Instrumentation in Binani Cement

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INTRODUCTION

ABOUT BINANI:

It was the turbulent times that Binani took a plunge into the abyss of business in

1872. The initial pot and pan trading was taking desirable shape. As times matured,

the ancestors of Binani, Seth Parayadas & Seth Mathuradas mustered the available

resources & ventured into the trading of non-ferrous metals while quality focusing

on import & export. Those who are ready for these risks, never stop. First it was

Seth Mathuradas & later his son Seth Govardhandas, a man of great resolve & the

singleness of purpose, discerned the potential of manufacturing rather than mere

trading of nonferrous metal. Binani metal works Ltd. fully feathered on 25-Feb

1941 was the uncrowned “Metal King” of the nascent sector.

The Second World War at this time made import of alloys uncertain due to

invasion of German Submarines in the sea. Binani Metal Works came rightly as a

savior at this to render services to Indian industries including Railways. The plant

was set up in Howrah, West Bengal, to initiate the production of non ferrous

alloys, cad, casting, powders & solder wires in collaboration with multi-core

solders, UK. The trading operation, the force of Binani was simultaneously getting

stronger with an Antimony Smelter Joint Venture in Bombay, reckoned as Metal

Distributors Ltd.

The collaboration was one of the largest trading and indenting houses of non-

ferrous metals in India & soon spearheaded to establish its office in UK.

The company went public for the first time in 1953. In 1983, Binani Metal Works

Ltd. and Metal Distributors went into merger, to be known world over, as Binani

Metals Ltd., the largest importer and distributor of non-ferrous metals in India

neither too.

With active participation of Seth Govardhndas Binani’s only son Ghanshyan

Binani, another enterprise came into being, Multi-metals Ltd. The factory was

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established in Kota, Rajasthan for production of Copper and copper alloys

extrusion in terminal and financial collaboration with Reverse Copper & Brass

Inc., USA. The fascination metal was unrelenting. The real of Zinc that of Binani.

In 1962 Binani entered into collaboration with the world leader.

Into the field of non-ferrous metals, Canada based Cominco Ltd. Cominco Binani

Zinc Ltd. seized the limelight for being the first procedure of primary zinc in India.

Cominco Ltd. latered catered off its support in alignment with their world wide

policy. The entity was renamed as Binani Zinc Ltd. on March 03, 1991.

The business skills were inherited by successive generations. The attentiveness of

his two sons Mr. Gokul Binani and Mr. Braj Binani, steered Binani into liver

suffocation of eminent industrial enterprises in1996, Binani Glass Fiber at Goa and

Binani cement Ltd., in Rajasthan.

To signify its status as a multi product & multi location company a name was

inevitable, to Binani Industries Ltd.

As amalgamation of new operation, new leadership and enter prencurial skills,

innovative thinking and indigenous strategies called for up-gradation of

organizational structure. Thus the cement division of Binani Industrial Ltd. has

been lived off and transferred to Binani Cement Ltd. as a wholly owned subsidiary

in Nov. 01, 1997 while Binani Glass Fiber has been likewise transferred Goa Glass

Fiber Ltd., a wholly owned subsidiary with effect from Dec. 01, 1999.

Activities have been remarkable overseas with the acquisition of Copper Mines,

Copper Swelter, Tea Gardens & a Copper Rod manufacturing plant, all in Zambia

besides setting up cement grinding unit at Dubai.

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CEMENT

Definition

Cement is any substance, which can join two or more pieces of

some other substance together to form a unit mass. It’s 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. In other words Cement

is a mixture of limestone, clay, silica and gypsum. It is a fine powder which when

mixed with water sets to a hard mass as a result of hydration of the constituent

compounds. It is the most commonly used construction material.

Type of Cement:-

There are different varieties of cement based on different

compositions according to specific end uses namely

Ordinary Portland cement in different grades.

Portland Pozzolana Cement (PPC)

Portland Blast furnace slag cement (BBFS)

White Cement

Sulphate resisting cement (SRC)

Oil well cement

Masonry Cement etnal.

Ordinary Portland Cement (OPC) Is develops enough compressive strength in 3

days, 7 days or 28 days to be suitable for all types of modern civil engineering

construction and White Cement (WC). Portland cement types are grayish color due

to complex formed with iron oxide. If iron oxide is reduced to less than 0.4% the

color of cement becomes white. Iron oxide helps in improving burning condition,

therefore, with low iron oxide in white cement raw mix, burning becomes difficult.

Even traces of iron oxide present in white cement impart a dirty shade, to remove

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which clinker has to be conditioned suitably. It can be used for all types of

construction in which ordinary Portland cement is used but it’s costly.

Grade of Cement

It refers to the minimum compressive strength of cement and standards and mortar

cube as per Indian Standard Specifications. For e.g. 33-grade cement should give

minimum compressive strength of 33 Mpa after 28 days. The various grades of

cement are 33, 43, and 53.

Manufacturing of Cement

Steps

Fig: 2.1 Steps of Cement Manufacturing

The limestone having been received in required size (1500 MM max.) is passed

through FLS make E.V.Crusher and crushed into product size less than 80MM

size.

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The crushed limestone is stacked and reclaimed in CIMMCO make continuous

stock pile of 60,000 MT capacity with blending efficiency of 10:1 crushed

limestone is fed through weigh feeders into Loesche make Vertical Roller Mill

(VRM) with production capacity of 225 TPH where further crushing takes place.

