A

SUMMER TRAINING REPORT

Undergone

“SHREE CEMENT LIMITED”

Batchelor of Engineering in Electrical Engineering

Submitted

BY
“VIKAS RAJ”

Government Engineering College, Barmer

2025-2026
DEPARTMENT OF ELECRTICAL ENGINEERING

1
 CERTIFICATE

This is to certify that a seminar report on summer training undergone

at “SHREE CEMENT PVT. LTD.” is submitted by VIKAS RAJ ,
student of B.E IV year (VII semester) of Electrical Engineering
from Government Engineering College , Barmer (MBM University
Jodhpur), during the academic year 2025-2026. The report has
been found satisfactory and is approved for submission.

Mr. MULAYAM SINGH CHAUDHARY Mr. VINOD KUMAR

Head Of Department Training Coordinator
Deptt. Of EE (AssistantProfessor)

2
 ACKNOWLEDGEMENT

We the student of [Link] considers the training to be challenging

job. We feel that excellence in any field cannot be achieved without
the help of our learned instructors. At the completion of our training
in SHREE CEMENT LTD. We will prefer to make some
acknowledgements, which is indeed a difficult task.
First of all I would like to pay my sincere regards to Mr. GOPAL
TRIPATHI sir for being so kind, co-perative and helping during
the entire training period.
I also express my thanks and sincere regards to my Head of
Department Mr. MULAYAM SINGH CHAUDHARY for his
support and help for this report and other faculty members for
their valuable support.

( VIKAS RAJ)

3
 INDEX

TOPIC Page No.

1. INTRODUCTION 9

1.1 LOCATION OF PLANTS 11

1.2 COMPANY POLICY 12

1.3 CEMENT&TYPES 13

1.4 OVER ALL CEMENT PROCESS 14

2. MINES AND CRUSHING SECTION 15

2.1 MINES 15

2.2 CRUSHING 16

3. HANDLING AND MAINTAINING 17

3.1 STACKER 17

3.2 RECLAIMER 18

4. RAW MILL: 18

4.1 VERTICAL ROLLER MILL 20

4.2 [Link] 21

5. CYCLONE PRE-HEATER 22

5.1 4 STAGE CYCLONE PREHEATER 22

6. CEMENT KILNS 24

7. COOLERS 26

8. CEMENT MILL 27

9. FINAL PRODUCT AND PACKING 29

4
10. INSTRUMENTS USED 31

10.1 TEMPERATURE MEASUREMENT 31

10.2 PRESSURE MEASUREMENT 34

10.3 LEVEL MEASUREMENT 36

10.4 INSTRUMENT USED IN PACKING PLANT 37

10.5 SAFETY INSTRUMENTS 38

10.6 WEIGH FEEDER 39

10.6 METAL DETECTOR 43

10.7MAGNETIC SEPERATOR 44

10.8FILTERS

11. BIBLIOGRAPHY 47

5
 TABLE INDEX

Table Page No.

1.1 PLANTS LOCATION 11

6
 FIGURE INDEX

FIGURE Page No.

