INTERNSHIP REPORT

DG CEMENT
HUB PLANT

Internee Ihtisham Arif

Department Electrical
Program Coordinator Mr. Junaid Zia
Training Coordinator Mr. Tariq Nawaz
HOD (E, I &C) Mr. Pasha Mustafa
Training Duration 8 Weeks (11 Oct - 4 Dec)
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ACKNOWLEDGEMENTS
In the name of ALLAH, the most beneficent and the most merciful. All praises to ALLAH
Almighty who showered his blessings upon me and give me a great chance to work on this
plant. May ALLAH always bless me in each and every field of life and make me a benefactor
of the human race.
I offer my gratitude to HOLY PROPHET HAZRAT MUHAMMAD (SAWW) who has given us
the lesson of love, humanity, justice and also broken the cage of servitude for this golden
saying:” To seek knowledge is obligatory for all human beings (male & female)”.
Before writing down what I’ve learned and did in this internship, I would always remain
thankful to those people who helped me very gently in these days:
I would like to thank the staff at DG Cement who in spite of being extraordinarily busy
with their duties, took time out to hear, guide and keep me on the correct path of
learning. They helped me to gain a lot of information regarding the company and
cement industry and also provide me an opportunity to learn and understand the
working of organization as an internee. They gave me chance to improve my industrial
skills that will surely help me in the practical field. I’m also thankful to respected Mr.
Mr. Pasha Mustafa (HOD E, I&C), Mr. Shahid Ghazanfar (GM Works), and Mr.
Fawad (DGM Works) who gave me the opportunity of this outstanding experience and
allowed me to carry out my internship program at their esteemed organization.
And finally, my deepest and warmest appreciation to the whole team of D.G. Kham
Cement Company Limited (DGKCC).

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Grid Station
The grid station in DGKCC (Dg Khan Cement Company) Hub Plant is receiving a 132 kV
supply from K-Electric. The grid station is the first entry point receiving the electricity and
then after stepping it down to 6.3 kV providing it to different substations of the plant for
utilization.

Transmission Line
15 km long transmission line is being used to transfer 132 kV from K-Electric to DGKCC
Hub Plant grid station. A total of 75 poles are used in this transmission line and they are of
two types.
Pole types
1. Suspension poles
2. Dead end poles
Along with the electricity transmission line, there is an OPGW (Optical ground wire) at the
top of the poles. This wire protects against lightning
by providing ground and keeping the transmission
line safe. This wire is also a way of communication
to the K-Electric Hub station.
Serge Arrestor
It is a safety device preventing grid stations from
receiving excessive voltage and current. It has two
parts separated by semiconductor balls. If
semiconductor balls start conducting all the voltage
will start going to the ground instead of the grid
station. It happens after 10 seconds of continuous
extra voltage and semiconductor balls melt and i Serge Arrestor
become conductors.
Wall Bushing
Wall bushing is the point where two systems
combine.
1. AIS (Air-insulated switchgear)
2. GIS (Gas-insulated switchgear)
Before wall bushing all the wiring was air-insulated
and after wall bushing a gas-insulated switchgear
system was installed.

ii Wall Bushing
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GIS
Its gas-insulated switchgear uses SF6(Sulphur
hexafluoride) as insulation gas. It allows electric wires with much higher voltages like in this
grid station 132 kV to travel at much closer distances than air insulation as the sf6 gas
prevents electromagnetic waves from interfering with the flow of electricity.
Company
This GIS system is from GE Alstom.
Isolator
Isolators are used to physically isolate or de-energize a section of the power system, allowing

iii GIS

maintenance personnel to work on the equipment without any electrical hazards. There are
three isolators placed in GIS for three different lines i.e., 1 for the incoming line and 2 for 2
GIS lines going towards transformers.
Breaker
In GIS systems, circuit breakers are employed to control and protect the electrical network,
isolating faulty parts and preventing damage to the system during short circuits or abnormal
conditions.

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Potential Transformer (PT)

A PT, also known as a voltage transformer, is used to step down high voltages to a
standardized low voltage suitable for measurement and protection purposes. It provides a
reduced voltage proportional to the high-voltage input. This reduced voltage is then fed to
instruments or meters for voltage measurement or protective relaying systems. As voltage is
measured in parallel, they are connected parallel to the transmission lines.
Current Transformer (CT)
A CT is used to step down high current levels to a standardized lower level. It produces a
current that is proportional to the current flowing in a power line. The reduced current output
is then used for metering, protection, or control purposes. They are connected in series with
transmission lines of GIS.
Bus Bar
The bus bar connects the two outgoing lines of electricity towards transformers with the
incoming line of electricity from K-electric.
Safety components
1. Rupture Disc
The rupture disc is a precisely engineered device designed to rupture or burst at a pre-
determined pressure level. When the pressure exceeds the specified limit, the disc
ruptures, allowing the gas to escape safely.
2. Earthing Switch
They help discharge any residual electrical energy in case of maintenance or repair on
the system.
3. Switch Counter
It keeps the record of how many times the system has been turned on from its off
state. Its record goes back to the time this system was first installed.

Transformer
Transformers are electrical devices used to transfer electric energy from one alternating-
current circuit to one or more other circuits, either increasing (stepping up) or reducing
(stepping down) the voltage.
Two step-down transformers that are stepping down 132 kV into 6.3 kV are used in the grid
station. Its power ratings are 31.5/40 MVA.
OLTC
The On-Load Tap-Changing feature allows for altering the turns ratio by changing the
connection points (taps) on the transformer winding while it is in service, enabling
adjustments to the secondary voltage level as needed without interrupting the power supply.
This type of transformer is particularly useful in situations where the input voltage may
fluctuate, requiring adjustments to the output voltage level to maintain a consistent supply to
the connected load. As the incoming voltage varies the taps continue to change to provide a
smooth supply of 6.3 kV.

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Number of taps = 1-25

OLT Breather
It removes moisture from the air that is entering the transformer using silica gel.
PRD
It’s a pressure-release device that’s used in transformers for safety purposes. It provides an
opening for releasing gas pressure that can be built inside the transformer due to a short
circuit or any other reason.
Cooling Method
ONAN
This cooling method primarily relies on
natural convection for heat dissipation. The
transformer uses the surrounding air and the
natural circulation of oil to maintain its
temperature within acceptable ranges during
operation.
ONAF
ONAF involves natural convection but also
includes forced air circulation. It has fans to
enhance the cooling process by actively iv Transformer
moving air across the radiator surfaces,
providing better cooling performance compared to ONAN. There are 12 fans used on each
transformer for the ONAF cooling method.

MV Room
The transformer's output of 6.3kV are connected to MV panel JO4 and J08. Both of these MV
panels energize the busbar of the MV room. This room has the following MV panels.
1. J11 Niigata incomer
2. J01 Spare
3. J02 Outgoing 891 Substation
4. J12 Bus coupler for Niigata
5. J04 Transformer
6. J05 Bus pt
7. J06 Bus coupler
8. J07 Bus pt
9. J08 Transformer
10. J09 Outgoing 891 Substation
11. J10 Admin outgoing
MV Panel
All these MV panels have 3 compartments.
Control compartment
This compartment has all the controls and displays of the MV panel including voltmeter,
energy meters, local control, fan control etc.
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VCB (Vacuum circuit breaker)

This breaker is placed to connect and disconnect the supply from mv panel to the cables.
Cable Compartment
This compartment is dedicated to cables. cables from the cable compartment are sent directly
to the tunnel below the substation from where they travel to the desired substation or
transformer.
Rating
 6.7-7.2kV
 Normal Rated current 3150 A.
 Main busbar current 4000 A.
 Peak withstand current 100 kA.
 Degree of protection Ip4X.
 Withstand voltage 20 kV.
 Impulse withstand voltage 60 kV.
 Rated frequency 50Hz.
Control Room
This room has all the control panels and relay panels of the grid station. This includes control
panels for
Control Panels
 CP Line Bay E07
 CP Transformer 2 E08
 CP Transformer 1 E09
The following controls and displays are given on these control panels.
o Analog/Digital voltage and current meters
o Announcement window
o Energy meter on E07
o Test blocks
o 220 DC supply supervision
4 Relay panels included.
Relay Panel
 Transmission line
 GIS
 Transformers 1
 Transformer 2
These relay panels have the following controls and displays.
o Lockout/electromagnetic trips
o Breaker failure relay
o HV over current relay

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o Neutral over current relay

o Testing blocks
AC Distribution
Two 400 V AC distributions for running the grid station and its equipment are present. 1 st that
is normally used is powered by supply coming from the KE. In case of any power failure ac
distribution 2 will be active that is powered by the kiln generator.
Battery Room
An inhouse battery backup is available in grid station in case of emergency. This battery room
has two rows of 92 batteries on each side providing a total of 220 V DC and a third row of 20
batteries providing 48 V DC. Each row has a separate charger and these are.
1. 220 V DC charger 1
2. 220 V DC charger 2
3. 48 V DC charger 3
Two charging modes are used for charging these batteries.
Float Charging
This is used under normal circumstances to charge batteries slowly.
Boost Charging
When batteries are drained below a set limit i.e., below 35-40% level the charging mood is
shifted to boost charging for faster charging.

Power Plants
Niigata Power Plant
It’s a thermal power plant with a power generation capacity of 24 MW. Its name originates
from the name of engine provider company.
Total generators = 4
Single generator generation capacity = 5.96 MW
Generation type = MV(6.3kV)
Engine Room
Four 18V2CLX engines are in place in the engine room along with an auxiliary for the power
generation.
Engine
4 stroke engines are used for power generation.
These strokes are as follows.
1. Intake stroke: The intake valve opens, and it takes air and fuel inside as piston
moves down.
2. Compression stroke: Piston moves up the cylinder compressing the air fuel mixture.
It increases the temperature and pressure inside.

