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LAFARGE SURMA CEMENT PLANT

Chapter - 8

Functional Specification
Kiln

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 1 of 204
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CONTENTS

8 Kiln.........................................................................................................................5
8.1 Process Flow Sheets........................................................................5
8.2 Instrument Flow Sheets...................................................................5
8.3 List of Sequences.............................................................................6
8.3.1 Kiln Interlock Table.............................................................................7
8.4 316.S01: Kiln Auxiliaries..................................................................8
8.4.1 Sequence Flow Sheet.........................................................................8
8.4.2 Consumer List...................................................................................10
8.4.3 Analog Sensors Lists........................................................................11
8.4.4 Operators Selections........................................................................12
8.4.5 Operators Mode Description.............................................................12
8.4.6 Sequence Interlocks and Alarms......................................................13
8.4.7 D/D Interlocks and Alarms................................................................14
8.4.8 Process Protections..........................................................................19
8.4.9 Regulation Loops..............................................................................20
8.4.10 Cyclic and Special Functions............................................................21
8.4.11 Messages and Alarm........................................................................34
8.5 314.S02 Kiln / Raw Mill ESP & GCT ESP Dust Transport System36
8.5.1 Sequence Flow Sheet.......................................................................36
8.5.2 Consumer List...................................................................................37
8.5.3 Analog Sensors Lists........................................................................39
8.5.4 Operators Selections........................................................................40
8.5.5 Operation Mode Description.............................................................41
8.5.6 Sequence Interlocks and Alarms......................................................43
8.5.7 D/D Interlocks and Alarms................................................................44
8.5.8 Process Protections..........................................................................55
8.5.9 Regulation Loops..............................................................................55
8.5.10 Cyclic and Special Functions............................................................55
8.5.11 Messages and Alarms......................................................................58
8.6 314.S03 Kiln / Raw Mill ESP Fan....................................................60
8.6.1 Sequence Flow Sheet.......................................................................60
8.6.2 Consumer List...................................................................................61
8.6.3 Analog Sensors Lists........................................................................61
8.6.4 Operators Selections........................................................................62
8.6.5 Operator Mode Description...............................................................62
8.6.6 Sequence Interlocks and Alarms......................................................63
8.6.7 D/D Interlocks and Alarms................................................................64
8.6.8 Process Protections:.........................................................................66
8.6.9 Regulation Loops..............................................................................67
8.6.10 Cyclic and Special Functions............................................................68
8.6.11 Messages and Alarm........................................................................68
8.7 316.S04: Primary Air Fan...............................................................69
8.7.1 Sequence Flow Sheet.......................................................................69
8.7.2 Consumer List...................................................................................70
TITLE FUNCTIONAL SPECIFICATION
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Date : 11/02/2007
Chapter : 8 Page 2 of 204
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8.7.3 Analog Sensors Lists........................................................................71

8.7.4 Operators Selections........................................................................72
8.7.5 Operator Mode Description...............................................................72
8.7.6 Sequence Interlocks and Alarms......................................................73
8.7.7 D/D Interlocks and Alarms................................................................74
8.7.8 Process Protection............................................................................78
8.7.9 Regulation Loops..............................................................................78
8.7.10 Cyclic and Special Functions............................................................79
8.7.11 Messages and Alarm........................................................................81
8.8 313.S05: Pre-Heater ID Fan............................................................82
8.8.1 Sequence Flow Sheet.......................................................................82
8.8.2 Consumer List...................................................................................83
8.8.3 Analog Sensors Lists........................................................................84
8.8.4 Operators Selections........................................................................85
8.8.5 Operator Mode Description...............................................................85
8.8.6 Sequence Interlocks and Alarms......................................................85
8.8.7 D/D Interlocks and Alarms................................................................86
8.8.8 Process Protections..........................................................................88
8.8.9 Regulation Loops..............................................................................88
8.8.10 Cyclic and Special Functions............................................................89
8.8.11 Messages and Alarm........................................................................90
8.9 316.S06: Kiln Burner.......................................................................91
8.9.1 Sequence Flow Sheet.......................................................................91
8.9.2 Consumer List...................................................................................93
8.9.3 Analog Sensors Lists........................................................................93
8.9.4 Operators Selections........................................................................94
8.9.5 Operator Mode Description...............................................................95
8.9.6 Sequence Interlocks and Alarms......................................................96
8.9.7 D/D Interlocks and Alarms................................................................97
8.9.8 Process Protection............................................................................99
8.9.9 Regulation Loops..............................................................................99
8.9.10 Cyclic and Special Functions............................................................99
8.9.11 Messages and Alarm......................................................................108
8.10 316.S07: Rotary Kiln.....................................................................112
8.10.1 Sequence Flow Sheet.....................................................................112
8.10.2 Consumer List.................................................................................113
8.10.3 Analog Sensors Lists......................................................................113
8.10.4 Operators Selections......................................................................114
8.10.5 Operator Mode Description.............................................................116
8.10.6 Sequence Interlocks and Alarms....................................................118
8.10.7 D/D Interlocks and Alarms..............................................................119
8.10.8 Process Protections:.......................................................................124
8.10.9 Regulation Loops............................................................................125
8.10.10 Cyclic and Special Functions..........................................................125
8.10.11 Messages and Alarm......................................................................126
8.11 314.S08: GCT Water Injection System........................................128
8.11.1 Sequence Flow Sheet.....................................................................128
TITLE FUNCTIONAL SPECIFICATION
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Date : 11/02/2007
Chapter : 8 Page 3 of 204
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8.11.2 Consumer List.................................................................................129

8.11.3 Analog Sensors Lists......................................................................130
8.11.4 Operation Selection........................................................................131
8.11.5 Operation Mode Description...........................................................131
8.11.6 Sequence Interlocks and Alarms....................................................131
8.11.7 D/D Interlocks and Alarms..............................................................132
8.11.8 Process Protections:.......................................................................134
8.11.9 Regulation Loops............................................................................134
8.11.10 Cyclic and Special Functions..........................................................135
8.11.11 Messages and Alarm......................................................................138
8.12 312.S09: Feed to Kiln....................................................................139
8.12.1 Sequence Flow Sheet.....................................................................139
8.12.2 Consumer List.................................................................................141
8.12.3 Analog Sensors Lists......................................................................145
8.12.4 Operators Selections......................................................................145
8.12.5 Operation Mode Description...........................................................146
8.12.6 Sequence Interlocks and Alarms....................................................150
8.12.7 D/D Interlocks and Alarms..............................................................151
8.12.8 Process Protections........................................................................169
8.12.9 Regulation Loops............................................................................169
8.12.10 Cyclic and Special Functions..........................................................170
8.12.11 Messages and Alarm......................................................................181
8.13 313.S10: Calciner Burner.............................................................183
8.13.1 Sequence Flow Sheet.....................................................................183
8.13.2 Consumer List.................................................................................184
8.13.3 Analog Sensors Lists......................................................................184
8.13.4 Operators Selections......................................................................184
8.13.5 Operator Mode Description.............................................................185
8.13.6 Sequence Interlocks and Alarms....................................................185
8.13.7 D/D Interlocks and Alarms..............................................................186
8.13.8 Process Protections:.......................................................................187
8.13.9 Regulation Loops............................................................................187
8.13.10 Cyclic and Special Functions..........................................................188
8.13.11 Messages and Alarm......................................................................194

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 4 of 204
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8 Kiln

8.1 Process Flow Sheets

SUR311L01 Rev. E Homogenization Storage Silo

SUR312L01 Rev. E Silo to Silo Material Re-Circulation & Kiln Feed
SUR313L01 Rev. D Pre-Heater ID Fan and Barring
SUR314L01 Rev. E Kiln/Raw-mill ESP Fan & GCT Dust Transport
SUR316L01 Rev. F Kiln Burner, Barring and Main Motor

8.2 Instrument Flow Sheets

SUR311L51 Rev. H Homogenization Storage Silo

SUR312L51 Rev. H Silo to Silo Material Re-Circulation & Kiln Feed
SUR313L51 Rev. H Pre-Heater ID Fan and Barring
SUR314L51 Rev. H Kiln/Raw-mill ESP Fan & GCT Dust Transport
SUR316L51 Rev. H Kiln Burner, Barring and Main Motor

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 5 of 204
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8.3 List of Sequences

Sequence Start- Shut-

Description Remarks
Tag up down
Stoppage with
316.S01 Kiln Auxiliaries 1 8 delay of t1 (= 1
hr)
Stoppage with
Kiln / Raw Mill ESP And
314.S02 1 8 delay of t2 (=20
GCT-ESP Dust Transport
min)
314.S03 Kiln / Raw Mill ESP Fan 2 7
316.S04 Primary Air Fan 3 6
313.S05 Pre- Heater ID Fan 4 5
316.S06 Kiln Burner 5 4
316.S07 Rotary Kiln 6 3
GCT Water Injection
314.S08 7 2
System
312.S09 Feed To Kiln 7 2
313.S10 Calciner Burner 8 1

TITLE FUNCTIONAL SPECIFICATION

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8.3.1 Kiln Interlock Table

TITLE FUNCTIONAL SPECIFICATION

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8.4 316.S01: Kiln Auxiliaries

8.4.1 Sequence Flow Sheet

TITLE FUNCTIONAL SPECIFICATION

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TITLE FUNCTIONAL SPECIFICATION

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8.4.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
316DR01MT50 Gear Box Oil 1 1 Y Y If P1 not
Pump selected
(Main)
316DR01MT60 Gear Box Oil 1 1 Y Y If P1 selected
Pump (Standby)
316DR02MT50 Gear Box Oil 1 1 Y Y If P2 not
Pump selected
(Main)
316DR02MT60 Gear Box Oil 1 1 Y Y If P2 selected
Pump (Standby)
316PU01MT10- Support 1 1 N Y
316PU04MT10 Bearing
Lubrication
Pumps
316PU05MT10- Support 1 1 N Y
316PU08MT10 Bearing
Lubrication
Pumps
316TH01 Hydraulic 1 1 Y Y Mechanical
Thrust Device no
Device run feedback
316FA01MT10 Kiln Inlet 1 1 Y Y
sector
Cooling Fan
316FA22MT10 Kiln nose ring 1 1 Y Y
Cooling Fan
316VA02VA10 Throttle IND IND N Y Default
Valve Position is
open. Not to
be operated
Material
313VV01MT10 1 1 N N
Dividing Gate
Hoisting
Damper in
313VN01MT10 1 1 Y N
tertiary Air
Duct
Cooling Air Delayed
Fan for stoppage
313FA02MT10 1 1 Y Y
Hoisting after 2 hrs.
Damper

TITLE FUNCTIONAL SPECIFICATION

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8.4.3 Analog Sensors Lists

Tag Eng. Units Alarm Limits

Low High Unit LL L H HH
316DR01YT40 0 150 Deg C 85 90
316DR02YT40 0 150 Deg C 85 90
316FA01YI10 0 52 A 38 46
316FA22YI10 0 80 A 55 65
316KR01YT10 0 150 Deg C 100 110
316KR01YT11 0 150 Deg C 100 110
316KR02YT20 0 150 Deg C 100 110
316KR02YT21 0 150 Deg C 100 110
316KR03YT10 0 150 Deg C 100 110
316KR03YT11 0 150 Deg C 100 110
316KR04YT20 0 150 Deg C 100 110
316KR04YT21 0 150 Deg C 100 110
316TH01YP10 0 160 Bar 2 80 90
316TH01YZ10 -25 +25 mm -20 -15 +15 +20
313VN01YZ10 0 100 %
313VV01YZ10 0 100 %

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 11 of 204
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8.4.4 Operators Selections

P1 not selected - Start Gear Box Oil Pump 316DR01MT50
P1 selected - Start Gear Box Oil Pump 316DR01MT60
P2 not selected - Start Gear Box Oil Pump 316DR02MT50
P2 selected - Start Gear Box Oil Pump 316DR02MT60

8.4.5 Operators Mode Description

Start-up details:

 Start Gear Box Oil Pumps 316DR01MT50 OR 316DR01MT60 based

on P1 Selection, and start Gear Box Oil Pumps 316DR02MT50 OR
316DR02MT60 based on P2 selection. Start Support bearing
Lubrication pumps 316PU01MT10-316PU04MT10 and
316PU05MT10-316PU08MT10, Open Throttle Valve 316VA02VA10 if
not open. Start Hydraulic Thrust Device 316TH01. Operate Material
Dividing Gate 313VV01 (if required), Open Hoisting Damper in tertiary
Air Duct 313VN01 (As required), Start Cooling Air Fan for Hoisting
Damper 313FA02

 Start Kiln Inlet Sector Cooling Fan 316FA01MT10 and Kiln Nose Ring
Cooling Fan 316FA22MT10 individually.

Shut-down details:

 Stop Kiln Inlet Sector Cooling Fan 316FA01MT10 and Kiln Nose Ring
Cooling Fan 316FA22MT10 if running individually.

 Stop Gear Box Oil Pumps 316DR01MT50, 316DR01MT60,

316DR02MT50, 316DR02MT60 if running. Stop Support bearing
Lubrication pumps 316PU01MT10 - 316PU04MT10 and
316PU05MT10 -316PU08MT10, Stop Hydraulic Device 316TH01. Stop
Cooling Air Fan for Hoisting Damper 313FA02 after 2 Hrs.

TITLE FUNCTIONAL SPECIFICATION

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8.4.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

Not of U828GN01EC10B1 in Auto 
Mode

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

TITLE FUNCTIONAL SPECIFICATION

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8.4.7 D/D Interlocks and Alarms

 316DR01MT50

Interlocks:

Description DSI DPI DCR DEI Remarks

316DR01MT60 not Run  If P1 not

selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

316DR01XF10  10 s

 316DR01MT60

Interlocks:

Description DSI DPI DCR DEI Remarks

316DR01MT50 not Run  If P1

selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

316DR01XF10  10 s

TITLE FUNCTIONAL SPECIFICATION

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 316DR02MT50

Interlocks:

Description DSI DPI DCR DEI Remarks

316DR02MT60 not Run  If P1 not

selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

316DR02XF10  10 s

 316DR02MT60

Interlocks:

Description DSI DPI DSQI DEI Remarks

316DR02MT50 not Run  If P1

selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

316DR02XF10  10 s

TITLE FUNCTIONAL SPECIFICATION

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 316PU01-04MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

316DR01YS10<0.5 rpm 
Not of 316PU01XL20  (Tank
Level not
Low)
Alarms:

Description BP PE1 PE2 Remarks / Delays

316PU01-PU04XF10  10 s

 316PU05-08MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

316DR01YS10<0.5 rpm 
Not of 316PU01XL20  (Tank
Level not
Low)

Alarms:

Description BP PE1 PE2 Remarks / Delays

316PU05-PU08XF10 

TITLE FUNCTIONAL SPECIFICATION

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 316TH01

Interlocks:

Description DSI DPI DSQI DEI Remarks

Not of 316TH01XZ10 
Not of 316TH01XZ20 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 316FA01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Not of 316VA01XZ11   At least

OR one flap is
Not of 316VA01XZ21 not fully
closed

Alarms:

Description BP PE1 PE2 Remarks / Delays

316FA01YI10HH 

TITLE FUNCTIONAL SPECIFICATION

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 316FA22MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

316VA02XZ10  

Alarms:

Description BP PE1 PE2 Remarks / Delays

316FA22YI10HH 

 316VA02VA10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

316VA02XZ10 
316VA02XZ11 

 313VV01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

313VV01XZ10  1s
313VV01XZ11  1s

TITLE FUNCTIONAL SPECIFICATION

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 313VN01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

313VN01XZ10  1s
313VN01XZ11  1s

 313FA02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

8.4.8 Process Protections

 Individual start / stop of Kiln Shell Cooling Fan (316FA02-17) / Tyre

Cooling fans (316FA18-21) is permitted.
 By Default the Throttle valve 316VA02 will be open. In case of Power
Failure the Fan 316FA22 will start automatically through the emergency
power to cool the nose ring.

TITLE FUNCTIONAL SPECIFICATION

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8.4.9 Regulation Loops

 Hoisting Damper Position 313VN01YZ10

Controlled Measurement :Not Applicable

D/D Controlled :Hoisting Damper Position

313VN01YZ10

Manual Mode :Operator manipulates the Hoisting

Damper Position 313VN01YZ10 from
the Analogue Damper faceplate in
manual mode.

Automatic Mode :Not Applicable

The Combustion air to the Calciner is controlled by speed variation of

the pre-heater fan and by adjusting the position of the damper
313VN01 in the tertiary air duct.

 Material Dividing Gate Position 313VV01YZ10

Controlled Measurement :Not Applicable

D/D Controlled :Material Dividing Gate Position

313VV01YZ10

Manual Mode :Operator manipulates the Material

Dividing Gate Position 313VV01YZ10
from the Analogue Damper faceplate in
manual mode.

Automatic Mode :Not Applicable

During Initial start-up Material Dividing Gate 313VV01 will be 100%

open to Calciner. The Material Dividing Gate 313VV01 shall be used
to distribute the material between Calciner and Kiln riser pipe if
operator observes coating formation in Kiln riser pipe.

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8.4.10 Cyclic and Special Functions

8.4.10.1 Kiln Support Roller Lubrication System (316PU01-316PU08)

System Description :

Kiln Support Roller Lubrication system consists of the following :

Mechanics /Subsystem :

- An oil tank (Common for all 8 pumps), from which the oil is
pumped to the inlet and the outlet kiln support rollers
- 4 no. Feed and return pumps (PU05-PU08) for the support
roller lubrication at the Kiln Inlet
- 4 no. Feed and return pumps (PU01-PU04) for the support
roller lubrication at the Kiln Outlet

Electrics/ Sub Control System:

- Sub Control function / logic of the pump motor control &

operation , implemented in the Plant Control System
- Starter feeder for the pump motors, located in the Plant MCC
& the
- Field Sensors viz,
 Flow Switch (316PU01XF10 – 316PU08XF10) for each
support roller Lubrication
 Oil Temperature in Kiln support roller bearing Sensors (RTD)
o 4 nos. for Oil in Kiln inlet Support bearing ( 2 nos. at
each roller) (316KR01YT10, 316KR01YT11,
316KR02YT20 and 316KR02YT21)
o 4 nos. for Oil in Kiln outlet Support bearing ( 2 nos. at
each roller) (316KR03YT10, 316KR03YT11,
316KR04YT20 and 316KR04YT21)
for monitoring & control of the lubrication system.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 21 of 204
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Operation :

The Support Roller lubrication system’s main function is to lubricate

the Kiln Support Rollers during the following scenarios of Kiln
Operation.

1. Before kiln start

2. Before start of barring device
3. During Barring
4. When Kiln speed is 0.5 or lower
5. when connected to emergency power supply

Beyond 0.5 rpm Lubrication is self-sustaining. Below 0.5 rpm

Lubrication will be continuous.

Operation of the Support Roller Lubrication system

Before start, the support roller lubrication pump motors must be

available and there shall be no alarms (i.e. 316PU01XF10 –
316PU08XF10) must be present associated with the system.

The following interlocks shall be implemented in the PCS

The oil pump (say 316PU01) shall start if there is no Alarm for Oil
flow (316PU01XF10).

The pump Motor (say 316PU01) shall trip under the following
condition.
- If Oil Flow not healthy (316PU01XF10) after 10 sec of Pump
run.
The above interlocks are valid for each pump.

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LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 22 of 204
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8.4.10.2 Kiln Gearbox Lubrication System (316DR01 & 316DR02)

System Description :

Kiln Gearbox Lubrication system consists of the following :

Mechanics /Subsystem :

- Oil Sumps
- Two Pumps per Gearbox ; (Main and Standby) .
- Pressure Limiting Valve at the outlet of the pump
- Oil Cooling Unit

Electrics/ Sub Control System:

- Sub Control function/ logic of the pump motor, implemented in

the Plant Control System
- Starter feeder for the pump motor , located in the in the Plant
MCC & the
- Field Sensors viz,
o Flow Switch 316DR01XF10, 316DR02XF10 for the
Lubrication Pump
o Temperature Transmitter (T/C) 316DR01YT40 and
316DR02YT40: 1 nos located in each bearing
housing.
for monitoring and control of the Gearbox lubrication system

Operation :

The Gearbox lubrication system’s main function is to lubricate the

Kiln gearbox during the following scenarios of Kiln operation.
1. Normal Operation of kiln
2. During Kiln Barring
3. During Kiln Barring on Emergency Power Supply
4. Reversing the kiln from side-heavy position to neutral
position.

