A

SEMINAR REPORT
On
SUMMER TRAINING
Undergone
ULTRA TECH CEMENT
KOTPUTLI(JAIPUR)
Submitted
By
MUKESH JAKHAR
Department of
Mechanical Engineering

Raffles University
Neemrana
Year 2015

ACKNOWLEDGEMENT
As a part of engineering curriculum, I have been placed in ULTRA TECH CEMENT
KOTPUTLI . The summer training at ULTRA TECH Cement Works was a great
experience to me.
I am very grateful to Mr. G.C.Pant for his guidance & useful lectures.In addition, I pay my
sincere thanks to all staff and workers of KOTPUTLI CEMENT WORKS for their help
during practical training.

(Mukesh Jakhar )

INDEX
S.No.

Topic

Page No.

Introduction of birla cement works

5-6

Cement

7-8

Manufacturing process

9-15

Instrumentation & Automation in cement

16-19

Sensor

20-21

Resistance thermometer

22-23

Programmable logic control

24-30

Safety

31-32

Some good habits

33

10

Application & Advantages of cement

34

11

Conclusion

35

FIGURE INDEX
S.No.

Name

Page No.

3.1

Mining process

3.2

Preheater tower

11

3.3

Pyro processing

12

3.4

Clinker & Grinding

14

3.5

Packing process

15

5.1

General use of sensor

20

6.1

Film thermometer

22

6.2

Wire-Wound thermometer

22

7.1

Programmable logic control

25

7.2

Ladder logic

27

7.3

Programming

28

7.4

PLC Connection

28

7.5

Ladder logic input

29

7.6

Ladder logic output

29

7.7

Ladder logic output

30

TABLE INDEX
S.No.

Name

Page No.

Table No. 2.1

Table No. 2.2

Table No. 4.1

17

Table No. 4.2

18

Table No. 4.3

18

Table No. 4.4

18

Table No. 4.5

19

Table No. 4.6

19

1.INTRODUCTION OF BIRLA CEMENT WORKS

1.1 History Behind Birla Cement

Grasim Industries Limited, a flagship company of the Aditya Birla Group, ranks among
Indias largest private sector companies. Starting as a textiles manufacturer in 1948, six
years later Grasim pioneered the production of viscose staple fibre (VSF), a man-made
biodegradable fibre with characteristics akin to cotton. Today, Grasim is the countrys
largest producer of VSF and the largest manufacturer of caustic soda, which is used in the
production VSF.
In mid 1980s, with the opening up of the cement industry, Grasim diversified into cement.
In 1998, Grasim acquired from its group company Indian Rayon & Industries Ltd., a
cement capacity of 3.2 million tonnes. In 1999, it acquired Shree Digvijay Cement
Company Ltd. (SDCCL) from the Kolkata based Bangurs. SDCCL had a cement plant of
1.1 million tonnes
ADITYA BIRLA GROUP is a multi product, multi interest Rs. 5000/- crore plus
conglomerate. It plays significant roles in the cement, jute products, blended yarn, PVC
floor covering, carbide, industrial gases, auto trim and steel casting industries.
The story of Birla Corporation Limited began 85 years ago, when the young G. D. Birla
came to the then Calcutta. A man of vision and Enterprise, Shri Ganshyam Dasji set up the
first Indian owned jute mill near Kolkata. The year was 1919.
The name of the company was changed to Birla Jute & Industries Ltd. in 1983. In view of
the opportunities offered by the liberalized, fast growing economy and to promote brand
equity and international image, the name was changed to Birla Corp Limited in 1997. In
1998, the name was changed to Birla Corporation Limited, to establish the size, image and
conglomerate character of the company.
It was Shri Madhav Prasadji Birla (nephew of Shri G.D. Birla) who gave shape to the
world of Birla Corporation Limited. As chairman of the company he helped transform it
from a manufacturer of jute goods to a leading multiproduct corporation with widespread
activities.

1.2 Plant and their capacity

The seven cement plants under Birla Corporation Limited are:

Cement unit
Satna cement works

Established In
1959

Capacity
15, 50,000 Tonnes

Birla vikas cement

Raebareli
Birla cement works
Chanderia cement works
Durgapur cement works
Durga hitech cement

1982
1998
1967
1986
1974
2004

15, 50,000 Tonnes

6, 30, 000 Tonnes
20, 00, 000 Tonnes
20, 00, 000 Tonnes
6, 00,000 Tonnes
10, 00,000 Tonnes

Types of cement made here are:

Ordinary Portland cement [OPC]

Portland puzzolana cement [PPC]
Low alkali Portland cement
Portland slag cement

1.3 Awards received by BCW

S. NO.
1.
2.
3.
4.
5.
6.
7.

8.

9.

Name of Award
Awarding Institute
ISO 9001 : 2000 Certification BVQI, UK in 2002 to BCW
& CCW
IS / ISO : 14001 Certification BIS, New Delhi in 2002 to
BCW & CCW
Best Productivity Award
NPC to CCW in 1989-90 &
again in 1993-94
Best improvement in Thermal NCB to BCW in 1992-93
Energy Performance
Best improvement in Energy NCB to BCW in 1992-93
Performance
Bhama Shah Award for
Government of Rajasthan to
Educational Activities
BCW in 1996-97
Excellent award for
IIT, Chennai & Vibration
Maintaining Health
Engineers Consultants (P)
Condition of Machinery
Ltd. to BCW & CCW in
1996-97
Merit Award
VEC (P) Ltd., Chennai for
sustained implementation of
condition monitoring and
continued machine health
improvement in 2001.
Workers Education Trophy
Central Board for Workers
Education, Udaipur, Ministry
of Labour, Government of
India to BCW & CCW in

10.