1. 1.1 CEMENT PROCESS 14

2.1 MINES SITE 15

2.2 ROTARY BREAKER 16

3.1 STACKER MACHINE 17

3.2 RECLAIMER MACHINE 18

4.1 VERTICAL RAW MILL 19

4.2 RAW MILL 21

4.3 C.F. SILO 22

5.1 FOUR STAGE CYCLONE PREHEATER 23

6.1 CEMENT KILL 24

6.2 ROTARY KILN TUBE 25

7.1 COOLERS 26

8.1 CEMENT MILL 27

9.1PACKING MACHINE 30

10.1 RTD 32
10.2THERMOCOUPLE 33

10.3 RADIATION PYROMETER 34

10.4 BOLLEN TUBES 35

10.5BALL FLOAT METHOD 35

10.6 COUNTERS USED IN PACKING PLANT 36

10.7 LOAD CELL 37

7
10.8 PULL CHORD SWITCH 38

10.9 BELT SWAY SWITCH 39

10.10 ZERO SPEED SWITCH 40

10.11 PROXIMITY SWITCH 41

10.12 WEIGH FEEDER 42

10.13 METAL DETECTOR 44

10.14 MAGNETIC SEPERATOR 45

10.15 ESP 46

8
 ABSTRACT

This report is intended to give necessary background to understand the

process by which cement is manufactured at SHREE CEMENT LTD . It
focuses on the role of instrumentation in the cement industry and the
operation of an instrumentation system.
Although this report only identifies the main components and techniques
of a typical instrumentation system, it is not intended to give an all-inclusive
operations of every possible instrumentation system present in the cement
plant. Subsystems and topics include mines, raw mill, kiln, Preheater, cooler,
cement mill, packing plant and the various instruments being used and also
PLC. All the devices whether mechanical, electrical or instrument all are
connected and controlled by the programmable logic controllers (PLC) and
for the visual experience of this SCADA (supervisory control and data
acquisition system) is used. SCADA is used to show the current
condition the process and also to keep the record of all the past data.
Each of the above subsystems is explained in detail as to its function
and [Link] report also includes information on temperature, pressure,
flow,and level detection systems which are used in the cement plant. This
information will provide personnel with an understanding of the basic
operation of various sections of the cement plant, the role of instrumentation
and control systems.

9
 CHAPTER -1
INTRODUCTION & COMPANY POLICY

SHREE CEMENT LIMITED is an energy conscious & environment friendly

business organization. Having ten Directors on its board under the
chairmanship of Shri B.G. Bangur, the policy decisions are taken under the
guidance of Shri H.M. Bangur, Managing Director. Shri M.K. Singhi,
Executive Director of the company, is looking after all day to day affairs. The
company is managed by qualified professionals with broad vision who are
committed to maintain high standards of quality & leadership to serve the
customers to their fullest satisfaction.
The largest cement manufacturing plant at a single location in Northern
India, under the flagship of Executive Chairman Shri B.G. Bangur&
Managing Director Shri H.M. Bangur. The Company is aiming for
20 Million Ton Annual production by the year 2015

1.1 PLANT LOCATION

The plant is located near the city of Beawar, Dist. Ajmer inCentral Rajasthan,
sate ling the Beawar city at radius of 10 Kms. However the Beawar
subdivision is will connected through Rail and Road both, situated on National
Highway No. 8.

Some of another plant located in RAS. The RAS plants are far from
Beawar at least 35 k.m. All the same activities are doing in this plant & this
plant is used High grade material our compression in BEAWAR plant and this

10
material send in BEAWAR plant & mix both the Material & get the superior
quality product.

UNIT -1 at Beawar UNIT -2 at Beawar

Incorporated in 1979,
Established in 1985 Cement Put up in 1997
Production (Expected)-1.20 million Cement Production -2.10 million
tones tones
UNIT -3 at Ras Distt: Pali UNIT -4 at Ras Distt: Pali
Incorporated in 2005 Cement Production - 1.0 million
Cement Production - 1.0 million tones
tones
UNIT -5,6 &7 at Ras Distt: Pali Khuskheda Grinding unit (Distt.
Production – 1.00 million tones each Alwar)
(also having a world record of 367 Suratgarh & Roorkee Grinding unit
days) of 1.5 & 1.0 MTPA under
commissioning

TAB.1 PLANTS LOCATION

One of newly grinding unit started in KHUSHKHERA–Distt-Bhiwadi, the
plant is far from the BEAWAR plant almost 500 KM.

11
1.2 COMPANY POLICY

1.2.1QUALITY POLICY
To provide products conforming to National standards and meeting customers
requirements to their total satisfaction.
To continually improve performance and effectiveness of quality management
system by setting and reviewing
quality objectives for:
 Customer satisfaction
 Cost effectiveness
“JO SOCHE, WOH PAAVE”

1.2.2 ENVIRONMENT POLICY

To ensure:

 Clean, green and healthy environment

 Efficient use of natural resources, energy, plant and equipment

 Reduction in emissions, noise, waste and green house gases

 Continual improvement in environment management

1.2.3 HEALTH & SAFETY POLICY

To ensure Good Health and Safe Environment for all concerned by:

 Promoting awareness on sound health and safe working practices

 Identifying and minimising injury and health hazards by effective risk

control measures

 Complying with all applicable legislations and regulations

“PROSPERITY THROUGH HEALTH & SAFETY”

1.3 CEMENT& TYPES

12
In the most general sense of the word, cement is a binder, a substance that sits
and hardens independently, and can bind other material together.
Cement is a fine,soft,powdery type substance. It is made from a mixture of
elements that are found in natural materials such as limestone,clay,sand and
slash or [Link] cement is mixed with water it can bind sand and gravel
into a hard,solid mass called [Link] is usually [Link] cement can
also be found but is usually more expensive than gray cement.
 Cement mixed with water,sand and gravel forms concrete.
 Cement mixed with water and sand forms cement plaster.
 Cement mixed with water,lime and sand forms mortar.

