ENG450 Engineering Internship

Engineering Internship at Rio Tinto Iron Ore Yandicoogina mine site: Dust
Collection System Project

Final Report

“A report submitted to the School of Engineering and Energy, Murdoch

University in partial fulfilment of the requirements for the degree of
Bachelor of Engineering”

Prepared by: Jamie-Leigh Delgado ( 30351559)

Academic supervisor: Graeme Cole
Industrial supervisor: Sang Nguyen

November 2008
 Contents
LIST OF FIGURES ........................................................................................................................... 6

LIST OF TABLES ............................................................................................................................. 8

EXECUTIVE SUMMARY.................................................................................................................. 9

ACKNOWLEDGEMENTS ................................................................................................................10

Chapter 1 - INTRODUCTION........................................................................................................... 11

1.1 Engineering Internship ......................................................................................................................................... 11

1.2 Scope of the Report............................................................................................................................................... 12

1.3 Data Collection and Referencing ......................................................................................................................... 12

1.4 Report Organisation ............................................................................................................................................. 13

Chapter 2 - ENGINEERING INTERNSHIP ....................................................................................... 15

2.1 Introduction...........................................................................................................................................................15

2.2 Rio Tinto Iron Ore .................................................................................................................................................15

2.3 Operations............................................................................................................................................................. 16

2.4 Role on site............................................................................................................................................................20

2.5 Internship Plan .....................................................................................................................................................20

2.6 ProWORX 32 ........................................................................................................................................................ 22

2.7 Citect HMI/SCADA .............................................................................................................................................. 22

2.8 Conclusion............................................................................................................................................................. 22

Chapter 3 - MINOR PROJECTS ...................................................................................................... 23

3.1 Introduction.......................................................................................................................................................... 23

3.2 Fixed Plant Electrical Maintenance ..................................................................................................................... 24

3.2.1 Electrical inspection .................................................................................................................................. 24

3.2.2 Nobles WII 300kN Load cells................................................................................................................... 26

3.2.3 Microwave Sensors.................................................................................................................................... 26

3.2.4 IPC – 14 Electronic Weighting Controller................................................................................................28

3.3 Oil Cooler Gearbox Pressure Readings................................................................................................................ 29

3.3.1 Introduction............................................................................................................................................... 29

3.3.2 Description and work included................................................................................................................. 29

3.3.3 Results and Outcome ................................................................................................................................ 32

3.4 iMAC...................................................................................................................................................................... 33

3.4.1 Introduction............................................................................................................................................... 33

3.4.2 Description and work included................................................................................................................. 35

3.4.3 Results and Outcome ................................................................................................................................ 35

CONTENTS Page 3 of 158 November 2008

3.5 Conclusion............................................................................................................................................................. 35

Chapter 4 -SYSTEM IDENTIFICATION...........................................................................................37

4.1 Introduction.......................................................................................................................................................... 37

4.2 Dust Collection System......................................................................................................................................... 37

4.3 Hopper .................................................................................................................................................................. 39

4.4 Fan.........................................................................................................................................................................40

4.5 Rotary Valve.......................................................................................................................................................... 45

4.6 Conveyor ...............................................................................................................................................................46

4.7 Pulse Jet Control System......................................................................................................................................48

4.8 Conclusion..............................................................................................................................................................51

Chapter 5 - CONTROL SYSTEM DESIGN ........................................................................................ 52

5.1 Introduction.......................................................................................................................................................... 52

5.2 Yandicoogina Network ......................................................................................................................................... 52

5.3 Functional Specification....................................................................................................................................... 53

5.4 ProWORX32 Logic ............................................................................................................................................... 61

5.4.1 Fan..............................................................................................................................................................64

5.4.2 Rotary Valve............................................................................................................................................... 65

5.4.3 Conveyor .................................................................................................................................................... 65

5.4.4 Pulse Cleaning System .............................................................................................................................. 65

5.5 Citect......................................................................................................................................................................66

5.5.1 Fan..............................................................................................................................................................66

5.5.2 Rotary Valve............................................................................................................................................... 70

5.5.3 Conveyor .....................................................................................................................................................71

5.5.4 Pulse Cleaning System .............................................................................................................................. 73

5.6 Conclusion............................................................................................................................................................. 75

Chapter 6 -SYSTEM EVALUATION AND COMMISSIONING.......................................................... 76

6.1 Introduction.......................................................................................................................................................... 76

6.2 Maintenance Order............................................................................................................................................... 77

6.3 Point-to-Point Testing.......................................................................................................................................... 78

6.4 Scope Of Work ...................................................................................................................................................... 79

6.5 Construction .........................................................................................................................................................83

6.6 Commissioning ..................................................................................................................................................... 85

6.7 Conclusion............................................................................................................................................................. 85

Chapter 7 - CONCLUSIONS ............................................................................................................ 86

7.1 Engineering Internship Outcomes.......................................................................................................................86

CONTENTS Page 4 of 158 November 2008

7.2 Project Status ........................................................................................................................................................ 87

7.3 Future Intentions & Recommendations ..............................................................................................................88

REFERENCES 89

BIBLIOGRAPHY ............................................................................................................................91

Rio Tinto Standard Specifications .................................................................................................................................. 91

Standard Drawings .......................................................................................................................................................... 92

APPENDICES 96

Appendix A - Dust Collector System diagram ................................................................................ 96

Appendix B - Citect Help Display ................................................................................................... 97

Appendix C - IPC-14 Electronic weighting Controller .................................................................... 98

Appendix D - iMAC descriptor list example .................................................................................. 101

Appendix E - Oil Cooler Gearbox Pressure Reading .....................................................................102

Appendix F - I/O Modules Analog Input Modules.........................................................................105

Appendix G - Fan Schematic Diagram ..........................................................................................109

Appendix H - Rotary Valve Schematic Diagram ............................................................................ 110

Appendix I - Conveyor Schematic Diagram ....................................................................................111

Appendix J - Pulse Cleaner Schematic Diagram ........................................................................... 112

Appendix K - Strip P4 Termination Diagram ................................................................................ 114

Appendix L - Strip P5 Termination Diagram ................................................................................ 115

Appendix M -PLC I/O Modules Typical Termination Diagram ...................................................... 116

Appendix N - Dust Collector Control Panels Termination Diagram .............................................. 117

Appendix O - I/O addresses allocation.......................................................................................... 118

Appendix P - YDU210 Logic..........................................................................................................124

Appendix Q - PLC I/O ...................................................................................................................158

CONTENTS Page 5 of 158 November 2008

LIST OF FIGURES
Figure 2–1 Stockpile layout .....................................................................................................................................................17
Figure 2–2 Reclaimer ..............................................................................................................................................................17
Figure 2–3 Stackers ................................................................................................................................................................ 18
Figure 2–4 Train loadout ....................................................................................................................................................... 18
Figure 3–1 Belt rip diagram.................................................................................................................................................... 24
Figure 3–2 Belt drift example ................................................................................................................................................ 25
Figure 3–3 Stacker microwaves ............................................................................................................................................. 27
Figure 3–4 Microwave orientation ........................................................................................................................................ 27
Figure 3–5 Microwave Pulse Switch ...................................................................................................................................... 28
Figure 3–6 Weighting Controller display [2] ........................................................................................................................ 28
Figure 3–7 Oil Cooler A Analog Scaling..................................................................................................................................31
Figure 3–8 Oil Cooler A Analog Scaled Pressure Tag ............................................................................................................31
Figure 3–9 Oil Cooler A Pressure Broken Wire Tag ..............................................................................................................31
Figure 3–10 Oil Cooler A Pressure Trend Tag....................................................................................................................... 32
Figure 3–11 Oil Cooler A Pressure Broken Wire Alarm Tag ................................................................................................. 32
Figure 3–12 iMAC example configurations ........................................................................................................................... 34
Figure 4–1 YDU210 Dust Collection System .........................................................................................................................40
Figure 4–2 YDU210FN01 Fan piping .....................................................................................................................................41
Figure 4–3 PLC Input [E-001-58463] ................................................................................................................................... 42
Figure 4–4 PLC Output [E-001-58463] ................................................................................................................................ 42
Figure 4–5 wiring between termination strip [E-001-58463] ............................................................................................. 43
Figure 4–6 Fan field start button wiring [E-001-58463] ..................................................................................................... 43
Figure 4–7 Internal motor relay example.............................................................................................................................. 44
Figure 4–8 MCC relay configuration [8] ............................................................................................................................... 44
Figure 4–9 Fan motor configurations [E-001-58463].......................................................................................................... 44
Figure 4–10 Line referencing within diagram [E-001-58463]............................................................................................. 45
Figure 4–11 External diagram line referencing [E-001-58463] ........................................................................................... 45
Figure 4–12 YDU210RV01 - Rotary Valve photo .................................................................................................................. 45
Figure 4–13 Under speed sensor wiring diagram [E-001-58464] ....................................................................................... 46
Figure 4–14 YDU210CV01 - Conveyor photo ........................................................................................................................ 47
Figure 4–15 Pull wire switch wiring diagram [E-001-58501] .............................................................................................. 47
Figure 4–16 Start warning siren wiring diagram [E-001-58501].........................................................................................48
Figure 4–17 Start warning siren PLC connection diagram [E-001-58501] .........................................................................48
Figure 4–18 YDU210PN01 - Pulse cleaning controller photo .............................................................................................. 50
Figure 4–19 Hopper Arial View photo....................................................................................................................................51
Figure 5–1 Network description............................................................................................................................................. 53
Figure 5–3 ProWORX display................................................................................................................................................ 63
Figure 5–4 T1.0 Block structure [1] ....................................................................................................................................... 63
Figure 5–5 UCTR Block structure [1] .................................................................................................................................... 64
Figure 5–6 BLKM block structure [1] .................................................................................................................................... 64
Figure 5–7 Dust Collection System Citect display................................................................................................................. 66
Figure 5–8 Citect control panel.............................................................................................................................................. 67
Figure 5–9 YDU210FN01 Popup window .............................................................................................................................68
Figure 5–10 YDU210FN01DCOK define genie window........................................................................................................68
Figure 5–11 YDU210FN01DCOK symbol parameters........................................................................................................... 69
Figure 5–12 YDU210FN01 Interlock popup window............................................................................................................69
Figure 5–13 YDU210RV01 Status display window ............................................................................................................... 70
Figure 5–14 YDU210RV01 Interlock status window............................................................................................................. 70
Figure 5–15 YDU210CV01 Status window............................................................................................................................. 72
Figure 5–16 YDU210CV01 Interlock status window............................................................................................................. 72
Figure 5–17YDU210 Diagnostics status window................................................................................................................... 74
Figure 5–18 YDU210PN01 Status window ............................................................................................................................ 74
Figure 6–1 GAW-5 Pressure switch .......................................................................................................................................80
Figure 6–2 Pressure switch ....................................................................................................................................................80
Figure 6–3Location display and possible wiring route......................................................................................................... 81
Figure 6–4 Location of where the pressure switch is to be terminated ............................................................................... 81
Figure 6–5 Under speed switches type 1 ............................................................................................................................... 82
Figure 6–6 Under speed switches type 2............................................................................................................................... 82
Figure 6–7 Under speed location display .............................................................................................................................. 83
Figure 6–8 electrical works underway................................................................................................................................... 83
Figure 6–9 Installed pressure switch..................................................................................................................................... 83
Figure 6–10 under speed switch wiring.................................................................................................................................84

LIST OF FIGURES Page 6 of 158 November 2008

Figure 6–11 Pipe barrel union fitting.....................................................................................................................................84
Figure 6–12 Fixed pipe view...................................................................................................................................................84

LIST OF FIGURES Page 7 of 158 November 2008

LIST OF TABLES
Table 4-1 PLC Input communications [9] ............................................................................................................................. 49
Table 4-2 PLC Output communications [9] .......................................................................................................................... 49
Table 5-1 Step by step process flow........................................................................................................................................ 54
Table 5-2 YDU210 Fan sequence interlocks .......................................................................................................................... 59
Table 5-3 YDU210 Rotary valve sequence interlocks............................................................................................................ 59
Table 5-4 YDU210 Conveyor sequence interlocks ................................................................................................................ 59
Table 5-5 YDU210 Fan warning and trip alarms...................................................................................................................60
Table 5-6 YDU210 Rotary valve warning and trip alarms ....................................................................................................60
Table 5-7 YDU210 Conveyor warning and trip alarms .........................................................................................................60
Table 5-8 YDU210 Pulse cleaner warning and trip alarms....................................................................................................61
Table 5-9 YDU210FN01 Variable tags ................................................................................................................................... 69
Table 5-10 YDU210RV01 Variable tags ..................................................................................................................................71
Table 5-11 YDU210CV01 Variable tag .................................................................................................................................... 72
Table 5-12 YDU210PN01 Variable tags.................................................................................................................................. 74

LIST OF TABLES Page 8 of 158 November 2008

 EXECUTIVE SUMMARY

Rio Tinto Iron Ore Yandicoogina is in the business of mining, and producing Iron Ore for
shipment. The ore is extracted from a giant Ore body that runs through an old creek bed. The
process of production follows numerous amounts of crushing and screening procedures before
stacking the ore on a stockpile waiting for train collection to transport the ore to the coast for
shipment.

In the process of ore size reduction there are many different types of equipment being used
and controlled by Programmable Logic Controllers (PLC). The majority of this engineering
internship was concerned with the process control sector at Yandicoogina. Throughout the
internship the major project was to prepare the YDU210 Dust Collection System for
commissioning which includes:

• Process identification

• Conceptual and detailed control strategy documentation

• Logic implementation

• Display and controls

• Commissioning and troubleshooting

The Dust Collection System is an important asset within Rio Tinto Iron Ore as they focus on
prevention and elimination of any Environmental Hazards within the workplace. Dust
emission is one of these environment hazards that Rio Tinto chooses to eliminate as much as
possible as there is a frequent probability of creating dust from the open Iron Ore
transportation through the different stages of the process and the human impact within the
environment.

EXECUTIVE SUMMARY Page 9 of 158 November 2008

 ACKNOWLEDGEMENTS
Thank you to Rio Tinto Iron Ore for the coordination with Murdoch University to allow for the
opportunity of this engineering internship, and to all those who gave support and guidance
throughout the internship form the team at Yandicoogina. Without this support the final year
internship unit would not have been as informative and an extraordinary experience.

Particular acknowledgments to:

Mark Rodgers General Manager, For the preliminary organisation of the internship.

Sang Nguyen Engineering Superintendent Planning & Engineering – Industrial

Supervisor, For the initial organisation and on going support
throughout the entire internship.

Neil Sirr Process Control Technician, for answering any questions that arose and
offering assistance then needed especially the electrical aspect of the
work exposed throughout the progression of the internship.

James Shilcock Graduate Electrical Engineer, for providing valuable information and
assistance during the internship, and giving an insight into the role of a
graduate electrical engineers within industry.

Graeme Cole Academic Supervisor, for the assistance throughout the duration of the
engineering degree and internship.

ACKNOWLEDGEMENTS Page 10 of 158 November 2008

Chapter 1 - INTRODUCTION

1.1 Engineering Internship

The ENG450 Engineering Internship has been undertaken during Semester 2,

2008 as a final semester unit for a Bachelor of Engineering with a double major in
Instrumentation and Control Engineering and Industrial Computer Systems. The
internship took place at Rio Tinto Iron Ore Yandicoogina Western Australia during
the period of 20th of August 2008 to 10th of December 2008. The main focus
throughout the internship but not limited to, is the Dust Collection System project,
with a variety of other tasks and activities along the way. These included exposure
to the Iron Ore industry, and an overall view into RioTinto’s operations and
practices from engineering prospective.

Chapter 1 - INTRODUCTION Page 11 of 158 November 2008

 The Internship major project was titled YDU210 – Dust Collection System, and
involved creating logic, control displays and an investigation into what works needs
to be completed in order to commission the Dust Collection System. At the
conclusion of the investigations, the work required was scheduled into be
completed. The final internship summery with all the work completed during the
internship will not be included in this report due to the commencement of the
internship and the assessment deadlines. Therefore, a section of this report will
cover the future works completed during the final four weeks of the internship.

1.2 Scope of the Report

This report provides information on all key areas of the internship undertaken with
a main focus on the YDU210 – Dust collection System

The five key areas are summarised below:

• Task undertaken throughout the internship

• Identification and background information of the Dust Collection System

• Control information and requirements of the Dust Collection System

• System evaluation and commission of the Dust Collection System

• Future Work throughout the remainder of the internship

1.3 Data Collection and Referencing

The majority of the information within this report has been sourced from Rio Tinto
technical manuals, functional specification documents and drawings. A
collaboration of documents was referenced from other Dust Collection Systems on
site in order to create the YDU210- Dust Collection System functional specification
document as there was no previous documentation. However the drawings for the
YDU210 Dust Collection System were created before the time of installation. In
addition to these documents more additional information was sourced through
books, web sites and communications with personnel on site to acquire a greater
understanding of different equipment and procedures that were required to be
understood throughout the internship.

Chapter 1 - INTRODUCTION Page 12 of 158 November 2008

 1.4 Report Organisation

The report will include the following major sections:

Chapter 2 – Engineering Internship:

This chapter will outline the internship giving a description about the internship
process, the overall plan developed for guidance, where it was conducted,
information about the company and specific site operations. It will also include the
information about the roles played on site by the engineers as to where they fit in
and the Engineering practices that were encountered during the internship.

Chapter 3 – Minor Projects:

This chapter will include information, work performed and outcomes from the
completion of a variety of different tasks undertaken throughout the internship.
This chapter is included in the report as the YDU210 – Dust Collection System
project was not the only task that has been given throughout the internship. These
tasks aided in the understanding of field devices, control and display software that
made the Dust Collection System project completion readily obtainable.

Chapter 4 – System Identification:

This chapter will introduce the Dust Collection System and it is importance within
the company. It will also provide an understanding of the status of the YDU210
Dust Collector at the commencement of the internship, an overall layout and
location of the system. All components of the system will also be detailed in this
chapter.

Chapter 5 – Control System Design:

This chapter is concerned with how the Dust Collection System should be
controlled. One of the requirements of the Dust Collection System project is to
create a functional specification document which will be discussed. At the
completion of the YDU210 – Dust Collection System functional specification
document the logic and control display creation will be discussed in detail.

Chapter 1 - INTRODUCTION Page 13 of 158 November 2008

 Chapter 6 – System Evaluation and Commissioning:

This chapter will discuss the system evaluation performed throughout the project,
which includes Maintenance Order, and Point-to-point testings. This chapter will
also discuss the need and details of a Scope Of Work (SOW) and the work
completed subsequently due to SOW.

Chapter 7 – Conclusions:

This chapter will focus on the experiences gained throughout this internship, a
conclusion of the YDU210 – Dust Collection System project status at the time of this
report and the future works. The chapter will also include the recommendations for
future improvements of the Dust Collection System.

References:

The sources of information that are usedfor additional information on specific

topics.

Bibliography:

The sources listed are provided by Rio Tinto and have been cited during the
internship.

