Customer: SHAURYA CEMENT Title

LIMITED
Project:
NEPAL
KILN
Project No:Chec Appr Versi
Appr. Date Critical Interlock List
ked oved on
1.0
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written
consent from
FLSmidth.

ITE CONDITION ACTION INTE EQUIP STAT

M
1 Preheater Exit CO > 1.2% Stop all firing, Stop preheater ID Fan Safety KilnMENT OK
RLOC US
K
2 Preheater Exit CO > 0.9% (H2)for 3 minutes consecutively All fuel firing Stops Kiln and ILC Safety Kiln OK
3 Preheater Exit CO > 0.5% Alarm Safety Kiln OK
4 Preheater Exit Analyser test mode for > 5mins All fuel firing Stops Kiln and ILC Safety Kiln OK
5 Kiln Inlet CO > 2.5% for 10 minutes Stop preheater ID Fan Safety Kiln OK
6 Main Baghouse Fan Stops Stop preheater ID Fan Operatio Kiln OK
7 Preheater ID Fan Inlet Temperature (Cond Tower Exit Temp) < Precondition to Start Preheater ID Fan nal
Start Kiln OK
8 370c
Preheater ID Fan Inlet Temperature (Cond Tower Exit Temp) > Stop Preheater ID Fan Safety Kiln OK
9 450c
Stage 1Exit Temperature > 450c Stop Preheater ID Fan Operatio Kiln OK
10 Preheater ID Fan Bearing vibration > 4.5 MM/S Stop Preheater ID Fan nal
Safety Kiln OK
11 Preheater ID Fan Bearing Temperature > 85c (two bearings) Stop Preheater ID Fan Safety Kiln OK
Preheater
fan motor ID
12 Preheater winding temp>110
Fan Damper c Limit Switch or Analog < 5%
Closed Precondition to Start Preheater ID Fan Start Kiln NA

