CHAPTER 1 INTRODUCTION

1.1) HISTORY, STRUCTURE AND ASPECT OF JK

ORGANISATION:
The family of JK hails from a small but beautiful town of Kanpur in Uttar Pradesh. This is place from where the illustrious and magnificent history of the JK Industrial House began. The JK Industrial House rests on the strong foundations built on the vision, dedication, commitment and hard work of our beloved and visionary leader late Shri Juggilal Singhania and Lala Kamlapat Sighania. The name JK stands for the name of these great father and son.

1.2) INDUSTRIAL VIEW OF JK CEMENTS:-

JK Cements Ltd includes:

1. JK White cement Works, Gotan (Nagaur) 2. JK Cement Works, Nimbahera 3. JK Cement Works, Mangrol 4. Thermal Power Plant, Shambhupura 5. JK Grey Cement Plant, Gotan 6. JK Cement Works Plant, Mudhol.

1.3) ABOUT JK WHITE CEMENT WORKS:1. Today, J. K. Cement Ltd. is one of the largest cement manufacturers in Northern India.

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2. They are also the second largest white cement manufacturer in India by production capacity. The white cement enjoys demand in the export market including countries like South Africa, Nigeria, Singapore, Bahrain, Bangladesh, Sri Lanka, Kenya, Tanzania, UAE and Nepal.

3. They have 27 years of experience in the Indian cement industry, which they believe provides us with the skills to maximize production efficiency, expand production capacity quickly and reduce costs.

4. Their WHITE CEMENT MANUFACTURING, GOTAN manufacturing facility was chosen by the World Bank and Corporated with F.L SMITH (DENMARK) as one of the four training centers in India to serve as the Regional Training Center for Northern India. There are only four regional training centers for the cement industry in India. 6. Architect of the Year Award (AYA) began way back in the year 1996 (1st Architect of the Year Award). Awards were subsequently extended to architects of neighboring countries from the year 2000 (7th Architect of the Year Award).

7. J.K CEMENT LTD. is the holder of the ISO ENVIRONMENT PROTECTION AND ENHANCEMENT AWARD . 8. This is the only plant after operated with the 5th HAVER PACKER machine for cement packing and logistics enhancement.

9. At present, the JK white cement plant, gotan is undergoing a huge money project of DOLOMITE for putty manufacturing. As DOLOMITE is the main material used with the putty manufacturing. A Raw mill project is going to be start in the nearby future.

10. It is also the winner of many quality awards such as TPM (Total Productive Maintenance), ISO etc. & is working well to upgrade its certificates day by day. All the employees have been made responsible to take care of all these awards & to maintain the quality of the production as required by the certifying authorities.

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1.4)GOALS AND VISION:-

Goals by 2015: 1) 2) 3) 4) Vision: 1) 2) 3) 4) 5) 6) 7) Lowest fuel consumption. Lowest power consumption. Use of the alternate fuels. Low SOx and NOx emission. Waste heat recovery. Dense deep rooted plantation. Use of renewable energy resources. Increase the Production by the establishment of a new KILN. Achieve global benchmark in terms of environmental norms. Productivity and energy efficiency by 2015. Establishment of the high capacity SILO upon 20,000 ton.

1.5) Special Features Separating JK from other Cement Plant:

1) Entire process is fully computerized, leaving no scope for human errors. All the control systems are Windows based. 2) Cement and other raw material are checked as per our quality plan. 3) All the raw materials are stacked in separate bins and are stored under cover so that aggregates are not exposed to direct sunlight and environment pollution.

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4) Cement, Fly ash, Slag etc. are stored in separate silos for better control on recipe.

5) Handling of fly ash and slag are done from closed bunkers to silos directly. 6) Separate weigh-batchers are provided for each ingredient like cement, water, admixtures and aggregates. The weighing is done on sophisticated electronic weigh batchers. Precise weighing of all materials is done through electronic load cells made up of special alloys. 7) Homogeneous mixing of concrete is ensured by use of special high-efficiency mixers like pan-type or turbo-twin shaft mixers. 8) A fully equipped onsite plant laboratory is available at each plant. 9) A Sprinkler system is installed to ensure temperature control of aggregates in hot weather. 10) In line with Groups focus towards environment and eco-friendliness all silos are installed with bag filters and level indicators to avoid any kind of pollution.

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11) Processes are in place for effective and periodic maintenance and calibration of all critical components. 12) Well trained and experienced engineers are available at every plant to take care of the quality of concrete. 13) The JK CEMENT WORKS (JK) products and the services offer distinctive customer solution worldwide. The group has operation in 25 countries:

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CHAPTER 2
VARIOUS SECTIONS AND DEPARTMENT

1. CRUSHER

2. RAW MILL

3. INSTRUMENTATION DEPARTMENT

4. ELECTRICAL DEPARTMENT

5. MECHANICAL DEPARTMENT AND WORKSHOP

6. CIVIL DEPARTMENT

7. KILN SECTION

8. CCR (CENTRAL CONTROL ROOM)

9. PETROCOKE MILL

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10. CEMENT MILL

11. PACKING PLANT

12. TECHNICAL DEPARTMENT

13. POWER GENERATION (THERMAX)

14. ENVIRONMENT LAB AND MANUALS DRAWING LIBRARY

15. QUALITY CONTROL DEPARTMENT AND LAB

16. WALL PUTTY SECTION

17. DOLOMITE SECTION

18. EDP DEPARTMENT ( ELECTRONICS DATA PROCESSING )

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CHAPTER 2
PROCESS FOR CEMENT PRODUCTION:
Cement is basically produced by two processes: - Dry & Wet. In JK WHITE CEMENT dry process is used for cement production as it is less power consuming & easy to manufacture. The basic raw material used for cement production is the Limestone. JK Cement has its own mines for acquiring limestone located near 40 km away from Gotan. The basic process for the cement production is being described here under:-

RAW MATERIAL FOR CEMENT MANUFACTURING

MATERIAL NAME
Calcium carbonate For Calcium Oxide. Clay 1 for Silica Oxide.