Appendices:

The appendices contain additional drawings and photos that were not contained
within the main text body but provide a greater perspective of the internship and it
is projects. Also the documents created throughout the internship will be a part of
the appendices.

Chapter 1 - INTRODUCTION Page 14 of 158 November 2008

Chapter 2 - ENGINEERING INTERNSHIP

2.1 Introduction

The intention of this chapter is to give an understanding of the internship. General

information about Rio Tinto Iron Ore and the specific site operations at
Yandicoogina will be detailed. Following on from this, the role of engineers and
internship plan will be discussed as it will provide some background to the certain
tasks undertaken and the layout of the internship.

2.2 Rio Tinto Iron Ore

Rio Tinto Iron Ore (RTIO) falls under the Rio Tinto group banner and consists of
operations in:

• Pilbara, Western Australia

• Kwinana, Perth Western Australia

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 • Labrador City and Sept-Iles, Canada

• Simandou, Guinea West Africa

• Corumba, Brazil

• Orissa, India

In the Pilbara region of Western Australia there are 11 mines consisting of:

1. Yandicoogina 7. Channar

2. Paraburdoo 8. West Angelas

3. Brockman 9. Hope downs

4. Marandoo 10. Eastern range

5. Mount Tom Price 11. Nammuldi

6. Mesa J

Also within Pilbara operation of RTIO there are two shipping terminals which
consist of Dampier and Cape Lambert and the largest privately owned heavy freight
railway in Australia. Pilbara operations produce over 163 million tonnes of Iron Ore
and the current goal is 22o million tonnes. Thirteen percent of Rio Tintos operating
assets and twenty six percent of the gross sales revenue come from RTIO.[12]

Yandicoogina commenced operation in 1999 and is located 95km North West of

Newman. Yandicoogina has been recognised for it is unique quality of Iron Ore as it
is low in alumina, and was subsequently sold as a stand alone fines produce.
Yandicoogina also holds the title of largest producing Iron Ore mine within Rio
Tinto with 52 million tones annual production. [12]

2.3 Operations

The operation at RTIO Yandicoogina consists of open-cut mining, processing the

ore to obtain the required size and grade and transporting the Iron Ore fines
product to the port by trains. Three processing plants are used at Yandicoogina
which are the Dry Plant (Plant One), Wet Plant (Plant Two) and Junction South
East (Plant Three or JSE). These three plants collectively supply their Iron Ore after

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 processing to the stacker (figure 2-3), which creates up to four stockpiles, see figure
2-1.

Figure 2–1 Stockpile layout

Figure 2–2 Reclaimer

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 Figure 2–3 Stackers

Figure 2–4 Train loadout

The ore placed on the stockpiles is collected by one of two Reclaimers (figure 2-2),
depending on the location of the stockpile. The reclaimers only run when the bin
level in the train loadout (figure 2-4) needs to be maintained to allow trains to be
loaded. The overall processing procedure that takes place is:

Mine pit

The ore obtained from the mine pit is done by drilling holes into the ore body in the
designated locations selected by mine planning and grade control who know the pit
layout and the future intentions. The holes are then prepared with explosives for
blasting, as the ore in it is natural state can not be dug efficiently. After blasting the
ore, a digger and haul trucks are used to load and transport the ore to the primary
crusher ROM bin.

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 Primary crusher

The primary crusher is used as the first point of contact from the mine to the
processing plant. The crushing process at the primary consists of feeding the ore via
a grizzly vibe feeder into a Jaw crusher. The grizzly splits the ore into two streams
by allowing ore less then 250mm in size to move straight to the secondary crusher.
The Jaw crusher is used to crush the ore until the ore can pass through the grids.

Secondary crusher

The ore is then screened at the scalping screens and split into three sizes. The sizes
are classified as fines, middlings and oversize. The fines are sent straight to the
stacker as they do not require anymore crushing. The middlings proceed to the
tertiary crusher and the oversize progresses to the secondary crusher. The
secondary continues to crush the oversize ore until it passes through the Jaw
crusher.

Screening

The screening house is used to check if the ore is at the correct size. If the ore size is
correct it proceeds along the conveyors to the stacker. Otherwise it is conveyed to
the tertiary crusher for further sizing.

Tertiary crusher

The tertiary crusher is used to crush the ore that was not at the correct size needed
to pass through the screen mats at the screening house. After the tertiary crusher
has completed crushing, the ore is passed back through the screen house and the
procedure continues until the ore is at the correct size and placed in a stockpile.

The Wet Plant process alters between the primary and secondary crushing
procedure that is been stated above for the Dry Plant. The additional process
consists of splitting the ore flow from the primary crusher into two scrubbers. The
scrubbers use water to clean clay and other impurities from the ore like a washing
machine. After the scrubbers, the ore is separated from the water based solution
and proceeds to the secondary crusher. The solution that is separated from the ore
is sent to a thickener tank where flocculent is added to reclaim the water from the
impurities. From the secondary crusher the ore is combined with the ore leaving the
JSE primary and secondary sizer. The ore is then conveyed to the inner loop where

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 it is screened and sent to the tertiary crusher if required, otherwise conveyed to the
stacker.

2.4 Role on site

An electrical engineer’s role on site is to:

• Offer electrical maintenance support,

• Deal with instrumentation and control throughout the site,

• Power systems

• Project management

• System design

2.5 Internship Plan

The Internship plan was created and followed from the commencement of the
internship. The tasks that required completion were:

Inductions

The inductions are a compulsory component when commencing working with Rio
Tinto. The inductions included four days within the Perth office to complete the:

• Lock holder and personal Isolation Officer training

• Health Safety Environment (HSE) induction

• General Site induction

• Iron Safe standards

And three days on site to complete

• Environmental induction

• Personal Protective Equipment (PPE) Awareness

• Safety interaction training/ Behavioural Observation/ Hazard ID Training

• Job Hazard Analyses (JHA) and TAKE 5 training

• Basic fire training

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 • Worksite fitness and manual handling course

• Dust management

• Kaizen system and Lean

• Change management

• Light vehicle assessment

• Safety leadership training

Engineering Systems

This section of the internship was given a set time frame and an overall explanation
of the different engineering systems used within Rio Tinto was given as basis of
what may be expected or be exposed to in the course of the internship. Throughout
the internship there was more exposure to different systems, which allowed for a
greater understanding and appreciation of the systems.

Drawing and Schematics

An explanation of different symbols that may appear in schematics and how to read
them throughout the internship was given.

Citect training

A three day Citect HMI/SCADA configuration training manual was reviewed and
activities completed.

Fixed Plant electrical team

Some time was spent with the Electrical team which gave a more hands on
experience and provided a greater understating of the site layout, visual
confirmations of how and where the PLC/CPU communication took place and
different measurement devices used throughout different areas on site.

Process Control technicians

Small projects or day to day tasks that were given during the allocated period with
the Process control technicians gave more exposure to the industry and different
engineering systems that Rio Tinto Iron Ore uses. In particular, this exposure
helped with the YDU210 Dust Collector project.

Project work

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 YDU210 Dust Collection System

2.6 ProWORX 32

ProWORX 32 is a programming software platform that is used for the Modicon PLC
range. Yandicoogina uses PorWORX to program, control and analyse all of the plant
operations in real time. ProWORX has a number of features which includes:

• Online – Offline state which allows programming in either.

• Manage I/O for all PLC

• Testing project prior to running it in the PLC run time

• 984 Ladder Logic

Throughout the internship ProWORX was used a lot for process understanding of
equipment interaction, fault finding, and the creation of additional logic.

2.7 Citect HMI/SCADA

CitectSCADA is the current software package used at Yandicoogina to provide a

fully integrated Human Machine Interface for control and monitoring of the
runtime operations. Citect functions allow for the collection of information and
provide an interface to control the Programmable Logic Controllers (PLC). Citect
used within the internship was to display the status of the logic created for the Dust
Collection system. Citect was also used for fault finding as the status bit descriptor
provided the ProWORX location.

2.8 Conclusion

The aim of this chapter has been to provide information to allow for the
understanding of the internship procedure and the environment in which it took
place. Knowledge about Rio Tinto Iron Ore and it is operations were also given to
outline the fundamentals of Iron Ore mining in the Pilbara region of Western
Australia. The background and necessity of electrical engineers on site has been
discussed. Following on from this chapter is a discussion of some of different minor
projects that occurred throughout the internship.

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Chapter 3 - MINOR PROJECTS

3.1 Introduction

In this chapter a variety of different tasks undertaken throughout the internship

that were not apart of the YDU210 – Dust Collection System project will be
discussed.

These will include:

• Microwave Sensor adjustments

• IPC - 14 Electronic Weighting Controller additional analog output and logic

• Oil Cooler Gearbox Pressure logic and control display

• iMac control error display

Chapter 3 - MINOR PROJECTS Page 23 of 158 November 2008

 3.2 Fixed Plant Electrical Maintenance

As discussed previously part of internship was spent with the fixed plant electrical
maintenance team. This was put in place to give a more hands on knowledge of the
site and the devices used to control or feedback information to the PLC’s. Some of
the work undertaken during this time was:

3.2.1 Electrical inspection

Electrical inspection on YCV33 – Loadout conveyor 2 was observed

during the time with the fixed plant electrical maintenance team. The
inspection included:

1. Start/Stop button – these are the manual start/stop buttons in the

field. To indicate whether the wiring and operation of the button
were correct, the buttons were physically pushed and the Citect
display would indicate a Input healthy display [See appendix B],
which represents that the button is being pressed

2. Belt rips – detects whether the belt has been ripped by having
detection at the tail end of the belt as shown in figure 3-1 however
are also located at transfer chutes and impact areas. The belt rip is
detected by breaking the tensioned rope. A visual inspection was
performed on the tensioned ropes as it is not desirable to
purposely break the rope.

Figure 3–1 Belt rip diagram

Chapter 3 - MINOR PROJECTS Page 24 of 158 November 2008

 3. Belt Drift – these are devices positioned along the belt at a set
distance from the side of the belt as shown in figure. 3-2 and if
they are pushed out of this position then a belt drift trip will come
up. Therefore to inspect if the device is operational the arm was
manually moved.

Figure 3–2 Belt drift example

4. Level indication –The train loadout bin uses a tilt probe to indicate
the High Level, if the Iron Ore in the chute reaches the level of the
probe and continues to increase the probe will be tilted and when
this happens it sends a signal to the PLC. The PLC logic gives a
“high high” level trip which is indicated on Citect with an Input
Faulted symbol [See appendix B]. This inspection was done by
taking the tilt probe out of the chute and manually tilting it. During
this inspection it was noted that the electrical cord and the chain
that the tilt probe was attached to were damaged.

Chapter 3 - MINOR PROJECTS Page 25 of 158 November 2008

 3.2.2 Nobles WII 300kN Load cells

At the end of the stacker boom conveyor there are two Nobles WII 300kN
Load cells. These are put in place to show the belt tension on the
conveyor, and to allow for its correction and calibration. When the Load
cells were inspected it was found that one of them was not wired up and
the other one needed to be turned 90 degrees as the stain gauge inside the
load cell would not detect a reading unless it had the right orientation in
the direction of force. The load cells send a 4-20 mA current to PLC which
is then scaled and displayed on Citect.

3.2.3 Microwave Sensors

Microwave sensors are used in several applications on site such as block

chute detection but in this instance the microwaves are located on the
Stacker boom. It was required to inspect the Microwave sensors as they
kept indicating a trip on Citect. The Microwave sensors are used to
prevent the stacker from colliding with the stock pile as shown in figure 3-
3. The sensor is a Hawk Measurement system Microwave Pulse Switch
which operates by the use of three electrically isolated units:

1. The Microwave Sender (MRS) – emits a microwave 200 times a

second towards the receiver.

2. The Microwave Receiver (MRR) – switches a relay when a state

change is detected. This is triggered when the line of sight is
interrupted, for example the stacker boom is to close to the stock
pile and the ore brakes to line of sign between the send and
receive.

3. The Microwave Amplifier (MRA) - is used to set the parameters

such as:

• On delay

• Off delay

• Sensitivity

and check whether the system is operation by the Three LED

• LD1 – Power Applied

Chapter 3 - MINOR PROJECTS Page 26 of 158 November 2008

 • LD2 – Signal Detected

• LD3 – Relay Energised after Delay

Microwaves

Figure 3–3 Stacker microwaves

There are two pairs of microwave sensors on the stacker to protect both the
left hand side and right hand side of the boom. The correct orientation of all
four sensors in respects to the boom is as shown below:

Figure 3–4 Microwave orientation

The status of the microwave sensor was checked, and it was found that the
send and receive position of both pairs of sensors were at the same end of the
stacker boom. Due to microwaves being on both sides of the stacker it was
recommended not to have the sends or receives at the same end of the boom
otherwise the signal may be received by the wrong receiver and interrupt the
signals. The right hand side (RHS) pair of microwaves were swapped and the
receiver was replaced to eliminate a cause of the faults. The microwave the

Chapter 3 - MINOR PROJECTS Page 27 of 158 November 2008

 alignment was corrected, as the datasheet for the Microwave pulse switches
recommended that they should be aligned correctly for best performance.

After the mounting was corrected, the parameters were recalibrated. This
resulted in no more false detections and no constant interruption in stacker
movement and consequently production delays.

Figure 3–5 Microwave Pulse Switch

3.2.4 IPC – 14 Electronic Weighting Controller

The Stacker boom conveyor has a history of a numerous amount of under

speed trips on the head pulley and a lot of time has been invested in changing
the under speed sensors. An under speed trip is determined by a proxy
switch sending pulses back to the PLC and a timer set to a particular time, if
the proxy switched at the stacker boom conveyors head pulley does not send
a pulse within 1.1 seconds a under speed is detected . It has been questioned
whether the under speed trips are a result of a faulty proxy or have been
legitimate, or whether there is a problem with belt tension or alignment. To
ascertain the root cause, an additional measurement system was utilised to
confirm whether or not the belt is slowing down or the proximity switch is
faulty.

Figure 3–6 Weighting Controller display [2]

Chapter 3 - MINOR PROJECTS Page 28 of 158 November 2008

 The Stacker boom conveyor has an IPC – 14 Electronic Weighting Control to
determine the amount of tonnes an hour the conveyor is putting onto the
stock pile. It was determined that the IPC – 14 could also give an analog
speed reading through an extra analog output card. The Maintenance order
requested that a specific analog output card be attached to the controller and
wired back to the PLC as the drawing indicated. It was done during the time
with the electrical team and the further works involved creation of logic in
the correct PLC to display the numerical reading on the Citect as shown in
appendix C.

3.3 Oil Cooler Gearbox Pressure Readings

3.3.1 Introduction

The Oil cooler gearbox pressure readings for YCV212A, YCV212B and
YCV212C had been recently added and a task given was to create logic for the
analog scaling of the raw pressure values from the field. The Citect display
that retrieves the scaled pressure value from ProWORXs was also a required
task. Within the next two subsections a detailed explanation will be given on
the process undertaken. The explanation will only be given on YCV212A as
the procedure is to same for all three pressure reading.

3.3.2 Description and work included

The first task that is required when proceeding to create new logic within the
PLC is:

• To find the correct PLC, as to where the pressure signal has been
wired into.

• Locate where the new code is going to be inserted

• Find and allocate all the PLC addresses that are going to be used, and
confirm that the addresses are not already being used.

• Assign symbols and description to the addresses to allow for easy

understanding and fault finding.

Chapter 3 - MINOR PROJECTS Page 29 of 158 November 2008

 The figure 3-7 shows the analog scaling for YCV212ACL01PT01 and consists
of:

1. Move 1000 into the maximum value address using a SUB block, to set
the maximum scale parameter of the pressure switch.

2. Move 0 into the minimum value address using a SUB block, to set the
minimum scale parameter of the pressure switch.

3. Move the maximum and minimum addresses into the corresponding

SUBR_MAX and SUBR_MIN analog scaling subroutines using a
BLKM block, which is a block move that copies registers to another
register.

4. Move 1 into the SUBR_FACTOR analog scaling subroutine, using a

BLKM block.

5. Move the raw pressure valve YCV212CL01PT01_RAW into the

SUBR_RAW analog scaling subroutine, using a BLKM block.

6. Retrieve the value from the SUBR_SCALED analog scaling subroutine

and move it to YCV212ACL01PT01, using a BLKM block.

7. A broken wire warning is used to indicate a problem with the pressure

device or the wiring. The ninth input addresses in the PLC’s card is
used to determine if the pressure signal returns a current reading
below 4mA. If this occurs the corresponding ProWORX addresses are
energised. To determine the corresponding broken wire addresses
refer to appendix F. When the signal from the determined address is
active and the drive is auto running the broken wire warning coil
YCV212ACL01 PT01_BW_W is activated. The coil will be latched on if
the alarm reset is not activated and also default the pressure reading to
1000.

Chapter 3 - MINOR PROJECTS Page 30 of 158 November 2008

 Figure 3–7 Oil Cooler A Analog Scaling

After the PLC ladder logic was created for the pressure readings, Citect
graphical displays were set up. Before adding any displays to the required
pages the following tags need to be created:

Variable Tags
For all three pressure readings a real time scaled pressure reading (PT01)
and alarm (PT01_BW_W) tags were created. The parameters data type
(INT), Zero Scale (0) and Full Scale parameters were filled correctly,
however the broken wire tag is a digital input and only the PLC number
(YPL206) and address reference (002962) was needed.

Figure 3–8 Oil Cooler A Analog Scaled Pressure Tag

Figure 3–9 Oil Cooler A Pressure Broken Wire Tag

Chapter 3 - MINOR PROJECTS Page 31 of 158 November 2008

 Trend Tags
The trend tags were created to graphically represent the pressure reading
over time. When creating the trend tag the variable tag reference, sample
period and the location to where the data is going to be saved was required.

Figure 3–10 Oil Cooler A Pressure Trend Tag

Alarm Tags
The alarm tag was created to enable to having the broken wire warning to
appear on the alarms page within Citect. This page has already been set up to
list all the alarms that have been triggered and the time they occured.

Figure 3–11 Oil Cooler A Pressure Broken Wire Alarm Tag

3.3.3 Results and Outcome

The Oil cooler gearbox pressure readings for YCV212A, YCV212B and
YCV212C were successfully implemented, however there were some other
problems with the location of the pressure sensors. Due to a recent blockage
and consequently the spike in pressure that did not reach the trip limit that
would have stopped the motor and the pressure build up caused the
equipment to break. Creating the logic in ProWORXs and a Citect display

Chapter 3 - MINOR PROJECTS Page 32 of 158 November 2008

 gave valuable experience in exploring and be able to navigate easier around
the different software.