13 Reduction Zone or Calciner Exit Temperature > 750c Permissive for Start ILC firing Operatio Kiln OK
14 Kiln Main Motor Running Permissive for Start ILC firing nal
Operatio Kiln OK
15 Kiln Feed Recirculating > 40tph Permissive for Start ILC firing nal
Start Kiln OK
16 Calciner Exit Draft >1.0 mbar Permissive for Start ILC firing Start Kiln OK
17 Calciner Exit or Stage 5 Exit Temperature > 930 C Reduce Calciner Firing 50% and controller comes to Manual Operatio Kiln OK
18 Calciner Exit or Stage 5 Exit Temperature > 980 C Reduce Calciner Firing to minimum and controller comes to nal
Operatio Kiln OK
Manual nal
19 Reduction Zone or Kiln Backend or Kiln Feed Inlet Temperature Permissive For Kiln Burner Coal Firing Operatio Kiln OK
> 450
20 Preheater ID Fan Stops or Kiln Shutdown All ILC, kiln Fuel Firing Stops, Coal nal
Safety Kiln OK
C
21 Preheater ID Fan Stops or Kiln Shutdown Set Preheater ID Fan Inlet Damper to 0% Manual One Kiln OK
22 Preheater ID Fan Stops or Kiln Shutdown Set Preheater ID Fan Speed to 10% Manual Shot
One Kiln OK
Shot
23 Preheater ID fan stops then pre heater fan damper should close This is should be start up interlock for the pre heater fan start up One Kiln OK
to <5% Shot
24 Preheater ID Fan Stops or Kiln Shutdown Reduce Kiln Speed to Minimum Speed 0.5 rpm One Kiln OK
25 Preheater ID Fan Stops or Kiln Shutdown Reduce the ABC Fan Speed to Preset Valur. Shot
One Kiln OK
26 Preheater ID Fan Stops or Kiln Shutdown Reduce CB1 Fans Speed to Preset Value. Shot
One Kiln OK
27 Preheater ID Fan Stops or Kiln Shutdown Stop Tower Blasters Shot
One Kiln OK
28 Preheater ID Fan Stops or Kiln Shutdown One Shot Cooler Drives to Minimum Speed 2 st/min Shot
One Kiln OK
29 Kiln Main Motor Running Or Auxiliary Motor Running Continuous Permissive to Run Kiln Shell Fans Shot Kiln OK
30 Kiln Inlet seal air fan or Kiln outlet seal air fan trips for 15 Kiln Shutdown Operatio Kiln OK
Minutes nal
31 Main Motor Running < 1 rpm or Auxilliary Motor Running Run Supporting roller Bearing Lube Pumps Autostart Kiln OK
32 To start kiln auxilary or kiln main motor the bearing lubrication Start permissive for Kiln auxillary/Main motor Operatio Kiln OK
pumps nal
to be start up interlock
33 Kiln gear box lubrication temperature greater than 85 deg C Stop Kiln Main Drive and Shutdown Kiln Safety Kiln OK
then kiln
main motor will trip.
34 Kiln Gear box lubircation pumps When Pump is Required to Run, if Flow Switch Fails Stop Kiln Main Safety Kiln OK
Motor and Gearbox Lube Pump
35 Any Support roller Kiln Bearing Temp > 65 C Stop Kiln Main Motor Safety Kiln OK
36 Support roller lubrication group running > 3 mins Start permissive for Kiln Main/Auxillary motor Motor Safety Kiln OK
37 Support roller lubrication pump flow low Stop pump and create alarm, and not to trip kiln Safety Kiln OK
38 Not possible to Run Main Motor and Aux Motor Together Start permissive for Kiln Main/Auxillary motor Motor Operatio Kiln OK
39 Barring Schedule Auxillary drive nal
Operatio Kiln OK
40 Kiln Position is Not Interlocked to Auxiliary Motors Allowed to Run Aux Motors Regardless of Kiln Position. nal
Operatio Kiln OK
41 If Kiln is uphill 15mm from Analog Kiln Main Motor Stops / permissive to Start nal
Safety Kiln OK
42 If Kiln is downhill 15mm from Analog Kiln Main Motor Stops / permissive to Start Safety Kiln OK
43 If Kiln is uphill 15mm Limit Switch Kiln Main Motor Stops / permissive to Start Safety Kiln OK
44 If Kiln is downhill 15mm Limit Switch Kiln Main Motor Stops / permissive to Start Safety Kiln OK
45 Kiln Position < -5 mm (More than 5 mm Downhill) Start Hydraulic Thrust Pump Autostart Kiln OK
46 Kiln Position > 0 mm (Not Downhill) Stop Hydraulic Thrust Pump Autostart Kiln OK
47 Kiln Position > 5 mm (More than 5 mm Uphill) Open Hydraulic Dump Valve Autostart Kiln OK
48 Kiln Position < 0 mm (Not Uphill) Close Hydraulic Dump Valve Autostart Kiln OK
49 Kiln winding temp >100 deg C Stop kiln main motor Safety Kiln OK
50 Kiln bearing temp >90 deg C Stop kiln main motor Safety Kiln OK
51 Kiln follower main motor not ready Stop kiln main motor Safety Kiln OK
52 Kiln auxillary motor not ready Stop kiln auxillary motor Safety Kiln OK
53 Hydraulic Thrust Stytem Functionality Only Functions if Main Drive or Aux Drive Running Working Kiln OK

