INTERNSHIP REPORT

DG KHAN CEMENT COMPANY LIMITED

Prepared By | Osama Majeed Butt

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Dated: |0
23-08-2013
 OSAMA MAJEED BUTT

AKNOWLEDGEMNET

In the name of Allah who is the most Gracious and Merciful. Allahmudullilah I have completed my
internship by the great assist of Allah who helped me at every stage. Secondly I m thankful to my
parents who supported me and prayed for my success.

An endeavor over a period can be successful only with the advice and support of well wishers. I take this
opportunity to express my gratitude and appreciation to all those who encouraged me to complete this
Internship.

I deeply indebted to Mr. Atif Rasool (Manager Power House) for my successful and acquaintance
completion of internship.

I express my profound and sincere thanks to Mr. Zaheer (Deputy Manager E&I) who acted as a
mariner’s compass and steered me throughout the internship.

My report will remain incomplete if I do not mention the efforts of Mr. Safdar Kamal who did not
only helped me, but also responsible for arranging this vast and edifying internship program.

I also extend my thanks to all other staff and administrative staff of DG Khan Cement Co. Limited
for their external support and guidance.

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Introduction

Nishat being largest and most diversified Industrial house in South East Asia, with assets over
PRs.300 billion, ranks amongst the top five business houses of Pakistan. Nishat has strong
presence in following most important business sectors of the region:
1. Textiles
2. Cement
3. Financial and Insurance
4. Power Generation both IPP and Captive
5. Paper Products
Nishat is considered at par with multinationals operating locally in terms of its quality of
products, services and management skills.

CEMENT and SACKS:

 DG Khan Cement Company Limited
 Nishat Paper Products Company Limited

POWER GENERATION (IPPs):

 Nishat Power Limited (200MW)
 Nishat Chunian Power Limited(200MW)
 Lalpir Power Limited (362MW)
 Pak Gen Power Limited (365MW)

CAPTIVE POWER GENERATION:

 DG Khan Site:
Gas power generation 25.50 MW
Oil based power generation 23.84 MW
Total 49.34 MW
 Khairpur Site:
Duel Fuel (Gas & Oil) power 33.00 MW

TEXTILES
 Nishat Mills Limited
 Nishat (chunian) Limited

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DG Khan Cement Company Limited

DG Khan Cement Company Limited is considering being the largest company in private sector. It
is 2nd largest company of producing cement in Pakistan. It not only full fills the cement demands
of the country but also exports it. DG khan Cement Co. Ltd. has ISO 9001:2008 & 14001:2004
certified systems for it’s extremely environment friendly production process.

ESTABLISHMENT:
DG Khan Cement Company Limited (DGKCC) was established under the management control of
State Cement Corporation of Pakistan Limited (SCCP) in 1978 as private limited company.
DGKCC started its commercial production in April 1986 with 200 tons per day clinker based on
dry process technology.

MISSION STATEMENT:
To provide quality products to customers and explore new markets to promote, expand sales of
the company through good governance and foster a sound and dynamic team, so as to achieve
optimum prices of products to company for sustainable and equitable growth and prosperity of
the company.

VISION STATEMENT:
To transform the company into modern and dynamic cement manufacturing company with
qualified professionals and fully equipped to play meaningful role on sustainable basis in the
economy of Pakistan.
DG Khan Cement Co. Ltd. has two working plants while one is under erection.
1. Dera Ghazi Khan Site
2. Khairpur Site
3. Hub (Sindh, under construction)

Dera Ghazi Khan Site:

It is the first cement plant established by Nishat Group of Companies at Dera Ghazi Khan in
Punjab which started its commercial production in April 1986 with 2000 tons per day clinker
based on dry process technology.

Khairpur Site:

Second plant was established at Khairpur in district Chakwal. It was intact in 2007 with a
production of 6700 tons per day. It is also based on dry process technology and has the most
advanced, sophisticated and environmental friendly plant of cement production in the Asia and
biggest of Pakistan.