TYPES

1.3.1. Ordinary Portland cement

1.3.2 Portland pozzolana cement

1.3.1. Ordinary Portland cement

Cement is made by heating limestone (calcium carbonate) with small

quantities of other materials (such as clay) to 1450 °C in a kiln, in a process
known as calcination, whereby a molecule of carbon dioxide is liberated from
the calcium carbonate to form calcium oxide, or quicklime, which is then
blended with the other materials that have been included in the mix. The
resulting hard substance, called 'clinker', is then ground with a small amount of
gypsum into a powder to make 'Ordinary Portland Cement', the most
commonly used type of cement (often referred to as OPC.

1.3.2 Portland pozzolana cement

It includes fly ash cement, since fly ash is a pozzolan, but also includes
cements madefrom other natural or artificial pozzolans. In countries where
13
 CHAPTER-2
MINES& CRUSHING

2.1 MINES

Limestone is the main raw material of cement. Shree cement has two mines
first at Shree & another at RAS. Which is almost 35 KM far from Beawar.
There are two plants having production capacity of almost 8000 M.T. of
Clinker. For making 1 M.T. of clinker almost 1.5 MT lime stone is required
and lime stone is sent by conveyer belt mines to plant.

FIG 2.1 MINES SITE

They have sufficient dumpers, cranes, excavator machines that are carrying the
work smoothly and at high pace. In the mean time i.e. duration of two shifts
blasting is done. Before blasting alarming by sound through specific
equipment so that avoid the misshapen. In this way they may not face problem
of shortfall of material during production schedule. We are also researching a
lot in mines where to extract material and how much.

15
2.2 CRUSHING

At site itself I got acquainted that crushing is done by Impact crusher. The
following activity is watched by me:

 Approximately 100-150 cm rock is fed to hopper of crusher by dumper.

f any rock is left outside the hopper then it is fed by dozer.

 It goes slowly to the hopper of crusher by Apron feeder. I had seen that
very small rock is dropped from Apron to the chute & directly goes to
the belt with crushing product.
 Water spraying is also done in the hopper of crusher.
 This crushed product is directly come from mines to raw mill
 Hopper through belt conveyor.
For any cement plant essential thing is the availability of Limestone. It is
the most important ingredient. For production of Cement 75% calcium
carbonate (limestone) is required. Limestone is taken by open cast Mines.

FIG. 2.2 ROTARY BREAKER.

16
 CHAPTER-3

HANDLING & MAINTAINING

3.1 STACKER

A stacker is the large machine which is used in bulk material handling

[Link] is mainly used to arrange the incoming feed in piles. It is
important to maintain the homogenous and uniformity before discharging to
further process A stacker usually operates on a rail-like structure with movable
wheels, but the main operation is performed on a fixed place.

FIG. 3.1 STACKER MACHINE.

17
3.2 RECLAIMER

Its main function is to recover the material and at the same time maintaining
uniformity. At this stage the material is collected in hoppers via conveyer
[Link] are volumetric machines and are rated in m3/h (cubic meters
per hour) for capacity, which is often converted to t/h (tones per hour) based
on the average bulk density of the material being reclaimed. Reclaimers
normally travel on a rail between stockpiles in the stockyard. A bucket wheel
reclaimer can typically move in three directions: horizontally along the rail;
vertically by "luffing" its boom and rotationally by slewing its boom.
Reclaimers are generally electrically powered by means of a trailing cable.

FIG. 3.2 RECLAIMER MACHINE.

18
 CHAPTER-4
VERTICAL ROLLER MILL (RAW MILL)

FIG. 4.1 VERTICAL RAW MILL.

