Fioear ‘Project uriber al TED H |_fENNA CEMENTS UAE 2% 100 igh Raw ginsing _Prvo4020-729 _——— Ere yO by aepeweby Pes ; Faw bi Systom SaaS at Ns Sait sesnnee Beta y a Poser Sean —Saonane ROR STS 150m 748 mm S. i = Desonton _ TUMS 42x10.85 + 1.65 0¢ Spoea Sumer earn ‘exe Motor few) ba it equipment 2500. Genuine te act om contr aton : ramatoodcton agent Feed point a No Feeder capac toh Sorts) ie Beperatr Designation — en ©-Sepaneov0 ped) 120 FINAL FOR RECORDS 50-100 = Lt so Fa mow TS OFF Specteatans —Desiravan % ir mt Nomina ameter) . : . . pels darter ran 2 : : : Design valves Gas ow (pra) 7 7 Ta ia wes ‘Temperature [°C] 83 221 83 240 Density oi] om | ons ors | ors Dust concerto (9 dusty Fi Q ° ° Rela et preaur(eal Sea 2002 soo | stoe Relate outlet presure [Pa] “200 “200 a 200 tach deaan Max peak omporaars fC} 150 a 785 370 Rotor speed pm) ° : : " Requred motorsnat power) | 1-820 | 1x eis | tums | ar00 Regulation Pe Foxedapeed | 23-109 | Fuaeapecd | 33-100 ousting fae tise fice tive Flere SOMIEOHW oF TOMS OFF Specticatons Type avers Ar bagnouss | —— Baghouse Baghouse Designation : : ; Max allowable enision = : : Design values ites Tow fs) TSE 7 Ta intemperate (°) 2 29 20 init cewpoint(C] 2 2 a Inlet density (kg/m?) 0.728 0876 0.704, iit dst concotaon fg dst 38 2a 38 Relative inlet pressure [Pa] 392 3740, 392. [Mech. design - Temperature, continuous [°C] - 120 240 |max values Temperature, peak [°C] - 130) ara) Relative outlet pressure [Pa] ~ 6040 se02 Pressure drop [Pa] 1470 1470 Fite toad nein) : Notspeciiod | not seciod ‘Template: CMclosed, release 8.18.0 of 20041026. Program: .4.2.7.2.8,25.20.5.12.9.5.0 of 20041111 Scanned with CamScannerPret Piject number cr miptH PENNA UAE: 2x 110 TPH CEMENT GRINOING u04.020729 i ENGPD ade by ‘Checked by ‘Approved By ae 06-12-2004 Cement Mit System [Siapge——Rsw_s_sld_t2. 2004 _ PO diagram py Page 2013 Elsah Baronet pa Cae 150m 746 mm ig tr Se tor para Resanan vusienes [Sen osnanicn Speed om) Seo | sorta zt cose) 3508, Regulation [2] See) Motor) 3548 Gyelone(s) p.m} NA it equipment Ginging aid a Capcity (kar) Water ditaton Choate reducton agent No Feed point Fader capaciy kom] one) om NA [Fans Separator iter] Ta ter Specioatans —Deagnaion iT 1 Nerina ameter fn) - . Imps ameter [rn : Design values — Gas fow per tn a] ae Tos Tempeatre['C] 8 105 Density on oan 0896 Dust concentration [g dust ° ° Felatve inlet pressure [al -s620 3490 Felatve ot pressure (Pa) ° ° ach, cesar —Hiax peak tompotts CT 7 = Rotor speed (pm : ° Feguired motor shat powertkw] | tx eet | ax se Regulation] Fred speed | Fined epecd ousting Free Free tere Separatar 7a Specincalons Type Baghouse Baghouse Designation 024 564 cetate-t0 Max allonsble emission é : ion values it gas Row ry ms 35 Int temperature") 12 mt Inet denpont() 2 58 Inet density tk) oars oss7 Inlet dust concentration (9 dustin a2 50 Folate inet pressure (Pal 3490 1590 [Mech and bag —Ternpeature,coninuous "CT 120 720 Jdesion-max’ Temperature, peak") 120 180 fates Felave out pressure [Po] 5820 4190 Pressure crop [Pal 1470 1470 Fite lad min Not secited Not pects [Rat gasses / Hast generator Tomi a Ret RT Temperature [°) eat goneator Capacity [MW] == Fuel ype ! Fd but es aa FINAL FOR RECORDS Fuel consumption [kh Comments Teanplate: CMvemiop, release 8.19.0 of 20081026. Program: €.42.7:2.8.25.20.5.12.95,0 of 20041111, Scanned with CamScannera Eon mip PEN [ee Prelow 920.729 1 TH TRA VAE: 2x 110 TPH CEMENT GRINDING POs 020-728 Date ENG-PD a Checked by Reprverty Pract oats Cement Mill System | Distibuton SM. NS. PD diagram list Page s.ot3 Eros Roqueney Erevalon —~ Barometie proses ‘30 H2 m 748 mn ig Ducts Poston ro ‘Code | Romina dimension | ——Uning Ta Topas | Ma cum ny c bit tet 201 : 710 ° so ite ] gs : ‘s es - i 7 800 ° 150 ban iter out : 00. ° 150 nee hat fiter fan out I 00 ° 150 eat [Separator primary ambient air : 0 150 La |Separator secondary ambient air . . ° 150 on Separator iter out : ao a {50 cats |Separator filter fan out e 2000 ° 150 1982 Separator recycle : pe a 450 1962 Separator out : 1200 ° 150 e216 | Separator (primary) inlet - 1600 Oo 150 Ld [Separator stack : 1120 ° 150 $81 [Transports Code | Moisture [%] Diy capacities [Uh] ‘Wet capacities [vn] Nominal Maximum | _Norninal__ Maximum Rew teed to mil 5 oF 710 132 110 138 Mit elevator . 00 202 315 262 318 Material to separator 00 275 330 215 330 ejects from separator 09 165 220 165 220 Material trom separator filter : 00 110 132 110 12 Material from mil fiter oo 162 207 162 207 PD diagram edition history FINAL aL FOR RECORDS Scanned with CamScannerProject : Penna Cements LLC - UAE INITIAL_MILL_CHARGE Equipment : Cement Mill UMS 4.2x14.5 Lg. Contract Ns ism 10. PRJ04-020-729- Contract No. (Equip. No. 531.BM100 & 532.BM100) Ball % of Ss Tons Compartment | Size_|_Charge ita | Correction 1 100 0 0 8 90. 23 18 2 80, 32, 25 3 70 21 16 2 60 24 18 2 50 oO 1) oO Total Comp. 1 5 100 7 7 12 106 2 40 0 0 0 0 9 | 30 0 0 0 0 0 25 40 61 6 15, 82 20 40 61 6 0 67 15 20 30. 3 0 33 10 0 0 0 0 0 ‘Total Comp. 2 - 100 152 15 15 182__| Total Mill - - 229 | 32, 27 | Correction is in running in. Compensation is for wear first 6 months. The composition of grinding bodies for individual compartment shown above is for guidance only. The correct composition is to be determined during the run-in period. Refer separate sheet for specification of grinding balls (See Annexure II). Note: In order to avoid damaging the lining plates and grinding balls the following must be observed. Before starting, the mill the first time or charging the first compartment with grinding balls, there must be always be a suitable amount of materials in the compartment. The amount of materials should be ¥4 of weight of the grinding balls. ac tt a Scanned with CamScanner; Annexure LL. wal | SPECIFICATION OF GRINDING MEDIA ce | 1.1 Material specification | High chrome heat-treated and oil quenched grinding media in the form of balls as follows - [Alloy Dia 15-50 mm. Dai 60-100 mm Carbon 2.5 10 3.5% 2.0 to 3.0% | Chromium 10 to 14% 14 to 18% Manganese. 1% max 1% max a | Molybdenum 0.4% max 0.4% max - | Sulphur 0.06% max 0.06% max Phosphorus (0.06% max (0.06% max Silicon 1% max 1% max 1.2 Qnality 1.2.1 The balls shall be supplied in heat-treated condition, oil quenched and tempered so as to obtain a microstructure of chromium carbides in martensitic matrix. Continuous carbide network should not be present. 