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Working at Khairpur Plant

I worked at DG Cement Company limited, Khairpur Plant as an intern (Electrical Engineer). I

visited different units at the plant regarding the production of cement.

There are two main processes at DG Cement, Khairpur Site:

 Cement Production
 Power Production

Cement Production
Cement production comprises of following processes performed at DG Cement:
 Raw Material Crushing
 Clay Mixture
 Storage for pure Limestone
 Feed bins to Raw Mill
 Raw material grinding
 Kiln Feed
 Clinker cooler
 Gas handling and Dedusting
 Clinker storage
 Cement grinding department
 Cement storage and dispatch

RAW MATERIAL CRUSHING DEPARTMENT:

Crusher mill is EV 200 x 300 typed, with a capacity of 1,500 ton per hour. The diameter of the
rotor is 2.0m and the width is 3.0m. The peripheral speed is 35m/s. mixture of the limestone
and clay is done in a controlled environment according to their chemistry. For this, these
materials are fed to the crusher by two separate apron feeders with individually controlled feed
rates.
The crusher is a single rotor hammer mill. In the EV the crushing process is a two stage process:
a primary by impact and a secondary by compression and sheering. To make the hammer
service easier the crusher is equipped with a hydraulic opening device of the machine. There is
also a hydraulic tool for extraction of hammer bolts, where one row of hammers may be
removed at a time.

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The drive train comprises of a four poled slip ring motor and a directly coupled reducer. This
arrangement will give a low over-all cost which requires a minimum of maintenance.

STORAGE FOR PURE LIMESTONE/CLAY MIXTURE:

The crushed limestone is transported to the storage for the clay mixture by a conveyor belt. In
the storage the clay is stored and pre-blended in a two-pile system. While one pile is being
reclaimed from, the other one is stalked into. The live capacity of the storage is about 35,000
tons per one pile. The raw materials are stacked with a capacity of 1,500 ton per hour.

FEED BINS TO RAW MILL:

Apron belts are used for feeding limestone/clay mixture and for pure limestone. The steel
apron belt offers excellent wear resistance and high friction against sticky materials so as to
ensure smooth extraction.

RAW MATERIAL GRINDING:

ATOX-52.5 roller mill is used for grinding of raw material for a production of 500 ton per hour
driven by 4300KW motor. The ATOX- mill is an air swept vertical roller mill featuring a
drying/grinding chamber and a high efficient built-in separator.
A belt conveyor transfers the raw materials from the weigh feeders below the feed hoppers for
the different components in the raw mix to the rotary feed sluice at the mill inlet. The rotary
sluice provides an air seal, so that the raw material can enter the mill without air infiltration
into the mill. A chute directs the raw materials to the centre of the grinding table.
The centrifugal force from the rotating table moves the materials outward, and on its way the
material is ground between the rotating table and three rollers. The grinding rollers are forced
downward onto the material by the force developed by their own weight and a hydraulic
system. These rollers can be lifted clear of the table during start and stop of the mill.
The raw mill installation has been designed for drying away 8% moisture in the raw materials. It
is found that at the raw mill (500 tph) maximum moisture content in the raw materials of ~7%
can be accepted, when the kiln is operated as a five stage preheater.
The grinding table is horizontal and the rollers are cylindrical. Wear elements on rollers are
designed to be reversed to ensure prolonged life. The roller bearings are oil lubricated. The oil
is constantly filtered and conditioned in the oil handling unit placed next to the mill. A separate
fan ensures that sealing air will keep the roller bearing free from dust by keeping over pressure
inside.

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In order to protect the mill against mechanical overload, it has been equipped with vibration
measuring equipment. The conveyor belt, which feeds the raw materials to the mill, is equipped
with a magnetic separator and a metal detector in order to prevent the entrance of metallic
objects to the mill. The feed of raw materials is automatically controlled through the differential
pressure across the nozzle ring. The drying process in the mill is also automatically controlled by
the outlet temperature of the gases from the mill. Finally the flow of air through the
mill/separator (measured by a venture placed before the mil fan) is also automatically
controlled by regulating the position of the damper for the mill fan.

