

M-01.02.11 5121-SVP-2001M2 Electric motor Main motor, drive 2 0 2 rpm i FC HW F K

M-01.02.11-SI SI-1211 Speed alarm and indication Dryer drum rotating speed, DCS display 0 2 rpm 0.05 2.05 i PLC 1 SW D -

M-01.02.11-TE1 TE-1211 Temperature sensor Main motor winding, P100, motor 2 0 200 °C PT100 FC 1 HW F K

M-01.02.11-XI NI-1211 Torque display Main motor load torque signal from frequency 0 200 % 1025 Nm i PLC 1 SW D -

converter 2
M-01.02.12 5121-SVP-2001M4 Electric motor Main motor fan, motor 2. IOBus MS 1 HW F K

E-01.02.13 Space heater Gearbox space heater, drive 2 1

TE-01.02.13 TE-1213 Temperature sensor Gear oil temperature, drive 2 -10 120 °C 10 90 4…20mA PLC loop 1 HW F K sensor integrated in
gearbox

TI-01.02.13 TI-1213 Temperature indication i PLC SW D -

TT-01.02.13 TT-1213 Temperature transmitter i PLC HW F K

M-01.02.15 5121-SVP-2001M6 Brake thruster Main drive brake, electro-hydraulic thruster, drive ? Nm IOBus MS 1 HW F K

2
M-01.02.15-ZS ZS-1215 Limit switch Status of brake, 1=open, drive 2 off on mech. PFC PLC 1 HW F K

A-01.02.20 XL-1220 Alarm device Alarm beacon for dryer movement off on 1 HW F O?

A-01.03.-XI XA-1230 Fault alarm Lubrication unit alarm on off PFC PLC 1 SW D -

A-01.03.-XS Lubrication unit Start command, 1= lubrication on off on PFC PLC 1 SW D -

A-01.03. Lubricator Lubrication of girth gear and pinion. Includes i PLC 120Vac HW F K

control unit.
M-01.04.01 5121-TCL-3003M Electric motor Hoist motor, element handling ?3 ton - MS HW F O

XS-01.05.01 ZSH-1501 Proximity sensor Jump preventor status, support roller 1 off on inductive 120IO PLC loop 1 HW F K

XS-01.05.02 ZSH-1502 Proximity sensor Jump preventor status, support roller 1 off on inductive 120IO PLC loop 1 HW F K

XS-01.05.03 ZSH-1503 Proximity sensor Jump preventor status, support roller 2 off on inductive 120IO PLC loop 1 HW F K

XS-01.05.04 ZSH-1504 Proximity sensor Jump preventor status, support roller 2 off on inductive 120IO PLC loop 1 HW F K

XS-01.05.05 ZSH-1505 Proximity sensor Jump preventor status, support roller 3 off on inductive 120IO PLC loop 1 HW F K

XS-01.05.06 ZSH-1506 Proximity sensor Jump preventor status, support roller 3 off on inductive 120IO PLC loop 1 HW F K

XS-01.05.07 ZSH-1507 Proximity sensor Jump preventor status, support roller 4 off on inductive 120IO PLC loop 1 HW F K

1/6 27.11.2017
Kumera Customer Tag / Instrument /signal /device Service Measuring/ operation range Instrument data Process material Process pipe I/O for DCS (or PLC) Instrument/ Remark Rev
Tag (Subcontractor tag) signal
Information
Signal Connection Transmitte Material p T Type Loc. Scope

r,
(automatic 0% 100 % unit SP LL L H HH Sensor Class Type Connec- Power Type D L Approvals, Actuator nom. max nom. max max DN PN/ Dig in Dig out An in An out IO bus Barrier Cont
column) tion to supply (min) (min) instrum /materia CL roller
type material,
mm mm ATEX, IP ent l
kPa(g) kPa(g) °C °C °C
XS-01.05.08 ZSH-1508 Proximity sensor Jump preventor status, support roller 4 off on inductive 120IO PLC loop 1 HW F K

FT-02.00.01 WT-2075 Plant system Input material feed rate to steam dryer 0 260 t/h 230 20 250 4…20mA PLC - 1 HW D O

XY-02.00.02 Signal Signal to plant system for giving permission to on off PFC PLC SW D -

wet material feed

M-02.01.01 5121-AVB-2001M Electric motor Input feeder vibration motor kg/h IOBus MS - - 1 HW F K

LS-02.01.04 LSH-2104 Level switch Material level high high alarm in input hopper on off PFC PLC 120Vac CU-conc. 1 HW F K

PI-03.01.01 PI-3101 Pressure indication Pressure inside the discharge end i PLC SW D -

PIC-03.01.01 Pressure controller Discharge chamber pressure controller 0 100 % i PLC 1 SW D - I

PT-03.01.01 PT-3101 Pressure transmitter Pressure inside the discharge end chamber 0 -0.5 kPa -0.1 -0.4 -0.01 -0.005 4...20mA PLC loop thread G1/2" ATEX II 3 D Air (wet), -0.1 105 130 40 - - 1 HW F K
HART (impulse dust,
pipe)
V-03.01.01 Gauge valve Pressure sensor shut-off valve - - impulse G1/2" air - - - F K
pipe, thread

XY-03.01.01 Calculation element Concentrate feed rate signal effect to exhaust - - - - SW D -

gas flow
TE-03.01.02 TE-3102 Temperature element Temperature of the dryed material, hopper 0 150 °C 115 95 125 135 PT100, 4- A 4...20mA, PLC loop flange, 27 /18 225 ATEX II 3 D head- Cu-concentr. -0.1 0 - - 1 HW F K

wire HART DN25 PN40 mounted

TI-03.01.02 TI-3102 Temperature indication Temperature of the dryed material i PLC - - SW D -

