PLANT LINE DESIGN DATA COAL MILL TYPE COAL MILL DESIGN CAPACITY POWER CONSUMPTION DESIGN (MILL ONLY) FUEL ANALYSIS - AS PER DESIGN CV ASH TOTAL MOISTURE INHERENT MOISTURE VM S Cl HGI PRODUCT RESIDUE 90 um COAL MILL MOTOR POWER INSTALLED COAL MILL GEARBOX POWER TABLE DIAMETER BALL MILL DIAMETER BALL MILL DRYING CHAMBER LENGTH BALL MILL GRINDING CHAMBER LENGTH SEPARATOR SEPARATOR SUPPLIER SEPARATOR SEPARATOR TYPE MILL FILTER AREA TOTAL MILL FILTER AREA ACTIVE (OFFLINE CLEANING) MILL FAN DESIGN VOLUME Kiln coal dosing system capacity Calciner coal dosing system capacity Note: adb - air dried basis asr - as received
ARASMETA CEMENT PLANT, PLANT, INDIA MILL1 Ball Mill 15 NA NA NA NA NA NA NA NA 12 405 NA 3 2.8 4.4 FLS/L&T Static 340.34 24600 14
MILL2 Vertical Mill 25 tph product 24.5 kW h/t 4300 32.7 20(max) 3 25.5 0.4 NA 50 12 365 NA 2 LNVT LVT type 1000 84000 20
kcal/kg net adb % adb % asr % asr % adb % adb % adb % kW kW m m m m
m2 m2 m3/hr tph tph
PLANT LINE CURRENT OPERATION RAW MEAL Chloride KFUI CLINKER CHEMISTRY S = SO3 Na2O K2O Chloride COAL MILL PERFORMANCE PRODUCTION PRODUCT RESIDUE 90 UM PRODUCT RESIDUE 200 UM MILL POWER ABSORBED POWER CONSUMPTION PRODUCT MOISTURE FUEL 1 PROPORTION FUEL 2 PROPORTION FUEL ANALYSIS - CURRENT CV ASH TOTAL MOISTURE INHERENT MOISTURE VM S Cl HGI ALTERNATIVE FUEL NOT THRU MILLS KILN FEEDRATE VARIATION COAL FEED RATE VARIATIONS KILN COAL FEED RATE VARIATIONS PC BURNER MOMENTUM AXIAL ALIGNMENT OF BURNER
GAS ANALYSIS RELIABILTY GAS ANALYSIS KILN INLET GAS ANALYSIS PC OUTLET GAS ANALYSIS P/H OUTLET SPLASH BOXES INSTALLED MEAL CURTAIN INSTALLED BLASTERS ON RISER AND HEARTH SILICON CARBIDE ON RISER AND HEARTH
ARASMETA CEMENT PLANT, INDIA
0.012-0.02 3 to 4
%
0.6 - 0.8 0.25 - 0.3 1.5 -1.6 0.020 - 0.025 MILL 1 MILL 2 15 27 15.8 25.26 1.92 2.5 371 276 36.0 26.0 1.85 1.14 100 100 0 0 FUEL 1 FUEL 2 4888 4568 30.36 34.06 1.85 1.14 26.16 24.77 0.3 0.3 0.015 0.015 68 69
% % % %
3.0 +/- 10 +/- 6 3.8 20 mm down & 20mm towards feed
70 to 80 95 to 98 95 to 98 Yes Yes No
tph product % % kW kWh/t % % total CV input % total CV input kcal/kg net adb % adb % asr % asr % adb % adb % adb % cv replacement % tph % tph % tph Nh/GJ
% % %
Actual for
002
ANSWERS TO THIS QUESTIONNAIRE SHOULD BE ACCURATE AND SPECIFIC please add any comments you might feel of help at the end of the questionnaire. If there is an area where the answer is not know please state not known. Note cells are auto formated yes = green no = red Completion target date 10th October 2003
COAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION 1
PREHEATER EXIT
P r e h e a te r g a s a n a l y s i s
Preheater exit gas analyser installed (y/n) O2 measured (y/n) CO measured (y/n) Service factor of analyser >95% (y/n) 2
COAL MILL
Coal mill design pressure DCS system installed if not what type of control system Using hot gas from cooler,pre-heater or hot gas generator
coal mill temperature monitoring
coal mill exit thermocouple installed (y/n) Normal operating exit temperature © Alarms configured for exit temperature First alarm level for coal mill exit temperature © Second alarm level for coal mill exit temperature © inlet thermocouples installed (y/n) Normal operating Inlet Temperature © Alarms configured for inlet temperature First alarm level for mill inlet temperature © Second alarm level for coal mill inlet temperature © Temperature controlled by Recirculation damper (y/n) Automated shutdown for high high coal mill exit temperature (y/n) OXYGEN LEVEL at filter (%) Tramp metal detection installed Coal mill explosio n relief
Explosion relief installed on coal mill (y/n) Venting direction inside or outside building ? Position (e.g. on coal mill body in inlet or exit duct etc) Type of protection explosion flap, rupture panel Area of explosion flap, panel (m2)
Lifting/ breaking pressure of flap , panel Manufacturer of explosion relief Extra Venting fitted on duct from coal mill to filter (y/n) Venting direction inside or outside building ?