KILN FEED:

For storing and blending of the raw meal CF (Controlled Flow) silo with an inner diameter of 23
m and a total height of silo section of 54 m is used. The storage capacity is expected to be
25,500 ton. The operating principle of the CF silo is multi-plug flow. The blending is attained by
multi point extraction by differential speed. Because of the relieving effect of the cones, the
operating bulk density of the CF silo is much higher than silos without cones.
To enhance the smooth silo operation, each of 42 aeration segments is separately filtered. This
prevents the raw meal from entering the compressed air system.
The final short range blending of the kiln feed is made in a fluidizing tank underneath the silo.
There are two reasons for this small size: to minimize the height of the silo and to avoid
segregation.
The tank underneath the silo also serves as hopper of the kiln feed system. The name of the
system is FLS LoW; Loss on Weight. The control of the LoW system is integrated with the CF silo.
The operating principle is a combination of gravimetric and volumetric control mode. The tank
is filled in periods and when not under filling, the control mode is gravimetric. During filling the
mode is volumetric where the system compensates for hydrostatic pressure differences in the
tank so as to make the extraction rate stable. An apparent advantage of the LoW system is the
low cost since no extra equipment is needed, such as feed tank control gates, solid flow meters
or separate PLC. There are two valves in cascade; the first one is a pneumatically controlled one
for cut-off in case of blockages downstream. The second valve is motor controlled for metering.
There is a stand-by feeder.
The vertical transport is by means of a bucket elevator, which is a reliable transport system
which minimizes the amount of false air introduced to the kiln system.
Dry process installation comprising:
 Two string, five stage cyclone preheator with precalciner type ILC (In-line-Calciner).
 A rotary kiln (Dia 5.5x66.0m) with two supports.
 A SF (Smidth-Fuller) grate cooler (SF4* 7F) for the clinker.
 A hot air duct from the cooler (extended kiln hood) to the precalciner.

The above installation features a high-economy kiln with preheating and precalcining in
suspension based on low-pressure drop cyclones.

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The characteristic feature of the precalciner is the homogenous mixing of raw meal, fuel and
combustion air.
The combustion air is drawn from the (extended) kiln hood as tertiary air.
The 4th stage cyclone is fitted with a dividing gate in bottom for dividing the material flow.
The fuel is supplied to the riser duct below the reduction section of the calciner (lower part).
The coal is introduced via two burners.
The combustion in the reduction part of the calciner, which is only sustained by excess oxygen
from the combustion in the kiln + oxygen from false air from the kiln inlet seal, will be completed
, due to lack of oxygen.
The gases formed by this incomplete combustion in the lower part of the calciner (reduction
zone) combines with the kiln gases from the burning zone.
New 2-support kiln (ROTAX-2) offers the following advantages compared to the traditional 3-
support kiln the new ROTAX-2:

 Lower overall kiln length saves space.

 Reduced kiln surface reduces the radiation heat loss from the kiln shell.
 Lower machine weight and less foundation requirements reduce the initial cost and
erection time.

As the kiln drive system for the ROTAX-2 kiln is a mechanical drive via the pair of supporting
rollers, which are nearest to the kiln inlet.
The kiln system has been designed on the basis of our experience with several 2-support calciner
kilns.
The dimension of the kiln (Dia, 5.5 x 66m) corresponds to a specific load of the kiln tube of 5.0
tpd clinker/m3 free kiln volume at 6,700tdp.