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3. Power stroke: At top of compression stroke a spark ignites the air fuel mixture
resulting in an explosion that pushes piston downwards.
4. Exhaust stroke: Exhaust valve opens after the power stroke and piston moves up
pushing burnt gasses into the exhaust system.

v. Engine Room

Fuel
Two type of fuel is being used in this power plant.
1. Diesel
2. HFO (High furnace oil)
Fuel Storage
2 big tanks with a storage capacity of 1000 metric tons are available, one for diesel oil and
one for HFO.
Circulation
 To reach the engine fuel is first passed down to the settling tank where impurities and
moisture are removed from the oil via a purifier.
 Then clean oil is sent to a clean oil tank where it is readily available for use at any
time.
 From the clean tank fuel is transferred into the circulating pump. HFO is continuously
circulated in these lines as it will freeze in case the circulation stops.
 A temperature of 45-50 degrees Celsius is also maintained for HFO.
 After circulation lines the oil is transferred to the candle filter.
 Then it goes into the secondary filter and at last goes into the fine filter.
 At the end fuel pump sends it to the injector.

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Filter line
1. Candle Filter
2. Secondary Filter
3. Fine Filter
Lubrication oil Tank
This tank contains the lubrication oil for the engine. It is connected with a purifier to remove
carbon particles and moisture from it.
L-O Cooler
When L-O oil comes out of engine it is passed down to cooler to decrease its temperature. Its
normal working temperature is 50 degree Celsius.
Cooling Method
Three type of cooling methods are being used into cool air, water and fuel entering the
engine.
1. Cooling lines
2. Fings
3. Plates

Control Room
 There are 4 control panels for the generator control in this room.
 An interface panel.
 Protection relay panel.
Generator Startup
To start the power generation, it needs some electricity beforehand for control operations and
to run the auxiliary of generators.
Two ways we can provide that initial electricity.
1. Grid station: This will be our go to source for that initial electricity. Grid station has
a MV panel J11 dedicated to Niigata power plant. 6.3 kV from grid station is stepped
down using an in-house generator to 440 V before it is used in power plant.
2. LV Generator at Packing Plant: This source will be only utilized in emergency if K-
E transmission line is interrupted. This will then be used to run the auxiliary and the
control of power plant.
When the initial auxiliary and controls are ready the generator 1 will be started using the
synchronization method.
Synchronization
In case the starting source is K-E supply from the grid station, this will be our master side and
generator output will be synchronized with it before it is added in the grid. This
synchronization will need to match following things.
1. Voltage (6.3kV +-0.01%)
2. Frequency (50 Hz)
3. Phase sequence (Red, Blue, Green)
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It’s done by using synchronization panel inside the control room.

Master side = K-E’s Supply
Follower side = generator output
Similarly, if another generator needs to be started the 1 st generator will be set as master side
and its output will be synchronized with it.

vi. Synchronization Panel

Battery Room
A 110 V DC power backup is available in power plant for emergency situations to give a
backup before generators can start generating electricity.
Transformer Room
In this room a step-down transformer is being used to step down 6.3 kV coming from grid
station to 440 V so that it can be used to run plant equipment and generators auxiliary.
NGR Room
In case of short circuit in the power plant this room provide a low resistance ground for that
extra current to flow saving the control equipment from any damage.

CFPP
Coal fired power plant or CFPP is using coal as a fuel. It burns coal and uses that heat to run
a boiler. The steam of that boiler is than used to run the turbine of electricity generation.
Power Generation Capacity = 30 MW
Voltage = 6.3 kV
Power Generation Process
Firstly, the coal is transferred from storage to coal crusher and from there it is transferred to
coal bins. From there it is sent to coal mill and from there it is sent to the boiler. Between all
these places conveyor belts are used for coal transportation.
Boiler
Steam boiler burns the coal and creates high temperatures that is used for creation of steam.
This steam is extremely high pressure and temperature steam.

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Steam Turbine
The high-pressure steam is directed onto the blades of steam turbine resulting in running of
the turbine. NT 6000 controller is controlling the steam supply to the turbine.
Electricity Generation
Following are the condition is required for power generation in CFPP.
 Required rpm = 3000 rpm
3000 rpm is required because it will allow to generate electricity at 50 Hz frequency.

Exciter
When the turbine reaches the 3000 rpm, the exciter will be energized. It’s a device that
provides the initial electric current to the stator for creation of magnetic field around it.
Stator and Rotor
Stator is the stationary part of the generator and rotor spins with the turbine and cuts through
the magnetic field created by stator.
Electromagnetic Induction
The relative motion of rotor in the magnetic field of stator induces an electric current in the
stator windings through electromagnetic induction.
AVR
Automatic Voltage regulator ensures that the voltage input to the stator remains stable and
within the specified range.
Synchronization
The output of CFPP is synchronized with that of K-E’s supply before its transferred to its
incomer panel in the 891 substation.

WHRPP
This power plant generates power using the waste hate from the cement creation process to
run a turbine. There are two boilers placed at pre-heater side and cooler side to recycle heat
and create steam.
1. SP Boiler (Pre-Heater)
2. AQC Boiler (Cooler)
Generation Capacity = 10MW
Voltage = 6.3 kV
The electricity generation process is same to that of CFPP generation process. In this case the
steam’s supply is controlled using the 505 controller via the throttle valve.
Safety
 Protection Relays
In case of sudden increase or decrease in the voltage/current the protection relay is
placed to trip the mv panels controlling the generators.
 Sensors
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Multiple sensors are placed on turbine and generator to provide feedback to relays and
stop the process at any time in case of unusual behavior. These sensors include.
1. Vibration sensors
2. Speed sensors
3. RTD

Field Instruments
Instrumentation
Instrumentation is the science of using instruments for measurement, monitoring, recording,
data logging, analysis, and control of physical variables.
Major process variables:
 Temperature
 Flow
 Pressure
 Level

Temperature
Temperature measurement is required for a lot of machinery and processes inside a cement
plant. As high temperature in some machinery can cause them to malfunction so continuous
monitoring of their temperature is required. Some common temperature measurement
instruments in cement plants are thermocouples and RTDs.
Thermocouple
A thermocouple is a device that measures temperature. It consists of two wires made from
different metals that are joined together at one end. One junction is placed where the
temperature is to be measured, and the other is kept at a constant lower temperature.
When the junction is heated or cooled, a small voltage is generated in the electrical circuit of
the thermocouple. This voltage is used to measure temperature.
Thermocouple used in DG:
K-type
K-type thermocouple is the most used type of thermocouple used in DG hub cement plant.
The K-type thermocouple specifically uses chromel (an alloy of nickel and chromium) as one
conductor and alumel (an alloy of nickel, manganese, aluminium, and silicon) as the other
conductor. The temperature range for a K-type thermocouple is typically from -200°C to
+1,372°C (-328°F to +2,502°F). This thermocouple is installed in various parts of preheater,
mills, and feed pipes.

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vii. Thermocouple
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S-type
In the case of an S-type thermocouple, the conductors are made of platinum-rhodium alloys.
Specifically, one conductor is made of pure platinum (Pt), while the other is a platinum-
rhodium (Pt/Rh) alloy. The composition of the alloy can vary, but common configurations
include 90% platinum and 10% rhodium for one leg and 100% platinum for the other leg.
S-type thermocouples are known for their excellent accuracy and stability at high
temperatures. They have a temperature range of approximately 0°C to 1,621°C (32°F to
2,950°F), making them suitable for applications where extreme temperatures need to be
measured.
Kiln temperature is being monitored using this type of thermocouple. Its placed on the outlet
of kiln as well near the burner.

RTD
Resistance Temperature detectors use the resistance change of the metals with respect to
temperature change for measuring the temperature. The most used type of RTD is Pt-100.
Pt-100
Pt-100 uses platinum and its change in resistance to measure the temperature. The resistance
of platinum at 0 degrees Celsius is 100 ohms and 138.4 ohms at 100 degrees Celsius. With
increase in temperature the resistance of platinum increases as well. This resistance change is
converted to mA using a temperature transmitter and the output of transmitter is used to
measure the temperature.
Temperature Transmitters
Temperature transmitters are used to convert the mV and Ohms generated by the temperature
sensors to 4-20mA that can be read by the PLC for communication with the control system.
They are crucial part of an automation system and it is not possible to directly send these
Ohm and mV to out control system.

Flow
Magnetic Flow Meter
This is used for measuring liquid flow that is water based or conductive as the flow is
measured based on faradays law that uses voltage to measure the flow and that liquid. It
considers the voltage that depends on average velocity of liquid, the magnetic strength and
the length of the conductor.

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viii. Magnetic Flow Meter

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They are best to be used in places where liquid contain dirt or small particles that would
cause blockage in a mechanical flow meter.
Belt Scale
Belt scales are used for measuring flow of solid materials on conveyor belts. They use load
cells to measure the weight of material and speed sensor such as an encoder are used to
measure the speed of belts carrying the material. A controller takes into account both values
and provide us with the material flow rate in kg/min or Ton/hr.

Pressure
Pressure is one of the most crucial aspect while operation of a process and slight changes in
pressure can result in disaster if proper instruments are not in place to warn and inform about
the pressure change.
Pressure Transmitter
Pressure transmitters generate mA ranging 4-20 to represent the pressure in a gasses chamber
or a pipe and are connected with control cables conveying this information to the control
system

ix. Pressure transmitter

Pressure Gauge
Unlike pressure transmitters pressure gauges are not connected with the
control system rather
they display the pressure of the system they are connected with on a
display that is connected with them. They are generally used to check the
pressure of fuel or air going into a kiln burner or calciner.
x. Pressure Guage

Level
Level measurement is another common factor for which multiple
instruments are used in the cement plant. They include:
Radar Sensor
Used on silo tops for measurement of material inside of it. They have long
range of detection that makes them suitable of this job. LR460 by siemens
in one of the level sensors used on silo top. The Siemens SITRANS LR460
is a 4-wire, 24 GHz FMCW radar level transmitter. It has a high signal-to-

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xi. Radar Level Senor
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noise ratio and advanced signal processing for continuous monitoring of solids up to 100 m
(328 ft). It is ideal for measurement in extreme dust.
Capacitance Level Switch
CLS 300-A5E by siemens is one of the capacitance level switch installed on silos for level
measurement. It is designed for use in high pressure and temperature conditions. The CLS300
is an inverse frequency shift capacitance level switch with configurable output.