TIC-03.01.02 TIC-3102 Temperature controller Dryed material temperature control loop, setpoint 0 100 % i PLC - - 1 SW D -

to steam pressure
TT-03.01.02 TT-3102 Temperature transmitter Temperature of the dryed material i PLC - - HW F K

TE-03.01.03 TE-3103 Temperature element Temperature of the dryed material, hopper 0 150 °C 115 95 125 135 PT100, 4- A 4...20mA, PLC loop flange, 27 /18 225 ATEX II 3 D head- Cu-concentr. -0.1 0 - - 1 HW F K

wire HART DN25 PN40 mounted

TI-03.01.03 TI-3103 Temperature indication Temperature of the dryed material i PLC - - SW D -

TT-03.01.03 TT-3103 Temperature transmitter Temperature of the dryed material i PLC - - HW F K

TE-03.01.04 TE-3104 Temperature sensor Exhaust gas temperature 0 200 °C 125 100 135 140 PT100, 4- A 4...20mA, PLC loop thread 12 580 ATEX II 3 D head- Air (wet), -0.1 - - 1 HW F K

wire HART G1/2" mounted dust

TI-03.01.04 TI-3104 Temperature indication Exhaust gas temperature i PLC SW D -

TIC-03.01.04 TIC-3104 Temperature controller Temperature (exhaust gas flow) control of the 0 100 % i PLC 1 SW D -

discharge end, high/low -alarm

TT-03.01.04 TT-3104 Temperature transmitter Exhaust gas temperature i PLC HW F K

LS-03.01.06 LSH-3106 Level switch Level of concentrate in discharge end, highhigh on off vibration PFC PLC 120Vac flange DN50 A 300 ATEX II 3 D Cu-concentr. -0.1 110 130 - - 1 HW F K

XV-03.01.07 Sample extraction hole Output material sample - - - - HW F K manual, not DCS

E-03.01.08 Trace heating Discharge chamber heating - - HW F O 1)

LS-03.01.10 LSH-3110 Level switch Level of concentrate in reject hopper, highhigh on off vibration PFC PLC 120Vac flange DN50 A 300 ATEX II 3 D Cu-concentr. -0.1 110 130 - - 1 HW F K

LS-03.01.12 LSH-3112 Level switch Level of concentrate in discharge end, highhigh on off vibration PFC PLC 120Vac flange DN50 A 300 ATEX II 3 D Cu-concentr. -0.1 110 130 - - 1 HW F K

V-03.02.01 Gate valve Manual shut-off for dry material - - - HW F O

V-03.02.11 Gate valve Manual shut-off for dry material - - - - HW F O

V-03.02.21 Gate valve Manual shut-off for dry material - HW F O

M-03.03.01 5121-TRS-3001M Electric motor Screw feeder for reject IOBus MS 1 HW F O

M-03.03.02 Electric motor Airlock feeder for reject IOBus MS 1 HW F K E

SS-03.03.02 Speed monitor Speed detection of reject airlock feeder off on 120IO PLC thread M30 1 HW F K G

V-03.03.02 Gate valve Manual shut-off for reject - - - HW F O

XY-03.04.01 Signal Signal from plant system to allow dry material off on PFC PLC - - 1 SW D -

output from dryer

XY-03.04.02 Signal Signal from plant system to allow reject output off on PFC PLC - - 1 SW D -

from dryer
FI-04.01.01 FI-4101 Flow display Input steam flow SW D K

FIT-04.01.01 FIT-4101 Flow sensor Input steam flow 0 50000 kg/h 44672 500 47000 vortex 4...20mA PLC loop flange 8" 316L Steam 2200 2500 220 226 226 8" 300 1 HW F K scaling 4...20mA/
HART 0...5000 m3/h, local
(5000) (m3/h) (3878) display
PI-04.01.01 PI-4101 Pressure indication Pressure of supply steam (high pressure side) 0 2500 kPa(g) i PLC SW D -

PT-04.01.01 PT-4101 Pressure transmitter Pressure of supply steam (high pressure side) 0 2500 kPa(g) 2200 50 2250 2280 4…20mA PLC loop impulse G1/2" 316L Steam 2200 2500 220 226 80 8" 300 1 HW F K
HART pipe, thread

TE-04.01.01 TE-4101 Temperature sensor Input steam temperature (high pressure side) 0 250 °C 220 240 PT100, 4- A 4…20mA PLC loop weld-in 24 200 AISI 316 head- Steam 2200 2500 220 226 8" 300 1 HW F K

wire HART /65 mounted

TE-04.01.01-TW Thermowell Input steam temperature (high pressure side) - - i ASME HW F K

TI-04.01.01 TI-4101 Temperature indication Supply steam temperature (high pressure side) i PLC SW D -

TT-04.01.01 TT-4101 Temperature transmitter mA -transmitter i PLC HW F K

V-04.01.01 Gauge valve Pressure sensor shut-off valve - - impulse G1/2" steam 2500 226 120 8" 300 - F K
pipe, thread

V-04.01.05 Flow conditioner Steam flow measurement flow stabilizing - - flange 2500 226 8" 300 HW F K

V-04.01.11 Shut-off valve Shut-off for input pipe steam trap - - flange 2500 226 1" 300 - F K

V-04.01.12 Steam trap Steam trap for input pipe - - flange 2500 226 1" 300 - F K

V-04.01.13 Shut-off valve Shut-off for input pipe steam trap - - flange 2500 226 1" 300 - F K

V-04.01.14 Shut-off valve Water draining from impulse pipe flange 1/2" 2500 226 8" 300 - F K

CV-04.02.01 ???PV-4201 Control valve Manual control valve for steam adjusting steam 0 4000 kg/h - - flange 2-1/2" manual Steam, 2200 2500 220 226 2 1/2" 300 1 HW F K

input in start-up
PIC-04.02.01 PIC-4201 Pressure indicating controller Pressure control of dryer steam 0 100 % - - 1 SW D -