Products from VRM are fed into Fuller make IBAU continuous Flow Silo (C F

Silo with a storage capacity of 1600 MT and blending efficiency of 10:1. In

Blending Silo the blending is done with help of compressed air and discharged into

Kiln feed bin for onward transportation to Kiln for clinker production.

Kiln feed for old plant is also transported from CF Silo to old Blending & Storage

for clinker manufacturing with the help of FK Pump, bucket elevator and

pneumatic gravity conveyor. Form KF Bin, the material is fed to 6 stages Pre-

heater equipped with SLC-S Calciner. Here the material is heated with hot gas

production in Kiln and Calciner to the tune of around 8800C.

Heated material discharged from pre-heater then enters in Kiln having size of 4.27-

M dia. and 61 Meters long with a slope of 4%.

Hot clinker discharged at a temperature of around 1250 dg.c from Kiln is then

cooler to around 120 dg.c in Fuller make CLS/CFG/RFT 2 grate horizontal cooler.

Clinker produced in Kiln 1 is also transported to clinker silo with the help of Deep

Pan Conveyor.

Cooled clinker is stored in 2 Nos. Pre-stressed concrete clinker silo having

capacity of 40,000 MT each we have an extra facility of open yard and off space

silo for storing of clinker produced from all three Kilns.

Clinker is then grinded with gypsum into 5 cement mills with high efficiency

separator.

Different grades of cement produced are stored in 6 silos of different grades and

packed in HDPE bags and transported by wagons and trucks.

The whole plant is divided into three sections

Mines

Processing area

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Dispatch or Packing Plant

The lime stone which is the basic raw material for cement manufacturing is

obtained from mines. Then it will undergo processing at different stages at

processing area and final product i.e. cement is dispatch from packing plant. A

brief explanation about each section will be explained afterwards. An oral view

about each section will be discussed as under.

Mines

Binani cement has wide range of mining area spread over 390.625 hectares

including shovels, dumpers, and dozers. The raw material i.e. limestone is

obtained by blasting over the required places. Then the raw material is

accumulated by dozers and shovels along with dumpers get through crusher. Then

the crushed material gets accumulated at limestone pile. From there with the help

of stacker and belt conveyors goes to the hopper building as per its grade.

Processing Area

Process area includes VRM section, Kiln Section along with Cement mills. Process

area is divided into three phases which includes Unit1, Unit 2 Phase 1, and Unit 2

Phase 2. Unit 1 only includes only clinker producing part i.e. Kiln area only. Unit 2

Phase 1 and Unit 2 Phase 2 includes all the above mentioned section i.e. VRM,

Kiln, Cement mills. Going for particular section we found that VRM is comprised

of hydraulic rollers through which the material is grind. This material with the help

of raw mill fan lift up and with the help of air slides goes to C.F. silo i.e.

continuous flow silo. From there the material is lifted to pre heater through two

different methods, one is through air lift and another with the help of bucket

elevator. Mostly material is lifted with the help of bucket elevator only. This

material is then passed from pre heater and goes to kiln and fro heating, and there

only it will change its phase at temperature of 1300 deg C. This material is then

cooled down in grate cooler drive with the help of coolers. And with the help of

pan conveyor lifted to clinker silo. From clinker silo the clinker with the help of

belt conveyors goes to cement mill hopper building at where clinker along with

gypsum and fly ash for the required grade of cement sent to ball mill drive with the

help of weigh feeder and belt conveyors. The final product from the cement mill

with the help of air slides goes to cement silo. This section comes under processing

area.

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Packing Plant

From cement silo the material is sent to packer from where the material is packed

in cement bags and dispatched by the wagon loaders. There are two units in

packing plant. Unit 1 And Unit2, Unit 1 has got 8 truck loaders and 4 diverters.

Unit 2 has got 8 truck loaders and 4 wagon loaders. There are 5 cement silos. The

material in Unit1 can be taken from cement silo 1,2,3,4. And in Unit 2 material can

be taken from silo no. 3, 4, 5 silos. The packers used in Unit 1 are of two types

Ventomatic packers and another type is EEL packers. In Unit 2 there are on

ventomatic packers with 12 nozzles and double discharge.

MINES

As we know that limestone is the basic raw material for cement manufacturing.

Thus it is required in bulk quantity for production of cement. So therefore cement

plants are thus established near the place where there is abundance of limestone.

As discuss earlier that Binani cement has got limestone mines spread over 390.625

hectares area. The area is divided into 6 blocks. Open cast mines are there and

mining operation is done in benches and each block is divided into 11 benches of

height 9 meter each. In these benches to obtained raw material hole of 9 meter

deep are drilled by drilling machine. These holes are then filled with explosives &

then they are blasted. The scattered material is then collected by dozers & by the

help of shovel they are loaded in dumpers. These dumpers transport raw material

to crusher.

Fig: 2.2 Mines Blasting

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CRUSHER:

The limestone had been received in required size (1500 mm max) is passed

through FLS make EV crusher and crushed into product size less then 80 mm,

crushed material is passed through Bulk Material Analyzer (BMA) to find out the

composition of material, only 25% of material is analyzed by BMA, rest sample is

taken manually and tested in laboratory for composition identification. For filtering

out material less then 80 mm size we use vibrating screen from where the material

greater then 80mm size is rejected

Fig:2.3 Matrial sand Crusher

STACKER AND RECLAIMER:-

Stacker: - Stacker is use for pre-mixing the raw material Lime Stones and

store the raw material in form of piles. Three types of operation can be

selected by switch in the control room. These

three modes are such as:

1- Auto Mode

2- Manual Mode

3- Local Mode

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Stock piling with stacker:-

[i] Process Description:- The mix bed consists of two equal consequentially

arranged material.These material oils are used both for the storing and pre-

homogenisation of the material to be stacked. The material pile arranged at the rear

can be excavated as the material pile is stock pile.