Instruments on Belt Conveyors

Motion Detector
A motion detector is a proximity sensor used to detect movement of the conveyor belts.
Motion detector by telemecaniqu is used on belt conveyors in DG cement Hub plant.
Pull Rope Switch
A pull rope switch on a belt conveyor is a safety device used to immediately stop the
conveyor in case of an emergency. When activated by pulling the rope or triggering an
emergency stop line, the switch sends a signal to the conveyor control system, leading to an
immediate halt of the conveyor belt. This ensures the rapid prevention of potential hazards
and protects personnel.
Pull rope switch by Kiepe company are being used in this plant.
Belt Drift/Misalignment Switch
A belt drift switch on a conveyor is a safety device designed to
detect and prevent belt misalignment. It typically consists of a sensor
that monitors the alignment of the conveyor belt. If the belt starts to
drift or deviate from its intended path, the switch is triggered,
sending a signal to the conveyor control system. An alarm or stop to
the belt will occur as a result of triggering the switch.
Belt drift switches by Kiepe company are being used.
xii. Drift Switch
Belt Weigher
Belt weighers are used in the belt conveyor to measure the material coming on belt conveyors
in kg/min or Ton/hr. These belt weighers use two components for that purpose.
1. Load cell
Load cell measures the weight of the material passing through the effective belt
length.
2. Speed Sensor
Speed sensor such as Tachometer is used to measure the speed of the belt conveyor.
Both these values are sent to the controller that calculates the belt feed rate based on speed
and weight of conveyor belt.
Magnetic Separator
A magnetic separator on a belt conveyor is a device that separates ferrous metals from fast-
moving materials on conveyors. Magnetic separators are also known as cross-belt or

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overhead magnetic separators. Magnetic separators are installed above or in the conveyor
belt. They have separators for magnetic substances and detectors for harmful metals.
Metal Detector
Metal detectors on conveyor belts can detect magnetic and non-magnetic metal
impurities. They can protect equipment, reduce downtime, and protect product quality. In DG
multiple metal detectors are used with DG(diverging gates) to divert feed incase any metal
comes with the material on belt.

xiii. Metal detector

Weigh feeders
Weigh Feeders are installed in DG cement plant before the belt conveyors provide their feed
to the 3 Mill that are installed in this plant. These 3 mills include Raw mill, Coal mill and
Cement mill. Multiple weigh feeders each carrying different material is placed before them to
provide them with material in a composition that is suitable for that mill. All these weigh
feeders have following common parts and instruments.

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Storage bin
This is the first part of the weigh feeder where material is stored. The storage bin have level
sensors in them indicating
 Low level and High level
This is achieved using a rope level switch. When material reaches that level the level switch
indicates that to the controller.
Weighing belt
From bin the material is dropped to the weighing belt. This belt is composed of rollers and a
belt, load cells are connected with a one roller and the before and after roller all three
xiv. Weigh Feeder

combine together to form a weighing belt.

1. Load cell
Load cell measures the weight of the material passing through the effective belt
length. The load is measured in kgs or Tons.
2. Speed Sensor
Speed sensor such as Tachometer is used to measure the speed of the belt conveyor.
Speed is measured by calculating the pulses and dividing that with the cycle time of
the belt. In this way we get the speed of our weigh feeder.
Gravimetric Mode
This mode is used in weigh feeders by giving them a setpoint like 70 Ton/hr. Then based on
feedback of load cell and speed sensor the controller changes the rpm of belt to match that
setpoint. This is a closed loop process that keeps repeating until the exact setpoint is
achieved.
Volumetric Mode
This mode is utilized at the time of calibration of weigh feeder. In this mode the weight is not
considered, and the belt is run at a specific feed rate. This mode helps in finding the factor of
weigh feeder that is initially considered to be 1.
Calibration of Weigh feeder
There are of two types of calibrations done on a weigh feeder.
1. Tare Calibration
This calibration is done on the empty weigh feeder belt where belt continuous to run
for some time taking in account the weight of belt itself, the equipment of weigh
feeder and after calculating that weight it is set as tare of that weigh feeder and the
load cell shows 0 on scale. This tare weight can be seen on the controller HMI.
2. Span Calibration
After setting the tare span calibration is done where slandered weights are attached to
the weigh feeder and belt run for few second with those weights attached and checked
how the weigh feeder reads those weights.

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Weigh Feeder Drop Test

Testing a weigh feeder is crucial to make sure it accurately weighs materials. During the test,
the feeder is exposed to controlled conditions resembling normal operation impacts and
vibrations. It involves dropping a known amount of material onto the feeder, letting it pass
through, and checking if the measured weight matches the expected value. This test ensures
the feeder's accuracy under realistic conditions.
Two weights are important for this test.
1. Display Weight
Weight that is shown on the weigh-feeder controller display
2. Actual Weight
Wight checked by a reference weighing system e.g., a weigh bridge.
Steps for the drop test:
 Keyboard mode is enabled on the HMI of weigh feeder to take it to the local control.
 A feed rate set point like 70 Ton/hr is set on the weigh feeder and calculated feed is
sent for example 10 Ton (Display weight).
 A vehicle is used during the drop test for taking that material sent by weigh feeder to
the weigh bridge.
 The weight reading form weigh bridge (Actual weight) is used to calculate the
percentage error.

Display Weight = 10 ton

Actual weight = 10.020 Ton
Acutal Weight – Display Weight
% Error = ×100
Actual Weight
10−10.020
= ×100
10
=-0.20%
As this error is under the +-0.5% tolerance range of weigh feeder so no changing to the weigh
feeder range correction required.
Range correction/Factor
This is the factor or range corrector that controller calculates while span calibration. During
operation this factor can be updated if a 0.5% or greater difference is observed between actual
weight (Weighbridge) and display weight (weigh feeder). The new range correction will be
calculated using this formula:
New factor = (Actual Weight / Display weight) * old factor.

Analyzers
There are a total of 6 gas analyzers in the pre-heater section and on coal mill. 4 of them are
on pre-heater and 2 are placed on coal mill.
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Per-Heater Analyzers
1st Floor Analyzer
The analyzer on first floor of preheater is connected at the kiln inlet and is continuously
monitoring gases including oxygen, NO, CO and CH4. Analyzer by ABB, EL3040 is
installed here. It has two types of analyzer cells installed in it.
Uras26
Principle: NDIR (non-dispersive infrared) technology is utilized, where the gas sample is
exposed to specific infrared wavelengths. The absorption of infrared light by the gas
molecules allows for the determination of gas concentration.
Measuring scale
O2 0-25 Vol%
CO 0-5 Vol%
CH4 0-3 Vol%
NO 0-2000 ppm
Sample Probe
In kiln due to very high temperature the sample prob is continuously being cooled by using
water. Also, the sample prob comes out every 3-4 min for cooling and is sent again to take
new sample. This sample prob is placed at the kiln inlet on preheater side.
6th Floor Analyzers
Two ABB EL 3040 analyzers are placed on the two ID FAN ducts on the 6th floor of
preheater. Like 1st floor analyzer O2, CO, NO and CH4 are measured in these analyzers.
Analyzer Cell = Uras26

xv. Analyzer

Measuring scale
O2 0-25 Vol%

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CO 0-5 Vol%
CH4 0-3 Vol%
NO 0-2000 ppm
Sample Probe
Two sample probs are taking sample from the ID fan ducts. The reason for placing two
sample probs is the dust and material particles in ID fan ducts. So, when one prob is receiving
sample gases the other prob is at cleaning mode. High pressure air is used for the cleaning of
sample prob.
Interlocking
This floor analyzers are on one of the most crucial part of the plant that’s why they are
interlocked with kiln and preheater operations. Incase these analyzer stop working the kiln
and preheater operation will immediately stop.
8th Floor Analyzer
This is the final analyzer on the pre-heater side. It is analyzing the gasses that are leaving the
bag house to the environment. ABB EL 3040-gas analyzer is placed for analyzing these
gases.
Analyzer Cell = Uras26
Measuring scale
O2 0-25 Vol%
CO 0-5 Vol%
CH4 0-3 Vol%
NO 0-2000 ppm
Sample Probe
The sample probe is placed on the exhaust form where the gases are released to the
atmosphere. This analyzer is making sure that bag house is working properly as well as there
are no toxic gases are being released to atmosphere.

Coal Mill Analyzer

Inlet Analyzer
On the inlet of coal mill O2 analyzer by ENOTEC is placed that is measuring the oxygen
percentage in the coal mill. This analyzer is only measuring oxygen gas as excessive amounts
of oxygen can cause burning and eventually blasting inside of coal mill. So, oxygen level
needs to be monitored regularly. This analyzer is highly durable and can work normally in the
high temperature range of 800-1400 degrees Celsius.

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Zirconia Cell
Zirconia is a ceramic material known for its high oxygen ion conductivity at elevated
temperatures. In zirconia-based oxygen sensors, a thin disc or tube of zirconia is used
as the solid electrolyte.
Construction of the Sensor:
The sensor typically consists of a zirconia electrolyte placed between two electrodes – a
reference electrode and a measuring electrode. These electrodes are usually made of materials
such as platinum.
Diffusion of Oxygen Ions:
At elevated temperatures (800-1400°C), oxygen ions from the surrounding gas sample diffuse
through the zirconia crystal lattice. Zirconia becomes conductive to oxygen ions at high
temperatures.
Electrochemical Reaction:
 On one side of the zirconia cell (the cathode), oxygen reacts with electrons and
diffusing oxygen ions to form oxide ions.
 This reaction generates a flow of electrons through the external circuit.
Voltage Generation:
The difference in oxygen partial pressure between the cathode (measuring electrode) and the
anode (reference electrode) leads to the generation of a voltage. This voltage is directly
proportional to the logarithm of the ratio of oxygen concentrations at the cathode and the
anode.
Outlet Analyzer
On the outlet analyzer two analyzing units are testing the same sample. Both are ABB EL
3020 analyzer units. One is using Uras26 and the other is using manganese206. They are
measuring following gasses,
URAS26 CO 0-10000 ppm
Magnos206 02 0-100 Vol%

Magnos206
The Magnos206 operates on the magneto mechanical principle, where changes in the
magnetic properties of a material are used to detect variations in oxygen concentration.