The two preheater stings have been dimensioned as follows:

1st state: 6.6m diameter single
2nd state: 6.6m diameter single
3rd state: 6.9m diameter single
4th state: 6.9m diameter single
5th state: 6.9m diameter single
Calciner dimension (diameter x height):
Reduction zone (lower part): 3.8 x 3.0 m
Combustion zone (upper part): 8.0 x 37.0 m
Gas retention time in reduction zone: approx. 0.2 sec
Gas retention time in combustion zone: approx. 3.2 sec
Expected amount of fuel to calciner: approx. 57%

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Clinker cooler:

For cooling the clinker SF (Smith Fuller) Cross Bar Cooler is installed.
The cooler is equipped with a fixed inlet module of 5 grate rows arranged to form an inclination
of approximately 15o.
Cooling air to this module is supplied from a separate fan.
Clinker will build up to form a natural inclination of more than 15 o and in this way the grate plates
are not exposed too much wear.
The SF-cooler, which is a cross flow cooler is characterized by the following main features.
 Fixed grate line for air distribution.
 No wear on grate plates.
 No fall through of clinker to the under grate compartment, which allows the elimination
of the under grate clinker transport, resulting in a low installation height.
 Easy cooler operation by automatic control of the air distribution and eliminating the
sealing air.
 Clinker conveying separate from the air distribution.
 Dynamic flow control unit in each grate plate.
 Cooler is built up of modules.
 Possibility of having different drive speeds across the cooler.
 High thermal efficiency throughout the whole lifetime of the cooler.

The specific load of the clinker cooler is about 42t/m2d @ 6,700 tpd and the installed capacity of
the cooling fans (8 nos. ) is designed for cooling the clinker to a temperature equal to about 80oC
above ambient temperature (i.e. temperature of the cooling air) at a production of 6,700tpd.

Gas Handling and Dedusting:

Whenever the kiln is in operation, the raw mill can either be running or be stopped. With raw mill
stopped the exhaust gases from the kiln are by passing the raw mill installation through a
separate duct in which a gas condition tower has been installed. By passing the gas conditioning
tower the gases are cooled to 150oC by water injection into a gas conditioning.
The cleaning of the gases takes place in an electrostatic precipitator (common to kiln and raw
mill).
The dust precipitated in the electrostatic precipitator and the gas conditioning tower will be sent
to a separate dust bin from where the dust can eithe4r be sent to be CF-Silo or be returned
directly back to the kiln (mixed with the raw meal extracted as kiln feed from the CF-Silo).

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Clinker Storage:

Clinker is store in storage with dimension of Ø 60 x 46 m for normal OPC cement. The capacity of
the storage is 110000ts.
Before the clinker transport discharges the clinker into the clinker storage, the clinker transport
passes a small silo to which clinker can be discharged in case of off-standard clinker or for making
weighing tests of the production of the kiln. Extraction of clinker from the silos is by bottom
extraction.

Cement Grinding Department:

For the grinding of cement two OK 36-4 vertical roller mills each for a production of 175 tph OPC
(to 3,200 Blaine) driven by a 3,400 KW motors. The OK-mill is an air swept vertical roller mill with
a built in high efficient separator (type ROKS 40.0). The OK-mill combines drying, grinding and
separator in one unit. Because of the highly effective drying performance, the OK- mill is an
optimal solution for grinding blended cements with one or more wet components.
The heat, which is required for the drying of the wet components, is supplied from a diesel oil
heat generator (Only installed for one of the mills). The heat generator is not used under normal
conditions, but is required for cases where “cold” clinkers are used or the drying requirement is
high.
A belt conveyor is transferring the components (clinker, gypsum and additive) from the weight
feeders below the feed hoppers for the different components in the correct proportion to a
rotary feed sluice at the mill inlet.
The rotary sluice provides an air seal, so that the materials can enter the mill without air
infiltration into the mill.
The transport belt to be mill inlet is equipped with a magnet separator to sort out magnetic
objects of the mill feed. Just before the mill feed is discharged into the rotary feed sluice it passes
a metal detector. This is installed for protection of the mill.
Any metal detected will activate a change-over gate, hence causing the feed containing the
metallic object to go to a waste bin instead of into the mill.
From the rotary feed sluice a chute directs the material to the centre of the grinding table.
The centrifugal force from rotating table moves the material outward and on its way the material
is ground between the rotating table and 4 grinding rollers.
The grinding rollers are forced downward onto the material by the force developed by the
hydraulic system (and by their own weight). These rollers are in a lifted position, when the mill is
started, thus assuring a trouble free started-up.
Having passed the grind rollers the material falls over the dam ring along the periphery of the
grinding table and enters the nozzle ring area. From here the gas passing through the mill carries
some material to be a dynamic separator, which is built-in in the top of the mill and return some
material back to the table.