3
COAL MILL BAG FILTER
Bag filter design pressure Bag filter temperature mon itoring
Inlet thermocouple fitted (y/n) Outlet thermocouple fitted (y/n) Differential temperature monitored and displayed (y/n) Position of probes (e.g. in filter or ducts) Typical differential temperature © First alarm level of differential temperature Second alarm level of differential temperature Does second alarm trigger automatic shutdown (y/n) Temperature measured in bag filter bottom (y/n) Material discharge temperature of bag filter measured (y/n)
B a g f i l t er G a s m o n i t o r i n g
Bag filter gas exit analyser installed (y/n) Position inside filter or in exit duct CO measured (y/n) O2 measured (y/n) Normal operating level of CO ppm Normal operating level of O2 % First alarm level (O2 %) Second alarm level (O2%) First alarm level (CO ppm) Second alarm level (CO ppm) Do the second alarms for CO or O2 trigger an automatic shutdown Bag filter level devices
Any level devices installed in bag filter (y/n) position of level devices Any blockage devices fitted to filter discharge (y/n) Bag filter isolation
Fast acting isolation dampers installed outlet and inlet of filter (y/n) B a g f i l t e r E x p l o s i o n p r o t e c t io n
Explosion relief installed on bag f ilter (y/n) Type of protection (self closing doors rupture panels etc) Area of explosion doors, panels (m2) Lifting/ breaking pressure of flap , panel Number of explosion doors panels etc Position of doors panels (side venting etc) 4
PULVERIZED FUEL STORAGE
Fuel storage design pressure
Pulverized fuel Storage silo gas mo nitoring
Number of storage silos Capacity of silos /s (t) CO analyser installed on individual silo/s (y/n) Pulverized fuel Storage silo temperature mon itoring
Thermocouples installed in silo/s (y/n) Number of measuring points Position of points ( silo bottom, body, top etc) First alarm level Second alarm level Any other temperature monitoring devices installed (describe) p u l v e r i ze d f u e l s t o r a g e s i l o / s ex p l o s i o n p r o t e c t i o n
Explosion relief installed on silos (y/n) Type of protection (self closing doors rupture panels etc) Number of explosion doors panels etc Area of explosion flap, panel (m2) Lifting/ breaking pressure of flap , panel 5
RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)
Fire suppression system installed (y/n) Temperature monitoring for hopper Explosion vents installed (y/n) CO monitoring installed (y/n) 6
OPERATOR TRAINING
Have operators had training on fire suppression techniques 7
DOCUMENTATION
Is there a written procedure in case of fire or suspected fire on the coal mill system Are there any written procedures covering general house keeping in coal grinding area Any formal training attend (with suppliers Atc etc)
8
SYSTEM GENERAL
Is there a cleaning schedule for the coal plant area (y/n) Have earthing straps been installed and tested on all conveying pipes (y/n) Is there any horizontal ducting in the system
9
FIRE SUPPRESSION SYSTEM
Date installed Manufacturer Type of suppression used CO2 (gas) CO2 (liquid & gas) N2
Storage capacity Storage in bulk or bottles Refill delivery time from time of order (hrs)
Deliver capacity (M3/hr) Available discharge areas (coal mill, filter, silos others etc) Any alternative or secondary system used Automatic raw meal blanket system installed Any explosion suppression system fitted ( dry powder or other) What areas have explosion the suppression system installed
10
ANSWERS TO THIS QUESTIONNAIRE SHOULD BE ACCURATE AND SPECIFIC please add any comments you might feel of help at the end of the questionnaire. If there is an area where the answer is not know please state not known. N o t e c e l l s a r e au t o f o r m a t e d yes = green no = red.