54 Primary Air Fan Stops / Permissive to Run Stops Fuel Firing at Main Burner and Oil firing Safety Kiln OK

55 Primary Air Fan Stops Emergency Cooling Fan Starts Automatically, Shutoff Damper Safety Kiln OK
Opens
56 Primary Air Fan Damper Closed or < 5% Start Permissive for Primary Air Fan Safety Kiln OK
57 All Main Fuel Firing Stops (with Kiln Feed on) Kiln Shutdown Operatio Kiln OK
58 ILC Fuel Firing Stops (with Kiln Feed on) for 3 Minutes Kiln Shutdown Bit nal
Operatio Kiln OK
59 Kiln Pfister Fuel Feeder Stops Set controller to 10% of full range and manual Operatio
nal Kiln OK
60 Calciner Pfister Fuel Feeder Stops Set controller to 10% of full range and manual nal
Operatio Kiln OK
61 Correct Coal blowers Running Permissive to Start Pfister Fuel Feeders nal
Start Kiln OK
62 Preheater ID Fan Running If False, Inhibit Feed Selection Operatio Kiln OK
63 Main Baghouse Fan Running If False, Inhibit Feed Selection nal
Operatio Kiln OK
64 Kiln Feed Recirculating If False, Inhibit Feed Selection nal
Operatio Kiln OK
65 Kiln Coal Pfister Running If False, Inhibit Feed Selection nal
Operatio Kiln OK
66 Calciner Coal Pfister Running If False, Inhibit Feed Selection nal
Operatio Kiln OK
67 Calciner outlet temperature > L2, i.e 750 deg c If False, Inhibit Feed Selection nal
Operatio Kiln OK
68 Splitter gates and slide gates should be healthy If False, Inhibit Feed Selection nal
Operatio Kiln OK
69 Rotary Airlocks RF385 running Feedback If False, Inhibit Feed Selection nal
Operatio Kiln OK
70 All Cyclone Cone draft < H2 If False, Inhibit Feed Selection nal
Operatio Kiln OK
71 Kiln Main Drive Stops Force Kiln Feed to Recirculation nal
Operatio Kiln OK
72 Preheater Blaster Group Preheater fan running nal
Operatio Kiln OK
73 Clinker handling material path Interlock Operation of subsequent conveyor is precondition for previous nal
Operatio Cooler OK
74 Digital High level in Clinker Bin conveyor
The cooler trips after two minutes and the DPC keeps on nal
Operatio Cooler OK
running till the operator stops. nal
75 Pan Conveyor After Clinker Cooler Stops Stop all Cooler Drives and Clinker Breaker Operatio Cooler OK
76 Clinker Breaker Stop all Cooler Drives nal
Operatio Cooler OK
77 Grease Sustained Low Level for 1:30 MIN Stop Separator Motor nal
Operatio Cooler OK
78 Grease System Distributor Fault If pump is running and no pulse is received in 90 Seconds nal
Autostart Cooler OK
alarm and Stop Grease Pump
79 Grease Pump Cycling Time On Time = 90 Seconds or until Pulse; Off Time = 15 minutes Autostart Cooler OK

80 Breaker bearing temp > 90 deg C Stop clinker breaker Operatio Cooler OK
81 Breaker winding temp > 110 deg C Stop clinker breaker nal
Operatio Cooler OK
nal
82 Any Cooler Fan Stops - Permissive to Run Cooler Drives Stop all Cooler Drives Operatio Cooler OK
nal

83 Undergrate Pressure > Then Lo Lo The tag number is 441CC100N01P01Permissive to Run Any Operatio Cooler OK
Cooler Drives nal

84 Preheater ID Fan Stops or Kiln Shutdown Reduce ABC Fans Speed to 30% and the damper to 20% One Shot Cooler OK
85 Preheater ID Fan Stops or Kiln Shutdown Reduce CB2,3,4,5,6,7,8,9 Fans Speed to 20% One Shot Cooler OK
86 CIS Cooler Fans Stops Shutdown Kiln One Shot Cooler OK
87 Cooler Vent Fan Stops Reduce ABC Fans Speed damper to 20% Operatio Cooler OK
88 Cooler Vent Fan Stops Reduce fan speed for 305-335 to 20% nal
Operatio Cooler OK
89 Cooler Vent Fan Stops Stop fan 325,330 and 335 nal
Operatio Cooler OK
90 Both Preheater ID Fan & Cooler Vent Fan Stop Reduce ABC Fan Dampers to 10 % Manual nal
Operatio Cooler OK
nal
91 Both Preheater ID Fan & Cooler Vent Fan Stop Stop Cooler Fans CB1,2,3,4,5,6 Operatio Cooler OK
nal
92 ESP Outlet Temp > H2 C for (380 C) 5 minutes Cooler Vent Fan Stops Safety Cooler OK

93 ESP Outlet Temp > H3 i.e. (400 C) Cooler Vent Fan Stops Immediately Safety Cooler OK
94 Cooler Vent Fan Stops Set Cooler Vent Fan Inlet Damper to 0% manual, And Speed to Operatio Cooler OK
95 Cooler Vent Fan Bearing Vibration > 4.5 mm/s 10
Cooler Vent Fan Stops nal
Safety Cooler OK
% Manual

96 Cooler Vent Fan Bearing Temperature > 85 C, cooler fan motor Cooler Vent Fan Stops Safety Cooler OK
winding
97 temp>110
Cooler Ventc Fan Damper Closed (Limit Switch or Analog < 5%) Permissive to Start Cooler Vent Fan Start Cooler OK

