Document No.

: IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 1 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

1.0 RESPONSIBILITY:

1.1 Head of department, assisted by functional personnel, is responsible for the

operation of Raw meal grinding.

1.2 Other specific responsibilities are as given in the operational details.

2.0 OPERATIONAL DETAILS:

2.1 PART-1 : PROCESS DESCRIPTION:

2.1.1 MAIN EQUIPMENTS AND ACCESSORIES:

2.1.1.1 Feeding hoppers, weigh feeders, Roller press, V-Separator, Ball mill, Raw mill fan,
SKS-L Separator, Bucket elevator, Air slide.

2.1.2 PROCESSING:

2.1.2.1 Limestone as a main raw material and Al. Laterite/ Haematite/ Flyash as additives
are extracted from respective hoppers through weigh feeders and fed to a bucket
elevator. Roller press product is fed separately to the same bucket elevator, which in
turn discharges the material into the V-Separator from top.

2.1.2.2 On-line X-Ray analyser located at CCR-III controls the chemical composition of the
raw mix.

2.1.2.3 In the V-Separator, the feed material falls over the cascade due to gravity, the
smaller particals are entrained by the transverse air flow and directed to the guide
vane system, where the fine fraction is discharged from the separator top with the
air. The coarse particles slide back, fall over the cascade with the very coarse
particles and leave the separator at the bottom to the Roller press bin, circulating air
and/or hot gas from Kiln are used as separating air. Fine fraction along with air is
directed to the dynamic separator from bottom side. Coarse material is processed in
the Roller press and again fed back to V-Separator from top as stated earlier. Fine
fraction is again classified in the dynamic separator. Coarse fraction from the
dynamic separator goes to ball mill and fine fraction which is collected in 4 Nos.
cyclones is directed to silo feed bucket elevator which in turn sends the final product
to Raw meal silo.

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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 2 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

2.1.2.4 In case Ball Mill degree of filling increases beyond the permissible limit then there
is a provision of diverting a part of dynamic separator reject to Roller press again
through a variable speed screw conveyor.

2.1.2.5 V-Separator/Ball mill fines are simultaneously lifted to dynamic separator from
bottom side under the effect of Raw mill fan which creates draught across the Ball
mill/ V-Separator. Remaining Ball mill product which is relatively coarser is
discharged in a bucket elevator which in turn feeds this material into the dynamic
separator from the top.

2.1.2.6 Ball mill contains grinding media of different sizes for grinding the feed material to
the mill. A separate register F-2 (IMS-OCP-168) is maintained for recording the
grinding media loading pattern.

2.1.3 Monitoring of important process parameters is done at frequent intervals in CCR on

the monitor by the CCR operator. One Mechanical foreman carries out the routine
checks of the equipments at site and also assists the CCR operator by
checking/rectifying the local defects and gives proper feed-back to the CCR
operator.

2.2 PART-2: GENERAL OPERATIONAL PROCEDURES:

The Operator at Central control room is to take action as follows for:

(i) Start-up (ii) Operation without Ball mill/ with Ball mill (iii) Shut-down and (iv)
During regular production.

2.2.1 START UP PROCEDURE:

2.2.1.1 Start Raw Mill if the silo level is 30 meter or less as indicated by silo level sensors
or the actual measurement as the case may be.

2.2.1.2 Take clearance from shift Mechanical Foreman and also from Sub-station incharge
before every start up.

2.2.1.3 Start the following eight groups in the following sequence.

(i) Silo feed (ii) BH dust transport

(iii) BH Fan (iv) Separator group
(v) Mill lubrication group (vi) Mill drive
(vii) R.P. group (viii) Weigh feeder group
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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 3 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

2.2.2 Starting sequence under each group:

2.2.2.1 Silo feed:

Dust collector rotary air lock (silo top), Dust collector fan (silo top), Dust collector
timer, HP fan for 6 Nos. air slides, Parallel distributor, Air slide blower, Bucket
elevator main drives, Sampler, 8 Nos. HP fans for the air slides feeding to silo feed
bucket elevator, Dust collector rotory air lock, Dust collector fan, Dust collector
timer, 4 Nos. Pressure screw conveyors below cyclones.

2.2.2.2 BH Dust Transport:

3 Nos. Flow conveyors, 8 Nos. Rotary air locks.

2.2.2.3 BH Fan:

BH Fan, Open BH Fan inlet damper.