PSV-04.02.01 PSV-4201 Pressure safety valve Dryer steam pressure 2300 kPa(g) 41734 - - flange 4" /6" Steam 2000 2500 215 226 4"/6" 300 HW F K not to DCS D

kg/h
PT-04.02.01 PT-4201 Pressure transmitter Dryer steam pressure 0 2500 kPa(g) 2000 50 2100 4…20mA PLC loop impulse G1/2" 316L Steam 2000 2500 215 226 80 10" 300 1 HW F K
HART pipe, thread

PV-04.02.01 PV-4201 Control valve Pressure regulating valve for adjusting steam 0 50000 kg/h 19100… 4…20mA PLC loop flange 8" ASME pneumatic, Steam, 2000 2500 212 240 8" 300 1 HW F K

input to dryer 44700 HART Section VIII, FC

div.1 ed.
2013
PV-04.02.01-XI ZT-4201 Control valve Control valve position feedback 4…20mA PLC - - - - 1 HW F K

V-04.02.01 Gauge valve Pressure sensor shut-off valve - - impulse G1/2" steam 2500 215 120 8" 300 - F K
pipe, thread

ZY-04.02.01 Calculation element Detecting of sudden pressure drop, derivative of - - SW D -

pressure PT-4.2.1

2/6 27.11.2017
Kumera Customer Tag / Instrument /signal /device Service Measuring/ operation range Instrument data Process material Process pipe I/O for DCS (or PLC) Instrument/ Remark Rev
Tag (Subcontractor tag) signal
Information
Signal Connection Transmitte Material p T Type Loc. Scope

r,
(automatic 0% 100 % unit SP LL L H HH Sensor Class Type Connec- Power Type D L Approvals, Actuator nom. max nom. max max DN PN/ Dig in Dig out An in An out IO bus Barrier Cont
column) tion to supply (min) (min) instrum /materia CL roller
type material,
mm mm ATEX, IP ent l
kPa(g) kPa(g) °C °C °C
PI-04.02.02 PI-4202 Pressure meter Dryer steam pressure, mechanical 0 2500 kPa(g) - - impulse G1/2" Steam 2000 2500 215 226 10" 300 HW F K not to DCS
pipe, G½"
V-04.02.02 Shut-off valve Separating for steam control valve, before - - flange 8" 2500 226 8" 300 - F K

V-04.02.03 Shut-off valve Separating for steam control valve, after - - flange 8" 2500 226 10" 300 - F K

V-04.02.04 Gauge valve Pressure meter shut-off valve - - impulse G1/2" steam 2500 215 120 8" 300 - F K
pipe, thread

V-04.02.10 Shut-off valve Water draining from impulse pipe - - flange 1/2" condensate 2500 226 10" 300 - F K

V-04.02.11 Shut-off valve Water draining from impulse pipe - - flange 1/2" condensate 2500 226 10" 300 - F K

TE-04.03.01 TE-4301 Temperature sensor Input steam temperature (low pressure side) 0 250 °C 215 240 PT100, 4- A 4…20mA PLC loop weld-in 24 200 AISI 316 head- Steam 2000 2400 10" 300 1 HW F K

wire HART /65 mounted

TE-04.03.01-TW - - i ASME HW F K

TI -04.03.01 TI-4301 Temperature indication Dryer input steam temperature i PLC SW D -

TT-04.03.01 TT-4301 Temperature transmitter mA -transmitter i PLC HW F K

V-04.03.02 Shut-off valve Shut-off valve for connection to pipe - - flange 2500 226 1" 300 - F K

TE-05.01.01 TE-5101 Temperature sensor Condensate temperature before steam trap 0 250 °C 210 100 220 PT100, 4- A 4…20mA PLC loop weld-in 24 200 AISI 316 head- steam, 2000 2300 212 226 4" 300 1 HW F K

wire HART /65 mounted condensate

TE-05.01.01-TW Thermowell Condensate temperature before steam trap - - i ASME HW F K

TI-05.01.01 TI-5101 Temperature indication Concdensate temperature before steam trap i i SW D -

TT-05.01.01 TT-5101 Temperature transmitter Concdensate temperature before steam trap i i - - HW F K

V-05.01.01 Shut-off valve Condensate line shut-off valve - - flange 2500 226 2" 300 - F K

XV-05.01.01 Steam trap Condensate handling from steam dryer, 0 21000 kg/h - - flange 2" steam, 212 226 2" 300 HW F K

expansion chamber type (0.5MPa condensate

)
PI-05.01.02 PI-5102 Pressure indication Pressure of condensate before steam traps i PLC DN50 SW D -

PT-05.01.02 PT-5102 Pressure transmitter Pressure of condensate before steam trap 0 2500 kPa(g) 2000 10 2100 4…20mA PLC loop impulse DN50 316L steam, 2000 215 215 226 70 4" 300 1 HW F K
pipe, thread condensate

V-05.01.02 Shut-off valve Condensate line shut-off valve - - flange 2500 226 2" 300 - F K

XV-05.01.02 Steam trap Condensate handling from steam dryer, 0 21000 kg/h - - flange 2" steam, 212 226 2" 300 HW F K

expansion chamber type (0.5MPa condensate

)
V-05.01.03 Shut-off valve Condensate line shut-off valve - - flange 2500 226 2" 300 - F K

XV-05.01.03 Steam trap Condensate handling from steam dryer, 0 21000 kg/h - - flange 2" steam, 212 226 2" 300 HW F K

expansion chamber type (0.5MPa condensate

)
PI-05.01.04 PI-5104 Pressure meter Condensate line pressure before steam traps 0 2500 kPa(g) - - impulse G1/2" steam, 212 226 4" 300 HW F K not to DCS
pipe, thread condensate