Analyzer Calibration
Analyzer Calibration is one of the most important task for analyzers as the readings during
operations will depend on this calibration. So, two types of calibrations are done:
Zero calibration
Zero calibration is a critical aspect in the field of instrumentation and control, especially in
processes where accurate measurements are essential. In various instruments, particularly
sensors zero calibration ensures that the device provides accurate readings by compensating
for any inherent offset or drift.

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In this calibration a neutral gas to the analyzer is given to it as sample gas. This gas can be
any gas that contains 0% of gasses that are being calculated in the analyzer. In our case the
gasses being analyzed on preheater are nitrogen oxide, carbon monoxide, methane, and
oxygen. So, nitrogen is used as the sample gas. Calibration is done in the following steps.
 First a neutral gas i.e. nitrogen is provided as sample gas to analyzer from a nitrogen
gas cylinder.
 As its pure nitrogen so analyzer should read any of the other 4 gasses to be 0.
 If analyzer shows any values for NOx, CO, O2 and CH4 it has error, so we will
manually set that to zero via the analyzer controller.
Span Calibration
Span calibration for a gas analyzer is a critical procedure to ensure accurate and reliable
measurements of gas concentrations. In this context, the term "span" refers to the instrument's
measurement range, from the lower detection limit to the upper limit.
For the span calibration following steps can be followed.
 Gas like CO with a known concentration e.g., 4 vol% mentioned on its cylinder is
provided at the input as a sample gas.
 Analyzer output is checked that how it reads that gas.
 If analyzer does not read the span gas exactly, its manually entered on the analyzer
that this much concentration of gas is entering as a sample to set the scale.
 Similarly other 3 gases are provided in the sample to set the span.
In this way a gas analyzer can be calibrated properly.

Weighbridge
A weighbridge is a large set of scales used to measure the weight of heavy vehicles and their
loads. They are also known as truck scales or loading scales. It uses multiple load cells to
measure the weight of the vehicle carrying the material before and after the material is
loaded. Material can be cement or clinker.

The vehicle weight is subtracted from the total weight after loading and we get the total
weight of loaded material.
Material Weight=Total Weight−Vehicle Weight .
Total of 8 weigh bridges are installed on the DG Cement HUB plant and their details are
given in the table below.
Weighbridge No W.B Capacity Total Load Cells Single Load Cell Company
(Ton) Capacity
(Ton)
1 150 10 45 Avery
Weigh-Tronix
2 150 10 45 Avery
Weigh-Tronix
3 150 10 45 Avery

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Weigh-Tronix
4 150 10 45 Avery
Weigh-Tronix
5 150 10 50 Metller Toleedo
6 150 10 50 Metller Toleedo
7 120 8 33 Schenk Process
8 120 8 33 Schenk Process

xvi. Weigh Bridge Load Cell

Weigh bridge 1-6 are located at Gate No 2 of DG Cement and 7-8 are located under the
cement silo no 1 and 2.

Bag House
A bag house or bag filters are placed in a cement plant to filter outgoing gases by collecting
the dust particles and complying with the environmental regulations.
The bag house in the DG cement plant is located with the pre-heater cleaning dust coming
from the raw mill and ID fans tubes. This bag contains:
Total Chamber = 8
Purging Valve in each chamber = 64
Total Purging Valve = 512
All these valve have multiple bags connected to them that entrap the raw meal dust inside of
them. Continuous purging is used to clean these bags and the dust material is dropped onto
the hopper from where a rotary feeder moves this dust material to the drag chains.
Pulse Air filter
The purging system for cleaning the bags is pulse air filter. This system uses high pressure
gas for purging in pulses when the command is provided by the controller to the SOV valve
of the air filter.

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System Pressure
Compressed gas pressure that is used for purging is refer to as the system pressure. Its normal
working range is:
Range = 2.8-3.9 bar
If the pressure drops or exceeds this working range a alarm is generated indicating a problem
with the system.
Differential pressure
The differential pressure DP is indication of the amount of dust inside the bag house by
comparing the air pressure inside the bag filters and outside pressure. It’s measured in mbar
as the pressure difference is very little.
Lower range = 12 mbar
This will mean that the dust amount is vey little inside the gasses coming from raw mill so
the purging will stop. As soon the pressure exceeds the 12-mbar limit purging will start once
again.
Higher range = 28mbar
Higher pressure than 28 mbar will generate an alarm and warning indicating a higher-than-
normal dust inside the bag house that could be caused by bag filter choking or bag being
damaged. In that case the bags will be replaced.
SOV
Solenoid valves placed on each purging valve acting as switch. They are pneumatically
operated. Whenever they receive the signal from controller they change their normally open
position to close for a pulse of a second generating the purge and this continues for every
valve. The whole sequence of 512 valve takes nearly 30-35 minutes.

Substations and Equipment

(VFDs, UPS, DC Bank)

Raw Mill Substation

MV Panels
1. AO5
Incomer panel from 891 substation with 6.3kV voltage.
2. A01
This panel provides its output for LV transformer that then connects its output to LV
panels to power equipment that needs 440v transmission.
3. A02
Raw mill system fan panel.
4. A03
Raw mill classifier panel. Its output is stepped down to 690V and provided to raw mill
classifier.
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5. A04
A04 is providing its output power to RDF.

xvii. MV Panel

DC Bank
110V DC bank is available in raw mill substation. It has 9 batteries providing 12V each
totaling a voltage of 108V. its rated current is 30A.
UPS
A 30 kVA UPS by AEG is available in raw mill substation.
o 32 batteries
o One battery output voltage = 12V
o Total output voltage = 384 V

VFD
VFD (variable frequency drive) by Abb are installed in raw mill substation. They include.
o ABB ACS 2000
o ABB ACS 880

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Two main VFD ACS 2000 are for cope drives. These cope drives are 1250kW with input
voltage of 690V.

xviii. VFD

Kiln Substation
MV Panel
A04
Incomer panel from 891 substation.
A01
Kiln drive panel. Its output is going to a transformer that steps it down to 690V and provides
it to its VFD.
A02
ID FAN-1 Panel. Similar to kiln drive panel its output is also going to a transformer that steps
it down to 690V.
A03
ID FAN-2.
A05
Filer Fan.
A06
Kiln department.

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A07
EGC (exhaust gas conditioning) and Coal Dosing.
A08
Compressor Room
DC Bank
110V DC bank is available in raw mill substation. It has 9 batteries providing 12V each
totaling a voltage of 108V. its rated current is 30A.
UPS
A 40 kVA UPS is installed in the kiln substation to provide emergency backup in case of any
power failure. It’s by AEG company.
VFD
ABB
Three main ABB ACS 880 VFD are installed for:
o Filter fan
o ID FAN 1
o ID FAN 2
These ID fan motors have following rating:
Power output = 2515 kW
Input voltage = 690 V
Other VFD by ABB including ACS 850 are installed as well.
Schneider
Two VFD by schneiders are in place for the Master-Follower Kiln drive. These drive have to
work in synchronized manner to rotate the kiln so master drive takes the commands and
follower drive follows master drive.

Coal Mill Substation

The equipment in this substation is similar to
The equipment in this substation is similar with raw mill station as both substation equipment
is by same company named Schneiders.
MV Panel
A03
Incomer panel
A01
Coal Mill Main Drive
A02
Coal Fan Drive

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A04
Coal Mill Department
A05
Coal Intake
DC Bank
Similar to Raw mill substation 110 V DC bank is installed in the substation that is powering
all the panels and equipment of substation.
UPS
A 30 kVA UPS by AEG is available in coal mill substation.
o 32 batteries
o One battery output voltage = 12V
o Total Output Voltage = 384V

VFD
ABB
Two main VFD by ABB are installed for.
 Coal Mill Main Drive
Power Output = 840kW
Speed = 1100rpm
 Coal Mill Fan Drive
Power Output = 840kW
Speed = 993rpm
Some other VFDs that are installed are:
o Belt conveyor
o Water injector
o Coal Mill classifier

Cement Mill Substation:

Some main MV panels in cement mill substation are:
MV Panel
A05
Incomer panel from 891 substation.
A01
Cement Mill department
A02
Cement Mill Fan
A03
Cement Mill classifier

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A04
Cement Mill spare feeder
A06
Cement Mill Cope Drive
DC Bank
Similar to Raw mill substation 110 V DC bank is installed in the substation that is powering
all the panels and equipment of substation.
UPS
A 30 kVA UPS by AEG is available in cement mill substation.
o 32 batteries
o One battery output voltage = 12V
o Total Output Voltage = 384V

VFD
Siemens
The main VFD in cement mill substation is by siemens and is for the system fan. The system
fan motor has 5600 kW of power output. The VFD is taking 6.3 kV at its input and is
providing the system fan same 6.3 kV.
ABB
 Two main VFD by ABB are installed for Cope drives. These cope drives have an
output power of 1250kW.
 9 ABB ACS 580 VFD are installed for other motors in cement mill as well.
 1 ACS 880 VFD is used for a 250-kW motor in cement mill.

