1. 2014
Muhammad Saim Nasir Siddiqui
INTERN(LUCKY CEMENTS LTD)
6/16/2014
LUCKY CEMENTS INTERNSHIP REPORT

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PREFACE
The report discusses the lucky cement manufacturing and designing
process. It includes all the information about the sensors along with their
location in the plant as well as PLC connected with sensor and control the
input and generate control output signal
I must thank to all who supported me academically and administratively
and who gave me support specially General Manager Mr.Mashkoor
Ahmed , Mr.Fahad (HR officer Lucky Cement), Senior Engr.Hafiz
Junaid, Associate Manager Engr.Qaisar ,AM Engr.Israr, Senior
Technician Saleem,Yousuf,Waqar and Technician Ahsan
(Instruments) and Manager Engr.Waseem and AM Engr.Taha and
(DCS deppt)
The story remains incomplete without the mention of my professor
"Engr.Ikram-e-Khuda " who encourages me to work as an intern and
explore the world of Instrumentation & Controlling Automation.
Last but not the least, the sacrifices made and patience shown by my
family and giving me enough space to achieve the goal.

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TABLE OF CONTENTS
Sno TOPIC Page no
1 Intoduction to Lucky Cements
Products
OPC
SRC
Clinker
Block Cement
ProcessFlow Diagram
Cement Manufacturing Process
Raw material preparation
Pre-homogenization
Finishing, Packaging and Distribution
3
4
5
6-8
2 INSTRUMENTATION DEPARTMENT
Signalused in instrumentation
Load Cells
Actuators
Proximity Sensor
DP Cell
DP Transmitter
RTD PT-100
Thermocouple
9
9
9-10
11
12
13-14
14-15
16-17
18-19
3 DCS DEPARTMENT
PLC
TECHNICAL DATA S7-400
TECHNICAL DATA S7-200
PLC ORDER NO AND SPECIFICATIONS:
RMP (Raw Mill Proportionator)
Weigh Feeder(Pyro Area)
Kiln and PreheaterArea
Cement Mill (Weigh Feeder)
PackerArea
20
20
21
22
22
23
24
25
26

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LUCKY CEMENTS
INTRODUCTION
Sponsored by well known “Yunus Brothers Group” – one of the largest export houses of
Pakistan, Lucky Cement Limited currently has the capacity of producing 25,000 tons per day of
dry process Cement.
Lucky Cement Limited (LCL) is Pakistan’s largest producer and leading exporter of quality cement
with the production capacity of 7.75 million tons per annum. The company is listed on Karachi,
Lahore, Islamabad and London Stock Exchanges.
Over the years, the Company has grown substantially and is expanding its business operations with
production facilities at strategic locations in Karachi to cater to the Southern regions, Pezu and
Khyber Pakhtunkhwa to furnish the Northern areas of the country. Lucky Cement is Pakistan’s first
company to export sizeable quantities of loose cement being the only cement manufacturer to have
its own loading and storage terminal at Karachi Port.
Lucky Cement is an ISO 9001:2008 and 14001:2004 certified company and also possesses many
other international certifications including Bureau of Indian Standards, Sri Lankan Standard
Institute, Standards Organization of Nigeria, Kenya Bureau of Standards and South African Bureau
of Standards.
 Lucky Cement registered Rs. 8.185 billion profit after tax for nine months. The company recorded
17.2% rise in its profit for the period ending March 31st 2014. The earnings per share (EPS) for the
period increased to Rs. 25.31 against an EPS of Rs. 21.59 of corresponding period last year. The
local sales volume during the period registered a growth of 7.7% that rose to 2.9 million tons as
compared to 2.7 million tons of same period last year.
 Lucky Cement Limited led the cement industry with a rise in its half yearly net profit for the year
2013-14. It recorded a net profit for the half year ending 31st December 2013, of Rs. 5.161 billion
which is 20.3% higher than the corresponding period last year. The local sales volume of Lucky
Cement during the half year registered a growth of 4.3% that rose to 1. 9 million tons as compared
to 1.8 million tons of same period last year, whereas export sales volume for Lucky Cement
registered a growth of 19.10% to 1.2 million tons as compared to 1.0 million tons of the same
period last year.
 Lucky Cement, for the third consecutive year, powered Earth Hour 2014 to create awareness about
the importance of energy conservation. The employees vowed to switch off unnecessary lights at
8:30 pm on March 29, 2014 in order to show their commitment to save electricity.