1.2.2 Hardness of balls shall be : a. Balls of size 60-90 mm Surface ~ 59-62 HRC Variation in hardness from surface to core should not exceed 2 HRC. b. Balls of size 15-50 mm Surface - 62-68 HRC Variation in’hardness from surface to core should not exceed 2 HRC ‘The strength should be such that the grinding media will not break or spalling will not occur during operation 1.2.4 Stability of shape is important so that when worn out smallest diameter these can still be used 1.2.8 Deformed, broken, spalled balls will be Jess than 3% of total supply, lop 2 Scanned with CamScanner1.3, Other specification d from 1.3.1 The steel used to cast the grinding media shall be produce electric arc/induction furnace. be 1.3.2 The retained austenite content in the first chamber balls should be less than 7%. d 1.3:3 The grinding ball should be free from injurious defects such as san Incl eons, blow holes; cracks, pit marks etc., which will affect their uniformly spherical in shape and no appreciable f same size is expected. will be taken by vendor to ensure surface smoothness ing media. The materials will be passed through tumbling mill so that all projections in the castings are chipped off. 1.3.5 Dueipre: on the 1.3.6 The sample testing of material should be removed with the help of spark erosion machine so that the metallurgy of the sample to be tested is not disturbed. 1.3.7 The dimensional tolerances shall be Scanned with CamScanner2. 1. PENNA CEMENTS UAE TABLE OF CONTENTS INTRODUCTION ... SYSTEM DESCRIPTION .. INSTRUMENTATION .... PRESTART AND OPERATIONAL CHECKOUT START-UP... STARTING SEQUENCE. NORMAL OPERATION... STOPPING SEQUENCE TROUBLE SHOOTING CHART ... EQUIPMENT FLOW SHEET WARNING Read this instruction manual before performing any installation, operation or maintenance procedures. All equipment must be operated and maintained in accordance with all applicable governmental safety and health laws and regulations and generally recognized industrial standards. Scanned with CamScanner— INSTRUCTION MANUAL, PENNA CEMENTS UAE 1 INTRODUCTION The following instructions are for the ball mill as raw grinding system of M/s Hates Cements, UAE. The circuit consists of a two-compartment ball mill operating in a clo circuit with an O-Sepa separator with the mill being vented to a separate bag hous These subsystems are The entire system may be divided into three subsystems. described as follows: Weighing and proportioning the Raw Materials, and additives, feeding the e fan. mixture into the mill inlet. Grinding the mill feed and classifying the mill discharge to the desired product fineness. : Conveying the finished product to the blending silo. Each instruction is to be used in conjunction with other manufacturer's instructions furnished with other pieces of equipment or mill auxiliaries. Scanned with CamScannerPENNA CEMENTS UAE ‘SYSTEM DESCRIPTION ficron. Lime The system is designed to grind 100 tph (dry) at 15% residue on 20 Mer stone, clay and additives in predetermined controlled proportions inlet. The milling system consists of the following equipment: Raw material storage hopper. . Additives storage hopper Raw materials and additives to . ensures the correct ratio of Weigh feeders to weigh and proportion the tal tonnage being handled. the grinding circuit. The proportioning devic Raw materials & additives regardless of the to! Belt conveyors to convey the feed from the weigh feeders to mill inlet feed chute. Two (2) TUMS 4.2m 9 X 10.85 m long + 1.65 DC, 2 compartment ball mill with 2600 KW motor. _ Series of air slides and a bucket elevator to convey the mill discharge product to the O-Sepa separator. Two (2) Fuller O-Sepa of size N-3000 high efficiency separator. Flow meter to measure the rejects from the O-Sepa to the ball mill. Cyclone Separator L-5600 for recovering the final product from the separator vent air. O-Sepa Induced Draft Fan for handling the separator air Mill venting bag filter with fan. Series of air slides to gather the cyclone collector catch and transport it to the silo feed elevator. Raw materials & additives are withdrawn from their respective storage hopper and proportioned by individual weigh feeders. A proportional controller to maintain the correct ratio of Raw materials & additives controls the weigh feeders. A series of belt conveyor transports the material from these weigh feeders to the mill inlet. There, it is combined with rejects from the separator and fed by gravity into the mill. The mill discharge material is conveyed by a series of air slides and a bucket elevator to the O-Sepa separator where the fineness of the finish product is controlled by the Page 4 of 19 Scanned with CamScanner21 INSTRUCTION MANUAL PENNA CEMENTS UAE separator rotor speed, There are typically two or four feed inlets on the separator: air slides to allow for a reasonably equal Flow control gates should be installed in the distribution of material to the feed inlets. For good operation of the separator, Doth the correct airflow through the separator and its feed rate are essential. The entire finish product is conveyed by the separator air stream into a downstream cyclone collector. The tailings from the separator are reintroduced into the mill for further grinding. Control of the separator air flow is achieved by the setting on the remotely operated inlet damper or speed of the separator ID fan. The mill is ventilated by a duct from the mill discharge housing to bag house fan. The draft through the mill is controlled by setting the fan damper position or speed to maintain a state pressure of approximately -100 to -120 mmwg at the mill discharge jousing. Classifying Mechanism The schematic diagram of O-Sepa is shown in figure 1.The particles to be classified are fed through chutes highly dispersed by means of dispersion plate and buffer plate and thrown into the classifying air introduced through the tangentially extended ducts . The classifying air is led into the classification zone through the fixed guide vanes, where a very precise horizontal vortex is