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The gas velocity in the nozzle ring is so adjusted, that a small fraction of the material will fall
through the nozzle ring. Scrapers are arranged on the lower side surface of the table to scrape
and move the spillage falling through the nozzle ring through the reject chutes.
The rejects from below the mill table is transported back to the mill feed by the re-circulation
system. The re-circulation system is equipped with a magnet separator for removal of iron nips.
The material carried by the gases to the separator, is separated into a coarse fraction (rejects)
and a fine fraction (finished product). The rejects fall down through the separator reject cone
onto the mill table for further grinding.
The finished product leaves the separator at the top, transported by the separator to a bag filter,
where the particles are collected. The finesses of the product is a function of the gas flow through
the mill and the speed of the separator rotor.
The finished product collected in the bag filter is transported to the cement silos.

Cement Storage and Dispatch:

The product from the two cement mills is stored in 3 cement silos (each with a capacity of 21000
tons). The product from each of the cement mill can be conveyed to any of the cement silos.
One loader for bulk cement will be installed, but it will be possible to extract cement for bulk
loading from any of the silos. A Total of 5 packers for cement will be installed. Cement from any
of the silos can be extracted to any of the five packers.

POWER PRODUCTION

In DG Cement there are two main sectors regarding power sector. One is to produce Power for
the plant and the second is to distribute this power to different departments of the plant
appropriately.

ELECTRIC POWER GENERATION:

DG Cement plant has a total of 40 MW of system. From which 33 MW is produce in the power
house of DG Cement (located on the khairpur site adjacent to cement plant) and the rest 7 MW
is introduce through WAPDA.

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Power House:
Power house is equipped with two sets of 16 MW generators. For this purpose WARTSILA
installed its equipment. It has 18V50DF engine to run the turbine. The Wartsilä 50DF is a four-
stroke dual fuel
engine that can be run on natural gas, light fuel oil (LFO) or heavy fuel oil (HFO). Moreover, the
engine can switch over from gas to LFO/HFO and vice versa smoothly during engine operation.
The Wartsilä 50DF is manufactured in configurations from 6L up to 18V giving 950 kW per
cylinder and a total maximum mechanical output of 17,100 kW. The engine speed is 500 or 514
rpm for use with 50 or 60 Hz applications. The engine has a maximum thermal efficiency of 47%
(± 0% tolerance), higher than for any other gas engine.

The fuel system of the Wärtsilä 50DF tri fuel has been divided into three: one for gas, one for
backup fuel and a separate pilot fuel system. The Wärtsilä 50DF is normally started in diesel
mode using both main diesel and pilot fuel. Gas admission is activated when combustion is
stable in all cylinders. When running the engine in gas mode, the pilot fuel amounts to less than
1% of full-load fuel consumption. The amount of pilot fuel is controlled by the engine control
system. When running the engine in backup fuel mode the pilot is also in use to ensure nozzle
cooling. The power plant engine can also be delivered without the backup fuel system. In this
case the engine is started on pilot fuel with gas admission activated when engine is up in speed.
The synchronization and loading is done on gas. The pilot fuel consumption is here the same
less than 1 % of full load fuel consumption.