PERCENTAGE
60-65%

USE
primary comp.

17-25%

secondary comp.

Clay 2 for Aluminum Oxide Feldspar Stone for Ferric Oxide

3-8%

quick setting

5-6%

Hardness.

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Magnesium Oxide

5-4%

To improve the Colour and hardness.

Gypsum for Calcium Sulphate

5-3%

To Increase settling time.

3.1) MINES:
The process of mining which is used here to extract Limestone from the Earth is Open cast mining. The process of mining includes three things:

Prospecting: It is the process of finding potential at place from where very useful & bulk quantity of limestone can be extracted.

Drilling: After providing with a better place for mining, the process of drilling takes place, in which the place is drilled with the drilling machines, for inserting the dynamites.

Blasting: After drilling holes, this place is blasted by blasting materials inserted inside the drilled part to break the huge rocks into pieces. These pieces of rocks are brought near to the crusher & are further processed.

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3.2) CRUSHER SECTION:

PURPOSE: In every cement industry plant, a regular visiting of the trucks loaded with
different types of rocks (limestone, clay 1, clay 2, clay 3 feldspar stone) takes place. The purpose of the crusher section is to help in the converting these stones into the fine material as it is easy to process the material in its fine form.

Process and Components involve in the crushing of the material:

Crusher Mouth: The loaded truck goes at the mouth of the crusher mouth. Then the operator operate the 3 phase induction motor operates a piston to lift the truck in the back downward position approx. around 45 degree to allow the rock to drop into the mouth of the crusher. An ALARM get evoke when the angle of inclination is 45 degree.

Motor used in lifting: 3 phase induction motor. Sensor used: Limit switch and proximity sensor.

PUSH FEEDER: The Push Feeder is the vibrator used to push the large stones into the crusher hammer section.

CRUSHER MILL: The crusher mill consists of the hammer. The hammer continuously applied over the large bulky stone and the crushing of stones takes place.

MOTOR RATING for CRUSHER: 143.5KW

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VIBRATING SCREEN: The material after the screw conveyor and dust collector through the conveyor belt comes to the vibrating screen. The Vibrating screen consists of a fine 1000 micron filter sheet. This sheet separates down the fine particle form the stone big particle. The small particle is allowed to pass to the yard after filtration. The large stony particle is again send out to the ball hammer crusher for fining. The two belt system (forward and backward) is shown in below fig. .

Fig shown: The Vibrating screen of the Crusher.

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3.2.1) INSTRUMENTATION USED IN CRUSHER SECTION:

1) Solenoid Valve: It is a combination of two terms: 1) Solenoid (coil). 2) Valve (mechanical operated valve).

Image shown: Solenoid Valve.

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2) Differential Pressure Valve and Transmitter:

The differential pressure valve is used to measure the differential pressure of the two points or two different chamber. It is used to measure the differential pressure of above and below the solenoid valve in Dust Collector.

The DP has two input and one connection plate, the DP transmitter converts the differential pressure into 4-20 MA, the output of transmitter is being passed on to the analog JB(junction box).

The wire from junction box then move on to the analog input/output module of PLC.

FUNCTIONAL BLOCK DIAGRAM OF DIFFERENTIAL PRESSURE:

(4-20ma) Air supply Pressure transmitter Analog JB

(4-20ma) Remote I/O Module PLC

24 volt

24 volt

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Image shown: The differential Pressure Transmitter.

3.3) YARD:
The yard is the storage house used for storage of material on a large volume and scale and for relatively large period of time.

The yard for crusher purpose consist of the three separate rectangular storage tanks for limestone, clay1 and clay 2 and clay 3. The yard is shown in the right most side of given fig 2. The material from these storage tanks is being taken out with the help of 5 hopper. The hopper is the conical part at the bottom of the yard. The hopper consist of the gate system at the bottom mouth. The material from these Hopper is being taken out by the utilization of the piston movement done by the solenoid valve.

The material from the yard is move on to the Raw mill as per requirement.