1998-99 and again in 200102

Regional Training Centre
(North), Nimbahera in 199899, 2000-01 & 2001-02.

Best Supporting Core Plant

2. CEMENT
Cement can be defined as any substance, which can join or unite two or more pieces of
some other substance together to form a unit mass. Cement, as used in construction
industries, is a fine powder which when mixed with water and allowed to set and harden can
join different components or members together to give a mechanically strong structure.

2.1. History of Cement

The history of cement is the story of civilization from Egyptians utilized gypsum plaster as
cementing material as early as 3000 BC building their monuments. However, It was in
1824, sixty-eighty years after the discovery of hydraulic properties of lime Joseph Aspdin
patented his product, which was called "Portland Cement" The plants manufacturing
portland cement outside England were commissioned in Belgium and Germany in 1855.
The interest that is evoked in the technology of cement resulted in the development of
Rotary kilns in 1886. Modern cement is the outcome of the combined research and
development efforts of chemists, technologists and architects.
Types of Cement

Application

Ordinary Portland Cement (OPC)

General construction

Portland Slag Cement

General construction and marine works.

Portland Pozzolona Cement (PPC)

General construction, hydraulic construction &

marine.

White Portland Cement

Architectural purposes, decorative work and in

manufacturing of titles.

Oil Well Cement

Connecting the steel casing to the walls of gas oil

wells at high temperature and to seal porous
formations in petroleum industry.

Low Heat Portland Cement

Where low heat on hydration is required as in mass

concrete for dams.

Super Sulphated Cement

In a varity of aggressive conditions like marine

works, concrete sewers carrying industrial effluents.

High Alumina Cement

Mainly as refractory cement and as structural

material giving high early strength development in
cold regions.
Table 1.1

2.2. Raw Material

2.2.1. Ingredients
Limestone (calcareous) and clays (argillaceous) are the conventional raw materials mostly
used in cement industry. Sometimes sandstone (siliceous),bauxite (aluminous) and iron ore
(ferruginous) are used, as corrective material to maintain desired composition for potential
property of clinker.
2.2.2. Technological Assessment of Raw Material
Raw materials are characterized by
Chemical composition
Mineral composition
Physical composition
Mechanical characteristics

2.3. Composition of Ordinary Cement

Ordinary Portland Cement is the basic cement and it has three grades namely 33, 43 and 53
respectively.
Cement consumption growth is highly correlated to the GDP growth and serves as a leading
indicator.
Ingredient
Percentage
Range
lime

64

64-68

Silica

22

17-25

Alumina

3-6

Calcium sulphate

3-5

Iron Oxide

3-4

Magnesia

0.1-3.0

Sulphur

1-3

Alkalize

0.2-1.0

Table 2.2

3. MANUFACTURING PROCESS
There are three production lines involving five significant manufacturing stages, namely
crushing, raw meal grinding, clinkerisation, cement grinding and packing.
Basic steps involved in the manufacture of cement are :
3.1.
Mining
3.2.
Crushing
3.3. Stacking and reclaiming
3.4. Raw material grinding
3.5. Raw meal storage & blending
3.6. Preheating and burning
3.7. Clinker cooling
3.8. Clinker storage
3.9. Clinker grinding
3.10. Cement storage in silos
3.11. Packing & dispatch

3.1. MINING
Most of the raw materials used are extracted from the earth through mining and quarrying
and can be divided into the following groups:
lime (calcareous), silica (siliceous), alumina (argillaceous) and iron (ferriferous).
Quarry operations consist of drilling, blasting, excavating, handling, loading, hauling,
crushing, screening, stockpiling, and storing.
Mining Functions :
Planning and executing a systematic exploration programme.
Draw scope of drilling campaign. How to carry out survey and perform drilling
activities for exploration purpose.
Establish system for computerized mine-planning in order to ensure supply of
limestone with consistent quality.
Planning and executing drilling and
blasting program in normal course at
site to take optimum output from
blasting as well as achieving
economy in explosive consumption.
Loading and transportation of lime
stone boulders to crusher site.
Implementing statutory requirement
for safety and environment.
Approximate boulder size : 1.0 M *
1.4 M * 1.1M
Figure 3.1

3.2. CRUSHING
It is a process in which the limestone from the mines comes into the crusher for further size
reduction. This process is based on the reduction ratio (R).
The size is reduced from 1.0M * 1.4M * 1.1M boulder to 25mm size of limestone pieces.
R = largest linear dimension of material before crushing
largest linear dimension of material after crushing
Common type of Crushers used are :
Double Toggle Jaw Crusher is used as primary crusher & capacity is 400 TPH.
Swing Hammer Crusher is used as secondary crusher & capacity is 200 TPH.
Compound Impactor is combined unit of primary and secondary crusher & capacity
is 800 TPH.

3.3. STACKING
Stacker : The stacker moves on longitudinal rails longitudinal pile is formed.
Details of Piles: 20000 30000 tonnes per pile. Height of pile upto 11.00 meters.
Rated capacity : 1000 tonnes per hour. It varies from plant to plant depending upon the
production requirement. In stacking, limestone and clay are metered and fed simultaneously
to the feed conveyor for Homogenization process.
There are two major Stacking systems :

Chevron : Stacking is done in layers along single axis with the feed conveyor
sweeping backwards and forward along the length of pile on the longitudinal rail.
Windrow : Stacking is done in longitudinal strips side by side and then in
successive layers. This avoids segregation which is the characteristics shown by
Chevron Stacking. Windrow requires more complex and expensive stacking belt
arrangement.