V-05.01.04 Shut-off valve Condensate line shut-off valve, discharge - - flange 2500 226 1" 300 - F K

V-05.01.05 Shut-off valve Condensate line shut-off valve, discharge - - flange 2500 226 1" 300 - F K

V-05.01.06 Shut-off valve Condensate line shut-off valve, discharge - - flange 2500 226 1" 300 - F K

V-05.01.07 Shut-off valve Condensate line shut-off valve, by-pass - - flange 2500 226 2" 300 - F K

V-05.01.08 Shut-off valve Condensate line shut-off valve, discharge - - flange 2500 226 1" 300 - F K

V-05.01.09 Gauge valve Pressure meter shut-off valve - - impulse G1/2" steam, 2500 215 120 4" 300 - F K
pipe, thread condensate

V-05.01.10 Gauge valve Condensate pressure sensor shut-off - - impulse G1/2" steam, 2500 215 120 4" 300 - F K
pipe, thread condensate

TE-05.02.01 TE-5201 Temperature sensor Condensate temperature after steam trap 0 250 °C 144 90 160 PT100, 4- A 4…20mA PLC loop weld-in 24 200 AISI 316 head- condensate 300 700 144 150 8" 300 1 HW F K

wire HART /65 mounted

TE-05.02.01-TW Thermowell Condensate temperature after steam trap - - i ASME HW F K

TI-05.02.01 TI-5201 Temperature indication Concdensate temperature after steam trap i i SW D -

TT-05.02.01 Temperature transmitter Concdensate temperature after steam trap i i - - HW F K

V-05.02.01 One direction valve Condensate line one direction valve - - flange 2500 226 3" 300 - F K

PI-05.02.02 PI-5202 Pressure indication Pressure of condensate after steam traps - - SW D -

PT-05.02.02 PT-5202 Pressure transmitter Pressure of condensate after steam trap 0 2500 kPa(g) 300 10 2100 4…20mA PLC loop impulse G1/2" 316L condensate 300 700 144 170 70 8" 300 1 HW F K
pipe, thread

V-05.02.02 One direction valve Condensate line one direction valve - - flange 2500 226 3" 300 - F K

V-05.02.03 One direction valve Condensate line one direction valve - - flange 2500 226 3" 300 - F K

V-05.02.04 Shut-off valve Condensate line shut-off valve - - flange 2500 226 3" 300 - F K

PI-05.02.05 PI-5205 Pressure meter Condensate line pressure after steam traps 0 2500 kPa(g) - - impulse G½" condensate 8" 300 HW F K not to DCS
pipe, thread

V-05.02.05 Shut-off valve Condensate line shut-off valve - - flange 2500 226 3" 300 - F K

V-05.02.06 Shut-off valve Condensate line shut-off valve - - flange 2500 226 3" 300 - F K

V-05.02.07 Shut-off valve Condensate line shut-off valve, discharge - - flange 2500 226 1" 300 - F K

V-05.02.08 Shut-off valve Condensate line shut-off valve, discharge - - flange 2500 226 1" 300 - F K

V-05.02.09 Shut-off valve Condensate line shut-off valve, discharge - - flange 2500 226 1" 300 - F K

V-05.02.10 Gauge valve Pressure meter shut-off valve - - impulse G1/2" condensate 2500 226 120 8" 300 - F K
pipe, thread

V-05.02.11 Gauge valve Condensate pressure sensor shut-off - - impulse G1/2" condensate 2500 226 120 8" 300 - F K
pipe, thread

QE-05.03.01 QE-5301 Conductivity sensor Conductivity of condensate water 0 1000 uS/cm 20 200 4...20 mA PLC thread G1" condensate 2500 226 1/2" 300 HW F K I

QIT-05.03.01 QIT-5301 Conductivity transmitter Conductivity of condensate water i i HW F K J

V-05.03.02 Control valve Manual adjusting water flow to conductivity 0.006 m3/h condensate 2500 226 1/2" 300 HW F K

sensor
V-05.03.04 Shut-off valve Conductivity measuement shut-off valve
TI-05.03.03 Temperature meter Temperature of water to conductivity sensor, 0 200 °C 60 condensate 2500 226 1/2" 300 HW F K

mechanical
LS-06.01.01 LSH-1100 Level switch Level of dust in bag filter hopper, highhigh, on off capacitive PFC PLC 120Vac thread 1-1/4" ? ATEX II 3 D Cu-concentr. -0.1 110 130 1 HW F K D

chamber 1
LS-06.01.02 LSH-1200 Level switch Level of dust in bag filter hopper, highhigh, on off capacitive PFC PLC 120Vac thread 1-1/4" ? ATEX II 3 D Cu-concentr. -0.1 110 130 1 HW F K D

chamber 2
LS-06.01.03 LSH-1300 Level switch Level of dust in bag filter hopper, highhigh, on off capacitive PFC PLC 120Vac thread 1-1/4" ? ATEX II 3 D Cu-concentr. -0.1 110 130 1 HW F K D

chamber 3
LS-06.01.04 LSH-1400 Level switch Level of dust in bag filter hopper, highhigh, on off capacitive PFC PLC 120Vac thread 1-1/4" ? ATEX II 3 D Cu-concentr. -0.1 110 130 1 HW F K D

chamber 4
E-06.02.01 HTR-1100 Trace heater Wall heating, hopper 1 on off IOBus MS 1
TE-06.02.01 TE-1100 Temperature sensor Bag filter temperature, hopper 1 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.01 TT-1100 Temperature transmitter Bag filter temperature, hopper 1 i i
E-06.02.02 HTR-1200 Trace heater Wall heating, hopper 2 on off IOBus MS 1