Sensor used: Solenoid valve for operating the piston gate of hopper. Proximity sensor detecting the opening and closing of the gate. PCE/EIC/10/49/014

3.3.2) INSTRUMENTS Utilized In the YARD SECTION:

a) Proximity Sensor: the proximity sensor is the very important sensor serve as an eye for the plant. The proximity sensor consist of a coil which is supplied with the phase supply, the inductive coil inside the proximity produces the magnetic flux. Whenever any metal piece is brought near to the proximity sensor then the cutting of the magnetic flux takes place, and the switch gets normally closed. The return from the proximity gives the response or return when flux get intruppt by the any metal piece In this way, it is used to detect the motion of conveyor, motor shaft, packer spout etc

3.4) Raw Mill Section:

In Raw-mill section, this conveyed material is transferred into hopper which feeds and regulated amount of material to the mill. This feeding is carried out with TFG (Triple Feed Gate) or weigh-feeder, which is a hydraulic gate used to avoid overfeeding of material in PCE/EIC/10/49/015

mill. Raw-Mill consists of large rollers, which is used to grind this crushed material into fine powder. This fine powder is collected & is stored in Raw-mill silos, which is called Raw-Meal for Kiln.

Raw mill section consists of:

1. Clay1 and clay 2 common crusher. 2. Limestone crusher. 3. Clay 3 (Feldspar mill). 4. Dryer mill. 5. Raw mill. 6. Two separators. 7. ESP. 8. Raw Mill Fan. 9. Silo.

3.4.1) Raw Mill Crusher:1. There are two separate crusher arrangement for limestone and clay1, clay2.

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2. The crusher work here is to make the raw material more fine them in the initial crusher stage.

Fig shown: The Raw Mill Crusher

3.4.2) Dryer Mill:1. The material from the crusher of clay and limestone is put into the dryer mill. 2. The Dryer mill is the long cylindrical mill of the axis length of 72 m and 3.2 m diameter. 3. The Dryer mill consists of the two chambers or section. 4. The input chamber is filled with the steel balls and output chamber is filled with ceramic balls. 5. The material after dust removal, crushing, etc. get mixed up and pass into the raw mill. 6. The motor rotating the raw mill is provided with that of the flow valve or RTD to measure the bearing temperature. PCE/EIC/10/49/017

7. The raw mill rotates and a suction fan on the outlet side to suck the fine (mixed) material. 8. The motor used for running the mill is synchronous motor of 1000 KW rating. It is also provided with that of gear box for running the motor. 9. The motor is provided with the RTD to measure the bearing temperature. It is around of the range of 150 degree Celsius. 10. The oil lubrication is also provided with that of 1000KW motor and for the mill for providing the smoothness and cooking of the bearing. The HP-LP lubricating system is used here.

Fig shown: The Dryer Mill 3.4.3) Feldspar Mill:1. The feldspar hopper is provided with the feldspar material. The material from the feldspar hopper is inserted into the feldspar mill with the help of weigh feeder. 2. The functioning of feldspar mill is same as that of the other mill. 3. The feldspar mills consist of 815 KW, 3-phase synchronous motor. 4. The motor is provided with that of the RTD to measure the temperature.

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3.4.4) Raw Mill:1. All the material clay1, clay2 and limestone, feldspar from their respective mill come to a common final raw section mill known as Raw mill. 2. The motor used for driving the Raw mill is of 1050 KW. The Raw mill motor is provided with the RTD and its normal operating is 150 to 200. The hot air is supplied across the raw mill input. 3. The dust produced during the production outlet of the raw mill is put into the ESP for dust settling and smoke removal. 4. The raw mill is provided with the grease system for HP-LP lubricating system. 5. The Folaphone Sensor helps in detecting the level of the charge in the raw mill. 6. The material from the outlet of the raw mill is move to the silo with the help of bucket elevators.

Picture shown: Rotating Raw mill with Folaphone Sensor mounted on its side face. PCE/EIC/10/49/019

3.4.5) Description of Raw/dryer/feldspar mill:

Principle of working of Mill: The material fed to the mill from its input side, and the mill is allowed to rotate at the rate of 74-77% of the critical speed. The mill is driven by a motor connected through MAAG c.p.u gear unit.

Physical Description of Mill:

Inlet: This is the side through which the feeding of the material is being carried out.

Sensor used: RTD: To sense the temperature of the bearing of the motor. Techogenerator: Used to sense the RPM of the motor driving the Mill.

Grinding Media: The grinding media consist of the steel balls in the first chamber and ceramic balls in the other chamber. Dimensions of balls: Balls in the first chamber are 90-60 mm. Balls in the second chamber are 30-15 mm.

Hp-Lp Lubricating System:

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1. The purpose of this lubrication system is two fold. Firstly, it is to ensure that there is always a film of oil at the bearing to minimize the effect of friction. 2. Secondly, it is to ensure to heat that is removed from the bearing is cooled effectively to ensure that oil viscosity is retained. 3. Because, the hot oil become less viscous and fabrication property is reduced in hot oil case.

High pressure low pressure System:-

1. A low pressure pump and a high pressure pump are started simultaneously through a PLC. 2. Oil is suck by a suction strainer filter to ensure the restriction of large particles impurity. 3. The high pressure pump, pump the oil at a fairly high rate to make sure that there is a jacking effect in the bearings. 4. The low pressure pump supplies the greater the volume of oil than that of the high pressure. 5. The low pressure pump, pump the oil through the common header to the bearing. 6. Thus, it provides the lubrication as well as the cooling of the bearing of the ball.

System consist of the heat exchanger:

1. The oil circulated from bearing to the heat exchanger. 2. The Heat Exchanger consist of the tube structure, outside which the water is passed. 3. An alarm is set with the PLC whenever the cooled water temperature gas above 45c and the flow of oil is below 80% of the rated of the pump. 4. Various other instrument with lubricating system are:

Outlet casing: The finally grinded material is being pass on to the bucket elevator and then into the Silo.