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LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 23 of 204
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Operation of the Lubrication system

Before start, the Lubrication system must be ready i.e. no alarms

must be present in the system (Not of 316DR01XF10,
316DR02XF10).
Oil flow switch at pump discharge and the temperature
measurements (RTD’s) in the Gearbox bearing house are provided
for Lubrication system control and monitoring.

The following interlocks shall be implemented in the PCS

The pump Motor shall start under the following condition:

- No Alarm for Oil Flow (316DR01XF10, 316DR02XF10)

The pump Motor shall trip if Oil Flow not healthy (316DR01XF10 &
316DR02XF10) after 10 sec of Pump run.

Flowsheet :

A flow sheet for the Kiln Gearbox Lubrication system along-with the
Alarm signals with Lafarge codification is depicted here below.

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Chapter : 8 Page 24 of 204
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TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 25 of 204
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8.4.10.3 Hydraulic Thrust Device

System Description :

During operation of kiln a small part of axial thrust generated due to

kiln inclination is taken up by the supporting rollers. The rest of the
axial thrust is taken up by Hydraulic Thrust Device (HTD).

The system of Hydraulic Thrust Device consists of the following :

Mechanics /Subsystem :

- Hydraulic Pump station comprising of

o Oil Tank
o Oil Pump : 2 nos.(Main and Standby) (316PU09MT10
and 316PU09MT20)
- Hydraulic Cylinder
- Accumulator(s) to absorb pressure variation & ensuring thrust
contact face between the thrust roller and Kiln Tyre.
- A set of solenoid valve(s)
- for charging accumulator (1 no) – 316TH01VA10
- for throttling (1 no) – 316TH01VA20
- for arresting Kiln migration (1 no) – 316TH01VA30
These are in connection to direct the oil to Hydraulic Cylinder.

Electrics/ Sub Control System:

- PCS based Sub Control function which controls the operation
of the Pump motor , and the oil supply /cut-off solenoid valves.
- Starter feeder for the pump motor which is located in the Plant
MCC &
- Field Sensors viz,
o Kiln Position Transmitter (LVDT)
o Pressure Transmitter for monitoring oil line working
pressure
o Oil level switch (2 nos.)
o DP switch for filter blockage
o Safety limit switches for the Kiln ‘UP’ (MAX) and
‘Down’(MAX) position
Operation :

The HTD system’s main function is to guide the kiln axially within a
preset position and transfer the axial thrust to one or several
supports.

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Chapter : 8 Page 26 of 204
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Before start, the Pump motor for the HTD system must be available
and there shall be no alarms must be present associated with the
system.

Thruster working cycle inclusive of pump operation , Charging of

the accumulator, Throttling shall be operative if ID01/ (&) ID02 is
running between <-25mm to +25mm

If within the working cycle the Kiln stops for any reason, anywhere,
the HTD has to complete the working cycle (throttling) to come to
the initial position on initiation of start once again and subsequently
shall work in tandom with the requirement.

The following interlocks shall be implemented in the PCS

The Hydraulic oil pumps (“8” and “8a” as shown in figure 2 below)
(316PU09MT10 or 316PU09MT20) shall start under the following
conditions

- Working Pressure Low (316TH01YP10L)

- Oil tank level OK (316TH01XL10)
- If Kiln is between –25mm to +15mm and Kiln is running through
Barring Motor.
- If Kiln is between –15mm to +15mm and Kiln is running through
Main Motor.

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Chapter : 8 Page 27 of 204
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TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 28 of 204
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The 316TH01VA10 (“18” as shown in figure 3 below) Solenoid for

charging accumulator shall energised under the following
conditions

- Either of the Pump is maintained in operation, the directional

control valve is activated and the pump will now deliver pressure
to accumulator until a signal is received from the pressurestst
indicating that the accumulator is fully charged. At this point of
time, the pump is stopped.

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Chapter : 8 Page 29 of 204
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The 316TH01VA20 (“21” as shown in figure 4 below) Solenoid for

throttling shall energised under the following conditions

- Throttling is started when the kiln position is +15mm and the

function is continued until the position is –15mm viewed in
relation to the neutral position of kiln. The function is controlled
by a timer pulse/pause sequence in order to ensure smooth kiln
migration.

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 30 of 204
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The 316TH01VA30 (“17" as shown in figure 3 below) Solenoid for

arresting Kiln migration shall energised under the following
conditions

- If Kiln is between > +15mm and < +25mm and Kiln is running
through Barring Motor.

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Chapter : 8 Page 31 of 204
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The Sequence / Schematic Diagram for Pump Station

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TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 33 of 204
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8.4.11 Messages and Alarm

Tag Description Priority Delay

316DR01YT40H Gear Box Oil Temperature High 2 1s

316DR01YT40HH Gear Box Oil Temperature High 1 1s
High
316DR02YT40H Gear Box Oil Temperature High 2 1s
316DR02YT40HH Gear Box Oil Temperature High 1 1s
High
316TH01FG10 “Kiln not traveling Time” Too Long 2 1s
316KR01YT10H Oil temp in Support Roller 1 2 1s
Bearing-1 High
316KR01YT11H Oil temp in Support Roller 1 2 1s
Bearing-2 Temp High
316KR01YT10HH Oil temp in Support Roller 1 2 1s
Bearing-1 High High
316KR01YT11HH Oil temp in Support Roller 1 2 1s
Bearing-2 Temp High High
316KR02YT20H Oil temp in Support Roller 2 2 1s
Bearing-1 Temp High
316KR02YT21H Oil temp in Support Roller 2 2 1s
Bearing-2 Temp High
316KR02YT20HH Oil temp in Support Roller 2 2 1s
Bearing-1 Temp High High
316KR02YT21HH Oil temp in Support Roller 2 2 1s
Bearing-2 Temp High High
316KR03YT10H Oil temp in Support Roller 3 2 1s
Bearing-1 High
316KR03YT11H Oil temp in Support Roller 3 2 1s
Bearing-2 Temp High
316KR03YT10HH Oil temp in Support Roller 3 2 1s
Bearing-1 High High
316KR03YT11HH Oil temp in Support Roller 3 2 1s
Bearing-2 Temp High High
316KR04YT20H Oil temp in Support Roller 2 2 1s
Bearing-1 Temp High
316KR04YT21H Oil temp in Support Roller 2 2 1s
Bearing-1 Temp High
316KR04YT20HH Oil temp in Support Roller 2 2 1s
Bearing-1 Temp High High
316KR04YT21HH Oil temp in Support Roller 2 2 1s
Bearing-1 Temp High High
TITLE FUNCTIONAL SPECIFICATION
LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 34 of 204
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316TH01XZ10 Kiln at –25 mm 1 1s

316TH01XZ20 Kiln at +25 mm 1 1s
316TH01YZ10LL Kiln at –20 mm 1 1s
316TH01YZ10HH Kiln at +20 mm 1 1s
316TH01YZ10L Kiln at –15 mm 2 1s
316TH01YZ10L Kiln at +15 mm 2 1s
316TH01YZ10H Kiln at >+15 mm 2 1s
316VA02XZ10 Throttle Valve Position Open 2 1s
316VA02XZ11 Throttle Valve Position Close 2 1s
316FA01YI10H Cooling Fan current High 2 1s
316FA22YI10H Cooling Fan current High 2 1s
316DR01L01 Standby Pump 316DR01MT60 3 1s
Selected
316DR02L01 Standby Pump 316DR02MT60 3 1s
Selected

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8.5 314.S02 Kiln / Raw Mill ESP & GCT ESP Dust Transport
System
8.5.1 Sequence Flow Sheet

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 36 of 204
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8.5.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
314VV02VA10 Pneumatic 1 8 N N Default
Gate Position open
towards
314DG04.
Auto-change
over towards
218BE01 and
back.
314DG04MT10 Drag Chain 2 7 Y N
Conveyor
314BE01MT20 Bucket IND IND N N Local
Elevator Operation
Barring (only for
maintenance
purpose)
314BE01MT10 Bucket 3 6 Y N
Elevator
314FA02MT10 Filter Fan 3 6 N N
314RA04MT10 Air Sluice 3 6 N N
314DC02EC10 Dust Collector 4 5 N N
Sequencer
314DG03MT10 Drag Chain 4 5 Y N
Conveyor
314DG02MT10 Drag Chain 5 3 Y N
Conveyor
314DG01MT10 Drag Chain 5 4 Y N
Conveyor
314RA01MT10 Air Sluice 6 2 Y N If P1 not
Selected
314RA02MT10 Air Sluice 6 3 Y N
314RA03MT10 Air Sluice 6 3 Y N
314VV01MT10 Motorized Flap 7 2 Y N If P1 is
Selected
314SC01MT10 Screw 8 1 Y N If P1 is Not
Conveyor Selected.
Material Flow
Towards
314RA01

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314SC05MT10 Screw 7 2 Y N
Conveyor
314SC04MT10 Screw 8 1 Y N
Conveyor
314SC03MT10 Screw 7 2 Y N
Conveyor
314SC02MT10 Screw 8 1 Y N
Conveyor
314DC01EC10 ESP Field #1 IND IND Y N
314DC01EC20 ESP Field #2 IND IND Y N
314DC01EC30 ESP Field #3 IND IND Y N

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8.5.3 Analog Sensors Lists

Eng. Units Alarm Limits

Tag
Low High Unit LL L H HH
314BE01YJ10 0 11 kW 8 9
314SC01YI10 0 30 A 24 27
314SC02YI10 0 10 A 8 9
314SC03YI10 0 15 A 12 13.5
314SC04YI10 0 10 A 8 9
314SC05YI10 0 15 A 12 13.5
314DC01YI10 0 1300 mA 200 800 1000
314DC01YI20 0 1300 mA 200 800 1000
314DC01YI30 0 1300 MA 200 800 1000
314DC01YE10 0 110 KV 90 100
314DC01YE20 0 110 kV 90 100
314DC01YE30 0 110 kV 90 100
314DC01YT10 0 500 Deg C 90 100 400 450
314DC01YP10 -200 0 mmWG -100 -50
314SK01TR10 0 250 mg/m3 235 240

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Chapter : 8 Page 39 of 204
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8.5.4 Operators Selections

P1 Not Selected – The Screw Conveyor 314SC01 will start in Forward

direction i.e. towards Air Sluice 314RA01.

P1 Selected – During the running of Sequence 314S02, if the operator

selects P1, the Screw Conveyor 314SC01 (which was running towards
314RA01) will stop. It will start the Motorized Flap 314VV01MT10. After
the run of Motorized Flap 314VV01MT10, the Screw Conveyor 314SC01
will start in Reverse direction i.e. towards Motorized Flap 314VV01MT10.

The P1 selection will be enabled only if “Truck in position –

314SC01SY10” feedback is available. The Truck Driver / Field Supervisor
will generate “Truck in Position” signal by pressing the push button
(provided in the field), after positioning the truck at desired location. Once
the Truck is full Truck Driver / Field Supervisor has to release the Push
Button, which will automatically deselect the P1 selection and stop the
Screw Conveyor 314SC01 & Motorized Flap 314VV01MT10. Operator
can start the Screw Conveyor 314SC01 in forward direction by giving the
Start command.

During this course the other drives of the sequence will continue to run.
The selection / de-selection of P1 will not stop the sequence.

If desired the operator can start the Motorized Flap 314VV01MT10 &
Screw Conveyor 314SC01 towards 314VV01MT10 in local mode when
the sequence 314S02 is not running.

Start/Stop (316DC01SY10) – Button to Start / Stop the ESP Rectifier

(316DC01EC10) by the CCR Operator.
Start/Stop (316DC01SY20) – Button to Start / Stop the ESP Rectifier
(316DC01EC10) by the CCR Operator.
Start/Stop (316DC01SY30) – Button to Start / Stop the ESP Rectifier
(316DC01EC30) by the CCR Operator.

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Chapter : 8 Page 40 of 204
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8.5.5 Operation Mode Description

Default Position for the Pneumatic Gate shall be open towards
314DG04 if 216WF01EC10 Run AND 316DR01MT10 Not Run (This
condition to be connected to SST1 of DAB Block). and it will
Automatically changes its position towards 218BE01 if 216WF01EC10
Run for 5 min AND 316DR01MT10 Run (This condition to be
connected to SST1 of MAB Block) and vice versa.

Operator can start / stop the ESP Rectifier individually.

Start-up details:

 Open Pneumatic Gate 314VV02VA10 to default position

 Start Drag Chain Conveyor 314DG04MT10
 Start Bucket Elevator 314BE01MT10, Start Filter Fan 314FA02MT10
and Air Sluice 314RA04MT10
 Start Drag Chain Conveyor 314DG03MT10 and Dust Collector
Sequencer 314DC02EC10
 Start Drag Chain Conveyor 314DG02MT10 according to the selected
direction ie., P1 Selection and 314DG01MT10
 Start Air Sluice 314RA01MT10 according to the selected direction ie.,
P1 Selection, 314RA02MT10 and 314RA03MT10
 Open Pneumatic Gate 314VV01MT10 to default position if P1 is
selected and Start Screw Conveyors 314SC05MT10, 314SC03MT10.
 Start Screw Conveyors 314SC01MT10 according to the selected
direction ie., P1 Selection, 314SC02MT10 and 314SC04MT10
 Start ESP Rectifiers 314DC01EC10, 314DC01EC20 and 314DC01EC30
individually.

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Shut-down details:

 Stop ESP Rectifier 314DC01EC10, 314DC01EC20 and 314DC01EC30

individually.
 Stop Screw Conveyors 314SC01MT10, 314SC02MT10 and
314SC04MT10
 Stop Screw Conveyors 314SC05MT10, 314SC03MT10, Air Sluice
314RA01MT10.
 Stop 314RA02MT10 and 314RA03MT10, Drag Chain Conveyor
314DG02MT10
 Stop Drag Chain Conveyor 314DG01MT10
 Stop Drag Chain Conveyor 314DG03MT10 and Dust Collector
Sequencer 314DC02EC10
 Stop Bucket Elevator 314BE01MT10, Stop Filter Fan 314FA02MT10
and Air Sluice 314RA04MT10
 Stop Drag Chain Conveyor 314DG04MT10

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8.5.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

Not of U828GN01EC10B1 

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

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8.5.7 D/D Interlocks and Alarms

 314VV02VA10

Interlocks:

Description DSI DPI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

314VV02XZ10  1s
314VV02XZ11  1s

 314DG04MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

314VV02XZ11 
Not of Kiln Feed Bin
312HO01XL10
OR
 
Kiln Feed Bin
312LX01YW10 < High-
High (HH)

Alarms:

Description BP PE1 PE2 Remarks / Delays

314DG04XS10  5s

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 314BE01MT20

Interlocks:

Description DSI DPI DSQI DEI Remarks

314BE01MT10 Not Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 314BE01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

{(314DG04MT10 Run
AND
314VV02XZ11 )
Switchover
OR
 delay 20
(216WF01EC10 Run
sec.
AND
314VV02XZ10)}AND
314VV02F3
Barring
314BE01XZ20  Disengage
d
314BE01MT20 not Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

314BE01XS10  5s

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 45 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314FA02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314BE01MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

Continuous for 30
314DC02XP20 
min

 314RA04MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Delayed
314FA02MT10 Run  stoppage
2 min

Alarms:

Description BP PE1 PE2 Remarks / Delays

314RA04XS10  5s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 46 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314DC02EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote
314DC02EC10SL  
Selected
Delay 30
314RA04MT10 Run 
min
314DC02XP10 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 314DG03MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314BE01MT10 Run 
314BE01XL10 

Alarms:

Description BP PE1 PE2 Remarks / Delays

314DG03XS10  5s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 47 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314DG02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314DG03MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

314DG02XS10  5s

 314DG01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314DG03MT10 Run 
314VN04XZ11  Close

Alarms:

Description BP PE1 PE2 Remarks / Delays

314DG01XS10  5s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314RA01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314DG02MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

314RA01XS10  5s

 314RA02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314DG01MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

314RA02XS10  5s

 314RA03MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314DG01MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

314RA03XS10  5s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 49 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314VV01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314SC01L01 AND

314SC01SY10

Alarms:

Description BP PE1 PE2 Remarks / Delays

314VV01XS10  5s

 314SC01MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

If P1 not
314RA01MT10 Run 
selected
If P1 not
314VN01XZ10  
selected
If P1
314VV01MT10 Run 
Selected
If P1
314SC01SY01 
Selected
Alarms:

Description BP PE1 PE2 Remarks / Delays

314SC01XS10  5s
314SC01YI10HH  5s

 314SC05MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314RA03MT10 Run 
314VN03XZ10   open

Alarms:
TITLE FUNCTIONAL SPECIFICATION
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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

Description BP PE1 PE2 Remarks / Delays

314SC05XS10  5s
314SC05YI10HH  1s

 314SC04MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314SC05MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

314SC04XS10  5s
314SC04YI10HH 

 314SC03MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314RA02MT10 Run 
314VN02XZ10   Open

Alarms:

Description BP PE1 PE2 Remarks / Delays

314SC03XS10  5s
314SC03YI10HH  1s

 314SC02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314SC03MT10 Run 

Alarms:

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 51 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

Description BP PE1 PE2 Remarks / Delays

314SC02XS10  5s
314SC02YI10HH  1s

 314DC01EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote Mode
314DC01EC10SL  
Selected
313AG03YX10 < H  (PH exit CO)
313AG02YX30 < H  (CY-4 Exit CO)
(CY-4 Exit
313AG02YX20 < H 
CH4)
313AG03YX10 < HH  (PH exit CO)
313AG02YX30 < HH  (CY-4 Exit CO)
(CY-4 Exit
313AG02YX20 < HH 
CH4)
No fault in PH
313AG03FG10.   exit gas
analyzer
No fault in CY-
313AG02FG10.   4 exit gas
analyzer
314DC01YT10 > LL  
(ESP Hopper
Not of 314DC01XL11   Pass #1 Level
High-High)
313AG02FG10 
314FA01VS10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 52 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314DC01EC20

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote Mode
314DC01EC20SL  
Selected
313AG03YX10 < H  (PH exit CO)
313AG02YX30 < H  (CY-4 Exit CO)
(CY-4 Exit
313AG02YX20 < H 
CH4)
313AG03YX10 < HH  (PH exit CO)
313AG02YX30 < HH  (CY-4 Exit CO)
(CY-4 Exit
313AG02YX20 < HH 
CH4)
No fault in PH
313AG03FG10.   exit gas
analyzer
No fault in CY-
313AG02FG10.   4 exit gas
analyzer
314DC01YT10 > LL  
(ESP Hopper
Not of 314DC01XL11   Pass #1 Level
High-High)
(ESP Hopper
Not of 314DC01XL21   Pass#2 Level
High-High)
313AG02FG10 
314FA01VS10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 53 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314DC01EC30

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote Mode
314DC01EC30SL  
Selected
313AG03YX10 < H  (PH exit CO)
313AG02YX30 < H  (CY-4 Exit CO)
(CY-4 Exit
313AG02YX20 < H 
CH4)
313AG03YX10 < HH  (PH exit CO)
313AG02YX30 < HH  (CY-4 Exit CO)
(CY-4 Exit
313AG02YX20 < HH 
CH4)
No fault in PH
313AG03FG10.   exit gas
analyzer
No fault in CY-
313AG02FG10.   4 exit gas
analyzer
314DC01YT10 > LL  
(ESP Hopper
Not of 314DC01XL21   Pass#2 Level
High-High)
313AG02FG10 
314FA01VS10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.5.8 Process Protections

ESP Rectifiers shall trip if CO measured in pre-heater exhaust gas
(313AG03YX10) > HH or CO / CH4 measured in cyclone 4-exit gas
(313AG02YX30 / 313AG02YX20) > HH or any fault in the Pre-heater
Exhaust Gas Analyser and Cyclone 4 Exit Gas Analyser. However
the rapping mechanism will continue to run.

