PYRO SYSTEM - CONTROL LOOPS V0.

0 DATA TO BE FILLED BY PLANTS

Control Loop
Control Loop in Reason for run in Manual
Controlled Parameter Actuator Target Comments Available in PCS Comments [if any]
Auto/Manual Mode
(Y/N)
In case of limited vent fan capacity, back fans in cooler set point
Clinker cooler firing hood pressure Cooler Vent Fan Small negative pressure, typically - 30 pa
should be adjusted by operator. Y
Drive 1 speed controls pressure, downstreem drives are slaved
Maintain a constant depth of clinker in the clinker
Undergrate pressure of compartment one or two Cooler drive speed to drive 1 based on ratio. Grate 2 & 3 could also have
cooler
independent control loops. Y
EP inlet temperature < limit defined by mechanical
Clinker Cooler EP inlet temperature Fresh air adjustable damper Temperature based control by fresh air adjustable damper.
safety Y

Clinker cooler compartment fans airflow fan speed According to suggested blowing density calculation
Y
Fuel rate controls temperature to a set point that is normally in
Gas temperature at final (lowest) cyclone stage. Calciner fuel 92 - 95% calcination of material entering the kiln
the range of 850 - 900° C Y
Kiln feed bin level (weight)(need to be checked) Silo Extraction 75%

Feed rate is changed according to required production. Feed can

Loop controls output to maintain kiln feed rate to set also be raised or lowered according to kiln operating conditions,
Kiln feed rate According to Operator or Lucie control.
point. - Actuator depends upon dosing device if kiln suffers severe cool outs, reducing feed rate will help the
kiln to recover.
N
Kiln speed will be adjusted based on kiln feed rate to maintain
Kiln Feed Kiln Speed Maintain constant material loading of kiln.
constant speed/feed ratio. N
Grate speed 2 Grate speed 1 Y
Grate speed 3 Grate speed 2 Y

ID fan inlet temperature Downcomer Water Spraying According to whether raw mill is on or off. Reduce gas volume to save ID Fan power
Y

Baghouse <240° C according to temperature rating for

Main filter inlet temperature (for bag filter only) Fresh air adjustable damper
bags

Minimum negative pressure that will prevent over Too negative pressure should be avoided to prevent excessive
ID fan exit pressure Main filter fan speed or damper pressure in duct from ID fan to filter fan. Make false air, however increasing negative pressure can help ID fan
downstream circuit independant from exhaust circuit flow if the production is fan limited.
Y

Conditioning tower exit temperature is controlled by water

sprays. The set point for GCT outlet temperature will depend on
Outlet Temperature GCT GCT Water injection Protection of bag filter, efficient ESP operation
raw mill ON / OFF. It is important to monitor material temperature
at bottom of GCT to avoid wet material.
Y

Some of the values mentioned above may not be applicable for all plants. Plant need to set the values based on circuit configuration/supplier/OEM
Note:-
recommendation.
 Depends on the
Clinker Pan Conveyor Clinker Storage <H >HH
distance

120(need to be
Clinker Breaker Clinker Transport ON OFF No transport of clinker
checked)

Cooler Fan Damper
Grate Fan and Fan Damper
Cooler Fan Close 300 Close to 0%, Operator should increase air to the fans either side of
stopped fan. If fans from 4-8 stop the cooler can continue to run for
a period if kiln output is controlled accordingly. Note that wear rate
will increase on side seals in effected area. In a well sealed
modern cooler the grate has to be stopped to avoid dust
penetration into the plate slots. Follow OEM recommendation
All cooling fans to minimum flow except chamber 1&2, to prevent
Cooler Filter fan OFF 3
over pressure danger
10% of setting, stop fan and damper to 0% if both kiln and filter ID
Kiln ID Fan (Stopped or Minimum Speed) OFF 3
fans are stopped

Kiln Hood Pressure > HH 3 > 50 Pa, All cooling fans to minimum flow except chamber 1&2, to
prevent over pressure danger

Cooler Filter inlet temperature <H >HH 600

Cooler Filter Fan Cooler Filter inlet temperature <H >HH 3 Protect bags
Filter DP >HH 3
Cooler Filter Hopper Level >HH 1800

If bag filter to protect the bags. Auto operation of water spray

Cooler Filter Fresh Air damper Cooler Filter inlet temperature <H >HH 3 system to control EP inlet temperature <H. Fresh air damper to
open if water spray is not able to reduce temperature