formed by means of vertical flow adjusting rotating blades and horizontal partition plates. Particles are at first roughly classified on entering the classification zone, and the principal classification is made in the uniform vortex flow according to the balance of Scanned with CamScannerINSTRUCTION MANUAL PENNA CEMENTS ORIVE SHAFT a FINE PRODUCT RAW MATERIAL FEED: DISPERSION RAW MATERIAL FEED PLATE A seconpary Air (DUST-LADEN) PRIMARY AIR ROTOR SWIRL BLADE ROTOR GUIDE VANES PARTITION COARSE GRAIN DISCHARGE FULLER - 0- SEPA forces that of the centrifugal and the other of inward) i i tha ly flowing ir. classification fine products are carried out and collected. The ears See et they swirl down inside the guide vanes, are rinsed by the air coming inside theuch Page 6 of 19 Scanned with CamScannermiptT PENNA CEMENTS UAE INSTRUCTION ‘MANUAL 22 the lower parts of di these unique mech afforded to to a well-ref The rot conventional sm: classifying and multiple way. By virtue of vertical flo Pa a precise horizontal vor fact ensures a wide ran, blades in O-Sey equipment. anisms a great many every particle and more over, fined balanced forces. fields of industries. Specifications of core equipment all scale vortex classifier, Zone is fairly long and the clas ucts, finally flow out from the bottom part of the classifier. By y changes of classification are repeatedly ; each classification is performed according nal speed of inner parts of the classifier need not be so high as in since the retention time of particles in the sification itself is performed in a step wise Ww adjusting blades and horizontal partition tex can be formed even in large volume 199 of applicability for this classifier in various Type Ball mill, closed circuit Size TUMS 4.2 X 10.85 + 1.65 DC Mill speed 16.18 pm No. of compartments 2 Mill Drive 2600 KW First Compartment details Effective Length of the compartment 2.92 m Type of Liners Step Filling of Grinding Media 28% Grinding Media Pattern Ball Dia_[ Weight Wt. Of Balls_| Correction (mm) (%) (MT) (MT) 90 23 10.27 1.02 80 32 14.21 1.42 70 21 9.32 0.93 60 24 10.66 1.07 Total 100 44.40 4.44 Scanned with CamScannerSecond Compartment details PENNA CEMENTS nsTRUGTION MANUAL UAE Eff.Length of the compartment 7.10m Type of Liners Classifying Filling of Grinding Media 28% Grinding Media Patter Ball Dia__| Weight Wi. Of Balls _| Correction (mm) (26) (MT) (MT) 50 8 9.22 0.92 40 8 9.22 0.92 30 32 36.88 3.68 25 32 36.88 3.68 20 20 23.05 2.31 Total 700 115.25 11.51 Separator Type O-Sepa Size N-3000 Drive 221 Kw, Speed of the Rotor 190 rpm Exit operating gas vol.(m* in) | 2,11,820 Exit Dust con.(gm/m*) 538 Cyclone Size 1"5600 mm O-Sepa_Fan Gas volume (m°/hr) 2,382,200 Temperature 83°C Pressure (mm WG) -660 0.893 Density (Kg/m’) Scanned with CamScannerINSTRUCTION MANUAL PENNA CEMENTS UAE OPERATING INSTRUCTIONS AND REFERENCE MANUAL Ae a CUSTOMER : PENNA CEMENTS PLANT LOCATION UAE FL.SMIDTH LIMITED +: PRY04-020-729 WORK ORDER Prepared by: ‘A'SRINIVASAN Doe.No. = Checked by: N.V.THIRUNAVUKKARASU| Rev.z 0 ‘Approved by: ‘SSARAVANAN Scanned with CamScannerINSTRUCTION MANUAL PENNA CEMENTS UAE 3. INSTRUMENTATION The following is a brief functional description of each process control loop in the raw grinding area, WARNING In these operating instructions, it is assumed that all control loop tuning Cporatencts: limits, and alarm settings are properly established betore, the ‘Operator can switch a loop from the MANUAL mode to the AUTO or CASCADE. mode. All control loop parameters must be established through prior ‘manipulation of the process by qualified personnel, Any attempt to switch an untuned control loop to the AUTO or CASCADE mode Could result in a major process upset endangering equipment and personnel. 34 Automatic Control Loops 3.1.1 Mill Feed Rate The mill sound level and the mill discharge bucket elevator power draw nay also be used to control the material flow out of the mill, and often all three are used in some combination, A proportional controller also ensures that the fresh feed will always Contain the proper ratio of Raw Materiais and additives 3.1.2 Mill Discharge Material Temperature The mill inlet bleed air damper controls the mill discharge material temp. The temperature is maintained at 85-95°C, 3.1.3 Mill air flow Air flow through mill can be controlled by adjusting the damper placed in dust collector fan inlet. 3.2 Manual Control Loops 3.2.1 Separator Rotor Speed 3.2.2 The Primary air damper position. 3.2.3 Secondary air damper position re nerPENNA CEMENTS UAE 3.3.1 3.32 3.3.3 3.3.5 3.3.6 7 ‘3.3 Control Interlocks The following items and process parameters for interlocked and/or stop contacts for critical equipment the raw grinding system are in the control circuits. Material Handling Systems except the weigh n_systems, All material, gas handling and lubrication sy aia feeders must be running before the system will be permitted to Itis recommended that whenever the Osepa fan starts, the lubrication systems for the separator reducer and the separator shaft bearings must be operating. This is because the separator rotor will tend to wind mill as air is induced through the separator. Bearing Lubrication System bearing lubrication system must be operating. These lubrication systems, together with those for the mill main drive gear, drive pinion and main reducer must be energized if either the mill main drive or its inching drive are activated. -Sepa Bearing Temperature High/High The High/High alarm for the O-Sepa bearing temperatures will stop the grinding system. Mill feed & discharge end trunion bearing Temperature High/High The High/High alarm for the mill bearing temperatures will stop the grinding system. Mill main gear box flow low The low alarm for the main gear box oil flow will stop the grinding system, Drive Pinion Bearing Temperature High/High The High/High alarm for the Drive pinion bearing temperature will stop the grinding system. Mill Motor Temperature High/High The High/High alarm for the mill motor winding temperatu i Sinan 1g Ipé res will stop the Page 10 of 19 Scanned with CamScanner44 4.2 43 44 45 46 47 48 4.09 INSTRUCTION MANUAL, PENNA CEMENTS UAE 3.3.8 Osepa Fan Bearing Temperature High/High The High/High alarm for the fan bearing temperature will stop the grinding system. 