Raw mill is grinding equipment which is used to grind the incoming feed fed
through hoppers. There are three hoppers in each unit. The first one carrying
high grade calcite from RAS mines. The second one contains the average
grade limestone from Shree mines nearby and lastly the hopper containing
Laterite(zinc slag i.e. molten residue at the bottom of zinc smelter). Laterite
has a high percentage of iron.

19
 FIG. 4.2 RAW MILL.

According to desired quality of cement, raw material (either of high grade, low
grade) is taken with the help of apron feeder, weigh feeder, and belt conveyors
taken to vertical raw mill... Vertical Raw Mill has got four hydraulic rollers
and one horizontal circular disc. The material coming from hopper building is
grind between horizontal circular disc & hydraulic rollers. The grinded
material is sucked from top by raw mill fan and coarse material is recycled
back to main feed to VRM. Fine material as sucked by raw mill fan goes to
cyclones where the material is separated from air through these four cyclones
and one bag house.

The material is accumulated and with the help of screw conveyors feed
back to CF silo. The material is blended with the help of compressed air and
the material is discharged to kiln feed bin for onward transportation to Kiln for
clinker production with the help of bucket elevator. There are two methods
through which the material is lifted to pre heater either with the help of bucket
elevator or through airlift. In case if bucket elevator fails because of any reason
the material is lifted through airlift.

20
4.2 [Link]

FIG. 4.3 C.F. SILO.

Are basically storage units the advantage of using them is that they not let the
material stick together. That is why they are called CFS or Continuous Flow
Silos.
The CF (Controlled Flow) silo is a continuously operating system for
homogenizationand storage of cement raw meal,where the material is extracted
simultaneouslyat different flow rates froma number of outlets in the silo
[Link] CF system, including suitable kilnfeed equipment, ensures stable
kiln feed composition at minimum powerconsumption and investment [Link]
efficient performance of the CF homogenizing silo results in stable
kilnoperation so that changes in kiln speedor firing rate are rarely needed
andstable coating in the kiln is maintained.

21
 CHAPTER-5

CYCLONE PRE-HEATERS

4 stage Cyclone PreHeater

The key component of the gas-suspension preheater is the cyclone. A cyclone
is a conical vessel into which a dust-bearing gas-stream is passed tangentially.
This produces a vortex within the vessel. The gas leaves the vessel through a
co-axial "vortex-finder". The solids are thrown to the outside edge of the
vessel by centrifugal action, and leave through a valve in the vertex of the
cone. Cyclones were originally used to clean up the dust-laden gases leaving
simple dry process kilns. If, instead, the entire feed of rawmix is encouraged to
pass through the cyclone, it is found that a very efficient heat exchange takes
place: the gas is efficiently cooled, hence producing less waste of heat to the
atmosphere, and the rawmix is efficiently heated. This efficiency is further
increased if a number of cyclones are connected in series.

FIG. 5.1 FOUR STAGE CYCLONE PREHEATER.

22
The number of cyclones stages used in practice varies from 1 to 6. Energy, in
the form of fan-power, is required to draw the gases through the string of
cyclones, and at a string of 6 cyclones, the cost of the added fan-power needed
for an extra cyclone exceeds the efficiency advantage gained. It is normal to
use the warm exhaust gas to dry the raw materials in the raw mill, and if the
raw materials are wet, hot gas from a less efficient preheater is desirable. For
this reason, the most commonly encountered suspension preheaters have 4
cyclones. The hot feed that leaves the base of the preheater string is typically
20% calcined, so the kiln has less subsequent processing to do, and can
therefore achieve a higher specific output. Typical large systems installed in
the early 1970s had cyclones 6 m in diameter, a rotary kiln of 5 x 75 m,
making 2500 tonnes per day, using about 0.11-0.12 tonnes of coal fuel for
every tonne of clinker produced.
A penalty paid for the efficiency of suspension preheaters is their tendency to
block up. Salts, such as the sulfate and chloride of sodium and potassium, tend
to evaporate in the burning zone of the kiln. They are carried back in vapor
form, and re-condense when a sufficiently low temperature is encountered.
Because these salts re-circulate back into the rawmix and re-enter the burning
zone, a recirculation cycle establishes itself. A kiln with 0.1% chloride in the
rawmix and clinker may have 5% chloride in the mid-kiln material.
Condensation usually occurs in the preheater, and a sticky deposit of liquid
salts glues dusty rawmix into a hard deposit, typically on surfaces against
which the gas-flow is impacting. This can choke the preheater to the point that
air-flow can no longer be maintained in the kiln. It then becomes necessary to
manually break the build-up away. Modern installations often have automatic
devices installed at vulnerable points to knock out build-up regularly. An
alternative approach is to "bleed off" some of the kiln exhaust at the kiln inlet
where the salts are still in the vapor phase and discard the solids.
23
 CHAPTER-6

CEMENT KILN

FIG. 6.1 CEMENT KILL.