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Fig shown: Lubricating system for Mill, and Motor.

3.4.5) Silo (RAW MILL STORAGE):Silo is the cylindrical structure of large height to store the material for long purpose and on a large scale. The two silo after the raw mill is double storage silo building. The height of the silo building is 27.1m and diameter is of around 9.3m. The level of the filling of the silo is measured by the help of the analog sensor known as the Radar sensor.

3.4.6) Instrument used in the Raw Mill Section: a). Folaphone Sensor Used in Mill(mounted on the inlet side of the mill):
Physical Description:It is used to sense the sound pressure signal or the sound vibration and then transfer it to the electrical signal (mv). The voltage generated is a measure of the sound pressure.If the sound vibration is large, it means that there is less material inside the mill and vice-versa. It consists of microphone and an electronic amplifier.

Its microphone should be mounted in the direction of motion downward of the mill.

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 The folaphone is mounted at a distance of 10-15mm. The folaphone is mounted on the inlet section side. b). Weigh Feeder (for the discharging of material from the hopper):
The material from the hopper is taken out as per the % requirement through the weigh feeder as shown in fig. 1. The weigh feeder consist of hopper outlet at its top and the material comes out through the hopper is driven or controlled by the rotary encoder through a motor controlled which is also by VFD panel in panel room as shown in fig 2. The material falls over the conveyor belt is move on in the forward direction by the weigh feeder. 3. The motor driving the conveyor belt controlled by VFD and speed is detected by the encoder. 4. The motor is provided with the Proximity Sensor to detect the motor running status.
5. The RTD is adjusted in the bearing of the motor to sense the temperature of the

bearing of the motor. This is to provide the safety to the motor as requirement by the electrical department. The conveyor motor is also provided with RTD to detect the temperature.

b). RTD (Resistance temperature detector):

Resistance thermometers, also called resistance temperature detectors or resistive thermal devices (RTDs), are temperature sensors that exploit the predictable change in electrical resistance of some materials with changing temperature. As they are almost invariably made of platinum, they are often called platinum resistance thermometers (PRTs). They are slowly replacing the use of thermocouples in many industrial applications below 500 C, due to higher accuracy and repeatability. Functions:

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The RTDs are used in weigh-feeder to check the bearing temperature of the motor Resistance thermometers are constructed in a number of forms and offer greater stability, accuracy and repeatability in some cases than thermocouples.

Range of RTD: It is of the range of 0-150 degree Celsius. The generally used RTD is the PT-100. The PT refers to the platinum material used. The 100 refers to the indication of 0 deg. In 100 ohm Formula used: Rt= Ro (1+T). The wire from the RTD is being connected to the panel Transmitter. Then from the panel transmitter. Then from the panel transmitter it goes to the analog I/O module of the PLC.

f). Weigh Feeder Panel:1. It is industrial equipment to measure and record the rate of flow and the total quantity of material transferred over the conveyor belt. 2. The rate information is obtained by multiplying the speed of belt with the instantaneous weight of the material over the conveyor. Rate of discharge of Hopper= (Belt Speed in RPM* inst. Wt of the material) 3. The signals are to the CCR (Central Control Room) to the PLC. 4. The two signals operate are the set point and processing point. The processing point always follows the set point. 5. Like other panel the weigh-feeder panel also consist of the current transformer (CT), input/output terminal blocks, MCB (miniature circuit board), switches, SMPS or siemens 24 volt converter.

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Fig shown: Weigh-feeder panel.

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3.5) Pre-Heater Section:

Consist of:

1. 5 stage preheater (height 85 m). 2. Gas Analyzer. 3. Cooling Tower. 4. ESP 5. Smoke gas fan. 6. 3 Heat Exchanger.

Role of smoke gas fan: The smoke gas fan works as a Air suction fan, it sucks the air by making the cyclone the dust particle get fall down at the bottom of each cyclone. The preheater consist of the 3 heat exchanger , the hot

air+dust led to the heating of the pipe, the hot pipe convert the cold air into the hot air. The outlet of the heat exchanger, the hot air is utilized in the dry mill, raw mill, the kiln.

Advantages: Preheating is necessary to raise the temperature of raw miil and to utilize waste heat for further calcinations of kiln feed.

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3.5.2) ESP (Electrostatic Precipitator for dust collection):-

Most industries have smoke or dust problem of some kind. The smoke can be made up of solid or fluid particles suspended in the gas. Sometimes the particle are waste which must be removed for removal for reason of hygiene and comfort before the gas is released into the atmosphere, Equally, after the materials may be useful product which must be recovered for the purpose to be profitable. For the control of dust, Electrostatic Precipitator is often used. Principle of ESP:

An Electrostatic Precipitator is an electrical equipment where a DC voltage is imparted through emitting electrode creating an electrical field around it. Dust particles carried by the gas, while passing through the field is charged to saturation and migrate towards the collecting electrone , usually in the form of plate curtain, where they are deposited in layers. By suitable rapping the dust is displayed into the hopper.

The dust filled gas enter the precipitator at A and the clean gas leaves atB. The electrodes E are called emitting electrodes and C usually known as collecting electrodes form a no. of gas passages. The C electrodes along with E electrodes form a frame.