3.3.9 Osepa Fan Bearing Vibration High/High HighHigh vibration alarm of the separator (Raw Mill) fan will stop the grinding system. 3.3.10 Product Conveying System The failure of the drive motor for the silo feed bucket elevator should stop the mill feed system and the mill motor. In addition, the bucket elevator motor cannot start unless the blending silo venting system is functioning. 3.3.11 Ifthe mill feed trips for more than 5-10 minutes, mill should trip. PRESTART AND OPERATIONAL CHECKOUT Prior to any system start, the following items must be checked: Fluid levels in all cabinets, receivers, and reservoirs. ‘Main bearing circulating lube oil temperature for the O-Sepa and the ball mill. Reducer lube oil temperatures for the O-Sepa and the ball mill. All auxiliary equipment must be operational and should be checked. All inspection ports, access doors and clean-out openings must be closed to avoid leakage of air and/or spillage of material. ‘All material handling systems are ready for operation. ‘All dampers and actuators are calibrated, operational and functioning. ‘There is sufficient stock of materials for operation. Mill liners are fastened. Pane 11 ned Oo Scanned with CamScannerINSTRUCTION MANUAL, PENNA CEMENTS UAE 4.10 441 5.0 Faw meal blending system is operational i lI bag dust collectors used for venting the silos. perational including all bag di Consult the manuals for the ball mill and the separator for the procedures to conduct the no-load tests on this equipment. START-UP When the mill is first started it should contain neither media nor material. It is to be ‘operated under no load conditions. Prior to starting the mill, verify all components have adequate lubricant coverage for initial start-up. Put oll into the trunion. Turn on the cooling water to the main bearings. Put the main bearing lubrication system into operation at least 30 second before starting the mill. If the mill has a gear and pinion drive, the pinion lubrication system should also be started 30 seconds before the mill and the gear spray system should be placed in operation. Start the mill, run it for a period of one to three minutes, then stop it. Check for adequate lubrication. If the lubricant coverage on the main gear and pinion is not adequate add some manually. if the lubrication is satisfactory and no unusual noises were heard, restart the mill run it for another 15 minutes, stop it and inspect it again. Upon satisfactory completion of inspection, the mill can be restarted to begin a 24- hour no-load break in run. After 8 hours, however, the mill should be stopped and all fasteners checked and tightened as necessary. These include those accessible only from the inside of the mill as well as those on the outside. Check those on the foundation, sole plates, heads, liners, diaphragm, grates and gear. Using the gear instructions provided separately check the contact between the gears to verify that conditions have not changed. Restart the mill and allow it to run for the remainder of the 24-hour period, During this period, inspect it every two or three hours for adequate lubrication. NOTE A constant check for over heating must be carried out on all bearings. If over heating does occur, the mill must be stopped immediately and corrective action taken, These periods of initial operation are primarily for the initial running in of the main bearings. It is essential that they are checked closely and adequately lubricated, Periodically check the bearings internal lubrication system to verify that lubricant is being distributed to the mill bearings as the mill rotates. Its operation can be observed through the inspection covers on the bearing housing. Scanned with CamScannerINSTRUCTION MANUAL MIDTH PENNA CEMENTS UAE When 24-hour period is com , , an ipleted, stop the mill and inspect it carefully. Again all the Rateners shoud be checked and tighiened in the same manner as was done after ‘Ours of operation. Recheck i .d pinion for proper tooth contact and lubricate jeck and inspect the gear and pi Partial Load Operation The initial 24-hour period of operation should have conditioned the bearings for operation under loaded conditions. Charge about 25% of the normal load of both grinding media and material in the mill. Start the lubrication systems and bearing Cooling water; then in 30 seconds start the mill, Adjust the feed rate as necessary to keep the charge at about 25% level and allow the mill to run for a 24-hour period. During this period close watch is to be maintained on all bearings for overheating. On a gear driven both gears should be checked for possible binding. When the run has been completed, stop the mil, inspect it carefully, retighten all fasteners again and check gear contact. Mill load should be increased gradually with consultation of FIL personnel. 85% Load Operation At this point the reminder of the media is added. When the mill is restarted, increase the load of the material gradually until the rated charge is reached and adjust the feed rate to maintain it. When a gear and pinion mill is placed in operation under full load, stop it once each shift and inspect the gear and pinion for proper tooth contact and lubrication. During this shut down period all fasteners including diaphragm grate bolts should be tightened. The tightening process should continue for at least one week or until it is evident that they require no further tightening. After one week of operation under fully loaded conditions the pinion and gear tooth contact pattern is to be examined. Refer to the separate instructions covering gear installation and alignment. Any misalignment is corrected by placing shims under the pinion bearings. If shimming is necessary the contact pattern must be rechecked at eight points around the gear. Scanned with CamScanner6.1 62 6.3 64 65 6.6 67 68 6.9 6.10 INSTRUCTION MANUAL PENNA CEMENTS UAE STARTING SEQUENCE Start silo feed group. Start the Mill lubrication Group. 