[ii] Stocking the mix bed unit:- Stockpiling the mix bed is carried out is

accordance with the called "CHEVRON METHOD" with the aid of a stacker with

a travelling tripper. The stacker with the travelling tripper discharges the incoming

material in layer on to the ground during its travel pile. In this way until it has

reached its full capacity. As a result the pile consists of a mix of about 400 layers.

Reclaimer:-

Reclaimer is used for transferring raw material to hopper from the piles stock

through a R.B.C. Reclaimer is noting it is just chain arrangement

Diffrence between Stacker and Reclaimer:-

1 Stacker have only D.C. motor drive while the Reclaimer has D.C as well as

A.C drive A.C drive motor is used for transferring from one pile to another

pile.

2 Stacker has a level control sensor for contracting the pile height where as

in the Reclaimer. There is no use of level sensor.

3 Stacker has a belt arrangement while Reclaimer consist chain arrangement

for transferring the material.

The crushed limestone of less then 80 mm size is stacked & reclaimed in

CIMMCO making continuous stock pile of 6000 MT capacity with blending

efficiency of 10:1. Using conveyors belts, raw material is transferred to hopper, in

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Fig: 2.4 Stacker & reclaimer

hopper building. We have four varieties of hoppers in hopper building one is for

low grade, other is for high grade, and one for blended and last is for sand hopper.

VERTICAL RAW MILL

According to desired quality of cement, raw material (either of high grade, low

grade) is taken with the help of apron feeder, weigh feeder, and belt conveyors

taken to vertical raw mill. Vertical Raw Mill has got four hydraulic rollers and one

horizontal circular disc. The material coming from hopper building is grind

between horizontal circular disc & hydraulic rollers. The grinded material is

sucked from top by raw mill fan and coarse material is recycled back to main feed

to VRM. Fine material as sucked by raw mill fan goes to cyclones where the

material is separated from air through these four cyclones and one bag house. Kiln

Fine material is now with the help of air slides goes to feed silo or CF silo.

Similarly the role of bag house fan. Air from pre heater fan divided into three

ways. One of the ways is to bag house where the material coming from pre heater

stick to bags of bag house and emit out but the material which stickled to bags gets

accumulated by the purging. The material is accumulated and with the help of

screw conveyors feed back to CF silo. CF silo having the capacity of 16000 MT

and blending efficiency of 10:1, in blending silo the material is blended with the

help of compressed air and the material is discharged to kiln feed bin for onward

transportation to Kiln for clinker production with the help of bucket elevator. There

are two methods through which the material is lifted to pre heater either with the

help of bucket elevator or through air lift. In case if bucket elevator fails because of

any reason the material is lifted through air lift.

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Fig: 2.5 Vertical raw mills

Hence special mill safety for the gear box, three high power lubricant pumps and For

grinding table's and roller's and roller's safety. Hydraulic pumps unit is used which is

specially design to done roller up/down motion by means of solenoid values.

In the raw mill bed thickness is controlled by hydraulic pressure and to making the bed

thickness water spray is used. By means of bed thickness, grinding table can be avoid the

problem of vibration and friction.The differential pressure of raw mill is about 600 mm

wg (max) linear voltage differential transformer (L. V. D. T.) is used for sensing the

position of roller by which we adjust the bed thickness.

Raw mill is used to convert the small pieces of 1ime stone into fine grinding

powder (known as raw meal). The capacity of Raw Mill is about 280 T/hrs.

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Advantages:-

1. Cheaper, simple in installation.

2. Low power consumption

3. Lower time is required for grinding.

Draw Back:-

1. Large Quality of air is required.

2. Higher wears and tear.

3. Higher maintenance cost.

4. More Vibration.

5. More sensitive to vibration in feed

PRE-HEATER & KILN SECTION:

From Kiln feed bin the material is feed to 6 stage pre heater equipped with SLC-5

Calciner. Here the material is heated with the help of hot gas produced in Kiln and

Calciner to various temperatures at various stages. Material from the pre heater top

is divided into double string pre heater i.e. new pre heater and old pre heater for

better efficiency. So the material is divided at the pre heater top and then it will

pass through various cyclones and heated at various temperatures at each cyclone.

Adding to this some of the material is also heated in pre calciner which is

connected to cyclones no 5 for high efficiency so that pre calcinations is done

before entering into Kiln.

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Fig: 2.6 Pre-heater

Heated material discharged from pre heater is then enters into Kiln area. The Kiln

has a diameter of 4.27 m and length is 61 mtr with a slope or inclination of 4%. It

has got two sections, burning zone and heating zone. In heating zone the material

is heated up to the temperature of 1300 0C. In burning zone the material is fused

and its changes.

Fig: 2.7 cooler

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Hot material into fused state is discharged from Kiln at a temperature of 13300C is

then cooled around 1200C in fuller make CIS/CFG/RFT 2 grate horizontal cooler.