Electronics Workshop

Task Prepare a Circuit

In the electronics workshop, I was asked to design and prepare a circuit that will
perform some useful task. I chose to design a water level indicator circuit that helps
know the water level of a tank.
Circuit Design
I used the following components in the circuit design.
Vero board
The circuit is made on Vero board.
NPN Transistor C945
They were used for the switching purposes i.e., when the voltage reaches the base of
transistor, it will allow the circuit to be closed at the point of contact of transistor
otherwise it will remain open. LED will be connected to collector;
base will be connected to tank and emitter will be connect with xix. Circuit prepared.
power supply.
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Resistors
For the safety of diode led, transistor and buzzer.
Diode LED
For indication of water level. They will be indicating level 25%, 50% and 75% respectively.
Buzzer
For the indication of max level of tank
Connecting wires
for connecting emitters to supply and base with water tank.
Power supply
Power supply to power the circuit.
Circuit Working
When the power supply is connected to the circuit nothing will light up as all the transistors
are keeping the circuit open. One positive terminal from the circuit will remain at the bottom
of the tank. The wires from the base of transistors will be connected in tank at levels 25%,
50% ,75% and 100%.
When water will be below 25% level no led will show indication that will mean that water is
below this level.

When water reaches 25% level the positive wire at the bottom of tank and wire from base of
transistor 1 will be connected as water is a conductor of electricity. When voltage reaches at
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base of transistor it will turn from its normally open position to closed, this will allow the
collector and emitter to have a closed loop connection as long as there is voltage at the base
of the transistor. In this way the diode led 1 will light up. In similar fashion when water level
will increase led and buzzer at their specific level will light up.

DCS & PLC

DCS or distributed control system is an integral part of an automation and control system
infrastructure in a cement plant. It plays crucial role in:
 Monitoring
 Controlling
 Optimizing.

Introduction to DCS:
Basic Terminologies
HMI Human Machine Interface
PLC Programable Logic Controller
I/O Input/Output
RTU Remote Terminal Unit
ECS Expert Control Supervision
DI Digital Input
DO Digital Output
AI Analog Input
AO Analog Output

DCS Room
Engineering Station
Two engineering stations are used in the DCS room. They are:
1. ECS2536ENG01
2. ECS2536ENG02
All the equipment that is installed in the field is configured in automation using these two
engineering stations.

Software
They have software by FLSMIDTH installed that is known as:
ECS (Expert Control Supervision) v8.0
Test Station
A test station is placed in DCS for testing and creating new programs using
Simatic step 7 software. This test station contains following equipment as
well:

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 PLC-416
 PLC-315
 PLC-1500
 I/O card
 SIMOCODE PRO V
 SIMOCODE PRO S
Server Room xx. Test Station
This room contains main servers of the plant containing all the data that is
coming from the field as well as the backup of all data of previous years. Three main server
compartments are placed. They contain following servers:
1. ECS2536SVR01
2. ECS2536SVR02
3. CEM2536SVR01
4. QCX2536SVR01
5. PXP2536SVR01
6. PLG2536SVR01

PLC
Programmable logic controllers. Simatic S7 PLCs by Siemens are installed in the DGKCC
Hub Plant.The Simatic S7 is a modular mini-PLC system developed by Siemens. It's a
programmable logic controller (PLC) that's used for industrial automation and production.
The Simatic S7 series offers a variety of CPUs with different performance levels and
functionality. Some of the Simatic S7 PLCs that are used in this plant are:
S7-400
S7 400 or CPU 416 type PLCs are the main PLCs used in
this plant at 7 important substations. They include:
1. Crusher
PLC01 101CS100
2. Raw Mill
PLC03 301CS100
3. Kiln
PLC04 401CS100
4. Cooler
PLC05 401CS200
5. Cement Mill xxi. PLC 416
PLC07 501CS100
6. Utilities
PLC08 701CS100

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7. Coal Mill
PLC10 401CS300
All these PLCs are directly connected to DCS servers via Optical
fiber communication protocol.
S7-300
S7-300 CPU-315 is also a central processing unit by Siemens. It is
used with the local controllers in the field e.g., in the packing plant
they are used in every packer and are controlling that specific
packer specifically. These PLC are then connected with the main
plc of packing plant that S7 416 PLC placed in the packing plant
substation.
They don’t have inbuilt I/O cards, so they are added separately on
the rack with them.
S7-1200
xxii. PLC 314
This series of Seimens PLC has inbuilt I/O cards. They are used on
some places like crusher but are not commonly used
elsewhere. This is a compact PLC that has its power supply
and card atteched with the CPU.
Digital Signal
A signal in the form of:
‘0’ or ‘1’
Digital signal types:
DI 321 Digital input I
DO 322 Digital output O xxiiiPLC 1200

Analog Signal
These signals will range from:
4-20 mA
Analog signal types:
AI 331 Analog input IW
AO 332 Analog output QW

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xxiv. I/O cards

Communication Protocol
Communication between field instruments, PLC and DCS servers is carried out via following
three ways:
Ethernet Communication
Uses ethernet cables for transfer of data. It offers high bandwidth, scalability, and
compatibility with standard IT equipment for connecting PLCs, HMI systems, control
components.
Profibus Communication
Used for communication between plc and field instrument and controllers. Normally we use
profibus over distances smaller than 100m as it can have data losses over distances larger
than that. Repeaters can be used to extend its length without data losses.
Optical Fiber
Optical Fiber provides capability of transferring data over large distances without any data
losses and high speed of transfer as well. They are used to transfer data from substations to
the DCS servers. A media converter converts the data from profibus and ethernet cables from
its electric signal form to optical signal that are then transferred via optical fiber cables.

SIMATIC Manager STEP 7

SIMATIC Manager, also known as STEP 7, is a software tool for configuring and
programming Siemens S7-300 and S7-400 PLCs. It is the primary platform for designing,
configuring, and maintaining automation projects. It uses 3 programming languages for the
design of automation processes.
1. LAD (Ladder Logic)
2. STL (Structured text language)
3. FBD (Functional Block Diagram)
In DGKCC Hub plant the main programming language used by FLSmidth for designing the
automation process is the FBD language.
Adding Hardware
For us to start programming inside the step 7 software we first need to configure the hardware
that will be attached to the PLC and the PLC itself in the software. It's known as adding
hardware in Step 7 software.
The following main steps are taken while adding hardware in Step 7:

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 Create a new project file inside the Step 7 software and name it.
 Add the S7 300 or S7 400 station depending on which PLC you will be using for
programming.
 Next select your station, go to hardware, select and open it by double-clicking.
 Add a rack so that hardware can be placed on it. It can be added by selecting the insert
new object option.
 Add PS 407 10A power supply on the 1st row of rack.
 In the 2nd row CPU S7-416-3DP will be added.
416-3XS07-0AB0
In this step, a communication type will also be selected that will be either ethernet or
Profibus depending on the cable that’s used.
 Next CP 443-I will be added to the rack.
443-1EX30-0XE0
 CP 443-5 will be added next.
443-5DX05-0XE0
 The hardware will be saved and complied before trying to online it.
 It will be set to online mode to check that the hardware has been added properly and
our software is successfully communicating with the PLC.
 In case there is a mistake in the hardware-adding process either it will fail to set plc to
the online mode or the PLC will show an error.
Adding VFD
To control a VFD using the STEP 7 software we will need to add the hardware for the VFD
first. Following steps can be followed for that purpose:
 Create a new project file inside the Step 7 software and name it.
 Add S7 400 station in the project as we will be working with S7-416 CPU.
 Next select the station, go to hardware, select and open it by double-clicking.
 Add a rack so that hardware can be placed on it. It can be added by selecting the insert
new object option.
 Add PS 407 10A power supply on the 1st row of rack.
 In the 2nd row CPU S7-416-3DP will be added.
416-3XS07-0AB0
In this step, a communication type will also be selected that will be either ethernet or
Profibus depending on the cable that’s used.
 Next CP 443-I will be added to the rack.
443-1EX30-0XE0
 CP 443-5 will be added next.
443-5DX05-0XE0
 The hardware will be saved and complied before trying to online it.
 It will be set to online mode to check that the hardware has been added properly and
our software is successfully communicating with the PLC.
 In case there is a mistake in the hardware-adding process either it will fail to set plc to
the online mode or the PLC will show an error.

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 Next a Profibus will be connected with the VFD and its connection will be shown
inside the Simatic Step 7 software.
 In case the light on VFD showing profibus connection remains red that means that
profibus is not able to communicate between VFD and PLC.
 In this case enable FPBA mode inside the VFD controller that will allow for profibus
communication.
 Next step will be mapping the FPBA in-data and out-data.
 Next motor addressing inside the step 7 software.

MCC
MCC or motor control center is an assembly of one or more sections containing motor
control units. It provides a centralized location for controlling and distributing power to
various electrical motors in industrial settings.
It receives inputs firm sensors and switches, provides the data to control room and receives
commands that are executed via MCC. Following are some common inputs and command on
MCC:
Inputs
 Run
 Fault
 Load
 Ready/Not Ready
 Speed(rpm)
Commands
 Start/Stop
 Auto/local
 rpm Change
Motor operating sequence
For starting a motor generally following steps of I/O signals are used:
 Initially a DI signal provides motor ready/not ready state.
 Incase motor is ready a DO signal is sent that starts the motor.
 A DI signal for run confirms that motor is running.
 An AI signal will convey the rpm of motor if they are required.
 In case any changes in rpm are required an AO signal will convey that information.
 Further more I/O signals can be added based on sensors or switches that will be
placed.

Ladder Logic
Ladder logic is a visual programming language that uses graphical symbols to represent
functions and operations. It is based on the principles of relay logic, which is the foundation
of traditional control systems.
Ladder Logic uses graphical programming functions that look like the symbols used in hard-
wired control diagrams. It's read from left to right and top to bottom.
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Following are some of the ladder logic programs designed and practiced during internship
period.
Ladder logic for Motor operation
This is a single network ladder logic. This program contains:
1. Start/Stop inputs.
Start = I4.0
Stop = I4.1
2. A normally closed fault input that will break the circuit in case the fault occurs. It will
be connected in series.
Fault = I4.2
3. An output coil for the motor.
Output coil=Q8.0
4. An auxiliary contact of output Q8.0 will be connected in parallel to the start push
button to hold the circuit until the stop push button is pressed.

xxv. Motor operator Ladder logic

Ladder logic Practice

The following two are some design challenges that need to be programmed in Ladder logic.
Ladder Logic for Wood Saw Cutter
Conditions
The following conditions also need to be fulfilled during the running operations of the wood
saw cutter:
1. A wood saw cutter, a fan, and a lubrication oil pump start simultaneously when the
start push button is pressed.
2. The stop-push button only stops the saw cutter and lubrication oil pump.
3. The fan should run 20 extra sec before turning off.
4. If the saw cutter ran for more than one min then the fan should stay ON until a fan
stop button is not pressed.
Following ladder logic made in Simatic Manager satisfies all requirements.
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Network 1. In this network, there is a start push button, a stop push button and a
wood cutter coil and its contact for holding the command once start push button is
released.

