GENERAL COMBUSTION INTERLOCKS

Customer: CBMEC for Arkan cement in UAE Contract number: 07.44.13.65.00

Combustion interlocks and process safeties

The interlocking conditions listed (combustion interlocks) in the following are to be intended as
additional technological conditions for the start up and operation of the kiln main burner and the calciner
burners, beyond the “machines” and “sequence” interlocks programmed by CBMEC which are intrinsic to our
two firing system units (see chapter 8 Functional Description of User Guideline for more details). In addition,
the customer is free to add his own safeties in order to stop the burners {process safeties = combustion
interlocks (requested by Fives Pillard) + customers safeties}

1. Kiln main burner (release for burner light-up and fuels feeding into the burner)
1.1 Operating modes of the burner

At present time, it must be possible to operate the kiln main burner in the following mode:

− Natural gas firing from DCS (from CCR Central Control Room)

− Natural gas firing from BMS cabinet on kiln burner platform (BMS = Burner Management System)

1.2 General starting interlocks {valid for feed of any fuel (HFO, natural gas ...) to kiln burner}

The authorization for natural gas feeding into the burner can be released only while;

a. DCS is getting the feedback that ignition flame is effectively present {this can be provided and
managed by auxiliary igniting device equipped with flame detection (ignition spark given by electric
standard "igniter" in many instances)} if not (one none electric torch in use) operator must keep a
watch on flame presence. Operators notice, it is absolutely forbidden to start-up the natural gas
burner without any igniting device.
b. The frequency of primary air fan is higher than the minimum value (to be adjusted during
commissioning) in order to get the minimum primary air pressure of 50 mbar at inlet of the burner
(with no delay)

c. The primary air fan of calciner burners must be in run (minimum air flow rate if required by operator)
d. The gas under-pressure inside kiln hood must be higher than the L limit of ... mbar specified by
CBMEC, and lower than the H limit of ... mbar specified by CBMEC.
e. The CO (Carbon monoxide) concentration measured at kiln inlet overcomes the H limit value of ...
ppm (with a delay time of ... minutes)

f. The CO concentration measured at pre-heater outlet overcomes the H limit value of ... ppm specified
by CBMEC (with a delay time of ... minutes)

It must act as starting interlocking conditions only.

Operators will never overlap the rule a), to be more explicit it is NOT conceivable to directly feed
natural gas into the kiln burner without necessity to light up the "igniter" even if shell temperatures of
combustion chamber are higher than 750°C because it remains risky.

1.3 General process safeties and stoppage interlocks

All the following conditions must not be present in order to get the consent for feeding of any fuel to the
 GENERAL COMBUSTION INTERLOCKS
Customer: CBMEC for Arkan cement in UAE Contract number: 07.44.13.65.00

burner, during normal operation of the burning line; in case even one among the following conditions takes
place, the authorization for feeding of any fuel to kiln main burner must be interdicted (with the time delay
specified for each condition)

a. The gas under-pressure inside kiln hood goes below the LL limit value of ... mbar specified by
CBMEC (with a delay time of ... seconds)
b. The gas under-pressure inside kiln hood overcomes the HH limit of ... mbar specified by CBMEC
(with a time delay of ... seconds)

c. The CO concentration measured at pre-heater outlet overcomes the HH limit value of ... ppm
(specified by CBMEC) (with a delay time of ... minutes)
d. If raw meal feeding system to pre-heater is in service and the final air fan trips /.stops, or the
confirmation is lost by DCS that it is in operation (with no delay time)

2. Calciner burners (release for feeding any fuels into the two burners)
2.1 Operating modes of the burners

At present time, it must be possible to operate the calciner burners in the following modes:

− Natural gas firing from DCS (from CCR Central Control Room)

− Natural gas firing from BMS cabinet on calciner floor

2.2 General starting interlocks (valid for feed of any fuel to calciner burners)

The authorization for Natural gas feeding to the burners can be released by DCS only if;

a. The kiln main burner must be in service.

b. Gas temperature inside calciner is higher than the L limit value of 750°C.

This must act as a starting interlock only.

2.3 General process safeties and stoppage interlocks

All the following conditions must not be present in order to get the consent for feeding of any fuel to
the calciner burners, during normal operation of the burning line; in case even one among the following
conditions takes place, the authorization for feeding of any fuel to calciner burners must be interdicted (with
the time delay specified for each condition)

a. All fuel feeding (HFO or natural gas) to kiln burner is stopped due to process interlock, stoppage of
calciner burners must take place with no delay.
b. The ID fan trips /.stops, or the confirmation is lost by DCS that it is in operation (with no time delay)
c. The gas under-pressure inside the calciner overcomes the HH limit of ... mbar specified by CBMEC
(with a time delay of ... seconds)

d. The CO concentration measured at pre-heater outlet overcomes the HH limit value of ... ppm
specified by CBMEC (with a delay time of ... minutes)