Here the material is cooled down and transformed into another state i.e. now

clinker is formed. Hence the clinker produced is the with the help of pan conveyors

goes to clinker silo. There are two pan conveyors one is for clinker or main silo

another is for off spec silo. This is for ready to sell clinker from here the clinker is

readily sold to the market. And from main silo the material is use in cement mills.

The capacity of clinker silo is 40000 MT each. The facility of off spec silo is

provided into both of two phases, Phase 1 and 2. Like wise the material as

discussed earlier transformed into Unit 1 silo there the material is passes through

various stages. Such that the material is taken to kiln feed bucket elevator with the

help of air slides. This material is then passed to pre heater and the material is then

going to Kiln. Here also the same procedure takes place and finally the product is

clinker which with the help of drug chain goes to main silo or clinker silo.

KILN:-

Speed of Kiln : 3.8 RPM(max)

Length of Kiln : 56m

Dia. of Kiln : 3.945m

O/L shell temp. : 3040C

Internal temp. : 14000C-1500

0C c

Angle of Kiln : 3.8

Capacity of Kiln : 180t/max)

Kiln motor : DC225kw.1000RPM

Cyclones:-

There are two cyclones in raw mill section. Cyclone is nothing but in this material

is separating come zone chamber. Here heavy particles of material are separated

from the raw material. From these cyclones raw mill is send through air sluice into

air sealed, blowers are used to transfer the fine powder i.e. meal.

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GAS CONDITION TOWER (G.C.T):-

Kiln gas temp. at GCTI/L : 370c

GCTO/L temperature : 170c

Height of GCTG : 20.5meter

Diameter : 07 meter

Separated flue gases from the top of preheated CO gas is measured with the help of Co

gas analyzer, goes into GCT to suction of smoke fan (S.G. Fan) or preheated fan. In the

Conditioning tower, remaining raw material with flue gases from the Pre-heater is

separated out by the help of water spray methods. In the conditioning tower water spray is

done according to temp of flue gases. There is also heat exchange property between water

and gases used. Separated material from GCT through screw conveyor and air slide goes

into air lift by the air again go to C.F. silo.

COAL MILL:-

Another important circuitry is of coal, which is as important as any other circuitry.

Here the coal mill is used to grind coal into powder from. The coal used are of two

types pet coke and Chinese coal. The most important difference between two is

that of sulphur which plays an important role in jamming of cyclone. Pet coke had

7% of sulphur and in Chinese coal that percentage will be reduced to 2%. The

process of coal circuitry is as discussed below. First the coal is emptied in coal

gantry by the truck with the help of truck tippler. Now with the use of belt

conveyors it is taken to coal yard. Here with the help of EOT crane and belt

conveyors the coal is taken to coal stock pile. Binani cement has got to EOT crane

with the use of what the coal is emptied in belt conveyors which take it to the coal

stock pile. From there the coal is taken to coal mill where the coal is grind in

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powder form up to its maximum finesse. Now with the help of coal mill fan the

powder coal is sucked from coal mill and it will taken to separator then to bag

house with the air. Now this air is emit out just like in raw mill bag house and the

remaining fine coal is accumulated with the help of purging and with the use of

screw conveyors the coal is transported to fine coal bin where it is transferred to

simplex bin from where it is taken for two purposes.

The first purpose of fine coal is in main firing which is required in Kiln main firing

so it is only used whenever we have to fire or light up the Kiln.

The another purpose of fine coal is for PC firing operation for pre calcinations of

raw material so as to obtained the better efficiency. It is continuous operation and

so in this coal has to be continuously supplied. The separator of coal mill is just

used to separate the fine coal from the coarse material. The rejected material is

then send again to coal mill, where it will again crushed to its ultimate finesse the

same procedure will be repeated again and again.

Now again coming to clinker cycle. As we discuss earlier the clinker is emptied in

clinker silo from where with the use of belt conveyors the clinker is continuously

emptied in clinker hopper. Similarly the gypsum from the gypsum yard is taken

with the help of belt conveyors and emptied in gypsum hopper. As according to the

requirement the fly ash is also used to make the required quality of cement. So

form making the PPC the fly ash is also used. From these hoppers the material with

the help of screw conveyors, weigh feeder and belt conveyors is taken to cement

mill inlet chute. Now coming to cement mill section.

CEMENT MILL

Sections :

1. Weigh Feeder

2. Mill Inlet

3. Mill outlet

4. Bucket elevator

5. Separator

6. Bag House

7. Cement Silo

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Cement mill has got three sections

1. Inlet section

2. Intermediate Diaphragm

3. Outlet Diaphragm

There is also classifier in cement mill to classify the fine and coarse material.

Intermediate Diaphragm consists of holes through which pipes are connected

among which fine cement passes to other segment. Outlet Diaphragm inside which

air passage screen is connected. The use of air passage screen is to create negative

suction so as to suck the cement from the inside of cement mill. In outlet

diaphragm like intermediate diaphragm pipes are connected among which some of

the piped are make dummy. These pipes like wise allow the cement to pass through

it. The pipes are created dummy so to limit the excess of the cement from outlet.

From cement mill fine material is suck to mill vent bag house and from which with

the help of rotary air lock, screw conveyors, air slides cement passes through

cement silo. The coarse material is raised through bucket elevator.With the bucket

elevator the air slides are connected. This air slides takes material to separator.