3.4 iMAC

3.4.1 Introduction

The iMAC system on site used to monitor the status of pull wires along a
conveyor and help with the identification of which pull wire as tripped. There
has been some difficulties with differentiating the iMAC devices that have
faulted and the reading from the different devices because the signal from
the modules furthest from the iMAC controllers are not being received
clearly. The problems initiated at installation, as the iMAC system were not
installed correctly. Performing a fault diagnosis is difficult and time
consuming, which will create a loss in production, therefore the counter
measures created are:

• Correct wiring faults on YCV302

• Parameter modification of the units

• iMAC controller to be modified to display faults

• Check baud rate

• Modify cable tray orientation

The wiring, and parameter modifications are completed, and the baud rate
checked prior to the commencement of the internship. The cable tray
modification was cancelled, and the final procedure was to modify the iMAC
controller to display faults. A contracting company were delegated the task of
creating the program for the iMAC controllers however they required a
descriptor list which contains all the iMAC addresses for the different
conveyors and what display were wanted for each address on the screen.

The iMAC I/O Modules out in the field such as RTD4 (Resistance
Temperature Detector) and TCD4 (Thermal Conductivity Detector), collect
data and report the data back to the iMAC controller over the iMAC signal
line. The four in the name TCD4 and RTD4 indicates how many field devices

Chapter 3 - MINOR PROJECTS Page 33 of 158 November 2008

 can connect to the module such a pull wires to determine which pull wire trip
has occurred. Each module has a unique serial number, which identifies the
module during programming. Addresses (range of 1 to 255) were assigned to
the iMAC modules, which are used to reference the module rather than the
serial number. The iMAC controller performs regular scans of the I/O
Modules to collect data for updating the status of the addresses. Each scan
comprises of the controller reading 4 addresses and updating the data
associated with the I/O modules. The 4 address that are scanned are known
as a block, so for address 1 to 255 there are 64 blocks. [11]

Figure 3–12 iMAC example configurations

Figure 3-12 portrays the iMAC system functionality at Yandicoogina. There

are three wires that are connected to the iMAC controller that continue to
the end of the line, which is demarcated by the End of Line modules (EOL).

Chapter 3 - MINOR PROJECTS Page 34 of 158 November 2008

 The EOL module indicates the signal line in healthy by successfully
communicating with the controller on a separate part of the communication
protocol, this is to ensure that the data is not corrupted. The Lightning
Protection Module (LPU) that is located between the signal lines and the
TCD4 modules to protect the TCD4 from lightning. [11]

The three lines labelled Com, A and B represents:

• Com is the common line that can be referred as the ground

• A is the line that contains the hardwired switches which gives a pull
wire trip.

• B is the line used for monitoring the pull wires along the conveyor, so
that when a pull wire trip occurs the iMAC controller can indicate
which pull wire has tripper for easy location.

3.4.2 Description and work included

To finalise the iMAC project, the iMAC address information for conveyors
YCV211, YCV212, and YCV302 were required. In Addition, a brief description
of the devices at the particular addresses were collected for programming.
This information is to appear on the iMAC controller screen to make fault
finding easier. The list was created by viewing the Citect displays for each
conveyor and the corresponding addresses in ProWORXs. An example of the
displays used for creating the list can be are in appendix D.

3.4.3 Results and Outcome

The descriptor list has been completed, however the programming has not
been completed due to delays. Therefore, no outcomes can be given at the
present.

3.5 Conclusion

The varieties of different tasks detailed above that occurred throughout the
internship have provided opportunities to learn about different devices from a
hands on experience and obtain useful knowledge about the onsite operations,
throughout the different departments. There were many day to day tasks that
have not been mentioned however these tasks had a fair amount of time spent

Chapter 3 - MINOR PROJECTS Page 35 of 158 November 2008

 on them and demonstrate some of the work involved in the operations at
Yandicoogina and the roles on site.

Chapter 3 - MINOR PROJECTS Page 36 of 158 November 2008

Chapter 4 - SYSTEM IDENTIFICATION

4.1 Introduction

This chapter the Dust Collection System will be explained in great detail which will
allow for the understanding of the subsequent chapters. The chapter will start by
explaining the reason for dust collection systems and their importance within Rio
Tinto Iron Ore. The overall layout of the Dust Collection System is discussed in the
Hopper section. Following on from there an explanation of the different pieces of
equipment, which include the Fan, Rotary Valve, Conveyor and Pulse Cleaning
System.

4.2 Dust Collection System

The YDU210 Dust Collection System was part of a recent expansion project and was
assigned as the major project throughout the internship. The project comprised of

Chapter 4 - SYSTEM IDENTIFICATION Page 37 of 158 November 2008

 creating PLC logic, Citect display/controls and organise any other works that was
required to see the Dust Collector operational. The aim of the YDU210 Dust
Collection System is to control airborne dust emissions from the transfer of Iron
Ore from YCV212 to YFB205 and YFB206 then to YCV213 by collecting the dust
through fan suction. The Dust collected is feed back onto a process conveyor
YCV213, as shown in appendix A.

The Ion Ore operations at Yandicoogina have a very high potential to create dust
from the open Iron Ore transportation through the different stages of the process
and the human impact within the environment. The main dust emissions are from:

• Mining, transporting and stockpiling Iron Ore

• Blasting

• Vehicle movement

• Wind

• Non maintenance house keeping

Rio Tinto’s focuses on the prevention or elimination of any Environmental Hazards

within the workplace that may arise before, during and after operations. Dust
emissions are an environment hazards that Rio Tinto takes a key interest in as:

• High levels of dust exposure or exposure over a long period of time has the
potential for health problems.

• The safety within the mine site operation is minimised with high levels of
dust as the visibility, is dramatically lowered and personal concerns such as
eye irritation.

• One of Rio Tinto’s legal obligations is to minimise dust emissions

• Vegetation destruction is a environmental symptom of dust, which creates a

greater potential of dust emission as vegetation minimises dust, and water
pollution of water bodies with sediment.

[6]

There are a numerous amount of controls implemented at Yandicoogina to

minimise the amount of dust emission around the mining and process operations.
The controls implemented are:

Chapter 4 - SYSTEM IDENTIFICATION Page 38 of 158 November 2008

 • Water application to the roads and open areas via Water trucks, and the
Conveyors, stacker, reclaimers, and transfer points via water sprays

• Minimise Speed limits on unsealed roads

• Vegetation rehabilitation

• Incident reporting to identify and make improvements to dust emission

areas

• On sealed roads have periodic vacuum road sweeps

• Plan all works to be able to identify and minimise all potential dust
emissions

• Dust Collection Systems

• Housekeeping including removing spillages and potential dust sources

• Minimise ground disturbance

[6]

4.3 Hopper

The hopper bin contains the filter bags that collect the dust as the fan sucks air
through them. The hopper bin is the main centre point of the Dust collection
system, as the Fan, Rotary valve, Conveyor, and Pulse cleaning are all attached to
the Hopper. Figure 4-1 below shows the overall Dust Collection System and the
positioning of the equipment detailed in the following sections.

Chapter 4 - SYSTEM IDENTIFICATION Page 39 of 158 November 2008

 Pulse Cleaning
Control Panel
Piping Duct

Hopper

YDU210CV01
Conveyor

Air Discharge
Rotary Valve Vent

YCV213
Conveyor

YDU210MB01
Marshalling box

Fan
Field Start and
Stop buttons

Figure 4–1 YDU210 Dust Collection System

4.4 Fan

The dust collection system utilises a fan to extract dust from YCV212 surge bin,
YFB205, YFB206 (Feeder Belt) and YCV213 Conveyors, in to the Dust Collector
Hopper. The Hopper contains bags that collect the dust particles as the fan sucks
the air through them from the duct that separates into four as shown in Figure 4–2
YDU210FN01 Fan piping. The fan then disburses the dust free air through a
discharge vent supported by the fan. The specification of the extraction fan are:

Chapter 4 - SYSTEM IDENTIFICATION Page 40 of 158 November 2008

 DUTY

Flow Rate: 5875 l/s

Inlet pressure: -2468 Pa

Outlet Pressure: 632 Pa

Speed: 2657 rpm

Power: 25 kW

MOTOR 37 kW 1470 rpm

415V 3 phase 50Hz

YCV212 Surge Bin

YFB206

YFB205

YCV213

Figure 4–2 YDU210FN01 Fan piping

The fan’s schematic diagram displayed in appendix G shows the electrical

connections information, which helped create the control logic. The main features
of the diagram are:

PLC I/O

The Fan PLC inputs include:

Chapter 4 - SYSTEM IDENTIFICATION Page 41 of 158 November 2008

 • 24V DC supply ok indication

• Isolator Closed indication

• Thermal Overload indication

• Contactor Closed indication

• Lock Off Stop indication

• Local Start Push Button indication

The Fan PLC output includes:

• Start Relay

The I/O on the schematic diagram displayed as shown in figure 4-3. The
downwards arrow indicated that the wire from the PLC is connected in a
marshalling cubicle and the text on top indicates which terminal strip. In this cases
the PLC Input is connected to terminal strip P4 at terminal number 211 shown in
appendix K. The number next to the hexagon gives the PLC information, for
example in the figure 4-3 the PLC input is located in PLC 206 drop 4, Slot 6,
channel 9. The number within the hexagon indicates to PLC terminal number which
is explained in appendix M.

Figure 4–3 PLC Input [E-001-58463]

In figure 4-4 the PLC Output is connected to terminal strip P5 in between terminal
number 183 – 184 as shown in appendix L. The number next to the Oval gives the
PLC information, for example in the figure below the PLC Output is located in PLC
206 drop 4, Slot 11, channel 10. The number within the Oval indicates to PLC
terminal numbers which is explained in appendix M.

Figure 4–4 PLC Output [E-001-58463]

Chapter 4 - SYSTEM IDENTIFICATION Page 42 of 158 November 2008

 Marshalling Cubicle

The marshalling cubicle indication explained above also indicates the wiring
between the different terminal strips. The different terminal strips used to denote
where the wires are terminated in the MCC within the Substation are P (PLC), R
(Relay), F (Field), and M (MCC starter motor). The clear indication between the
different terminal strips provides a standard organisation practice to maintain and
install new electrical works, and also makes for easy fault finding activities. Figure
4-5 shows the wiring between M2 – 224 and R3 – 108.

Figure 4–5 wiring between termination strip [E-001-58463]

In figure 4-6 it displays the wire termination in the field. The Marshalling box
YDU210MB01 is located at the base of the YDU210 Dust Collection System, next to
the fan equipment and contains the termination strips A1 and B1. B1 is the
termination strip for the equipment in the field, and A1 is the termination strip that
is wired back to the MCC within substation. The example below shows that the field
start button is wired to B1 – 3 and B1 – 4 and then to A1 – 3 and A1 – 4. F2 – 146
and F2 – 147 is the termination location in the substation of the push button before
being wired to the P4 strip to go into PLC206, Drop 4, Slot 6.

Figure 4–6 Fan field start button wiring [E-001-58463]

Symbols

Figure 4-7 indicates two symbols that are important in understanding the schematic
diagram. The rectangles represent relays and the circles with a cross in the middle
represent Motor control centre module. Therefore, figure 4-7 indicates that relays
K40 and K42 are within the motor control.

If the motor control symbol does not appear around a relay symbol then the relay is
located within the Marshalling cubicle. These relays are Omron LY2N 24V DC
general purpose relay, where the 2 indicates the number of contacts and the N
indicates that the relays have LED indications that turn ON when voltage is applied
to the coil. Figure 4-8 shows the internal terminal arrangement of the relays, which

Chapter 4 - SYSTEM IDENTIFICATION Page 43 of 158 November 2008

 clearly indicates that there are two contacts that can be wired to the relay and that
the two settings of normally open (NO) and normally closed (NC) can be chosen.
For example wiring between 1 and 5 is a normally closed switch and wiring between
4 and 6 is a normally open switch.

Figure 4–7 Internal motor relay example

[E-001-58463]
Figure 4–8 MCC relay configuration [8]

Figure 4-9 displays the three phase fan motor with the wiring component of the
Isolator (Q02) with indication (F07, F08, F09) Thermal overload (F02) and main
contactor (K18). These were then used throughout the remaining part of the
schematic diagram to indicate their states to the corresponding PLC inputs.

Figure 4–9 Fan motor configurations [E-001-58463]

Line referencing is also a component of the schematic diagram that were required
to be understood. The example displayed in figure 4-10 shows that the wire
continues at line 42 and shown in figure 4-11. There are also line references that
refer to other diagrams, the wire will have a diagram reference also shown in the
figure 4-11.

Chapter 4 - SYSTEM IDENTIFICATION Page 44 of 158 November 2008

 Figure 4–10 Line referencing within diagram [E-001-58463]

Figure 4–11 External diagram line referencing [E-001-58463]

4.5 Rotary Valve

The functionality of the Rotary valve is to empty the dust accumulation in the
bottom of the Hopper. The rotary valve shaft rotates, creating a passages for the
Iron Ore to move from the bottom of the hopper to the below conveyor. The device
used to trigger the running of the valve is a rotary paddle bin monitor, which
indicated the hopper dust level by the bin monitor paddle ceasing to move and
signalling that there is a blockage in the hopper. When there is no dust build up the
bin monitor paddle rotates freely inside the hopper.

Figure 4–12 YDU210RV01 - Rotary Valve photo

Chapter 4 - SYSTEM IDENTIFICATION Page 45 of 158 November 2008

 The Rotary Valve schematic diagram displayed in appendix H shows the electrical
connections information, which helped create the control logic. The main features
of the diagram have the same layout as the fan, however there are additional under
speed sensor, shown in figure 4-13. The under speed sensor is a poxy switch that is
triggered by a T piece as the rotary valve spins.

Figure 4–13 Under speed sensor wiring diagram [E-001-58464]

The PLC I/O for the Rotary Valve is:

The Rotary Valve PLC inputs include:

• 24V DC supply ok indication

• Isolator Closed indication

• Thermal Overload indication

• Contactor Closed indication

• Lock Off Stop indication

• Local Start Push Button indication

• Under speed sensor pulse

The Rotary Valve PLC output includes:

• Start Relay

4.6 Conveyor

The Dust Collector Conveyor Tail is located underneath YDU210RV01 Rotary valve
and the Head is above YCV213 Conveyor, it is used to transfer the fine dirt particles
back onto the YCV213 process conveyor that continues to the loop Screen House.

Chapter 4 - SYSTEM IDENTIFICATION Page 46 of 158 November 2008

 Figure 4–14 YDU210CV01 - Conveyor photo

The Conveyor electrical connections information obtained from appendix I and was
used to create the control logic. The main features of the diagram have the same
layout as the Rotary Valve, however there are additional Pull wire switches and start
warning siren, shown figure 4-15, 4-16 and 4-17. The Pull wire switches are
compulsory on all conveyors as they provide an emergency stop then near the
conveyor. The start warning siren is put in place to warn any nearby personal that
the conveyor is about to start.

Figure 4–15 Pull wire switch wiring diagram [E-001-58501]

Chapter 4 - SYSTEM IDENTIFICATION Page 47 of 158 November 2008

 Figure 4–16 Start warning siren wiring diagram [E-001-58501]

Figure 4–17 Start warning siren PLC connection diagram [E-001-58501]

The PLC I/O for the Conveyor is:

The Rotary Valve PLC inputs include:

• 24V DC supply ok indication

• Isolator Closed indication

• Thermal Overload indication

• Contactor Closed indication

• Lock Off Stop indication

• Local Start Push Button indication

• Under speed sensor pulse

• Pull wire Switch 1

• Pull wire Switch 2

The Rotary Valve PLC outputs includes:

• Start Relay

• Start Warning Siren Relay

4.7 Pulse Jet Control System

The Jet Pulse Cleaning Control Panel is a standalone filter cleaning control system
for reverse jet-pulse dust collectors. The system has a control interface which
controls the pulse cleaning system however, there are signal I/O options. Every
Dust Collection System at Yandicoogina has a Pulse Panel fitted to the dust collector

Chapter 4 - SYSTEM IDENTIFICATION Page 48 of 158 November 2008

 hopper that controls the cleaning cycles of the hopper bags. The controller also
allows for alarm monitoring, alarm remote reset and activate a manual cycles when
a Cleaning Cycle is required.

The Inputs and Outputs communication between the Pulse cleaner and the
appropriate PLC are:

Table 4-1 PLC Input communications [9]

PLC Inputs Description

Cycling Remote indication of when a valve is being actuated

Watchdog Alarm Indicates failure of microprocessor

High dP Alarm Indicates that differential Pressure has reached the programmed alarm
trigger

Service Alarm Indicates that either 100K, 500K or 950K cycles have been reached

Coil Failure Alarm Indicates solenoid failure on the system

Auxiliary Alarm Indicates the alarm state of an auxiliary input device

Power OK signal Indicates system power is OK

Low header alarm Indicates low tank pressure, when connected to an appropriate switch.

Auxiliary Input Allows the connection of an auxiliary device

Table 4-2 PLC Output communications [9]

PLC Outputs Description

Differential Pressure 4-20mA output indicating the pressure difference between the clean
and dirty side of the hopper bags

Reset General Alarm Resets all alarms but the service alarm

Reset Service Alarm Reset service alarm

Manual Cycle Forces a full cleaning cycle

Demand / Continuous switch Allows remote switching between continuous and demand control
modes

Blowdown cycle There is a input to the control panel that allows for the fan to be
hardwired to activate a final cleaning cycle, however this has been
connected to a PLC output, therefore the PLC can initiate a blowdown
cycle

Chapter 4 - SYSTEM IDENTIFICATION Page 49 of 158 November 2008

 TBo1

Figure 4–18 YDU210PN01 - Pulse cleaning controller photo

The Pulse Cleaning Controller schematic diagram displayed in appendix J shows

the electrical connections information, which helped create the control logic. The
main features of the diagram are more complex then the previous diagrams that
were referred too, however the symbols used are the same apart from the addition
of the solenoid valve and the miscellaneous terminal TB01. The Solenoid valve
shown in the figure 4-19 is located on the top of the Hopper, and there are 28
solenoid valves to provide pulses of compressed air into the bag for cleaning. The
TB01 terminal strip is located in the Dust Collector Control Panel marshalling box
(YDU210PN01) shown in the figure 4-18 and in appendix N.

Chapter 4 - SYSTEM IDENTIFICATION Page 50 of 158 November 2008

 Pulse Cleaning
Control Panel
YDU210PN01

Manifold

Solenoid

The blue indicates

Piping used to direct
the compressed air
into the bags that
are cylinder shaped
and progress down
Figure 4–19 Hopper Arial View photo into the hopper

4.8 Conclusion

This chapter has given a detailed explanation of the equipment that comprises the
YDU210 Dust Collection System. The Dust Collection System has been identified as
a key contributor to the minimisation of dust at Yandicoogina therefore, it will be a
great asset to complete the YDU210 Dust Collection System project.

Chapter 4 - SYSTEM IDENTIFICATION Page 51 of 158 November 2008

Chapter 5 - CONTROL SYSTEM DESIGN
5.1 Introduction

The aim of this chapter is to explain the control theory, implementation and
functionality of the YDU210 – Dust Collection System. The Yandicoogina network
section will include an explanation of the network configuration on site with details
of some of the components. In the following sections the required functional
specification document will be detailed, and then a description of the ProWORXs
and Citect implementation is outlined.