3.4. RECLAIMING
Reclaimer cuts Stack Pile in slice from parallel to face of pile. Shifting material (limestone)
to belt with the help of scrapper. The Reclaimer reclaims the stack piles of raw meal using a
Bridge Scrapper type Reclaimer which cuts stack pile into slice from parallel to face of pile
shifting limestone to belt.of the scrapper.
Type: Bridge Scrapper Type.
Rated Capacity : 600 tonnes per hour. It will vary from plant to plant depending on the
production requirement (in TPD).
There are two types of Reclaims are available:

End Reclaim : The Reclaim Drag Chain scraps the end of the pile and limestone is
shifted to the discharge conveyor.
Side Reclaim : The Reclaim Drag Chain scraps the pile sideways and reclaim boom
provide raw material to the discharge conveyor.

3.5. RAW MILL GRINDING

Raw milling involves mixing the extracted raw materials to obtain the correct chemical
configuration and grinding them to achieve the proper particle-size, to ensure optimal fuel
efficiency in the cement kiln and strength in the final concrete product.
Transport belt conveyor transfers the blended raw materials to ball mills where it is ground.
The chemical analysis is again checked to ensure excellent quality control of the product.
The resulting ground and dried raw meal is sent to a homogenizing and storage silo for
further blending before being burnt in the kilns.
In the dry process, each raw material is proportioned to meet a desired chemical
composition and fed to either a rotating ball mill or vertical roller mill. The raw materials
are dried with waste process gases and ground to a size where the majority of the materials
are less than 75 microns. The dry materials exiting either type of mill are called "kiln feed".
The kiln feed is pneumatically blended to insure the chemical composition of the kiln feed
is well homogenized and then stored in silos until required.

3.6. RAW MEAL STORAGE AND BLENDING

Raw meal after Grinding is stored in large silos until required for further process.
The rawmix is formulated to a very tight chemical specification. Calcium and silicon are
present in order to form the strength-producing calcium silicates. Aluminium and iron are
used in order to produce liquid ("flux") in the kiln burning zone. The liquid acts as a solvent
for the silicate-forming reactions, and allows these to occur at an economically low
temperature. Insufficient aluminum and iron lead to difficult burning of the clinker, while
excessive amounts lead to low strength due to dilution of the silicates by aluminates and
ferrites. The relative amounts of each oxide are therefore kept constant in order to maintain
steady conditions in the kiln, and to maintain constant product properties. Remaining
chemical variation is minimized by passing the raw mix through a blending system that
homogenizes up to a day's supply of rawmix (15,000 tonnes in the case of a large kiln).
Pneumatic dry Blending involves consists of porous ceramic plates or fibers covered boxes
permeable to air. The is passed into the raw meal through the porous plates where the fine
air current fluidize the raw meal.

3.7. PREHEATING AND BURNING

The raw meal is fed into the preheater tower
equipped with four cyclone stages. In the dry
process, Preheater Tower is150 meters high.
Material from the preheater tower is discharged
to a rotary kiln having the same diameter as a
wet process kiln i.e.2-3 meters but the length is
much shorter approximately 45.0 m. The
preheater tower and rotary kiln are made of
steel and lined with special refractory materials
to protect it from the high process temperatures

As raw meal falls in the preheater tower, the meal is heated up by the rising hot gases and
reaches 800C. At this temperature, the meal dehydrates and partially decarbonizes.
In per-heater kiln, the first five transformations will take place in pre-heater tower.
The decomposition of limestone and other carbonates will primarily take place in the
calciner vessel where the calculate of temperature is maintained by injection of fuel. The
last two transformations will take place in the rotary kiln.
Figure 3.2
The carbonate CaCO3 decomposes between 600 800oC to
form CaO. Quartz and clay will have started decomposing slightly before that to liberate
free reactive Al2O3 and SiO2.
The CaO being formed at this stage, now reacts with SiO 2 to form C2S and later with more
CaO to form C3S. Some CaO will also react with Al2O3 and Fe2O3 to form various
intermediate components such as CA, C12A7 and others, which will decompose at higher
temperature at later stage.
C2S content is seen to grow steadily during the heating and reach maximum content at
approx. 1300oC which is a point where liquid phase appears. The major part of C 2S is then
transformed to C3S in the liquid phase and the final content of C 2S in the clinker is less than
the content of C3S.
The meal then enters a sloping rotary kiln, which is heated by a 1,800C flame, which
completes the burning process of the meal. The meal is heated to a temperature of at least
1450C. At this temperature the chemical changes required to produce cement clinker are
achieved. The dry process kiln is shorter than the wet process kiln and is the most fuelefficient method of cement production available.
3.7.1. PYROPROCESSING
In order to manufacture cement from the raw mix, it is required to heat raw meal to a
temperature of 1450oC, thus
carrying out SINTERING OR
CLINKERISATION. The burning
process requires an oxidising
atmosphere in the kiln, the
clinker of brown colour (contrary
to the normal greenish gray) will
be formed and the resulting
cement will be quicker setting
and with lower strength. Clinkers
are hard, gray, spherical nodules
with diameters ranging from 0.32
- 5.0 cm (1/8 - 2") created from
the chemical reactions between
Figure 3.3
the raw mtrs.
The pyroprocessing system involves three steps:
a. Drying or Preheating (dehydration of the argillaceous minerals)
b. Calcining (decarbonisation or expulsion of CO2)
c. Burning (reactions in solid phase and reactions with the participation of one liquid
phase and crystallizations)
The raw mix is supplied to the system as a slurry (wet process), a powder (dry process). For
the wet and dry processes, all pyroprocessing operations take place in the rotary kiln, while
drying and preheating and some of the calcination are performed outside the kiln on moving

grates supplied with hot kiln gases. These processes are influenced by chemical factors in
the raw meal (such as its chemical composition), by mineralogical factors (its mineralogical
composition), by physical factors (fineness or particle size in the raw meal), homogeneity
and other factors. The complete course of these endothermic reactions plays a decisive role
in quality of the resulting cements.