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Products
Ordinary Portland Cement (OPC):
We offer Ordinary Portland Cement (OPC) that is used in all general constructions, especially in
major and prestigious projects where cement is needed to meet stringent quality requirements. It
can also be used in concrete mortars and grouts, etc. Ordinary Portland Cement is
compatible/consumable with admixture/ retarders, etc.
OPC has easy workability and lower heat of hydration. We maintain our technical standard of
quality parameter at high level and with high strength at all ages. Our OPC cement satisfies EN 196
/ 197 – 1, SABS, BIS, SLSI & PSS – 232 ~ 1983 (R).
SRC:
By maintaining C3A level within the specified limit of 3.5%, our Sulphate Resistant Cement is
more resistant to Sulphate attacks and is suitable for use in foundations near seashore and canal
linings.
SRC has lower heat of hydration and its strength satisfies B.S 4027 / 1980 & PS 612 / 1989.
Clinker:
We also offer clinker to the customers with their own grinding units. Clinker can be easily handled
by ordinary mineral handling equipment and can be stored for several months without
compromising on the quality. Clinker is the primary product in the cement manufacturing process
where limestone, clay and sand are grinded and heated, before the gypsum is added to produce the
final product of cement.
Block Cement:
By the nature of product, Block Cement is similar to the SRC, with a significantly darker color and
some low setting time to meet the requirements of the market and for the production of blocks.
Block Cement also maintains C3A level within the specified limit of 3.5%.

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PROCESS FLOW DIAGRAM
Lime Stone
Coal (Crusher) Crushing
Storage
RMP(Raw Material proportional)
Raw Mill
Storage
Coal Mill Pre-heater,Clink
Cooler
Storage
CMP
Cement Mill
Storage
Packing

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Cement Manufacturing Process
Cement is a fine, soft, powdered substance, made from a mixture of elements that are found in
natural materials such as limestone, clay, iron ore and sand. When cement is mixed with water, it
can bind sand and turns into a hard, solid mass called concrete.
Raw MaterialPreparation
The key element – Limestone and clay are mined through blasting from rock quarries by setting off
explosives. Limestone and clay contains calcium, silicon, aluminum and iron, which are the
essential elements for cement manufacturing. Latest technology is used for blasting so as to
ensuring vibration, dust, and noise emissions are kept at a minimum level. Blasting produces
materials in a wide range of sizes from approximately 1.5 meters in diameter to smaller particles
less than a few millimeters in diameter. Quarried material is the loaded into trucks or belts for
transportation to the crushing plant. Through a series of crushers and screens, the Limestone is
reduced to a size less than 100 mm and is stored until required.
Pre - Homogenization
In the dry process, each raw material is proportioned to meet a desired chemical composition and
fed to a vertical steel mill. The raw materials are dried with waste process gases and grinded
through the pressure exerted by three conical rollers in a rotary kiln. The rotary kiln is fired with an
intense flame produced by burning coal, coke, oil, gas or waste fuels. The dry materials exiting the
mill are called "kiln feed". The kiln feed is pneumatically blended to ensure the chemical
composition is well homogenized and is then stored in separate silos until required.
Basic chemical reactions that take place in the kiln, at 1400 °C are: Evaporation of moisture,
calcinations of the Limestone to produce free calcium oxide and reaction of the calcium oxide with
other materials (sand, shale, clay, and iron). This results in a final, nodular, red-hot product known
as "Clinker" which is 3 – 4 centimeters in diameter and can be stored for several months.