5.2 Yandicoogina Network

The network configuration was not a major concern in the works of the YDU210
Dust Collection system as all the schematics diagrams had been created and
provided from the expansion project that was been previously mentioned before as
the YDU210 was installed during the recent expansion project. A basic

Chapter 5 - CONTROL SYSTEM DESIGN Page 52 of 158 November 2008

 understanding of the network explained in figure 5-1 was enquired to understand
how the PLC data is obtained from the field and accessed on the office Control
computers. The PLC’s as shown in figure 5-1 consist of Power module and two
NOE’s. The NOE cards are used to convert the Modbus Data so that it can travel
along Ethernet which follows the IP protocol. All PLC’s on site communicate to a
Hirschman which have individual IP address and allow the communication between
all devices connected to the controls network. The I/O server acts as an IP to
Modbus driver and is connected to a Hirschman through two Ethernet cables. The
purpose of the two Ethernet cables it the equally divide data transfer to allow faster
communications to the PLC’s. [10]

Figure 5–1 Network description

5.3 Functional Specification

The functional specification document was a requirement for the project to give a
detailed control philosophy of the YDU210 Dust Collection System. A functional
specification document is created for all control systems within Rio Tinto, as it
allows other personnel to enquire information about the control systems and
familiarise them self with the process flow to gain greater understanding of the
process and equipment requirements from a control perspective.

The functional specification document comprised:

• Equipment Design Overview

• Process Description

Chapter 5 - CONTROL SYSTEM DESIGN Page 53 of 158 November 2008

 • Control system parameters

• Sequence interlocks

• Critical and non critical interlocks

• Equipment trips and alarms

• Fault Handling

• Construction and Commissions

The importance of the functional specifications document became more apparent at

the commencement of creating the ladder logic within ProWORXs. The functional
specification document defines the logic sequence and interlocks that need to be
understood, to allow the Dust Collection System equipment to run without causing
harm to personnel or the equipment. With the sequences documented and carefully
review the process of programming was in the final stages.

The description of the YDU210 Dust Collector Control process with the associated
equipment which, includes the YDU210FN01 Fan, YDU210RV01 Rotary Valve,
YDU210CV01 Conveyor, and the YDU210PN01 Pulse cleaning system, has been
displayed below in Table 5-1 and Figure 5-2. Table 5-1 steps through the automatic
process flow and shows which conditions will effect the course of the of operations.
For example if YCV213 is auto running and all of the YDU210 Dust Collection
System equipment is auto ready and its status is healthy then the YDU210 fan will
start and if it starts and the differential pressure in the hopper is low then the fan
will continue to run without the pulse cleaner running.

Table 5-1 Step by step process flow

Step Step Normal Exception Exception

No. Description Operation Condition 1 Condition 2
Condition
1 Auto Start • YCV212 Auto • YCV213 Non Running
System idle running • YDU210FN01 Unhealthy
• YDU210FN01 All • YDU210RV01 Unhealthy
Healthy & Auto • YDU210CV01 Unhealthy
• YDU210RV01 All • YDU210PN01 Unhealthy
Healthy & Auto Move to Step 2
• YDU210CV01 All
Healthy & Auto
• YDU210PN01 All
Healthy & Auto
Move to Step 3

Chapter 5 - CONTROL SYSTEM DESIGN Page 54 of 158 November 2008

 2 Auto Stop • YDU210FN01
Stopped
• YDU210CV01
Stopped
• YDU210RV01
Stopped
• YDU210PN01
Stopped
Move to Step 1
3 Fan Auto • YCV212 Running • YDU210FN01 Unhealthy • YCV212 Non Running
Running • YDU210FN01 Move to Step 4 Move to Step 9
Continuous Started
Move to Step 5
4 Stop Fan • YDU210FN01 • YDU210FN01 Stopped • From Step 4
Stopped • Manual Cleaning cycle • Conveyor or rotary
• Not from step 4 Started complete valve running
Move to Step 1 Move to Step 2 • Hopper low limit

Move to Step 8
5 Auto Running • YDU210SR01 • Differential Pressure Low • Differential pressure
Cleaning Cycle Started Move to Step 6 High Timer complete
• Differential Move to Step 4
pressure High
Move to Step 7
6 Auto Stopped • YDU210SR01 • Hopper bin Low
Cleaning Cycle Stopped • YDU210RV01 NOT
Move to Step 7 Running
Move to Step 3
7 Auto Running • YDU210RV01 • YDU210RV01Started • Hopper bin level High
Rotary Valve Started • YDU210CV01 Started Timer 2 complete
and Conveyor • YDU210CV01 • Hopper bin Low Move to Step 4
Started • Rotary Timer 1 complete
• Hopper bin level Move to Step 8
High
Move to Step 3
8 Stop Rotary • YDU210RV01 • From step 4
Valve and Stopped
Conveyor • YDU210CV01 Move to Step 1
Stopped
Move to Step 3
9 Manual shut • YDU210FN01 • YDU210FN01 Not
down Cleaning Running Running
cycle • Fan Shutdown Move to Step 1
timer 1 complete
Move to Step 4

Chapter 5 - CONTROL SYSTEM DESIGN Page 55 of 158 November 2008

 AUTO
START

Is Conveyor YCV213
Running?

NO

YES

FAN
YES
RUNNING?
YES YES
YES YES
Is FAN Healthy? Is Pulse Cleaner Healthy? Is RV Healthy? Is Conveyor Healthy?
Wait 10 min

NO NO NO NO
NO

STOP FAN
Auto
TRIP TRIP TRIP
RUN

Chapter 5 - CONTROL SYSTEM DESIGN

TRIP
AUTO
DISABLED
IF FAN was Running FAN
Running

Cleaning Cycle
Running STOP Pulse
WAIT 5 M IN Low
Cleaning

Differential Runnung for 1 Hr

Running for 2hrs
Pressure?
High for 15 min and NO Cleaning cycle and RV NOT started

? High for 15s

Page 56 of 158
Cleaning Cycle
Running

WARNING Hopp er Level?

High For 10 min

IF LOW HIGH

Roatary RUNNING

WAIT 5 M in Rotary Valve

Running
Auto Sequence

TRIP Trip s And Warning Alarms RUN RV

WARNING
STOP
Rotary Valve
Equip ment Stopped WAIT 5 M in

Equip ment Running

RUN
STOP Conveyor
Questions
Conveyor

November 2008
Figure 5–2 Process flow
diagram
 Figure 5-2 graphically displays the table 5-1, as it shows the auto sequence of the
Dust Collection System. The diagram runs is a cyclic motion to represent the action
of the PLC’s scan cycle. For example if all of the YDU210 equipment is healthy and
YCV212 is running then the fan will start, checks the differential pressure and the
hopper level. If the differential pressure and hopper level are both low then the
cycle starts at the beginning again, checking the status of all the equipment and
whether YCV212 is still running, and then the differential pressure and hopper
level. This cycle continues until one of the conditions changes.

At the completion of creating the process flow description the required interlocks
were determined. The three types of interlocks defined throughout the creation of
the functional specification process are:

• Critical interlocks, determine what conditions will cause the motor for each
piece of equipment to cease operation or not allow the equipment to start.

• Non Critical interlocks, indicate situations will cause the equipment to trip
however the severity in minimal compared to the critical interlocks

• Sequence interlocks, are defined to allow the understanding of the sequence

start, run and stop for every piece of equipment.

The critical, non critical and sequence interlocks for the Fan, Rotary Valve,
Conveyor and Pulse cleaner are defined as follows:

Critical Interlocks

YDU210FN01

• YDU210FN01DCOK – 24V DC Supply OK

• YDU210FN01IS01 – Isolator Closed
• YDU210FN01LOS01 – LOS OK
• YDU210FN01TO01 – TOL Tripped
• YDU210FN01MC01 – Main Contactor

YDU210RV01
• YDU210RV01DCOK – 24V DC Supply OK
• YDU210RV01IS01 – Isolator Closed

Chapter 5 - CONTROL SYSTEM DESIGN Page 57 of 158 November 2008

 • YDU210RV01LOS01 – LOS OK
• YDU210RV01TO01 – TOL Tripped
• YDU210RV01MC01 – Main Contactor

YDU210CV01
• YDU210CV01DCOK – 24V DC Supply OK
• YDU210CV01IS01 – Isolator Closed
• YDU210CV01LOS01 – LOS OK
• YDU210CV01TO01 – TOL Tripped
• YDU210CV01MC01 – Main Contactor
• YDU210CV01OW01 – Pull wire Switch OK
• YDU210CV01OW02 – Pull wire Switch OK

YDU210PN01
• YDU210DCOK – 24V DC Supply OK
• YDU210PS01 – Air Pressure OK

Non Critical Interlocks

YDU210FN01
• YDU210DCOK – 24v DC Supply OK
• YDU210 PWR – Power OK
• YDU210ALM01_T – Watchdog Alarm
• YDU210ALM02 – High dP Alarm
• YDU210ALM04 – Coil Alarm

YDU210RV01
• YDU210RV01NS01 – Under speed Sensor OK

YDU210CV01
• YDU210CV01NS01 – Under speed Sensor OK

YDU210PN01
• YDU210PWR – Power OK

Chapter 5 - CONTROL SYSTEM DESIGN Page 58 of 158 November 2008

 • YDU210ALM04 - Coil Alarm

Sequence Interlocks
YDU210FN01 - Dust Collector Fan

Table 5-2 YDU210 Fan sequence interlocks

SEQUENCE START SEQUENCE RUN SEQUENCE STOP

- YCV213 Running - YDU210FN01 Running if - YCV213 Stopped for 10
the process conveyor is in
Mins
AUTO and is running.

YDU210RV01 - Dust Collector Rotary Valve

Table 5-3 YDU210 Rotary valve sequence interlocks

SEQUENCE START SEQUENCE RUN SEQUENCE STOP

- Hopper Level High - YDU210CV01 Running - Hopper Level Not high for 5
min
- YDU210 in Auto and 2 - Hopper Level High (Run
Hours Since Operation until 5 minutes after Level
OK)

- 2 Hours Since Operation

(Run for 5 minutes)

YDU210CV01 - Dust Collector Conveyor

Table 5-4 YDU210 Conveyor sequence interlocks

SEQUENCE START SEQUENCE RUN SEQUENCE STOP

- YDU210RV01 Running - YDU210CV01 Running - YCV213 Stopped

- YDU210RV01 Required To - YDU210CV01 Stopped

Run
- YDU210CV01 Run Off

The last important requirement of a detailed functional specification document is to

stipulate the system alarms and warnings. This indicates the systems particular
points what will or have the potential to cause damages or faults left
unacknowledged. The trip and warning alarms for YDU210FN01 fan, YDU210RV01

Chapter 5 - CONTROL SYSTEM DESIGN Page 59 of 158 November 2008

 rotary valve, YDU210CV01 conveyor and YDU21oPN01 pulse cleaner are presented
in tables 5-5 to 5-8.

YDU210FN01 – Dust Collector Fan

Table 5-5 YDU210 Fan warning and trip alarms

TRIP ALARMS WARNING ALARMS

24 V DC supply trip Pulse Panel Service Alarm

Isolator open trip Air Pressure Not OK

LOS active trip Dust collector Hopper level high warning

TOL trip Required and Not Running

Main contactor failure trip Hopper level high warning

Dust collector hopper level high trip Differential pressure High Warning

Pulse panel 24 V DC supply trip Cleaning Cycle not Complete

Pulse Panel Power OK Pulse Panel Cleaning Cycle on too long

Watchdog Alarm Trip
Watchdog Alarm Warning
Pulse Panel Coil Failure Alarm

Pulse dP alarm

YDU210RV01 – Dust Collector Hopper Rotary Valve

Table 5-6 YDU210 Rotary valve warning and trip alarms

TRIP ALARMS WARNING ALARMS

24 V DC supply trip Required and not running

Isolator open trip Dust collector Hopper fail to empty warning

TOL trip

Main contactor failure trip

LOS active trip

Under speed trip

YDU210CV01 – Hopper Out feed Conveyor

Table 5-7 YDU210 Conveyor warning and trip alarms

Chapter 5 - CONTROL SYSTEM DESIGN Page 60 of 158 November 2008

 TRIP ALARMS WARNING ALARMS
24 V DC supply trip Required and not running

Isolator open trip Start warning siren

LOS active trip

TOL trip

Main contactor trip

Pull wire 1 trip

Pull wire 2 trip

Under speed trip

YDU210PN01 – Pulse Cleaning Control Panel

Table 5-8 YDU210 Pulse cleaner warning and trip alarms

TRIP ALARMS WARNING ALARMS

24 V DC Supply Trip Dust collector Hopper 1 Level High Warning

Hopper 1 Level High Trip Required and not running

Watchdog Alarm Trip Watchdog Alarm Warning

High db Alarm Trip

Service Alarm Trip

Coil Alarm Trip

AUX Alarm Trip

Power Trip

Air Pressure Trip

5.4 ProWORX32 Logic

After creating the functional specification document and review of the previous
ProWORXs tasks undertaken at Yandicoogina and the logic implementation was
commenced. Before implementation a hard copy of the logic and a list of all the
logic that needed an assigned address were created [see appendix O]. The addition
of the Dust Collection System ladder logic in ProWORXs was split into four sections
as follows:

• YDU210 FN01
• YDU210 PN01
• YDU210 RV01

Chapter 5 - CONTROL SYSTEM DESIGN Page 61 of 158 November 2008

 • YDU210 CV01
Apart from the YDU210 PN01 section, all sections followed the same format with
the corresponding register addresses for each section, which is as listed below. The
logic is also displayed in appendix P.

• Critical interlocks

• Non critical interlocks

• Trips and warnings

• Alarm reset

• Mode selection section consists of the logic allowing for the entering of either
Auto, Maintenance (maint) or Out Of Service (OOS) mode

• Auto Sequence consists of the logic that allows for the auto start seal
interlock to be energised

• Maintenance Sequence consists of the logic that allows for the maintenance
start seal interlock to be energised

• Run interlock will be discussed in the following subsections below as all

different for each section.

• Citect display consists of sequence and status indication interlocks

The main concern when programming in ProWORX was the address allocations.
When the task of implementing all the logic was undertaken, the layout of YPL206
register were investigated and locations of the required trips/warning,
timer/counters, Citect commands registers were noted and checked using three
methods to determine that the addresses were not currently in use. These methods
included searching for the addressed using the search tool, using an up to date logic
traffic cop to see if the addresses indicated if they were being used, and finally the
checking if there were any descriptors allocated to the address in question these are
indicated in the figure 5-3.

Chapter 5 - CONTROL SYSTEM DESIGN Page 62 of 158 November 2008

 Search for the address The Logic Traffic Cop
and seeing if the indicates whether an
addresses are used for address is in use in the
any logic logic

Inputting the corresponding

addresses into the reference
and looking to see if there
are any symbols or
descriptions

Figure 5–3 ProWORX display

The logic construction and functionality between ProWORXs used at RTIO

Yandicoogina and Siemens simatic manager used at Murdoch University are
simular which made for an easier transition between the two software packages.
However, there were some blocks used within the logic that information was
obtained for. These blocks were:

Timer T0.1 and T1.0

Both the T0.1 and the T1.0 timers are used for delays. The T1.0 represents that the
timer is in seconds and T0.1 is the tenths of seconds for example if the timer preset
equals #00030 in a T1.0 timer is 30 seconds and in a T0.1 timer is 3 seconds.

Figure 5–4 T1.0 Block structure [1]

Chapter 5 - CONTROL SYSTEM DESIGN Page 63 of 158 November 2008

 Counter UCTR

The UCTR is an upwards counter with the counter preset setting the maximum
counting limit and the accumulated count indicating the present count number. The
counter is initiated when both the input controls are active and the counter is reset
when the reset accumulator is de-energised. The top output is energised when the
preset and accumulated are equal and the bottom is energised at all times until the
preset and accumulated are equal.

Figure 5–5 UCTR Block structure [1]

Block move BLKM

A block move copies an individual or an entire table of register to another register

or registers.

Figure 5–6 BLKM block structure [1]

5.4.1 Fan

The control logic for the fan has been created to follow the sequence
stipulated in the functional specification document and can be viewed in
appendix P. The fan will only operate when the YCV212 conveyor is running

Chapter 5 - CONTROL SYSTEM DESIGN Page 64 of 158 November 2008

 and the fan is in auto mode. However, in maintenance mode the fan will
operate when ever it is given a start command provided that the critical
interlocks are healthy

5.4.2 Rotary Valve

The control logic for the rotary valve has been created to follow the sequence
stipulated in the functional specification document and can be viewed in
appendix P. The rotary valve will only operate when the YDU210 conveyor is
running and the hopper high level activated when the rotary valve is in auto
mode. However, in maintenance mode the rotary valve will operate when the
YDU210 conveyor is running and it is given a start command provided that
the critical interlocks are healthy.

5.4.3 Conveyor

The control logic for the conveyor has been created to follow the sequence
stipulated in the functional specification document and can be viewed in
appendix P. The conveyor will only operate when YCV213 conveyor is
running and also has been given the “required to run” signal when in auto
mode. However in maintenance mode the conveyor will operate when the
YCV213 conveyor is running and it is given a start command provided that
the critical interlocks are healthy.

5.4.4 Pulse Cleaning System

The pulse cleaner is not controlled by the PLC, therefore it does not have the
same sequence logic operations as the fan, conveyor and rotary valve. The
pulse cleaner has an onboard controller that controls the initiation of the
pulse cleaning cycles and when cycling is no longer required. The pulse
cleaner does however send signals to the PLC indicating alarms, cycle
initiation and differential pressure reading. It also receives signals from the
PLC to reset alarms and initiate blowdown cycles. The PLC can be used to
control more of the operation of the pulse cleaner, however this has not been
included in the logic as it is the function of the pulse cleaner controller.

Chapter 5 - CONTROL SYSTEM DESIGN Page 65 of 158 November 2008

 5.5 Citect

The display of the Dust Collection System was created within Citect as shown in
figure 5-7. The format of the YDU210 Dust Collection System follows the same
format as the other Dust Collection Systems on site. The physical display of the Fan,
Rotary Valve and Conveyor were obtained from a Dust Collection System that
followed the same layout as the YDU210 Dust Collection System. In the next four
sub-sections the Citect display and corresponding mimic pages will be discussed for
each piece of equipment that comprises the YDU210 Dust Collection System. Figure
5-7 displays the layout of the YDU210 system in Citect.

Figure 5–7 Dust Collection System Citect display

5.5.1 Fan

The Fan mimic display and corresponding text is situated at the top of the
YDU210 Dust Collection System. The text is programmed to open the
YDU210FN01 popup mimic page when selected with the left mouse button. If
selected with the right mouse button the text has been programmed to open
a standard control panel, however this can only be accessed with the
appropriate access such as the engineering or controller login access. The
Control panel contains five buttons which include Start, Stop, Auto,
Maintenance and OOS. When selecting Auto, Citect communicates with
PorWORXs and allows the Auto Mode to be entered which proceed the fan to
run in auto. Selecting Maintenance allows the fan to enter the
maintenanceenance mode, when in Maintenanceenance mode the Citect
Start and Stop buttons or the field Start and Lock off stop button is required
to be pressed for the fan to follow the corresponding action.