3.8. CLINKER COOLING

The clinker cooling operation recovers up to 30% of kiln system heat, preserves the ideal
product qualities, and enables the cooled clinker to be maneuvered by conveyors. The
clinker discharging from the kiln is cooled by air to a temperature of 70C above ambient
temperature and heat is recovered for the process to improve fuel efficiency. The most
common types of clinker coolers are reciprocating grate, planetary, and rotary. Air sent
through the clinker to cool it is directed to the rotary kiln where it nourishes fuel
combustion. The fairly coarse dust collected from clinker coolers is comprised of cement
minerals and is restored to the operation. Based on the cooling efficiency and desired cooled
temperature, the amount of air used in this cooling process is approximately 1-2 kg/kg of
clinker. The rotary kiln discharges the red-hot clinker under the intense flame into a clinker
cooler. The clinker cooler recovers heat from the clinker and returns the heat to the
pyroprocessing system thus reducing fuel consumption and improving energy efficiency.
Clinker leaving the clinker cooler is at a temperature conducive to being handled on
standard conveying equipment.

3.9. CLINKER STORAGE

Some of the air from the cooler is dedusted and supplied to the coal grinding Plant. The remaining
air is used as preheated secondary air for the main combustion burner in the kiln. Clinker is analyzed
to ensure consistent product quality as it leaves the cooler. Metal conveyors transport the clinker to
closed storage areas.
The black, nodular clinker is stored on site in silos or clinker domes until needed for cement
production, a plant can normally store 5-25% of the total clinker. Equipment such as conveyors and
bucket elevators is used to transfer the clinkers from coolers to storage areas and to the finish mill.
Gravity drops and transfer points typically are vented to dust collectors.

3.10. CLINKER GRINDING

Fineness of output materials
Raw Mix :
15 17 % Residue
1.8 2.2 % Residue
Coal Powder :
15 17% Residue
18-22 % Residue
Cement :
33 Grade 2600 To 2800 Blaine
43 Grade 2850 To 3000 Blaine
53
Grade 3200 To 3400 Blaine
Grinding Systems :
Ball Mill
Vertical Roller Mill
Combination of Roller Press and Ball Mill
(Generally open circuit is used in wet process and closed circuit is used in dry process. In
closed circuit systems, fixed and dynamic separators are used.)
In the manufacture of Portland cement, clinker is the solid material produced by the cement
kiln stage that has sintered into lumps or nodules, typically of diameter 3-25 mm. Clinker is

ground (usually with the addition of a little gypsum, that is, calcium sulfate dihydrate) to
become Portland cement. It may also be combined with other active ingredients or organic
compounds to avoid powder agglomeration. Triethanolamine (TEA) is commonly used at
0.1 wt. % and is proved to be very effective. Other additives are sometimes used, such as
ethylene glycol, oleic acid, dodecylbenzene sulfonic acid.
During the final ,,stage of portland cement production known as finish milling, the clinker is
ground with other materials (which impart special characteristics to the finished product)
into a fine powder. Up to 5% gypsum or natural anhydrite is added to regulate the setting
time of the cement. Other chemicals, such as those which regulate flowability or air
entrainment, may also be added. Many plants use a roll crusher to achieve a preliminary
size reduction of the clinker and gypsum. These materials are then sent through ball or tube
mills (rotating, horizontal steel cylinders containing steel alloy balls) which perform the
remaining grinding. The grinding process occurs in a closed system with an air separator
that divides the cement particles according to size. Material that has not been completely
ground is sent through the system again.
http://en.wikipedia.org/wiki/File:LDFMBallMill.jpgA ball mill is a horizontal cylinder
partly filled with steel ball that rotates on its axis, imparting a tumbling and cascading
action to the balls. Material fed through the mill is crushed by impact and ground by
attrition between the balls. The smaller grades are occasionally cylindrical ("pebs") rather
than spherical. Ball mills are normally operated at around 75% of critical speed, so a mill
with diameter 5 meters will turn at around 14 rpm.
The mill is usually divided into two chambers, allowing the use of different sizes of

Figure 3.4
grinding media. The grinding media are usually made of high-chromium steel. Large balls
are used at the inlet, to crush clinker nodules (which can be over 25 mm in diameter). Ball
diameter here is in the range 60-80 mm. In a two-chamber mill, the media in the second
chamber are typically in the range 15-40 mm, although media down to 5 mm are sometimes
encountered.
A current of air is passed through the mill. This helps keep the mill cool, and sweeps out
evaporated moisture which would otherwise cause hydration and disrupt material flow. The
dusty exhaust air is cleaned, usually with bag filters.