Kiln minimum speed, operator should reduce kiln rpm during the
Grate 1 Drive ON OFF 300
stop delay
Kiln Drive Kiln to min. speed, no risk to the fixed grate since its well protect
Cooler Fixed Grate Fan ON OFF 600
with a layer of clinker
Kiln Feed OFF/ Recirculation 300 Operator decision to reduce kiln speed or to stop

Kiln Auxiliary Drive Kiln main drive OFF ON 120 If possible to have an automatic change over between main drive
and auxiliary
Kiln main drive ON Stopped/minimum speed 300 Kiln feed to stop or circulation or stopped
Main Burner Fuels ON OFF 120 Kiln feed to stop or circulation or stopped
Kiln Feed Calciner Fuel ON OFF 3 For ILC Kiln
Gamma and cone pressure calciner cyclones
> H (alarm only) 300 Immediate cyclone inspection for possible blockage
level or bottom stage cyclones

ID fan inlet temperature (Protection of impellor <H >HH 3 ID fan trips and damper closes to prevent deformation of impellor
and shaft, H at 420C, HH at 450C
Applicable for plants having water spray in downcomer to protect
Preheater Exit temperature <H >HH 3
the duct, HH at 500C
Calciner CO level <H >HH 3
Downcommer CO level <H >HH 3
Kiln ID fan and Fan Damper ID fan inlet pressure <LL 3 LL is the design underpressure of the downcomer
Minimum speed If raw mill stopped. If H is reached, increase
ID fan outlet pressure <H >HH 60 exhaust fan if existing margin, if not ID fan and feeding should be
limited
Kiln Filter Fan ON OFF 3
Cooler Filter Fan OFF 3 Prevent over pressure
Kiln Feed OFF/recirculation 120
Kiln Main Drive OFF 300
Kiln ID Fan Stopped/Minimum Speed 3
Kiln ID fan Damper Closed
Calciner Outlet temperature <H >HH 3 Alarm at 920C, HH at 1000C
Main burner fuel stops. Standby primary air(if available) to start.
Primary Air Fan ON OFF 3 Delay of main burner fuel stop will depend on time required to start
standby PA fan
Main burner Fuels Calciner CO level >H(alarm) 20 Burner fuel to minimum
Calciner CO level <H >HH 3
Downcommer CO level >H(alarm) 20 Burner fuel to minimum
Downcommer CO level <H >HH 3
Kiln Hood pressure <H >HH 2
Kiln Hood pressure >H(alarm) 60
Nose Ring Fan ON OFF 3600 To protect Kiln outlet seal
Kiln feed OFF/ Recirculation 3
Calciner CO level >H(alarm) 20 Calciner Fuel to minimum
Calciner CO level <H >HH 3
Donwncommer CO level >H(alarm) 20 Calciner Fuel to minimum
Donwncommer CO level <H >HH 3
Calciner Fuels
Calciner Primary air blower ON OFF 3
Calciner Outlet temperature >HH 3
Bottom Cyclones Gas Temperature >H(alarm) 3 Reduce calciner fuel
Bottom Cyclones Gas Temperature >HH 3 Prevent kiln flush
Downcommer CH4 level >HH 3
Kiln Filter Hopper Level ON 1200 Protect Bags
Kiln Filter Outlet Pressure <LL 3 Protect filter from underpressure
Kiln Filter Inlet Gas Temperature <H >HH 3 Protect filter bags
Kiln Filter Control Unit and Kiln Screw under filter ON OFF 1200
Filter Fan
Kiln ID Fan Outlet Pressure <LL 3 Protect against underpressure (particularly if GCT fitted)

Kiln Filter Differential Pressure <H >HH 3 Protect filter bags

Kiln Filter Fresh Air Damper
Kiln Filter Inlet Gas Temperature <H >HH 3
Open
Kiln ID fan outlet pressure >HH 60 Interlocks coverd in Raw Grinding also
Raw mill Kiln ID Fan Stopped or Minimum Speed 3 Interlocks coverd in Raw Grinding also
Kiln ID fan Damper Closed 3 Interlocks coverd in Raw Grinding also
Downcommer CO level <H >HH 3 >0.8% CO to prevent explosion
ESP Tension Field
Downcommer CH4 level <H >HH 3 To prevent explosion
Shell Cooling Blowers Kiln Main Drive ON OFF 3 Prevent kiln shell deformation