Chapter 5 - CONTROL SYSTEM DESIGN Page 66 of 158 November 2008

 Figure 5–8 Citect control panel

The Fan mimic pages follow the same format as the mimic pages created and
used for other Dust Collection System fans already located in the Citect
explorer. With using the already created pages the underlining programming
is required to be understood otherwise there will be errors in the Citect
display status of the fan compared to the ProWORXs status. The following
creation description of the fan mimic pages are the same for all the mimic
pages created throughout the task of adding YDU210 Dust Collection System
to the required corresponding main Citect pages.

At the beginning of the task a similar fan and interlock mimic pages were
found by looking through other Dust Collection Fan mimic pages in the
development version of Citect. The development version is where all changes
to the Citect displays are made before compiling and rolling out to all of
Yandi’s Runtime Citect access. Once the pages were found copies were saved
into the correct project file with the corresponding title and location, as the
YDU210FN01 text is programmed to open the corresponding mimic page. If
the process of editing happen on the existing pages, problems would arise
with the Dust Collection system as the pages would display information from
the wrong tags as all pages use a standard genie. The next step in creating the
new pages is understand the underlining programming which has been
previously created and using different genies, super genies and cicode.

A genie that is within Citect is a combination of several related objects that

are saved as a group in the genie library. Genies are used when the particular
object is used in several different applications, for example the face displays.

Chapter 5 - CONTROL SYSTEM DESIGN Page 67 of 158 November 2008

 A super genie is a page that is used to pass information. It can be re-used for
different applications as different sets of tags can be allocated, for example
the control panel display page.

Figure 5–9 YDU210FN01 Popup window

In the main fan mimic page the faces change their picture status from
referencing the different variable tags, for example 24VDC Supply face
reference YDU210DCOK and YDU210DCOK_T. The genie tag referencing is
defined by the displayed in figure 5-10. The description is the text added
beside the face to notify what the face is representing, and the tag field
stipulates which variable tag is used for this face display.

Figure 5–10 YDU210FN01DCOK define genie window

Using cicode and genies the tag text is added to the sections shown below,
and the corresponding faces are displayed depending on the status that is
received from ProWORXs. This programming is applied to all the face
displays on the YDU210FN01 page.

A %Tag%

B %Tag%_T

Chapter 5 - CONTROL SYSTEM DESIGN Page 68 of 158 November 2008

 Figure 5–11 YDU210FN01DCOK symbol parameters

The interlocks page displays the information that was determined for the
functional specification document as stated in the sequence interlock section.
This page is accessed from the “i” at the bottom of the YDU210FN01 page.

Figure 5–12 YDU210FN01 Interlock popup window

The Variable Tags added to the 206 Citect project for the YDU210 fan are:
Table 5-9 YDU210FN01 Variable tags

Description Symbol
Start Relay YDU210FN01SR01
24VDC CB Q29 Supply OK YDU210FN01DCOK
Isolator Closed YDU210FN01IS01
TOL Tripped YDU210FN01TO01
Main Contactor Closed YDU210FN01MC01
LOS OK YDU210FN01LOS01
Local Start PB Activated YDU210FN01PB01
24VDC Supply Trip YDU210FN01DCOK_T

Chapter 5 - CONTROL SYSTEM DESIGN Page 69 of 158 November 2008

 Isolator Open Trip YDU210FN01IS01_T
TOL Trip YDU210FN01TO01_T
Main Contactor Failure Trip YDU210FN01MC01_T
LOS Active Trip YDU210FN01LOS01_T
Select Auto Cit Command YDU210FN01SELAUTO
Select Maintenance Cit Command YDU210FN01SELMAINT
Select OOS Cit Command YDU210FN01SELOOS
Select Stop Cit Command YDU210FN01SELSTOP
Select Start Cit Command YDU210FN01SELSTART
Auto Mode YDU210FN01AUTO
Maintenance Mode YDU210FN01MAINT
OOS Mode YDU210FN01OOS
Drive Status Bit 1 YDU210FN01STAT1
Drive Status Bit 2 YDU210FN01STAT2
Drive Status Bit 3 YDU210FN01STAT3
Sequence Status Bit 1 YDU210FN01SEQ1
Sequence Status Bit 2 YDU210FN01SEQ2
Run Off Time YDU210FN01RUNOFFTME

5.5.2 Rotary Valve

The Citect rotary valve display created, followed the same procedure as
stated in the fan section. The differences between the two displays are that
the rotary valve has an additional under speed face display.

Figure 5–13 YDU210RV01 Status display window

Figure 5–14 YDU210RV01 Interlock status window

Chapter 5 - CONTROL SYSTEM DESIGN Page 70 of 158 November 2008

 The variable tags added to the 206 Citect project for the YDU210 Rotary
Valve are:

Table 5-10 YDU210RV01 Variable tags

Description Symbol
Start YDU210RV01SR01
24VDC CB Q31 Supply OK YDU210RV01DCOK
Isolator Closed YDU210RV01IS01
TOL Tripped YDU210RV01TO01
Main Contactor Closed YDU210RV01MC01
LOS OK YDU210RV01LOS01
Local Start PB Activated YDU210RV01PB01
Under speed Pulse YDU210RV01NS01
24VDC Supply Trip YDU210RV01DCOK_T
Isolator Open Trip YDU210RV01IS01_T
TOL Trip YDU210RV01TO01_T
Main Contactor Failure Trip YDU210RV01MC01_T
LOS Active Trip YDU210RV01LOS01_T
Under speed Trip YDU210RV01NS01_T
Select Auto Cit Command YDU210RV01SELAUTO
Select Maintenance Cit Command YDU210RV01SELMAINT
Select OOS Cit Command YDU210RV01SELOOS
Select Stop Cit Command YDU210RV01SELSTOP
Select Start Cit Command YDU210RV01SELSTART
Auto Mode YDU210RV01AUTO
Maintenance Mode YDU210RV01MAINT
OOS Mode YDU210RV01OOS
Auto Running YDU210RV01AUTORNNG
Drive Status Bit 1 YDU210RV01STAT1
Drive Status Bit 2 YDU210RV01STAT2
Drive Status Bit 3 YDU210RV01STAT3
Sequence Status Bit 1 YDU210RV01SEQ1
Sequence Status Bit 2 YDU210RV01SEQ2

5.5.3 Conveyor

The Citect conveyor display was created following the same procedure as
stated in the fan section. The difference between the two displays is that the
conveyor has additional face displays which include under speed, pull wire 1
and pull wire 2.

Chapter 5 - CONTROL SYSTEM DESIGN Page 71 of 158 November 2008

 Figure 5–15 YDU210CV01 Status window

Figure 5–16 YDU210CV01 Interlock status window

The variable tags added to the 206 Citect project for the YDU210 conveyor
are:
Table 5-11 YDU210CV01 Variable tag

Description Symbol
Start Relay YDU210CV01SR01
Start Warning Siren Relay YDU210CV01HS01
24VDC CB Q33 Supply OK YDU210CV01DCOK
Isolator Closed YDU210CV01IS01
TOL Tripped YDU210CV01TO01
Main Contactor Closed YDU210CV01MC01
LOS OK YDU210CV01LOS01
Local Start PB Activated YDU210CV01PB01
Under speed Pulse YDU210CV01NS01
Pull wire 1 OK YDU210CV01PW01
Pull wire 2 OK YDU210CV01PW02
24VDC Supply Trip YDU210CV01DCOK_T
Isolator Open Trip YDU210CV01IS01_T
Main Contactor Failure Trip YDU210CV01MC01_T
LOS Active Trip YDU210CV01LOS01_T
TOL Trip YDU210CV01TO01_T
Under speed Trip YDU210CV01NS01_T
Pull wire 1 Trip YDU210CV01PW01_T
Pull wire 2 Trip YDU210CV01PW02_T
Not Required To Run YDU210CV01NREQD

Chapter 5 - CONTROL SYSTEM DESIGN Page 72 of 158 November 2008

 Select Auto Cit Command YDU210CV01SELAUTO
Select Maintenance Cit Command YDU210CV01SELMAINT
Select OOS Cit Command YDU210CV01SELOOS
Select Stop Cit Command YDU210CV01SELSTOP
Select Start Cit Command YDU210CV01SELSTART
Auto Mode YDU210CV01AUTO
Maintenance Mode YDU210CV01MAINT
OOS Mode YDU210CV01OOS
Drive Status Bit 1 YDU210CV01STAT1
Drive Status Bit 2 YDU210CV01STAT2
Drive Status Bit 3 YDU210CV01STAT3
Sequence Status Bit 1 YDU210CV01SEQ1
Sequence Status Bit 2 YDU210CV01SEQ2
Run Off Time YDU210CV01RUNOFFTME

5.5.4 Pulse Cleaning System

The Citect pulse cleaning display was created following the same procedure
as stated in the fan section however referencing the correct corresponding
pages. There is a significant difference between the previous three equipment
status page displays as the YDU210PN01 pulse cleaning window conveys all
the information concerning the Precision P2 pulse cleaning controller. There
are also three additional buttons on the YDU210PN01 window and one on
the YDU210 Diagnostics window which have the functionality of:

YDU210PN01 Pulse Cleaner

• Reset is used to reset only the service alarm

• Initiate provides a signal to ProWORXs when pressed to initiate a

blowdown cycle

• Diagnostics is used to open the YDU210 Diagnostics window

YDU210 Diagnostics
• The reset button on this page allows for the reset of all the figures that
are presented on the window only with privileged access, for example,
controllers and engineering access.

Chapter 5 - CONTROL SYSTEM DESIGN Page 73 of 158 November 2008

 Figure 5–17YDU210 Diagnostics status
window

Figure 5–18 YDU210PN01 Status window

The variable tags added to the 206 Citect project for the YDU210 Pulse
Cleaner are:

Table 5-12 YDU210PN01 Variable tags

Description Symbol
24VDC CB Q35 Supply OK YDU210DCOK
Air Pressure OK YDU210PS01
CYCLING YDU210CS
WATCHDOG ALARM YDU210ALM01
HIGH dp ALARM YDU210ALM02
POWER OK YDU210PWR
General Alarm Reset YDU210RST01
Service Alarm Reset YDU210RST02
Cleaning Cycle Start Relay YDU210SR01
24VDC Supply Trip YDU210DCOK_T
Comp. Air Press Low Warning YDU210PS01_W
Power OK Trip YDU210PWR_T
Watchdog alarm Trip YDU210ALM01_T
COIL ALARM Warning YDU210ALM04_W
SERVICE ALARM Warning YDU210ALM03_W
Diff. Pressure Hi Warning YDU210PT01_HI_W
Diff. Pressure Broken Wire YDU210PT01_BW_W
COIL ALARM Trip YDU210ALM04_T
Initiate Cit Command YDU210SELCC
Diagnostic Reset Cit Command YDU210SELBC
Diff. Pressure Scaled (inH20) YDU210PT01
No. of Coil alarms Current Cycle YDU210CYCCOILALM

Chapter 5 - CONTROL SYSTEM DESIGN Page 74 of 158 November 2008

 No. Cycle Complete YDU210CYCCMPLT
No. Of Blowdown Cycles Started YDU210CYCSTTD
Total No. of Coils Alarms YDU210TOTCOILALMS
No. Cycle Incomplete YDU210CYCINCMPLT
No. of Coil Alarms 1 Cycle ago YDU210COILALMSCYC1
No. of Coil Alarms Last 10 Cycles YDU210LST10COILALM

5.6 Conclusion

The intentions of this chapter stipulated an introduction to the control design and
implementation for the YDU210 Dust Collection System and achieved through the
sections of:

• Yandicoogina network

• Functional specification

• ProWORX32 logic

• Citect

The information provided in this chapter concerns the fundamentals of the YDU210
Dust Collection System control philosophy. The use of ProWORXs and Citect have
been an exceptional learning experience, as the knowledge required and obtained to
complete the control aspect of this project can be used in future control software
encounters as the fundamental principle of leaning and obtaining new skills can be
used. Once the programming implementation was completed the communications
were tested between the two programs. This was done by pressing buttons on Citect
and validating with the online state logic. Also forcing different coils on and off and
viewing the display changes on Citect. Aside form the control logic and display the
work progression on the Dust Collection System will be discussed in the next
chapter.

Chapter 5 - CONTROL SYSTEM DESIGN Page 75 of 158 November 2008

Chapter 6 - SYSTEM EVALUATION AND COMMISSIONING

6.1 Introduction

This chapter will go through the sequence of events that took place on the YDU210
Dust Collection System during the course of the internship up to the 13th of
November 2008. However, the final results of the project will not be included as the
internship finishes after the submission of this report. The sequence includes:

1. Maintenance Order

2. Point-to-Point Testing

3. Scope of Work (SOW)

4. Commissioning

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COMMISSIONING
 6.2 Maintenance Order

A Maintenance order is a process put in place within Rio Tinto Iron Ore to keep
track of all works that are:

• Requested on all equipment and electrical devices on site

• Planned corresponding to the time allocation, the worker availability, and

additional operations or shutdowns taking place

• Completed or incomplete

• Results or outcomes

The first Maintenance order requested for the YDU210 – Dust Collection System
was to investigate what is required to commission the system. This request was
made and completed before the commencement of the internship but the
information was past on to assist in understanding the current status of the Dust
Collection System.

The findings from this Order were as listed below:

YDU210RV01 – Rotary valve

The rotary valve motor cable was checked by meggering the cable which is when the
cable is feed a high DC voltage for several minutes and megohmeter indicated the
current leakage through the insulation. The wiring in the MCC was said to be
complete, and the motor connections still needed to be checked. The motor was not
checked with this maintenance order as it was stated that scaffolding is required.
Also it was observed that a contactor was required.

YDU210FN01 – Fan

The fan undertook the same test as the rotary valve, and the motor connection was
able to be checked, and the statement received was that it is all complete and the
megger result was good.

YDU210CV01 - Conveyor

The Conveyor also went through the same tests, the megger test result came back as
down therefore the motor connection may not be connected and this is unknown as
the motor can not be check went production is happening.

Chapter 6 - SYSTEM EVALUATION AND Page 77 of 158 November 2008

COMMISSIONING
 6.3 Point-to-Point Testing

At the commencement of the project a point-to-point test was required on all of the
wiring detailed in the schematic diagrams for the YDU210 Dust Collection System.
The reason for performing a point-to-point test was to determine if all wiring was
completed, and in the correct location from installation. The uncertainty of the
wiring was created through the time period between installation and
commissioning. An electrician was required to help perform the point-to-point test
which in turn required a maintenance order to be able to schedule and allow
enough time to complete the test. Determining whether the wiring is done correctly
by measuring the resistance in Ohms between two points and if the resistance is
zero or really low this indicates that a wire is present.

At the completion of the point-to-point testing the knowledge of the schematic

diagrams and the corresponding wiring was increased due to looking over the
diagram in more depth. Also from the point-to-point performed the following
information was obtained.

• YDU210PS01 – Air pressure sensor missing, and installation and wiring are
needed.

• YDU210RV01NS01 – Rotary Valve Under speed sensor missing, and

installation and wiring are needed.

• Four Heinelec 2A SFM-H3 - 24V circuit Breakers need to be installed

• Links were needed between

• P4 240 and P4 241

• P5 – 187, and P5 – 191

• P5 – 221, P5 – 223, P5 – 225, P5 – 227, P5 – 231, and P5 – 233

• R3 – 103, R3 – 104, R3 – 105, R3 – 106, and R3 – 107

• R3 – 111, R3 – 112, R3 – 113, R3 –, 114, and R3 – 115

• R3 – 116, and R3 – 117

• R3 – 120, R3 – 121, R3 – 122, R3 – 123, and R3 – 124

• R3 – 125, R3 – 126, R3 –127, R3 – 128

• R3 – 138, R3 – 139, R3 – 140, and R3 – 141

Chapter 6 - SYSTEM EVALUATION AND Page 78 of 158 November 2008

COMMISSIONING
 • R3 – 142 and R3 – 143

• Wiring is needed between

R3 - 122 P4 – 228 R3 - 105 P4 - 211

R3 - 132 P4 – 237 R3 - 104 P5 - 183

R3 - 133 P4 – 238 Refer to appendix G

R3 - 134 F2 – 184

R3 - 127 F2 - 185 R3 - 138 P5 – 1

R3 - 121 P5 – 187 R3 - 140 F2 - 186

P5 – 191 R3 - 141 P5 - 221

R3 - 129 P5 - 192 Refer to appendix J

Refer to appendix I

R3 - 113 P4 - 217

P5 - 9 P4 – 256 R3 - 112 P5 - 185

P5 - 10 P4 - 241 Refer to appendix H

Refer to appendix L

• The Black and White wires that are wired into 206-4-07 need to be reversed

6.4 Scope Of Work

The Scope Of Work (SOW) is a document that is prepared to detail the work
required on a specific project, while defining and reinstating the:

• Safety

• Standards applicable to follow

• General information about Rio Tinto Iron Ore and it is policies and
procedures

• Equipment supplied and required under the contract

• Details about the work required, location and procedures

Chapter 6 - SYSTEM EVALUATION AND Page 79 of 158 November 2008

COMMISSIONING
 • Drawing references and supplied

• Requirements of the contractors before during and after the works stipulated
in the SOW

When creating a SOW for the YDU210 Dust Collection System an internal template
was used from the Rio Tinto Shared drive. The template provided information
about what is required in each section and the additional help from reviewing other
SOW and the Engineering Superintendent allowed for the SOW to be completed
and passed onto the Contractors completing the required electrical works. The
Work stipulated in the SOW is the electrical works that were found not completed
through the point-to-point testing and are listed above.

When determining what switches could be installed for the compressed air pressure
and under speed switches an investigation took place by looking at other Dust
Collection Systems on site and trying to obtain any documentation on the YDU210
installation. Two types of air pressure switches were found, as shown in figure 6-1
and 6-2. The installation requirements and the availability of the switch were taken
into consideration when deciding between the different switches. The GAW-5
pressure switch was chosen as the other switch required the additional work of
drilling and taping into the top of the manifold. Once the type of switch to be used
was identified the availability of the switch was determined, as a spare GAW-5 was
found on site.

Figure 6–1 GAW-5 Pressure switch Figure 6–2 Pressure switch

Chapter 6 - SYSTEM EVALUATION AND Page 80 of 158 November 2008

COMMISSIONING
 Within the SOW the possible wiring layout and termination of the air pressure
switch were presented using the figures 6-3 and 6-4

Location of the
Pressure Switch to
be installed

Figure 6–3Location display and possible wiring route

Air Pressure Switch

Wiring to be
terminated

Figure 6–4 Location of where the pressure switch is to be terminated

Chapter 6 - SYSTEM EVALUATION AND Page 81 of 158 November 2008

COMMISSIONING
 The same procedure was followed for the investigation into the required under
speed switch. When looking at the Dust Collection Systems on site that have rotary
valve two types of switches were found to be used, as shown in figure 6-5 and 6-6.
The availability of the T piece and casing was limited however one of the type
displayed in figure 6-5 was found not in uses and added to the works required in the
SOW.