3.11 PACKING AND LOADING

Once the production of portland cement is complete, the

finished product is transferred using bucket elevators and
conveyors to large storage silos in the shipping department.
Each cement product is stored in an individual bulk silo until
needed by the customer. Bulk cement can be distributed in
bulk by truck, rail, or water depending on the customer's
needs. Cement can also be packaged with or without color
addition and distributed by truck or rail.
Most of the portland cement is transported by railway, truck,
or barge, or in 43 kg (94 pound) multiwalled paper bags used
primarily to package masonry cement.Once the cement leaves
the plant, distribution terminals are sometimes used as an
intermediately holding location prior to customer distribution.
Figure 3.5

4. INSTRUMENTATION & AUTOMATION IN CEMENT

4.1. History & Advances in Automation :
The modern cement plant today is equipped with latest technology of automation. The
automation of cement plant is comparable to any industry such as steel, petroleum etc.
Some of the rate feats of Indian Cement Industry are :

First programmable controller was introduced in 1978.

Thyristor/Transistor based analogue variable speed AC drive in various applications.
First fuzzy control for cement got commissioned in 1987.
Most powerful advance SCADA/DCS are in use since 1986-2000.
The cement plants in India are very competitive today; they are very efficient in terms of
thermal & electrical energy consumption, in terms of productivity.
Some of the latest Plants commissioned in 2004 are operating at 72kWh/ton of cement.
Today we can control plant from remote distance. The same can be demonstrated at
Chittorgarh.
the CCR of typical Cement Plant of 1 million tons/annum capacity is equipped with
atleast 4-Operator Stations (OS).
Seven colour desktops are available for Kiln, raw mill & Cooler burning view and some
communication facility such as Phones, Wireless and PA system etc.

4.2. Needs of Process Control Automation :

Every Industrial Process has three types of main flows :
Material Flow
Energy flow
Information Flow
So the aim of Plant Automation is to identify the Information flow i.e. to take related
information and control material and enegey flow in desired manner.

4.3. Benefits of Automation:

Increase in production
Improvement in quality
Reduction in cost
Optimal use of available resources

Environmental pollution control

Safety

4.4. Typical Automation measurement in cement plant :

crusher
o BRG Temperature
Stacker & Reclaimer
o Maximum level of material
o Maximum travel
Ball Mill
o BRG Temperature
o Oil flow & Pressure
o Sound level
Vertical Mill
o Vibration
o Presence of metal
Kiln System
o BRG Temperature
o Shell & Lining temperature
o Position (L.S. UP, DN)
Larger Motors
o WNG & BRG Temperature
o Cooling Air flow & PR
Elevators
o Alignment
o Speed Monitor
Conveyors
o Alignment (Belt Sway)
o Speed Monitor

4.5. Instruments/Equipments used in cement industry

I. CRUSHER
S.No. Equipment Name

Location

Application

1.

Apron Feeder

Crusher

To measure & control speed of apron

feeder

2.

Laterite Feeder

Crusher

To measure & control the feed of

Laterite (Additive)

3.

Wireless

Crusher, Stacker, To send & receive information from & to

Communication
4.

Reclaimer

CCR from moving equipments.

Power
Measurement

Power Calculation
Table 4.1

2.RAW MILL
S.No.

Equipment
Name

Location

Application

Weight
Feeders

Inlet
Mill

Metal Detector

To detect metal pieces on belts.

Metal
Separator

To separate metal pieces from raw material which is

detected by metal detector.

Power

Mill Power

to To feed & control limestone & Laterite to raw mill

inlet in raw mill.

Table 4.2
3.ESP, GCT & PREHEATER
S.No. Equipment
Name

Location

1.

Thermocouple

Bottom of For
cyclone K Type
cyclone
material
temperature.

2.

Thermocouple

top
of For cyclone gas K Type
cyclone
temperature.

3.

Draught
(PR Tx.)

Bottom of For
cyclone Gives idea of material feeded in
cyclone
bottom draught
cyclone & also idea of cyclonic
action taking place

ESP panel

ESP Panel

4.

Application

Other information

To measure &
control kV & mA
Table 4.3

4.BELTS
S.No.

Equipment Name

Location

Table 4.4

Application

5.PACKING PLANT
S.No. Equipment
Name

Location

Application

Other
information

1.

Level
sensors

In
various To sense level
hoppers/tanks,
feeding MAT. To
PKR.

2.

Proximity
Switches

Bag conveying belts

To sense belt running

3.

Limit
Switches

Packer

For
providing
various
safeties in PKR like
pendulum switch, pull cord
surrounding PKR etc.

4.

Solenoid
Valves

Packer

For performing
actions

E
&H/
Sapcon make

various

Involved in bag filling to

evacuation.
Table 4.5
7.KILN & COOLER SECTION
S.No. Equipment
Name

Location

Application

Other information

1.

Thermocouple

Kiln inlet

For measuring Kiln inlet

temperature.

K Type

2.

RTD

Kiln Roller For measuring kiln inlet

temperature

Shoe type RTD

3.

RTD

Kiln Gear
Box

Simple PT-100 RTD

4.

RTD

Kiln Motor For measuring kiln G.Box

oil temperature

Simple PT-100 RTD

5.

Analyzers

Kiln Inlet

For measuring kiln motor

WDG & BRG. Temperature

02 0-10%, co 0-2%,
nox 0-3000 PPM

6.

Tacho

Kiln Drive

Kiln Speed

Hubner make

7.

Solid flow
Feeder

C.F.Silo

Material feed to Kiln

J&N, Ranchi

8.

ESP panel

ESP panel

To measure & control kV &

mA

Hind Rectifier
controller

For measuring kiln roller

brg temperature

9.