2.2.2.4 Separator Group:

Before starting this group, ensure that Isolating damper is fully open and hot gas to
V-Separator inlet, Raw mill fan outlet to V-separator inlet, Raw mill fan outlet to V-
Separator outlet, Raw mill fan outlet to Mill inlet, Hot gas to mill inlet dampers are
open. Separator lubrication pump, Raw mill fan, Separator drive, 2 Nos. HP Fans of
Separator feeding air slide, Mill outlet bucket elevator, HP Fan for mill outlet
airslide, Full open Raw mill fan inlet damper.

2.2.2.5 Mill Lubrication group:

Trunion bearing inlet and outlet lubrication pumps, prejacking pumps (Ball mill inlet
and outlet) Grease spray for the girth gear of Raw mill, Lubrication pumps for main
gear boxes, Grease spray compressor.

2.2.2.6 Mill Drive : Mill Main drives.

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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 4 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

2.2.2.7 Roller Press Group:

V-Separator feeding belt conveyor, Dust collector rotary air lock, Dust collector fan,
Dust collector timer, Roller press discharge bucket elevator, Belt conveyor at RP
Discharge, Dust collector Rotory Air lock, Dust collector fan, Dust collector timer,
RP Gear oil pumps for stationary and moveable rollers, Roller press, RP Grease
pump, Reject screw conveyor to RP, RP Slide gate.

2.2.2.8 Weigh feeder group:

a) Magnetic separator, Metal detector, Belt conveyor at Weigh feeder discharge, Dust
collector Rotory Air lock, Dust Collector fan, Dust collector timer, Pneumatic
diverting gate, All 3 weigh feeders of Limestone, Al.Laterite and Haematite
simultaneously.

b) Flyash group:

Rotary Air Lock, Dust Collector Fan, Air Slide HP Fan, Aeration Blower, Flow
meter of Flyash.

2.2.3 SHUT DOWN PROCEDURE:

2.2.3.1 Stop Raw mill if the silo level is 36.5 meter as indicated by silo level sensors or the
actual measurement as the case may be.

2.2.3.2 Stopping is to be done in the following sequence:

i) Weigh feeder group.

ii) R.P. group.
iii) Mill drive.
iv) Separator group.
v) Silo feed group is stopped after 10 minutes of the IV group stoppage.
vi) Mill Lubrication group.

2.2.3.3 All equipments are stopped just opposite to the starting sequence in each group.

2.2.4 OPERATION WITHOUT BALL MILL:

2.2.4.1 Whenever there is a break down in the ball mill circuit or ball mill cannot run due to
power restriction, bypass the ball mill circuit as follows:

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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 5 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

2.2.4.2 Inform Shift mechanical foreman to close the slide gate towards mill inlet and also
towards reject screw conveyor. Simultaneously ask him to open the slide gate of
reject bypass line to R.P. bin.

2.2.4.3 Bypass the ball mill in the monitor and close fully circulating air and hot gas
dampers to mill inlet.

2.2.4.4 Start the system as per the starting procedure except Mill lubrication group and Mill
drive group. This operation will be decided by Raw mill production head.

2.2.5 CROSS FEEDING OF RAW MEAL TO UNIT-II:

2.2.5.1 There is a provision for partial transfer of Raw meal from Unit-III to Unit-II.

2.2.5.2 Starting procedure:

2.2.5.2.1 Follow the steps in the points 2.2.1.3 and 2.2.2. Ensure from CCR-II Operator that
their transport system is in operation. After confirming from Unit-II CCR Operator,
take clearance from Mechanical Engineer/ Foreman that Unit-III transport system
including airslides is clear.

2.2.5.2.2 Select Unit-II group for transfer of Raw meal. Give `Start' command to raw meal
silo feed group. Ensure transfer quantity by observing the load of silo feed elevator.

2.2.5.3 Stopping procedure:

Follow the reverse of the starting sequence as given under 2.2.5.2.

2.2.6 DURING REGULAR OPERATION:

2.2.6.1 The following important process parameters influencing the quality of process
outputs directly or indirectly are maintained by the Operator at Central control room
as per the range and frequency of monitoring indicated against each, through the
monitor.