Figure 6–6 Under speed switches type 2

Figure 6–5 Under speed switches type 1

Chapter 6 - SYSTEM EVALUATION AND Page 82 of 158 November 2008

COMMISSIONING
 Under seed
Sensor

Figure 6–7 Under speed location display

6.5 Construction

The commencement of the electrical work outlined in the SOW started on the 1st of
November and the work completed in the following two days included:

• Installation and wiring of the compressed air pressure switch, which can be
seen in figures below.

Figure 6–8 electrical works underway

Figure 6–9 Installed pressure switch

Chapter 6 - SYSTEM EVALUATION AND Page 83 of 158 November 2008

COMMISSIONING
 • Wiring to the field marshalling box for the under speed switch however the
obtained casing and T piece were not installed due to their incorrect size. The
wiring present time is completed and waiting the correct switch as shown in
the figure 6-10.

Figure 6–10 under speed switch wiring

• All MCC wiring stipulated in the SOW was completed

• Additional relay wiring that was discovered to be incomplete during the

contractors electrical works and was not identified in the point-to-point test,
was completed

The other work that has also been completed on the YDU210 Dust Collection
System was to fix the compressed air supply pipe. Maintenance supervisor was
approached and asked to fix the compressed air supply pipe and was completed.
The piping was fixed by removing the section of pipe between the broken nipple
fitting and the next nipple fitting and was replaced with a new piece of piping using
barrel union fitting on both ends. The barrel union fittings were used as they allow
for easier installation due to the swivel connection on one side of the fitting.

Figure 6–11 Pipe barrel union fitting

Figure 6–12 Fixed pipe view

Chapter 6 - SYSTEM EVALUATION AND Page 84 of 158 November 2008

COMMISSIONING
 6.6 Commissioning

The Commissioning of the YDU210 Dust Collection System has not occurred,
however in the remaining four weeks of the internship the commissioning is
scheduled to be completed.

6.7 Conclusion

The sequence of events throughout the internship that have been completed and
detailed in this chapter have created opportunities to communicate with different
departments and companies, and also get a greater understanding and appreciation
of the different procedures that are required throughout the course of a project. The
progression of the project would have altered somewhat if not under the timeline
constraints of the internship, however all procedures were completed and
alternative procedures were discussed. The remaining tasks required to be able to
commission the YDU210 Dust Collection System will be discussed in the next
chapter and are on track to be completed during the remaining time of the
internship.

Chapter 6 - SYSTEM EVALUATION AND Page 85 of 158 November 2008

COMMISSIONING
Chapter 7 - CONCLUSIONS

7.1 Engineering Internship Outcomes

Throughout the course of the internship many different activities that gave different
experiences such as:

• Working with the fixed plant electrical team gave an understanding of the
site operation.

• Creating a SOW and functional specification document gave exposure to

some of the engineering practices used within Rio Tinto Iron Ore

• Organising the electrical works on the YDU210 Dust Collection System and
continuing the forward progression of the project allowed for the
experience of self management and engineering planning practices

Chapter 7 - CONCLUSIONS Page 86 of 158 November 2008

 • Determining what devices are required and allocating them for the Dust
Collection System gave the opportunity to communicate with different
departments and companies

• With have the YDU210 Dust Collection System as an independent project

experience and knowledge was obtained on engineering project
management.

• The internship contributed to the progression of the YDU210 Dust

Collection System commissioning as there was no timeline dedicated to the
to it is completion

• Attending the different meetings throughout the internship gave exposure

to:

o environmental management in the safety and environmental

refresher meetings

o Engineering planning and project management in the monthly

engineering meetings

o Engineering operations in the daily Production Lean meeting, the

weekly engineering Lean meeting and the general day to day
interactions with the engineering department

Overall the internship has been a great asset to the completion of the Murdoch
University Bachelor of Engineering degree as it gave practical engineering
experience and allowed for the development of new competencies that can be used
in the future as an engineer.

7.2 Project Status

The project work completed for the YDU210 Dust Collection System from the
commencement of the engineering internship to the 13th of November has been
detailed throughout this report and is summarised below:

• The completion of the ProWORXs ladder logic implementation

• The completion of the Citect Dust Collection System display and

corresponding controls

Chapter 7 - CONCLUSIONS Page 87 of 158 November 2008

 • Functional specification document

• SOW document

• Point-to-point testing

• Electrical works

7.3 Future Intentions & Recommendations

As the completion of the internship falls after the submission of the final report
there will be further progression on the project. The commissioning of the YDU210
Dust Collection System at present will be completed by the end of the internship.
Also the task of investigating and scoping the work required for installing and
commissioning of a replacement ORCA bed level sensor for the thickener tank in
the wet plant, has been allocated with intentions of completing the SOW by the end
of the internship. However the installation and commissioning will most likely
proceed after the completion of the internship.

Commissioning the YDU210 Dust Collection System in comprised of:

• Checking the operational availability of each item

• Checking all manual and automatic contacts and interlocks within the
relevant plant and equipment

• Test to demonstrate performance in accordance with the specifications

Future recommendations for the YDU210 Dust Collection System is to install the
rotary valve under speed switch, which is currently been forced active in the control
logic due to no switch being present so the rotary valve will run. The pulse cleaning
control logic could be changed to allow for full automatic control through the PLC
however this will not utilise the functionality of the Pulse Cleaning controller.
Finally an optional suggestion for the Dust Collection System is to install a draining
on the compressed air pipe as the air is supplied from the process compressor and
may contain traces of water and oil that will affect the efficiency of the dust collector
over time.

Chapter 7 - CONCLUSIONS Page 88 of 158 November 2008

 REFERENCES

1. Modicon, Schneider Electric, 2001, Ladder Logic Library User Guide, USA (accessed
17/09/08)

2. Control System Technology, Joomla, 2008,

http://www.controlsystems.com.au/products/electronics/model-ipc-14 (accessed
02/11/08)

3. Hawk Measurement Systems, Remote amplifier version presence & absence detection
Microwave Pulse Switch, 2008,
http://www.hantor.fi/media/pdf/microwave_remote_data_sheet.pdf (accessed
10/09/08)

4. Hawk Measurement Systems, Microwave Pulse Switch Data sheet, 2008,

http://www.wesmar.se/datablad/microwave-datablad.pdf (accessed 10/09/08)

5. Anixer wire wisdom wire & cable group, Field tests, 2008,
http://www.anixter.com/AXECOM/AXEDocLib.nsf/(UnID)/874BBCCFEDFCB5D480
256F2400744785/$file/F-1_16.pdf (accessed 01/11/08)

6. IEMS, Dust management, 2008,

http://iodms/iodms/Wsapi?message=getfile&objectid=090188a38006b2f2&docbase=i
odms_v2&web=true&name=RTIO-HSE-0010313 (accessed 02/11/08)

7. Citect Real-time Intelligence, 2007, CitectSCADA Configuration Training Manual

edition V7.0, Australia

8. Omron electronic components, General Purpose Realy LY, 2008,

http://www.omron.com (accessed 02/11/08)

9. Goyen, Precision Filter Cleaning System Controls, 2007

http://www.cleanairsystems.com/__data/page/11833/CAS_Precision_Instruction_Ma
nual_072008.pdf (accessed 20/10/08)

10. Schneider Electric, 2004, Quantum 840 USE 100 00 manual

11. Ampcontrol CSM Pty Limited, October 2004, iMAC Integrated Monitoring & Control
Training Manual, Warners Bay NSW

12. Rio Tinto Iron Ore, Business overview,

http://www.riotintoironore.com/179_business_overview.asp (accessed 20/10/08)

REFERENCES Page 89 of 158 November 2008

REFERENCES Page 90 of 158 November 2008
BIBLIOGRAPHY
The applicable documents for this Progress Report are listed below.

Rio Tinto Standard Specifications

Specification No. Title

SS-E101 The Electrical Wiring & Materials for Major Equipment II functional specifications
document covers the standards and requirements for all electrical wiring and
materials for industrial applications within RTIO.

SS-E118 The Programmable Logic Controller equipment functional specifications document

covers the requirements for the design, manufacture, performance, testing and
delivery of PLC equipment.

SS-E115 The Testing and Commissioning of electrical installations functional specifications

document covers the requirements for testing and commissioning of electrical
installations.

YXP-SPE-E-019 The Citect Functional Specification for detail functional specifications document
covers the procedures and conventions for creating new Citect projects at the
Yandi site, as well as and outlining the functions of the Citect KERNEL project.

YXP- SPE-E-018 The PLC Functional Specification for detail functional specifications document
defines the format of the standard logic and it is associated documentation. To
standardise PLC logic and implementation with new projects unless otherwise
stated.

YXP-SPE-E-045. The Yandi Junction South East Expansion Project Control System Functional
Specification for Dust Collection System document covers the control philosophy
for the JSE expansion Dust Collection System within Plant 2 and 3. It also shows
details about:
• Sequence interlocks
• Equipment trips / alarms
• Process description
• Links to reference documents
• Parameters
For YDU 209, 212, 213, 216, 301, 302, 303, 304, 305, 306, 308

The Yandi Upgrade Project Specification for Control System Philosophy

YEP-SPE-E-002 specifications document defines the control philosophy of the Yandi upgrade
project and is focused equipment operation and how the process fits together.
The Standard Specification Template document has been created for the use of
SD-D102
writing a function specification document.

BIBLIOGRAPHY Page 91 of 158 November 2008

 Standard Drawings

Drawing No. Title

The Tertiary Crushing and Product Screening YMC45 Marshalling Cubicle Strip
E-001-50168
P1(PLC1 strip) Termination Diagram displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour
The Differential Pressure input is between 214 – 215.

E-001-50171 The Tertiary Crushing and Product Screening YMC45 Marshalling Cubicle Strip P4
(PLC4 strip) Termination Diagram displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour
The Fan, Rotary Valve and Conveyor digital input are located on this strip between
211 – 241.

E-001-58487 The Tertiary Crushing and Product Screening YMC45 Marshalling Terminal Strip
P5 (PLC Strip 5) Termination Diagram. Contains the Digital inputs for the Pulse
control panel (1 -10), Digital outputs for the Pulse control panel (221 – 235), and
digital outputs for the Fan, Conveyor, and Rotary Valve (181 – 193). It also
displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour

The PLC INPUT/OUTPUT Modules Typical Termination Diagram Displays the

E-009-2890
layout of the different cards used:
• Analog Input Card
• Analog Output Card
• RTD Input Card
• Digital Input Card
• Digital Output Card
With the following information:
• Cable core / Pair No.
• Plug Pin No.
• Terminal No.
• Plug/Socket
• Channel No.

BIBLIOGRAPHY Page 92 of 158 November 2008

 Drawing No. Title

E-001-58504 The Tertiary Crushing and Product Screening Pulse Cleaning Control Panel
YDU210PN01 Schematic Diagram Sheet 1 shows the wiring layout of the Pulse
Cleaner that is used in the Dust collector system to send pulses to the solenoids
which remove the collected dust on the bags within the hopper . The diagram
shows the PLC Input:
• YDU210DCOK – 24V DC Supply OK
• YDU210LS01 - Hopper 1 Level High
• YDU210PS01 – Air Pressure OK
• YDU210CCS – Cycling
• YDU210ALM01 – Watchdog Alarm
• YDU210ALM02 – High dp Alarm
• YDU210ALM03 – Service Alarm
• YDU210ALM04 – Coil Alarm
• YDU210ALM05 – AUX Alarm
• YDU210PWR Power OK
• YDU210PT01 – Differential Pressure
And PLC Outputs:
• YDU210SR01 – Start Relay
• YDU210RST01 – Reset General Alarm
• YDU210RST02 – Reset Service Alarm
• YDU210ALM06 – Low header Alarm
• YDU210AUX01 – AUX Input
• YDU210RMC – Manual Cycle
•
The diagram also shows the connections between the termination strips and Pulse
Cleaning Solenoid Panel YDU210PN03.

E-001-58505 The Tertiary Crushing and Product Screening Pulse Cleaning Control Panel
YDU210PN01 Schematic Diagram Sheet 2 shows the wiring of the Pulse Cleaning
Solenoid YDU210PN04 and YDU210PN05.

E-001-58463 The Tertiary Crushing and Product Screening YCV212 Dust Collector Fan
YDU210FN01 Schematic Diagram shows the wiring layout of the Fan that is used
in the Dust collector system to draw air from the transfer point, through the bags
within the hopper that in turn will collect the dust. The diagram shows the PLC
Input:
• YDU210FN01DCOK - 24V DC Supply OK
• YDU210FN01IS01 – Isolator Closed
• YDU210FN01TO01 – TOL (Thermal Overload) Tripped
• YDU210FN01MC01 – Main Contactor Closed
• YDU210FN01LOS01 – LOS ( Lock Off Stop) OK
• YDU210FN01PB01 – Local Start
And PLC Outputs:
• YDU210FN01SR01 – Start Relay
The diagram also shows the connections between the termination strips.

BIBLIOGRAPHY Page 93 of 158 November 2008

 Drawing No. Title

E-001-58501 The Tertiary Crushing and Product Screening Dust Collector Conveyor
YDU210CV01 Schematic Diagram show’s the wiring layout of the Conveyor that is
used in the Dust collector system to transfer the collected dust that is discharged
from the bottom of the hopper to the YCV213 Process conveyor. The diagram
shows the PLC Input:
• YDU210CV01DCOK - 24V DC Supply OK
• YDU210CV01IS01 – Isolator Closed
• YDU210CV01TO01 – TOL (Thermal Overload) Tripped
• YDU210CV01MC01 – Main Contactor Closed
• YDU210CV01LOS01 – LOS ( Lock Off Stop) OK
• YDU210CV01PB01 – Local Start
• YDU210CV01NS01 – Under speed Sensor OK
• YDU210CV01PW01 –Pull wire Switch OK
• YDU210CV01PW02 –Pull wire Switch OK
•
And PLC Outputs:
• YDU210CV01SR01 – Start Relay
• YDU210CV01HS01 – Start Warning Siren Relay
The diagram also shows the connections between the termination strips.

E-001-58464 The Tertiary Crushing and Product Screening Dust Collector Rotary Valve
YDU210RV01 Schematic Diagram show’s the wiring layout of the Rotary Valve
that is used in the Dust collector system to discharge the accumulated fine dirt at
the bottom of the hopper to the YDU210CV01 Conveyor. The diagram shows the
PLC Input:
• YDU210RV01DCOK - 24V DC Supply OK
• YDU210RV01IS01 – Isolator Closed
• YDU210RV01TO01 – TOL (Thermal Overload) Tripped
• YDU210RV01MC01 – Main Contactor Closed
• YDU210RV01LOS01 – LOS ( Lock Off Stop) OK
• YDU210RV01PB01 – Local Start
• YDU210RV01NS01 – Under speed Sensor OK
And PLC Outputs:
• YDU210RV01SR01 – Start Relay
The diagram also shows the connections between the termination strips.

E-001-58465 The Tertiary Crushing and Product Screening YDU210 Dust Collector Control
Panels Termination Diagram shows the Mashing box layout that is located at the
top of the Hopper bin and also displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour-+

BIBLIOGRAPHY Page 94 of 158 November 2008

 Drawing No. Title

E-001-58490 The Tertiary Crushing and Product Screening Dust Collector Marsh Box
YDU210MB01 Termination Diagram displays what has been wired into the
Marshalling box that is beside the Dust Collector system on the ground level. It
also Diagram displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour

E-001-58489 This Tertiary Crushing and Product Screening YMC45 Marshalling Terminal Strip
R3 Termination Diagram displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour
The Fan, Rotary Valve, Pulse Cleaner and Conveyor relays are located on this
strip between 95 – 142

This Tertiary Crushing and Product Screening YMC45 Marshalling Cubicle Strip F2
E-001-50176 (Field2 strip) Termination Diagram displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour
The Fan, Rotary Valve, Pulse Cleaner and Conveyor are located on this strip
between 144 -215

This Tertiary Crushing and Product Screening YMC45 Marshalling Cubicle Strip
E-001-50167
M2 (MCC2)Termination Diagram displays the following information:
• Fly wire destination
• Terminal No.
• Link if Fitted
• Equipment No.
• Wire No.
• Cable core No./ Colour
The Fan, Rotary Valve and Conveyor are located on this strip between 212 – 243.

This HPS/Keller Dust Collection System Schematic layout for system 210 diagram
YPAS1124-V-018
displays the equipment and associated equipment connections.

BIBLIOGRAPHY Page 95 of 158 November 2008

APPENDICES
Appendix A - Dust Collector System diagram

Figure A1: System overview refer (YPAS1124-V-018)

Appendix A Page 96 of 158 November 2008

 Appendix B - Citect Help Display
This page was created to help identify the different meaning and control commands that may
arise on the Citect mimic pages. The main incentive of this page was that there were a number
of personnel using the Citect display, that were not apart of the programming phase or have
not had not had sufficient background with Using Rio Tinto’s mimic pages and did not have a
full understanding of the different meanings. This page can be accessed from the Menu page if
the question mark is selected.

Figure B1: Citect help page

Appendix B Page 97 of 158 November 2008

 Appendix C - IPC-14 Electronic weighting Controller
Citect Display

The page below can be accessed through the stacker 2 page if ‘Limits & Analogs’ is selected.
The green arrow demarcates the added analog belt speed that has been created.

Figure C1: Stacker analog and limits page

Belt Speed Trend

The below window will pop up on top of the above screen then the right mouse button is
pressed over the belt speed reading. This occurs as the Citect mimic has been programmed to
call on that trend.

Appendix C Page 98 of 158 November 2008

Figure C2: Belt speed Trend window

Variable Tags

When creating new displays in Citect that reference back to a PLC, a variable tag needs to be
created for each input address that Citect will be looking at. In the case of the Belt speed
display there were only two tags that needed to be added, which were the scaled belt speed
integer valve and the digital broken wire indication.

Figure C3: Belt speed Variable tags window

Figure C4: Belt speed broken wire warning Variable tags window

Trend Tags

A Trend tag was required to be created, this is done by entering the correct information in the
below window and pressing enter. The Trend that was displayed above reference a trend tag
which defines the parameter of the trend and the file to which the data will be stored.

Appendix C Page 99 of 158 November 2008

Figure C5: Belt speed trend tags window

Alarm Tags

In the case of the belt speed display addition the only alarm tags required to be added was the
broken wire warning. The alarm tag is triggered by the variable tag and a description is given
when making the alarm tag so when the alarm pops up the alarm is identifiable. Also the other
parameters that are entered when creating the alarm tags are the category and area fields
which are used to select which alarms are wanted to be viewed on the alarm window.