98 Cooler Fan Damper Closed (Limit Switch or Analog < 5%) Start Interlock for Each Cooler Fan 300 & 305 Start Cooler OK

99 Cooler Vent Fan Running Start Permissive for Cooler Fans Group Start Cooler OK
100 Cooler Drive Stops for 5 minutes Shutdown Kiln Operatio Cooler OK
101 Cooler Drive Stops Put Pressure Controller in Manual and to 2 spm nal
Operatio Cooler OK
102 Cooler Drives Running Permissive for Cooler Blasters Auto Sequence nal
AutoStar Cooler OK
103 CIS Undergrate Pressure > Then Lo Lo Permissive for Cooler Blasters Auto Sequence tAutoStar Cooler OK
104 Cooler Air Blaster supply Air Pressure Alarm Stop Cooler Blaster Sequence tStart Cooler OK
105 Kiln Shutdown Bit or Main Drive < 0.8 rpm One Shot Stop Cooler Blaster Auto Sequence One Cooler OK
Shot/Op
erational
106 Cooler Fan motor Bearing Temperature > 85c (two bearings) Stop Corresponding Cooler Fan Safety Cooler OK
cooler fan motor winding temp>110 c
107 Bleed Air Damper To Cooler Vent recirculation fan Controls Cooler Fan Inlet Temperature Controller Cooler NA
108 Main Baghouse Fan stops Stop Raw Mill Fan Operational Main Bag OK
109 Main Baghouse Fan stops Stop Preheater ID Fan Operational House
Main Bag OK
110 Main Baghouse Fan stops Close Main Baghouse Fan Damper to 0% one-shot House
Main Bag OK
and Set Speed Output to 10% House

111 Main Baghouse Fan Bearing Temps >85c Bag house fan stops Safety Main Bag OK
112 Main baghouse hopper level switch > 2 switch acted Bag house fan stops Safety House
Main Bag OK
113 Main Baghouse Fan Bearing Vibration > 4.5 mm/s Bag house fan stops Safety House
Main Bag OK
114 Bag house transport or cyclone transport Stoped for >25 minutes Bag house fan stops Operational House
Main Bag OK
House
115 Main Baghouse Inlet Temperature > 230c FOR 10 MINUTES Stop Main Baghouse Fan Safety Main Bag OK
House
116 Main Baghouse Inlet Temperature > 250 c Stop Main Baghouse Fan Safety Main Bag OK
117 Preheater Fan Exit Pressure Controller Using Main Baghouse Fan Auto loop for Pre heater out let pressure PID House
Main Bag OK
Speed House
118 Fan Damper Closed (Limit Switch or Analog < 5%) Start Interlock for Main Baghouse Fan Start Main Bag OK
119 Baghouse dust conveying material path interlock When a conveyor stops all conveyors up HouseBag OK
Start/Operati Main
stream stop onal House
120 Dust Elevator Main Motor Running Stop Dust Elevator Inching Motor Safety Main Bag OK
121 Dust Elevator Inching Motor Running Stop Dust Elevator Main Motor Safety House
Main Bag OK
122 Dust Elevator Inching Motor Only Available to Run In Local Protective House
Main Bag OK
123 Dust Elevator Boot Level Alarm (0 second Delay) Stop Screw Feeding Elevator Operational House
Main Bag OK
124 Dust Elevator Boot Level Alarm (10 Minutes Delay) Stop Elevator Operational House
Main Bag OK
House
125 When any of the cooler fan o/l pressure is less than L3 then cooler drives will trip immediately. Operational/s Cooler OK
This is also a starting interlock afety drive
126 When any of the cross bar temperature increases more than H3 Then cooler drive will trip immediately. Operational Cooler OK
drive
127 When the cooler bag house DP is higher than H3 Then cooler vent fan will trip. OK
128 When the cooler drive inlet or out let hydraulic pressure is more Then cooler drive will trip. Operational Cooler OK
than drive
250 bar
129 When the system pressure of cooler bag house is less than 3 bar Then cooler vent fan will trip. NOT GIVEN

130 Cooler fan compartment temp > H2 120 deg C Stop fans 320,325 and 330 correspondingly Operational Cooler OK
drive
131 Baghouse fan & Preheater fan running Start permissive for kiln startup burner Operational kiln burner OK
132 Primary air blower running Start permissive for kiln startup burner Operational kiln burner OK
133 DOT oil tank level low Start permissive for kiln startup burner Operational kiln burner OK
134 Oil control valve > 20% Start permissive for kiln startup burner Operational kiln burner OK
135 Cooler drive trip Reduce Kiln Speed to Minimum Speed 0.5 One Shot Kiln OK
136 PC firing LIW trips rpm
Reduce Kiln Speed to Minimum Speed 0.5 One Shot Kiln OK
137 PC firing LIW trips rpm trip after 3 mins
Kiln Operational Kiln OK
138 Calciner outlet draft > 1 mbar Start permissive for PC firing LIW Operational LIW OK
139 Kiln feed diverted to recirculation more than > 2mins Stop PC firing LIW Operational LIW OK
140 Kiln feed diverted to recirculation Kiln firing LIW setpoint to preset value 1 tph One shot LIW OK
141 Minimum 2 cooler fans running Start permissive for Kiln firing LIW Operational LIW OK
142 Selected FKPump and Blower to run in the path Start permissive for Kiln & PC firing LIW Operational LIW OK
143 CO2 injection in LIW calibration bin Start permissive for Kiln & PC firing LIW Operational LIW OK
144 CO2 injection in FKPump Start permissive for corresponding LIW Operational FKPump OK
145 Preheater fan O/L pressure > 0 mbar for 2 mins Start permissive for preheater fan Operational Kiln OK