3/6 27.11.2017
Kumera Customer Tag / Instrument /signal /device Service Measuring/ operation range Instrument data Process material Process pipe I/O for DCS (or PLC) Instrument/ Remark Rev
Tag (Subcontractor tag) signal
Information
Signal Connection Transmitte Material p T Type Loc. Scope

r,
(automatic 0% 100 % unit SP LL L H HH Sensor Class Type Connec- Power Type D L Approvals, Actuator nom. max nom. max max DN PN/ Dig in Dig out An in An out IO bus Barrier Cont
column) tion to supply (min) (min) instrum /materia CL roller
type material,
mm mm ATEX, IP ent l
kPa(g) kPa(g) °C °C °C
TE-06.02.02 TE-1200 Temperature sensor Bag filter temperature, hopper 2 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.02 TT-1200 Temperature transmitter Bag filter temperature, hopper 2 i i
E-06.02.03 HTR-1300 Trace heater Wall heating, hopper 3 on off IOBus MS 1
TE-06.02.03 TE-1300 Temperature sensor Bag filter temperature, hopper 3 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.03 TT-1300 Temperature transmitter Bag filter temperature, hopper 3 i i
E-06.02.04 HTR-1400 Trace heater Wall heating, hopper 4 on off IOBus MS 1
TE-06.02.04 TE-1400 Temperature sensor Bag filter temperature, hopper 4 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.04 TT-1400 Temperature transmitter Bag filter temperature, hopper 4 i i
E-06.02.11 HTR-1102 Trace heater Wall heating, upper part, chamber 1 IOBus MS 1
TE-06.02.11 TE-1102 Temperature sensor Bag filter temperature, upper chamber 1 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.11 TT-1102 Temperature transmitter Bag filter temperature, upper chamber 1 i i
E-06.02.12 HTR-1202 Trace heater Wall heating, upper part, chamber 2 IOBus MS 1
TE-06.02.12 TE-1202 Temperature sensor Bag filter temperature, upper chamber 2 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.12 TT-1202 Temperature transmitter Bag filter temperature, upper chamber 2 i i
E-06.02.13 HTR-3102 Trace heater Wall heating, upper part, chamber 3 IOBus MS 1
TE-06.02.13 TE-1302 Temperature sensor Bag filter temperature, upper chamber 3 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.13 TT-1302 Temperature transmitter Bag filter temperature, upper chamber 3 i i
E-06.02.14 HTR-1402 Trace heater Wall heating, upper part, chamber 4 IOBus MS 1
TE-06.02.14 TE-1402 Temperature sensor Bag filter temperature, upper chamber 4 0 200 °C 110 90 140 J-type 4...20mA PLC 1
TT-06.02.14 TT-1402 Temperature transmitter Bag filter temperature, upper chamber 4 i i
PDIT-06.03.01 PDIT-1002 Differential pressure sensor Pressure difference accross the bag filter 0 4 kPa 4…20mA PLC 1 HW F K integrated in cleaning
unit A-6.3

A-06.03.11-XS1 KY-1104 Cleaning unit Remote control, 1= cleaning forced, Chamber 1 off on 1 HW F K

A-06.03.11-XI1 KC-1104 Cleaning unit Status, 1= last pulse active, Chamber 1 off on 1 HW F K

A-06.03.11-XI2 KY-1104 Cleaning unit Mode, 1=forced cleaning on, Chamber 1 off on 1 HW F K

A-06.03.11-XI3 PSL-1104 Pressure switch Cleaning unit air, low pressure, chamber 1 off on 1 HW F K

A-06.03.12-XS1 KY-1204 Cleaning unit Remote control, 1= cleaning forces, Chamber 2 off on 1 HW F K

A-06.03.12-XI1 KC-1204 Cleaning unit Status, 1= last pulse active, Chamber 2 off on 1 HW F K

A-06.03.12-XI2 KY-1204 Cleaning unit Mode, 1=forced cleaning on, Chamber 2 off on 1 HW F K

A-06.03.12-XI3 PSL-1204 Pressure switch Cleaning unit air, low pressure, chamber 2 off on 1 HW F K

A-06.03.13-XS1 KY-1304 Cleaning unit Remote control, 1= cleaning forced, Chamber 3 off on 1 HW F K

A-06.03.13-XI1 KC-1304 Cleaning unit Status, 1= last pulse active, Chamber 3 off on 1 HW F K

A-06.03.13-XI2 KY-1304 Cleaning unit Mode, 1=forced control on, Chamber 3 off on 1 HW F K

A-06.03.13-XI3 PSL-1304 Pressure switch Cleaning unit air, low pressure, chamber 3 off on 1 HW F K

A-06.03.14-XS1 KY-1404 Cleaning unit Remote control, 1= cleaning forced, Chamber 4 off on 1 HW F K

A-06.03.14-XI1 KC-1404 Cleaning unit Status, 1= last pulse active, Chamber 4 off on 1 HW F K

A-06.03.14-XI2 KY-1404 Cleaning unit Mode, 1=forced cleaning on, Chamber 4 off on 1 HW F K

A-06.03.14-XI3 PSL-1404 Pressure switch Cleaning unit air, low pressure, chamber 4 off on 1 HW F K

M-06.05.01 M-1102 Electric motor Airlock feeder of bag filter chamber 1 IOBus MS 1 HW F K

SS-06.05.01 SSL-1102 Proximity switch Airlock feeder of bag filter speed detection, off on 120IO PLC thread M18 1 HW F K

chamber 1
M-06.05.02 M-1202 Electric motor Airlock feeder of bag filter chamber 2 IOBus MS 1 HW F K

SS-06.05.02 SSL-1202 Proximity switch Airlock feeder of bag filter speed detection, off on 120IO PLC thread M18 1 HW F K

chamber 2
M-06.05.03 M-1302 Electric motor Airlock feeder of bag filter chamber 3 IOBus MS
SS-06.05.03 SSL-1302 Proximity switch Airlock feeder of bag filter speed detection, off on 120IO PLC thread M18 1 HW F K

chamber 3
M-06.05.04 M-1402 Electric motor Airlock feeder of bag filter chamber 4 IOBus MS
SS-06.05.04 SSL-1402 Proximity switch Airlock feeder of bag filter speed detection, off on 120IO PLC thread M18 1 HW F K

chamber 4
V-06.05.11 Slide gate Shut-off above airlock feeder, manual HW F K removed