Figure C3: Belt speed broken wire alarm tags window

Appendix C Page 100 of 158 November 2008

 Appendix D - iMAC descriptor list example
iMAC Address Screen Comment

YCV211

MSG07 MB20, K95 SIREN CONF

MSG09 MB03, RTD01-02
MSG10 MB03, RTD3-02 N/U
MSG11 MB03, RTD3-03 N/U
MSG12 MB03, RTD3-04 N/U
MSG13 MB20 BC01 BD01/02
MSG14 MB03, BD03/04
MSG21 MB04, ESPB01/02
MSG23 MB19, PW01/02
MSG24 MB18, PW03/04
MSG25 MB17, PW05/06
MSG26 MB16, PW07/08
MSG27 MB15, PW09/10
MSG28 MB14, PW11/PW12
MSG29 MB13 PW13/14 K78 SRN
MSG30 MB12, PW15/16

Table D1: iMAC descriptor example

Appendix D Page 101 of 158 November 2008

 Appendix E - Oil Cooler Gearbox Pressure Reading

Figure E1: YCV212ACL01PT01 logic

Figure E2: YCV212BCL01PT01 logic

Appendix E Page 102 of 158 November 2008

Figure E3: YCV212CCL01PT01 logic

Figure E4: Window access location

Appendix E Page 103 of 158 November 2008

Figure E5: YCV212ACL01, YCV212BCL01 and YCV212BCL01 citect windows

Appendix E Page 104 of 158 November 2008

 Appendix F - I/O Modules Analog Input Modules

Appendix F Page 105 of 158 November 2008

Appendix F Page 106 of 158 November 2008
Appendix F Page 107 of 158 November 2008
Appendix F Page 108 of 158 November 2008
 Appendix G - Fan Schematic Diagram

Figure G1: Fan Schematic diagram

Appendix G Page 109 of 158 November 2008

 Appendix H - Rotary Valve Schematic Diagram

Figure H1: Rotary valve Schematic diagram

Appendix H Page 110 of 158 November 2008

 Appendix I - Conveyor Schematic Diagram

Figure I1: Conveyor Schematic diagram

Appendix I Page 111 of 158 November 2008

 Appendix J - Pulse Cleaner Schematic Diagram

Figure J1: Pulse cleaner Schematic diagram sheet 1

Appendix J Page 112 of 158 November 2008

 Figure J2: Pulse cleaner Schematic diagram sheet 2

Appendix J Page 113 of 158 November 2008

 Appendix K - Strip P4 Termination Diagram

Figure K1: P4 Termination strip

Appendix K Page 114 of 158 November 2008

 Appendix L - Strip P5 Termination Diagram

Figure L1: P5 Termination strip

Appendix L Page 115 of 158 November 2008

 Appendix M - PLC I/O Modules Typical Termination Diagram

Figure M1: PLC modules termination

Appendix M Page 116 of 158 November 2008
 Appendix N - Dust Collector Control Panels Termination Diagram

Figure N1: Pulse Cleaner marshalling box

Appendix N Page 117 of 158 November 2008

 Appendix O - I/O addresses allocation
Dust Collection System

101217 Dust Coll. Sys 24VDC CB Q35 Supply OK YDU210DCOK

101218 Dust Coll. Sys Hopper Level High YDU210LS01
101219 Dust Coll. Sys Air Pressure OK YDU210PS01
101220 Dust Collector CYCLING YDU210CS
101221 Dust Collector WATCHDOG ALARM YDU210ALM01
101222 Dust Collector HIGH dp ALARM YDU210ALM02
101223 Dust Collector SERVICE ALARM YDU210ALM03
101224 Dust Collector COIL ALARM YDU210ALM04
101225 Dust Collector AUX ALARM YDU210ALM05
101226 Dust Collector POWER OK YDU210PWR
000105 Dust Coll. Sys General Alarm Reset YDU210RST01
000106 Dust Coll. Sys Service Alarm Reset YDU210RST02
000107 Dust Coll. Sys Low Header Alarm YDU210ALM06
000108 Dust Coll. Sys AUX Input YDU210AUX01
000109 Dust Coll. Sys Manual Cycle YDU210RMC
000110 Dust Coll. Sys Demand / Continuous YDU210DCM
000111 Dust Coll. Sys Cleaning Cycle Start Relay YDU210SR01
300024 Dust Coll. Sys Diff. Pressure Raw YDU210PT01_RAW
004122 Dust Coll. Sys 24VDC Supply Trip YDU210DCOK_T
004124 Dust Coll. Sys Comp. Air Press Low Warning YDU210PS01_W
004125 Dust Coll. Sys Hopper Level High Trip YDU210LS01_T
004126 Dust Coll. Sys Hopper Level High Warning YDU210LS01_W
004127 Dust Coll. Sys Power OK Trip YDU210PWR_T
004128 Dust Coll. Sys Watchdog alarm Trip YDU210ALM01_T
004129 Dust Coll. Sys HIGH dp alarm Trip YDU210ALM02_T
004130 Dust Coll. Sys COIL ALARM Warning YDU210ALM04_W
004131 Dust Coll. Sys SERVICE ALARM Warning YDU210ALM03_W
004132 Dust Coll. Sys Diff. Pressure Hi Warning YDU210PT01_HI_W
004133 Dust Coll. Sys Diff. Pressure Broken Wire YDU210PT01_BW_W
004134 Dust Coll. Sys COIL ALARM Trip YDU210ALM04_T
018099 Dust Collector 24VDC Supply OK YDU210DCOK1
018100 Dust Collector Cleaning Cyc Initiate YDU210CI01
018101 Dust Collector Cleaning Cyc Manual Initiate YDU210RMCI01
018102 Dust Collector Cleaning Cyc Unlatch YDU210SR01_UL
018103 Dust Collector Cleaning Cyc Manual Unlatch YDU210RMC01_UL
018104 Dust Collector Shutdown Cycle YDU210SDC01
018105 Dust Collector Diagnostic Reset YDU210DIAGRST
018106 Dust Collector Cleaning Cycle On Too Long YDU210CS_W
018107 Dust Collector Cleaning Cycle Complete YDU210CYCCMP
018108 Dust Collector Was Running Now Stopped YDU210FN01RNNGSTPD
018109 Dust Collector Blowdown Cycle Complete YDU210BDCCMP
018110 Dust Collector Cleaning Cycle Done Reset YDU210CYCRST
016001 PLC Not First Scan Tert Crushing NOT_FIRST_SCAN
010735 O/Land Convyng Crash Stop Cit Command OLC206_GP_CRASH
016018 O/Land Convyng Group Stop Seal P2_OLC_GPSTP_SEAL
010733 O/Land Convyng Group Start Cit Command OLC206_GP_START
010737 O/Land Convyng Group Maintenance Cit Command OLC206_GP_MAINT
010736 O/Land Convyng Group Auto Cit Command OLC206_GP_AUTO
010734 O/Land Convyng Group Stop Cit Command OLC206_GP_STOP

Appendix O Page 118 of 158 November 2008

010738 O/Land Convyng Group Alm Reset OLC206_GP_ALMRST
016004 Run Minutes General Pulse MINUTE_PULSE
016005 PLC CPU Running PLC_CPU_RUNNG
011032 Service Alarm Reset Cit Command YDU210SELSERVALMRST
011030 Dust Collector Initiate Cit Command YDU210SELCI01
Dust Collector Diagnostic Reset Cit Command YDU210SELDR
407340 Dust Coll. Sys Diff. Pressure Scaled (inH20) YDU210PT01
407341 Dust Collector Air Pressure Low Timer W YDU210PS01_W_TMR
407342 Dust Collector Air Pressure Low Timer T YDU210PS01_T_TMR
407343 Dust Collector Hopper 1 Level High Timer YDU210LS01TMR
407344 Dust Collector Hopper 1 Level Hi Hi Timer YDU210LS01TMR_T
407345 Dust Collector Watchdog Alarm Timer YDU210ALM01TMR
407346 Dust Collector Coil Alarm Timer YDU210ALM04TMR
407347 Dust Collector Diff Pressure MIN YDU210SR01TMR
407348 Dust Collector Diff. Pressure High Timer YDU210PT02TMR
407349 Dust Collector Diff Pressure MAX YDU210SR02TMR
407350 Dust Collector Cleaning Cycle 1Hr Timer YDU210SR03TMR
407351 Dust Collector Cleaning Cycle 5min Timer YDU210RMCTMR
011033 Dust Collector General Alarm reset Cit Command
407352 Dust Collector No. of Coil alarms Current Cycle YDU210CYCCOILALM
407353 Dust Collector No. Cycle Complete YDU210CYCCMPLT
407354 Dust Collector No. Of Blowdown Cycles Started YDU210CYCSTTD
407355 Dust Collector Total No. of Coils Alarms YDU210TOTCOILALMS
407356 Dust Collector No. Cycle Incomplete YDU210CYCINCMPLT
407357 Dust Collector Total No. of Coils Installed YDU210COILSINSTLLD
407358 Dust Collector Coils Plused in Last Cycle YDU210LSTCOILSPULSED
407359 Dust Collector Time bewteen Cycles YDU210COILTMEPLSE
407360 Dust Collector Pulse Cycle Time YDU210CYCLETME
407361 Dust Collector Coils Pulsed in Current Cycle YDU210CYCCOILSPULSED
407362 Dust Collector Cycle Fault Timer YDU210CCSFLTTME
407364 Dust Collector No. of Coil Alarms 1 Cycle ago YDU210COILALMSCYC1
407365 Dust Collector No. of Coil Alarms 2 Cycle ago YDU210COILALMSCYC2
407366 Dust Collector No. of Coil Alarms 3 Cycle ago YDU210COILALMSCYC3
407367 Dust Collector No. of Coil Alarms 4 Cycle ago YDU210COILALMSCYC4
407368 Dust Collector No. of Coil Alarms 5 Cycle ago YDU210COILALMSCYC5
407369 Dust Collector No. of Coil Alarms 6 Cycle ago YDU210COILALMSCYC6
407370 Dust Collector No. of Coil Alarms 7 Cycle ago YDU210COILALMSCYC7
407371 Dust Collector No. of Coil Alarms 8 Cycle ago YDU210COILALMSCYC8
407372 Dust Collector No. of Coil Alarms 9 Cycle ago YDU210COILALMSCYC9
407373 Dust Collector No. of Coil Alarms 10 Cycle ago YDU210COILALMSCYC10
407374 Dust Collector No. of Coil Alarms Last 10 Cycles YDU210LST10COILALM
410009 Reg 1
410010 Reg 2
410011 Reg 3
410012 Reg 4
410013 Reg 5
410014 Reg 6
410015 Reg 7
410016 Reg 8
410017 Reg 9
410018 Reg 10
410025 SUBR_SCALED
410026 SUBR_RAW
410027 SUBR_Factor
410028 SUBR_MIN

Appendix O Page 119 of 158 November 2008

410029 SUBR_MAX
410030 Constant_0
410031 Constant_1
016267 BrknWire

FAN

000090 Dust Coll. Fan Start Relay YDU210FN01SR01

100649 Dust Coll. Fan 24VDC CB Q29 Supply OK YDU210FN01DCOK
100650 Dust Coll. Fan Isolator Closed YDU210FN01IS01
100651 Dust Coll. Fan TOL Tripped YDU210FN01TO01
100652 Dust Coll. Fan Main Contactor Closed YDU210FN01MC01
100653 Dust Coll. Fan LOS OK YDU210FN01LOS01
100654 Dust Coll. Fan Local Start PB Activated YDU210FN01PB01
004114 Dust Coll. Fan 24VDC Supply Trip YDU210FN01DCOK_T
004115 Dust Coll. Fan Isolator Open Trip YDU210FN01IS01_T
004116 Dust Coll. Fan TOL Trip YDU210FN01TO01_T
004117 Dust Coll. Fan Main Contactor Failure Trip YDU210FN01MC01_T
004118 Dust Coll. Fan LOS Active Trip YDU210FN01LOS01_T
004119 Dust Coll. Fan Required And Not Running YDU210FN01REQD_W
011025 Dust Coll. Fan Select Auto Cit Command YDU210FN01SELAUTO
011026 Dust Coll. Fan Select Maintenance Cit Command YDU210FN01SELMAINT
011027 Dust Coll. Fan Select OOS Cit Command YDU210FN01SELOOS
011028 Dust Coll. Fan Select Stop Cit Command YDU210FN01SELSTOP
011029 Dust Coll. Fan Select Start Cit Command YDU210FN01SELSTART
018068 Dust Coll. Fan 24VDC Supply OK YDU210FN01DCOK1
018069 YDU210FN01 Dust Fan Comment Coil COMMENT_46
018070 Dust Coll. Fan Critical Interlocks OK YDU210FN01CIL
018071 Dust Coll. Fan Non Critical Interlocks OK YDU210FN01NCIL
007394 Dust Coll. Fan Auto Mode YDU210FN01AUTO
007395 Dust Coll. Fan Maintenance Mode YDU210FN01MAINT
007396 Dust Coll. Fan OOS Mode YDU210FN01OOS
018074 Dust Coll. Fan Auto Cmd Selected YDU210FN01AUTOCMD
018075 Dust Coll. Fan Maintenance Cmd Selected YDU210FN01MAINTCMD
018070 Dust Coll. Fan Alarm Seal YDU210FN01ALMSEAL
018071 Dust Coll. Fan Alarm Acknowledged YDU210FN01ALMACK
018073 Dust Coll. Fan Maintenance. Alarm Reset YDU210FN01MALMRST
018072 Dust Coll. Fan Alarm Reset YDU210FN01ALMRST
018080 Dust Coll. Fan Auto Running YDU210FN01AUTORNNG
018081 Dust Coll. Fan Auto Start Seal YDU210FN01ASTTSL
018082 Dust Coll. Fan Auto Ready YDU201FN01AUTORDY
018076 Dust Coll. Fan Group Start Seal YDU210FN01GPSTTSL
018077 Dust Coll. Fan Maintenance Start Seal YDU210FN01MSTTSL
018078 Dust Coll. Fan Maintenance Running YDU210FN01MAINTRNNG
018079 Dust Coll. Fan Maintenance Ready YDU210FN01MAINTRDY
007397 Dust Coll. Fan Drive Status Bit 1 YDU210FN01STAT1
007398 Dust Coll. Fan Drive Status Bit 2 YDU210FN01STAT2
007399 Dust Coll. Fan Drive Status Bit 3 YDU210FN01STAT3
018084 Dust Coll. Fan Drive Starting YDU210FN01STTG
018093 Dust Coll. Fan Drive Run Off YDU210FN01RUNOFF
018083 Dust Coll. Fan Drive Run Up YDU210FN01RUNUP
018085 Dust Coll. Fan Unacknowledged Faulted YDU210FN01UNACKFLT
018086 Dust Coll. Fan Acknowledged Faulted YDU210FN01ACKFLT

Appendix O Page 120 of 158 November 2008

007400 Dust Coll. Fan Sequence Status Bit 1 YDU210FN01SEQ1
007401 Dust Coll. Fan Sequence Status Bit 2 YDU210FN01SEQ2
018087 Dust Coll. Fan Sequence Enabled YDU210FN01SEQEN
018088 Dust Coll. Fan Sequence Stopping YDU210FN01SEQSTPG
018089 Dust Coll. Fan Sequence Disabled YDU210FN01SEQDIS
018090 Dust Coll. Fan Sequence Stop Interlocks YDU210FN01SEQSTPIL
018091 Dust Coll. Fan Sequence Start Interlocks YDU210FN01SEQSTTIL
018092 Dust Coll. Fan Sequence Run Interlocks YDU210FN01SEQRUNIL
407329 Dust Coll. Fan Drive Run Minutes YDU210FN01RM
407330 Dust Coll. Fan Run Off Time YDU210FN01RUNOFFTME
407331 Dust Coll. Fan Run Off Timer YDU210FN01RUNOFFTMR
407332 Dust Coll. Fan Main Contactor Failure Timer YDU210FN01MCTMR
407333 Dust Coll. Fan 24VDC Supply OK Timer YDU210FN01DCOKTMR
407334 Dust Coll. Fan Run Up Timer YDU210FN01RUNUPTMR
407335 Dust Coll. Fan Required Not Running Timer YDU210FN01REQDTMR
407336 Dust Coll. Fan Maintenance. Alarm Reset Timer YDU210FN01MALMTMR

ROTARY VALVE

000091 Rotary Valve Start Relay YDU210RV01SR01

100655 Rotary Valve 24VDC CB Q31 Supply OK YDU210RV01DCOK
100656 Rotary Valve Isolator Closed YDU210RV01IS01
100657 Rotary Valve TOL Tripped YDU210RV01TO01
100658 Rotary Valve Main Contactor Closed YDU210RV01MC01
100659 Rotary Valve LOS OK YDU210RV01LOS01
100660 Rotary Valve Local Start PB Activated YDU210RV01PB01
100661 Rotary Valve Underspeed Pulse YDU210RV01NS01
004099 Rotary Valve 24VDC Supply Trip YDU210RV01DCOK_T
004100 Rotary Valve Isolator Open Trip YDU210RV01IS01_T
004101 Rotary Valve TOL Trip YDU210RV01TO01_T
004102 Rotary Valve Main Contactor Failure Trip YDU210RV01MC01_T
004103 Rotary Valve LOS Active Trip YDU210RV01LOS01_T
004104 Rotary Valve Underspeed Trip YDU210RV01NS01_T
011017 Rotary Valve Select Auto Cit Command YDU210RV01SELAUTO
011018 Rotary Valve Select Maintenance Cit Command YDU210RV01SELMAINT
011019 Rotary Valve Select OOS Cit Command YDU210RV01SELOOS
011020 Rotary Valve Select Stop Cit Command YDU210RV01SELSTOP
011021 Rotary Valve Select Start Cit Command YDU210RV01SELSTART
YDU201RV01 Dust Rot Valve Comment Coil COMMENT_45
018001 Rotary Valve Critical Interlocks OK YDU210RV01CIL
018002 Rotary Valve Non Critical Interlocks OK YDU210RV01NCIL
018003 Rotary Valve 24VDC Supply OK YDU210RV01DCOK1
018004 Rotary Valve Underspeed Pulse YDU210RV01NSPULSE
018005 Rotary Valve Alarm Seal YDU210RV01ALMSEAL
018006 Rotary Valve Alarm Acknowledged YDU210RV01ALMACK
018007 Rotary Valve Alarm Reset YDU210RV01ALMRST
018008 Rotary Valve Maintenance Alarm Reset YDU210RV01MALMRST
018009 Rotary Valve Auto Cmd Selected YDU210RV01AUTOCMD
018010 Rotary Valve Maintenance Cmd Selected YDU210RV01MAINTCMD
007378 Rotary Valve Auto Mode YDU210RV01AUTO
007379 Rotary Valve Maintenance Mode YDU210RV01MAINT
007380 Rotary Valve OOS Mode YDU210RV01OOS
018011 Rotary Valve Group Start Seal YDU210RV01GPSTTSL
018012 Rotary Valve Maintenance Start Seal YDU210RV01MSTTSL

