Process Measurements Schedule

INDEX
Summary Table
Weighing
CCR data collection
Cooler Fans
Flow Rate Measurements
Preheater_gas analyses_Pst_T (C )
Preheater_meas.&sampling codes
Clinker T (C )_Tertiary Air (C )
Shell loss kiln
Shell loss _kiln hood
Shell loss_cooler
Shell loss_preheater
Shell loss_preca_riser duct
Shell loss_tertiary air
Measurement
Area Tools to be used Measurement to be done Responsibility During of Reading Person in charge
dates
Cyclones inlet&outlet gas analyse, Pst, T (C ) Process 1/day
Down comer gas analyse, Pst, T (C ) Process 2/day
Down comer duct gas flow rate Process 1/day
Gas analyser
Manometer Kiln Inlet gas analyse, T( C), Pst Process 2/day
Thermocouple Precalciner burner fan flow rate Process 1/day
preheater,kiln
S-tube/pitot tube Preheater cyclones incl. calciner shell
Anemometer Production 1/day
temperature
Hand, Pyrometer
Kiln hood shell temperature Production 1/day
Tertiary air shell temperature Production 1/day
Kiln shell temperature Production 1/day
Cooler fans flow rate Process 1/day
Cooler fans Pst (before&silencer, before and after
Process 1/day
Stube/Pitot tube, fan)
Manometer, Cooler stake gas flow rate Process 1/day
Cooler Thermocouple, Water injection to cooler (24 Hrs)( Production 24 hrs
pyrometer,counters Cooler exit gas temperature Production/Process 6/day
Tertiary air temperature Production/Process 6/day
Clinker temperature Production 6/day
Cooler shell temperature Production 1/day
Anemometer, Manometer,
Main Burner Thermocouple Primary air fan flow (from fan) Process 1/day
Counters of kiln feed, main burner coal,

every 4 hours and at
CCR printers precalciner coal, print out shell scaner. Production
any shut down
Kiln and cooler mimic screen
Clinker weighing for 24 hours, Production 24 Hrs

Phsycial Weighing 2times(Starting and
Kiln dust weighing 1hour Production
ending of audit)
99440.103
KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 1
Plant Name Fujara Kiln Feed Preheater dust Bypass Dust Clinker Clinker t/d
Name of the Kiln Kiln Flowrate wet, kg/h 8068
Kiln Type H2O, %
Date and start time year: Temperatures,°C
Date and end time Crystall Water, % 0
If preheater dust is added after kiln feed weighing
Ambient temperature, °C
Altitude above sea level, m. 150 Kiln Feed Preheater dust Bypass Dust Clinker Hot meal
Atmospheric pressure, hPa 994.44 150 SiO2 ,%
Ambiente relative humidity, % Al2O3 ,%
Fe2O3 ,%
SO2 trapping % of S-2 CaO, %
TOC burnt in calciner Decarb. before calciner: MgO, %
Ratio hot meal/kk LOI ,%
Kiln inlet dust g/kgck CO2 ,% ###
K2O ,%
Is there a by-pass in the kiln? Na2O ,%
Volume of bypass gas extracted at kiln inlet, Nm³/h 0 SO3 ,%
TiO2 ,%
P2O5 ,%
Non Carbonated CaO in Kiln Feed / Total CaO, % 0 Fuel Carbon-TOC,%
Non Carbonated MgO in Kiln Feed / Total MgO, % 0 Cl- , %
S-2 ,% free lime:
Kiln feed dry - back calculated, kg/h: 478114 509141 LOI check 0.00 0.00
Total 0.00 0.00 0.00 0.00 0.00
KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 2
KILN FUELS on Burner BACK END FUELS OTHERS

Choose Fuel Typeð
Name of Fuel Coal Petcoke Coal Petcoke Sludge Others TOC SNCR S-2
Flowrate, kg/h fired 8379 5132 12546 7685 3125 25 0.00
Analyse (dry / wet) wet wet wet wet wet dry dry dry
Carbon, % 0.00 0.00 100
Hydrogen, % 0.00 0.00
Sulphur, % 0.00 0.00 100
Oxygen, % 0.00 0.00
Nitrogen, % 0.00
Ash, % 0.00 1.00
Cl-, %
Total, % 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1.0 0.0 0.0 100.0 0.0 100.0
LHV [kJ/kg] 0 0 33830 0 13120
H2O, % 0.00 0.00 0.00 0
Temperatures,°C
volatiles,% 0 0 46
fossil carbon, %
oil density, kg/dm³
Ash 1 Ash 2 Ash 3 Ash 4 Ash 5 Ash 6 Ash 7 Ash 8 Ash 9 Ash 10
SiO2, % 0
Al2O3, % 0
Fe2O3, % 0
CaO, % 0
MgO, % 0 7151.935
K2O, % 0
Na2O, % 0
TiO, %
P2O5, %
Fe metallic, %
AL metallic, %
Total, % 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Weighing Team Plant Process & Production Team
Weighing Start Weighing Finish

