SHAURYA CEMENT NEPAL-ATOX 20 / Coal Mill Critical Interlock

Customer: SHAURYA CEMENT- NEPAL Title

Project: Project No:
ATOX 20
Checke Approv Appr. Date Version Critical Interlock List
d ed 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.
ITEM CONDITION ACTION INTERLO EQUIPM
1 Mill exit temperature < 55 deg C Coal Mill Feeding stops and rollers goes up. CK ENT
Operational Coal Mill
2 Mill exit temperature > 60 deg C Allows start of Coal Mill Start Coal Mill
3 Mill exit temperature > 80 deg C Water pump run interlock Operational Coal Mill
4 Mill exit temperature > 80 deg C Shut down coal mill Operational Coal Mill
5 Mill Inlet temperature > 350 deg C Stop Coal Mill Fan Operational Coal Mill
6 Mill fan power > LoLo Allows start of Coal Mill main drive Start Coal Mill
7 Mill fan power > LoLo Allows operation of water spray pump Start Coal Mill
8 Gearbox Lube Table Start Permissive Allows start of Coal Mill Motor (start permissive comes in 5 Start Coal Mill
minutes after Gear box Lube start up)

9 Gearbox Lube Table Run Interlock Permissive to Run Coal Mill Motor Safety Coal Mill
10 Roller Lube Run Permissive Permissive to Run Coal Mill Motor Safety Coal Mill
11 Table Run Permit from Hydraulics Permissive to Run Coal Mill Motor Safety Coal Mill
12 Coal mill Vibration signal healthy Permissive to Run Coal Mill Motor Safety Coal Mill
13 Mill Motor Bearing Temperature < 90 deg C Permissive to Run Coal Mill Motor Safety Coal Mill
14 Rollers Raised Permissive to Start Coal Mill Motor Start Coal Mill
15 Rollers raised with Pump Running Permissive to Start Coal Mill Motor Start Coal Mill
16 Loss of Feed <5 tons for 10 Sec Raise Rollers Operational Coal Mill
17 Layer thickness <5 mm for 3 sec Raise Rollers Operational Coal Mill
18 Mill Vibration > 4 mm/s for 3 sec Raise Rollers Safety Coal Mill
19 Mill Vibration > 6 mm/s Stop Mill main motor Safety Coal Mill
20 If Mill table stops Raise Rollers Operational Coal Mill
21 If Mill table stops Reducer lube pump continue to run for 2 hours Operational Coal Mill
22 If Mill table stops Stop water spray pump Operational Coal Mill
23 If Mill table stops Set system fan inlet damper to manual and 0% & Fan One Shot Coal Mill
speed to min ~10 %
24 If Mill table stops Shut off Damper 463SD430 Should close 0% One Shot Coal Mill
25 If Mill table stops Coal transport group should not stop for 30 minutes / If Operational Coal Mill
26 If Mill table stops fine
Stopcoal
Feedbin level high trpt group will trip Operational Coal Mill
27 Mill Fan stops Stop grinding system Operational Coal Mill
28 Mill Fan stops Isolate Baghouse with inlet (463BV290) and exit Operational Coal Mill
(463BV330) Butterfly Valve
29 Mill Fan stops Mill Fan Damper to manual and remains at 100% & speed One Shot Coal Mill
to min.
30 Mill Fan stops Close Hot Gas Shutoff Damper and Close Hot Gas Louvre One Shot Coal Mill
Damper

31 Mill Fan stops Stop Booster Fan Operational Coal Mill

32 Mill Fan stops Close Recirculation Damper One Shot Coal Mill
33 If Booster Fan stops Close inlet slide damper Operational Coal Mill
34 If Booster Fan stops Stop Mill Motor Operational Coal Mill
35 Booster Fan bearing temps >87C Stop Booster Fan motor Protective Coal Mill
36 Booster Fan bearing vibration >7mm/sec Stop Booster Fan motor Protective Coal Mill
37 Feed system material path interlocks When conveyor stops all conveyors up stream stop Operational Coal Mill