The DC voltage is applied across the E electrode. Due to the high electric field around the E electrode, the surrounding gas get ionized and the region is filled with ve and +ve ions. This is called as corona formation.

The Dust particles carried by gas from a section are charged to saturate. The charged particles are then pulled towards the collecting electrodes. Movement of particle is opposed by the viscous drag force and a resultant velocity called migration or drift velocity is attained by the particle.

Hence, a deposit of the dust layer formed over the collecting electrodes. When the layer is sufficiently thick and agglomerated of it is dislodged from the plate by rapping. The dust cakes slide along the plate down into the storage hopper and then screw conveyor.

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It is seen that principle of electrostatic precipitator has four phases:1. Corona formation or ionization. 2. Charging of particles. 3. Migration and precipitation of particle. 4. Removal of deposited dust. Advantages of using ESP:1. Low pressure drop. 2. Low sensitive to high pressure. 3. Accuracy up to 99.5%. 4. Low maintenance required.

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3.5.3) Cooling Tower:

Purpose: The material supplied to the ESP must be under the certain temperature range otherwise it affects the performance of the ESP. Gas is cooled at 3c of the respective application outlet set point during normal condition. The water spry is based on the PID controller principle. The water booster pumps required to deliver the flow and pressure to the valve rack. The dust from Preheater cyclone is being supplied to the cooling tower for cooling before sending to the ESP.

Fig shown: the cooling Tower from the Top of Preheater.

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3.5.5) Gas Analyzers:

Gas analyzers are mainly used to measure the amount of different gases inside the heating machines, such that for a definite reaction definite amount of gas should be evolved & to reduce the harmful gases evolved during the reactions. The amount of gas evolved can be measured by using gas analyzers. There are mainly two types of gases that should be maintained in this plant for completing the required reactions in it, these are oxygen & carbon mono oxides. There amount is measured by using gas analyzers. The gas analyzers work on the principle that different gases absorb different amount of heat radiations. As such the change in the properties of the gas in accordance with the heat absorbed gives the amount of gas. For measuring the gas amount an infrared source is used. This infrared radiation is passed on to a mirror which absorbs this radiation & allows it to pass through two different paths. One path having inert gas tank, which has the property that it does not alter the properties of the radiation. While the other path having the gas inlet. The gas evolved during the reaction is given as a inlet at this point. CO measurement:

The CO gas when comes into this tank absorbs a definite amount of radiation, thus
changing the amount of heat flow through the second path. By measuring the

Fig shown: abb panel for gas analyzer. PCE/EIC/10/49/030

3.5.6) Instruments and instrumentation Panel Used In Preheater:

1. Gas analyzer (Rota meter, Probe, Filter lubricant). 2. Pressure meter and transmitter. 3. Thermocouple. 4. RTD. 5. Air blaster. 6. Solenoid valve.

1. Gas analyzer:

It is used to check the level of the oxygen, carbon monoxide {CO}, and nitrogen compound {NOx}.

Purpose: To check the level of oxygen, carbon monoxide, and NOx in the Preheater cyclone. If the CO is larger, then the more fuel or petrocoke is needed. Should be <0.1. If the oxygen is larger, then the large material can be burnt out with the same fuel, should be <3.5. The NOx compound are prevented as they led to the increase in temperature of the kiln, should be equal to zero.

Instrument & Sensor used: Rota meter: is used to check the level of the incoming air from preheater. PLC: advent controller31, vendor- ABB, consist of the 8 I/P and 6 delays O/P.

2). Pressure meter:

The model Rosemount 1151 ALPHALINE series of pressure transmitters brings true precision to the measurement of flow, level, gauge & absolute pressure, vacuum & specific

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gravity. Direct electronic sensing with the completely sealed delta-cell capacitance sensing element allows significant improvement & stability in pressure measurement. Installation, calibration and commissioning are simplified by compact design, integral junction box and local span and zero adjustment.

Construction:

The isolating diaphragms and fill fluids on the high & low sides transmit the process pressure to the oil fill fluid. The fluid in turn transmits the process pressure to a sensing diaphragm in the center of delta-cell sensor. The sensing diaphragm functions as a stretched spring element that deflects in response to differential pressure across it.

Working Principle: In AP transmitters, a reference pressure is maintained on the low side. The displacement of the sensing diaphragm is proportional to the pressure. Capacitor plates on both sides detect the position of the sensing diaphragm. The differential capacitance between the sensing diaphragm & the capacitor plates is converted electronically to an appropriate current, voltage or digital HART(Highway addressable remote transducer) o/p signal. Features: 1) Superior Performance: 0.1% accuracy, 15:1 range ability.

2) Smart, analog or low power electronics. 3) Compact, rugged construction resistant to vibration. 4) Differential pressure from 30 in H2O to 1000 psig. 5) Gage pressure from 30 in H2O to 6000 psig. 6) Absolute pressure from 150 in H2O to 1000 psig.