621 6.22 623 6.2.4 6.2.5 O-sepa main bearing & reducer lubrication oil pump starts. Mill main gear box lubrication pump starts. Feed & discharge end trunion bearing lubrication pumps(LP) start. Feed & discharge end trunion bearing lubrication pumps(HP) start. Girth gear & pinion lubrication system starts Start raw mill bag house extraction Group. Start raw mill bag house fan. Start raw mill dust collector fan. Start Osepa fan group. Start Recirculation group. Start Mill Dustcollector filter and its Transportation group. Start Mill Group. Start Raw mill feed group. Scanned with CamScannerTA 72 73 74 75 7.6 PENNA CEMENTS UAE CAUTION ut new feed. minutes witho e xcessive damage, and to & The mill should not run for more than five (5) Failure to follow this procedure could lead to liner wear of the mill liners and ball charge. NORMAL OPERATION adjusting the separator Airflow through the O-Sepa system should be maintained by ID fan damper and Recirculation damper in recirculation duct. Airflow through the mill should be maintained by adjusting the Mill Dustcollector fan damper . Product fineness is controled by adjustments to the speed of the O-Sepa rotor. ial exit temperature is controlled by the mill inlet bleed air damper. Mater he selected weigh feeders. Materials are automatically proportioned by t! ‘ode with an initial feed rate of 80-85% of the design value. When the operation has stabilized, approximately 20-30 minutes, check the fineness of the product. Adjust the rotor speed to attain the target fneness. An increase in rotor speed produces a finer product, and vice versa. The mill will be started in the Manual mt SS | Scanned with CamScannerPENNA CEMENTS UAE a STOPPING SEQUENCE Stop Mill feed group. 8.1 2 Stop Mill Group. 8.3 Stop OsepaFan Group and Mill Dustcollector fan. 8.4 Stop Mill Dustcollector and its transportation group. 8.5 Stop Recirculation group 8.6 Stop Baghouse fan 87 Stop Mill Lubrication group 8.7.1 Girth gear & pinion lubrication system stop. 8.7.2 Feed & discharge end trunion bearing lubrication pumps(HP) stop. 8.7.3 Feed & discharge end trunion bearing lubrication pumps(LP) stop. 8.7.4 Mill main gear box lubrication pump stops. 8.7.5 O-sepa main bearing & reducer lubrication oil pump starts. 88 Stop Silo feed group and Baghouse extraction group. NOTE The high and low-pressure pumps will remain running for a 24-hour period before stopping. Failure of these pumps to operate could lead to damage of the mill bearings. During power failures the emergency power must be turned on immediately and these pumps restarted as quickly as possible. Scanned with CamScannerPENNA CEMENTS _ INSTRUCTION MANUAL UAE TROUBLE SHOOTING CHART POSSIBLE CAUSE REMEDY OUTPUT DECREASED, Increase in lime stone hardness and size Mill charge too wom. Mill volume loading too low. Too small bodies used for make up. Diaphragm slots partially blocked. Fractured diaphragm PRODUCT TOO COARSE Proper adjustment of O'Sepa rotor speed and correct quantity of air volume at O'Sepa outlet. Grinding media too largo. Mill volume loading too low. Diaphragms slots too worn, Last chamber media Examine raw mill feed bond work index and sleve analysis. Dump charge, regrade and make up new change. Measure each chamber and add correct tonnage of new bodies. Charge should be dumped and regraded, or (less satisfactory) use largest bodies for make up. Inspect diaphragms clean slots. Replace section(s). To get target product fineness , correct quantity of air volume at separator outlet as per process flow sheet is to be maintain .By adjusting the rotor speed ,product fineness can be controlled. Make up with smaller media ex. 50/50 of the two smallest sizes. Measure each chamber and add correct tonnage of new bodies. Replace as soon as possible, (with steel diaphragms, weld bar into worst slots as a temporary measure). Dump and recharge or make up with large media. Scanned with CamScanner3. MILLEMPTIES a. Insufficient feed. b. First diaphragm slots worn, c. Decrease in Lime stone hardness and size, 4. CHOKED DIAPHRAGMS 2 Steel diaphragm slots closed by metal flow. b Tramp metal in feed. c Grinding body pieces formed in mill Over wom grinding media. PENNA CEMENTS UAE INSTRUCTION MANUAL Increase feed slowly. See section 2d above. Check raw feed bond work index and sieve analysis. Burn/grind out slots to original width, replace diaphragm soonest. Use “harder” materials specification rather than steel. Greater care and tidiness when scrap metal is handled and repairs are carried out in proximity to clinker store and clinker handling systems. Examine cast iron and very hard grinding media for casting faults and casting excessive brittleness. Inspect mill for very large bodies mixed with very small bodies (If found, dump charge). Dump charge and make up with new. Scanned with CamScanneris mIptH nustauoTON PENNA CEMENTS oe UAE OPERATING INSTRUCTIONS AND REFERENCE MANUAL FOR CEMENT GRINDING CUSTOMER : PENNA CEMENTS PLANT LOCATION 2 UAE FL. SMIDTH LIMITED 1 PRIO4-020-729 WORK ORDER Prepared by? 7. SRINIVASAN Doe.No. Checked by: N.V.THIRUNAVUKKARASU | Rev. + 0 Approved by: ‘S.SARAVANAN Page 1 of 33 Scanned with CamScannerGism IDTH PENNA CEMENTS UAE INSTRUCTION ‘MANUAL contents: 1. PLANT DESCRIPTION PROCESS DESCRIPTION CONTROL SYSTEM AND CONTROL Loops START OF GRINDING INSTALLATION STOP OF GRINDING INSTALLATION MILL OPERATION OPERATIONAL FIGURES, ALARM SETTINGS AND CONTROL MODES EQUIPMENT FLOW SHEET 1. 16 22 24 28 ‘Scanned with CamScannerINSTRUCTION MANUAL Gismiotn PENNA CEMENTS UAE NOTE! The present instruction manual is dealing with the situations that, according to the experience of FLS, are the most likely to occur. An exhaustive enumeration of all conceivable situations that may occur during the erection / operation/maintenance of the plant/machine/equipment cannot be provided. Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual, and which the operator is/or feels unable to handle, we would recommend that FLS is contacted without undue delay for advice on appropriate action. SEPARATE INSTRUCTION MANUALS The plant under review also comprises several other instruction manuals containing detailed information about the single machines or arrangements. Page 3 of 33 Scanned with CamScannerINSTRUCTION MANUAL Gismiotn PENNA CEMENTS UAE 4, PLANT DESCRIPTION qhis manual covers the Cement Mi11 system. 