Appendix O Page 121 of 158 November 2008

018013 Rotary Valve Maintenance Running YDU210RV01MAINTRNNG
018014 Rotary Valve Maintenance Ready YDU210RV01MAINTRDY
018015 Rotary Valve Auto Running YDU210RV01AUTORNNG
018016 Rotary Valve Auto Start Seal YDU210RV01ASTTSL
018017 Rotary Valve Auto Ready YDU210RV01AUTORDY
007381 Rotary Valve Drive Status Bit 1 YDU210RV01STAT1
007382 Rotary Valve Drive Status Bit 2 YDU210RV01STAT2
007383 Rotary Valve Drive Status Bit 3 YDU210RV01STAT3
018018 Rotary Valve Drive Run Up YDU210RV01RUNUP
018019 Rotary Valve Drive Starting YDU210RV01STTG
018020 Rotary Valve Unacknowledged Faulted YDU210RV01UNACKFLT
018021 Rotary Valve Acknowledged Faulted YDU210RV01ACKFLT
007384 Rotary Valve Sequence Status Bit 1 YDU210RV01SEQ1
007385 Rotary Valve Sequence Status Bit 2 YDU210RV01SEQ2
018022 Rotary Valve Sequence Enabled YDU210RV01SEQEN
018023 Rotary Valve Sequence Stopping YDU210RV01SEQSTPG
018024 Rotary Valve Sequence Disabled YDU210RV01SEQDIS
018025 Rotary Valve Sequence Stop Interlocks YDU210RV01SEQSTPIL
018026 Rotary Valve Sequence Start Interlocks YDU210RV01SEQSTTIL
018027 Rotary Valve Sequence Run Interlocks YDU210RV01SEQRUNIL
407321 Rotary Valve Drive Run Minutes YDU210RV01RM
407322 Rotary Valve Run Off Time YDU210RV01RUNOFFTME
407323 Rotary Valve Run Off Timer YDU210RV01RUNOFFTMR
407324 Rotary Valve Main Contactor Failure Timer YDU210RV01MCTMR
407325 Rotary Valve 24VDC Supply OK Timer YDU210RV01DCOKTMR
407326 Rotary Valve Run Up Timer YDU210RV01RUNUPTMR
407327 Rotary Valve Underspeed Timer YDU210RV01NS01TMR
407328 Rotary Valve Maintenance Alarm Reset Timer YDU210RV01MALMTMR

Conveyor

000092 Dust Coll. Conv Start Relay YDU210CV01SR01

000093 Dust Coll. Conv Start Warning Siren Relay YDU210CV01HS01
100664 Dust Coll. Conv 24VDC CB Q33 Supply OK YDU210CV01DCOK
100665 Dust Coll. Conv Isolator Closed YDU210CV01IS01
100666 Dust Coll. Conv TOL Tripped YDU210CV01TO01
100667 Dust Coll. Conv Main Contactor Closed YDU210CV01MC01
100668 Dust Coll. Conv LOS OK YDU210CV01LOS01
100669 Dust Coll. Conv Local Start PB Activated YDU210CV01PB01
100670 Dust Coll. Conv Underspeed Pulse YDU210CV01NS01
100671 Dust Coll. Conv Pullwire 1 OK YDU210CV01PW01
100672 Dust Coll. Conv Pullwire 2 OK YDU210CV01PW02
004105 Dust Coll. Conv 24VDC Supply Trip YDU210CV01DCOK_T
004106 Dust Coll. Conv Isolator Open Trip YDU210CV01IS01_T
004107 Dust Coll. Conv Main Contactor Failure Trip YDU210CV01MC01_T
004108 Dust Coll. Conv LOS Active Trip YDU210CV01LOS01_T
004109 Dust Coll. Conv TOL Trip YDU210CV01TO01_T
004110 Dust Coll. Conv Underspeed Trip YDU210CV01NS01_T
004111 Dust Coll. Conv Pullwire 1 Trip YDU210CV01PW01_T
004112 Dust Coll. Conv Pullwire 2 Trip YDU210CV01PW02_T
004113 Dust Coll. Conv Not Required To Run YDU210CV01NREQD
011009 Dust Coll. Conv Select Auto Cit Command YDU210CV01SELAUTO
011010 Dust Coll. Conv Select Maintenance Cit Command YDU210CV01SELMAINT
011011 Dust Coll. Conv Select OOS Cit Command YDU210CV01SELOOS

Appendix O Page 122 of 158 November 2008

011012 Dust Coll. Conv Select Stop Cit Command YDU210CV01SELSTOP
011013 Dust Coll. Conv Select Start Cit Command YDU210CV01SELSTART
018035 Dust Coll. Conv Underspeed Pulses YDU210CV01NSPULSE
018036 Dust Coll. Conv Start Warning Complete YDU210CV01HSCOMP
018034 Dust Coll. Conv 24VDC Supply OK YDU210CV01DCOK1
018032 Dust Coll. Conv Critical Interlocks OK YDU210CV01CIL
018033 Dust Coll. Conv Non Critical Interlocks OK YDU210CV01NCIL
018041 Dust Coll. Conv Auto Cmd Selected YDU210CV01AUTOCMD
018042 Dust Coll. Conv Maintenance Cmd Selected YDU210CV01MAINTCMD
007386 Dust Coll. Conv Auto Mode YDU210CV01AUTO
007387 Dust Coll. Conv Maintenance Mode YDU210CV01MAINT
007388 Dust Coll. Conv OOS Mode YDU210CV01OOS
007389 Dust Coll. Conv Drive Status Bit 1 YDU210CV01STAT1
007390 Dust Coll. Conv Drive Status Bit 2 YDU210CV01STAT2
007391 Dust Coll. Conv Drive Status Bit 3 YDU210CV01STAT3
018060 Dust Coll. Conv Drive Run Off YDU210CV01RUNOFF
018050 Dust Coll. Conv Drive Run Up YDU210CV01RUNUP
018051 Dust Coll. Conv Drive Starting YDU210CV01STTG
018037 Dust Coll. Conv Alarm Seal YDU210CV01ALMSEAL
018038 Dust Coll. Conv Alarm Acknowledged YDU210CV01ALMACK
018039 Dust Coll. Conv Alarm Reset YDU210CV01ALMRST
018040 Dust Coll. Conv Maintenance Alarm Reset YDU210CV01MALMRST
018044 Dust Coll. Conv Maintenance Start Seal YDU210CV01MSTTSL
018045 Dust Coll. Conv Maintenance Running YDU210CV01MAINTRNNG
018046 Dust Coll. Conv Maintenance Ready YDU210CV01MAINTRDY
018047 Dust Coll. Conv Auto Running YDU210CV01AUTORNNG
018043 Dust Coll. Conv Group Start Seal YDU210CV01GPSTTSL
018048 Dust Coll. Conv Auto Start Seal YDU210CV01ASTTSL
018049 Dust Coll. Conv Auto Ready YDU210CV01AUTORDY
018052 Dust Coll. Conv Unacknowledged Faulted YDU210CV01UNACKFLT
018053 Dust Coll. Conv Acknowledged Faulted YDU210CV01ACKFLT
007392 Dust Coll. Conv Sequence Status Bit 1 YDU210CV01SEQ1
007393 Dust Coll. Conv Sequence Status Bit 2 YDU210CV01SEQ2
018054 Dust Coll. Conv Sequence Enabled YDU210CV01SEQEN
018055 Dust Coll. Conv Sequence Stopping YDU210CV01SEQSTPG
018056 Dust Coll. Conv Sequence Disabled YDU210CV01SEQDIS
018057 Dust Coll. Conv Sequence Stop Interlocks YDU210CV01SEQSTPIL
018058 Dust Coll. Conv Sequence Start Interlocks YDU210CV01SEQSTTIL
018059 Dust Coll. Conv Sequence Run Interlocks YDU210CV01SEQRUNIL
YDU201CV01 Dust Conveyor Comment Coil COMMENT_44
407305 Dust Coll. Conv Drive Run Minutes YDU210CV01RM
407306 Dust Coll. Conv Run Off Time YDU210CV01RUNOFFTME
407307 Dust Coll. Conv Stop Time YDU210CV01STPTME
407308 Dust Coll. Conv Not Required To Run Timer YDU210CV01NREQTMR
407309 Dust Coll. Conv Run Off Timer YDU210CV01RUNOFFTMR
407310 Dust Coll. Conv Run Up Timer YDU210CV01RUNUPTMR
407311 Dust Coll. Conv Main Contactor Failure Timer YDU210CV01MC01TMR
407312 Dust Coll. Conv Start Siren Warning Timer YDU210CV01HS01TMR
407313 Dust Coll. Conv 24VDC Supply OK Timer YDU210CV01DCOKTMR
407314 Dust Coll. Conv Underspeed Timer YDU210CV01NS01TMR
407315 Dust Coll. Conv Maintenance. Alarm Reset Timer YDU210CV01MALMTMR

Appendix O Page 123 of 158 November 2008

 Appendix P - YDU210 Logic

Appendix P Page 124 of 158 November 2008

 Fan Critical and Non-critical Interlocks

The above Three interlocks are Fan Trips

Appendix P Page 125 of 158 November 2008

 The above Three interlocks are Fan Trips
and alarm seal

The above Three interlocks are Fan alarm

reset interlocks

Appendix P Page 126 of 158 November 2008

 The above Two interlocks are Fan Auto and
Maint commands

The above Three interlocks are Fan Auto

Maint and OOS Mode

Appendix P Page 127 of 158 November 2008

 The above Four are Fan Auto sequence
interlocks

The above Two interlocks are Fan Auto and

Group start Seals

Appendix P Page 128 of 158 November 2008

 The above interlocks is Fan Maint Start seal

The above Two interlocks are Fan start relay

and indication

Appendix P Page 129 of 158 November 2008

 The above Two interlocks are Fan status
indications

The six interlocks are Fan Citect display

indications

Appendix P Page 130 of 158 November 2008

 The above Three are Fan Drive status
interlocks

The above Three are Fan sequence

interlocks

Appendix P Page 131 of 158 November 2008

 The above Three are Fan Sequence status
interlocks

Appendix P Page 132 of 158 November 2008

 The above Three interlocks are Trips,
indications and warning

The above Two interlocks are Trips

Appendix P Page 133 of 158 November 2008

 The above Three interlocks are Trips

The above Three interlocks are warnings

Appendix P Page 134 of 158 November 2008

 The above interlocks is a Trips

These two interlocks are for the Pulse

cleaner general alarm reset and service
alarm reset

Appendix P Page 135 of 158 November 2008

 Diagnostic reset and pulse cycle time

The above Three interlocks are pulse cleaner

cycle complete, cycle incomplete and cycle
done reset

Appendix P Page 136 of 158 November 2008

 Creation of the figures displayed in the pulse
cleaner diagnostics citect window

Pulse cleaner coil alarm history

Appendix P Page 137 of 158 November 2008

 The above Two are Citect display interlocks

The above Two are Citect display interlocks

Appendix P Page 138 of 158 November 2008

 Differential pressure scaling and broken wire
interlock

Appendix P Page 139 of 158 November 2008

 Critical and Non-critical Interlocks

The above Two interlocks are Rotary valve

Trips and 24VDC ok indication

Appendix P Page 140 of 158 November 2008

 The above Three interlocks are Rotary valve
Trips

The above Two interlocks are Rotary valve

Trip and alarm seal

Appendix P Page 141 of 158 November 2008

 The above Two interlocks are Rotary valve
underspeed pulse and Trip

The above Two interlocks are Rotary valve

alarm reset and acknowledgment

Appendix P Page 142 of 158 November 2008

 The above interlock is the maint alarm seal

The above Two are Auto and Maint

commands

Appendix P Page 143 of 158 November 2008

 The above Three interlocks are the Rotary
valve mode selection

The above Four interlocks are Rotary valve

auto sequence

Appendix P Page 144 of 158 November 2008

 Rotary valve Auto Start seal interlocks

Rotary valve Maint start seal interlock

Appendix P Page 145 of 158 November 2008

 Rotary valve start relay and indication

The six coils are Citect display interlocks

Appendix P Page 146 of 158 November 2008

 The above four are Rotary valve Sequence
and drive sequence Citect display interlocks

The above three are Rotary valve drive

status Citect display interlocks

Appendix P Page 147 of 158 November 2008

 The above Two are Rotary valve Sequence
status Citect display interlocks

Appendix P Page 148 of 158 November 2008

 Conveyor Critical and Non-critical
Interlocks

The above Two interlocks are Conveyor Trip

and 24VDC supply indication

Appendix P Page 149 of 158 November 2008

 The above Three interlocks are Conveyor
Trips

The above Three interlocks are Conveyor

Trips

Appendix P Page 150 of 158 November 2008

 The above interlocks are Conveyor alarm
seal

The above Two interlocks are Conveyor

underspeed pulse and Trip

Appendix P Page 151 of 158 November 2008

 The above Three interlocks are Conveyor
alarm reset, alarm acknowledgement

The above Two interlocks are Conveyor Auto

and Maint commands

Appendix P Page 152 of 158 November 2008

 The above Three interlocks are Conveyor
Mode selection

The above Four are Conveyor sequence

interlocks

Appendix P Page 153 of 158 November 2008

 The above interlock is the Conveyor
sequence stop

The above Two interlocks are Group and

Auto start seals for the Conveyor

Appendix P Page 154 of 158 November 2008

 The above is the maint start interlocks for the
Conveyor

The above Four interlocks are start relays

and indications for the Conveyor

Appendix P Page 155 of 158 November 2008

 The Six interlocks are Conveyor Citect
indications

The above Four interlocks are Conveyor

Citect indications

Appendix P Page 156 of 158 November 2008

 The above Three interlocks are Conveyor
drive Citect indications

The above Two interlocks are Conveyor

sequence Citect indications

Figure O1: ProWORX logic

Appendix P Page 157 of 158 November 2008

 Appendix Q - PLC I/O
DESCRIPTION SYMBOL EQUIPMENT DRAWING NO PLC206 ADDRESS
PLC INPUT
206-4-06-9 24V DC SUPPLY OK YDU210FN01DCOK FAN E-001-58463 100649
206-4-06-10 ISOLATOR CLOSED YDU210FN01IS01 FAN E-001-58463 100650
206-4-06-11 TOL TRIPPED YDU210FN01TO01 FAN E-001-58463 100651
206-4-06-12 CONTACTOR CLOSED YDU210FN01MC01 FAN E-001-58463 100652
206-4-06-13 LOS OK YDU210FN01LOS01 FAN E-001-58463 100653
206-4-06-14 LOCAL START YDU210FN01PB01 FAN E-001-58463 100654
206-4-06-15 24V DC SUPPLY OK YDU210RV01DCOK ROTARY VALVE E-001-58464 100655
206-4-06-16 ISOLATOR CLOSED YDU210RV01IS01 ROTARY VALVE E-001-58464 100656
206-4-06-17 TOL TRIPPED YDU210RV01TO01 ROTARY VALVE E-001-58464 100657
206-4-06-18 CONTACTOR CLOSED YDU210RV01MC01 ROTARY VALVE E-001-58464 100658
206-4-06-19 LOS OK YDU210RV01LOS01 ROTARY VALVE E-001-58464 100659
206-4-06-20 LOCAL START YDU210RV01PB01 ROTARY VALVE E-001-58464 100660
206-4-06-21 UNDERSPEED SENSOR OK YDU210RV01NS01 ROTARY VALVE E-001-58464 100661
206-4-06-22
206-4-06-23
206-4-06-24 24V DC SUPPLY OK YDU210CV01DCOK CONVEYOR E-001-58501 100664
206-4-06-25 ISOLATOR CLOSED YDU210CV01IS01 CONVEYOR E-001-58501 100665
206-4-06-26 TOL TRIPPED YDU210CV01TO01 CONVEYOR E-001-58501 100666
206-4-06-27 CONTACTOR CLOSED YDU210CV01MC01 CONVEYOR E-001-58501 100667
206-4-06-28 LOS OK YDU210CV01LOS01 CONVEYOR E-001-58501 100668
206-4-06-29 LOCAL START YDU210CV01PB01 CONVEYOR E-001-58501 100669
206-4-06-30 UNDERSPEED SENSOR OK YDU210CV01NS01 CONVEYOR E-001-58501 100670
206-4-06-31 PULLWIRE SWITCH OK YDU210CV01PW01 CONVEYOR E-001-58501 100671
206-4-06-32 PULLWIRE SWITCH OK YDU210CV01PW02 CONVEYOR E-001-58501 100672
206-4-07-1 24V DC SUPPLY OK YDU210DCOK PULSE CLEANING E-001-58504
206-4-07-2 HOPPER 1 LEVEL HIGH YDU210LS01 PULSE CLEANING E-001-58504
206-4-07-3 AIR PRESSURE OK YDU210PS01 PULSE CLEANING E-001-58504
206-4-07-4 CYCLING YDU210CS PULSE CLEANING E-001-58504
206-4-07-5 WATCHDOG ALARM YDU210ALM01 PULSE CLEANING E-001-58504
206-4-07-6 HIGH dP ALARM YDU210ALM02 PULSE CLEANING E-001-58504
206-4-07-7 SERVICE ALARM YDU210ALM03 PULSE CLEANING E-001-58504
206-4-07-8 COIL ALARM YDU210ALM04 PULSE CLEANING E-001-58504
206-4-07-9 AUX ALARM YDU210ALM05 PULSE CLEANING E-001-58504
206-4-07-10 POWER OK YDU210PWR PULSE CLEANING E-001-58504

206-2-04-6 DUCT COLLECTOR DP YDU210PT01 PULSE CLEANING E-001-58504 300024

PLC OUTPUT
206-4-11-10 START RELAY YDU210FN01SR01 FAN E-001-58463 ,000090
206-4-11-11 START RELAY YDU210RV01SR01 ROTARY VALVE E-001-58464 ,000091
206-4-11-12 START FORWARD RELAY YDU210CV01SR01 CONVEYOR E-001-58501 ,000092
START WARNING SIREN
206-4-11-13 RELAY YDU210CV01HS01 CONVEYOR E-001-58501 ,000093

206-4-12-9 RESET GENERAL ALARM YDU210RST01 PULSE CLEANING E-001-58504 ,000105

206-4-12-10 RESET SERVICE ALARM YDU210RST02 PULSE CLEANING E-001-58504 ,000106
206-4-12-11 LOW HEADER ALARM YDU210ALM06 PULSE CLEANING E-001-58504 ,000107
206-4-12-12 AUX INPUT YDU210AUX01 PULSE CLEANING E-001-58504 ,000108
206-4-12-13 MANUAL CYCLE YDU210RMC PULSE CLEANING E-001-58504 ,000109
206-4-12-14 DEMAND/CONTINUOUS YDU210DCM PULSE CLEANING E-001-58504 ,000110
206-4-12-15 START RELAY YDU210SR01 PULSE CLEANING E-001-58504 ,000111

Appendix Q Page 158 of 158 November 2008