Sl. Process Contingency Action range Frequency

No. Parameters range
i) Raw mill fan (350 – 650 mm (450 – 550 mmWg) Continuous review
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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 6 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

inlet draught Wg) (recorded hourly)

ii) Mill outlet (50 – 200)mm Wg (60 - 150 mmWg) Continuous review
draught (recorded hourly)

iii) Product residue 12.5 % Max. (4.0 - 12 % ) Alternate hour.

on 212 Micron

Note: The figures in the brackets is the range where the operator is not required to make
any process adjustments.

2.2.6.2 During normal operation raw mix chemical composition shall be controlled by
online X-ray analyser.

2.2.6.3 When On line system of X ray analyser is not working the mill operator will be
guided by X-ray man of QC department.

2.2.6.4 When X-Ray Analyser is not working, the Shift Chemist of Quality Control
Department controls the raw meal chemical composition through instructions to the
Mill Operator at Central Control Room, for changes required in the raw mix ratio.

2.2.7 LOCAL MONITORING:

2.2.7.1 It is being done by mechanical Engineer/Junior Engineer at site who is engaged in

routine check up of the machinaries/equipments. He also keeps contact with CCR
operator through telephone/PA system and gives required feed back.

2.2.8 SAFETY/STATUTORY REQUIREMENTS:

2.2.8.1 Work permit must be obtained from sub-station before starting any
repairing/maintenance after taking clearance from CCR on any electrically operated
equipment in this process. For restoration of power supply the work permit must be
returned to Sub-Station by the same person obtained it earlier. In case the permit is
lost, Head of the concerned department is authorised for restoring the power supply
after ensuring that the work is completed.

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same shall be treated as “Invalid Document”. For printout of the same please contact Management Representative
 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 7 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

2.2.8.2 The dust emission during production in the discharge should be limited to maximum
30, mg/NM3 as per State Pollution Control Board regulations. This is being done
with BH. (Refer IMS-OCP-164 Air Pollution Control) operated from Central control
room. The Operator at CCR monitors the operation of BH.

2.3 PART-3 : GUIDELINES FOR PROCESS ADJUSTMENTS TO CONTROL

VARIATIONS BEYOND LIMITS IN IMPORTANT PROCESS
PARAMETERS OR PROCESS OUTPUTS

2.3.1 Guidelines to be followed by the Operator at Central control room for process
adjustments when important process parameters vary beyond range indicated under
2.2.5.1 are as follows:

Sl. No. Parameters Action to be taken Reasons

1) Raw mill fan inlet draught (i) Check the Raw mill fan - Higher draught
above 550 mm Wg outlet draft and if it is more will result in
than 50 mmWg. then bring higher residue and
it down in between 5 to 50 also V-Separator
mmWg. by closing BH fan may get jammed.
inlet damper or/and Raw
mill fan outlet damper or
reduce BH fan speed.

(ii) Reduce fresh feed.

2) Raw mill fan inlet draught Open the Raw mill fan - Residue will go
below 450mmWg. outlet damper or/and BH below target
fan inlet damper or increase resulting into
the BH fan speed so that higher power
Raw mill fan outlet draft is consumption.
maintained in between 5 to
50 mmWg.

3) Mill outlet draught above (i) Increase Raw mill fan outlet - Mill grinding
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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 8 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

150 mm Wg. to V-Separator outlet efficiency will go

damper or reduce Raw Mill down causing
fan outlet to V-Separator higher residue and
inlet damper less output rate.

(ii) Reduce the fresh feed from

weigh feeder.

(iii) Reduce Mill feed by

increasing the speed of the
reject screw conveyor.

Sl. No. Parameters Action to be taken Reasons

4) Mill outlet draught below (i) Reduce Raw mill fan outlet - Empty running of
60 mmWg to V-Separator outlet the mill will result
damper or increase Raw into higher power
mill fan outlet to V- consumption.
Separator inlet damper.

(ii) Increase the fresh feed

from weigh feeder.

(iii) Increase Mill feed by

reducing the speed of the
reject screw conveyor.

5) Product residue on 212 Increase dynamic separator - Poor performance

Micron 12.1 % and above. RPM. of Kiln as well as
higher free lime
in clinker.
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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 9 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

Thermal energy in
Kiln will go high.

6) Product residue on 212 Reduce dynamic separator - To reduce power

Micron Sieve 3.9% and RPM. consumption per
below. metric tonne of
product.

2.3.2 If the desired results are not obtained by following the above guidelines and for any
doubts resulting in hold up of process adjustments, advice of concerned production
head should be sought immediately.