Cement kilns are used for the pyroprocessing stage of manufacture of

Portland and other types of hydraulic cement, in which calcium carbonate
reacts with silica-bearing minerals to form a mixture of calcium silicates .In the
second stage, the rawmix is fed into the kiln and gradually heated by contact
with the hot gases from combustion of the kiln fuel. Successive chemical
reactions take place as the temperature of the raw mix rises:

 70 to 110 °C - Free water is evaporated.

 400 to 600 °C - clay-like minerals are decomposed into their constituent

oxides; principally SiO2 and Al2O3. Dolomite (CaMg(CO3)2)

decomposes to calcium carbonate, MgO and CO2.

24
  650 to 900 °C - calcium carbonate reacts with SiO2 to form
belite(Ca2SiO4).
 900 to 1050 °C - the remaining calcium carbonate decomposes to

calcium oxide and CO2.

 1300 to 1450 °C - partial (20–30%) melting takes place, and belite

reacts with calcium oxide to form alite (Ca3O·SiO4).

FIG. 6.2 ROTARY KILN TUBE.

The rotary kiln consists of a tube made from steel plate, and lined with
firebrick. The tube slopes slightly (1–4°) and slowly rotates on its axis at
between 30 and 250 revolutions per hour. Rawmix is fed in at the upper end,
and the rotation of the kiln causes it gradually to move downhill to the other
end of the kiln. At the other end fuel, in the form of gas, oil, or pulverized
solid fuel, is blown in through the "burner pipe", producing a large concentric
flame in the lower part of the kiln tube. As material moves under the flame, it
reaches its peak temperature, before dropping out of the kiln tube into the
cooler. Air is drawn first through the cooler and then through the kiln for
combustion of the fuel. In the cooler the air is heated by the cooling clinker, so
that it may be 400 to 800 °C before it enters the kiln, thus causing intense and
rapid combustion of the fuel.
25
 CHAPTER-7

COOLERS

Coolers are used to cool the recently obtained clinkers from the kiln.

FIG. 7.1 COOLERS.

The energy obtained from the clinkers through heat transfer is recirculated in
the kiln. Coolers in power plantused water as coolant. The second function for
water in such a power plant is to cool the system so as to condense the low-
pressure steam and recycle it. As the steam in the internal circuit condenses
back to water, the surplus (waste) heat which is removed from it needs to be
discharged by transfer to the air or to a body of water. This is a major
consideration in sitting power plants.

26
 CHAPTER-8

CEMENT MILL

FIG. 8.1 CEMENT MILL

It is the heart of whole plant. Its main function is to convert CLINKER into
finished product say to cement. Main Raw materials of CEMENT MILL are:
-CLINKER
-POZZOLONA
-GYPSUM
-FLY ASH

For making the cement in this mill Gypsum & the pozzolona mixed with
CLINKER in fixed ratio. Weight feeders are run with D.C. Motor. Speed of
motor is controlled by thyristor. Grinding media is different compartment &
these grinding media are helped in ground to the feed material.

27
Now in the CEMENT MILL the O/P is in the form of cement. The cement is
transferred by the help of a BUCKET ELEVATOR. There are two BUCKET
ELEVATORS. Capacity of each Elevator is 100 tonnes from the BUCKET
ELEVATOR; cement is transferred by the air slide & pipes by the help of
pump to the cement Silo for storage & packing purpose.

A ball mill is a horizontal cylinder partly filled with steel balls (or occasionally
other shapes) that rotates on its axis, imparting a tumbling and cascading
action to the balls. Material fed through the mill is crushed by impact and
ground by attrition between the balls. The grinding media are usually made of
high-chromium steel. The smaller grades are occasionally cylindrical ("pebs")
rather than spherical. There exists a speed of rotation (the "critical speed") at
which the contents of the mill would simply ride over the roof of the mill due
to centrifugal action. The critical speed (rpm) is given by: nC = 42.29/√d,
where d is the internal diameter in metres. Ball mills are normally operated at
around 75% of critical speed, so a mill with diameter 5 metres will turn at
around 14 rpm.