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3.6) Rotary Kiln section:

A Kiln is a big rotating cylindrical shape horizontal structure about 72 long, 3.2 in diameter. Here the continuous heating of this preheated material takes place at around 1200-1600 oC. The Kiln cylinder is tilted to an angle of 3-4 degrees and is rotating at about 3 to 5.5 rpm to make the material flow in one direction only. Every day, the mechanical department is responsible for the reading of the temperature below its surface. The Rotary kiln is also provided with the 3 tier system and internal bricks on its internal surface. These bricks help in the heating of the charge. The temperature of the kiln is being measured by the help of thermocouple at its feed. The temperature is also sensed by the RTD (in Tyre), X Ray sensor.

Outlet side:

RTD:

Tyre:

Material feed/ Inlet Side:

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3.6.1) Fuel Used:.

1) The petro coke is also used as it is cheap and serve as a fuel replacing the large quantity of LDO into small one. 2) LDO and FO.

The LDO oil is being pumped by the 33 HP motor, having 75-80 mm at the rate of 1000 lit/hr. The steam is also passed along at outlet section to allow the formation of granules, and for the purpose of decreasing the temperature.

3.6.2) Cooler Section:

In this section, hot clinker coming out from kiln is fed. This hot clinker is cooled from air stream produced by various cooler fans. This cooled clinker is stacked in clinker stock piles.

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The clinker is then fed to dryer (dry mill) for cooling and then to the cement mill for further processing.

Another important aspect of coolers is that they are serving as an oxygen supplier for the burning of fuel inside.

3.7) Cement Mill:

Before feeding to cement mill, the clinker is further mixed with definite amount of Gypsum, which determines setting time for cement. This mixed material is then fed to cement mill, where this mixed material is further grounded in fine powder, forming cement. This cement thus produced is stocked in huge silos equipped with packing plant at the bottom from where the cement bags are filled, weighed & packed & hence supplied to the market through various transporters.

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Chemical used in Cement Mill:

The Tee (ethylene titrate) is mixed with the clinker, the chemical help in preventing the final cement grinding in the mill to get stick with the grinding media(steel balls and ceramic balls). Also the finally prepared product does not have granules or Solid Balls. The final prepared Cement is passing on to the SILO for storage from where it is taken out for packing in packer plant.

3.7.2) Instrumentation utilized in Cement Mill:

1. Weigh-feeders. 2. PID Controller valve. 3. RTD. 4. Folaphone (in cement mill). 5. Proximity Sensor.

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Weight Indicators / Feeders:

The reaction which is taking place inside, for cement production should be controlled, in order to produce a good quality of cement & in order to achieve this, the feeding & mixing of material should be proper. This constant feeding (say) is achieved by using weigh feeders. The principle behind the weigh feeder is that if we maintain a constant amount of material to flow into the processing machines then the above requirement can be fulfilled. A definite amount of material is maintained over the conveyor belts by analyzing the tones per hour (TPH) over the conveyor belts again & again & increasing or decreasing the material feed over it, for constant feed.

For above control the tones per meter are measured using two instruments, namely, Load cells & tacho generators.

Load cells :
Load cells are placed at the bottom of the conveyor belts. The load over it produces a pressure over it. Load cells probably functions on the principle that the value of resistance changes with the pressure over it producing a change in the voltage value across it. This change of value indicates the tones per meter of the belt.

Tacho generator:
Connecter at the rolling end of the conveyor belt rollers gives the speed of the rotating belt in meters per hour. These two values when multiplied using the software gives the value in tones per hour indicating the amount of feed per unit time. Thus by analyzing this value the

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operator in the CCR can analyze it & can increase or decrease the amount of feed into the machines by adjusting the feed into these conveying belts.

PID control valve:

The PID is used for contolling the amount of water sppray in the MILL. After measuring the temperature (PV), and then calculating the error, the controller decides when to change the tap position (MV) and by how much. When the controller first turns the valve on, it may turn the valve only slightly if cold water is desired, or it may open the valve all the way if very cold water is desired. This is an example of a simple proportional control.

Thus the main purpose is to cool the material when arrives hot from the feed.

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 In the event that cold water does not arrive quickly, the controller may try to speedup the process by opening up the hot water valve more-and-more as time goes by. This is an example of an integral control.

3.8) Packers section: 3.8.1)introducation:

1. The plant consists of total of 5 Packer machines. Two 1 kg packers. One 5 kg packers. Two 25/40/50 kg packers. 2. The HAVER ROTO PACKER is one of the latest advanced PACKERS. 3. The JK WHITE CEMENT is having the Asias 5th Haver packer equipped with the all modern and latest technology.

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The average operational output using paper and plastic bags with interior valves between 900 bags/hr. with 3 filling spouts, and 4000 bags/hr. with 12 filling spouts.

3.8.2) COMPONENTS AND SENSORS IN HAVERS: It is fully automated just after insertion of the bag. The pneumatic Valve is used to hold the bag on any spout, whenever the bag comes
,then the path of air passes get interrupt and the valve opening get seal.

The pressure switch is employed for this reason. The motor used for filling the bag is of 3 phase induction 5.5 kw motor with gear
box on the right side.

Anvil job is supplied with the 24 volt. PRESSURE SWITCH works opposite to the principle of the solenoid valve. The air dynamometer is used at the bag for pushing the chair car. The PISTON is operated by the help of the solenoid valve(ainec SE-14). The ainec se-14 are the worlds compact and most efficient solenoid valve. The Sonotrode transducer is used for welding the bag, the sonotrode produces the
vibration at the rate of 0.1 to 1 micron.