2.3.3 Record important process adjustments made in the log sheet F-1(IMS-OCP-168)
maintained in CCR.

2.4 PART-4: CONTINGENCY PROCEDURE:

2.4.1 Actions to be taken by the Operator at Central control room when contingencies
occur, are as follows:

Sl. No Nature of Actions to be taken Reasons/

Contingency Explanatory Notes
1) Raw Mill fan inlet (a) Inform Shift Mechanical foreman (i) May cause V-
draught below to check for: Proper operation of Separator
350 mm Wg. the Raw mill fan inlet damper and jamming.
its condition.
(ii) R.P. bin level will
(b) Inform Sub-station incharge to go up causing
check MV Drive fresh feed cut.

(c) Observe for 10 minutes then stop (iii) Less material feed
the fan. will go to mill.

2) Raw Mill fan inlet (a) Check Raw mill fan outlet draught (i) Product residue
draught above and if it is more than 50 mmWg. may exceed the
650 mm Wg. then reduce Raw mill fan outlet specified range.
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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 10 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

damper and/or BH fan inlet

damper or reduce BH fan speed to (ii) It may be due to
bring down Raw mill fan outlet V-Separator partial
draught in between 5 to 50 mmWg jamming.

(b) Even after maintaining Raw mill

fan outlet draft in between
5 to 50 mmWg. If Raw mill fan
inlet draught does not come below
700 mmWg. Then totally cut the
fresh feed.

(c.) Observe for 10 minutes then stop

the full circuit.

Sl. No Nature of Actions to be taken Reasons/

Contingency Explanatory Notes

3) Mill outlet (a) Inform Mechanical Foreman to Material flow to the

draught below check : mill might have
50 mm Wg. stopped due to :
(i) Mill condition for empty running. (i) Spillage of material
from the mill inlet
(ii) Material flow to the mill. chute.

(ii) Slide gate towards

the mill may be
closed.
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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 11 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

(b) Observe for 10 minutes, then (iii) Reject flap may

stop the mill. be jammed and not
opening.

(iv) Mill inlet chute

may be jammed.

4) Mill outlet (a) Bring down Raw mill fan outlet This may be due to
draught above draft in between 5 to 50 mmWg. the Mill discharge
150 mm Wg. by reducing Raw mill fan outlet diaphragm jamming:
damper and/or BH fan inlet OR
damper or by reducing BH fan Also due to over-
speed. filling of the mill: OR

(b) Mill condition for over-filled Due to Mill outlet air

running. slide jamming.

(c) Observe for 10 minutes, than

totally cut the fresh feed and
empty out the system.

5) Product residue (i) Stop the whole system. - May be due to the
on 212 Micron is reject chamber
above 12.5 % for (ii) Inform the Mechanical foreman to jamming.
consecutively check and rectify the fault in the
three readings. V-Separator or/and dynamic
separator circuit.

2.4.2 RECORDS:

2.4.2.1 Make a brief record of contingency, if any, in log sheet F-1(IMS-OCP-168)

maintained at the Control Desk.

2.4.2.2 Monthly reports of Productions statistics are available in SAP.

3.0 PROCESS INPUT:

Input Source Review Criteria

Limestone + Additives Captive Mines, External Quality and Quantity
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 Document No. : IMS-OP-168
Issue No. : 03
Revision No. : 04
OPERATIONAL PROCEDURE
Reviewed on : 15.11.2021
Page No. : 12 of 12
Effective Date : 12.03.2016
Unit: Rajashree Approved by: Issued by:
Cement Works
RAW MEAL GRINDING
(Unit-III)

Necessary Equipment Inhouse List of Equipments

Power Captive TG/ DG and KEB. Visual Display at Panel

Procedures and Work QMS List of Documents and

Instructions their currency

4.0 PROCESS OUTPUT:

4.1 Raw Meal with required quality.

4.2 Necessary records and reports.

5.0 PROCESS MONITORING:

Monitoring Criteria Responsibility Frequency

Monitoring of Various CCR Operator Continuously as described
Process Parameters in Production Instructions.

Residue of Production CCR Operator Alternate Hrs.

on 212 Micron

6.0 CONNECTED DOCUMENTS:

F-1 (IMS-OCP-168) Raw mill Logsheet

F-2 (IMS-OCP-168) Grinding media Loading pattern register

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same shall be treated as “Invalid Document”. For printout of the same please contact Management Representative