When 314VV02VA10 open towards 218BE01, the 314DG04 shall

stop. On stoppage 216WF01, start command will be issued to
314DG04 and 314VV02VA10 will come back to its default position.

8.5.9 Regulation Loops

None

8.5.10 Cyclic and Special Functions

For 314SC01, 314SC03 and 314SC05 to start and for being in

operation 314VN01, 314VN02 and 314VN03 respectively should be
in Open condition.

For 314DG01 to start 314VN04 shall be closed.

On boot level High Alarm for 314BE01, 314DG03 will stop (314BE01
will continue to run).

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 55 of 204
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WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.5.10.1 Kiln ESP System

System Description:

The ESP system consists of the following:

Mechanics/ Subsystem

o A series of baffles and perforated plates for distributing the

gas to be cleaned over the whole cross section
o Rectifier sets for applying negative high tension (peak value
(peak value of 110 KV) to discharge electrodes. At the tips of
these electrodes a corona effect is produced due to high
voltage. The corona effect separates the gas molecules into
negative and positive ions. The negative ions collide on their
way to earthed collecting electrodes with the dust particles in
the gas stream.
o The suspension bars for the discharge electrodes, equipped
with anvils. Flail hammers are hitting the anvils in a certain
sequence; the impact of the blow is transferred to the
discharge electrodes, thus shaking off the dust adhering to
them.
o The collecting electrodes are held in rows by rapping bars,
which are equipped with anvils. Flail hammers, which are
mounted in spirals on the rapping shaft, hit the anvils of the
rapping bars. The impact of the blow is transferred to the
collecting electrodes, shaking off the dust layer.
o Hoppers for collecting dust
o Hopper heaters to keep the hopper warm by hopper
heating , even during standstill periods. The hopper heating
are turned on and off by a thermostat. These thermostats are
located at the hopper sidewall. The hopper heating has to be
started before 4 hours before starting, respectively gas flows
through the ESP.
o Insulator Heaters for heating the supporting insulators which
keep the temperature inside the insulator compartments
above the dew point temperature of the gas to be cleaned.
The heating elements are constantly turned on and off
through a pre-set thermostat.

Electrics/ Sub control System :

Electric Enclosure per field to be placed in the substation comprising

:
A microprocessor based sub control system, consisting
TITLE FUNCTIONAL SPECIFICATION
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Chapter : 8 Page 56 of 204
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o microprocessor based control of the TRSET

o Microprocessor based control of the Rapping Mechanism
o Control of the Hopper and Insulator heaters
o Field Sensors & Actuators, as required for the Operation.

Operation :

The Operation of the ESP are for follows

Start up sequence :

o Box up ESP
o Set the Grounding switches of individual fields to operation
mode manually.
o Complete the safety interlock sequence and put TR Panel
keys in respective panel switches
o PCS to start dust conveying system below ESP in the reverse
sequence, i.e. the bottom most conveyors to start first
followed by subsequent upstream conveyors.
o Start rapping motors from Rectifier Panel depending upon
mode.
o Insulator heaters to be switched on manually from panel, 3 – 4
hours before taking hot gas.

Hot Gas Start up :

o Take Hot Gas through ESP

o Switch ON ESP fields from PCS one by one starting from
outlet when gas temp. is > 90 Deg C.

Shut Down Sequence :

o Switch off TR Set fields.

o Keep insulators ON for 2 Hrs. after stop.
o Keep rappers ON for at least 2 Hrs. after Stop.

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 57 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.5.11 Messages and Alarms

Tag Description Priority Delay

314BE01YJ10H Bucket Elevator Motor Power High 2 1s

Bucket Elevator Motor Power High- 1s
314BE01YJ10HH 2
High
314BE01XZ20 Barring Motor dis-engaged 1 1s
Drag Chain Conveyor Motor current 1s
314DG01YI10H 2
High
Drag Chain Conveyor Motor current 1s
314DG02YI10H 2
High
Drag Chain Conveyor Motor current 1s
314DG03YI10H 2
High
Drag Chain Conveyor Motor current 1s
314DG04YI10H 2
High
314SC01YI10H Screw Conveyor Motor current High 2 1s
314SC02YI10H Screw Conveyor Motor current High 2 1s
314SC03YI10H Screw Conveyor Motor current High 2 1s
314SC04YI10H Screw Conveyor Motor current High 2 1s
314SC05YI10H Screw Conveyor Motor current High 2 1s
314DC01YI10H ESP Field 1 current High 2 1s
314DC01YI20H ESP Field 2 current High 2 1s
314DC01YI30H ESP Field 3 current High 2 1s
314DC01YI10L ESP Field 1 current Low 2 1s
314DC01YI20L ESP Field 2 current Low 2 1s
314DC01YI30L ESP Field 3 current Low 2 1s
314DC01YE10L ESP Field 1 Voltage Low 2 1s
314DC01YE20L ESP Field 2 Voltage Low 2 1s
314DC01YE30L ESP Field 3 Voltage Low 2 1s
314DC01YT10H ESP Inlet temperature High 2 1s
314DC01YT10HH ESP Inlet temperature High-High 1 1s
314DC01YP10L ESP Inlet pressure Low 2 1s
314DC01YP10H ESP Inlet pressure High 2 1s
216WF01EC10 not
Feed to Raw Mill not running 2 1s
Run
314DC02XP10 Compressed Air Pressure Low 2 1s

TITLE FUNCTIONAL SPECIFICATION

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WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

314BE01XL10 Bucket Elevator Boot Level 2 1s

314DC01XL10 ESP Hopper 1 Level High 2 1s
314DC01XL20 ESP Hopper 2 Level High 2 1s
Material Flow towards Motorized
314SC01L01 3 1s
Flap 314VV01MT10
Not of
Remote mode not selected 3 1s
314DC02EC10SL
Not of
Remote mode not selected 3 1s
314DC01EC10SL
Not of
Remote mode not selected 3 1s
314DC01EC20SL
Not of
Remote mode not selected 3 1s
314DC01EC30SL

TITLE FUNCTIONAL SPECIFICATION

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WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6 314.S03 Kiln / Raw Mill ESP Fan

8.6.1 Sequence Flow Sheet

TITLE FUNCTIONAL SPECIFICATION

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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
314FA01VS10 Kiln / Raw 1 1 Y N
Mill ESP Fan
314DB01AC10 Louver 1 1 N N Default position
Damper 100% Open.

Operation based
on Raw Mill Fan
216FA05 Run

8.6.3 Analog Sensors Lists

Eng. Units Alarm Limits

Tag
Low High Unit LL L H HH
314FA01YV20 0 25 mm/s 4 6
314FA01YV21 0 25 mm/s 4 6
314FA01YV22 0 25 mm/s 4 6
314FA01YV23 0 25 mm/s 4 6
314FA01YT11 0 150 °C 100 110
314FA01YT12 0 150 °C 100 110
314FA01YT13 0 150 °C 100 110
314FA01YT20 0 150 °C 80 85
314FA01YT21 0 150 °C 80 85
314FA01YT30 0 150 °C 80 85
314FA01YT31 0 150 °C 80 85
314FA01YJ10 0 450 kW 380 420
314FA01YI10 0 100 A 70 80
314FA01YS10 0 100 % 70 75
314DB01YZ10 0 100 %
314TC01YP10 -800 0 mmWG -10 -5

* Alarms limit will be confirmed at the time of commissioning.

TITLE FUNCTIONAL SPECIFICATION
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WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6.4 Operators Selections

None.

8.6.5 Operator Mode Description

Start-up details:

 Start Kiln / Raw Mill ESP Fan 314FA01VS10

Shut-down details:

 Stop Kiln / Raw Mill ESP Fan 314FA01VS10

TITLE FUNCTIONAL SPECIFICATION

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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

314S02 (Kiln / Raw Mill ESP and GCT-   Stoppage with
ESP Dust Transport System) Running delay of 20 min

Kiln / Raw Mill ESP inlet Temperature  Delay 20 min

314DC01YT10 < High (H)
Kiln / Raw Mill ESP inlet Temperature 
314DC01YT10 < High-High (HH)
Not of 314DC01XL11  Continuous for
Not of 314DC01XL21  20 min
Not of U828GN01EC10B1 in Auto 
mode

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
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WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6.7 D/D Interlocks and Alarms

 314FA01VS10

Interlocks:

Description DSI DPI DSQI DEI Remarks

314FA01VS10

Alarms:

Description BP PE1 PE2 Remarks / Delays

314FA01YV20HH 
314FA01YV21HH 
314FA01YV22HH 
314FA01YV23HH 
314FA01YT11HH 
314FA01YT12HH 
314FA01YT13HH 
314FA01YT20HH 
314FA01YT21HH 
314FA01YT30HH 
314FA01YT31HH 
314FA01YI10HH 

TITLE FUNCTIONAL SPECIFICATION

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WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314DB01AC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

314DB01XZ10  1s
314DB01XZ11  1s
314DB01XZ12  1s

Conditional Start-up:

Description SST1 SST2 Remarks / Delays

216FA05VS10 Run 

TITLE FUNCTIONAL SPECIFICATION

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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6.8 Process Protections:

Stoppage of GCT – ESP dust transport system continuous for 20
min should not stop the sequence.

Sequence stoppage on Kiln / Raw Mill ESP inlet Temperature

314DC01YT10 > H continuous for 20 min

Sequence stoppage on Kiln / Raw Mill ESP Hopper level High-High

continuous for 20 min.

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 66 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6.9 Regulation Loops

 Damper Position 314DB01YZ10

Controlled Measurement :Not Applicable

D/D Controlled :Damper Position 314DB01YZ10

Manual Mode :Operator manipulates the position of

the Damper 314DB01YZ10 from the
Analog Damper faceplate in manual
mode.

Forced Mode :In Sequence Mode the Louver Damper

314DB01 will close 100% on running of
Raw Mill Fan 216FA05VS10 and opens
100% on stoppage of Raw Mill Fan
216FA05VS10.

 Pre-heater Fan Outlet Draft 314TC01YP10 control with Kiln / Raw

Mill ESP Fan Speed 314FA01YS10

Controlled Measurement :Pre-heater Fan Outlet Draft

314TC01YP10

D/D Controlled :Kiln / Raw Mill ESP Fan Speed

314FA01YS10

Manual Mode :Operator manipulates the Fan Speed

314FA01YS10 from the PID faceplate in
manual mode.

Automatic Mode :Pre-heater Fan Outlet Draft

314TC01YP10 will be controlled by the
manipulation of the Fan Speed
314FA01YS10 from the PID Controller.
Operator will give set point for the Pre-
heater Fan Outlet Draft.

Forced Mode :Not Applicable

In case if Drive is selected in Local Mode the Field operator shall be

able to increase / decrease the speed for the fan.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 67 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.6.10 Cyclic and Special Functions

None

8.6.11 Messages and Alarm

Tag Description Priority Delay

ESP Fan Motor Vibration DE-X

314FA01YV20H 2 1s
High
ESP Fan Motor Vibration DE-Y
314FA01YV21H 2 1s
High
ESP Fan Motor Vibration NDE-X
314FA01YV22H 2 1s
High
ESP Fan Motor Vibration NDE-Y
314FA01YV23H 2 1s
High
ESP Fan Motor Winding #1
314FA01YT11H 2 1s
Temperature High
ESP Fan Motor Winding #2
314FA01YT12H 2 1s
Temperature High
ESP Fan Motor Winding #3
314FA01YT13H 2 1s
Temperature High
ESP Fan Motor Bearing DE
314FA01YT20H 2 1s
Temperature High
ESP Fan Motor Bearing NDE
314FA01YT21H 2 1s
Temperature High
ESP Fan Bearing DE Temperature
314FA01YT30H 2 1s
High
ESP Fan Bearing NDE
314FA01YT31H 2 1s
Temperature High
314FA01YJ10H ESP Fan Motor Power High 2 1s
314FA01YJ10HH ESP Fan Motor Power High-High 2 1s
314FA01YI10H ESP Fan Motor Current High 2 1s
314FA01YS10H ESP Fan Motor Speed High 2 1s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 68 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7 316.S04: Primary Air Fan

8.7.1 Sequence Flow Sheet

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 69 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
316FA24MT10 Primary Air 1 1 Y N Start if P1 not
Fan Selected
316FA25 MT10 Primary Air 1 1 Y N Start if P1
Fan Selected
316VN03VA10 Pneumatic 2 3 N Y Default Position
Gate Normally Close.

If P1 selected it
will close by
Sequence start.
316VN04VA10 Pneumatic 2 3 N Y Default Position
Gate Normally Close.

If P1 not
selected it will
close by
Sequence start.
316FA24AC10 Primary Air 3 2 N N If P1 not
Fan Damper Selected it will
close 100% by
sequence start
command.
Default Position
Normally closed
316FA25AC10 Primary Air 3 2 N N If P1 Selected it
Fan Damper will close 100%
by sequence
start command.
Default Position
Normally closed
316FA23MT10 Emergency 1 1 Y Y Refer description
Air Fan in Sl. No. 8.7.10
316VN02VA10 Pneumatic 2 2 N Y Default Position
Gate Normally Close.
Refer description
in Sl. No.8.7.10

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 70 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.3 Analog Sensors Lists

Eng. Units Alarm Limits

Tag
Low High Unit LL L H HH
316FA24YV20 0 25 mm/s -1 0 6 9
316FA24YV21 0 25 mm/s -1 0 6 9
316FA24YT11 0 150 °C 5 10 90 100
316FA24YT12 0 150 °C 5 10 90 100
316FA24YT13 0 150 °C 5 10 90 100
316FA24YT30 0 150 °C 5 10 75 85
316FA24YT31 0 150 °C 5 10 75 85
316FA24YI10 0 220 A 0 175 198
316FA24YZ10 0 100 %
316FA25YV20 0 25 mm/s 0 6 9
316FA25YV21 0 25 mm/s 0 6 9
316FA25YT11 0 150 °C 5 10 90 100
316FA25YT12 0 150 °C 5 10 90 100
316FA25YT13 0 150 °C 5 10 90 100
316FA25YT30 0 150 °C 5 10 75 85
316FA25YT31 0 150 °C 5 10 75 85
316FA25YI10 0 220 A 0 175 198
316FA25YZ10 0 100 %
316FA24YP10 0 2500 mmWG 1500

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 71 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.4 Operators Selections

P1 not Selected – Start Primary Air Fan 316FA24MT10

P1 selected – Start Primary Air Fan 316FA25MT10

8.7.5 Operator Mode Description

Start-up details:

 If P1 not selected Start Primary Air Fan 316FA24MT10. If P1 selected

Start Primary Air Fan 316FA24MT10. In case of failure of
316FA24MT10 and 316FA25MT10 start Emergency Air Fan
316FA23MT10.

 If P1 not selected Open Pneumatic Gate 316VN03VA10. If P1 selected

Open Pneumatic Gate 316VN04VA10. In case of failure of
316FA24MT10 and 316FA25MT10 Close Pneumatic Gate
316VN03VA10 or 316VN04VA10 and Open 316VN02VA10

 If P1 not selected Open Primary Air Damper 316FA24AC10. If P1

selected Open Primary Air Damper 316FA25AC10.

Shut-down details:

 Stop Primary Air Fan 316FA24MT10 OR 316FA24MT10 based on P1

selection. In case if 316FA23MT10 is running stop the same.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 72 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

Not of U828GN01EC10B1 in Auto 
Mode

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 73 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.7 D/D Interlocks and Alarms

 316FA24MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

316VN03XZ11  Gate Close
Inlet Damper
316FA24XZ11 
100% close
316FA25MT10 not Run 
316FA23MT10 not Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

316FA24YT11HH  1s
316FA24YT12HH  1s
316FA24YT13HH  1s
316FA24YT30HH  1s
316FA24YT31HH  1s
316FA24YV20HH  1s
316FA24YV21HH  1s
316FA24YI10HH  65s

 316FA25 MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

316VN04XZ11  Gate Close
Inlet Damper
316FA25XZ11 
100% close
316FA24MT10 not Run 
316FA23MT10 not Run 

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 74 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

Alarms:

Description BP PE1 PE2 Remarks / Delays

316FA25YT11HH  1s
316FA25YT12HH  1s
316FA25YT13HH  1s
316FA25YT30HH  1s
316FA25YT31HH  1s
316FA25YV20HH  1s
316FA25YV21HH  1s
316FA25YI10HH  65s

 316FA23MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

Gate
316VN02XZ11 
Close
316FA24MT10 not Run 
316FA25MT10 not Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 316VN03VA10

Interlocks:

Description DSI DPI DCR DEI Remarks

316FA24MT10 Run 

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

316VN03XZ10  1s
316VN03XZ11  1s
 316VN04VA10
TITLE FUNCTIONAL SPECIFICATION
LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 75 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

Interlocks:

Description DSI DPI DCR DEI Remarks

316FA25MT10 Run 

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

316VN04XZ10  1s
316VN04XZ11  1s

 316VN02VA10

Interlocks:

Description DSI DPI DCR DEI Remarks

316FA23MT10 Run 

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

316VN02XZ10  1s
316VN02XZ11  1s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 76 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 316FA24AC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

316FA24XZ10  1s
316FA24XZ11  1s
316FA24XZ12  1s

 316FA25AC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

316FA25XZ10  1s
316FA25XZ11  1s
316FA25XZ12  1s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 77 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.8 Process Protection

None

8.7.9 Regulation Loops

 Damper Position 316FA24YZ10

Controlled Measurement :Not Applicable

D/D Controlled :Damper Position 316FA24YZ10

Manual Mode :Operator manipulates the position of

the Damper 316FA24YZ10 from the
Analog Damper faceplate in manual
mode.

Automatic Mode :Not Applicable

 Damper Position 316FA25YZ10

Controlled Measurement :Not Applicable

D/D Controlled :Damper Position 316FA25YZ10

Manual Mode :Operator manipulates the position of

the Damper 316FA25YZ10 from the
Analog Damper faceplate in manual
mode.

Automatic Mode :Not Applicable

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 78 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.10 Cyclic and Special Functions

316FA23 / 316FA24 / 316FA25 Auto Change over:

If P1 is not selected and start command is given to sequence,

following actions will be taken automatically:
1. By default Pneumatic Gate 316VN02, 316VN03 and 316VN04
are closed
2. Primary Air Fan 316FA24MT10 will start.
3. Pneumatic Gate 316VN03 will open.
4. Pneumatic Gate 316VN02, 316VN04 will remain close

If P1 is selected and start command is given to sequence , following

actions will be taken automatically:
1. By default Pneumatic Gate 316VN02, 316VN03 and 316VN04
are closed
2. Primary Air Fan 316FA25MT10 will start.
3. Pneumatic Gate 316VN04 will open.
4. Pneumatic Gate 316VN02, 316VN03 will remain close

If sequence is running with P1 not selected, on stoppage / failure of

Primary Air Fan 316FA24MT10, following actions will be taken
automatically
1. Selection will toggle i.e. to P1 selected (provided
316FA25MT10 was not running for past 10 min.)
2. Pneumatic Gate 316VN03 will close
3. Pneumatic Gate 316VN02 will remain close.
4. Primary Air Fan 316FA25MT10 will start.
5. Pneumatic Gate 316VN04 will open.
This changeover will not affect the sequence running.

