Site Requirement Specification

Contact data

1 Plant Name Bestway Cement Limited Farooqia.

Operating Company
Bestway Cement Limited

2 Technical Contact Maaz Jamal

Name
Address, email
phone number

3 Gas Flow / Application

(mark applicable conditions and note deviations)
Application: Temperature Dust Flow Conductive Input from Input from
Concentration range Dust/spray site: site:
water Deviation Confirmation
Downcomer, <400°C >100 mg/m³ 0-30 no
m/s

By Pass <400°C >100 mg/m³ 0-30 no

m/s

Clinker Cooler <400°C >100 mg/m³ 0-30 no

m/s

Tertiary_Air
(with dust >100 mg/m³
cyclone) 0-30
(no dust <1000°C >100 g/m³ m/s yes
cyclone)
Stack < 200°C <10 mg/m³ 0-30 no
m/s

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 Mill Inlet <20 mg/m³ no
(behind filter) 0-30
(behind <400°C >100 mg/m³ m/s
cyclone)
Mill Outlet <400°C >100 g/m³ 0-30 no
m/s

Other
Application:
(data
necessary)

Measurement Section (Duct Design) Unit Input from site

4 Number of air ducts / pipes to be measured [-]

5 Arrangement drawings of air piping to be supplied

6 Inner diameter – for rectangular cross section: [mm]

length of each edge (Comment)

7 Minimum straight length at mounting location [m] 5D Available downstream

(incl. min. measuring length ~ 500 mm, upstream/downstream
/[ID]
straight distance approx. 5 D)

8 Existing control devices? (e.g. flaps, dampers) [-] Dampers/VFD

(Upstream/ downstream?) Upstream

9 Cabling Distance between sensor and sensor box / McON Air [m] (10 m)
box (Cable length) (20 m default)
(30 m)

10 Range of ambient temperature at cabinet location [°C] ( 0 to +50°C default)

(-30 to +50°C)

11 Quencher upstream of planned measurement point Yes/No No

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 System integration / connection

12 DCS connection mA (0 - 40 m/s default)

Range (4-20mA = 0-40m/s) OK

13 Power supply: V (85-265V 50-60Hz)

Max Power Consumption < 0,8A (115 V) ok
< - 0,4 A (230V) ok

14 P&I Diagram of duct/air supply to be supplied

Delivery Details

15 Delivery address

16 Date of delivery

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Downcomer:
Kiln off gas from preheater tower.

Duct Design: Usually duct with long, straight length (>10D) and good flow conditions.
Temperature range: 200-300°C
Dust concentration: Sufficient (medium) dust concentration.
Recommended measurement location: In the lower ¼ of the duct.

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Tertiary Air.
Preheated combustion air duct from the grate cooler to pre- calciner. McON Air uses in this high
temperature application special sensors and mounting adapters. They provide a connection for
pressurized purging to enable an automated cleaning of the sensor ceramics and feed through the
refractory. Clinker dust is conductive at this temperature. Sensor life cycles highly depend on dedusting of
tertiary air.

Dust settlig box,

cyclone?

Duct Design: Usually duct with long, straight length (>10D) and good flow conditions. Refractory inside.
Temperature range: 700-1000°C
Dust concentration: Sufficient (low ) dust concentration after settling box,
or high without dedusting  limited sensor life.
Recommended measurement location: Sensors from top in the middle to 2nd half of the duct for good
flow conditions and limited influence of material deposition.

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Raw mill
The airflow through the mill can be measured at three different points mill Inlet, mill outlet and FD fan
Inlet depending on the layout and control philosophy.

Duct Design: Usually duct with little straight section, (<5D) and turbulent flows.
Temperature range: 80-120°C
Dust concentration: mill outlet high dust concentration.
Mill, fan inlet: low dust concentration depending on the efficiency of the filter or
cyclone
Recommended measurement location: section with maximum straight flow up front.

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Bypass
Gas extraction after the pre- calciner process either to the raw mill or filter, mixed with cooling air.

Duct Design: Depending on plant, straight sections possible.

Temperature range: 400-500°C
Dust concentration: Sufficient (medium ).
Recommended measurement location: depending on duct design, sensors in sections with sufficient
straight length after bends (>5D)

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Stack
The Mc ON air system can be used to measure the emission gas flow in the stack. (EN15267certified
version from 11/2019)

Duct Design: Usually duct with long straight section, (>10D) and turbulent flows.
Temperature range: 80-200°C
Dust concentration: low dust concentration depending on the efficiency of the filter.
Recommended measurement location: area of the emission monitoring equipment.