Network 2: When wood cutter will run its contact will start lubricatio pump as well.
And when wood cutter will stop so will lub-pump.

Network 3: this network is for fan operations. An off-delay timer is delaying the fan
stop time for 5s after the wood cutter is shutdown.

Network 4: Network 4 will satisfy the last requirement of program by keeping fan on while
wood cutter has operated for more than 60s or 1 min. its out puts contact is used with network
three in parallel to keep it running if wood cutter shuts down.

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Traffic signal for a road intersection

 Design of traffic light signal logic for a road intersection. Each side traffic gets equal
time to go through.
 When light is green on two sides of road intersection it should be red on the other two
side of road at the same time.
 Closed looped system should be self-repeating.
 Light timings:
1. Red light = 20sec
2. Yellow light = 5sec
3.
4. Green light = 20sec

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Packing Plant DCS

The packing plant has its individual DCS that uses a different software for the process
control.
Control Software = PCS 7 v8 (Process Control System)

Engineering Room
One engineering station is placed in this room that is used to make changes to the already
existing programs in case any equipment is added or removed from the automation process of
the packing plant.
Engineering Software = Simatic Manager
Programming Language = Control Flow Chart
Control Room
The packing process is being monitored and controlled in this room using the PCS 7
software. Two control systems are being used for observing the packing operations.
Following are some of the main controls of these two control stations:
 Silo 1 Aeration
 Silo 2 Aeration
 Silo 3 Aeration
 Discharge
 Packing lines 1 & 2
 Packing lines 3 & 4
 Packing lines 5 & 6
 Big Bag
 Generator
 System
PLC
Two types of PLC are installed in the packing plant.
1. S7-300
These PLCs are placed at individual packers of the packing plant that are 6 in total.
PLC-S7-314
These plc are then further connected to the main PLC of the Packing plant.
2. S7-400
PLC-S7-416
This PLC is the main PLC for packing plant controlling its automation process. Following
extra hardware is attached to the PLC rack as well.

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 Power Supply PS-401-10A

 Four CP-443-5
 Three CP-443-I
ET-200 are used to connect I/O cards with the PLC. This PLC is placed in the packing
plant substation.
Communication Protocol
The following three communication protocols are being used in the packing plant.
 CAT6 Ethernet cable
 Profibus
 Optical Fiber
Packer
6 packer by Haver and Boeker are being used for operating 9 loader lines. Each packer has 12
spouts.
Capacity = 2600 bag/hr
Spout
Spout is the individual part of packer filling one bag at a time. It has 3 main compartments:
 Electrical Panel
 Pneumatic Panel
 Bag Filling Section
An empty bag is shouted at the spout by a radimat system. Spout holds the bag and starts
filling. During this time packer is continuously circulating. As the packer completes its
rotation spout has filled the bag and drops the bag on a conveyor belt. A load cell
continuously monitors the filling weight and provides info when the bag reaches 50kg so that
filling can stop.
Radimat System
Empty bags are place on its one end and it takes them in and shoots them at spouts of packer
one by one.
Loader
Nine loaders are present in the loading section that are connected with the 6 packers. Each
packer pair of 2 can provide bags to 3 loaders like:
 Paker 1 and 2 for loader 1, 2, and 3
 Paker 3 and 4 for loader 4, 5, and 6
 Paker 5 and 6 for loader 7, 8, and 9
At loading time one loader for each packer acts as a spare loader and only two loader with
each packer pair will be active.

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Mechanical
Crusher Area
QUARRY
Quarry is a place from where raw material is extracted. Drilling and blasting is done to
extract the material. Then this extracted material is loaded on dumper trucks and conveyed to
the crusher.
DRILLING
Drilling is done in the quarry with the help of drilling machine. A space of about 10-15
cm is created for the powder explosives.
BLASTING
The powder explosive is blasted under a controlled process to get the rocks in the form of
small pieces of different sizes.
Limestone crusher
Capacity: 1350 tons/hr
Supplier: FLSmidth
Input Size: 1000 – 1200 mm3
Final Product Size: 65 – 75 mm3
Type of Crusher Used: Jaw Crusher (Primary Crushing)
Cone/Gyratory Crusher (Secondary Crushing)
Motor Power & RPM: 375 kW & 200 RPM (Jaw Crusher)
750 kW & 700 RPM (Cone Crusher)
Block flow diagram

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Jaw Crusher
In a jaw crusher the feed is admitted between two jaws, set to form a V open at the top. One
jaw is stationary; the other, driven by an eccentric, reciprocates in a horizontal plane and
crushes lumps caught between the jaws. Jaw crusher reduces large size rocks by placing the
rock into compression.
Process
In primary crushing process, the high-grade (HG) limestone and medium grade (MG)
limestone are dumped into their respective hoppers by dumper trucks. From there the material
falls on their respective apron feeder and from there falls into the grizzly feeder. The grizzly
feeder vibrates and the particles below 300 mm3 size falls directly on the conveyor belt
111.BC110 and 111.BC190 which conveys the material from primary crushing process to
secondary crushing process. The particles above 300 mm3 are fed to the jaw crushers
(111.JC100 & 111.JC185). Each jaw crusher has a capacity of 675 tons/hr. The output particle
size from the jaw crushers is around 150 – 300 mm3. All the crushed material from primary
crushing falls on conveyor belt 111.BC200 having a capacity of 1350 tons/hr which conveys
the material to the secondary crushing.
Cone Crusher
In a cone crusher a conical crushing head gyrates inside a funnel-shaped casing, open at the
top. An eccentric drives the shaft carrying the crushing head. Solid caught between the head
and the casing are broken and rebroken until they pass out the bottom. A gyratory crushers
uses compressive force for breaking of particle.
Process
The material from the primary crushing process falls on to a vibrating screen which separates
particles below 75 mm3. The smaller particles falls on the conveyor belt 111.BC550 while the
bigger particles falls into a bin (111.BI400). From the bin the material falls in a vibrating
feeder (111.VF410) which feed a calculated amount of material to a gyratory/cone crusher
(111.GC500) having a capacity of 900 tons/hr where the material is reduced to a final product
size of around 65 – 75 mm3. The final product with the help of long conveyor belt 121.BC200
is then conveyed to the storage area where it is stored in the form of piles. The total length of
long belt conveyor (LBC) is approximately 3.2 km and its capacity is 1350 tons/hr. The LBC
is a steel cord type conveyor belt because of the distance it covers and weight it bears. To
control the dust produce during the whole crushing process, several bag filters of various
sizes are employed.
MAGNETIC SEPARATOR:
A magnetic separator (111.MS605) is installed over the belt conveyor 111.BC600. It attracts
and removes metallic objects from the crushed material. The magnetic separator installed is
very sensitive and capable of removing coarse to ultra-fine metal particles.
Bag filters
The dust produced by crushing process can cause work place safety hazards and also makes it
harder for the workers working with the equipment, to overcome this problem a bag filter is
employed. A fan blows air and all the dust goes to the bag filter. Inside the bag filter a special
type of canvas cloth is used. When air passes through this filter cloth, the dust particles stick

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to the cloth and clean air passes through. The dust particles are then collected and sent to the
conveyor.
COMPOSITION ANALYZER:
A composition analyzer is installed upon the conveyor belt 111.BC600. This analyzer detects
the composition/Lime saturation factor (LSF) of the crushed limestone before it goes to the
storage area. The LSF is set according to the requirement and this value is maintained using
apron feeders located below the main inlet hoppers. The element emits beta rays which pass
through the material and are deflected back to the analyzer, which then checks the
composition/LSF.

Storage Area
The crushed material is stored in the form of piles in the storage yard. There are 9 piles in the
storage yard. Mixed grade piles are used in larger quantity where as high grade and additive
piles are used in small quantity.
 Mixed Grade Pile Capacity: 35000 tons
 Total No. of Mixed Grade Piles: 2
 High Grade Pile Capacity: 5000 tons
 Total No. of High Grade Piles: 2
 Clay Pile Capacity: 3500 tons
 Total No. of Clay Piles: 2
 Shale Pile Capacity: 3500 tons
 Total No. of Shale Piles: 2
 Gypsum Pile Capacity: 3000 tons
 Total No. of Gypsum Piles: 1
Stacker:
A stacker is a device which forms conical piles of the crushed material. Feed is conveyed to
the stacker through conveyor belts. This stacker then moves to and fro to make pile.
From conveying this material from piles to the conveyor belt following equipment are used:
 Side Scraper Reclaimer
 Bridge Reclaimer
Side Scraper Reclaimer:
Side scraper reclaimer is a device which picks the crushed feed from the piles through its feed
belt called “hoist”. This belt has a number of small buckets of low capacity. When this belt
moves, the buckets picked feed from the pile and put it on the belt conveyor. Side scraper
reclaimer is used for those piles which are required in low quantity like high grade, clay,
shale, and gypsum.

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BRIDGE RECLAIMER:
A bridge reclaimer is a large machine used in bulk material handling. Its function is to
recover bulk material from a stockpile, which has been stacked by the stacker. Reclaimer
travel on a rail between stockpiles in the stockyard. It is electrically powered by means of a
trailing cable. Bridge type reclaimer has two arms called “Harrows”. These harrows are
inserted into the pile, when they move sideward, the feed drops down the pile. Their
movement tends to cut pile from top. This feed in then collected by high capacity buckets
installed in the bottom of the reclaimer. These buckets pick the feed and put it on the belt
conveyor. It is a large capacity equipment and for those piles which are required in high
quantity like Mixed grade pile.