Weighing Period Weighing Method
Time/Date Time/Date Back to INDEX!!!
Kiln feed 24 hours From kiln feed system counter
Clinker 24 hours By truck weighing

Preheater dust 1 Hr By truck weighing
Water injection to cooler 24 hours From water injection system counters
Coal Main burner 24 hours From Coal counters
Coal Calciner burner 24 hours From Coal counters

Sludge 24 hours From the level of the hopper
Responsible Team Plant Process & Production Team
Back to INDEX!!!
Start time Finish time
Kiln feed counter
Cooler water injection counter
Main burner counter
Calciner burner counter
Sludge
Start date Finish date Frequency Period

Kiln&Preheater mimic screen print out 6x 4 hours 24 hours
By pass mimic screen print out 6x 4 hours 25 hours
Cooler mimic screen print out 6x 4 hours 26 hours
All kiln and cooler data 24 hours from plant data collection system plant guide (minute by minute as average of seconds)
Calculations will be done according to plant average data which were corrected according to audit measurements.
That's why data collection is highly important !!!!
Measurement Point Cooler Fans
Measurement Team To be decided during plant visit
Measurement Tools Manometer/anemometer, thermocouple, 1 meter Pitot tube/anemometer pro
31.01.2013
Pst T (oC) T (oC) fan Pd1 or Pd2 or Pd3 or Pd4 or Pd5 or Pd6 or Pd7 or Pd8 or
Time Pst suction rpm kW
fan exit suction exit V1(m/s) V2(m/s) V3(m/s) V4(m/s) V5(m/s) V6(m/s) V7(m/s) V8(m/s)
Fan 1
Fan 2
Fan 3
Fan 4
Fan 5
Fan 6
Fan 7
Fan 8
Fan 9
31.01.2013
Pst T (oC) T (oC) fan Pd1 or Pd2 or Pd3 or Pd4 or Pd5 or Pd6 or Pd7 or Pd8 or
Time Pst suction rpm kW
fan exit suction exit V1(m/s) V2(m/s) V3(m/s) V4(m/s) V5(m/s) V6(m/s) V7(m/s) V8(m/s)
Fan 1
Fan 2
Fan 3
Fan 4
Fan 5
Fan 6
Fan 7
Fan 8
Fan 9
T (oC) fan
Time Pst in duct T (oC) suction V1 (m/s) V2 (m/s) V3 (m/s) V4 (m/s)
exit
Burner Pipe Primary Air Fan
Burner Pipe Swirl Air
Burner Pipe Axial Air
T (oC) fan
Time Pst in duct T (oC) suction V1 (m/s) V2 (m/s) V3 (m/s) V4 (m/s)
exit
Burner Pipe Primary Air Fan
Burner Pipe Swirl Air
Burner Pipe Axial Air
DC
C1 (e)
Back to INDEX!!!
C1 (i)
C1
C2 (e)
C1 T (C)
C2
C2 (i)
C3 (e)
C2 T (C)
C3 (i)
C3
C4 (e)
C3 T (C)
C4 (i)
C4
C4 T (C)
RZ (T)
K2
K1
Measurement Point Preheater, preca, downcomer
Measurement Tools Water cooled probe, gaz analyzer, straight metal pipe for Pst, thermocouple
Supplier for Tools Plant
Pst T gaz( C) T mat (C ) %O2 Nox ppm CO2 % SO2 ppm CO ppm
Kiln Inlet K1
After kiln inlet sealing K2
Cyclone 5 inlet C5(i) C5(T)
Cyclone 5 exit C5(e)
C4(T)
Cyclone 4 inlet C4(i)


Cyclone 1a inlet C1a(i) C1a(T)
Cyclone 1a exit C1a(e)

Cyclone 1b inlet C1b(i) C1b(T)
Cyclone 1b exit C1b(e)
Down comer DC
Measurement Point Cooler Exit,
Measurement Tools Thermocouple, isothermal vessel
Cold Clinker Temperature Tertiary Air Temperature Cooler exit gas temperature
10:00
14:00
18:00
31.01.2013, 1.02.2013
22:30
11:50
1:05
Measurement Point Kiln Shell
Measurement Team To be decided
Measurement Tools Pyrometer
04.02.2013
Ambient Temperature (°C) 31.6
Diameter (m) 5.25
Production (kg/h) 327000.0
Wind (m/s) 3.6
Length (m) 82
Radiation coefficient e 0.95
Zone Fans
T°C
Length Surface Tmax Tmin m/s
average
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
1.00 16.49
Measurement Point Kiln Hood
04.02.2013
Name Front Side
Geometry Temperature Wind
Ambiant Surface speed
Height Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Name Right Side