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Finishing, Packaging and Distribution
The clinker is cooled and grinded into a fine grey powder. The grinding is done through different-
size steel balls. A small amount of gypsum and other process are also added during the final
grinding. The amount of gypsum and process added during the process varies in all of the final
cement products. Each cement product is stored in an individual silo from where it is transported to
packaging facility for either sack – packaging or bulk transportation. Bulk cement is distributed
through bulkers or is shipped; depending on the customer's needs.

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INSTRUMENTATION DEPTT.
Standard Signals for Instrumentation:
(1) 0-10 V : use for signal
(2) 3-15 PSI: it is a unit of pressure abbreviated as (Pound Square Inch) used to measure the
differential pressure. It starts other than is zero is for line and dead zone
(3) 4-20mA: It is standard adopted by tradition and also ANSI 50.1 and most process instruments
and controller use it
the 4mA "BOTTOM OF SPAN" signal allows the reciver to detect the broken wire since the
loop current never fall to zero.
20mA is safe enough to be made intrinsically safe
Load Cells - an Introduction
What is a Load Cell?
A load cell is a transducer which converts force into a measurable electrical
output. Although there are many varieties of load cells, strain gage based load
cells are the most commonly used type.
Strain gage load cells offer accuracies from within 0.03% to 0.25% full scale and
are suitable for almost all industrial applications.

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Load Cell Performance Comparison
Type Weight
Range
Accuracy
(FS)
Apps Strength Weakness
Mechanical Load Cells
Hydraulic
Load Cells
Up to
10,000,000
lb
0.25% Tanks, bins
and hoppers.
Hazardous
areas.
Takes high
impacts,
insensitive to
temperature.
Expensive,
complex.
Pneumatic
Load Cells
Wide High Food
industry,
hazardous
areas
Intrinsically
safe.
Contains no
fluids.
Slow
response.
Requires
clean, dry air
Strain Gage Load Cells
Bending
Beam Load
Cells
10-5k lbs. 0.03% Tanks,
platform
scales,
Low cost,
simple
construction
Strain gages
are exposed,
require
protection
Shear Beam
Load Cells
10-5k lbs. 0.03% Tanks,
platform
scales,
off- center
loads
High side load
rejection,
better
sealing and
protection
Canister
Load Cells
to 500k lbs. 0.05% Truck, tank,
track, and
hopper scales
Handles load
movements
No
horizontal
load
protection
Ring and
Pancake
Load Cells
5- 500k lbs. Tanks, bins,
scales
All stainless
steel
No load
movement
allowed
Button and
washer
0-50k lbs
0-200 lbs.
1% Small scales Small,
inexpensive
Loads must
be centered,
no

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Load Cells typ. load
movement
permitted
Load cells are used in Weigh feeders, Crusher, Silo , Bag house etc
Electric Solenoid Actuators:
A typical electric solenoid actuator is shown in Figure 3. It consists of a coil, armature, spring, and
stem. The coil is connected to an external current supply. The spring rests on the armature to force
it downward. The armature moves vertically inside the coil and transmits its motion through the
stem to the valve. When current flows through the coil, a magnetic field forms around the coil. The
magnetic field attracts the armature toward the center of the coil. As the armature moves upward,
the spring collapses and the valve opens. When the circuit is opened and current stops flowing to
the coil, the magnetic field collapses. This allows the spring to expand and shut the valve.
FIGURE 3 Electric solenoid actuator.