Raw Mill Area

Feeding Bins
The raw mill feed area consists of 5 bins:
Name Code Capacity
1. Mixed Grade 311.BI100 900 tons
2. High Grade 311.BI200 450 tons
3. Shale 311.BI300 450 tons
4. Clay 311.BI400 450 tons
5. Laterite 311.BI500 150 tons
The feed material from each pile is conveyed to their respective bins through conveyor belts.
Each bin has a weigh feeder below it.
Weigh Feeder
In a weigh feeder, the material falls on to a conveyor belt through an inlet slide gate or
automatic pre-feeder. Load cells under the belt continuously measure the weight of the
material over a definite length of belt. From the bins, the feed is required in different
proportion. CCR set the required values and the by controlling the speed of the weigh
feeders.
Name Material Capacity
 311.WF150: Mixed Grade 600 tons/hr
 311.WF250: High Grade 100 tons/hr
 311.WF350: Shale 110 tons/hr
 311.WF450: Clay 110 tons/hr
 311.WF550: Laterite 10 tons/hr

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Raw Mill
Raw mill involves the mixing of extracted raw materials to obtain the correct chemical
configuration and grinding them to achieve the proper particle size to ensure optimal fuel
efficiency in the rotary kiln and strength in the final concrete product. At DGKCC,
LOESCHE vertical roller mill type LM 72.5 is used.
The raw mill has three sections:
1. Table with 5 rollers.
2. Separator/Classifier.
3. Bottom Scraper
RAW MILL SPECIFICATION:
 Mill type: Vertical Roller Mill
 No. of rollers: 5
 Capacity: 654 tons/hr
 Model Name: LM 72.5
 Mill fan motor power: 8000 kW
 RPM of grinding table: 20.04 RPM
 Diameter of table: 7200 mm
 Cope Drive: 1250 kW (each)
Process
Limestone, shale, clay, and laterite from their respective bins falls on the belt conveyor
311.BC600 with the help of weigh feeders. The raw mill feed quality is controlled by the QC
lab with the help of a composition analyzer 881.QC030. The raw mill feed is then fed to a
vertical roller mill 321.RM100 with the help of belt conveyors 311.BC620, 321.BC050 and a
rotary feeder 321.RF090. Hot gas, having a temperature of around 145°C, along with the
recycled gas is fed from the bottom of the mill. The material is comminated in the mill and,
after passing through the mill classifier, is transported by the gas stream into two hurriclon
separators 321.CN301 & 321.CN311 with the help of raw mill fan 321.FN400. The exit
temperature of product is about 85°C. The hurriclons separates the fine material from the gas.
The fine solid product, from air slides 321.AS320 & 321.AS330 drops in a bucket elevator
341.BE050 which then drop the material on air slide 341.AS060 which drops the material in
the raw meal silo 341.SI100. Some fraction of the gas from the hurriclons is recycled back to
the raw mill while other fraction is transported to the bag house 331.BF300. Here the gas is
further cleaned. The dust is sent to air slide 321.AS330 and from there to the raw meal silo
while the gas is sent to the stack 331.SK410 for disposal.
INDUCED DRAFT (ID) FAN:
Induced draft fan is used to create a vacuum or negative pressure in a system. There are two
ID fans, 331.FN110 and 331.FN120, located between preheaters chimney and grinding mills.
These ID fans takes the hot gases from the preheaters exit chimney and deliver these hot
gases to the grinding mills for grinding operation. Both ID fans are driven by two motors,
each having 2515 kW power. The motor RPM is 994 with a maximum RPM of 1500.
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Preheater
Preheaters are cyclones arranged vertically, in series, and are supported by a structure known
as the preheater tower. It can be considered as a heat transfer tower supports a series of
vertical cyclone chambers through which the raw material passes on the way to the kiln. To
save energy modern cement plants preheat the raw material before they enter the kiln. Rising
more than hundred-meter, hot exit gases from the kiln heat the raw meal as they swirl down
the cyclone string.
Process description
The raw material from the raw meal silo 341.SI100 is dropped on air slid 351.AS350 with the
help of bucket elevator 351.BE340. The raw material from the air slid is put on top of the 2nd
cyclone 421.CN120. The hot gases from the kiln flow with very high velocity in
countercurrent direction. The hot gases lift the material from the top of 2 nd cyclone and puts it
in the 1st cyclone (2 cyclones) 421.CN110 and 421.CN111. From there the material falls on
the top of the 3rd cyclone 421.CN130 and the hot gases sends it into the 2 nd cyclone. Then the
material falls on the top of 4th cyclone 421.CN140 and hot gases takes it into the 3rd cyclone.
Then the material falls on the top of the 5th cyclone 421.CN150 and hot gases takes it into the
4th cyclone and then the material falls on top of the 6th cyclone 421.CN160 but hot gases take
it into the 5th cyclone. The cyclone 421.CN150 has a multi diverter gate 421.DG180 at the
bottom which splits the material into 4 streams. From the pre-calciner the material goes
inside the calciner 421.CI400 and from there into the 6 th cyclone pre-heater. Finally, from
there the material goes into the inlet of the kiln 431.KL100. There is a tertiary air duct TAD
coming from the hood of the kiln which provide hot air to the pre- calciner.
These cyclones serve the purpose of preheating as well as the separation of solid (dust), from
the feed material with hot gases of kiln. These cyclones, pre-calciner and calciner are
internally lined with high alumina bricks. There are total 12 cyclone preheaters, 6 are on the
right side of the pre calciner and 6 on the left of the pre calciner. This makes the two strings.
The temperature of feed increases as the feed flows downwards the preheaters. These strings
are connected in parallel fashion. The temperature in calciner reaches up to 900°C due to flue
gases from the kiln. 95% calcination is done in calciner while rest of 5% in kiln. There are
two gas analyzers 851.AM820 and 851.AM822 installed, one on top of each string, to
monitor the emission of SOx, NOx, CO2, and other gases from the pre-heaters.
Advantages

 It raises the yield of the kiln significantly.

 It eases the kiln burning zone of thermal load, as a result of prolonging the
service life of the lining and raising the running rate.
 It is easy to burn the inferior coal with low heat loss per ton of clinker.
 It exhausts lower content of NOx in the waste gas, and the pollution of the
environment is comparably small.

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Block Diagram

ROTARY KILN
The rotary kiln is a long cylindrical vessel, inclined slightly to the horizontal, which is rotated
slowly about its axis. The material to be processed is fed into the upper end of the cylinder.
As the kiln rotates, material gradually moves down towards the lower end, and may undergo
a certain amount of stirring and mixing. Hot gases pass along the kiln usually in the opposite
direction (counter-current). The hot gases may be generated in an external furnace, or may be
generated by a flame inside the kiln. The fuel for this may be gas, oil, or pulverized coal. It is
the most important part of the cement manufacturing process, also called heart of process, as
materials are baked here to produce clinker. A Rotary Kiln is a pyro processing device used
to rise temperature of material into a continuous process.

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Figure 28 Schematic diagram of rotary
kiln
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Refractory lining
The purpose of the refractory lining is to insulate the steel from the high temperatures inside
the kiln, and to protect it from the corrosive properties of the process material. The refractory
selected depends upon the temperature inside the kiln and chemical nature of the material
being processed. The refractory life is prolonged by maintaining a coating of the processed
material on the refractory surface. A typical refractory will be capable of maintaining a
temperature drop of 1000°C or more between its hot and cold faces. The shell temperature
needs to be maintained around 300 – 350°C in order to protect the steel from damage, and
infrared scanners are used which monitors the temperature and give early warning of hot
spots indicative of refractory failure.
There are many types of refractory but in DGKCC Hub plant two types of refractory bricks
are used.
High alumina bricks
They are high refractory whose reactiveness increases with increase of alumina content,
having high mechanical strength at high temperature. They are resistant to spalling. High
alumina bricks are lined in the kiln calcination zone, safety zone, in preheaters and in pre-
calciner.
Magnesite bricks
They are extremely high refractory and has high thermal resistance. They are chemical
bounded to the kiln surface and are resistant to spalling. Magnesite bricks are lined in the kiln
transition zone and burning zone.
Kiln Drive
There are two kiln tiers which are resting on four rollers. Two rollers near the kiln inlet are driven by
two induction motors which impart rotary motion to the kiln while other two rollers rotate with the
kiln. The kiln rotates freely between the two ends so, to keep the kiln intact in its place a thrust rollers
is installed at the bottom of the kiln.

Kiln burner
On the other end of the kiln, there is huge burner having a supply of coal/furnace oil and air.
The burner emits a flame which is prolonged with high pressure air. The flame burn the
material and the product is formed.
Rotary kiln specifications:

Kiln Length 69 m
Kiln Internal Diameter 5.75 m
Kiln Inclination 3.5%

Kiln RPM 3.8 – 4.2 RPM

Kiln Feed Rate 585 tons/hr
Kiln Product Rate 9000 tons/day

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Total Coal Feed Rate 42 tons/hr

Fuel Used Furnace Oil/Coal

Power Consumption 25 kWH per ton of cement

PROCESS INSIDE THE KILN:

The kiln may be divided into following seven zones:
The inlet zone: This is the first zone of the kiln in which feed enters from the pre-heater.
Temperature of this zone is about 900-1000˚C. In this zone, decomposition of calcium
carbonate occurs which is present in limestone.
The calcining zone: Here remaining 5% calcination takes place. The temperature of this
zone is about 1100˚C.
The safety zone: Here complete calcination is achieved. Temperature is again around
1100˚C.
Upper Transition zone: Here liquefaction of material occurs and temperature tend to rises
up to 1250˚C.
Burning zone: This is the largest zone of kiln here main reaction takes place at around
1400˚C. Clinker formation occurs and material turns to red hot.
Lower transition zone: After burning zone, for safety and complete reaction this zone is
placed. Length of this zone is 10m.
Cooling Zone: After the formation of clinkers, they required sudden cooling to maintain their
quality and size.
These zones are not marked but are imaginary portions that we have divided.