28
 CHAPTER -9

FINAL PRODUCT & PACKING UNIT

9.1 FINAL PRODUCT

These are the various products manufactured by the plant.
 O.P.C. (Ordinary Portland Cement): no constituent other than clinkers
and gypsum is introduced in the manufacture process, it is available in
43 grade and 53 grade in accordance with respective compressive
strength.
 P.P.C. (Portland Pozzolana Cement): this product contains a certain
quantity of flyash as an additive along with gypsum.
9.2 PACKING UNIT

Being final product, the cement is stored in cement silos. There are five silos in
our company, three for Unit-I and two for Unit-II.
Cement is carried forward to an elevator and is collected in cement bin .Bin is
connected to vibrating screen through which cement is passed down to cement
tank. There is a valve attached between vibrating screen and cement tank
which regulates the flow of cement, level sensor senses the level of hopper
attached to cement tank. The gate valve is connected to solenoid valve. The
capacity of tank is 45 tons. To measure the temperature of cement, a RTD is
connected to cement tank. There is also a direct pathway (optional) from
vibrating screen bin to loader if there is no requirement for packing the
cement.

29
FIG. 9.3PACKING MACHINE

30
 1.
2. CHAPTER- 10

INSTRUMENTS USED

10.1 FOR TEMPERATURE

10.1.1 Resistance Temperature Detector

RTD, basically works on the principle, that the value of resistance changes
with the change in temperature. It is a three terminal device. Two of its
terminals are connected to the two ends of the platinum bulb, & the third
terminal to one of its endof the bulb to nullify the effects due to the resistance
of the transmission wires. The temperature dependency of the resister can be
shown as, resistance temperature detector
Rt= R0 (1+ αT)

for positive temperature coefficient of platinum. The resistance thermometers

can be made up of mainly three materials namely, platinum, nickel, copper,
where each one is used according to its application.

31
 FIG.10.1 RTD

10.1.2 THERMOCOUPLES:

Thermocouples will cause an electric current to flow in the attached circuit

when subjected to changes in [Link] amount of current that will be
produced is dependent on the temperature difference between the measurement
and reference junction; the characteristics of the two metals used; and the
characteristics of the attached circuit.

Heating the measuring junction of the thermocouple produces a voltage which

is greater than the voltage across the reference junction. The difference
between the two voltages is proportional to the difference in temperature and
can be measured on the voltmeter (in mill volts). For ease of operator use,
some voltmeters are set up to read out directly in temperature through use of
electronic circuitry.

32
 FIG. 10.2THERMOCOUPLE

10.1.3 PYROMETERS:

Pyrometers are used where hot bodies are moving, where thermometers
are cannot brought in contact. Measurements is done by measuring energy
radiated by a hot body. It is used for the measurement of high temperature
range which is about 600-3000`[Link] intense heat needed to convert the raw
meal into clinker in the preheater and kiln must be carefully controlled.

Pyrometers which is used in plants is basically of two types:

• optical pyrometers
• radiation pyrometers

33
 FIG. 10.3 RADIATION PYROMETER

10.2 FOR PRESSURE

10.2.1 PRESSURE TRANSDUCER

Bellows-Type Detectors
The need for a pressure sensing element that was extremely sensitive to low
pressures and provided power for activating recording and indicating
mechanisms resulted in the development of the metallic bellows pressure
sensing element. The metallic bellows is most accurate when measuring
pressures from 0.5 to 75 psig. However, when used in conjunction with a

34
heavy range spring, some bellows can be used to measure pressures of over
1000 psig.

FIG. 10.4 BOLLEN TUBES

10.3 FOR LEVEL MEASUREMENT

BALL FLOAT

The operation of the ball float is simple. The ball floats on top of the liquid in
the tank. If the liquid level changes, the float will follow and change the
position of the pointer attached to the rotating shaft.