The vibrating sonotrode when striked with the ANVIL then the heat is produced. Due to this heat, the sealing of bag takes place. Load cell is provided at the just above and behind the nozzle(pneumatic) switch. Load cell section along with the SPOUT pipe is isolate from the lower section. When the saddle moves up and down, the position is determined by the Proximity
sensor.

The pneumatic pipe with air is inserted as shown below is called AERATION, it
allows the material to comes out with pressure without any chock.

POWER REQUIRED:
The whole packer work with the 3 phase supply for motor and 24 volt for all the sensor.

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Fig shown: The Check Weighing system

3.9) CCR (Central Control Room):

The CCR is responsible for maintaining the Automation throughout the Plant. Automation means the automatic controlling of any device or field using logic. Today, the automation of functions is also very important in buildings to allow costefficient, comfortable and reliable management. Some examples are heating, ventilating and air-conditioning systems, access control systems, lighting and rolling shutter control standardized for one building as well as individually for different rooms with also different requirements. To serve expanding machine and industrial CCR consist of the PLC with their I/O module, PCs, and SCADA software. Programmable Logic Controller (PLC) is a special purpose computer with digital processing capabilities, designed for real time control in industrial and manufacturing applications. This is the place from where the whole automation of the plant is being controlled and operated.

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 To accomplish this long process for definite amount of mixing & process control for
controlling various processes of the plant, as it is operated fully automatically, that is, no manual operation is needed, for which an upgraded & better control system is needed. And for making the control system functional & to take care of various electronic measuring systems, where the field electronics have its necessity.

The plant is equipped with PLCs (Programmable Logic Controls) controlling the
whole processes of the plant from a single office namely CCR (Central Control Room) with PCs controlling the operation of each machine in the plant all around 24 hours driving each & every electrical machines with definite supplies & frequency for accomplishing cement manufacturing.

WHAT THE PLC DOES? Monitors the state of field devices by receiving signals from its input modules and
CCTV Camera.

Solves a custom user logic program via its CPU component. Directs further field activity by sending control signals to its output modules. Receives Calls from different sites of the Field and Response to them. Architecture of PLC:-

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( )

PLC

CPU Peripheral Devices Control Section

Inp Out ut put Mod ule

Field Equipment

Features of PLC: Solid-State device for maximum reliability. Programmed with simple ladder diagram language. Easily reprogrammed if requirements change. LED indication to simplify trouble shooting. Communicated to a central computer for monitoring, data gathering and reporting. PLC Description:
A programmable logic controller or PLC is a computer used for automation of real-world processes, such as control of machinery controlling process operations. Where older automated systems would use hundreds or thousands of relays, a single PLC can be programmed as a replacement. The PLC is a microprocessor based device with either modular or integral input/output circuitry that monitors the status of the field connected sensor inputs PCE/EIC/10/49/043

and controls the attached output actuators (motor starters, solenoids, pilot lights/displays, speed drives, valves, etc.) according to a user-created, logic program stored in the microprocessors battery-backed RAM memory. The functionality of the PLC has evolved over the years to include capabilities beyond typical relay control; sophisticated motion control, process control, DCS and complex networking have now been added to the PLCs list of functions. Programmable logic fig. below COMPLETE SET UP OF PLC controllers contain a variable number of Input/output (I/O) ports, and are typically Reduced Instruction Set Computer (RISC) based. They are designed for real-time use, and often must withstand harsh environments on the shop floor. The programmable logic controller circuitry monitors.

Fig shown: The complete set of PLC component.

PLC CONNECTIONS: The status of multiple sensor inputs, which control output actuators, which may be
things like motor starters, solenoids, lights and displays, or valves. The programmable logic controller has made a significant contribution to factory automation. Earlier automation systems had to use thousands of individual relays PCE/EIC/10/49/044

and cam timers, but all of the relays and timers within a factory system can often be replaced with a single programmable logic controller. Today, programmable logic controllers deliver a wide range offunctionality, including basic relay control, motion control, process control, and complex networking, as well as being used in Distributed Control Systems. Digital signals yield an on or off signal, which the programmable logic controller sees as Boolean values. Analog signals may also be used, from devices such as volume controls, and these analog signals are seen by the programmable logic controller as floating point values. There are several different types of interfaces that are used when people need to interact with the programmable logic controller to configure it or work with it. This may take the form of simple lights or switches or text displays, or for more complex systems, a computer of Web interface on a computer running a Supervisory Control and Data Acquisition (SCADA) system. Programmable logic controllers were first created to serve the automobile industry, and the first programmable logic controller project was developed in 1968 for General Motors to replace hard-wired relay systems with an electronic controller.

Expandability:

P S

C P U

RIO Driver

TYPICAL RIO SYSTEM - DUAL CABLE

PS

PS

RIOR

RIOR

The plc used in the CCR are from Siemens vendor, and of symetic type. The siemens LOGO type PLC are also used in the panel. The only PLC of ABB is the Advent controller 31. PCE/EIC/10/49/045

Connection of PLC with that of Analog Sensor:

Connection of PLC with that of Digital Sensor:

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3.10) SCADA (By F.L SMITH):

SCADA stands for the Supervisory Control And Data Acquisition. SCADA provides the animation Approach to the user for handling and operating the every part of the plant very easily by sitting in the CCR .