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Clinker Cooler

Measurement of cooling airflow to grate cooler is possible, also including fresh ambient air and
measurements behind fans with sufficient straight duct length. Due to design, measurement locations
may differ and have to be determined on drawings and by CFD if necessary.

Duct Design: Depending on plant, straight sections possible.

Temperature range: 0-300°C
Dust concentration: Sufficient (medium ) or fresh air (low).
Recommended measurement location: depending on duct design, sensors in sections with sufficient
straight length after bends (>5D)

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Flow Range

This question is for verification of the flow range and to identify deviation to standard applications of
McONair measurements. You can enter the information in STP, actual flow or velocity.
Plant design usually intends to have flow ranges in the ducts between 15-25 m/s to minimize duct size
and pressure drop. The McONair system needs minimum flow of 5 m/s to get sufficient signalstability and
to evaluate the time of flight by correlation method, upper velocity is approximately 100 m/s.

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Temperature Range of Sensors

McONair Sensors have 3 temperature ranges depending on the application. With higher temperatures the
heat resistance, wear and conductivity of clinker dust have to be taken into account:

400°C: 15mm antenna, stainless steel type 1.4571

600°C: 15mm antenna, heat resistant steel type 1.4841
1000°C: 25mm antenna with purged mounting adapters and heat resistant steel type 1.4841

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Dust Content

The McON Air system can be applied to the existing ductwork with minimized pressure drop. It uses the
triboelectric charged dust in the air to determine the velocity by correlation method. This method is time
based and absolute drift free.

It is capable for low dust concentrations 10mg and 2500g/m³. For dust free measurement behind
effective filters or process start with clean air and additional range can be used to mark the air flow by
ionization.

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Conductive Dust
The antenna must be electrically to scan the electrostatic fluctuations, isolating dust does not affect the
resolution and measurement performance. Bridges of conductive dust like metal dust, water droplets or
clinker dust hotter than 700°C shortcut sensors and affect the measurement. Those applications demand
mounting adapters with purge or bleeding connection.

Example: tertiary air measurement with purged mounting adapters with shock blowers, (sensors not
mounted)

Mounting behind spray coolers is not recommended but possible with sufficient distance distance, the
fluid must be above due point.

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Arrangement drawing
For installation, drawings are needed for correct recommendation of instrumentation and measurement
points. The ducting with bends dampers or other obstacles upstream and downstream of the
measurement section should be visible to supply sketches for the sensor positioning. In CFD’s can be
offered by PROMECON in complicated ducting or expected flow stratification.

Examle Downcomer application with 2x 30° bends

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Example flow measurement of grate cooler
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Inner Pipe Diameter

The measurement is covering the area around the antennas within the electrostatic field range of passing
charged clusters in the duct. For bigger diameters than 2500 mm the application should checked closely
on flow conditions and additional instrumentation with additional antennas should be taken into account.

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Minimum Distance

Changes in duct routing and dimension like bends or junctions cause stratification in the airflow. The
McONair system is averaging the flow within the reach of the electro static field of the charged dust
clouds and can cover stratification and swirls in certain limits. Distances shorter than 5 ID should be
avoided or demand instrumentation with larger amount of sensors. This will be checked after receiving
the relevant information for the project with this questionnaire.

Example: flow development after the bend

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Control devices and Dampers

Flaps and dampers are used control the flow by producing pressure drop and stratification. It is to place
mandatory measurement upstream of those devices to avoid cross coupling of the control on the
measurement results unless there is a long straight duct section with more than 10 ID to the control
device.

Example: Stratification behind a one flap damper

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Distance of Sensorbox

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Ambient Temperature

McON Air Measurement box is cape able of ambient temperature between 0 -50 °C, sensor electronics up
to 80°C. Ducts with higher surface temperatures should be insulated in the measurement section to
reduce heat by radiation.
Electrical heaters can be supplied for outdoor applications with temperatures lower than 0°C, with higher
temperatures alternative mounting positions of the box or cooling devices can be applied on demand.

Example thermal insulation of hot ducts to limit heat exposure of sensor head by radiation

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Compensation
The compensation to standard conditions or calculation to massflow is usually done in the DCS for better
diagnostics on the inputs.
On request is the McON Air system available with additional I/Os for compensation to standard
conditions.

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