35
 FIG. 10.5 BALL FLOAT METHOD

10.4 INSTRUMENT USED IN PACKING UNIT

10.4.1 COUNTERS

FIG. 10.6 COUNTERS USED IN PACKING PLANT

Counter is a device which stores (and sometimes displays) the number of

times a particular event or process has occurred.

We offer a wide range cement bag counter which are specially developed for
Indian bags and packing systems. These are accurate and take care of all

36
nuisance factors. Further these are available from 1 inch to 8 inches display
size. Cement Bag counter for Truck Loader & Cement bag counter for wagon
loader is most popular requirement now-a-days. These are having option of
interfacing with all required devices & dispatch monitoring system.

10.4.2 LOAD CELL

FIG. 10.7 LOAD CELL

Load Cell is the second most important device which is used in the packing
unit as well as in weight-belt feeders. It is a transducer that is used to convert a
force into electrical signal. This conversion is indirect.

Accurate high capacity load cells are needed for press tonnage monitor
calibration. They are also useful for some types of press testing. Calibration
load cells have a metal structure to which strain sensors or strain gages are
attached. The metal structure is compressed when subjected to load. The
attached gages provide an electrical output that is a linear function of applied
load if the of the proportion limits structure is not exceeded.
Strain gage based load cells are available in capacities ranging from a few
grams through 1,500 tons or more.

37
Weigh-belt feeders are key components in the production of portland cement
as they are relied on to accurately proportion materials for both kiln feed
preparation and finishing operations. Cement production weigh feeders are
expected to perform very accurately and repeatably, while constantly enduring
the harsh plant environment.

10.5 FOR SAFETY PURPOSE

10.5.1 PULL CHORD SWITCH
Pull cord switch also known as Rope Operated Emergency switch is used as a
safety switch to stop the conveyor belt in case of an [Link] is also
known as pull switch cord.

FIG. 10.8 PULLCHORD SWITCH

OPERARTION
Pull cord switch is mounted on the walkway side of the conveyor belt,
preferably at about every 20-25 meters. When the rope is pulled from any side.
The switch get operated . Unless and until the handle is reset to normal
position manually, the switch remains in operated [Link] Rope switch
All the Pull Cord Switches installed along an individual belt are electrically
wired in series and connected to the control station by a two core cable.

38
Therefore actuation of any one of these Pull Cord Switches will stop the
concerned conveyor until the particular switch is manually reset.

10.5.2 BELT SWAY SWITCH

The switch allows smooth running of the conveyor and protects it from
damages by over swaying which can occur due to uneven loading of material,
worn out idler roller bearings etc. Belt sway switch is also known as Run Off
Switch.

FIG.10.9 BELT SWAY SWITCH

OPERATION
For normal running of the belt with acceptable swaying, the belt-sway switch
is generally mounted on both sides and near the edge of the conveyor belt. A
is generally mounted on the both sides and near the edge of the conveyor belt.
A small clearance is allowed between contact roller and the belt edge to allow
the normal running of the belt with acceptable swaying. When swaying
exceeds normal limit, the belt edge pushes the contact roller, which drives the
switch and operates the contacts. The switch reset automatically when the
belt resumes normal running.

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10.5.3 ZERO SPEED SWITCH
Electronic Speed Monitor is used to monitor speed of conveyors, crushers,
rolling mills, agitators, mixers, stirrers, screw conveyors, and other industrial
machinery. This device actuates relay contacts at preset speed. Using these
contacts desired control action such as zero speed protection/ under speed
protection/ over speed protection can be achieved.

FIG.10.10 ZSS

Operation
The basic principle of speed monitor is comparison of pulses received from
sensor with standard pulses. The unit consists of two parts: CONTROL UNIT
and “SENSOR PROBE”. The sensor is to be installed with its sensing face in
close proximity of rotating object. On this object, flags are to be fixed. The
sensor products strong electromagnetic waves, which get disturbed by the
flags, giving rise to corresponding pulses. These pulses are fed to the control
unit where they are compared with standard pulses to sense the speed.

10.5.4 PROXIMITY SWITCH

When the object enters in the sensing zone of the switch, capacitance between
two plates of capacitor (one plate is represented by electrode at sensing face of
the switch and another by all surrounding material which is connected to the
40
earth) changes. As soon as capacitance value crosses preset level, oscillator
starts. This change is detected and resulted in an output signal.