Fig shown: Cement Mill 1.

Features of SCADA:
SCADA provides the user compatibility access. It provides the alarms for the critical condition. It provides the recipe management facility. It provides the care safety and security to the instrument and Workers. PCE/EIC/10/49/047

It provides the security towards the redundancy and theft condition by the accurate calculation and storage of data. It provides us the various Real and Historical trends.

Fig shown: Rotary kiln.

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Fig shown: Raw Mill Yard

3.10) TYPES OF CEMENT:

There are many types of cement in the market to suit every need. Some of them which are included in the revised ISO: 456-2000 is as follows: 1) White Portland Cement. 2) Ordinary Portland Cement 33, 43, 53 grades (OPC), 53-S (Sleeper Cement) 3) Portland Pozzolana Cement (PPC), 4) Portland Slag Cement (PSC) 5) Sulphate Resisting Portland Cement (SRC) 6) Low Heat Portland Cement

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White Portland Cement (manufactured at Gotan)

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Chapter 4
Sensor/Transducers Used in Various Section Of the Plant:
Crusher: Limit Switch, Proximity Sensor in Truck Tripler. Yard: Solenoid valve, Proximity Sensor. Raw Mill: Techo-generator, RTD, Load cell, Proximity sensor, Limit switch, Folaphone, Pressure transmitters, Pressure meter, Level sensor (digital type). Silo: Radar level sensor (analog type), RTD. Pre Heater: Pressure meter in analyzer, Rota meter, PLC, Thermocouple in analyzer. Kiln: Thermocouple, Proximity sensor. Cement Mill: Proximity Sensor, Limit Switch, Load Cell, Solenoid valve, RTD, PID controller Valve. Cement Silo: Radar level sensor (analog type), RTD, Solenoid valve (for compressor o/p at the bottom of Silo). Packing Plant: Proximity Sensor, Load cell, Photo sensor, Solenoid valve, Pressure Switch, Pneumatic Valve, Sonotrode, VFD, PLC, NRV (Not return valve).

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CHAPTER 5

Scope of Instrumentation Department:

Aims/Objectives and Scope of Instrumentation Department:

The instrumentation department in cement plant has various aims and responsibilities: The Instrumentation Department is to maintain and control the healthy Automation in the plant. The Instrumentation Department is responsible for the maintenance of the various transducer and electronics gadget. The Instrumentation Department aims to provide the safety at the work site by the installation of various Sensor and safety Equipment. The inst. Department is responsible for the erection of the different machines and Gadgets. The inst. Department is responsible for all the design of communication networking inside the plant, to handle any problem in communication and to solve it. Maintenance and operation of various process PLCs, VFD, W/f, Sub-panel, analog and digital Panel and Junction Box. The Instrumentation Department is the Analyzer Handlers, Telephone exchange, Air conditioner, and UPS handlers.

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CHAPTER 5

PRECAUTION AND SAFETY

Precautions/safety condition that must be taken while working in the Plant:
One must wear the Helmet every time while inside the Plant. The working persons must have the special tough shoes. No Inflammable material is allowed inside the Plant. One must not use the compressor Air for personal cleaning. The faulty/damaged Instrument should not be used. The person should use the Nozzle-mask while in an area of high Dust. Any Chemical, Liquor or drugs by the Personal is strictly prohibited inside the Plant. Tools and Equipment must be checked before taking into the use.

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CHAPTER 6 REFERENCES

References
For drawings and functional Diagram: JK white cement drawing office. Practical Implementation Demo by: Om Prakash Sir. All written words are from the Manuals of different section of plant from library/drawing office. JKWC: Lib: CR: 04/ about the crusher component and working. JKWC: Lib: CR: 10/ about the sensors used and functioning in YARD. JKWC: Lib: KL: 28/ about the mechanical dimensions and 3 tier system. JKWC: Lib: PH: I: 02/ preheater component and working. JKWC: Lib: RMS: I: 01/ about the Raw Mill and the Folaphone sensors used. JKWC: Lib: INST: I: 48/ about the instrument used in Raw mill. JKWC: Lib: INST:I:82/ about the cooling Tower and instrumentation mounted, JKWC: Lib: PP:I:04/ about the HAVERs and Packers JKWC: Lib: CM3: I: 18/ about the cement mill 3 and inst. Mounted. JKWC: Lib: CCR: I: 19/ about the CCR and the PLC component. JKWC: Lib: INST:I: 58/ about the inst. In Gas analyzer. JKWC: Lib: INST: I: 63/ about the installation, maintenance of Inductive Proximity sensor. JKWC: Lib: INST: I: 86/ about the Pressure Transmitters. JKWC: Lib: INST:I:44/manual to show the various sensors used in the preheater. JKWC: Lib: RMS: I: 01/about Isolators. JKWC: Lib: RMS: I: 12/about weigh-feeder, VFD.

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CHAPTER 7 THANKING YOU

Thanking You
I am very grateful to all the members of the instrumentation department for their valuable practical guidance and clear Explanation.

This is my sincere thanks to all the Engineers of the department specially Rahul Sir, Om Prakash Sir, Nikhil Sir, Dharmendra Sir, for their support.

Also a great thanks to all the technical staff for helping me in analyzing the practical aspect of our course studies.

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