Heigh Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Name Left Side

Heigh Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Name Kiln Hood Ceiling Part (using side temp)

Lenght Surface
°C °C m/s
Horizontal S1 Up
Horizontal S2 Up
Horizontal S3 Up
Horizontal S4 Up
Horizontal S5 Up
Measurement Point Cooler
04.02.2013 04.02.2013
Name Cooler Crusher side Name Cooler Crusher side

Geometry Temperature Wind Geometry Temperature Wind
Ambiant Surface speed Ambiant Surface speed
Heigh Surface Heigh Surface
°C °C m/s °C °C m/s
Vertical S1 Vertical S1
Name Cooler Right Side Name Cooler Right Side
Name Cooler Left Side Name Cooler Left Side

Name Cooler Ceiling Part (using side temp) Name Cooler Ceiling Part (using side temp)
Lenght Surface Lenght Surface
Horizontal S1 Up Horizontal S1 Up
Measurement Point Preheater
05.02.2013 string A 05.02.2013 string B

Name cyclone 5 Name cyclone 5
Diam / Ambiant Surface speed Diam / Ambiant Surface speed

Surface Surface
Length °C °C m/s Length °C °C m/s
Cone (av. top /down diameter) Cone (av. top /down diameter) 31.0 83.3 1.5
Cylinder Part Cylinder Part 31.0 127.5 1.5
Ceiling Ceiling 31.0 90.0 1.5
Outlet Gas duct Outlet Gas duct 31.0 143.3 1.5
Outlet Meal duct Outlet Meal duct 30.0 118.3 1.5
Riser Duct Riser Duct 31.0 123.0 1.5

Diam/ Ambiant Surface speed Diam/ Ambiant Surface speed

Surface Surface
Cone (av. top /down diameter) Cone (av. top /down diameter)
Cylinder Cylinder
Ceiling Ceiling
Outlet Gas duct Outlet Gas duct
Outlet Meal duct Outlet Meal duct
Riser Duct Riser Duct
Name cyclone 3 Comments Name cyclone 3 Comments


Surface Surface
Cylinder Cylinder
Ceiling Ceiling


Surface Surface
Cylinder Cylinder
Ceiling Ceiling
Name cyclone 1a Name cyclone 1a


Surface Surface
Cylinder Cylinder
Ceiling Ceiling
Name Common riser Duct Name cyclone 1b


Surface Surface
Goose Neck Cone (av. top /down diameter)

Middle Cylinder
C.R.D to CN 150 Ceiling
C.R.D to CN 250 Outlet Gas duct
Outlet Meal duct
Riser Duct
Measurement Point Preca Riser Duct
05.02.2013
Name Calciner top Section
Diam/ Ambiant Surface speed
Surface
Length °C °C m/s
Vertical S1 31.0 74.0 2.2
Vertical S2 31.0 125.0 2.2
Vertical S3 31.0 130.0 2.2
Vertical S4 31.0 80.0 2.2
Vertical S5 31.0 95.0 2.2
Name Calciner Bottom Section

Heigh Surface
°C °C m/s
Vertical S1 31.0 105.0 1.35
Vertical S2 31.0 130.0 1.35
Vertical S3 31.0 160.0 1.35
Vertical S4 31.0 180.0 1.35
Vertical S5 31.0 190.0 1.35
Name Calciner Bottom Section Cone

Heigh Surface
°C °C m/s
Vertical S1 31.0 120.0 1.35
Vertical S2 31.0 180.0 1.35
Vertical S3 31.0 160.0 1.35
Vertical S4 31.0 150.0 1.35
Vertical S5 31.0 170.0 1.35
Vertical S6 31.0 200.0 1.35
Vertical S7 31.0 190.0 1.35
Vertical S8 31.0 180.0 1.35
Vertical S9 31.0 90.0 1.35
Vertical S10 31.0 1.35
Name Calciner Middle section

Heigh Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Name Riser Vertical Part Right Side

Heigh Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Vertical S6
Vertical S7
Vertical S8
Vertical S9
Vertical S10
Name Riser Vertical Part Left Side

Heigh Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Vertical S6
Vertical S7
Vertical S8
Vertical S9
Vertical S10
Name Riser Vertical part face to the kiln

Lenght Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Vertical S6
Name Riser Vertical Part Opposite to the Kiln