146 PH fan bypass interlock Start permissive for startup firing Operational Kiln OK
147 Kiln inlet CO> 2.5% for 10 mins Stop preheater fan Operational Kiln OK
148 ABC inlet temp >H2 Stop cooler air blasters Operational Blasters OK
149 Kiln speed > 0.8 rpm Start permissive for cooler air blasters Operational Blasters OK
150 Cooler drives running Start permissive for cooler air blasters Operational Blasters OK
151 Cooler tower pressure > L2 20 mbar Start permissive for cooler air blasters Operational Blasters OK
Customer: Title
SHAURYA CEMENT LIMITED
Project: KILN
NEPALChec Appr Versi Critical Interlock List
Appr. Date
Project No:ked oved on
1.0
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and
may not be duplicated, disclosed, or utilized without written consent from FLSmidth.
1 2 3 4 5
Conditions Causing Kiln System Forced Shutdown
( This Is Only Active When Feed Is On ) = Feed Selected To Kiln
Loss Of All Kiln Fuel
Loss Of All Calciner Fuel > 3 Min. Kiln Main Drive Stops
Cooler Drives Stopped > 5 Min. Preheater ID Fan Stops
Loss Of Kiln Feed > 1 Min.
Kiln Rotary Feeders Stop ( Rotary Feeding Kiln ) ABC Fan Stopped
Main Baghouse Transport Screw Down > 30 Min. Kiln Inlet or Kiln outlet Seal Air fan stops > 15 Min.
Actions To Be taken When Kiln System is Forced Shutdown
Reduce Preheater ID Fan To Minimum Speed and Close Damper Kiln Feed To Recirculation ( One Shot Selector To
Recirc )
Stop All calciner Fuel And Turn PID Controllers To Manual And Minimum Stop All Kiln Fuel And Turn PID Controllers
To Manual And Minimum
Reduce Cooler Speed To minimum And Turn PID Controllers To Manual And Minimum Stop Preheater Air Bla
Stop Cooler Air Blasters
Reduce Kiln Speed To minimum And Turn Off Feed To Speed Selector Reduce Kiln Primary Air blower speed To
10%
Move Dividing Gate position To Riser ( Gate That Splits Feed Between Riser And Upper Calciner )
Move Dividing Gate Position To Riser ( Gate That Splits Feed Between Riser And Lower Calciner )
Reduce Cooler Fans As per Below Chart For Kiln System Shutdown
Kiln System Forced Shutdown Or ID Fan Stops
CIS Fans Speed Reduced To 40% and the damepr to 20% CB1 Fans Speed Reduced To 20% and the damper to
20%
CB2 To CB6 Fans Speed Reduced To 20% and the damper to 10%
If cooler Vent Fan Stops
CIS Fans Speed Reduced To 40% and the damper to 20% CB1 Fans Speed Reduced To 20% and the damper to
20% CB2 To CB6 Fans Speed Reduced To 10%
Both Cooler Vent And ID Fans Stops
CIS Fans Speed Reduced To 10%
CB1 To CB6 Stopped And Dampers Closed
CB1 To CB6 Stopped And Dampers Closed
 tary and confidential property of FLSmidth, and
consent from FLSmidth.
5

o Kiln

outlet Seal Air fan stops > 15 Min.

n
Kiln Feed To Recirculation ( One Shot Selector To

nimum Stop All Kiln Fuel And Turn PID Controllers

anual And Minimum Stop Preheater Air Bla

ector Reduce Kiln Primary Air blower speed To

ween Riser And Upper Calciner )

ween Riser And Lower Calciner )
n

ans Speed Reduced To 20% and the damper to

ans Speed Reduced To 20% and the damper to