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Worldwide experience with the CELTROL System demonstrates that it is the ideal control system to:
There are three major components in the CELTROL System: a microprocessor for each reduction cell, a communications buffer for a group of pot controller microprocessors, and a supervisory, or host, computer for the complete system.
Existing CELTROL installations can be upgraded to new CELTROL capabilities without extensive hardware modifications.
Reduction facilities worldwide are experiencing the benefits of our new and improved CELTROL System enhanced graphics that communicate more information faster; have more built-in controls that produce faster action in the pots, and waste less energy.
The control logic for the CELTROL System can perform the following process control functions: Automatic Voltage Control, Noise Control, Tapping Routine, Anode Set Routine, Alumina Feed Control, Search Routine, Starve Routine and Anode Effect Termination. The CELTROL System makes better use of incoming power, helps to maintain proper heat balance in the pot to provide lower bath temperature, and produces more aluminum from the available energy.
The CELTROL System delivers improved control and greater efficiency in new and old potlines alike. Currently, CELTROL Systems are monitoring and controlling cells ranging from older Soderbergs to new, large, modern prebake cells.
Featuring highly versatile software, the CELTROL System provides long-term trend analysis as well as an early warning feature that allows operators to avoid emergencies.
At the very heart of the CELTROL System is a flexible control strategy. The system's adaptive control capabilities allow each cell within the plant to operate at a high efficiency. In addition, the current CELTROL System has been refined to represent the best cell process control technology on the market with a user network that provides access to continuing updates and improvements. Control parameters can be tailored to individual cell characteristics, and in the case of development work, the strategy can be modified for a particular cell or cells.
The CELTROL System helps to handle emergencies in the pot room because it keeps each pot in control, thus minimizing the chance for human error. The system also provides a wealth of data that makes normal operations more efficient. When trouble arises in the pot, CELTROL first endeavors to correct the abnormality. If the condition continues, there are two ways the operating group will be alerted. On the CRT, visual information immediately appears to identify the problem at an early stage. If action is not taken, the CELTROL System is capable of generating either an audio or radio message to alarm the operator.
In addition to trend analysis information, CELTROL provides first line supervision with the information to maintain smooth running potline operations. CELTROL also provides floor personnel with the tools to do their job better and safer.
When not being used for communicating, the CRT displays potline voltage, and the potline current. When an exception to normal operation occurs, the System prints out an Exception Report that includes the cell number, the exception message, and the time of day. The system generates four-hour exception logs at mid-shift and end of shift. Eight hour logs summarize Exceptions for the full shift.
The Communication Buffer transmits potline current information to the Pot Controllers at each reduction cell. Using this line amperage information, the Pot Controller calculates the present cell resistance. CELTROL Communication Buffers also handle all communications between the Pot Controllers and the Supervisory Computer.
The Potline Supervisory Computer, typically a personal or mini-computer, takes all the information from the CELTROL Potline controllers and outputs all reports and audio messages. Representative operations include collection of all operating history of the cells in a potline; printing shift reports, and changing control parameters for a specfic cell or cells.
The fully distributive control architecture of the CELTROL System helps ensure minimum downtime if any single component of the system fails. If the Supervisory Computer fails, each CELTROL por control unit continues to control its reduction cell without interruption. The only functions that cease are informational displays at the graphic workstations and generation of audio messages to the operating personnel. This operational independence provides a high degree of on-line reliability and flexibility through redundancy.
It is very easy to install the CELTROL System on existing potlines with no control systems, older AVC systems, or other less efficient systems thereby upgrading to the modern state-of-the-art CELTROL System.