AC/DC drives

Kiln
Cooler

Speed control

DC-Kiln main drive,

Fans-AC Drive

Table 4.6

5. SENSOR
A sensor is a device that measures a physical quantity and converts it into a signal which
can be read by an observer or by an instrument. For example, a mercury-in-glass
thermometer converts the measured temperature into expansion and contraction of a liquid
which can be read on a calibrated glass tube. A thermocouple converts temperature to an
output voltage which can be read by a voltmeter. For accuracy, all sensors need to be
calibrated against known standards.

5.1. USE
Sensors are used in everyday objects such as touch-sensitive elevator buttons and lamps
which dim or brighten by touching the base. There are also innumerable applications for
sensors of which most people are never aware. Applications include cars, machines,
aerospace, medicine, manufacturing and robotics.
A sensor's sensitivity indicates how much the sensor's output changes when the measured
quantity changes. For instance, if the mercury in a thermometer moves 1 cm when the
temperature changes by 1 C, the sensitivity is 1 cm/C. Sensors that measure very small
changes must have very high sensitivities. Ideal sensors are designed to be linear. The
output signal of such a sensor is linearly proportional to the value of the measured property.
The resolution of a sensor is the smallest change it can detect in the quantity that it is
measuring.

5.2. LEVEL SENSOR

5.2.1. General Application of Level Sensor :
Level Sensors designed to provide accurate and reliable level information of Solids (Powder
& Lumps), Liquids and Slurry applications for
point level detection in storage Bins, Silos,
Hoppers, Tanks and any other vessels where
material is stored, processed and discharged
even at high temperature/pressure/corrosive
applications.

Figure 5.2.1

5.2.2. Function of Level Sensor :

The oscillator generates low-power RF signal which is used to provide signals equal in
frequency phase and amplitude to both, active section and shield section of the probe. The
signal applied to the shield is held constant by use of compensating amplifier. The detector
is then used to compare the fixed shield signal with active signal which varies with the
dielectric constant of the material in contact with the probe. Difference in the signals
compared by the detector cause the output relay to activate.

6. RESISTANCE THERMOMETER
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).

6.1 Types

Film thermometers have a layer of platinum on a substrate; the layer may be extremely
thin, perhaps one micrometer. Advantages of this type are relatively low cost and fast
response. Such devices have improved in performance although the different expansion
rates of the substrate and platinum give "strain gauge" effects and stability problems.

Figure 6.1

Wire-wound thermometers can have greater accuracy, especially for wide

temperature ranges. The coil diameter provides a compromise between mechanical
stability and allowing expansion of the wire to minimize strain and consequential
drift.

Figure 6.2

6.2 Function
Resistance thermometers are constructed in a number of forms and offer greater stability,
accuracy and repeatability in some cases than thermocouples. While thermocouples use the
Seebeck effect to generate a voltage, resistance thermometers use electrical resistance and
require a power source to operate. The resistance ideally varies linearly with temperature.
Resistance thermometers require a small current to be passed through in order to determine
the resistance. This can cause resistive heating, and manufacturers' limits should always be
followed along with heat path considerations in design. Care should also be taken to avoid
any strains on the resistance thermometer in its application. Lead wire resistance should be
considered, and adopting three and four wire connections can eliminate connection lead
resistance effects from measurements.The two most common ways of measuring industrial
temperatures are with resistance temperature detectors (RTDs) and thermocouples.
Selection criteria: - Temperature, time, size, and overall accuracy requirements.

7. PROGRAMMABLE LOGIC CONTROL

7.1 Introduction
A programmable logic controller (PLC) or programmable controller is a digital computer
used for automation of electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or lighting fixtures. PLCs are used in many
industries and machines, such as packaging and semiconductor machines. Unlike generalpurpose computers, the PLC is designed for multiple inputs and output arrangements,
extended temperature ranges, immunity to electrical noise, and resistance to vibration and
impact. Programs to control machine operation are typically stored in battery-backed or
non-volatile memory. A PLC is an example of a real time system since ou tput results must be
produced in response to input conditions within a bounded time, otherwise unintended
operation will result.

7.2 What is Programmable Logic Control ?

A programmable logic controller (PLC) is a special data processor used as controller for
machines in industrial processes. As a part of process control, a programmable logic
controller is used to monitor input signals from a variety of input points which report events
and conditions occurring in a controlled process. During the execution of a stored control
program, they read inputs from the controlled process and, per the logic of the control
program, provide outputs to the controlled process.
On primary basis PLC is having following advantages over any other controlling element
invented before its invention :Cost effective specially for controlling complex systems.
Flexible and can be re-applied to control other systems quickly and without much
manipulation in the programme.
Computation abilities allow us do more sophisticated control.
Trouble shooting allows us to make programme more efficiently, hence reduce down
time.
The purpose of a PLC was to directly replace electromechanical relays as logic
elements, substituting instead a solid-state digital computer with a stored program, able
to emulate the interconnection of many relays to perform certain logical tasks.

Programming Devices

Power

CPU

Memory

Supply

I/O
System

Output

Modules

Devices

Input
Devices

Block Diagram PLC

Figure 7.1

7.3 Blocks of PLC

8.3.1. Inputs
8.3.2. Outputs
8.3.3. Memory
8.3.4. Central Processing unit (CPU)
8.3.5. Power Supply

7.3.1 Inputs
Input signals are real time signals. They may be analog\digital, low\high frequency etc.
But in general case they are represented as various voltages to the programmable controller
they can be from Switches, Pushbuttons, Proximity sensors etc.

7.3.2 Outputs
Output signals are generally a digital signal which is applied to three categories of output
devices.

Discrete (Pilot lights, Solenoid Valves etc.)