Again in separator reject material with the help of belt conveyors goes to ball mill

drive inlet chute where the material is again grinded. This fine material from

separator goes to cyclone by the suction created by CA fan. From there the

material goes to separator bag house which is again used to separate fine material

and coarse material. Now under separator bag house the rotary air lock, then screw

conveyors and air slide the material is sent to cement silo. From cement silo the

material goes to packer in packing plant for its packing and dispatch. From air

slide coming from cement mill the material with the help of bucket elevator goes to

cement silo. The material i.e. cements goes to packer.

PACKING PLANT

The Binani cement has got two units of packing plant. Unit 1 has got two packers

one is EEL packer and other is Ventomatic packer. Similarly Unit 2 has got two

Ventomaticpackers.Going to packing details in packing plant, the type of packing

media used are of two types. One is truck loader and other type of media used is

wagon loader. The cement coming form limestone mines can be converted into

cement and dispatched from packing plant. Going in details about the process flow

in packing plant the material from cement silo is taken with the help of air slides

taken to bucket elevator. The material is taken to air slides through root blower.

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This material from bucket elevator is taken to vibrating screen. At this point the

material is also again classified between fine and coarse material. At the vibrating

screen there is counter weight which is rotated with the help of motor and as

counter weight rotates the screen vibrates. Then material is passed to feed hopper

whose capacity is 35 MT for Ventomatic packer. Through this feed hopper the

material with the help of feed valve or butterfly valve pass through packer tank and

then discharge through the packer in the cement bags and then as final product to

the loading media.

Fig: 2.8 packing plant

Now we will discuss the various capacities involved in cement manufacturing start

from the beginning of raw material and up to the finish of dispatch.

ROTARY PACKER:-

In the rotary packer filling sponts monitored side by side.The sponts on the rotary

packer move one by one in position in front at the rotator. In this works, operator

has to fit the value tails on the as they successively pass him, there are twelve

sponts in one rotary packer. The speed of rotary packer is 3 RPM and is controlled

by thyristor panel.

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Role of Instrumentation in Cement Industry

Instrumentation is used for safety of equipments, measurement of important

parameters, and control of process parameter and quality control of the final

products.

Under Safety Instruments:

In Binani Cement there are: -

1. Pull Cord Switch

2. Belt Sway Switch

3. Boot Level Switch

4. Pressure Switch

5. Zero Speed Sensor

For measurement :

1) Thermocouple for higher temperature.

2) RTD for bearing and winding temperature of motors.

3) Pressure transmitter for flow measurement.

4) DP transmitter for differential pressure.

5) Temperature transmitter for temperature measurement

(in PID Loops)

6) Current transducer for measuring current of the drives

7) Kilowatt transducer for measuring power drawn by the

drives.

8) Tachogenerator- for measuring RPM

9) Vibration Sensor

10) Level measurement.

Control of process parameter is through DCS supplied by TATA

Honeywell, Model TDC 3000. In Binani Cement closed loop (feedback)

control scheme is used to run the Plant.

To check quality of cement production (final product) they use X-

raymachine to check the constituents of cement and for raw material they

were using BMA (Bulk Material Analyzer).

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SAFETY INSTRUMENTS

Pull cord switch:-Switches are attached to the belt at equal distances and these

switches are joined by cords. If the material splits from belt the switch is triggered.

Also, in case of some accident the operator can pull the cord which triggers the

switch and the belt is stopped. Used in belt conveyors, deep bucket conveyors.

Belt sway switch:-To prevent the excess swaying of belt on either side switches

are attached, therefore, if the belt sways to the sides the switch is tripped which in

turn stops the belt. Used in belt conveyors, deep bucket conveyors, bucket

elevators.

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Zero speed switch:-The belt has a driver side which has a motor and a driven

end to which a proximity is attached It has four flanges which also rotates with the

motor and generate four pulses detected by a detector. In case of jamming or some

problem due to which the belt does not move in that case the proximity also does

not rotate and therefore the pulse which were generated earlier will not be detected

now and since the four pulses can’t be sensed therefore the belt is stopped. Used in

belt conveyors, deep bucket conveyors, rotary air locks, screw conveyors etc.

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Boot Level Switch:- This is used in bucket elevators through which material is

carried to higher levels through a chain of buckets. This switch is present at the

bottom of the bucket elevator and therefore it’s called a boot level switch. Used in

bucket elevators.

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MEASURING INSTRUMENTS

Thermocouple:

According to seebeck effect if a circuit is formed consisting of two dissimilar

metallic conductors and if the two junctions are at different temperature. Then a

thermal emf is generated which causes of the flow of current through the circuit.

The emf is a parabolic function of the difference in temperature below the two

junctions given by

e = At+Bt2

There are many type of junctions like J & K type. In cement industry K type

which has Nickel & Nickel chromium as the two wires is used.Hot junction is kept

under temperature to be measured. At cold junction MV proportional to difference

in temperature is generated. K type has a range of 0-12000C. This mV is measured

or detected as it is by LLMUX or converted into mA through transmitter and then

detected. Used for cyclone temperatures, kiln inlet temperatures, cooler

temperatures

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RTD

This works on the principle of temperature dependence of resistance. It is used for

temperature measurement. Here Pt-100type of RTD is used. This means 00C

corresponds to 100 ohms. Max range of RTD is usually not more than 4000C.

RTD can be two/three/four wires RTD. The third & fourth wire helps in

compensation and therefore more precise measurement. Here usually Pt-100 with 3

wires is used. Mainly used in measuring bearing and winding temperatures of

motors

Thermocouples are more accurate and have wider range but RTD is more

economic also Pt-100 is lightweight, stable & easily calibrated.