Crossbar Cooler
The clinker cooler 441.CC100 is used to lower the temperature of clinker. The
clinker, having a temperature of around 1200 – 1300 °C is cooled to a temperature of
around 90 – 100 °C. The cooler has two sections (upper and lower section). Air
blowing takes place in the upper section which cool down the gases that are going to
the electrostatic precipitator 441.EP550. The cooler used is a “cross bar cooler”
which uses moving cross bars mechanism to move the clinker to the other end. Many
plates are present at a specific distance from each other to transfer the material to the

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other end. The plates move to and fro through hydraulic mechanism and drag the
material to the other end. This material is then crushed using a HRB MF (modular
frame) clinker breaker and finally moved to the bottom chamber. Here more air is
blown for further cooling. The bottom chamber also has water showering system
which is used to control the temperature (in case of higher gas temperature) of gases
going towards the electrostatic precipitator. There are 12 fans used for cooling of
clinker and the air used for cooling is referred to as secondary air. The cooled clinker
is then conveyed to the clinker silo 481.SI100 through a pan conveyor 471.AC100.

Cooler Drives = 9

Drive ratings = 75kW

Roller Breaker
3 drive rollers are placed to crush clinker by pressing between them and make them into
small pieces.
Electrostatic Precipitator:
The hot air from the clinker cooler still contains some clinker particles which have to be removed
before disposal. These particles are separated from air by passing it through the Electrostatic
precipitator 441.EP550. The clinker dust separated from the hot air is conveyed to the clinker silo
along with the cooled clinker.

Working
An electrostatic precipitator (ESP) works because of electrostatic attraction (like charges
repel; unlike charges attract). An ESP uses a high-voltage electrostatic field to separate dust,
fume, or mist from a gas stream. The precipitator consists of vertical parallel plates
(collecting plates/electrodes) forming gas passages 12 to 16 in. (30.5 to 40.6 cm) apart.
Discharge electrodes are electrically isolated from the plates and suspended in rows between
the gas passages. Every particle either has or can be given a charge - positive or negative. A
high voltage system provides power to the discharge electrode to generate an electrical field.
The particulate, entrained in the gas, is charged while passing through the electrical field. The
particulate is then attracted to the grounded collector plate and forms a dust layer on the plate.
Periodic rapping separates the accumulated dust layer from both the collector plates and
discharge electrodes (in case of wet ESP by spraying it with a liquid). The dust layer released
by the rapping collects in hoppers and is removed by material handling system.
Clinker Silo
The clinker from the deep pan conveyor 471.AC100 is stored in the clinker silo 481.SI100.
There is another silo 481.SI400 called off-standard clinker silo having a capacity of 3800
tons. This silo’s purpose varies according to the need of the plant. It could store off-standard
clinker, Ordinary Portland cement (OPC) clinker, Sulfur resistant cement (SRC) clinker and
exporting clinker. The silo 481.SI400 has a loading spout 481.LS430 which is used for
loading of dumper trucks. The dumper trucks dump the clinker in the clinker yard where it is
stored. There is also a manual clinker hopper 481.FY500 which is used for manual feeding of
clinker which is stored in the clinker yard.

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Specifications:

 Its capacity is 110,000 tons.

 Its height is 30 m and its width is 60 m.
 There are seven gates at the bottom of the clinker silo. Three gates are on the
middle pan conveyor 481.AC160, and two gates each on the pan conveyor
481.AC150 and 481.AC170 which conveyed the clinker to the belt conveyor.
Cement Mill
Feed Area
There are 6 bins in the cement mill feed area. Two bins for clinker (one for the cement mill
and one for exporting), and one bin each for high grade limestone, pozzolana, and gypsum.
The export clinker bin has an export loading spout 511.LS150 for loading of dumper trucks.
The cement contains 95 % clinker. Gypsum is added to about 3 – 5 % and other additives
(limestone and pozzolana) are added to about 2 % in the cement.

Bin Code Material Stored Capacity

511.BI100: Clinker (for export) 600 tons

511.BI200: Clinker (for cement mill) 600 tons

511.BI400: High Grade Limestone 450 tons

511.BI500: Pozzolana 450 tons

511.BI300: Gypsum 450 tons

Cement Mill
LOESCHE vertical roller mill type LM 72.4+4 C is used for clinker grinding. There are 4
master rollers (M) for grinding of material and 4 supporting rollers (S) for maintaining the
grinding bed. The motors used in cement mill are COPE (Compact Planetary Electric) drive.
N2 gas is used in shock absorbing system of rollers. Piston and bladder accumulators are used
for this and a total of 48 cylinders of N2 gas are used (32 for bladder accumulators & 16 for
piston accumulators).

Specifications:
 Mill type: Vertical Roller Mill
 No. of rollers: 4M + 4S
 Capacity: 445 tons/hr
 Model Name: LM 72.4+4 C
 RPM of grinding table: 20.04 RPM
 Diameter of table: 7200 mm
 Main motor Power: 1250 kW (each)
 Total no. of main motors: 8
 Mill fan motor power: 5600 kW

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Working
The feed material is discharged into the mill via an airlock and a downpipe to the centre
of the rotating grinding table. Magnetic tramp material is diverted from the feed
material before reaching the rotary feeder and is removed through a branched. The
material to be ground moves on the grinding track towards the edge of the grinding
table under the effect of centrifugal force and in this way passes under the hydro
pneumatically spring-loaded M rollers. These comminute the material while the smaller
S rollers, which each operate between the M rollers, support preparation of the grinding
bed by de-aeration and precomputation. The rollers are forced upwards as they roll on
the material bed. At the same time the functional unit consisting of M roller, rocker arm,
spring rod and the piston of the hydraulic are deflected. The piston displaces the oil
from the upper Nitrogen-filled rubber bladders in the accumulator units are compressed
and act as gas springs. The buffer stop prevents contact of the grinding roller with the
grinding track bed. Scrapers push the reject out of the ring duct and into the reject-
return. Rotation of the grinding table causes the ground material from the M rollers to
be thrown outwards over the edge of the table. In the area of the louvre ring, which
surrounds the grinding table, the upwardly directed hot gas stream captures the mixture
of ground material and material still to be ground and conveys this to the classifier.
Depending on the classifier settings coarse material is rejected. This falls into the
internal grit return cone and from there is returned to the grinding table for re-grinding
under the rollers. Final product material passes the classifier and is conveyed from the
Loesche mill with the gas stream. When grinding mixed cement, the water contained in
the feed material evaporates spontaneously through intimate contact with the hot gas
stream. The required mill outlet temperature of 80 – 90°C is therefore already achieved
in the grinding chamber.
Cement Silo Specifications:
Silo 611 Silo 612 Silo 613
Inner Silo Outer Inner Outer
Silo Code
611.SI 200 Silo Silo Silo
611.SI10 612.SI20 612.SI100
0 0
Capacity 10000 tons 20000 tons 10000 tons 20000 tons 30000 tons
Diameter 12 m 24 m 12 m 24 m 24 m
Filling Height 65 m 65 m 65 m 65 m 60.4 m
Total Height 77.8 m 77.8 m 77.8 m
Collecting Bin 611.BI252 611.BI152 612.BI252 612.BI152 613.BI152
Code
Collecting Bin 30 tons 30 tons 30 tons 30 tons 30 tons
Capacity

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Packing Plant
The packing plant comprises of 6 roto packers and 1 big bag loading system. For loading
packed bags, there are 9 loading bays/ terminals for roto packer and 1 loading bay/terminal is
for big bag loading. The packing plant is fully computerized and works on the Programmable
Logic Controller (PLC) while the PLC system is controlled from the Local Control Room
(LCR) which uses Distributed Control System (DCS). The DCS system is provided by
Siemens and the model is SIMATIC PCS 7 which is the latest model offered by the company.
Each roto packer has a capacity of 132 tons/hr which is equivalent to 2640 bags/hr when
working at full potential. Each Packer has 12 spouts with which the root packer fills bags.
When the bag is filled up to the required weight (50kg), it automatically falls on the conveyor
belt which takes the bags to the roller conveyor. From these rollers the bags slide to different
channels and finally cement bags are loaded on the trucks for dispatching. The big bag
loading line is used to fill big bags (1-ton standard weight). The packing plant has a capacity
of 10,200 tons/day.
Packer
6 packer by Haver and Boeker are being used for operating 9 loader lines. Each packer has 12
spouts.
Capacity = 2640 bag/hr
Spout
Spout is the individual part of packer filling one bag at a time. It has 3 main compartments:
 Electrical Panel
 Pneumatic Panel
 Bag Filling Section
An empty bag is shot at the spout by a radimat system. Spout holds the bag and starts filling.
During this time packers are continuously circulating. As the packer completes its rotation
spout has filled the bag and drops the bag on a conveyor belt. A load cell continuously
monitors the filling weight and provides info when the bag reaches 50kg so that filling can
stop.
Radimat System
Empty bags are place on its one end, and it takes them in and shoots them at spouts of packer
one by one.
Check Weigher
It rejects any bag that have bag weight over 51 kg or less than 49 kg. It also provides
feedback for individual spouts to increase or decrease the feed to reach exactly 50 kg.
Loader
Nine loaders are present in the loading section that are connected with the 6 packers. Each
packer pair of 2 can provide bags to 3 loaders like:
 Paker 1 and 2 for loaders 1, 2, and 3
 Paker 3 and 4 for loaders 4, 5, and 6
 Paker 5 and 6 for loader 7, 8, and 9.
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At loading time one loader for each packer acts as a spare loader and only two loader with
each packer pair will be active.

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AN INTERNSHIP REPORT

ON

Electrical, Instruments and Control

OF

D.G. KHAN CEMENT PLANT HUB, BALUCHISTAN

SUBMITTED TO:
HOD E, I & C
Mr. Pasha Mustafa

SUBMITTED BY:
INTERNEE
Ihtisham Arif

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