Register (Drive Panel meters)
Analog (Drive signals to variable speed)

7.3.3 Memory
It is the main storage area of a PLC, which is used to hold the set of instruction to be
executed by the processor/programming devices. Its size may very from 256 bytes to
several mega bytes.

7.3.4 CPU
Central processing unit is the brain of PLC controller. CPU itself is one of the
microcontroller. It perform task which are necessary to fulfill the function of PLC. Earlier it
was 8 bit microcontroller such as 8051 but now these are 16 and 32 bit microcontrollers.
CPU takes care of following functions : Scanning I/O devices (BUS traffic control)
Program execution
Memory Read/Write
External device communication
Generally speaking, CPU until makes a great no of check ups of the PLC controller itself so
eventual errors would be discovered earlier.

7.3.5 Power Supply

Power supply unit converts line voltage to a required voltage which is needed by solid
state components. Most PLC controllers work on 24 volt DC to 220 volt DC.

7.4 Main elements of PLC

While manufacturing as well as while programming a PLC following things are necessary
to keep in mind both by the manufacturer and user, they are :
7.4.1. Ladder Logic
7.4.2. Programming
7.4.3. PLC Connection
7.4.4. Ladder Logic Inputs
7.4.5. Ladder Logic Outputs

7.4.1 Ladder Logic

Ladder logic is the main programming method used for PLCs. Ladder logic has been
developed gic. By selecting ladder logic as the main programming method, the amount of
retraining needed for engineers and trades people was greatly reduced. Modern control
system still include relays, but these are rarely used for logic.
The example is shown in figure 2 does not show the entire control system, but only the
logic. When we consider a PLC these are inputs, outputs and the logic. Figure 2 shows a
more complete representation of PLC.
Here, there are two inputs from push buttons. We can imagine the inputs as activating 24
volt DC relay coils in the PLC. This is turn drives an output relay that switches 115 volt AC,
which will turn on a light. Note, in actual PLCs inputs are never relays, but outputs are
often relays.
A

Normally

Normally

Normally

Closed

Open

Open

Input A

Input B

Contactor

Figure 7.2
The ladder logic in the PLC is actually a computer program that notice that both push
buttons are normally open, but the ladder logicinside the PLC has one normally open
contact, and one normally closed contact.
The figure shows a simple ladder logic which consist of one NO-contact, NC-contact and a
contactor, can be consider as a simple relay controller.

7.4.2 Programming
The first PLCs were programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electrician, technicians and engineers how
to program a computer but, this method has stuck and it is the most common technique for
programming PLC today. Another example of ladder logic is shown in figure.

Program

To interpret the diagram imagines that the power is on the vertical line of the left hand side,
we called this the hot rail. On the right hand side is the neutral rail. In the figure 3 there are
two rungs, and on each rung there are combinations of inputs (two vertical lines) and
outputs (circle). If the input are opened or closed in the right combination the power can
flow from the hot rail, through the inputs, to power the outputs, and finally to the neutral
rail. An input can come from a sensor, switch or any other type of sensor. An output will be
some device outside the
PLC that is switched ON or
OFF, such as lights or
motors. In the top rung the
contact are normally open
and normally closed. This
means if input A is on and
input B is off, then power
will flow through the output
and activate it. Any other
combination of input values
will result in the output X
being off.

7.4.3

PLC

Figure
7.3

Connections

When a process is controlled by a PLC it uses input from sensors to make decisions and
update outputs to drive actuators, as shown in figure 4. the process is a real process that will
change over time. Actuator will drive the system to new states (or modes of operation).
This means that the controller is limited by the sensors available, if an input is not available,
the controller will have no way to detect a condition.
The control loop is a continuous cycle of the PLC reading inputs, solving the ladder logic,
and then changing the outputs. Like any computer this does not happen instantly. Figure 4
shows the basic operation cycle of a PLC.
When power is turned on initially the PLC does a quick sanity check to ensure that the
hardware is working properly. If there is a problem the PLC will halt and indicate there is an
error. For example, if the PLC battery is low and power was lost, the memory will be
corrupt and this will result in a fault. If
Connections
the PLC passes the sanity checks it will
PROCESS
then scan (read) all the inputs.
to Actuators

Feedback from

PLC

Sensors/Switche
s

Figure 7.4

After the input values are stored in

memory the ladder logic will be scanned
(solved) using the stored values not the
current values. This is done to prevent
logic problem when inputs change the
output will be scanned (the output values
will be changed). After this the system

goes back to do a sanity check, and the loop continues every scan. Typical times for each of
the stages are in the order of milliseconds.

7.4.4 Ladder Logic Input

X
Normally Open, an active input X will
close the contact and allow power to
flow
Normally Closed, power flows when

Immediate inputs will take current

the input X is not open

PLC inputs are easily represented in

ladder logic. There are three types of
inputs shown. The first two are normally
open and normally closed inscanned.
This allows ladder logic to examine
input values more often than once every
cycle.

values, not those from the previous

input scan. (NOTE: this instruction is
X

actually an output that will update the

II
T

input table with the current input

values. Other input contacts can now be
used to examine the new values.)

Figure 7.5

7.4.5 Ladder Logic Output

In ladder logic there are multiple type of outputs, but these are not consistently available on
all PLCs. Some of the output will be externally connected to devices outside the PLC, but it
is also possible to use internal memory locations in the PLC.
Three types of output are shown in figure.
When power is applied (ON)
the

output X is activated for the left

output, turned off for the output
X

An input transition on will cause

X

OS
R

the output x to go on for one

scan

Figure 7.6

The first is the normal output, when

energized the output will turn on, and
energize an output.
The circle with a diagonal line through
is a normally on output. When
energized the output will turn off. This
type of output is not available on all
PLC types. When initially energized
the OSR (One Shot Relay) instruction
will turn on for one scan.