Tachogenerator In this the armature of the tachometer is connected to the machine whose speed is

to be measured. When armature revolves in the field of permanent magnet emf

proportional to the speed is generated. This can be measured directly or after

suitable conversions to find the speed of the machine. In case of ac tachometers the

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permanent magnet is rotating type and emf is generated in the stator coil. Used to

measure the speed of the fans, weigh feeders etc.

Current transducers

The current transformers is used with its primary winding connected in series with

line carrying current to be measured or the line on buss bar itself is made the

primary. Therefore it has very few turns so there is not any appreciable voltage

across it. The secondary is connected to measuring instrument or transmitter. It has

large number of turns.The high current flowing in the primary is step down into the

required range (4-20 mA) which can be detected by the instruments in DCS after

suitable conversions.

Kilowatt Transducers

In potential transformer the primary winding of the transformer is connected across

the line carrying the voltage to be measured and the measuring, voltage circuit is

connected across secondary winding like in current transformer. Unlike current

transformer the potential transformer can be considered as parallel transformer

with its secondary nearly under open circuit condition. Together with the potential

transformer a current transformer attached in the circuit forms a kilowatt

transformer.The primary for both transformers is the line for which measurement is

to be made. The high voltage and current is step down to the required range.

Transmitter can convert voltage to mA (4-20) and by knowing the angle of

potential and current transformer power factor, cos is known.

Power is calculated by P = 3 VI cos

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Level measurement

Level measurement can be done by many methods: -

- Capacitive type

- Vibrating fork type

- Radio frequency type

- IR type

- Ultrasonic type

In capacitive type of level measurement, a plate is attached at a, desired level the

other capacitive plate is formed by the bottom of the container when material is

filled it acts as the dielectric and the capacitance decreases with the increase in

level of material. At a fixed value of capacitance desired level is obtained and the

flow of material is stopped.

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In case of vibrating fork type of measurement a fork is attached when the material

is filled the vibration of fork is reduced and when the vibration is equivalent to the

desired level then its detected and the flow is stopped.

In case of RF and IR & ultrasonic source method the RF or IR sensor is at one end

and a detector at the other end of hopper. The material allows some rays to pass

and absorbs some IR/RF rays therefore by knowing the amount of rays reaching

the detector and the nature of material flowing in the level or amount of material

can be determined.

The level measurement can be point measurement or continuous measurement. In

case of point measurement the level is determined at any particular point. In

continuous measurement the level is measured continuously. Used to measure the

filling of the hoppers and silo.

Vibration Sensor

It can be capacitive type or LVDT type of vibration sensor. In capacitive type one

of the capacitive plates is kept on the vibrating surface the movement of the plate

causes a change in capacitance.

Similarly in case of LVDT the core of LVDT moves due to vibration and the

secondary of LVDT give an ac output voltage. Used to measure the vibration of the

VRM and fan vibration etc.

Transmitter – Pressure Transmitter

In pressure transmitter, by using diaphragm pressure or draft (- ve press) is

measured. One of the diaphragms is fixed and pressure is applied to the other

diaphragm. The reduction or increase in value of capacitance depending of

application of pressure or suction respectively is measured.

In differential pressure transmitter measurement is made by the difference in

pressure causing the movement of both the diaphragm. Used to measure the cooler

and kiln drafts.

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Solenoid Valve:-It is used to change the direction of the diverter. By using

solenoid valve air is sent in through one of the two pneumatic inlet ports which

cause the movement of piston in cylinder this causes the movement of diverter.

Solenoid valve has a plunger by the movement of which the inlet and outlet port

open and close and piston of diverter is changed. Used in pneumatic cut off gates.

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Weighing equipments:

Weigh feeders: Load cells are attached to the belt, which weigh the weight of

material per meter in kg/gm or tons/hr. By using tachogenerator the speed of the

belt is measured in m/s considering both the factors we get the weight measured in

kg/s on T/H of the material on the belt. Used to measure and control the feed in the

VRM and Cement mills.

Solid flow meter: When the material flows on the load cell with a fixed speed

the weight is measured in kg/m since the speed and distance is constant therefore

only the weight varies. Solid flow meter only measures weight and does not

control the flow of material. Used to measure the feed in the kiln.

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Loss in Weight System: This not only weighs the material but also controls the

flow of the material. The set point is given from the DCS and the output regulates

speed of screw. The controlling is done by microcount, which has a PID loop. The

hoppers have a buffer level of 3600 kg or 3.6 tons. When the level goes below this

coal starts filling upto a level of 4.5 tons. This is the volumetric mode and at the

time of filling the bottom end of hopper is closed. When the filling stops it goes

into gravimetric mode and the coal starts flowing through the screws attached

below the hopper. The load cells attached to the hopper make the loss in weight

measurement if the flow is more than the required set point then the speed of the

screw is varied and therefore controlling is done. It is used to measure the coal

firing in the kiln.

Control Method

Distributed Control System

There are numerous field equipments in a plant for safety and proper control of

these equipments some control scheme is required. There are number of

parameters to be checked and controlled (e.g. press, temp, pos) these parameters

have to be kept within certain set point for the proper function of plant and good

result.

In present computer era, most of the controlling part is performed through

computer on microprocessor. These turn out to be most efficient.

Earlier and even today for small plants one single computer is used to control the

whole plant but there were some underlying drawbacks of such a centralized

control method. It could not prove its efficiency for lager plants since load will

grow beyond its handling capacity resulting in improper control of the plant. The

biggest drawback is that if computer fails whole plant will shut down.