38 Product conveying through fuel bins stops Stop mill table motor after 1 minuntes Operational Coal Mill
39 Baghouse DP > H2 (200mmwg) Stop Mill Fan Operational Coal Mill
40 Baghouse inlet temperature> H2 (85degC) Stop Mill Fan (Shut down mill and isolate baghouse) Protective Coal Mill

41 Baghouse differential temperature > 8 deg C Stop Mill Fan (Shut down mill and isolate baghouse) Protective Coal Mill

42 Baghouse exit temperature > H2 85deg C Stop Mill Fan (Shut down mill and isolate baghouse) Protective Coal Mill

43 Baghouse exit temperature >H2 85deg C Injects vapor into baghouse/ Isolate Baghouse and open Protective Coal Mill
exit damper to 10% deenergizes filter timer
44 Baghouse hopper temperature > H2 90deg C Stop Mill Motor Protective Coal Mill

45 Either baghouse hopper temperature > 100 deg C Injects vapor into baghouse Protective Coal Mill
46 Tank low water level switch low level Stop Water spray system Protective Coal Mill

47 If Mill table stops Body Water Controller goes to manual and valve to10% One Shot Coal Mill
48 Water spray Valve > 5% open Permissive to Start Water Spray System Start Coal Mill
49 Water Spray Valve not Closed Permissive to Run Water Spray System Safety Coal Mill
50 Dust collector exit O2 < 12% Start permisive for grinding system Start Coal Mill
51 Dust collector exit O2 > 12% Stop Coal Mill Feed Operational Coal Mill
52 Dust collector exit O2 > 12% Shut down Coal Mill Operational Coal Mill
53 Dust collector exit CO > 400 ppm Shut down Coal Mill Fan Operational Coal Mill
54 Seal air fan running Start permisive for separator Operational Coal Mill
55 CO2 Zone 1 or Zone 2 trouble Start Interlock of Coal Mill Fan and Coal Mill Motor Start Coal Mill
56 CO2 Discharging in Coal Mill Shut down Coal Mill Fan / Isolate Baghouse Operational Coal Mill
57 CO2 Discharging in Baghouse Shut down mill fan (stops Mill), de energizes bagfilter Operational Coal Mill
timer,isolate bag house and open exit damper to 10%
58 Liquid CO2 to Baghouse or Mill Stop Coal Mill Motor, Mill Fan, open exit damper to 10% Safety Coal Mill

59 CO2 Critical Low Level Permissive to Start Coal Mill Motor Start Coal Mill
60 Vapor injection on fine Coal bin Shut down coal conveying group,Mill and fan Operational Coal Mill
61 Temp high high in mill inlet ,outlet and baghouse Injects vapor into circuit Safety Coal Mill