When the L coil is energized, X will

X

be toggled on; it will stay on until

L
the U coil is energized. This is like
a flip flop and stays set even when

PLC will
is turned
ON.
Somethe
PLCs
allow immediate
U

Outputs that do not wait for the

Program scan to end before setting
An output. (NOTE: This instruction

IO
T

will only updates the outputs using

The L (latch) and (unlatch)

instruction can be used to locks
output on. When an L output is
energized the output will turn on
indefinitely, even when the output
coil is reenergized. The output can
only be turned off using a U output.
The last instruction is the IOT
(Immediate Output) that will allow
outputs to be updated without
having to wait for the ladder
logiccompleted.

The output table, other instruction

Figure 7.7

Must change the individual outputs.)

7.4.6 Communications
PLCs have built in communications ports usually 9-Pin RS232, and optionally for
RS485and Ethernet. Modbus, BACnet or DF1 is usually included as one of the
communications protocols. Other options include various field buses such as Device Net or
Profibus. Other communications protocols that may be used. Most modern PLCs can
communicate over a network to some other system, such as a computer running a SCADA
(Supervisory Control and Data Acquisition) system or web browser.
PLCs used in larger I/O systems may have peer-to-peer (P2P) communication between
processors. This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link. These communication
links are also often used for HMI devices such as keypads or PC-type workstations. Some
of today's PLCs can communicate over a wide range of media including RS485, Coaxial,
and even Ethernet.

8.SAFTEY:
In any Industry there are many chances of accidents, so it is very important
to take precaution measures for personnel safety like helmet and shoes. And the most
important thing is that a person have to be alert because accident occurs only due to
ones carelessness or overconfident. In an industry the carelessness of one person may
cost lives of many.
When we go to any industry then we should at first see all the exits from the industry,
then the knowledge of the products of the factory and in what way these products are
dangerous to us is a must. Following are some of the safety measures: In any industry or
in our personal life at every step safety is very important. In any

8.1 Safety can be achieved by the following five methods:

Engineering method

To prevent unsafe acts

Enforcement

To follow safety rules

Education and training

Enthusiasm

Example

To prevent unsafe acts

To maintain interest

To lead them to the correct way to

ensure safety

8.2 For safety following points should be taken into considaration

1. Safety in the use of hand tools.
2. Safety measures for different operation activities.
3.

Personal protective equipments for safety from toxic gases.

4. Helmets and fully covered flat shoes should be used.

5. If we are working on electrical instruments, we must ensure removal of fuses and

keep it in custody.
6. Use Proper insulated tools, hand gloves and shoes.
7. If working in acid area, acid proof clothes, hand gloves and shoes must be used.

8.3 SAFETY & HOUSEKEEPING

Keep yourself fully aware of the safety and fire hazards in your work area, all
preventives measures and safety system.
Make note of unsafe acts and unsafe practices in your work area and make an
immediate attempt to eliminate these. If you cannot, report to your superior. Do not
hesitate to correct any employee if see indulging in any unsafe act.

Follow all safety rules and regulations, including precautions for fire prevention.

Be fully aware of all operational measures to be taken in case of an emergency or an

accident.

Always keep your equipment and work area clean. Keep all items, paper, files,
spares, leaf tuck-skids, etc. in an orderly manner in places meant for the purpose, so that
you can find these promptly when needed.

9. SOME GOOD HABITS

Give due credit to others for their achievements and share credit
with other for your own achievements.
Recognize need for interdependence and cultivate an attitude to
team work.
Share your knowledge and experience with others and respect the
knowledge and expertise of other learn from them.
Help other in solving problems.
Politeness and courtesy always pay.
Be alert to the causes and indications of problems.
Rectify problems using your own knowledge, expertise and skills at
the first instance. Do not hesitate to seek help from others.
Keep a proper record of all problems, their analysis and action
taken. These become useful case studies for future reference and
learning.
Be punctual at your work place.
Resolve any differences with others on one-to-one basis. Seek help,
if necessary, from others including your superiors.

10.APPLICATION & ADVANTAGES OF CEMENT

10.1 Application

Building (floors, beams, columns, roofing, piles, bricks, mortar, panels, plaster).

Transport (roads, pathways, crossings, bridges, sleepers, viaducts, tunnels,

stabilization, runways, parking).

Water (pipes, culverts, kerbing, drains, canals, weirs, dams, tanks, pools).

Civil (piers, docks, retaining walls, silos, warehousing, poles, pylons, fencing).

Agriculture (buildings, processing, housing, feedlots, irrigation).

10.2 Advantages

Cement is very strong.

It can create large structures quickly.

It conforms to different shapes (arcs and circles, etc).

It has high thermal mass (moderates temperature

11.CONCLUSION
It was a great experience to be there in BCW for my practical training and like every good
thing it had to come to an end and so it did.

During the 30 days I certainly learnt a lot about every aspect of this field right from the
working environment to the technical details of various equipment and process relating
to my branch. I certainly learnt a lot about the mechanical accessories used in all plant
especially

The things are numerous while words are only few. To conclude I would rather say that
even after my full try I could pick up only a mouthful of knowledge out of sea. The time
was really less while there was lot to learn

Well thats how the life goes on. I hope I would have another chance to visit and learn more
if it.