FIG.10.11 CAPACITIVE PROXIMITY SWITCH

OPERATION
It has 3 cables which is apply to the contractors .It is generally NC(normally
closed).When metal is placed in front of it then it is NO(normally open) .

10.6 OTHER INSTRUMENTS:

10.6.1 WEIGH FEEDER

It is used to measure & control conveying material’s quantity.
The purpose of the system is to produce a flow of respective material,
proportional to a demand flow rate signal over a wide range. Each weigh
feeder is mounted at the bottom of a bin & the material is extracted out of the
bin of the weigh feeder.
The flow controlled by varying the speed of the weigh feeder. The
weigh feeder works only in conjunction with the respective group control

41
electronics. Weigh feeder maintain the output per time or the feed rate, weigh
feeder employ a Closed loop feedback control system.

FIG.10.12 WEIGH FEEDER

OPERATION
Weigh feeder is machine through which, flow rate (TPH) of material is
measured. The material passing over a belt conveyor exerts a down wards
force proportional to its weight. The product of this force and the speed of the
belt gives the rate of flow, the unit being Kg/min. or ton/hour.
it consists of load cells for weight measurement and tacho for belt speed.
Measuring Unit : TPH (TON PER HOUR)
TPH = BELT LOAD X BELT SPEED X 3.6 = KG / MTR X MTR/ SEC X
3.6
Belt Load is measured by the Load Cell & beltspeed is measured by
Tacho.
FLOW RATE= BELT LOAD  BELT SPEED
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=KG/MT  MT/SEC.
=KG/ SEC. OR TPH

The load is measured by a strain gauge load cell which does not have
practically any deflection, and speed of the belt is measured by a Tacho.
The quantity viz. load & speed available as electrical signals are then
multiplied to set the rate of flow of material. The rate of material flow
integrated in the time gives the total quantity of the material passed over the
conveyor belt. It is obvious that the rate can be kept constant at any desired
value either by varying load or speed.

10.6.2. METAL DETECTOR

The METAL DETECTING DEVICES are designed to be used on conveyor
systems as they are employed in various industries, wherever metal pieces in
the conveyed material may damage sensitive machinery, metal detecting
devices will prevent expensive repairs & production breakdowns.
Metal Detectors are used to detect metal pieces in the material to
prevent damage to the processing machineries like crushers, grinders,etc. It is made of
search& receiver coil . A high frequency electromagnetic gield is set up in the search coil.
When any ferrous metal passes through this field it gets detected by the receiver coil.

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 FIG.10.13 METAL DETECTOR

OPERATION
A high frequency alternating voltage is fed from the amplifier to a coil in the
probe. This generates an electromagnetic field. If a metal piece comes into this
field, induction current will generated that will drain power from the
oscillators.
If depending on the selected sensitivity an unwanted metal piece in the
conveyed material is identified by the electronics in the amplifier, the output
relay will switch to its other state for about 0.5 seconds.
The output relay has two potential free NC/NO contacts that are wired to the
terminal strip. These contacts can be used to stop the conveyor belt.

10.6.3 MAGNETIC SEPRATOR

Magnetic seprator is a process in which magnetically susceptible material

is extracted from a mixture using a magnetic force.
Magnetic seprator consist of an electromaget which pulls any magnetic
material placed on the surface of the material being conveyed by the conveyor

44
[Link] undesired material such as nuts,bolts, screw etc are then collected in a
reject chute.

FIG.10.14 MAGNETIC SEPARATOR

10.6.4 FILTERS

[Link] Electrostatic precipitator

[Link] Bag filters

[Link] Electrostatic precipitator

Electrostatic precipitator is an apparatus which cleans process gases by using

electrical forces to remove solid particles carried in the gas stream. The dirty
gases are passed through an intense electrical field set up between electrodes
of opposite polarity. The discharge electrodes -so called because of the corona
discharge which results from the application of high voltage-impart a negative
charge to the particles. These particles are then attracted to the collector
45
electrodes which are positive with respect to the discharge electrodes and in
practice are connected to ground through the structure or through ground
cables

FIG. 10.15 ESP

46
 BIBLIOGRAPHY

Vehicular Instrumation/Transidusar Commitee

Telementry Group Range Commanders Council,
“Instrumantation Handbook Published
in 2005

[Link]

Shree cement mannuals

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