62 Any of two fine fuel bin temps >90°C Injects vapor into fine fuel bin, BF 220 inlet TV103,TV104 Safety Coal Mill
63 Fine coal bin CO level > 400ppm close
Injectsand TV 107,TV207
vapor open
into fine fuel bin correspondingly Safety Coal Mill
64 Explosion vent open (On Mill or Baghouse) Shut down mill fan (Isolate baghouse, Stop Grinding Operational Coal Mill
System)
65 Explosion vent on fine coal bin open Shut down coal conveying group and Mill Operational Coal Mill
66 Fuel bin digital high level in fine coal bin Shut down coal conveying group and Mill Operational Coal Mill
67 Fuel bin Weight > H2 38 T Shut down coal conveying group and Mill Operational Coal Mill
68 Fuel bin Weight < H2 38 T Permissive to Start Coal Mill Motor Start Coal Mill
69 Raw Coal Bin Level > L1 Permissive to Start Coal Mill Motor Start Coal Mill
70 Raw Coal Bin Level < L1 Stop Coal Mill Motor Operational Coal Mill
71 Kiln ID fan stops Stop Mill Fan motor Operational Coal Mill
72 If one or more bin temperatures in fine fuel bin > 90 Shut down coal conveying group and Mill Operational Coal Mill
deg C
73 Coal Mill Fan stops Stop Coal Mill Motor Operational Coal Mill Fan
74 Coal Mill Fan stops Close Coal Mill Fan Damper to 0% and Set Speed Output to one-shot Coal Mill Fan
10%
75 Coal Mill Fan Bearing Temps >H2 85 degC Stops Coal Mill Fan Protective Coal Mill Fan
76 Coal Mill Fan Free Bearing Temps >85 C Stops Coal Mill Fan Protective Coal Mill Fan
77 Coal Mill Fan Free winding Temps >110 deg C Stops Coal Mill Fan Protective Coal Mill Fan
78 Coal Mill Fan Bearing Vibration > 4.5 mm/s Stops Coal Mill Fan Protective Coal Mill Fan
79 Coal Mill Baghouse Outlet Guillotine Damper Open Permissive to Run Coal Mill Fan Operational Coal Mill Fan
80 Coal Mill Baghouse Inlet Guillotine Damper Open Permissive to Run Coal Mill Fan Operational Coal Mill Fan
81 Motor Bearing Temperature > H2 85 degC Stop Coal Mill Fan Protective Coal Mill Fan
82 Fan Damper Open Start Interlock for Coal Mill Fan Operational Coal Mill Fan
83 Separator Running Permissive to Run Coal Mill Fan Operational Coal Mill Fan
84 Seal Air Pressure LowLow for 1 Minutes, < Stop Coal Mill Fan Safety Coal Mill Fan
85 150mmwg
Separator Stops Stop Grinding Mode (Raise Rollers & Stop Feed) Operational Coal Mill
86 Separator Stops Stop Coal Mill Fan Operational Separator
Coal Mill
87 Separator Running Permissive to Start Mill motor Start / Separator
Coal Mill
88 Any of 2 Separator Bearing Temp >H2 (100 degC) Stop Separator Motor Operational
Protective Separator
Coal Mill
Separator
89 Separator Grease Sustained Low Level for 1:30 MIN Stop Separator Motor Operational Coal Mill
90 Separator Grease System Distributor Fault If pump is running and no pulse is received in 90 Seconds Autostart Separator
Coal Mill
alarm. And Stop Grease Separator
Pump
91 Separator Grease System Distributor Fault Sustained for 24 Stop Separator Motor Safety Coal Mill
hours Separator
92 Separator Grease Pump Cycling Time On Time = 90 Seconds or until Pulse; Off Time = 15 Autostart Coal Mill
93 Separator Motor Temperature Monitor Fault minutes
Stop Separator Motor Safety Separator
Coal Mill
94 Separator Motor Temperature Monitor Alarm Start Interlock for Separator Motor Start Separator
Coal Mill
95 Separator Speed > 40% Permissive to Start Mill Fan Start Separator
Coal Mill
96 When any of the bag house hopper level is high for Trip the coal mill fan Operational Separator
Coal Mill Fan
more than 10 minutes
97 During operation if roller goes up and rollers are not kept After 120 sec the coal feeding group will trip. Operational Coal Mill Fan
in down position
98 Weigh feeder trip Roller lift after 30 sec Operational Hydraulic
99 Mill main motor current high Roller lift after 5 sec Operational Hydraulic
100 Grinding stop Weigh feeder stop after 60 sec Operational Mill feed
101 Mill differential pressure low low Stop mill feed Operational Mill feed
102 Mill gear box, roller lub or hydraulic stops Stop mill main motor Operational Coalmill
103 Roller lub tank temp >H2 67 degC Stop roller lubrication Operational Coalmill
104 Roller lub return oil temp >H2 72 degC Stop roller lubrication Operational Coalmill
105 Roller lub feed pump flow < 2.8lpm Stop roller lubrication Operational Coalmill
106 Roller lub Aqua sensor > H2 90% Stop roller lubrication Operational Coalmill
107 Gear box input shaft temp > H2 49 deg C Stop Mill motor Operational Coalmill
108 Gear box bearing temp > H2 85 deg C Stop Mill motor Operational Coalmill
109 Gear box vibration > H2 7mm/s with 5 sec delay Stop Mill motor Operational Coalmill
110 Mill main motor winding temp> 110 degC Stop Mill motor Operational Coalmill
111 Mill main motor bearing temp> 90 degC Stop Mill motor Operational Coalmill