If sequence is running with P1 selected, on stoppage / failure of

Primary Air Fan 316FA25MT10 following actions will be taken
automatically
1. Selection will toggle i.e. to P1 not selected (provided
316FA24MT10 was not running for past 10 min.)
2. Pneumatic Gate 316VN04 will close
3. Pneumatic Gate 316VN02 will remain close.
4. Primary Air Fan 316FA24MT10 will start.
5. Pneumatic Gate 316VN05 will open.
This changeover will not affect the sequence running.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 79 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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If Auto changeover has not taken place and either of Fans

(316FA24MT10 & 316FA25MT10) in not running within 30s, because
of any reason then following action will be taken automatically:
1. Pneumatic Gates 316VN03 and 316VN04 will close,
2. Emergency Air Fan 316FA23MT10 will start.
3. Pneumatic Gate 316VN02 will open

On stoppage of Primary Air Fan 316FA24MT10 / 316FA25 MT10,

the respective Inlet Dampers 316FA24AC10 / 316FA25AC10 will
close Automatically.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 80 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.7.11 Messages and Alarm

Tag Description Priority Delay

Primary Air Fan Motor Vibration

316FA24YV20H 2 1s
DE-X High
Primary Air Fan Motor Vibration
316FA24YV21H 2 1s
DE-Y High
Primary Air Fan Motor Winding #1
316FA24YT11H 2 1s
Temperature High
Primary Air Fan Motor Winding #2
316FA24YT12H 2 1s
Temperature High
Primary Air Fan Motor Winding #3
316FA24YT13H 2 1s
Temperature High
Primary Air Fan Bearing DE
316FA24YT30H 2 1s
Temperature High
Primary Air Fan Bearing NDE
316FA24YT31H 2 1s
Temperature High
316FA24YI10H Primary Air Fan Motor Current High 2 1s
Primary Air Fan Motor Vibration
316FA25YV20H 2 1s
DE-X High
Primary Air Fan Motor Vibration
316FA25YV21H 2 1s
DE-Y High
Primary Air Fan Motor Winding #1
316FA25YT11H 2 1s
Temperature High
Primary Air Fan Motor Winding #2
316FA25YT12H 2 1s
Temperature High
Primary Air Fan Motor Winding #3
316FA25YT13H 2 1s
Temperature High
Primary Air Fan Bearing DE
316FA25YT30H 2 1s
Temperature High
Primary Air Fan Bearing NDE
316FA25YT31H 2 1s
Temperature High
316FA25YI10H Primary Air Fan Motor Current High 2 1s
316FA24YP10L Primary Air pressure low 2 1s
Primary Air Fan 316FA25MT10
316FA25L01 3 1s
selected

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 81 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.8 313.S05: Pre-Heater ID Fan

8.8.1 Sequence Flow Sheet

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 82 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.8.2 Consumer List

Start Stop Essential Emergency

Tag Description Remarks
step step drive Power
Pre-heater ID
313FA01VS10 1 1 Y N
Fan Motor
Pre-heater ID
313FA01AC10 2 2 N N
Fan Damper
Pre-heater ID
313FA01MT20 1 1 Y Y
Fan Barring

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 83 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.8.3 Analog Sensors Lists

Eng. Units Alarm Limits

Tag
Low High Unit LL L H HH
313FA01YT11 0 150 °C 100 110
313FA01YT12 0 150 °C 100 110
313FA01YT13 0 150 °C 100 110
313FA01YT20 0 150 °C 85 90
313FA01YT21 0 150 °C 85 90
313FA01YT30 0 150 °C 75 80
313FA01YT31 0 150 °C 75 80
313FA01YV20 0 25 mm/sec 6 8
313FA01YV21 0 25 mm/sec 6 8
313FA01YV22 0 25 mm/sec 6 8
313FA01YV23 0 25 mm/sec 6 8
313FA01YI10 0 300 A 240 270
313FA01YJ10 0 1850 kW 1600
313FA01YS10 0 100 %
313FA01YZ10 0 100 %
313FA01YT40 0 500 °C 180 400 450
313FA01YP10 -900 0 mmWG -100 -50

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 84 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.8.4 Operators Selections

None

8.8.5 Operator Mode Description

Start-up details:

 Start the motor 313FA01VS10.

 Open the Damper 313FA01AC10 to 100% automatically.
 Start 313FA01MT20 Automatically on stoppage of 313FA01VS10 if Pre-
heater Fan inlet gas temperature 313FA01YT40 > 180 Deg C

Shut-down details:

 Stop the motor 313FA01VS10.

 Close the Damper 313FA01AC10 to 100% automatically.
 Stop Barring if it’s running.

8.8.6 Sequence Interlocks and Alarms

Interlocks:
Description SSI SPI Remarks
314.S03 Kiln / Raw Mill ESP Fan Run  
Not of U828GN01EC10B1 in Auto 
Mode

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 85 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.8.7 D/D Interlocks and Alarms

 313FA01VS10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Max 3 start per hour 

Pre-Heater Fan Inlet 
Gas Temperature
313FA01YT40 < H
Pre-Heater Fan Inlet 
Gas Temperature
313FA01YT40 < HH
Either  
314DB01 Open
or
(216VN01, 216VN02
and 216DB02) open

Alarms:

Description BP PE1 PE2 Remarks / Delays

313FA01YT11HH  1s
313FA01YT12HH  1s
313FA01YT13HH  1s
313FA01YT20HH  1s
313FA01YT21HH  1s
313FA01YT30HH  1s
313FA01YT31HH  1s
313FA01YV20HH  1s
313FA01YV21HH  1s
313FA01YV22HH  1s
313FA01YV23HH  1s
313FA01YI10HH  1s

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 86 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 313FA01AC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

313FA01XZ10  1s
313FA01XZ11  1s
313FA01XZ12  1s

 313FA01MT20

Interlocks:

Description DSI DPI DCR DEI Remarks

313FA01VS10 Not Run
AND

313FA01YT40L

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 87 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.8.8 Process Protections

When the Kiln Feed is running, If “Startup Key” (Refer Sl. No. Error:
Reference source not found for details of startup key) for kiln burner
is disabled (Interlocking on) And Kiln Feed Rate Measured value <
20 tph for more than 2 min when metering system is not bypassed
OR 312VV06 open to silo then Pre Heater ID Fan speed
313FA01YS10 shall be forced to minimum speed of 20%.

The Preheater Fan shall go to minimum speed on following

conditions:
 Stoppage of Kiln Main Motor
 Kiln Main Motor from Operating Speed to Barring Speed
 Stoppage of Cooler ESP Fan

8.8.9 Regulation Loops

 Damper Position 313FA01YZ10

Controlled Measurement :Not Applicable

D/D Controlled :Damper Position 313FA01YZ10

Manual Mode :Operator manipulates the position of

the Damper 313FA01YZ10 from the
Analog Damper faceplate in manual
mode.

Automatic Mode :Not Applicable

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 Fan Speed 313FA01YS10

Controlled Measurement :Not Applicable

D/D Controlled :Fan Speed 313FA01YS10

Manual Mode :Operator manipulates the Fan Speed

313FA01YS10 from the Setpoint
faceplate in manual mode.

Forced Mode : If “Startup Key” for kiln burner is

disabled (Interlocking on) And Kiln Feed
Rate Measured value < 20 tph for more
than 2 min, when metering system is not
bypassed or 312VV06 open to silo then
Pre Heater ID Fan speed 313FA01YS10
shall be forced to minimum speed of
20%.
In case if Drive is selected in Local Mode the Field operator shall be
able to increase / decrease the speed for the fan.

8.8.10 Cyclic and Special Functions

Pre-heater Fan Barring motor

Barring motor starts automatically on stoppage of Pre-heater Fan

AND if the Preheater Fan inlet gas temperature 313FA01YT40 > 180
Deg C. The Barring motor will be auto clutched when fan speed
lowers down to 80 rpm.

On start / running of Pre-heater Fan 313FA01VS10 barring motor will

get automatically disengaged when the fan speed exceeds 80 rpm

Barring Motor is not meant for rotating the fan from the stationary
condition.

Pre-heater Fan Inlet Damper

Pre-heater Fan Inlet Damper will close automatically on stoppage of

313FA01VS10 and Opens automatically on running of
313FA01VS10.

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Chapter : 8 Page 89 of 204
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8.8.11 Messages and Alarm

Tag Description Priority Delay

Pre-heater ID Fan Motor Winding

313FA01YT11H 2 1s
#1 Temperature High
Pre-heater ID Fan Motor Winding
313FA01YT12H 2 1s
#2 Temperature High
Pre-heater ID Fan Motor Winding
313FA01YT13H 2 1s
#3 Temperature High
Pre-heater ID Fan Motor Bearing
313FA01YT20H 2 1s
DE Temperature High
Pre-heater ID Fan Motor Bearing
313FA01YT21H 2 1s
NDE Temperature High
Pre-heater ID Fan Bearing DE
313FA01YT30H 2 1s
Temperature High
Pre-heater ID Fan Bearing NDE
313FA01YT31H 2 1s
Temperature High
Pre-heater ID Fan Vibration DE-X
313FA01YV20H 2 1s
High
Pre-heater ID Fan Vibration DE-Y
313FA01YV21H 2 1s
High
Pre-heater ID Fan Vibration NDE-X
313FA01YV22H 2 1s
High
Pre-heater ID Fan Vibration NDE-Y
313FA01YV23H 2 1s
High
Pre-heater ID Fan Motor Current
313FA01YI10H 2 1s
High
Pre-heater ID Fan Motor Power
313FA01YJ10H 2 1s
High
Pre-heater ID Fan Motor Power
313FA01YJ10HH 2 1s
High-High
313FA01YS10H Pre-heater ID Fan Speed High 2 1s
Pre-heater ID Fan Inlet
313FA01YT40H 2 1s
Temperature High
Pre-heater ID Fan Inlet Pressure
313FA01YP10H 2 1s
High

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8.9 316.S06: Kiln Burner

8.9.1 Sequence Flow Sheet

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Date : 11/02/2007
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8.9.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
Kiln Burner IND IND N Y Start/Stop
316ZX05 Suspension from
Local
Kiln Burner 1 2 Y N If P3 not
316XY05EC10
Station selected
Shock Blaster
If P2 not
313AL01 Sequencer for 2 1 N N
selected
Pre-Heater

8.9.3 Analog Sensors Lists

Eng. Units Alarm Limits

Tag
Low High Unit LL L H HH
316BD01YT10 0 1200 Deg C 900
316VD01YT10 0 1500 Deg C 1200 1400
313CY01YP10 -800 0 mmWG -100 -50
313CY01YP30 -800 0 mmWG -100 -50
313CY01YT10 0 500 Deg C 400 450
313CY01YT20 0 500 Deg C 400 450
313CY01YT30 0 500 Deg C 400 450
313CY01YT40 0 500 Deg C 400 450
313CY02YP10 -800 0 mmWG -100 -50
313CY02YP20 -400 0 mmWG -100 -50
313CY02YT10 0 800 Deg C 650 720
313CY02YT20 0 800 Deg C 650 720
313CY03YP10 -800 0 mmWG -100 -50
313CY03YP20 -400 0 mmWG -100 -50
313CY03YT10 0 1000 Deg C 800 900
313CY03YT20 0 1000 Deg C 800 900
313CY04YP10 -800 0 mmWG -100 -50
313CY04YP20 -400 0 mmWG -100 -50
313CY04YT10 0 1000 Deg C 800 900
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313CY04YT20 0 1000 Deg C 800 900

313CA01YT10 0 1000 Deg C 600 1000
313CA01YP10 -400 0 mmWG -100 -50
313AG01YX10 0 10000 Ppm 8000
313AG01YX20 0 2500 Ppm 2000 2250
313AG01YX30 0 2 % vol 0.4 0.6
313AG01YX40 0 10 % vol 1.5 4
313AG02YX10 0 10000 Ppm 8000
313AG02YX20 0 2500 Ppm 2000 2250
313AG02YX30 0 2 % vol 0.4 0.6
313AG02YX40 0 10 % vol 2 3
313AG03YX10 0 2 % vol 0.4 0.6
313AG03YX20 0 10 % vol 4 6
316XY05YX11 0 100 rpm
316XY05YP10 0 12 Bar
316XY05YP20 0 4 Bar

8.9.4 Operators Selections

P1 – Selection for “Startup Key”
P2 not selected – Enable the Shock Blaster Sequencer for Pre-Heater
313AL01EC10 in Sequence mode.
P2 Selected – Disable the Shock Blaster Sequencer for Pre-Heater
313AL01EC10.
P3 not selected – Kiln Burner (316XY05EC10) in Sequence mode
P3 selected – Kiln Burner (316XY05EC10) in local mode

Start / Stop button for Kiln Burner Suspension

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8.9.5 Operator Mode Description

Operator has to select the “Startup Key” during pre-heating of the
kiln system. This start-up key when enabled allows the operation of
Kiln burner without Sequence 314S05 (Pre-heater ID fan) running.
Running of the sequence 312S09 (Feed to Kiln) will automatically
disable this key.

Startup Key to be enabled in case of Kiln Burner Tripped.

Start-up details:

 Start the Kiln Burner (Gas Supply) 316XY05EC10

 Start Shock Blaster 313AL01

Shut-down details:

 Stop Shock Blaster 313AL01

 Stop the Kiln Burner (Gas Supply) 316XY05EC10

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8.9.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

Not 313AG01FG10 
Not of 316ZX05AV 
314FA01VS10 Run   If P1 not
selected
(Pre-Heater Fan Run  If P1 not
AND selected
Speed Pre-Heater Fan 313FA01YS10 > 25% )
AND
Pre-Heater Fan Damper 313FA01AC10 Not
closed
(Primary Air Fan 316FA24MT10 Run   If P1 not
AND selected
Primary Air Fan Damper 316FA24AC10 Not
closed) Change
OR Over
(Primary Air Fan 316FA25MT10 Run dalay 20
AND min
Primary Air Fan Damper 316FA25AC10 Not
closed)
Primary Air Fan 316FA24MT10 Run   If P1
OR selected
Primary Air Fan 316FA25MT10 Run
Not of U828GN01EC10B1 in Auto mode 

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

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8.9.7 D/D Interlocks and Alarms

 316ZX05

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 316XY05EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

316ZX05 Not Run 

Feed is ON If P1 not
(312VV06XZ10 Selected
AND
312VV06XZ21) Delayed
AND   Stoppage 1
Kiln Feed rate min
Measured Value > 20
tph (when Kiln Feed
Sequence 312S09 Run)

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

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 313AL01EC10

Interlocks:

Description DSI DPI DSQI DCR Remarks

316.S09 Kiln Feed Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

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8.9.8 Process Protection

In case of emergency cooling fan as well as either of the primary air
fans fails to run then operator can decide to take out the burner with
the help of drive provided with burner suspension. Kiln Burner
Suspension 316ZX05 is provided with Emergency Power Supply.

The Burner Gas control valve position will go to minimum i.e. 20%
with following conditions:
 Stoppage of Preheater Fan
 Preheater Fan at minimum speed

8.9.9 Regulation Loops

None

8.9.10 Cyclic and Special Functions

8.9.10.1 Kiln Burner System

System Description :

Mechanics/ Subsystem :

The kiln burner is a unit built of pipes, valves, cocks, measuring

instruments etc.

The Kiln Burner consists of the following :

- A flow Control Unit – Mainly consist of a Safety shut off valve

(SSV) and a flow control gate
- A Shut off / Leakage Control unit- Consists of a number of shut
off valves
- Main Burner System
- An igniter burner consisting of a burner lance including an
ignition coil, and ignition electrode, as well as a mixer unit for
gas/air ratio and a control unit containing a flame monitoring unit
based on the ion-rod principle Igniter

Electrics/ Sub control System :

The Kiln Burner System electrics comprises of the following :

A PLC based sub control system consisting :

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Control Logic for operation and start/stop sequence of the Burner,

implemented in the SCS PLC
- Control Display (CD) (Touch Screen) based Operator Interface &
- Interface with PCS over Profibus for reporting Information &
Alarm Conditions
- Field Sensors & Actuators, as required for the Operation.

The following are Monitored & controlled from a local control panel:

- Monitoring of compressed air on main burner, supply side.

- Monitoring of compressed air on main burner, machine side. .
(313XY01XP20)
- Position indication of SSV.(316XY05XZ10,XZ11)
- Monitoring igniter position inside burner lance.
- Monitoring of gas temperature.
- Monitoring of gas flow.(316XY05YF10)
- Monitoring of gas pressure (inlet).(316XY05YP10)
- Monitoring of gas pressure (outlet).(316XY05YP20)
- I/P converter for regulation of gas flow.(316XY05,YZ10)
- UV sensor for flame monitoring.(316XY05XX10)
- Monitoring Igniter (316XY05XZ40)
- Gas valve with position indication (open/close)
(316XY05XZ20,XZ21).
- Gas valve with position indication (open/close).
(316XY05XZ30,31)

The following solenoid operated valves are used for operation &
control

- Solenoid valve on igniter mixer unit, gas supply (NC).

(316XY05VA10)
- Solenoid valve, on igniter mixer unit, air supply (NC)
(316XY05VA20
- Solenoid valve on SSV, latch open position (NC)( 316XY05VA30)
- Solenoid valve, to control open/close of “V06”(NC)
(316XY05VA40).
- Solenoid valve, to control open/close of “V07” (NC)
- ( 316XY05VA50)
- Solenoid valve, to supply gas for leakage control on main burner
(NC)( 316XY05VA60)
- Solenoid valve, for venting of shut-off unit (NO) (316XY05VA70)

Operation :

There are three Steps of operation:

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Flow Control Unit

Safety shut-off valve (SSV):

When the burner station is powered up and no alarms are present

the "latch valve" 316XY05VA30 will be energised. This means that
the SSV can be opened manually.
The SSV only close when:
- There is a position fault on gas valves which are operated
through 316XY05VA40 or 316XY05VA50.
- The leakage control detects a leakage.
- There is a high downstream gas pressure in the system.
- There is a power cut.

Shut off Unit / Leakage control:

Leakage control is a test of shut-off valves between the SSV and the
main burner.
The leakage control sequence is:

Step No. Action Feed back.

Step 1 -Start unit Venting timer done (3
Start venting timer sec)

Step 2 Close (During control 1 check

316XY05VA70 for increasing pressure
Start control 1 on 316XY05YP20H)
timer Control timer 1 done.
(22 sec)

Step 3 Open Filling timer done (3

316XY05VA60 (fill sec)
shut-off unit with
gas)
Start filling timer.
Step 4 Close (During control 2 check
316XY05VA60 for decreasing pressure
Start control 2 on 316XY05YP20L)
timer Control timer 2 done
(22 sec)
Leak control done

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The leakage control is performed automatically in the following cases:

1. After opening of the SSV. When leakage control is done, the
valve 316XY05VA70 will be opened for venting.
2. When the igniter burner is started i.e 316XY05VA10 &
316XY05VA20 are energised , the leakage control is
performed. If no leakages is detected the igniter burner starts
automatically.
3. When the main burner station is started a leakage control is
performed.If no leakages are detected the main burner starts
automatically.
4. When the burner stops after the gas valve connected to
316XY05VA40 and 316XY05VA50 has been opened. A
leakage test is performed to make sure that the valves are
closed again.

NB!! A leakage control is valid for 1 hour i.e. if two of the above
mentioned cases are activated within 1 hour only 1 leakage control is
performed. When opening the SSV a leakage control is always
performed.

Igniter burner:

The control unit is situated inside the local control panel. Start of the
igniter burner can only take place if the signal "interlock OK" is given
from CCS.
When start igniter command is given a leakage control will be
performed, if the SSV is open.
If no leaks are detected the igniter burner starts immediately. If the
igniter burner is started when the main burner is in operation no
leakage control is performed. During a period of approx. 4 seconds
after start, a spark sequence takes place. Assuming the spark is
detected the spark L.E.D. in the front of the igniter burner cabinet is
activated. The mixer valves in the mixer unit will be energised.
Approx. 0.5 second after the spark stops a check is made for "flame
present

Main burner:
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The main burner can be started in 2 modes:

 When the temperature in the kiln inlet is <750°C
 When the temperature in the kiln inlet is >750°C
Start when T < 750°C
The main burner can be started when the igniter is in operation. The
main burner and the igniter burner must run together for 300 sec. After
the 3-10 sec. the UV monitor must detect a flame. If Flame is not
detected, the burner goes to off.
Start when T >750°C:
The main burner can be started when the igniter is in operation. The
main burner and the igniter burner must run together for 300 sec. The
burner station is now in operation.

Flame supervision:
The flame is monitored by the UV cell or kiln inlet temperature.
When the kiln is “cold” i.e. Kiln inlet temperature <750°C the flame is
monitored by the UV cell.