Completion target date 10th October 2003
COAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION 1
PREHEATER EXIT
P r e h e a te r g a s a n a l y s i s
Preheater exit gas analyser installed (y/n) O2 measured (y/n) CO measured (y/n) Service factor of analyser >95% (y/n) 2
COAL MILL
Coal mill design pressure (bar) DCS system installed if not what type of control system Using hot gas from cooler,pre-heater or hot gas generator
coal mill temperature monitoring
coal mill exit thermocouple installed (y/n) Normal operating exit temperature © Alarms configured for exit temperature First alarm level for coal mill exit temperature © Second alarm level for coal mill exit temperature © inlet thermocouples installed (y/n) Normal operating Inlet Temperature © Alarms configured for inlet temperature First alarm level for mill inlet temperature © Second alarm level for coal mill exit temperature © Temperature controlled by Recirculation damper (y/n) Automated shutdown for high high coal mill exit temperature (y/n) OXYGEN LEVEL at filter (%) Tramp metal detection installed Coal mill explosio n relief
Explosion relief installed on coal mill (y/n) Venting direction inside or outside building ? Position (e.g. on coal mill body in inlet or exit duct etc) Type of protection explosion flap, rupture panel Area of explosion flap, panel (m2) Lifting/ breaking pressure of flap , panel
Manufacturer of explosion relief Extra Venting fitted on duct from coal mill to filter (y/n) Venting direction inside or outside building ?
3
COAL MILL BAG FILTER
Bag filter design pressure Bag filter temperature mon itoring
Inlet thermocouple fitted (y/n) Outlet thermocouple fitted (y/n) Differential temperature monitored and displayed (y/n) Position of probes (e.g. in filter or ducts) Typical differential temperature © First alarm level of differential temperature Second alarm level of differential temperature Does second alarm trigger automatic shutdown (y/n) Temperature measured in bag filter bottom (y/n) Material discharge temperature of bag filter measured (y/n)
B a g f i l t er G a s m o n i t o r i n g
Bag filter gas exit analyser installed (y/n) Position inside filter or in exit duct CO measured (y/n) O2 measured (y/n) Normal operating level of CO ppm Normal operating level of O2 % First alarm level (O2 %) Second alarm level (O2%) First alarm level (CO ppm) Second alarm level (CO ppm) Do the second alarms for CO or O2 trigger an automatic shutdown Bag filter level devices
Any level devices installed in bag filter (y/n) position of level devices Any blockage devices fitted to filter discharge (y/n) Bag filter isolation
Fast acting isolation dampers installed outlet and inlet of filter (y/n) B a g f i l t e r E x p l o s i o n p r o t e c t io n
Explosion relief installed on bag f ilter (y/n) Type of protection (self closing doors rupture panels etc) Area of explosion doors, panels (m2) Lifting/ breaking pressure of flap , panel Number of explosion doors panels etc Position of doors panels (side venting etc) 4
PULVERIZED FUEL STORAGE
Fuel storage design pressure
Pulverized fuel Storage silo gas mo nitoring
Number of storage silos Capacity of silos /s (t) CO analyser installed on individual silo/s (y/n) Pulverized fuel Storage silo temperature mon itoring
Thermocouples installed in silo/s (y/n) Number of measuring points Position of points ( silo bottom, body, top etc) First alarm level Second alarm level Any other temperature monitoring devices installed (describe) p u l v e r i ze d f u e l s t o r a g e s i l o / s ex p l o s i o n p r o t e c t i o n
Explosion relief installed on silos (y/n) Type of protection (self closing doors rupture panels etc) Number of explosion doors panels etc Area of explosion flap, panel (m2) Lifting/ breaking pressure of flap , panel 5
RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)
Fire suppression system installed (y/n) Temperature monitoring for hopper Explosion vents installed (y/n) CO monitoring installed (y/n) 6
OPERATOR TRAINING
Have operators had training on fire suppression techniques 7
DOCUMENTATION
Is there a written procedure in case of fire or suspected fire on the coal mill system Are there any written procedures covering general house keeping in coal grinding area Any formal training attend (with suppliers Atc etc)
8
SYSTEM GENERAL
Is there a cleaning schedule for the coal plant area (y/n) Have earthing straps been installed and tested on all conveying pipes (y/n) Is there any horizontal ducting in the system
9
FIRE SUPPRESSION SYSTEM
Date installed Manufacturer Type of suppression used CO2 (gas) CO2 (liquid & gas) N2
Storage capacity kg Storage in bulk or bottles Refill delivery time from time of order (hrs) Deliver capacity (M3/hr) Available discharge areas (coal mill, filter, silos others etc) Any alternative or secondary system used Automatic raw meal blanket system installed Any explosion suppression system fitted ( dry powder or other) What areas have explosion the suppression system installed
10