Lenght Surface
°C °C m/s
Vertical S1
Vertical S2
Vertical S3
Vertical S4
Vertical S5
Vertical S6
Vertical S7
Vertical S8
Vertical S9
Vertical S10
Measurement Point Tertiary Air
05.02.2013
Ambient Temperature (°C) 31
Diameter (m) 3.35
Production (kg/h) 327000.0
Wind (m/s) 1.02
Length (m) 92
Radiation coefficient e 0.94
Zone Fans
T°C
Length Surface Tmax Tmin m/s
average
1 1.00 10.52
2 1.00 10.52
3 1.00 10.52
4 1.00 10.52
5 1.00 10.52
6 1.00 10.52
7 1.00 10.52
8 1.00 10.52
9 1.00 10.52
10 1.00 10.52
11 1.00 10.52
12 1.00 10.52
13 1.00 10.52
14 1.00 10.52
15 1.00 10.52
16 1.00 10.52
17 1.00 10.52
18 1.00 10.52
19 1.00 10.52
20 1.00 10.52
21 1.00 10.52
22 1.00 10.52
23 1.00 10.52
24 1.00 10.52
25 1.00 10.52
26 1.00 10.52
27 1.00 10.52
28 1.00 10.52
29 1.00 10.52
30 1.00 10.52
31 1.00 10.52
32 1.00 10.52
33 1.00 10.52
34 1.00 10.52
35 1.00 10.52
36 1.00 10.52
37 1.00 10.52
38 1.00 10.52
39 1.00 10.52
40 1.00 10.52
41 1.00 10.52
42 1.00 10.52
43 1.00 10.52
44 1.00 10.52
45 1.00 10.52
46 1.00 10.52
47 1.00 10.52
48 1.00 10.52
49 1.00 10.52
50 1.00 10.52
51 1.00 10.52
52 1.00 10.52
53 1.00 10.52
54 1.00 10.52
55 1.00 10.52
56 1.00 10.52
57 1.00 10.52
58 1.00 10.52
59 1.00 10.52 190 150 1.02
60 1.00 10.52 174 150 1.02
61 1.00 10.52 194 170 1.02
62 1.00 10.52 150 130 1.02
63 1.00 10.52 140 130 1.02
64 1.00 10.52 90 80 1.02
65 1.00 10.52 180 175 1.02
66 1.00 10.52 220 200 1.02
67 1.00 10.52 130 110 1.02
68 1.00 10.52 90 90 1.02
69 1.00 10.52 110 100 1.02
70 1.00 10.52 120 110 1.02
Measurement Point Cyclone Top Temp. Profile(Below Distribution box)
Measurement Tools thermocouple
05.02.2013
PT-1 PT-2 PT-3 PT-4 PT-5 PT-6
Cyclone top temp.Profile Time
CN110
CN210
CN120
CN220
CN130
CN230
CN140
CN240
CN150
CN250
Towards
Towards Opposite to
Time Quarry
Kiln Side Kiln side
Side
Kiln Riser Duct

Process Measurements Schedule

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INDEX

Counters of kiln feed, main burner coal,

Clinker weighing for 24 hours, Production 24 Hrs

KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 1

KILN FUELS on Burner BACK END FUELS OTHERS

Weighing Start Weighing Finish

Clinker 24 hours By truck weighing

Coal Calciner burner 24 hours From Coal counters

Start date Finish date Frequency Period

Cyclone 3 exit C3(e)

Cyclone 2 exit C2(e)

Cyclone 1a exit C1a(e)

Name Right Side

Name Left Side

Name Kiln Hood Ceiling Part (using side temp)

Name Cooler Crusher side Name Cooler Crusher side

Name Cooler Left Side Name Cooler Left Side

05.02.2013 string A 05.02.2013 string B

Diam / Ambiant Surface speed Diam / Ambiant Surface speed

Name cyclone 4 Name cyclone 4

Diam/ Ambiant Surface speed Diam/ Ambiant Surface speed

Name cyclone 3 Comments Name cyclone 3 Comments

Diam / Ambiant Surface speed Diam / Ambiant Surface speed

Name cyclone 2 Name cyclone 2

Diam / Ambiant Surface speed Diam / Ambiant Surface speed

Name cyclone 1a Name cyclone 1a

Diam / Ambiant Surface speed Diam / Ambiant Surface speed

Name Common riser Duct Name cyclone 1b

Diam / Ambiant Surface speed Diam / Ambiant Surface speed

Goose Neck Cone (av. top /down diameter)

Name Calciner Bottom Section

Name Calciner Bottom Section Cone

Name Calciner Middle section

Name Riser Vertical Part Right Side

Name Riser Vertical Part Left Side

Name Riser Vertical part face to the kiln

Name Riser Vertical Part Opposite to the Kiln

Kiln Riser Duct

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