The natural gas is supplied to the engine through a valve station. The gas is first filtered to
ensure clean supply. The gas pressure is controlled by a valve located in the valve station. The
gas pressure is dependent on engine load. At full load the pressure before the engine is 3.9 bar
(g) for LHV 36 MJ/m3. For lower LHV the pressure has to be increased. The system includes the
necessary shut-off and venting valves to ensure safe and trouble-free gas supply. On the
engine, the gas is supplied through large common-rail pipes running along the engine. Each
cylinder then has an individual feed pipe to the gas admission valve on the cylinder head. Gas
piping in marine installations is of double wall design as standard. The fuel oil supply on the
engine is divided into two separate systems: one for the pilot fuel and the other for backup
fuel. The pilot fuel is elevated to the required pressure by a pump unit. This includes duplex
filters, pressure regulator and an engine-driven radial piston-type pump. The high-pressure
pilot fuel is then distributed through a common-rail pipe to the injection valves at each cylinder.
Pilot fuel is injected at approximately 900 bar pressure and the timing and duration are
electronically controlled. The pilot fuel system is separated from the backup fuel system with
separate connections on the engine. The backup fuel is separated from the pilot fuel system
and is fed to a normal camshaft-driven injection pump. From the injection pump, the high-
pressure fuel goes to a spring-loaded injection valve of standard design for a diesel engine.

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There are five main systems which are responsible to run the engine and to produce electricity
in the efficient and safe way.
 Starting air system
 Cooling system
 Fuel system
 Lube oil system
 Exhaust system

1. Compressed air system

 Provides pressurized air of 18-30 barfor starting via air duct to combustion
chamber of engine.

2. Cooling system
 Comprises of
 Radiators for each engine
 Water towers for each engine.
 Helps to maintain:
 Body temperature
 Lube oil temperature
 Engine temperature.

3. Fuel system
 Electronic fuel system maintain the supply and pressure of fuel in the supply line
 Natural gas ideal pressure : 6 bar
 2.1 bar for low load i.e 7.5MW.

4. Lube oil system

 Maintain the lubricant oil level intact inside the engine’s pistons for smooth and
resistance less flow.

5. Exhaust system
 Check the proper and safe ejection of exhaust gases from engine to the
atmospheric air.

ENGINE STARTING SYSTEM:

The Wärtsilä 50DF engine is provided with a conventional pneumatic in-cylinder starting
system. Each cylinder head is equipped with a starting valve. A starting limiter valve prevents
the engine from starting if the turning gear is engaged.
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PISTON:

Pistons are of the low-friction, composite type with forged steel top and nodular cast iron skirt.
The design itself is tailored for an engine of this size and includes a number of innovative
approaches. Long lifetime is obtained using Wärtsilä’s patented skirt-lubricating system; a
piston crown cooled by ‘cocktail shaker’ cooling, and box type stiff robust skirt design.
Most of the frictional loss in a reciprocating combustion engine originates from the piston rings.
The piston ring set in the Wärtsilä 50DF is optimal with respect to both functionality and effi
ciency. It is located in the piston crown and has two compression rings and an oil control ring.
Every ring is dimensioned and profiled for its task. This three-ring concept has proved its
efficiency in all Wärtsilä engines.

CYLINDER HEAD:

The cylinder head incorporates the four-screw technology introduced by Wärtsilä. At high
cylinder pressures, it has proved its superiority, especially when liner roundness and dynamic
behaviour are considered. It offers reliability and ease of maintenance. In addition, the most
efficient air inlet and exhaust gas channels can be configured with this type of cylinder head.
Cooling water flow has been optimized to provide proper cooling of the exhaust valves, cylinder
head flame plate and the twin needle injection valve. This minimizes thermal stress levels and
guarantees a sufficiently low exhaust valve temperature. Both inlet and exhaust valves are
fitted with rotators for even thermal and mechanical loading.

ENGINE BLOCK:

The engine block is of nodular cast iron, cast in one piece. It features high rigidity, simplicity and
cleanliness. The crankshaft is under slung and gives very high stiffness to the engine block. This
provides excellent conditions for main bearing performance.

CRANKSHAFT AND BEARINGS:

The increasing cylinder pressures of the modern gas engines call for robustness and reliability of
the crank gear. The bearing loads are kept conservative by using large pin and journal
diameters, careful optimization of crank throw dimensions and fillets. Ample oil film thickness is
maintained in the main bearings by careful balancing of the rotational masses and by the use of
an ungrooved bearing surface in the critical areas of the big-end bearings.