V-06.05.12 Slide gate Shut-off above airlock feeder, manual HW F K removed

V-06.05.13 Slide gate Shut-off above airlock feeder, manual

V-06.05.14 Slide gate Shut-off above airlock feeder, manual
M-06.06.01 Electric motor Screw feeder of bag dfilter chamber 1 and 2 IOBus MS 1 HW F K

M-06.06.02 Electric motor Screw feeder of bag dfilter chamber 3 and 4 IOBus MS 1 HW F K

M-06.06.03 Electric motor Bag filter dust screw conveyor common IOBus MS 1 HW F O

XV-06.07.01 FV-1100 Shut-off valve Offgas duct shut-off before bag filter, chamber 1 1 HW F K

XV-06.07.01-XI1 ZSO-1100 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.01-XI2 ZSC-1100 Limit switch Offgas shutoff valve close status off on 1 HW F K

XV-06.07.02 FV-1200 Shut-off valve Offgas duct shut-off before bag filter, chamber 2 1

XV-06.07.02-XI1 ZSO-1200 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.02-XI2 ZSC-1200 Limit switch Offgas shutoff valve close status off on 1 HW F K

XV-06.07.03 FV-1300 Shut-off valve Offgas duct shut-off before bag filter, chamber 3 1

XV-06.07.03-XI1 ZSO-1300 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.03-XI2 ZSC-1300 Limit switch Offgas shutoff valve close status off on 1 HW F K

XV-06.07.04 FV-1400 Shut-off valve Offgas duct shut-off before bag filter, chamber 4 1

XV-06.07.04-XI1 ZSO-1400 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.04-XI2 ZSC-1400 Limit switch Offgas shutoff valve close status off on 1 HW F K

XV-06.07.11 FV-1108 Shut-off valve Offgas duct shut-off after bag filter, chamber 1 1 HW F K

XV-06.07.11-XI1 ZSO-1108 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.11-XI2 ZSC-1108 Limit switch Offgas shutoff valve close status off on 1 HW F K

XV-06.07.12 FV-1208 Shut-off valve Offgas duct shut-off after bag filter, chamber 2 1 HW F K

XV-06.07.12-XI1 ZSO-1208 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.12-XI2 ZSC-1208 Limit switch Offgas shutoff valve close status off on 1 HW F K

XV-06.07.13 FV-1308 Shut-off valve Offgas duct shut-off after bag filter, chamber 3 1 HW F K

4/6 27.11.2017
Kumera Customer Tag / Instrument /signal /device Service Measuring/ operation range Instrument data Process material Process pipe I/O for DCS (or PLC) Instrument/ Remark Rev
Tag (Subcontractor tag) signal
Information
Signal Connection Transmitte Material p T Type Loc. Scope

r,
(automatic 0% 100 % unit SP LL L H HH Sensor Class Type Connec- Power Type D L Approvals, Actuator nom. max nom. max max DN PN/ Dig in Dig out An in An out IO bus Barrier Cont
column) tion to supply (min) (min) instrum /materia CL roller
type material,
mm mm ATEX, IP ent l
kPa(g) kPa(g) °C °C °C
XV-06.07.13-XI1 ZSO-1308 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.13-XI2 ZSC-1308 Limit switch Offgas shutoff valve close status off on 1 HW F K

XV-06.07.14 FV-1408 Shut-off valve Offgas duct shut-off after bag filter, chamber 4 1 HW F K

XV-06.07.14-XI1 ZSO-1408 Limit switch Offgas shutoff valve open status off on 1 HW F K

XV-06.07.14-XI2 ZSC-1408 Limit switch Offgas shutoff valve close status off on 1 HW F K

TE-06.07.30 TE-1000 Temperature sensor Offgas in bag filter inlet 4...20mA, PLC 1 HW F K
HART
TE-06.07.32 TE-1004 Temperature sensor Offgas in bag filter outlet 4...20mA, PLC 1 HW F K H
HART
M-06.09.01 MY-1810 Electric motor Penthouse vent fan IOBus MS 1 HW M K

M-06.09.02 MY-1812 Electric motor Penthouse vent fan IOBus MS 1 HW M K

Y-06.10.01 VBR-1100 Vibrator Filter hopper pneumatic vibrator, chamber 1 off on 120Vac PLC - 1 HW F K

Y-06.10.02 VBR-1200 Vibrator Filter hopper pneumatic vibrator, chamber 2 off on 120Vac PLC - 1 HW F K

Y-06.10.03 VBR-1300 Vibrator Filter hopper pneumatic vibrator, chamber 3 off on 120Vac PLC - 1 HW F K

Y-06.10.04 VBR-1400 Vibrator Filter hopper pneumatic vibrator, chamber 4 off on 120Vac PLC - 1 HW F K

E-07.01.01 Trace heating (option) Offgas line heating - - HW F O 1)

G-07.01.05 Frequency converter Fan for reject dust IObus PLC 1 HW M K

M-07.01.05 Electric motor Fan for reject dust 0 1000 Nm3/h i FC dusty air 110 150 HW F K

M-07.01.06 Electric motor Airlock feeder of dust removal cyclone 0 1000 kg/h IOBus MS concentrate 110 150 1 HW M K H
dust
FE-07.02.01 FE-7201 Flow sensor Flow of the off gas to stack 0 90000 Nm3/h 70265 10000 80000 ultrasonic 4...20mA PLC 120Vac welded Air, 40% +2 -1/ +4 125 150 ?1000 1 HW F K Duct: Din=?1000,
H2O, s=?8, ins.thi. 100,
mat ?ASTM A36,
nom.point
vertical
FI-07.02.01 FI-7201 Flow indicatIon Flow of the output gas from bag filter, DCS i i - SW D -

display
FIT-07.02.01 FIT-7201 Flow transmitter Flow of the exhaust gas after bag filter i i i 1 HW F K