With a “hot” kiln i.e. Kiln inlet temperature >750°C the flame is
monitored by this temperature.
Interlock, and alarms from UV cell is disengaged.

Gas flow control:

Operator gives the set point for fuel flow in Nm3/hr.

Gas flow can only be controlled when the burner station is in

operation. The gas flow is controlled by a remote operated reduction
valve. This valve maintains a constant downstream pressure and thus
a constant flow. The downstream pressure is changed by altering the
set point to the I/P converter on the reduction valve and they’re by
altering the gas flow.

Local Mode selection (316XY05EC10CA copy of 316XY05L01) for the

Kiln Burner shall be passed from PCS to SCS.

Flow sheet :

An Instrument Flow sheet for the Kiln Burner system along with the
Alarm signals with Lafarge codification is depicted as under herewith:

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Chapter : 8 Page 104 of 204
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8.9.10.2 Kiln Shock Blaster System

System Description :

The compressed air is stored in an air receiver, which maintains the

air pressure at 6 to 7 kg/sq. cm. This compressed air is fed to the
point of discharge through operation of pneumatically controlled
valves. The sudden but controlled release of compressed air blasts
the accumulated material at a rate faster than the material can
absorb it, thereby causing the material to get dislodged and move.
The controlled release of air ensures that the reaction is not
transmitted to the support structure and also there is minimal effect
of noise or vibration. The actuation of the blaster can be effected
either manually or through Electronic Sequence Timer or through
Plant Control System based sub control function meant for blasting
sequence.

Shock Blaster system for Pre-heater consists of the following:

Mechanics /Subsystem :

- Air blaster Vessels (4 nos) each with capacity of 150 litres (Out of
the 4 nos. vessels 2 nos ( i.e 313AL01VA10 to 313AL01VA11 )
are in the smoke Chamber and the other 2 nos (313AL01VA12 &
313AL01VA13) . are in the bottom of 3 rd and 4th Cyclone.
- There are 4 no. shock blasters which are spare and can be used ,
as required.

- Each of the Blaster vessel is integral with the following :

o Quick Exhaust Valve (QEV)
o Safety Relief Valve
o Hose Connection etc
o Hanger Support
o Pneumatic part and accessories consisting :
Pneumatic panel (complete with header, non return valve, Manifold,
Solenoid valve Ball valve Connecting Hoses & Tubes and Fittings)
Mounting package consisting suitable nozzle with matching flanges ,
mounting bends with flanges ,nuts bolts with washers and gaskets.

Electrics/ Sub Control System:

- A PCS based sub control/ cyclic function, which control the

sequence for Pre-Heater air blasters.
The solenoids valves are operated from the PCS output, which
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are connected via Auxiliary Control Centre (ACC) and Junction

Boxes.

Operation :

The Pre-Heater Shock Blaster is used for dislodging the material

jammed inside the Cyclone bottom. There is only one mode of
operation.

PCS mode: Mode for Remote Operation

The operation of the Blasting Sequence in Remote mode is based on

Timer. There are two groups of solenoid valve.
2 no. Solenoid group for Cyclone Bottom
2 no. Solenoid group for Smoke Chamber

Two sets of timers are used for two group of blasters. Air Blasters
can be operated from the field with Field Push Buttons.

One Blasting cycle of filling and release is described as follows:

Filling: Compressed air is supplied through air pipeline controlled

by a solenoid valve to quick exhaust valve. The diaphragm of quick
exhaust valve closes the ¾ inch outlet. The compressed air flows
past the diaphragm into the piston chamber. The compressed air
flows past through an opening in the piston into the receiver and fill it
with air until the pressure in it equals that in the pipeline. The
pressure in the receiver is maintained and the unit is now READY
FOR FIRING.

Release : By actuating the solenoid valve, both the control air in

pipeline and the compressed air stored up behind the piston are
released by simultaneous actuation of the quick exhaust valve.

General Arrangement;

A general arrangement of shock blaster for Pre-heater is depicted

herewith.

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Date : 11/02/2007
Chapter : 8 Page 106 of 204
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LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 107 of 204
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8.9.11 Messages and Alarm

Tag Description Priority Delay

316XY05YF10H Flow Control Unit Gas flow High 2 1s

316BD01YT10L Kiln Hood Temperature 2 1s
316VD01YT10L Burning Zone Temperature 2 1s
316VD01YT10H Burning Zone Temperature 2 1s
Cyclone 1st Stage #1 Exit Pressure
313CY01YP10H 2 1s
High
313CY01YP20H Cyclone 1st Stage #1 Blocked 2 1s
Cyclone 1st Stage #2 Exit Pressure
313CY01YP30H 2 1s
High
313CY01YP40H Cyclone 1st Stage #2 Blocked 2 1s
Cyclone 1st Stage #1 Exit
313CY01YT10H 2 1s
Temperature High
Cyclone 1st Stage #1 Bottom
313CY01YT20H 2 1s
Temperature High
Cyclone 1st Stage #2 Exit
313CY01YT30H 2 1s
Temperature High
Cyclone 1st Stage #2 Bottom
313CY01YT40H 2 1s
Temperature High
Cyclone 2nd Stage Exit Pressure
313CY02YP10H 2 1s
High
313CY02YP20H Cyclone 2nd Stage Blocked 2 1s
Cyclone 2nd Stage Exit
313CY02YT10H 2 1s
Temperature High
Cyclone 2nd Stage Bottom
313CY02YT20H 2 1s
Temperature High
Cyclone 3rd Stage Exit Pressure
313CY03YP10H 2 1s
High
313CY03YP20H Cyclone 3rd Stage Blocked 2 1s
Cyclone 3rd Stage Exit Temperature
313CY03YT10H 2 1s
High
Cyclone 3rd Stage Bottom
313CY03YT20H 2 1s
Temperature High
Cyclone 4th Stage Exit Pressure
313CY04YP10H 2 1s
High
313CY04YP20H Cyclone 4th Stage Blocked 2 1s

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 108 of 204
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Cyclone 4th Stage Exhaust

313CY04YT10H 2 1s
Temperature High
Cyclone 4th Stage Bottom
313CY04YT20H 2 1s
Temperature High
Calciner Outlet Gas Temperature
313CA01YT10H 1 1s
High
313CA01YP10H Calciner Outlet Pressure High 2 1s
313AG01YX10H Kiln Inlet Analyser – NOx High 2 1s
313AG01YX20H Kiln Inlet Analyser – CH4 High 2 1s
313AG01YX30H Kiln Inlet Analyser – CO High 2 1s
313AG01YX40H Kiln Inlet Analyser – O2 High 2 1s
313AG01YX40L Kiln Inlet Analyser – O2 Low 2 1s
313AG01XZ10 Gas Analyser -Kiln Inlet System -
2 1s
Probe In
313AG01XZ11 Gas Analyser -Kiln Inlet System -
2 1s
Probe Retracted
313AG01XT10 Gas Analyser -Kiln Inlet System -
1 1s
Cooler Outlet Gas Temp. High
313AG01XT20 Gas Analyser -Kiln Inlet System -
1 1s
Cooling Water Temp. Low
313AG01XT30 Gas Analyser -Kiln Inlet System -
1 1s
Cooling Water Temp. High
313AG01XP10 Gas Analyser -Kiln Inlet System -
2 1s
Compressed Air Pressure Low
313AG01XP20 Gas Analyser -Kiln Inlet System -
2 1s
Sample Gas Pressure Low
313AG01XF10 Gas Analyser -Kiln Inlet System -
2 1s
Cooling Water Flow Low
Gas Analyser -Kiln Inlet System -
313AG01XX10 2 1s
CO High
Gas Analyser -Kiln Inlet System -
313AG01XX20 2 1s
NO High
Gas Analyser -Kiln Inlet System -
313AG01XX30 2 1s
CH4 High
Gas Analyser -Kiln Inlet System -
313AG01XX40 2 1s
O2 High
313AG01FG10 Fault in Kiln Inlet gas analyzer. 2 1s
313AG02YX10H Cyclone 4 Outlet– NOx High 2 1s
313AG02YX20H Cyclone 4 Outlet– CH4 High 2 1s
313AG02YX20HH Cyclone 4 Outlet– CH4 High-High 1 1s
313AG02YX30H Cyclone 4 Outlet– CO High 2 1s
313AG02YX40H Cyclone 4 Outlet– O2 High 2 1s
TITLE FUNCTIONAL SPECIFICATION
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Date : 11/02/2007
Chapter : 8 Page 109 of 204
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313AG02YX40L Cyclone 4 Outlet– O2 Low 2 1s

313AG02XZ10 Gas Analyser -Pre Calciner Outlet
2 1s
System -Probe In
313AG02XZ11 Gas Analyser -Pre Calciner Outlet
2 1s
System -Probe Retracted
313AG02XT10 Gas Analyser -Pre Calciner Outlet
System -Cooler Outlet Gas Temp. 1 1s
High
313AG02XT20 Gas Analyser -Pre Calciner Outlet
1 1s
System -Cooling Water Temp. Low
313AG02XT30 Gas Analyser -Pre Calciner Outlet
1 1s
System -Cooling Water Temp. High
313AG02XP10 Gas Analyser -Pre Calciner Outlet
System -Compressed Air Pressure 1 1s
Low
313AG02XP20 Gas Analyser -Pre Calciner Outlet
1 1s
System -Sample Gas Pressure Low
313AG02XF10 Gas Analyser -Pre Calciner Outlet
1 1s
System -Cooling Water Flow Low
Gas Analyser -Pre Calciner Outlet
313AG02XX10 1 1s
System -CO High
Gas Analyser -Pre Calciner Outlet
313AG02XX20 2 1s
System -NO High
Gas Analyser -Pre Calciner Outlet
313AG02XX30 2 1s
System -CH4 High
Gas Analyser -Pre Calciner Outlet
313AG02XX40 2 1s
System -O2 High
Fault in Cyclone-4 exit gas
313AG02FG10 1 1s
analyzer.
313AG03YX10H Pre-heater Outlet – CO High 2 1s
313AG03YX10HH Pre-heater Outlet – CO High-High 1 1s
313AG03YX20H Pre-heater Outlet – O2 High 2 1s
Gas Analyser -Pre Heater Outlet
313AG03XZ10 2 1s
System -Probe 1 in line
Gas Analyser -Pre Heater Outlet
313AG03XZ20 2 1s
System -Probe 2 in line
Gas Analyser -Pre Heater Outlet
313AG03XX10 2 1s
System -CO High
Gas Analyser -Pre Heater Outlet
313AG03XX20 2 1s
System -O2 High
Fault in pre-heater Outlet gas
313AG03FG10 1 1s
analyzer.
316XY05YP11L Flow control Unit Gas Pressure Min 2 1s
316XY05YP11H Flow control Unit Gas Pressure 2 1s

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Date : 11/02/2007
Chapter : 8 Page 110 of 204
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Max
316XY05YP20L Shut Off Unit Gas Pressure Min 2 1s
316XY05YP20H Shut Off Unit Gas Pressure Max 2 1s
316XY05XZ20 Shut off valve #1 Open 2 1s
316XY05XZ21 Shut off valve #1 Close 2 1s
316XY05XZ30 Shut off valve #2 Open 2 1s
316XY05XZ31 Shut off valve #2 Close 2 1s
316XY05XZ40 Igniter Fault 2 1s
316XY05XX10 Flame Fault 2 1s
316S06L01 Pre Heating of Kiln 3 1s
313AL01L01 Shock Blaster Sequencer Disabled 3 1s
316XY05L01 Kiln Burner in Local Mode 3 1s

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 111 of 204
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8.10 316.S07: Rotary Kiln

8.10.1 Sequence Flow Sheet

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Date : 11/02/2007
Chapter : 8 Page 112 of 204
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8.10.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
Kiln Barring
316ID01MT10 IND IND N Y Local Operation
Drive
Kiln Barring
316ID02MT10 IND IND N Y Local Operation
Drive
316DR01MT30 Cooling Fan 1 1 Y N Delayed Stoppage
316DR02MT30 Cooling Fan 1 1 Y N 30 min
Kiln Main
316DR01VS10 1 1 Y N
Motor
Kiln Main
316DR02VS10 1 1 Y N
Motor
316FA18MT10- Tyre cooling IND IND N N
316FA19MT10 fan
316FA02MT10- Kiln Shell IND IND N N
316FA17MT10 cooling fan

8.10.3 Analog Sensors Lists

Eng. Units Alarm Limits

Tag
Low High Unit LL L H HH
316ID01YI10 0 60 A 45 50
316ID02YI10 0 60 A 45 50
316DR01YV10 0 25 mm/sec 2 3
316DR01YI10 0 375 A 300 340
316DR01YJ10 0 355 KW 285 320
316DR01YT11 0 150 °C 5 10 70 80
316DR01YT12 0 150 °C 5 10 70 80
316DR01YT13 0 150 °C 5 10 70 80
316DR01YT20 0 150 °C 5 10 55 60
316DR01YT21 0 150 °C 5 10 55 60
316DR01YS10 0 100 % 75 85
316DR02YV10 0 25 mm/sec 2 3
316DR02YI10 0 375 A 300 340

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 113 of 204
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316DR02YJ10 0 355 KW 285 320

316DR02YT11 0 150 °C 5 10 70 80
316DR02YT12 0 150 °C 5 10 70 80
316DR02YT13 0 150 °C 5 10 70 80
316DR02YT20 0 150 °C 5 10 55 60
316DR02YT21 0 150 °C 5 10 55 60
316DR02YS10 0 100 % 75 85
316KI01YT10 0 800 °C 640 720
316VD01YT10 0 1500 °C 1200 1350
316KR01YT10 0 150 °C 120 130
316KR01YT11 0 150 °C 120 130
316KR02YT20 0 150 °C 120 130
316KR02YT21 0 150 °C 120 130
316KR03YT10 0 150 °C 120 130
316KR03YT11 0 150 °C 120 130
316KR04YT20 0 150 °C 120 130
316KR04YT21 0 150 °C 120 130

8.10.4 Operators Selections

P1 Selected – Kiln Barring with Main Motors by Operator
P2 Selected – Kiln Barring with Main Motors in pre-defined
sequence during initial Kiln start-up (New
Refractory Lining)
P3 Selected – Kiln Barring with Main Motors in pre-defined
sequence during Normal start-up of Cold Kiln
P4 Selected – Kiln Barring with Main Motors in pre-defined
sequence during Normal Kiln Cooling Process.
P5 Selected – Kiln continuous Barring with Main Motors
None of P1, P2, P3, P4, P5 Selected– Normal Kiln
Operation with Main Motors

Only one selection is permitted at any time.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 114 of 204
 Start/Stop (316FA02SY10 to 316FA17SY10) –
Button to Start / Stop the Kiln
Shell Cooling Fan
(316FA02MT10 –
316FA17MT10) by the CCR
Operator.
Start/Stop (316FA18SY10 to 316FA19SY10) –
Button to Start / Stop and Kiln
Tyre Cooling Fan
(316FA18MT10 –
316FA19MT10) by the CCR
Operator.
The Kiln Shell Cooling fan can be started / stopped
individually by the Operator

TITLE FUNCTIONAL SPECIFICATION

DOC NO SUR.860.L52 Rev No : C

Approved
K. S. Sokhi Project
LAFARGE SURMA CEMENT PLANT
Checked
T. Saha 3600 tpd Cement Plant, Bangladesh

Larsen & Toubro Limited

Approved
Senthil P. Resp. dept. INAT/ATPME OI No: ATPM-WB-3030
Checked
Kamlesh K.
Prepd
Ashutosh D Document 3BYN463030-FXA Rev No :
Identity
C

ABB Limited Page 115 of

Page No:
204
TEMPLATE: 3BSE012345 REV.B; FILENAME: 864257448.DOC; PRINTDATE: 7/29/2005 12:51:00 PM; SAVEDATE: 2/13/2007 08:41:00 AM SKELETON
3BYN200812E4006 REV ; OWNER: INAUT/AMME
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8.10.5 Operator Mode Description

Kiln Barring / Operation with Barring Motors

 If P1 is selected
Operator can rotate the kiln through Main Motors
at constant speed of 0.2 rpm.

 If P2 is selected
This mode of barring shall be selected by operator
for initial start-up of Kiln when the Refractory
Lining is new (drying-out refractory lining).

In this case the Kiln will be rotated at constant

speed of 0.2 rpm through main motors
automatically as per the sequence detailed below:

0 – 24h : Kiln rotation ~ 200 degrees

every 30 min.
24 – 64h : Kiln rotation ~ 200 degrees
every 15 min.
64 – 72h (or till deselected) : Continuous
rotation.

 If P3 is selected
This mode of barring shall be selected by operator
for normal start-up of cold kiln.

In this case the Kiln will be rotated at constant

speed of 0.2 rpm through main motors
automatically as per the sequence detailed below:

0 – 8h : Kiln rotation ~ 200 degrees

every 30 min.
8 – 16h : Kiln rotation ~ 200 degrees
every 15 min.
16 – 24h(or till deselected) : Continuous
rotation.

 If P4 is selected
This mode of barring shall be selected by operator
for Normal Cooling of Kiln.

In this case the Kiln will be rotated at constant

speed of 0.2 rpm through main motors
automatically as per the sequence detailed below:
0 – 1h :Continuous rotation
TITLE FUNCTIONAL SPECIFICATION
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Date : 11/02/2007
Chapter : 8 Page 116 of 204
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1 – 24h :Kiln rotation ~ 200 degrees

every 15 min.
24 – 48h :Kiln rotation ~ 200 degrees
every 30 min.
48+ :Kiln rotation ~ 200 degrees
every 30 min till shell
temperature < 40 °C

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 117 of 204
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 If P5 is selected

This mode of barring shall be selected by operator

for Continuous rotation of Kiln (e.g. Hot kiln is
subjected to cooling due to heavy rainfall). In this
case the Kiln will be rotated at constant speed of
0.2 rpm through main motors.

When Kiln barring is running with either of P2 /

P3 / P4 selection alarm by the thrust device
indicating that the kiln is not in the right position (>
+ 15mm), then the continuous barring program
(i.e. P5) will be automatically selected, till such
time the alarm from thrust device gets cancelled.
Once alarm gets cancelled the kiln barring
program previously selected will be continued
thereafter.

 If None of P1 / P2 / P3 / P4 /P5 is selected

Normal Kiln Operation through Main Motor. In this
case the kiln speed will change as per Operator’s
set-point / in relation to kiln feed rate (Refer
description under Sl. No. 8.10.9 for details).

Kiln Barring with Barring Motors

Kiln Barring motors (316ID01MT10 and

316ID02MT10) shall be started / stopped locally by
the Operator.
The barring device is mounted directly on the
planetary gear. It is provided with a brake, which is
capable of keeping the kiln fixed in any position
during shutdown. The barring device is an
automatic clutching device which activates of its own
and it need not have any operators intervention.
This is done by using an overrunning coupling
between the planetary gear and the barring gear
and a centrifugal brake on the barring motor shaft.

On running of the Main motor (barring / normal

operation) the barring motors will be declutched
automatically.

Start-up Details

 Start Cooling Fan 316DR01MT30 and

316DR02MT30 simultaneously and then Start Main
TITLE FUNCTIONAL SPECIFICATION
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Motor 316DR01VS10 and 316DR02VS10

simultaneously.