4.1. Cement mill department plant: Penna Cements, UAE Department: 2 x 110 mtph Cement Mill for OPC. The layout of the mill department is shown in the flow sheet. 1.2 Data of main machinery The closed circuit cement mill department includes: Feed system. © Ball mill 2xUMS 42 x 14.5 * Mill bag filter * 2 x N-3000 0-Sepa separator * Separator circuit Dedusting Bagfilter 1.3 Performance Cement mill system is designed for a production of 2 x 110 tph OPC cement, with a Blaine fineness of 3000 cm*/g. Feed composition is 95% clinker, and 5% gypsum. 1.4 safety and risks 1.4.1 General The cement mill production unit is operated from the operator panel in the central control room. It is seldom that the operators are very near the production units uring operational periods. Adjustment of process Parameters is only performed in very special situations in Page 4 of 33 acascil Scanned with CamScannerfis mort INSTRUCTION PENNA CEMENTS MANUAL UAE the cement mill or in the separator ing sto A uring stoppage, the maintenance crew will be active both inside and outside the machinery visitors to the plant may be around in the cement production unit. Therefore, they mist be instructed in the same way as the plant personnel about the risks and safety regulations with respect to the cement production unit. Every person, who may be around or inside the mill/separator or other machinery, must be instructed about the special safety aspects related to the cement mill production unit and equipped with the necessary safety equipment. 1.4.2 Cement The product from the cement mill is powder with dust i.e. cement. The cement is not aggressive to the skin, and in this respect there is no health risk involved. However, the cement is warm/hot and cannot be touched without wearing protective clothing, gloves masks, etc. This is general for the plant. Therefore, protective clothing - including spectacles and masks etc. - is worn as a general rule for the plant. In the cement mill, and when working in the cement mill production unit, a major risk is THE POSSIBILITY OF CREATION OF WARM/HOT CEMENT DUST. if the cement mill blocks This relates to the inside of the cement mill, a rt~—™T——C—“‘ :;S TTP Page 5 of 33 Scanned with CamScannerINSTRUCTION ‘MANUAL Gismiomn PENNA CEMENTS UAE transport system. There is also a possibility of touching the hot clinker feed on the feeder and when it is fed into the mill inlet. In order to reduce/eliminate these risks, it is necessary to maintain the plant as clean as possible, and to make sure that all personnel wear gloves, safety shoes, and safety equipment like masks, protective clothing, etc. Safety interlocks rg the mill inlet under pressure cannot be obtained the mill will stop after 2 minutes. The above interlock is performed in order to prevent dust emission from the mill inlet and thereby to eliminate the risk of dust hazards to the personnel. 4 Safety stops The machinery in the cement production unit must be able to be stopped when the respective emergency stops are activated. During repairs and inspections, inside and outside, the cement mill and other equipment must be secured against any possible start. These safety aspects must be coordinated with the safety policy of the plant. The plant must be tested with material before start-up. Please also refer to paragraph 3 in the present instruction. Scanned with CamScannerINSTRUCTION MANUAL PENNA CEMENTS UAE ilure a sudden power failure can cause dust emissions. A yestart after a power failure might be troublesome. The pneumatic transport line might be difficult to restart with cement powder in the pipeline. If leaks occur, severe dust emissions might occur. It is therefore necessary to wear full protective clothing, gloves, nasks, spectacles, etc. when present in the plant during a restart after a power failure, 1.4.6 Failure of control circuits @ prevented by the design of the Pangerous situations control circuits and interlock system, please refer to paragraphs 3 and 4 in this instruction. ‘The cement mill system is designed in such a way that if the mill fan stops, then the mill will stop after 2 till be risks of pressure minutes. However, there might in the mill inlet due to sequence delays in the system, error to the damper of the mill fan and electrical temporary connections made prior to start-up. M1 control circuits, interlocking, start and stop Sequences must be checked before start with material, Be in this stage of the plant as quential interlocking might aware of the special risks all for example safety oF No? be in installed 100%. Make sure that testing is agreed between the electrical, mechanical and production department. Scanned with CamScannerINSTRUCTION ‘MANUAL Gismiotn PENNA CEMENTS UAE 2. PROCESS DESCRIPTION PROCESS DESCRIPTION Feeding arrangement Separate weigh-feeders are extracting the feed components from the feed bins in the set Proportions. The feed is ee ee let Of cho li by means of the toca conveying system, Bee cottroller ig eninge ao between the feed components in accordance with the selected set points. UMS Cement _Mi11 For detailed description of the mill see the instruction for mill maintenance, The UMS mill is a two-compartment ball mill. The first compartment is filled with large grinding media with the main purpose of crushing the mill feed. The second compartment is filled with small grinding media with the nain purpose of fine grinding. The two grinding compartments are separated by a diaphragm and filled with an amount of grinding media corresponding to the desired power up-take of the mill. A water injection system is included for the mill outlet for automatically maintaining a constant temperature at the mill outlet under all operating conditions. The material, leaving the mill, is transported by a screw conveyor, a bucket elevator and an air slide to the inlet of the separator. L Page 8 of 33 Scanned with CamScannerEe IDTH wisraucTION PENNA CEMENTS ae UAE o-Sepa Separator The mill product is transported to the O-SEPA separator. The air to the O-SEPA separator is drawn by the O-SEPA fan to Bagfilter for material collection, In the separator the dispersed material is divided into two streams. The coarse rejects are returned to the mill