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TURBOCHARGER:

The Wärtsilä 50DF is equipped with the modular-built Spex (single pipe exhaust) turbo charging
system, which combines the advantages of both pulse and constant pressure charging. The
interface between engine and turbocharger is streamlined with a minimum of flow resistance
on both exhaust and air sides. High-efficiency turbochargers with inboard plain bearings are
used, and the engine lubricating oil system is used for the turbocharger. The waste-gate is
actuated electro-pneumatically.

AUTOMATION:

All engine functions are controlled by the engine control system, a microprocessor based
distributed control system mounted on the engine. The various electronic modules are
dedicated and optimized for certain functions and they communicate with each other via a CAN
data bus. The engine control system offers the following advantages:
Easy maintenance and high reliability due to point-to-point cabling, high quality cables
and rugged mounting of engine electronics
Easy interfacing with external systems via a data bus
Reduced cabling on and around the engine
High flexibility and easy customizing
Digitized signals - free from electromagnetic disturbance
Built-in diagnostics for easy troubleshooting.

MAIN CONTROL MODULE:

The core of the engine control system is the main control module. This is responsible for
ensuring the engine’s reliable operation and for keeping the engine at optimum performance in
all operating conditions such as varying ambient temperature and gas quality. The main control
module reads the information sent by all the other modules. Using this information it adjusts
the engine’s speed and load control by determining reference values for the main gas
admission, air-fuel ratio and pilot fuel amount and timing. The main control module
automatically controls the start and stop sequences of the engine and the safety system. The
module also communicates with the plant control system (PLC).

CYLINDER CONTROL MODULE:

Each cylinder control module monitors and controls three cylinders. The cylinder control
module controls the cylinder-specific air fuel ratio by adjusting the gas admission individually
for each cylinder. The cylinder control module measures the knock intensity, i.e. uncontrolled
combustion in the cylinder, information on which is used to adjust the cylinder specific pilot

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fuel timing and gas admission. Light knocking leads to automatic adjustment of the pilot fuel
timing and cylinder specific air-fuel ratio. Heavy knocking leads to load reduction or a gas trip.

MONITORING MODULES:

Monitoring modules are located close to groups of sensors, which reduces cabling on the
engine. The monitored signals are transmitted to the main control module and used for the
engine control and safety system. The monitored values are also transferred to the operator
interface on the external control system.

DISTRIBUTION OF ELECTRIC POWER TO PLANT:

There are two lines from WAPDA to full fill some of the demands of the plant (7MW) which are
coming from 132kV grid located at factory area.
The primary demand for the plant is 6.3kV, so the power deliver to Main sub-station is 6.3kV. to
full fill auxiliary requirements different transformer of the appropriate requirements are placed
adjacent to the sub-stations, to full fill the demands.
For distribution of electric power to different departments of the plant, substations are built
with every department to give power to the machines of its area according to their
requirements.
A main Distribution Station (Commonly known as 811 at the plant) is responsible for gathering
all the power from two sources and distribute those to further sub-stations according to
requirement .Following is the list of substations:

811 Main Substation

Cement Mill Substation
Coal Mill Substation
Cooler Substation
Crusher Substation
Raw Mil Substation
Kiln Substation
Packing Substation
Paper Mill substation

Distribution Station (Known as 811 at the Plant):

Here, there are four incoming lines of power. Two lines are coming from WAPDA 132kV grid
(situated at the plant) and two from generation plant. Than this power is distributed forward

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using four Bus-Couplers. Bus-Couplers are opened and closed according to the requirement of
load. At normal running condition plant uses 25 – 30 MW of power.

PANELS USED AT SUB-STATIONS:

 Medium Voltage Panel:

MV panels are used for voltages greater than 1KV.