Shut-down details

 Stop Main Motor 316DR01VS10 and 316DR02VS10

simultaneously. Cooling Air Fan shall be stopped
after 30 min from stoppage of Main Motor

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 119 of 204
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8.10.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

316.S01 (Kiln Auxiliaries) Run  
317.S05 (Cooler Grate Drive) Run  If P1/P2/P3/P4/P5
not selected

Delayed Stoppage
after 5 min
317.S04 (Cooling air fans for  If P1/P2/P3/P4/P5
Grate-1) Run not selected
317.S06 (Cooling air fan for fixed  If P1/P2/P3/P4/P5
inlet) Run not selected
316.S06 (Kiln Burner) Run  If P1/P2/P3/P4/P5
not selected,
Kiln shall go to the
barring speed ie.,
0.2 rpm.
Not of 316TH01XZ10 (No High-   If P1/P2/P3/P4/P5
High Alarm for Kiln Position) not selected
Not of 316TH01XZ20 (No Low-   If P1/P2/P3/P4/P5
Low Alarm for Kiln Position) not selected
Kiln Position between –15mm to  If P1/P2/P3/P4/P5
+15 mm (Within 316TH01YZ10L & not selected
316TH01YZ10H)

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

TITLE FUNCTIONAL SPECIFICATION

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8.10.7 D/D Interlocks and Alarms

 316ID01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

316ID02MT10 Run  Delay 5 s

316DR01MT10 Not Run  
316DR02MT10 Not Run  

Alarms:

Description BP PE1 PE2 Remarks / Delays

316ID01YI10HH 

 316ID02MT10

Description DSI DPI DSQI DEI Remarks

316ID01MT10 Run  Delay 5 s

316DR01MT10 Not Run  
316DR02MT10 Not Run  

Alarms:

Description BP PE1 PE2 Remarks / Delays

316ID02YI10HH 

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 316DR01MT30

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 316DR02MT30

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 316DR01VS10

Interlocks:

Description DSI DPI DSQI DEI Remarks

316ID01MT10 Not Run 
AND
316ID02MT10 Not Run
316DR02VS10FT  Delay 5 s
316DR01YT40HH 
316DR02YT40HH 
316ID01MT10 Not Run  
316ID02MT10 Not Run  
316DR01MT30 Run  30 s

TITLE FUNCTIONAL SPECIFICATION

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Alarms:

Description BP PE1 PE2 Remarks / Delays

316DR01YT11HH  1s
316DR01YT12HH  1s
316DR01YT13HH  1s
316DR01YT20HH  1s
316DR01YT21HH  1s
316DR01YV10HH  1s
316DR01YI10HH  1s

 316DR02VS10

Interlocks:

Description DSI DPI DSQI DEI Remarks

316ID01MT10 Not Run 
AND
316ID02MT10 Not Run
316DR01VS10FT  Delay 5 s
316DR01YT40HH 
316DR02YT40HH 
316ID01MT10 Not Run  
316ID02MT10 Not Run  
316DR01MT40 Run  30 s

Alarms:

Description BP PE1 PE2 Remarks / Delays

316DR02YT11HH  1s
316DR02YT12HH  1s
316DR02YT13HH  1s
316DR02YT20HH  1s
316DR02YT21HH  1s
316DR02YV10HH  1s
316DR02YI10HH  1s

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Chapter : 8 Page 123 of 204
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 316FA18MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

316DR01VS10 Run  If P1, P2,

AND P3, P4 &
316DR02VS10 Run P5 not
selected
(316KR01YT10H OR 
316KR01YT11H)

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 316FA19MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

316DR01VS10 Run  If P1, P2,

AND P3, P4 &
316DR02VS10 Run P5 not
selected
(316KR02YT20H OR 
316KR02YT21H)

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

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 316FA02-17MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

316XY05EC10B1 AND 
316DR01VS10 Run  If P1, P2,
AND P3, P4 &
316DR02VS10 Run P5 not
selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 125 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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8.10.8 Process Protections:

Kiln main motor shall go to Barring speed (if
P1/P2/P3/P4 or P5 are not selected) with following
conditions:
 Stoppage of Kiln Burner
 Stoppage of Calciner Burner
 Stoppage of Kiln Feed
 Kiln Feed Starvation
 Stoppage of Cooler Grate -1 with delay
 Stoppage of Cooler Air Fan for Fixed Inlet
(CFI) with delay
 Support Bearing Temp. High High
 Kiln Position High High
 Kiln Position Low Low

Kiln shell cooling fan shall stop, when Kiln main

motor goes to Barring speed (if P1/P2/P3/P4 or P5
are not selected).

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 126 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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8.10.9 Regulation Loops

 Manual Set-point

Operator gives the speed set point for kiln rpm

 Automatic

The Kiln speed shall be regulated automatically in

accordance with the following relationship

Kiln Speed (rpm) = C * Kiln Feed Rate (tph)

Subject to minimum speed of 0.5 rpm and
maximum of 5 rpm.

Where C = 0.0142 (typically)

Kiln Feed Rate = Set Point value
given by operator

The above formula can be modified with Password

Protection. Only the authorized person shall be able to
change the formula.

 Forced mode

The Kiln Main motor will go to barring speed. Please

refer Process Protections for details.

The change over from Manual Mode to Automatic Mode

of Kiln speed PID shall be possible only when the
difference in the calculated Kiln speed and the kiln
speed in the manual mode is within +/- 0.2 rpm with a
warning message for operator action.

In case if Drive is selected in Local Mode the Field

operator shall be able to increase / decrease the speed
for the fan.

8.10.10 Cyclic and Special Functions

None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 127 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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8.10.11 Messages and Alarm

Tag Description Priority Delay

316ID01YI10H Barring Motor #1 Current High 2 1s

316ID02YI10H Barring Motor #2 Current High 2 1s
316DR01YV10H Kiln Main Motor #1 Vibration High 2 1s
316DR01YI10H Kiln Main Motor #1 Current High 2 1s
316DR01YJ10H Kiln Main Motor #1 Power High 2 1s
Kiln Main Motor #1 Power High-
316DR01YJ10HH 2 1s
High
Kiln Main Motor #1 Winding #1
316DR01YT11H 2 1s
Temperature High
Kiln Main Motor #1 Winding #2
316DR01YT12H 2 1s
Temperature High
Kiln Main Motor #1 Winding #3
316DR01YT13H 2 1s
Temperature High
Kiln Main Motor #1 Bearing DE
316DR01YT20H 2 1s
Temperature High
Kiln Main Motor #1 Bearing NDE
316DR01YT21H 2 1s
Temperature High
316DR01YS10H Kiln Main Motor #1 Speed High 2 1s
316DR02YV10H Kiln Main Motor #2 Vibration High 2 1s
316DR02YI10H Kiln Main Motor #2 Current High 2 1s
316DR02YJ10H Kiln Main Motor #2 Power High 2 1s
Kiln Main Motor #2 Power High-
316DR02YJ10HH 2 1s
High
Kiln Main Motor #2 Winding #1
316DR02YT11H 2 1s
Temperature High
Kiln Main Motor #2 Winding #2
316DR02YT12H 2 1s
Temperature High
Kiln Main Motor #2 Winding #3
316DR02YT13H 2 1s
Temperature High

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 128 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

Kiln Main Motor #2 Bearing DE

316DR02YT20H 2 1s
Temperature High
Kiln Main Motor #2 Bearing NDE
316DR02YT21H 2 1s
Temperature High
316DR02YS10H Kiln Main Motor #1 Speed High 2 1s
316KI01YT10H Kiln Shell Temperature High 2 1s
316VD01YT10H Burning Field Temperature High 2 1s
Kiln Barring with Main Motors by 1s
316S07L01 3
Operator
316S07L02 Kiln Barring with Main Motors in 1s
pre-defined sequence during initial
3
Kiln start-up (New Refractory
Lining)
316S07L03 Kiln Barring with Main Motors in 1s
pre-defined sequence during 3
Normal start-up of Cold Kiln
316S07L04 Kiln Barring with Main Motors in 1s
pre-defined sequence during 3
Normal Kiln Cooling Process
316S07L05 Kiln continuous Barring with Main 1s
3
Motors
Difference Between Kiln Speed in 1s
2
Manual Mode and Auto Mode

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 129 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.11 314.S08: GCT Water Injection System

8.11.1 Sequence Flow Sheet

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 130 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.11.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
Water If P1 not
314AW01MT10 Injection 1 1 Y N Selected
Pump #1 (Main)
Water If P1 Selected
314AW01MT20 Injection 1 1 Y N (Standby)
Pump #2

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 131 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.11.3 Analog Sensors Lists

Tag Eng. Units Alarm Limits

Low High Unit LL L H HH

314TC01YT20 0 500 Deg.C 140
314TC01YT30 0 500 Deg.C 140
314TC01YP20 -200 0 mmWG -100 -50
314AW01YF10 0 65 m3/hr 52 58
314AW01YF10 0 65 m3/hr 52 58
314AW01YZ10 0 100 % 80 90
314AW01YP10 0 40 Bar 7 14 35 38
314AW01YI10 0 200 A 160 180
314AW01YT11 0 150 Deg.C 100 110
314AW01YT12 0 150 Deg.C 100 110
314AW01YT13 0 150 Deg.C 100 110
314AW01YI20 0 200 A 160 180
314AW01YT41 0 150 Deg.C 70 80
314AW01YT42 0 150 Deg.C 70 80
314AW01YT43 0 150 Deg.C 70 80
314TC01YT70 0 500 Deg C 80 100

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 132 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.11.4 Operation Selection

P1 not Selected – to start the Main Pump
314AW01MT10
P1 Selected – to start the Stand-by Pump
314AW01MT20

8.11.5 Operation Mode Description

Start-up Details

 Start the Selected Water Pump 314AW01MT10 or

314AW01MT20

Shut-down details

 Stop the Selected Water Pump 314AW01MT10 or

314AW01MT20

There is automatic switch from one pump to another

based on 314AW01YP10.

8.11.6 Sequence Interlocks and Alarms

Interlocks:
Description SSI SPI Remarks
Not of 314AW01XL20 
(Level in water tank not low)
Not of 314AW01XL21 
Level in water tank not low-low

Return water valve 314AW01YZ10 

>75% (i.e. fully open)
313S05 (Pre-heater ID Fan) Running  
Screw conveyor 314SC01 is running  
Not of U828GN01EC10B1 in Auto  
mode

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 133 of 204
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TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 134 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.11.7 D/D Interlocks and Alarms

 314AW01MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

GCT Outlet Temp. (Avg
of 314TC01YT20 &
314TC01YT30) > Low (L)
If P1 is not
AND 
Selected
GCT outlet material
Temp. (314TC01YT70) >
Low (L)
If P1 is not
314AW01MT20 Not Run 
Selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

314AW01YT11HH  1s
314AW01YT12HH  1s
314AW01YT13HH  1s
314AW01YI10HH  15s
(20s ) If P1 not
314AW01YP10LL 
selected

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 135 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

 314AW01MT20

Interlocks:

Description DSI DPI DCR DEI Remarks

GCT Outlet Temp. (Avg
of 314TC01YT20 &
314TC01YT30) > Low (L)
If P1 is
AND 
Selected
GCT outlet material
Temp. (314TC01YT70) >
Low (L)
If P1 is
314AW01MT10 Not Run 
Selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

314AW01YT41HH  1s
314AW01YT42HH  1s
314AW01YT43HH  1s
314AW01YI20HH  15s
(20s ) If P1
314AW01YP10LL 
selected

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 136 of 204
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8.11.8 Process Protections:

 GCT Outlet Temp. (314TC01YT20 & 314TC01YT30)
> Low (L)
 GCT Outlet Material Temp. > Low (L)
 314 S02 (GCT – ESP Dust Transport System)
running
 313 S02 (Pre-heater ID Fan) running

8.11.9 Regulation Loops

 GCT outlet Temperature 314TC01YY10 (average

of 314TC01YT20 & 314TC01YT30 ) control with
Water Valve Position 314AW01YZ10

Controlled Measurement : 314TC01YY10

(average of
314TC01YT20 &
314TC01YT30)

D/D Controlled : Water valve position

314AW01YZ10

Manual Mode : Operator

manipulates the
Water valve position
314AW01YZ10 from
the PID faceplate in
manual mode.

Automatic Mode : Average of

314TC01YT20 &
314TC01YT30 will
be controlled by the
manipulation of the
Water valve position
314AW01YZ10
from the PID
Controller. Operator
will give set point for
the GCT outlet
Temperature.

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 137 of 204
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8.11.10 Cyclic and Special Functions

8.11.10.1 Gas Conditioning Tower Control System

System Description:

The GCT System consists of the following:

Mechanics/ Subsystem:

- A water tank from which the water is injected

for GCT outlet temperature control.
- Water pumps (one working + one standby).
- Spillback nozzle for water injection
- Motorised control valve in return line

The water tank is equipped with a solenoid valve

for auto filling of tank based on level in tank.

Electrics/ Sub control System:

- A PCS based sub control system, consisting:

o Control Logic and operation for Control
Valve implemented in the PCS.
- Electrics viz, Motors for the Pumps & the
Starter Circuits in Plant MCC.
- Control and operation of Motor for the pumps
realised in PCS.
- Field Sensors & Actuators, as required for the
Operation of system.

Operation:

The GCT system’s main function is to maintain

outlet temperature of GCT for safeguarding ESP
inlet temperature.

Operation of the GCT Water Injection Valve

314AW01AC10

Regulating Control Valve provided in the return

water line is controlling GCT outlet temperature.
Set point for Control valve can be given from PCS.

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 138 of 204
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Flow meters are provided in supply and return line

of water.
Temperature sensor (RTD) at GCT bottom is
envisaged for material build up at GCT bottom.

Flow sheet:

An Instrument Flow sheet for the GCT system is

depicted as herewith.

Lafarge code for “Spillback nozzle gas cooling

tower for GCT” is 314L61.

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Date : 11/02/2007
Chapter : 8 Page 139 of 204
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TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 140 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.11.11 Messages and Alarm

Tag Description Priority Delay

314TC01YT20H GCT Outlet Temperature #1 High 2 1s
314TC01YT30H GCT Outlet Temperature #2 High 2 1s
314TC01YP20H GCT Outlet Pressure High 2 1s
314AW01YF10H GCT Water Injection Flow High 2 1s
314AW01YP10H GCT Water Injection Pressure High 2 1s
314AW01YI10H GCT Water Injection Pump # 1
2 1s
Current High
314AW01YT11H GCT Water Injection Pump # 1 Motor
2 1s
Winding Temperature #1 High
314AW01YT12H GCT Water Injection Pump # 1 Motor
2 1s
Winding Temperature #2 High
314AW01YT13H GCT Water Injection Pump # 1 Motor
2 1s
Winding Temperature #3 High
314AW01YI20H GCT Water Injection Pump # 2
2 1s
Current High
314AW01YT41H GCT Water Injection Pump # 2 Motor
2 1s
Winding Temperature #1 High
314AW01YT42H GCT Water Injection Pump # 2 Motor
2 1s
Winding Temperature #2 High
314AW01YT43H GCT Water Injection Pump # 2 Motor
2 1s
Winding Temperature #3 High
314AW01L01 Stand-by Pump 314AW01MT20
3 1s
selected
314AW01XL10 GCT Water Tank Level High 2 1s
314AW01XL11 GCT Water Tank Level High High 2 1s
314TC01YT70L GCT material Outlet Temp Low 2 1s
314TC01YT70LL GCT material Outlet Temp Low Low 2 1s

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 141 of 204
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8.12 312.S09: Feed to Kiln

8.12.1 Sequence Flow Sheet

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 142 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 143 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.12.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
312RA03MT10 Air Sluice 1 15 Y Y Automatically
start in case of
Power Failure
with Emergency
Power
Default position
Pneumatic open towards
312VV06VA10 2 14 Y N
Gate 311SO01.
Opens towards
Pneumatic 312RA03 during
312VV06VA20 2 14 Y N
Gate sequence start.
312FA08MT10 Fluxoslide 3 13 Y N
Fan
312FA04MT10 Fluxoslide 3 13 Y N
Fan
312FA06MT10 Filter Fan 4 12 N N
312RA04MT10 Air Sluice 4 12 N N
312DC03EC10 Dust 5 11 N N
Collector
Sequencer
312BE01MT20 Bucket IND IND N N Local Operation
Elevator (only for
Barring maintenance
purpose)
312BE01MT10 Bucket 4 12 Y N
Elevator
312SA01MT10 Auto Sampler 4 12 N N Delayed
stoppage after
the preset time
(1 Hr) from last
sample
collection (in
case of Bucket
Elevator
stoppage).

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 144 of 204
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Tag Description Start Stop Essential Emergency Remarks

step step drive Power
312VV05VA10 Pneumatic 5 11 Y N If P1 not
Gate selected
312VV05VA20 Pneumatic 5 11 Y N Default Position
Gate open to
312SA01.
312FA07MT10 Fluxoslide 6 10 Y N
Fan
312FA02MT10 Fluxoslide 6 10 Y N
Fan
312SM01EC10 KF Metering 7 9 Y N
System
312FA03MT10 Filter Fan 7 9 N N
312RA02MT10 Air Sluice 7 9 N N
312DC02EC10 Dust 8 8 N N
Collector
Sequencer
312VV04VA10 Pneumatic 9 7 Y N Default Position
Gate open to
312VV04VA20 Pneumatic 9 7 Y N 312SM01
Gate If P2 not
selected
312HD01EC10 Air Dryer for 10 6 N N
Aeration
Blower
312AB01 /
312AB02
312AB01MT10 Kin Feed Bin 10 6 Y N If P4 not
Aeration selected
Blower

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 145 of 204
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Tag Description Start Stop Essential Emergency Remarks

step step drive Power
312AB02MT10 Kin Feed Bin 10 6 Y N Stand By for
Aeration 312AB01 (if P3
Blower selected)
15 1 Y N Stand By for any
one of 311AB01-
03 (if P4
selected)
312FA01MT10 Filter Fan 11 5 N N
312RA01MT10 Air Sluice 11 5 N N
312DC01EC10 Dust 12 4 N N
Collector
Sequencer
311VV03VA10 Pneumatic 13 3 Y N Default position
Gate open.
If P7 selected
close during
sequence start
311VV04VA10 Pneumatic 13 3 Y N Default position
Gate open.
If P7 not
selected close
during sequence
start
311FA01MT10 Fan 14 2 Y N If P7 not
Selected
311FA02MT10 Fan 14 2 Y N If P7 Selected
311HD01EC10 Air Dryer for 15 1 N N
Aeration
Blower
311AB01
311AB01MT10 Aeration 15 1 Y N
Blower
311HD02EC10 Air Dryer for 15 1 N N
Aeration
Blower
311AB02
311AB02MT10 Aeration 15 1 Y N
Blower

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 146 of 204
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Tag Description Start Stop Essential Emergency Remarks

step step drive Power
311HD03EC10 Air Dryer for 15 1 N N
Aeration
Blower
311AB03
311AB03MT10 Aeration 15 1 Y N
Blower
311VV02 CF Silo 15 1 Y N Default position
Extraction closed.
Sequencer For detail
Operation refer

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 147 of 204
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8.12.3 Analog Sensors Lists

Tag Eng. Units Alarm Limits

Low High Unit LL L H HH
312BE01YJ10 0 160 kW 120 130
312SM01YF10 0 350 tph 20 300 320
312SM01YZ10 0 100 %
312AB01YI10 0 75 A 55 60
312AB02YI10 0 75 A 55 60
312LX01YW10 0 85 Tons 50 60 65 70
311SO01YL10 35 0 mtr 32 28 5 2

* Alarms limit will be confirmed at the time of

commissioning.

8.12.4 Operators Selections

P1 Selected – Pneumatic Gate 312VV05VA10 &
312VV05VA20 open for Truck
Loading
P2 Selected – Pneumatic Gate 312VV04VA10
for bypassing Kiln feed metering
system (for the maintenance
purpose) .
P3 Selected – Aeration Blower 312AB02 as Kiln
feed bin Aeration Blower.
P4 Selected – Aeration Blower 312AB02 as Silo
Aeration Blower.
P5 Selected – Silo to Silo material re-circulation.
P7 not Selected – Start the Main Air Slide Fan
311FA01
P7 Selected – Start the Stand-by Air Slide Fan
311FA02
P8 Selected – Local Permission for Control Box
–1 for operating the A & B flaps
P9 Selected – Local Permission for Control Box
–2 for operating the C & G flaps
P10 Selected – Local Permission for Control Box
–3 for operating the D, E & F
flaps

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 148 of 204
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TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 149 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
WITHOUT WRITTEN AUTHORITY IS STRICTLY FORBIDDEN. CONTRAVENTION WILL BE PROSECUTED. ABB LIMITED

8.12.5 Operation Mode Description

P1 Selection:

The P1 selection will be enabled only if “Truck in

position – 312VV05SY10” feedback is available.
If P1 is selected and operator gives start command
the 312VV05 will open towards Truck Loading.