inlet via an impact weighing unit for further grinding, and the fine product is transported out of the separator by the separator air and collected in the Bagfilter. The collected finished product is transported to the cement silos. Part of the air after the O-SEPA Bagfilter could be recycled to the separator via the recycle duct and damper and enters the separator through the large air intake. The remaining part of the air is vented through chimney. The temperature of the product is controlled by adding cold air through a motorized louver damper to the above mentioned recycling airflow. If additional cold air is needed then the cold air damper in front of the small air intake to the separator is opened and a suitable position for the operation is found. The cold air damper in front of the intake is then maintained in this position, making it possible for the other cold air regulation to operate. Mill gas system During operation the mill is ventilated with a certain amount of gas in order to remove water vapours from the mill and create a negative pressure at the mill inlet, Page 9 of 33 Scanned with CamScannerINSTRUCTION MANUAL PENNA CEMENTS UAE avoiding dust emission, the mill vent gases are cleaned in a separate bag filter. some of the particles transported by the mill vent gases to the filter may be coarser than the desired product, especially at high gas velocities in the mill. Depending on the fineness of the filter dust, the dust can be selected either returned to the separator feed inlet or the finished product stream by means of a changeover gate. Product Transport The finished product collected in the separator Bagfilter and transported to the cement silo. The transport line between the product collection filter and the product silos is equipped with a screw type material sampler for continuous sampling of the finished product. re oie Wee. eieaeasl Scanned with CamScannerINSTRUCTION UAL PENNA CEMENTS ee UAE Gismiomn 3, CONTROL SYSTEM AND cowPRoL Loops EE SERRE AND CONTROL LOOPS, Ore ee ee ings, Garces ana grace equipment are operated and controlled by the central control system. Programs for operation of mili department From the central control room the cement mill department can be operated by selection of a number of programs and a number of direct functions, The control system structure consists of a number of motor eee ees Of each groan cen be cea cre built-in sequence of the motor group. within a motor group a machine can only be started if the down stream machines are in operation. A motor group can only be started if the down stream groups are in operation. The programs, installed in the control system, will perform the start and stop procedures for the machines divided into groups. Further the operation is automatically supervised, checking constantly all interlocking for operation, protection and safety. Electrical interlocking The detailed information about the interlocking, as Programmed, is described in the interlocking diagrams, however the main philosophy is given as follows: Operational interlocking The general rule of operational interlocking is that no machine can be started before the subsequent machine has been started. Inversely, stop of any machine will cause Mie | Scanned with CamScannerism IDTH instAUTIN PENNA CEMENTS en UAE ene stop Of the preceding machine. This follows the process order. . Protection terlockin protection interlocking Like « Bearing temperature + Gear vibrations | + Motor winding temperature « Minimum oil level * speed monitors « Maximum material level, etc. will all stop the machine in question, in order to protect the machine. In most cases a pre-warning alarm will appear at first. Control loops To ensure operating stability, and hence a uniform product, the mill plant incorporates control loops, each separately maintaining one of the operating parameters of the mill plant. Mill feed proportioning Each of the feed components can be set to a certain Percentage of the total feed, which at all times must total 100%. The proportioning controller will maintain the set percentage of each individual feed component irrespective of changes to the total new feed rate. Si ssa ah cs ke ao esa cnecnelll Scanned with CamScannerINSTRUCTION MANUAL PENNA CEMENTS UAE ghe total mill feeq measured as the sum of the new feed and the rejects from the separator ig maintained at the selected set-point value by controlling the rate of new feed to the mill. The new feed rate is supervised by the sound level in the first compartment of the mill. The new feed rate will automatically be reduced if the sound level goes below a set minimum value, qhe set-point for the total mill feed is supervised by the power consumption of the mill elevator, The set-point for the total mill feed will automatically be reduced if the power consumption of the mill elevator is above a set naximum value. vaterial temperature at mill outlet The material temperature at the mill outlet is maintained constant at the set value by controlling the valve of the mill outlet water injection system, The water injection at the mill outlet can start when the material temperature at the mill outlet is above 110°C and must be stopped if the temperature at the outlet is below 105°C. Mill outlet temperature has also a high alarm max2 at 135°C which will stop the mill in order to protect personnel and equipment. Separator Airflow Maintaining a high and constant efficiency of the Separator requires a constant airflow through the separator. The airflow in the separator system is Page 13 of 33 Scanned with CamScannerPENNA CEMENTS UAE paincained at a constant level by maintaining constant wee consumption for the separator fan, The damper at the ceparator fan inlet is used for airtiow control genotely Controlled Devices from the above mentioned control loops, which can rk in manual mode, par! also WO? renotely controlled from CCR: the following devices can be yj inlet under-pressure qhe mill inlet under-pressure is maintained by adjustment of the damper of the mill ventilation fan. The inlet is to pe dust free. position of all dampers position of ali dampers all control dampers can be controlled manually from the | central control