TE-07.02.03 TE-7203 Temperature sensor Offgas temperature after bag filter 0 200 °C 115 100 135 150 PT100, 4- A 4…20mA PLC loop thread 9 580 AISI 316 head- Air (wet) +0.1 -0.1 / 1 HW F K

wire HART G1/2" mounted +0.1

TT-07.02.03 TT-7203 Temperature transmitter Offgas temperature after bag filter HW F K

G-07.03.01 Frequency converter Exhaust gas fan frequency converter, fan 1 0 1500 rpm IObus PLC 1 HW M O

M-07.03.01-SC SC-1700 Speed control Speed control from DCS i i 1 SW D -

M-07.03.01 M-1700 Electric motor Exhaust gas fan motor 1 0 1500 rpm i FC HW F K

M-07.03.01-TE1 TE-1700ABC Temperature sensor Offgas fan motor winding, PT100 0 200 °C 140 155 IObus FC 1 HW F K

M-07.03.01-TE2 TE-1716 Temperature sensor Offgas fan motor bearing D-end, PT100 0 200 °C 80 100 PT100 PLC 1 HW F K

M-07.03.01-TE3 TE-1718 Temperature sensor Offgas fan motor bearing N-end, PT100 0 200 °C 80 100 PT100 PLC 1 HW F K

M-07.03.01-XI JI-1700 Torque display Offgas fan motor load torque 0 200 % Tn= 1200 i i 1 SW D -
Nm
M-07.03.01-SI SI-1700 Speed indication Exhaust gas fan speed, DCS screen 0 1500 rpm i i 1 SW D -

G-07.03.02 Frequency converter Exhaust gas fan frequency converter, fan 2 0 1500 rpm IObus PLC 1 HW M K/O

M-07.03.02-SC SC-1800 Speed control Speed control from DCS 0 1500 rpm i i F K

M-07.03.02-XI JI-1800 Torque display Offgas fan motor load torque 0 200 % Tn= 1200 i i SW D -
Nm
M-07.03.02-SI SI-1800 Speed indication Exhaust gas fan speed, DCS screen 0 1500 rpm i i SW D -

M-07.03.02 M-1800 Electric motor Exhaust gas fan motor 2 0 1500 rpm i FC F K

M-07.03.02-TE1 TE-1800ABC Temperature sensor Offgas fan motor winding, PT100 0 200 °C 140 155 IObus FC 1 HW F K

M-07.03.02-TE2 TE-1816 Temperature sensor Offgas fan motor bearing D-end, PT100 0 200 °C 80 100 PT100 PLC 1 HW F K

M-07.03.02-TE3 TE-1818 Temperature sensor Offgas fan motor bearing N-end, PT100 0 200 °C 80 100 PT100 PLC 1 HW F K

TE-07.04.01 TE-1700 Temperature sensor Offgas fan bearing, inboard fan 1 0 200 °C 70 90 4...20mA PLC 1 HW F K

TE-07.04.02 TE-1702 Temperature sensor Offgas fan bearing, outboard fan 1 0 200 °C 70 90 4...20mA PLC 1 HW F K

XT-07.04.03 VT-1700 Vibration sensor Offgas fan bearing, inboard fan 1 4...20mA PLC 1 HW F K

XT-07.04.04 VT-1702 Vibration sensor Offgas fan bearing, outboard fan 1 4...20mA PLC 1 HW F K

TE-07.04.11 TE-1800 Temperature sensor Offgas fan bearing, inboard fan 2 0 200 °C 70 90 4...20mA PLC 1 HW F K

TE-07.04.12 TE-1802 Temperature sensor Offgas fan bearing, outboard fan 2 0 200 °C 70 90 4...20mA PLC 1 HW F K

XT-07.04.13 VT-1800 Vibration sensor Offgas fan bearing, inboard fan 2 4...20mA PLC 1 HW F K

XT-07.04.14 VT-1802 Vibration sensor Offgas fan bearing, outboard fan 2 4...20mA PLC 1 HW F K

XT-07.05.01 XT-7501 Dust detector Leak detecting after bag filter % triboelectric 4...20mA PLC 120Vac weld-in 500 air (wet) 1 HW F K

PIC-08.01.01 PIC-8101 Pressure controller Pressure of the steam in flash tank - SW D -

PT-08.01.01 PT-8101 Pressure sensor Pressure in condensate tank 0 600 kPa(g) 30 480 4…20mA PLC flange 1-1/2" 316L condensate 300 500 144 160 150 - 150 1 HW F K
HART /steam, max
LIC-08.01.02 LIC-8102 Level controller Controlling of water level - SW D -

LT-08.01.02 LT-8102 Pressure sensor Condensate level in flash tank 0 600 kPa(g) 30 480 4…20mA PLC flange 1-1/2" 316L condensate 300 500 144 160 150 - 150 1 HW F K
HART /steam, max
XY-08.01.02 XY-8102 Calculation element Calculation of water level in tank 0 3 m 1,5 0.2 2,8 - SW D -

PSV-08.01.03 PSV-8103 Pressure safety valve Safety valve of flash tank 550 kPa(g) 41700 - - flange 8" / 10" condensate 300 500 144 170 8"/10" 150 HW F K D

kg/h /steam
LS-08.01.06 LSH-8106 Level switch High level of condensate tank on off vibration PFC PLC 120Vac flange 1-1/2" 300 AISI 316 condensate 300 500 144 170 150 1 HW F K