If the Sequence is running and P1 is selected all

the D/D before 312VV05 (i.e. 312RA03MT10,
312FA08MT10, 312FA04MT10, 312FA06MT10,
312RA04MT10, 312DC03EC10, 312BE01MT10,
312SM01MT10) will continue to run if P1 selection
remain ON for less then 10 minutes. If selection
remains on for more then 10 Minutes above D/D
shall stop automatically. (Time to be confirmed
during commissioning)..

If the Sequence is not running and P1 is selected,

the operator will issue the start command and the
D/D before 312VV05 will start. (All the D/D
mentioned in Start step 5 to 14 will start in
sequence)

Selection of P1 and start command by operator

shall automatically change the position of
312VV06 to default position. (So that the Pre-
Heater ID Fan comes to the minimum speed, there
by avoiding the higher Pre-heater outlet
temperature).

P2 Selection:

If P2 is selected and operator gives start command

the 312VV04 will open towards 312AS01
bypassing the Kiln Feed Metering System
312SM01.

Only on selection of P2, the Pneumatic gate

312VV02 operation will be controlled by the
operator set point.

P3 Selection:

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 150 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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In case of failure of Kiln Feed Aeration Blower

312AB01, the operator can use 312AB02 as Kiln
Feed Aeration Blower by selecting P3. Before
starting of 312AB02 Operator shall adjust the
respective butter fly valves (same will be
confirmed by the PCS with the help of proximity
switches) such that 312AB02 air goes to Kiln Feed
bin.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 151 of 204
WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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P4 Selection:

In case of failure of any one of Silo Aeration

Blowers 311AB01, 311AB02 and 311AB03, the
operator can use 312AB02 as Silo Aeration
Blowers (alternative to failed blower) by selecting
P4. Before starting of 312AB02 Operator shall
adjust the respective butter fly valves (same will be
confirmed by the PCS with the help of proximity
switches) such that 312AB02 air goes via the path
of failed Silo Aeration Blower.

P5 Selection:

If P5 is selected and operator gives start command

the material will be re-circulated from Silo to Silo.
With P5 selection 312RA03 will not be considered
as a consumer of this sequence and all start and
permanent interlock at sequence level except Silo
Top JPF 218S01 will not be applicable.
If sequence is running with P5 selection,
deselecting P5 and sequence start command by
the operator shall start 312RA03 and on running of
312RA03, 312VV06 will change towards RA03. If
this doesn’t happen in 30 sec the sequence will
trip (312FA08 will trip).

For description for P6 and P7 selection refer Sl.

No8.12.10.3.

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 152 of 204
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Start-up details:

 Start Air Sluice 312RA03MT10

 Open Pneumatic Gate 312VV06VA10 &
312VV06VA20 towards 312RA03.
 Start Fluxoslide Fan 312FA08MT10 and
312FA04MT10
 Start Filter Fan 312FA06MT10 and Air Sluice
312RA04MT10. Start Bucket Elevator 312BE01MT10.
Start Auto Sampler 312SA01MT10.
 Start Dust Collector Sequencer 312DC03EC10. Open
Pneumatic Gate 312VV05VA10 & 312VV05VA20
towards 312SA01.
 Start Fluxoslide Fan 312FA07MT10 and
312FA02MT10
 Start KF Metering System 312SM01EC10. Start Filter
Fan 312FA03MT10 and Air Sluice 312RA02MT10. If
P2 not selected.
 Start Dust Collector Sequencer 312DC02EC10.
 If P2 not selected Open Pneumatic Gate
312VV04VA10 and 312VV04VA20 towards 312SM01
 Start Air Dryer 312HD01EC10 and Kiln Feed Bin
Aeration Blower 312AB01MT10. Start Stand-By
Blower 312AB02MT10 in case of failure of Kiln Feed
Bin Aeration Blower 312AB01MT10.
 Start Filter Fan 312FA01MT10 and Air Sluice
312RA01MT10.
 Start Dust Collector Sequencer 312DC01EC10.
 Open Pneumatic Gate 311VV03VA10 or
311VV04VA10 based on P7 selection.
 Start Fan 311FA01MT10 or 311FA01MT10 based on
P7 selection.
 Start Air Dryer 311HD01EC10, Aeration Blower
311AB01MT10, Air Dryer 311HD02EC10, Aeration
Blower 311AB02MT10, Air Dryer 311HD03EC10,
Aeration Blower 311AB03MT10. Start CF Silo
Extraction Sequencer 311VV02. In case of failure of
any one of the Aeration Blower 311AB01MT10,
311AB02MT10, 311AB03MT10 start Stand By Blower
312AB02MT10.

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 153 of 204
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Shut-down details:

 Stop Air Dryer 311HD01EC10, Aeration Blower

311AB01MT10, Air Dryer 311HD02EC10, Aeration
Blower 311AB02MT10, Air Dryer 311HD03EC10,
Aeration Blower 311AB03MT10. Stop CF Silo
Extraction Sequencer 311VV02. In case if
312AB02MT10 was running as Standby to any one of
the Aeration Blower 311AB01MT10, 311AB02MT10,
311AB03MT10 Stop Stand By Blower 312AB02MT10.
 Stop Fan 311FA01MT10 or 311FA01MT10 whichever
was running based on P7 selection.
 Stop Dust Collector Sequencer 312DC01EC10.
 Stop Filter Fan 312FA01MT10 and Air Sluice
312RA01MT10.
 Stop Air Dryer 312HD01EC10 and Kiln Feed Bin
Aeration Blower 312AB01MT10. Stop Stand-By
Blower 312AB02MT10 in case if it was running as
Stand by for Kiln Feed Bin Aeration Blower
312AB01MT10.
 Stop Dust Collector Sequencer 312DC02EC10.
 Stop KF Metering System 312SM01EC10. Stop Filter
Fan 312FA03MT10 and Air Sluice 312RA02MT10.
 Stop Fluxoslide Fan 312FA07MT10 and
312FA02MT10
 Stop Dust Collector Sequencer 312DC03EC10.
 Stop Filter Fan 312FA06MT10 and Air Sluice
312RA04MT10. Stop Bucket Elevator 312BE01MT10.
Stop Auto Sampler 312SA01MT10.
 Stop Fluxoslide Fan 312FA08MT10 and
312FA04MT10
 Stop Air Sluice 312RA03MT10

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Date : 11/02/2007
Chapter : 8 Page 154 of 204
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8.12.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

218.S01 (Silo Top JPF) Running   Delay 30
min
(316DR01YS10  If P1 or P5
AND not
316DR02YS10) selected
> 0.2 RPM (to be confirmed during
Commissioning)

316S06 (Kiln Burner) Running  If P1 or P5

not
selected
312VV06
will open
towards
silo in
case of
316.S06
Not Run

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

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LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 155 of 204
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8.12.7 D/D Interlocks and Alarms

 312RA03MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:
Description BP PE1 PE2 Remarks / Delays

312RA03XS10 

 312VV06VA10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Rotary Air Lock  On stoppage

312RA03 in operation of 312RA03,
the 312VV06
will
automatically
go to default
position i.e.
open for
material re-
circulation
Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

312VV06XZ10  1s
312VV06XZ11  1 s (Default Pos.)

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Date : 11/02/2007
Chapter : 8 Page 156 of 204
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 312VV06VA20

Interlocks:

Description DSI DPI DSQI DEI Remarks

Rotary Air Lock  On stoppage

312RA03 in operation of 312RA03,
the 312VV06
will
automatically
go to default
position i.e.
open for
material re-
circulation

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

312VV06XZ20  1 s (Default Pos)
312VV06XZ21  1s

 312FA08MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

(312VV06XZ10
AND
If P5 not
312VV06XZ21) 
selected
AND
312RA03MT10 Run
312VV06VA10F3
AND 
312VV06VA20F3
(312VV06XZ11
If P5
AND 
selected
312VV06XZ20)

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LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 157 of 204
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Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 312FA04MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312FA08MT10 Run  Delay 5 s

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 312FA06MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312FA08MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

Continuous for 30
312DC03XP20 
min

 312RA04MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Delayed
312FA06MT10 Run  Stoppage
2 min

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 158 of 204
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Alarms:

Description BP PE1 PE2 Remarks / Delays

312RA04XS10  5s

 312DC03EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote
312DC03EC10SL  
Selected
Delay 30
312RA04MT10 Run 
min
312DC03XP10 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 312BE01MT20

Interlocks:

Description DSI DPI DSQI DEI Remarks

312BE01MT10 Not Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 159 of 204
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 312BE01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312FA04MT10 Run 
312BE01MT20 not Run 
Barring
312BE01XZ20  Disengage
d

Alarms:

Description BP PE1 PE2 Remarks / Delays

312BE01XS10  5s
312BE01XZ10  210s
312BE01XZ11  210s
312BE01YT11HH  1s
312BE01YT12HH  1s
312BE01YT13HH  1s

 312SA01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312BE01MT10 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

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Chapter : 8 Page 160 of 204
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 312VV05VA10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

312VV05XZ10  1 s (Default Pos)

312VV05XZ11  1s

 312VV05VA20

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

312VV05XZ20  1s
312VV05XZ21  1 s (Default Pos)

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 161 of 204
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 312FA07MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

If P1 not
312BE01MT10 Run 
selected
If P1 not
312BE01XL10 
selected
If P1 not
selected,
312VV05XZ10 &
 Switch
312VV05XZ21
over delay
20 sec
If P1
selected,
312VV05XZ11 &
 Switch
312VV05XZ20
over delay
20 sec

Alarms:

Description BP PE1 PE2 Remarks / Delays

312BE01XZ10 70 s
312BE01XZ11 70 s

 312FA02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312FA07MT10 Run  Delay 5 s

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
Date : 11/02/2007
Chapter : 8 Page 162 of 204
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 312SM01EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

If P2 not
312FA02MT10 Run 
selected
312SM01EC10SL 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 312FA03MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312FA02MT10 Run 

Alarms:

Description BP PE1 PE2 Remarks / Delays

Continuous for 30
312DC02XP20 
min

 312RA02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Delayed
312FA03MT10 Run  Stoppage
2 min

Alarms:

Description BP PE1 PE2 Remarks / Delays

312RA02XS10  5s

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 163 of 204
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 312DC02EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote
312DC02EC10SL  
Selected
Delay 30
312RA02MT10 Run 
min
312DC02XP10 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 312VV04VA10

Interlocks:

Description DSI DPI DSQI DEI Remarks

If P2
Selected.
On
stoppage
of
312FA02MT10 Run 
312FA02,
the gate
will go to
default
position

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

312VV04XZ10  1 s (Default pos)

312VV04XZ11  1s

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 164 of 204
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 312VV04VA20

Interlocks:

Description DSI DPI DSQI DEI Remarks

If P2
Selected.
On
stoppage
of
312FA02MT10 Run 
312FA02,
the gate
will go to
default
position

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

312VV04XZ20  1 s (Default pos)

312VV04XZ21  1s

 312HD01EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote
312HD01EC10SL  
Selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
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Chapter : 8 Page 165 of 204
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 312AB01MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

312FA02MT10 Run 
If P3
312AB02MT10 Not Run 
selected
312AB02XZ11 (Close)  
P4 not selected  

Alarms:

Description BP PE1 PE2 Remarks / Delays

312AB01XS10  5s
312AB01YI10HH  1s

TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 166 of 204
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 312AB02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312FA02MT10 Run 
312AB02XZ21 (Close)  
If P3 selected
312AB02XZ10 (Open)  
312AB01MT10 Not Run  
Not of 312AB02XZ11
 
(Close)
If P4 selected
Not of 312AB02XZ20
 
(Open)
312AB02XZ30 (Open)  
If P4
312AB02XZ41 (Close)   selected,
312AB02XZ51 (Close)   standby for
311AB01
311AB01MT10 Not Run  
312AB02XZ31 (Close)  
If P4
312AB02XZ40 (Open)   selected,
312AB02XZ51 (Close)   standby for
311AB02
311AB02MT10 Not Run  
312AB02XZ31 (Close)  
If P4
312AB02XZ41 (Close)   selected,
312AB02XZ50 (Open)   standby for
311AB03
311AB03MT10 Not Run  

Alarms:

Description BP PE1 PE2 Remarks / Delays

312AB02XS10  5s
312AB02YI10HH  1s

TITLE FUNCTIONAL SPECIFICATION

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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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 312FA01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

312AB01MT10 Run
OR

312AB02MT10 Run ( If
P3 selected)

Alarms:

Description BP PE1 PE2 Remarks / Delays

Continuous for 30
312DC01XP20 
min

 312RA01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Delayed
312FA01MT10 Run  Stoppage
2 min

Alarms:

Description BP PE1 PE2 Remarks / Delays

312RA01XS10  5s

TITLE FUNCTIONAL SPECIFICATION

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WE RESERVE ALL RIGHTS IN THIS DOCUMENT AND IN THE INFORMATION CONTAINED THERIN. REPRODUCTION, USE FOR UNAUTHORISED PURPOSES OR DISCLOSURE TO THIRD PARTY
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 312DC01EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote
312DC01EC10SL  
selected
Delay 30
312RA01MT10 Run 
min
312DC01XP10 

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 311VV03VA10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

311VV03XZ10  1s
312VV03XZ11  1s

 311VV04VA10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

TITLE FUNCTIONAL SPECIFICATION

LAFARGE SURMA CEMENT DOC NO SUR.860.L52 Rev No: E
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Alarms:

Description BP1 & BP2 PE1 PE2 Remarks / Delays

311VV04XZ10  1s
312VV04XZ11  1s

 311FA01MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

311FA02MT10 Not Run 
311VV04XZ10   Switch
over delay
311VV03XZ11   20 sec

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 311FA02MT10

Interlocks:

Description DSI DPI DCR DEI Remarks

311FA01MT10 Not Run 
311VV03XZ10   Switch
over delay
311VV04XZ11   20 sec

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

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 311HD01EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

311HD01EC10SL   Remote Selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 311AB01MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

311AB01XS10  5s

 311HD02EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

311HD02EC10SL   Remote Selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

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 311AB02MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

311AB02XS10  5s

 311HD03EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

Remote
311HD03EC10SL  
Selected

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 311AB03MT10

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

311AB03XS10  5s

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 311VV02 (set of 7 pneumatic flaps A to G)

Interlocks:

Description DSI DPI DCR DEI Remarks

311FA01MT10 Run
OR  Delay 20s
311FA02MT10 Run
311LX01YW10 > L
AND 
312LX01YW10 < H
312LX01YW10 < HH
AND 
of 312HO01XL10

Alarms:

Description BP1 & PE1 PE2 Remarks / Delays

BP2
311VV02XZ10  1s 311VV02VA10
 1s (Flap A)
311VV02XZ11
311VV02XZ20  1s 311VV02VA20
 1s (Flap B)
311VV02XZ21
311VV02XZ30  1s 311VV02VA30
 1s (Flap C)
311VV02XZ31
311VV02XZ40  1s 311VV02VA40
 1s (Flap D)
311VV02XZ41
311VV02XZ50  1s 311VV02VA50
 1s (Flap E)
311VV02XZ51
311VV02XZ60  1s 311VV02VA60
 1s (Flap F)
311VV02XZ61
311VV02XZ70  1s 311VV02VA70
 1s (Flap G)
311VV02XZ71

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8.12.8 Process Protections

Feed will go to recirculation mode in following
conditions:
 Stoppage of Kiln Main Motor
 Kin Main Motor forced from operating speed
to barring speed

8.12.9 Regulation Loops

 Feed Rate control by manipulation of 312VV02

Controlled Measurement :Not Applicable

D/D Controlled :Pneumatic Gate

312VV02

Manual Mode :Operator manipulates

the Pneumatic Gate
position to vary the
Kiln Feed Rate.

Automatic Mode :Not Applicable.

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8.12.10 Cyclic and Special Functions

8.12.10.1 Auto Sampler

The collection of sample from the mixing tank of

Auto sampler is manual activity. After collecting
the sample the Sample Boy will empty out the
mixing tank with the help of release valve.
Activation of release valve will open bottom valve
of the mixing tank pneumatically to empty out the
mixing chamber to Raw Meal Transport path. The
operation of bottom valve will activate the REED
Switch, which will be registered as sample
collected (312SA01XX10) in the PCS.

Once the REED Switch is activated a timer will

start and after 1 Hr. It will generate a message
“Time for Sample collection” (312SA01XX20) in
the PCS.

The Auto sampler is provided with the facility to

transfer the excess material (Overflow) from
mixing tank to Raw Meal transport path. The
material overflow condition will arise in case the
sample is not collected at regular intervals.

If the Auto Sampler is in Local Mode it can be

started and stopped by operator discretion.

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8.12.10.2 Kiln Feed Consumption Totalisation:

When 312VV06 is open towards 312RA03, the

totaliser will accumulate Kiln Feed rate actual
value and display as “Kiln Feed Consumption” for
TODAY (as of time) and PREVIOUS DAY. The
clinker production shall be calculated based on
Kiln feed consumption by dividing “Kiln feed to
Clinker” conversion factor.

When kiln is running with Kiln Feed Metering

System Bypassed, the Kiln Feed Consumption /
Clinker Production for the period to be calculated
manually based on the Kiln Feed rate before
bypassing the Metering system and after the
Metering system are taken back in line. This
calculated value will be entered into the system by
Authorised Person and the same will be added to
the previous value.

8.12.10.3 311FA01 / 311FA02 Auto Change over:

If P7 not selected and Stop command is given to

sequence, 311VV03 will remain open (default
position), 311VV04 will be closed and Air Slide
Fan 311FA01 will Stop.

If P7 selected and Stop command is given to

sequence, 311VV04 will remain open (default
position), 311VV03 will be closed and Air Slide
Fan 311FA02 will Stop.

If sequence is running with P7 not selected,

stoppage / failure of Air Slide Fan 311FA01 will
automatically toggle the P7 selection provided
311FA02 was not running for past 10 min. During
this change over the respective gates will reverse
its position and the fan 311FA02 will Stop
Automatically. This changeover will not affect the
sequence running. If Fan 311FA02 was running for
past 10 min.(Adjustable) then the switchover will
not take place.

If sequence is running with P7 selected,

stoppage / failure of Air Slide Fan 311FA02 will
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automatically toggle the P7 selection provided

311FA01 was not running for past 10 min. During
this change over the respective gates will reverse
its position and the fan 311FA01 will Stop
Automatically. This changeover will not affect the
sequence running. If Fan 311FA01 was running for
past 10 min.(Adjustable) then the switchover will
not take place.

If Auto changeover is not taken place Silo

Extraction Sequencer will stop.

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8.12.10.4 CF Silo Extraction System

System Description :

The CF Silo extraction system consists of the

following :

Mechanics /Subsystem :

- 7 no. identical hexagonal sectors each

having an extraction outlet at the centre.
- 6 no of triangular segments per hexagonal
sector for aeration (311VV02VA11-16,
311VV02VA21-26, 311VV02VA31-36,
311VV02VA41-46, 311VV02VA51-56,
311VV02VA61-66, 311VV02VA71-76)
- 7 Air Solenoid (311VV02VA17,
311VV02VA27, 311VV02VA37,
311VV02VA47, 311VV02VA57,
311VV02VA67 and 311VV02VA77)
- 3 no of dedicated blowers for supplying air
to the aeration segments through (7X6) =
42 solenoid valves
- 1 no. of stand by blower for the above three
which is also a standby motor for the Kiln
Feed Aeration
- 7 flap Valves A,B, C,G, D,E,F, at the
extraction outlet by which material is
extracted and conveyed to the Air Slides
(311VV02VA10, 311VV02VA20,
311VV02VA30, 311VV02VA40,
311VV02VA50, 311VV02VA60,
311VV02VA70)
- A set of Air slides that transport feed
material to the Feed Bin below the silo.