room. Separator rotor speed since change of the separator rotor speed will influence the fineness of the product, the separator speed is used for adjustment of product fineness on an hourly basis. hen operating at a constant system gas flow, a higher separator speed will result in a finer product, a higher amount of separator rejects and lower production from the installation. Lower separator speed will give the opposite result. The separator speed set point is chosen by the operator on the basis of the cement fineness analysis from the laboratory. Page 14 of 33 Scanned with CamScannerINSTRUCTION ‘MANUAL PENNA CEMENTS UAE ario of individual feeders R : he feed ratio of the individual feed components can be contvoiied from the central control room cpange over gate for selection of cement silo poring mill operation the operator can change the selection of target cement silo chamber from the central gontrol room without stopping the mi11, Page 15 of 33 Scanned with CamScannerINSTRUCTION ‘MANUAL PENNA CEMENTS UAE oom goant_OF GRINDING INSTALLATION re | causa mmanamRUMR acre on | pyoroqussites g-hour no-load test 1s recommended prior to the initial | yart-up of the grinding plant si repair of main machinery, o and in case of replacement gefore the mill plant is started up, the operator must be guly familiar with the control system and its functions. qne control panel must be checked and all alarms - such as notor alarms, emergency stops, etc, — must be cancelled. sne plant personnel mist have reported the plant ready for operation from the mechanical and electrical maintenance departments. Please also refer to paragraph 1.4.6. yore specifically, this means: + That all mill adjustments according to the mill maintenance instruction have been made. + That repair, if any, have been completed. * That doors and inspection hatches are closed. * That filling of lubrication oil has been carried out, and that all oil levels are checked. * That the instruments are calibrated. * That all instruments function as intended, hence ensuring, in every aspect, full operational status of the machinery so that start-up of the plant can be conducted in a safe manner. * The process equipment must have been inspected and cleaned of any blockings and accumulations of Be ee Scanned with CamScannerPENNA CEMENTS “a UAE : ipti i prailed description of maintenance procedures is given é i > arate instru i one sep ction manuals for the single i actin tea qperatsonal tems, it is necessary that m 7 naw materials are available in quantities justifying start-up, and the product silo are not full cooling water is ensured in sufficient amount for all machinery . compressed air is ensured to all dedusting filters, and to all pneumatically controlled gates eating elements in the oil tanks and in the mill filter mst be activated aS Soon as possible, gtart_of the auxiliaries y sufficient oil temperature in the oil tanks is a condition for the start of the oil and circulating pumps, and start of the installation. In sufficient time before the installation starts the heating elements in the mill bag filter must be activated, hence the risk of condensation in the filters can be avoided. The following group of machinery must be started: * Mill bag filter heating. * Gearbox lubrication units. pee ee Page 17 of 33 Scanned with CamScannermipTH PENNA CEMENTS “SENOAL UAE | ¢ main machinery ° © 5 ‘ gs? lowing start procedure for main machinery is ane ‘ ended? seo goz taneport te coment sito g aitions: seas om yo alarms in the group. pil machines in central mode and ready to start. sufficient pressure in the compressed air supply system for use of the bag filters. yo maximum level in the chosen cement silo. » Filters for dedusting of transport from the product collection Bag filter to the cement silos, and filters for de-dusting of the cement silo ready for start. start sequence: + Dedusting filter for the chosen cement silo. + Dedusting filters for cement transport system. + Cement transport system for transport of the material from the product collection Bagfilter to the cement silo. * Automatic sampler for continuous sampling of the finished product, if chosen. * Air sluices below the product collection Bagfilter. Seas Page 18 of 33 F Scanned with CamScannerINSTRUCTION MANUAL, PENNA CEMENTS UAE 10 ak gi machines in central mode and ready to start. : gut ticden™ pressure in the compressed air supply cyocen £08 998 of the bag filters. «conan transport group in operation. | youver Gamer before separator fan mist be closed. | ues Gamer before mill fan must be closed. ve sequence! ysl fan " eperator bearings and gear lubrication units. separator drive. transport from separator to mill lowed despite the fact that Due to the limited pejectS inlet. tote: This action is a (etnil2 “is not in operation. material in this transport compared to the anount 0} inlet, starting the wvailable space in the mill reject transport will not cause problems) « + separator fan. tte dampers at the separator fan are opened. start sequence continued: mili outlet to separator inlet. * Transport from or to separator ‘transport of mill filter dust finished product. ‘Mil filter. ts 1 fan damper is opened. page 19 of 33 Scanned with CamScannerDT H INSTRUCTION ge mi PENNA CEMENTS aaa UAE axiliary equipment a» nen the product and material transport program groups are operating, the auxiliary equipment group can be started. start sequence: « High pressure ang circulation oil pumps for mill bearings. When the oil Pumps “have been in operation for 120 seconds, the mill motor can start. Equipment related to the gear unit, as required. * When the mill motor has been operating for 60 seconds, the high pressure pumps must be stopped. vill When the above program groups are in operation, the mill group can be started. Start conditions: * The separator fan in operation with minimum air flow. * High pressure pumps operating for minimum 120 seconds. * Inching device disengaged. Start sequence: * Mill motor * Mill bearing high pressure pumps mst stop 60 seconds after start of the mill. Mill Feea System When the mill group is in operation, the mill feed group can be started. Start conditions: LC Scanned with CamScanner