To overcome these drawbacks DCS, distributed control system came into

existence. The control is distributed. It reduces load on particular system and

failure of particular node does not affect other nodes and will not lead to the shut

down of entire plant. This control scheme is DCS.

We use TATA HONEYWELL’S DCS, the TDC 3000.

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System Characteristic of TDC 3000

TDC 3000 DCS architecture:

DCS consists of interconnected network, LCN & UCN. TDC 3000 is a data

acquisition and control system that can be tailored to meet your specifications. It

can be small or highly complex system with hundreds of devices.

The backbone of every TDC 3000 is a communication network, local control

network. LCN directly links those devices that provide following function.

1. Human interface.

2. Mass data storage.

3. Intensive advanced Control.

4. Interface blow multiple LCN’s.

5. Interface to computer.

6. Interface to process network.

LCN MODULES There are 13 LCN modules 8-US’s, 3 NIM’s and 2 HM’s.

The devices connected directly to the local control network are called LCN

modules. The standard modules according to their functions are -

1) Universal Station (Human Interface)

US is primary TDC 3000 human interface, it allows an easy and quick access to

data in any part of system. It has memory of 2 Mb & 3 Mb. An US can be

programmed to draw the schematic of different parts of plant using graphical

technique.

It works in three modules, called its personality.

Engineering personality.

Operator personality.

Universal personality.

Engineering Personality: The user is allowed to create on alter database,

display and load system software from HM on any storage device.

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Operator personality: Can see or send only object files. Operator monitors

or controls process and change process parameters through US and is not

concerned with technical aspects.

Universal personality: Can work in both engineering and operator modes.

System & process operation function includes following:

1. Monitoring & manipulating continuous & discontinuous operation.

2. Anticipating and handling alarms.

3. Displaying and printing trends, logs, journals and reports.

4. Monitoring and controlling system status and diagnostics.

Process engineering functions includes following.

1. N/W configuration.

2. Building process database.

3. Building custom graphics.

4. Designing reports.

5. Preparing control language programs.

Maintenance function includes.

1. Diagnosing system problem.

2. Displaying and printing information required during trouble shooting.

Design benefits:

Incremental expandability:-The functional specification of physical module

allows starting with those devices of internal requirement and available funds.

Expansion can be done by simple addition of hardware module without

reprogramming of software.

Global database:-TDC 3000 system function with a single database accessible

to all users by single access mechanism, which minimizes engineering costs.

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2.History Module:

It consists of hard disk a SMC card and a LCN interface card. Its main function is

to store data and system files data is stored on hard disks. SMC card is connected

to hard disks and LCN interface card. Personality of HM is loaded on SMC card,

which controls operation of disk and fetches the data from the disk. It in turn

supplies data to LCN interface card.

There are two history modules linked with LCN. HM is used for mass data.

Storage and therefore consists of hard disk and Helps in storage and quick access

of large blocks of data.

Stores process alarms, system status change, system files of all types and other data

when module is reloaded or US personality is changed required data and system

files are accessed from HM.

3.NIM : Network Interface Module

It provides an interface between UCN & LCN. NIM carries all the information of

the exit data points in network.

UCN based distributed control

Designed to be compatible with IEEE and ISO standards UCN is high-speed high

security process network. Its peer-to-peer communication capability allows for

easy sharing of process data, making it convenient to implement sophisticated

control schemes involving more than one process Manager, APM, LM or

combination of these.

UCN Modules:-Devices directly linked to UCN.

1. LM: Logic Manager

It performs digital and analog logic control function as an integral component of

Honeywell TDC 3000 DCS. The LM provides process automation for control,

communication monitoring of specific processes and a peer-to peer link with the

process manager system, or other LM’s on the UCN.

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LM system has high-speed programmable controller processor, power supplies,

option modules, serial and parallel I/0 links to field devices and a LMM that

provides an interface between the processor and UCN.

LM is programmed with ladder logic. LM system scans it’s I/0 interface, executing

control program for output devices and provides input status collected from input

devices. This information is processed and converted to UCN data format.

LM system consists of single/redundant LM processor. Redundancy in LM system

involves a single I/0 system controlled by dual process. Two redundant control

modules that reside in one-logic manager processor card files manage redundancy.

LM Processor:-It is composed of multi-modular units (cards) featuring remote

serial and local parallel I/0 capability. The memory is expanded to 32 K from 29 K

words of memory. The LM is designed to service high speed and complex control

operations.

LM I/0 System:-It offers several options for interfacing LM processors to

sensors and actuators of plant floor. The parallel and serial I/0 system includes a

wide variety of discrete analog special function I/0 modules and related I/0

hardware.

The I/0 system consists of many different i/p, o/p modules with varying number of

points and voltage types designed for compatibility with many different kind of

field devices and power sources. The LM gathers and measures physical machine

or process, variables such as proximity, pressure, temperature and voltage through

I/0 interface. Based on this status the LM processor then issues commands to

control the devices being mentioned (alarms, control relays, motor, pump &

valves).The I/0 system may be set up with the LM system in several

configurations. A parallel configuration is used for local placement of the control

processor and I/0.

Serial configuration permits I/0 to be located thousand of meters away from the

processor. This configuration also minimizes field wiring.

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HPM (High Performance Manager)

Designed to provide flexible and powerful process scanning and control capability.

It uses powerful multiprocessor dedicated to perform specific tasks. It consists of

HPMM & I/0 sub system.