Electrics/ Sub Control System:

- Timer based Sub Control function

implemented in the PCS , which controls
the operation of the Flap Gates
(AB,CG,DEF) and the Aeration solenoids.
- 3 no. of Local Control Boxes in the following
configuration
Box-1 : Flaps A,B
Box-2 : Flaps C,G

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Box-3 : Flaps D,E,F

to enable local operation of a Flap Group
(say (A/B) or (C/G) or (D/E/F), in each
case , solenoid by solenoid.

Operation :

The CF Silo Extraction system’s main function is

to homogenize the material inside silo through
segment aeration under a Flap Sector.
The homogenisation is achieved by triggering a
set of solenoid valves under different flaps for a
predefined time. as depicted in the below
mentioned timing diagram.

There are two modes of operation of the aeration

sector flap gates and aeration segment solenoid
valves.

PCS Mode : Mode for remote Auto operation

based on the Feed
Bin Level.
The extraction sequence will start
when the Bin Weight
312LX01YW10 is < 60 Tons and
stops when the Bin weight is > 65
Tons.
If the aeration stops due to Bin
Level High, the sequence will start
once again when the level falls
below the low level from the point
where it stopped.
In case of power resumptions also
the sequence shall start from the
last

LCB Mode: Mode for local operation from the

LCB for
maintenance of the Flap sector and
aeration
segment solenoids.

In this mode if a Flap Group

(AB/CG/DEF) is enabled for Local
operation, the rest of the sequence
excepting the faulty / selected Flap
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within the Flap group shall continue

to run from PCS according to the
defined time sequence.

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Timing Diagram :

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8.12.10.5 Air Drier

System Description:

The Air Drier envisaged are Refrigerated Type.

The Air Drier System consists of the following:

Mechanics/ Subsystem:

- A Refrigeration Compressor.
- Refrigerant Condenser.
- Air to Air heat exchanger.
- Moisture Separator

Electrics/ Sub control System:

- A Local Control Panel for controlling the

operation of the Refrigerated type Air Drier
system comprising:
o A relay based sub control system,
consisting:
o Control Logic and operation for Refrigerated
type Air Drier
o Interface with PCS for reporting Information
& Alarm Conditions.
- Electrics viz, Compressor & the Starter Circuits
in local control panel.
- Other Field Sensors & Actuators, as required
for the Operation of system.

Operation:

Air drier system’s main function is to provide Dry

(Moisture free) air for the system.

There are two modes of operation:

- PCS mode / CCS Mode: Mode for Remote

Operation
- SCS Mode/ Cabinet Mode/ Local Control:
Mode for Local Operation

Operation of Air Drier

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The incoming saturated, moist air is precooled in

the Air – to – Air heat exchanger by the outgoing
dry chilled air. Moisture separation takes place in
evaporator where air is chilled to low temperature
and moisture condenses. Moisture Separator
removes the condensate.

Flow sheet:

A Flow sheet for the Air Drier system is depicted

as under:

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8.12.10.6 Kiln Feed System

System Description :

A Kiln feed system consists of the following :

Mechanics/ Subsystem

o A Feed Bin along with Bin weighing System

o Fluxoslide along with interconnecting
equipment from Bin discharge to the Rotor
Weigh feeder
o A Manual shut off gate
o A Pneumatic flow control gate
o An aeration System for Bin and the
Fluxoslide
o A Rotor Weigh feeder for accomplishing the
following functions viz, Extraction,
Weighing, Accurate Measurement of Feed
rate Discharging of the material all in one
piece of equipment.

Electrics/ Sub control System:

An Electric Enclosure to be placed in the

substation comprising:
- A microprocessor based sub control system,
consisting:
o Control Logic for Kiln feed system
Operation, implemented in the Micro
Controller
o Keypad based Operator Interface &
o Interface Option with PCS for reporting
Information & Alarm Conditions
- Electro pneumatics viz, Pneumatic Control gate
for the Kiln feed and the Variable Speed
Drive starter circuits for the rotor weigh feeder ,
realised in the Electric Enclosure
- Field Sensors & Actuators, as required for the
Operation.

Operation :

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The Operation of the Kiln feed System is based on

the following :

o Bin Weight /Loss in weight measurement

o Check Weight measurement for the rotor
weigh feeder within pre determined limits by
an adjustment algorithm (with auto
calibration facility)
o Bin Aeration System
o Flow Control gate Operation
o Rotor Weighfeeder Operation

The controller shall perform the following functions

depending on the mode selection

In Gravimetric mode :

The rotor weighfeeder uses the operating principle

of a horizontal Air Lock gate operating
gravimetrically. The bulk material is extracted
directly from the bin by the rotary vane, carried
over the weighing section, metered directly into the
Pneumatic delivery line. The mass of the bulk
material present at any given moment in the rotor
weighing section is measured by Load cell . The
bulk material mass with the associated position is
stored in the microprocessor i.e the local loading
of the rotor is already known before discharge.
This result in a prospective (anticipatory) close
loop control when disturbances are compensated
and high accuracy is obtained.
In the gravimetric mode the controller performs
close loop control for Gravimetric feeding,
depending on the set point either from Cabinet
(Control Cabinet) or Remote (CCR) and the actual
feed rate in TPH (calculated on the basis of
loading sensed by load cell of a rotor weighfeeder
& the weighfeeder angular velocity i.e kg/ x
/s=kg/sec). and the Integrate the feed rate to
evaluate total feed.
Manipulate the speed of the variable speed drive
depending on the output of the above controller.

In Volumetric mode :

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Performs a control for feeding, depending on the

Speed of the variable speed Drive on the basis of
the speed set point either in Local (Control
Cabinet) or Remote (CCR).

Operator gives the set-point for the Kiln Feed Rate

in TPH.

On Line Calibration :

On Line calibration can be done from the PCS.

The Operator has to initiate the Online Calibration
by pressing the ‘Start of OLC’. On receipt of this
command the Kiln Feed System will give following
feedbacks one after other:
1 OLC started – Online Calibration initiated.
2 OLC Refilling Running – Refilling due to Online
calibration in Operation.
3 OLC in Operation - Online calibration in
operation
4 OLC Finished – Online calibration has been
finished and the calculated correction value is
available for acceptance.

On receipt of ‘OLC Finished’ from Kiln Feed

System the Operator can accept the result by
pressing the button ‘Accept result of OLC.

The operator can also break the Online calibration

if he desired so, by pressing the ‘Interruption of
OLC’.

8.12.11 Messages and Alarm

Tag Description Priority Delay

312BE01YJ10H Bucket Elevator Power High 2 1s
312BE01YJ10H Bucket Elevator Power High-High 2 1s
312SM01YF10H Kiln Feed System Material Flow
2 1s
Rate High
312AB01YI10H Aeration Blower Current High 2 1s
312AB02YI10H Aeration Blower Current High 2 1s

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312LX01YW10L Feed Bin Weight Low 2 1s

312DC03XP10 Compressed Air Pressure Low 2 1s
312BE01XL10 Bucket Elevator Boot Level 2 1s
312DC02XP10 Compressed Air Pressure Low 2 1s
312DC01XP10 Compressed Air Pressure Low 2 1s
312SA01XX10 Sample Collected 2 1s
312SA01XX20 Time for Sample Collection 2 1s
312S09L01 312VV05 open for Truck Loading 3 1s
312S09L02 312VV04 for bypassing Kiln feed
3 1s
metering system
312S09L03 Aeration Blower 312AB02 as Kiln
3 1s
feed bin Aeration Blower
312S09L04 Aeration Blower 312AB02 as Silo
3 1s
Aeration Blower
312S09L05 Silo to Silo material re-circulation 3 1s
312S09L07 Stand-by Air Slide Fan 311FA02
3 1s
Selected
312S09L08 Local permissive for Control Box –1 3 1s
312S09L09 Local permissive for Control Box –2 3 1s
312S09L10 Local permissive for Control Box –3 3 1s

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8.13 313.S10: Calciner Burner

8.13.1 Sequence Flow Sheet

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8.13.2 Consumer List

Tag Description Start Stop Essential Emergency Remarks

step step drive Power
Pilot Burner
313XY01EC11 IND IND Y N
for Calciner
Calciner
313XY01EC10 Burner 1 1 Y N
Station

8.13.3 Analog Sensors Lists

Eng. Units Alarm Limits

Tag
Low High Unit LL L H HH
313XY01YP10 0 12 Bar
313XY01YP10 0 2 Bar
313XY01YF10 0 14900 Nm3/Hr
313XY01YZ10 0 100 %
313DT01YT10 0 1200 Deg C
313DT01YP10 -200 0 mmWG -100 -50

8.13.4 Operators Selections

P1 selected – Operation of Calciner Burner
when Kiln is not in operation
P1 not selected – Operation of Calciner Burner
when Kiln is in operation
P2 not selected – Calciner Burner (313XY01EC10)
in Sequence mode
P2 selected – Calciner Burner (313XY01EC10)
in local mode
P3 selected – To Start the Calciner Pilot Burner.
P4 selected – Pilot Burner in Local Mode
P4 not selected – Pilot Burner in Remote Mode

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8.13.5 Operator Mode Description

Operator shall select the P1 during Raw Mill Start
up using Calciner Burner as Hot Gas generator.
This selection when enabled allows the operation
of Calciner burner without Sequence 316.S06 (Kiln
Burner) running and without any restriction for
Calciner outlet gas temperature.

Refer Raw Mill Functional Specification for details

of Raw Mill Operation using Calciner Burner as a
hot gas Generator.

Start-up Details

 Start Calciner Burner 313XY01,

Shut-down details

 Stop Calciner Burner 313XY01.

8.13.6 Sequence Interlocks and Alarms

Interlocks:

Description SSI SPI Remarks

316.S06 (Kiln Burner) Run   If P1 not
selected
Calciner outlet gas temperature  If P1 not
313CA01YT10L (> 600 Deg C) selected
Calciner outlet gas 
temperature313CA01YT10HH (< 1000
Deg C)
316S05 Run and 216S04 Run   If P1
selected

Alarms:

Description Consequences Remarks /

Quick Sequential Delay
Shutdown Shutdown
None

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Chapter : 8 Page 192 of 204
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TITLE FUNCTIONAL SPECIFICATION

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Date : 11/02/2007
Chapter : 8 Page 193 of 204
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8.13.7 D/D Interlocks and Alarms

 313XY01EC11

Interlocks:

Description DSI DPI DSQI DEI Remarks

None

Alarms:

Description BP PE1 PE2 Remarks / Delays

None

 313XY01EC10

Interlocks:

Description DSI DPI DSQI DEI Remarks

313XY01EC11 Run 
313AG02XX20HH 

Alarms:

Description BP PE1 PE2 Remarks / Delays

313XY01YP10LL 

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Chapter : 8 Page 194 of 204
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8.13.8 Process Protections:

Calciner Fuel Flow shall be reduced by 20% on
preheater outlet CO high.

Calciner fuel valve position shall be forced to 5%

opening on following conditions:
 Preheater outlet CO High High
 Cyclone 4 exit CH4 High High
 Calciner Outlet gas temp High High

8.13.9 Regulation Loops

 Cyclone –4 Outlet Gas Temperature

313CY04YT10 control with Gas (Fuel) Flow rate
313XY01YF10

Controlled Measurement : Cyclone –4 Outlet

Gas Temperature
313CY04YT10

D/D Controlled :Gas (Fuel) Flow rate

313XY01YF10

Manual Mode :Operator manipulates

the Gas (Fuel) Flow
rate 313XY01YF10
from the PID faceplate
in manual mode.

Automatic Mode : Cyclone –4 Outlet

Gas Temperature
313CY04YT10 will be
controlled by the
manipulation of the
Gas (Fuel) Flow rate
313XY01YF10 from
the PID Controller.
Operator will give set
point for the Cyclone
–4 Outlet Gas
Temperature
313CY04YT10.

 Gas (Fuel) Flow rate 313XY01YF10 with Control

Valve position control
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Controlled Measurement : Gas (Fuel) Flow rate

313XY01YF10

D/D Controlled : Control Valve

position control

Manual Mode :Operator manipulates

the control Valve
position from the PID
faceplate in manual
mode.

Automatic Mode : Gas (Fuel) Flow rate

313XY01YF10 will be
controlled by the
manipulation of the
Control Valve position
from the PID
Controller. Gas (Fuel)
Flow rate
313XY01YF10
setpoint to be
generated from
Cyclone –4 Outlet
Gas Temperature
313CY04YT10 control
with Gas (Fuel) Flow
rate 313XY01YF10
control loop in
cascade mode.

8.13.10 Cyclic and Special Functions

8.13.10.1 Calciner Burner System

System Description :

Mechanics/ Subsystem :

The Calciner burner is a unit built of pipes, valves,

cocks, measuring instruments etc.
The Calciner Burner consists of the following :

- A flow Control Unit – Mainly consist of a Safety

shut off valve (SSV) and a flow control gate
- A Shut off / Leakage Control unit- Consists of
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Chapter : 8 Page 196 of 204
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a number of shut off valves

- Main Calciner Burner System
- Pilot burner
The pilot burner consists of control unit including
ignition coil an ignition electrode as well as a flame
monitoring system based on the ion-rod principle.

Electrics/ Sub control System :

The Kiln Burner System electrics comprises of the

following :
A PLC based sub control system consisting :
- Control Logic for Operation and start/stop
sequence of the Burner implemented in the
SCS PLC
- Control Display (CD) (Touch Screen) based
Operator Interface &
- Interface with PCS over Profibus for reporting
Information & Alarm Conditions
- Field Sensors & Actuators, as required for the
Operation.

The following are monitored & controlled from a

local control panel:

- Pilot burner control unit

- Monitoring of compressed air on main burner,
machine side.(313XY01XP20)
- Position indication of SSV
(313XY01XZ10,XZ11).
- Monitoring of gas pressure on pilot burner,
supply side (313XY01XP31.
- Monitoring of gas pressure on pilot burner,
nozzle side. (313XY01XP32)
- Combustion air fan for pilot burner
(313XY01XP30)
- Monitoring position of Air damper motor/
Actuator (313XY01XZ40,41)
- Monitoring of gas temperature
- Monitoring of gas flow (313XY01YF10)
- Monitoring of gas pressure (inlet).
(313XY01YP10)
- Monitoring of gas pressure (outlet).
(313XY01YP20)
- I/P converter for regulation of gas flow.
(313XY01XZ10,XZ11& YZ10)
- Combustion air damper.
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Chapter : 8 Page 197 of 204
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- Gas valve with position indication (open/close)

(313XY01XZ20,XZ21,YZ20).
- Gas valve with position indication (open/close).
(313XY01XZ30,XZ31,YZ30)
- Solenoid valve on SSV, latch open position
(NC).(313XY01VA30)
- Solenoid valve, to control open/close of “V06”
(NC)(313XY01VA40).
- Solenoid valve, to control open/close of “V07”
(NC)(313XY01VA50).
- Solenoid valve, to supply gas for leakage
control on main burner (NC).(313XY01VA60)
- Solenoid valve, for venting of shut-off unit (NO)
(313XY01VA70)
- Solenoid valve, to supply gas to pilot burner,
step 1 valve (NC) (313XY01VA21).
- Solenoid valve, to supply gas to pilot burner,
step 2 valve (NC) (313XY01VA22).
- Solenoid valve, to supply gas to pilot burner,
step 1 valve (NC).(313XY01VA23)
- Solenoid valve, for venting pilot burner control
valves (NO) (313XY01VA20)..

Operation :

There are three Steps of operation:

Flow Control Unit

Safety shut-off valve (SSV):

When the burner station is powered up and no

alarms are present the "latch valve"
(313XY01VA30) will be energised. This means
that the SSV can be opened manually.
The SSV only close when:
- There is a position fault on gas valves “V06” or
“V07”.
- The leakage control detects a leakage.
- There is a high downstream gas pressure in
the system.
- There is a power cut.

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Date : 11/02/2007
Chapter : 8 Page 198 of 204
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Shut off Unit / Leakage control:

Leakage control is a test of shut-off valves
between the SSV and the main burner.
The leakage control sequence is:

Step No. Action Feed back.

Step 1 -Start unit Venting timer done (3 sec).
Start venting timer

Step 2 Close 313XY01VA70 (During control 1 check for

Start control 1 timer increasing pressure on
313XY01YP20H)
Control timer 1 done. (22 sec)

Step 3 Open 313XY01VA60 (fill shut- Filling timer done (3 sec)

off unit with gas)
Start filling timer.
Step 4 Close 313XY01VA60 (During control 2 check for
Start control 2 timer decreasing pressure on
313XY01YP20L)
Control timer 2 done (22 sec)

Leak control done

The leakage control is performed automatically in

the following cases:
1. After opening of the SSV. When the leakage
control is done the valve 313XY01VA70 will be
opened again for venting.
2. When the igniter burner is started, the leakage
control is performed. If no leakages is detected
the igniter burner starts automatically.
3. When the main burner station is started a
leakage control is performed. If no leakages
are detected the main burner starts
automatically.
4. When the burner stops after the gas valve
“V06” and “V07” has been opened a leakage
test is performed to make sure that the valves
are closed again.

NB!! A leakage control is valid for 1 hour. I.e. if

two of the above mentioned cases are activated
within 1 hour only 1 leakage control is performed.
When opening the SSV a leakage control is
always performed.

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Chapter : 8 Page 199 of 204
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Chapter : 8 Page 200 of 204
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Pilot burner:

The pilot burner is started in 2 steps.

- Step 1 with reduced gas and combustion air
flow (approx. 20% of full flow).
- Step 2 full flow on both gas and combustion air.
The pilot burner start sequence must be complete
before main is ready for start.
The pilot burner start sequence is:

Step Action Feed back.

No.
Step 0.1 Start Pilot Burner Damper closed
Close Damper

Step 0.2 -Start combustion air fan Combustion air fan start-up
-Start combustion air fan timer complete (10 sec).
start-up .timer
Step 0.3 -Open damper to start Damper in start position
position.
Step 1 -Start step 1 -Flame detected
Open 313XY01VA21 and OR
313XY01VA23. -Flame supervision timer
-Start flame supervision done without flame
timer detection.

Step 1.1 -Burner started if Flame -Flame supervision

detected. engaged.
-Start step 2 timer.
-Step 2 timer done (30 sec).
Step 2 -Start step 2. -Damper in 100% position.
Open 313XY01VA22 and
move damper to 100%
open.
-Pilot burner “in operation”

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Main burner

Initially the pilot burner will be started by the

operator. On detection of Pilot burner flame the
pilot burner operation will be sustained.

The main burner can be started and shall be in

operation only if the pilot burner is in operation and
the flame is ON.

The main burner can also be started and be

operational, if the Kiln feed is ON and either of the
calciner outlet temp. or 4th stage cyclone outlet
temp. is greater than 700 deg C. In this case
Flame detector is bypassed as the calciner pilot
burner flame will be extinguished when the kiln
feed is taken.

Gas flow control

Gas flow can only be controlled when the main

burner is “in operation”.
The gas flow is controlled by a remote operated
reduction valve. This valve maintains a constant
downstream pressure and thus a constant flow.
The downstream pressure is changed by altering
the set point to the I/P converter on the reduction
valve and they’re by altering the gas flow.

Local Mode selection (313XY01EC10CA copy of

313XY01L02) for the Calciner Burner shall be
passed from PCS to SCS.

Flow sheet :

An Instrument Flow sheet for the Calciner Burner

system is depicted in herewith :

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Date : 11/02/2007
Chapter : 8 Page 203 of 204
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8.13.11 Messages and Alarm

Tag Description Priority Delay

313XY01YP10L Calciner Burner Gas Pressure Low 2 1s

313XY01YF10L Calciner Burner Gas Flow Low 2 1s
313XY01YF10H Calciner Burner Gas Flow High 2 1s
313DT01YT10H Tertiary Air Temperature High 2 1s
313DT01YP10H Tertiary Air Pressure High 2 1s
313DT01YP10L Tertiary Air Pressure Low 2 1s
Selection for Operation of Calciner
313XY01L01 Burner when Kiln is not in 3 1s
Operation
Selection for Operation of Calciner
313XY01L02 3 1s
Burner in Local mode

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