 Each MV panel has a digital relay for protection.
 Provides power to high power electric machinery.
 For example:
 Kiln substation has MV panels for :
EP fan(1030KW)
Kiln(M01&M02, 2*500KW)
ID fan (1800KW)
Incoming feeder
ID fan (1800KW)
Kiln dept.1(2000KVA)
Kin dept.2(2000KVA)

 Low Voltage Panel:

LV panels are used for voltages less than 1KV.They has

 MCC (Motor control center).
 SIMOCODE (SIRIUS Motor Management and Control Device)

 Frequency Drive Panel:

It uses a variable-frequency drive (VFD) (also termed adjustable-frequency drive, variable-

speed drive, AC drive, micro drive or inverter drive) which is a type of adjustable-speed
drive used in electro-mechanical drive systems to control AC motor speed and torque by
varying motor input frequency and voltage.

 Power Factor Improvement Panel:

It contains a capacitor bank to improve power factor and to improve the efficiency of the
equipment.

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 Uninterrupted Power Supply (UPS) Panel:

UPS panel is used to supply power to all panels in a substation in emergency power failure
so the safety of electrical equipment remains uncompromised.
 55 cells (batteries) connected in series.
 Each cell is of 2V, supplying 110V.
 An inverter is connected to convert DC to AC for operating panels.

Controlling, Maintenance and Supervision of Plant:

For controlling all the operations at the plant, a Central Control Room (CCR) is responsible.

Central Control Room (CCR):

Central control room is the brain of the cement industry. Every move of the industry is being
observed from the central control room. It has the latest technology to control each and every
thing with a single command of computer using highly efficient automation software PLC.
The control room se situated on the very top Floor, where Engineers are watching different
sections of industry on PLC and respond very quickly to any fault in the section with the help of
automation software.
Programmable Logic Control (PLC):
Program able Logic Control (PLC) is the most advanced automation software which is used in
industries now-a-days. User can graphically visualize any process on his/her screen and easily
interfere it by giving different commands.
FLSmidth has designed PLC for DG Khan Cement which is one of the best in the world. Each
engineer watch his/her section and if there is any problem than the PLC indicate the problem
by completely addressing it (as discussed in addressing a panel)show problem level by colour
scheme.
PLC communicates via profibus.
 ITD ept. Exchange,
 Electrical Substations
 Power Plant
 Control Room
PLC Dept. has to look after every component in plant is working properly or not if there will be
any fault according to Automation they have to remove that. Plant has ten (10) major PLC
sections. Main controlling PLC port is of SEIMENS Co Ltd. Signals are sent to control room by
underground wiring of cable. Fiber optics also used for long distances.

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Electric &Instrumentation Department:

This department is responsible for maintaining all the electrical instruments installed on the
plant for monitoring and controlling. Following is the list of some of the important instruments
that are frequently used all over the plant:
PT-100
Thermocouple
Pressure Transmitter
Delta Pressure Transmitter
Level Transmitter
Level switches
Flow Transmitter
Motion Detector

Refused Derived Fuel (RDF):

Refused Derived Fuel (RDF) is the under construction project at DG Cement Plant. RDF indirectly
will clean the city from garbage all the garbage from nearby cities will bring to RDF and a
CRUSHER which using a squirrel cage (induction motor) low starting torque producer will cut-off
the garbage into small pieces that will be conveyed by conveyor belts to storage yard and from
there it will be cleaned from stones and metallic materials using same technology as discussed
before in cement mills. From preheaters this garbage will be thrown into KILN for burning
purposes.

Safety Department:
This department makes sure the safety of the cement plant and its workers in any emergency
case.
They have the most advance firefighting crew which includes the heavy duty Fire brigade which
is equipped with a tank of 5000 liters of water along with two cylinders of dry CO 2, 45kg each.
There are numerous water pipes fixed to ground in different sectors, where fire brigade can’t
reach or fire may be expected there at any time.
The safety department in collaboration with Rescue 1122 arranges different exercises for its
workers to train them for emergency situations.

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