HPMM consists of communication processor and modem, I/0 link interface

processor and control processor. HPMM redundancy can be optionally provided.

The communication processor is optimized to provide high performance N/w

communication handling such functions as n/w data access and peer-to-peer

communication. The control processor is the HPM resource dedicated to executing

regulatory, logic and sequence functions. The I/0 link interface processor is the

interface to the I/0 sub-system.

The I/0 sub-system consists of redundant I/0 link and the I/0 processor. These I/0

processors handle all fields I/0 for both data acquisition and control functions. The

I/0 processor provides functions as engineering unit conversion and alarm limit

checking independent of HPMM. All control operations are performed in HPMM,

with all data acquisition being performed in I/0 process . The process engineer has

complete flexibility of choice.

HPMM card file options:-The basic advanced process manager sub-system

configuration consists of a single High performance manager module residing in

HPMM card file. The card file also accommodates 10 IOP cards.

The redundant HPM sub-system has two configurations:

1. An HPM sub-system in which primary & secondary HPMM’s resides in the

same card file with also 5 IOP’s. The card file is designated redundant

HPMM card file.

2. The preferred redundant configuration is comprised of 2 HPMM card files

with HPMM in each. This provides:

1- A primary HPMM.

2- A redundant HPMM

3- 40 IOP card slots.

This alternative redundant HPM sub-system can be configured with the

redundant card file installed in the same cabinet or in another cabinet of a

cabinet complex with a separate power system. A redundancy cable connects

two HPMM together.

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HPM Architecture

HPM consists of:

1. HPMM

2. Redundant HPMM card files.

3. Filed termination assembly.

4. Power system.

HPMM provides:

1. Communication with LCN n/w interface modules through UCN.

2. Communication through I/0 link interface with IOP’s processors.

3. Memory for control processor database.

4. Control processor.

5. Redundancy control.

Process Manager Modules are comprised of five cards listed below:

Modem: A modem circuit board that interfaces with UCN. Its job is serial to

parallel conversion and vice-versa.

Advanced I/0 link interface: Provides communication link to the IOP’s.

Advanced communication: A communication controller that interfaces

with modem card. Provides external peer-to-peer communication.

Advanced Control: Provides control processing and calculating provided

the drive capability for exclusive redundancy interface blow redundant

HPMMs. All the points built in HPM came in this module.

Filler: A non-functional card (blank use)In HPM there are 3 files and in

each these are 15 modules and total 45 modules, out of these first 5 in file 1

is called HPMM. The remaining 10 are IOPS.

I/0 Processors used in Binani Cement:

High level Analog Input (HLAI)

Low level Analog Multiplier (LLMUX)

Analog output (AO)

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Digital output (DO)

Additional IOP card files slots can be added to any HPM.

High level Analog I/P:-Accept to 16 high level inputs. The inputs are

configurable as single ended on differential in relation to mater references ground.

Analog output:-Provides 4-20 outputs to proportioning cards such as valves:

Digital 0/P:-Provides 16 O/P that is isolated from each other.

LLMUX:-The FTA accepts one set of 16 low-level inputs such as thermocouples

or RTDS. The inputs are sequentially multiplexed.

Quality Control:

To check the consistency of cement:-2 X-Ray machines are used one by

Philips and the other by Oxford Presently Oxford MDX 1000 is in use, which

consists of a floor, standing XRF spectrometer and an associated PC. The principle on which it works is the multi depressive X-ray fluorescence

allowing quantitative multi-elemental analysis. It is based on windows and user

xpertEase software. It requires single-phase supply and may also need helium for

some applications like liquid analysis.

As soon as the power is switched on the window is automatically loaded. In XRF

menu icon software will start and XpertEase start up window will appear. The lid

is removed and the pallet is inserted. This pallet goes inside and the shutter is

removed so that the X-rays fall on the sample and analysis is done. There are

spectrometers attached for each constituent. The entire report is obtained on the

PC, which displays the analysis. This analysis is done for checking quality of

clinker produced in the kiln.

For checking the quality of raw material from mines Cross Belt Analyzer is

being used.

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CONCLUSION

All the production systems and power plant components were thoroughly studied

at the esteemed production plant of BINANI CEMENT LTD.

To do my summer training in such an esteemed organization like BINANI

CEMENT Ltd. was a phenomenal learning experience for me. This month was a

joy ride for me in the field of instrumentation, and now on completion of my

training I can say that I have gained very sound knowledge in the field of

instrumentation.

The INSTRUMENTATION department in the industry is well equipped with

latest technologies. All the working of various departments is completely

computerized. The company is following a firm base to adopt the new technologies

that are coming up these days; this ensures a healthy and prosperous future.

I am highly thankful to Mr. ASHISH MOHAN KANEWAL under whose expert

guidance I did my training, and came to learn about the various minor and major

aspects of instrumentation. I am also thankful to each individual who has helped

me during my course of training directly or indirectly.

And I am thankful to all those people who help me to get knowledge of power

plant.

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REFRENCES

List of books referred

I. Electrical Measuring Instruments -A.K.Sawhney

II. Control Engineering -Nagrath & Jairath

List of web surfed

www.binanicement.com

www.wikipedia.com

www.howstuffworks.com

List of search engines

www.google.co.in

http://www.binanicement.com/

http://www.wikipedia.com/

http://www.howstuffworks.com/

http://www.google.co.in/

Instrumentation in Binani Cement

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