V-08.01.07 Shut-off valve Shut-off valve for pressure transmitter - - flange 1-1/2" condensate 500 160 - 150 - F K

V-08.01.08 Shut-off valve Shut-off valve for pressure transmitter - - flange 1-1/2" condensate 500 160 - 150 - F K

G-08.03.01 Frequency converter Pumping of water from condensate tank, pump 1 IObus PLC 1 HW M O

M-08.03.01 Electric motor Pumping of water from condensate tank, pump 1 50 m3/h / i FC flange 3" / 2" condensate 300 500 144 170 3" 150 HW F K

head
60m
M-08.03.01-E Space heater Pump motor space heating MCC HW F K

M-08.03.01-XS Frequency converter Commands for ondensate pump 1, start/stop - 1 SW D -

M-08.03.01-SC SC-8301 Frequency converter Speed reference to pump 1 1000 3000 rpm 1100 2980 - SW D -

M-08.03.01-SI SI-8301 Frequency converter Condensate pump torque, pump 1 H

G-08.03.02 Frequency converter Pumping of water from condensate tank, pump 2 IObus PLC 1 HW M O

M-08.03.02 Electric motor Pumping of water from condensate tank, pump 2 50 m3/h / i FC flange 3" / 2" condensate 300 500 144 170 3" 150 HW F K

head
60m
M-08.03.02-E Space heater Pump motor space heating MCC HW F K

M-08.03.02-XS Frequency converter Commands for ondensate pump 2, start/stop - 1 SW D -

M-08.03.02-SC Frequency converter Speed reference to pump 2 1000 3000 rpm 1100 2980 - SW D -

M-08.03.02-SI Frequency converter Condensate pump torque, pump 2 H

V-08.03.10 Shut-off valve Condensate pump line shut-off valve - - flange condensate 500 160 6" 150 - F K

FS-08.03.11 FS-8311 Flow switch Detection of dry running of pump 1 120IO PLC 120Vac thread G1/2" condensate 300 600 144 170 6" 150 1 HW F K

V-08.03.12 Shut-off valve Condensate pump line shut-off valve, drain - - flange condensate 500 160 1" 150
V-08.03.13 One direction valve Condensate pump line non-return valve - - flange condensate 1000 160 3" 150 - F K

5/6 27.11.2017
Kumera Customer Tag / Instrument /signal /device Service Measuring/ operation range Instrument data Process material Process pipe I/O for DCS (or PLC) Instrument/ Remark Rev
Tag (Subcontractor tag) signal
Information
Signal Connection Transmitte Material p T Type Loc. Scope

r,
(automatic 0% 100 % unit SP LL L H HH Sensor Class Type Connec- Power Type D L Approvals, Actuator nom. max nom. max max DN PN/ Dig in Dig out An in An out IO bus Barrier Cont
column) tion to supply (min) (min) instrum /materia CL roller
type material,
mm mm ATEX, IP ent l
kPa(g) kPa(g) °C °C °C
V-08.03.14 Shut-off valve Condensate pump line shut-off valve - - flange condensate 1000 160 3" 150
V-08.03.20 Shut-off valve Condensate pump line shut-off valve - - flange condensate 500 160 6" 150 - F K

FS-08.03.21 FS-8321 Flow switch Detection of dry running of pump 2 120IO PLC 120Vac thread G1/2" condensate 300 600 144 170 6" 150 1 HW F K

V-08.03.22 Shut-off valve Condensate pump line shut-off valve, drain - - flange condensate 500 160 1" 150
V-08.03.23 One direction valve Condensate pump line non-return valve - - flange condensate 1000 160 3" 150 - F K

V-08.03.24 Shut-off valve Condensate pump line shut-off valve - - flange condensate 1000 160 3" 150
PI-08.03.30 PI-8330 Pressure meter Mechanical pressure meter 0 1.0 MPa(g) - - impulse G1/2" condensate 300 500 144 170 3" 150 HW F K
pipe, thread

V-08.03.30 Gauge valve Shut-off valve for pressure meter - - impulse G1/2" condensate 500 170 120 3" 150 - F K
pipe, thread

V-08.03.31 One direction valve Condensate line non-return valve - - ? condensate 1000 160 3" 150 - F K

V-08.03.32 Shut-off valve Condensate pump line shut-off valve, - - ? condensate 1000 160 3" 150 - F K

condensate out
V-08.03.34 Shut-off valve condensate draining from pump unit - - ? condensate 500 160 1" 150 - F K

V-08.03.35 Shut-off valve condensate draining from pump unit - - ? condensate 500 160 1" 150 HW F K

E-08.03.40 Heater Trace heating of pump pipe branch 1 HW F O

E-08.03.41 Heater Trace heating of pump pipe branch 1 HW F O

PV-08.05.01 PV-8501 Control valve Output steam flow from flash tank. 0 7000 kg/h 6600 4...20mA, PLC flange 6" ASME pneumatic, steam, 300 600 144 170 8" 150 1 HW F K
HART Section VIII, FO
div.1 ed.
2013
PV-08.05.01-XI ZT-8501 Control valve Valve position feedback 1
LV-08.10.01-A LV-8102A Control valve Controlling of condensate flow from flash tank 1 HW F O K

LV-08.10.01-B LV-8102B Control valve Controlling of condensate flow from flash tank, 1 HW F O K

stand-by
LIC-08.11.01 Level controller Level control of condensate tank 0 100 % SW D O level controller in
customer's system

LT-08.11.01 Level measurement Condensate level in condensate tank 0 100 %

G-29.01.01 Electric supply Plant electrical supply to dryer, status, 1= normal

G-29.01.02 Electric supply Plant electrical supply to dryer, reserve power

active

-..

57 20 49 5 49 4

Notes:
1) If trace heating will be installed, connection to DCS shall be defined separately

6/6 27.11.2017