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A major advantage of solenoid actuators is their quick operation. Also, they are much easier to
install than pneumatic or hydraulic actuators. However, solenoid actuators have two disadvantages.
First, they have only two positions: fully open and fully closed. Second, they don t produce much
force, so they usually only operate relatively small valve
Proximity sensor
Infrared proximity sensor.
A proximity sensor is a sensor able to detect the presence of nearby objects without any physical
contact.
TYPES:
there are two types of proximity sensor
1) Inductive sensor
2)Capacitive sensor
we are using inductive proxy sensors in different parts of plants like
Packer,Cement mill etc
they can make contact through the EV(Electro valve)

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Differential Pressure (DP Cell):
A steam flowmeter comprises two parts:
 The 'primary' device or pipeline unit, such as an orifice plate, located in the steam flow.
 The 'secondary' device, such as a differential pressure cell, that translates any signals into a
usable form.
In addition, some form of electronic processor will exist which can receive, process and display the
information. This processor may also receive additional signals for pressure and/or temperature to
enable density compensation calculations to be made.
Figure 4.4.1 shows a typical system.
Fig. 4.4.1
A typical orifice plate steam flow metering station
A DP cell is a device that measures the differential pressure between two inputs

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Working principle:
Measure the pressure drop across the two points on the basis of pressure difference
Types of DP cell:
DP cell have the following types,
v Diaphragm capsules DP cell
v Pneumatic DP cell
v Electronic DP cell
Primary Element:
Primary elements are:
 Orifies Plate
 Pitot Tube
SecondaryElement:
Differential pressure transmitter
construction:
A differential pressure transmitter has three functional parts.
1) Direct Pressure sensing element(locatedin the lower housing).
The majority of industrial DP Transmitters are fitted with diaphragm as the pressure sensing
element. This diaphragm is a mechanical device. It is placed in between the two pressure inlet ports.
The diaphragm will be deflected by the applied pressure.
This is clarified in Fig. This deflection is converted into an electrical signal. This is normally done
by the sensors. The commonly used sensors are (a) Strain Gauge (b) Differential Capacitance (c)
Vibrating wire. The sensor output is proportional to the applied pressure.

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2) Electronic Unit: The electrical signal generated at the lower chamber by the sensor is in the
range of milli-volt only.
This signal is to be amplified to 0-5V or 0-10V range or is to be converted to 4-20mA for onward
transmission to a remote instrument. This upper housing is the Transmitter portion of the DP
Transmitter which houses the Electronic Unit. See Fig-7 for further clarifications.

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3) 2-Wire 4-20mA Current Transmitter:
A DC output current is generated which is directly proportional to the pressure range of the
Differential Pressure Transmitter. The lower range is 4mA, and the upper range is 20mA. This
controlled current output is not affected by load impedance variation and supply voltage
fluctuations. This 4-20mA output is superimposed with digital communications of HART FSK
protocol.
6. Industrial applications of Differential Pressure Transmitters:
There are unlimited industrial applications of Differential Pressure Transmitters.
 Oil and Gas flow metering in onshore, offshore and subsea applications.
 Water and effluent treatment plants. It is largely used to monitor filters in these plants.
 It is used to monitor Sprinkler Systems.
 Remote sensing of Heating Systems for Steam or Hot Water.
Resistance Temperature Detector (Pt100)
What are the Pt100 connections?
Pt100 (RTDs in general) are available with four different leadwire configurations. The selection of
leadwire
configuration is based on desired accuracy and instrumentation to be used for the measurement.
Working Principal
When there is a temperature increase in the junction of rtd its electrical resistance on another
junction has been increased also.
A Pt-100 is a precision Platinium resistor that exhibits 100ohms on 0 degree centigrade
It has a positive Temperature Coefficient so as the temperature rises its resistances also rises
Rtd is used in Pre heaters, Klin and in other areas of plant
RTD WIRE CONFIGURATION:
Two wires RTD : the two wire RTD is the simplest wire configuration. One wire is
attached to each side of the element. A measure can be taken by any device
equipped to measure resistance, including basic Volt Ohm Meters. This is the least accurate way of
measuring temperature, due to the fact that the leadwire resistance is in series with the sensing
element. The leadwire is at a different temperature than the

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sensing element and also has different resistance verses temperature characteristics. The longer the
leadwire the greater the effect on the measurement.
Three Wire RTD : The three wire RTD is the most popular configuration for use in
industrial applications. When used correctly, the three wire configuration eliminates the series
resistance. This allows an accurate measurement of the sensing element. Two of the leads are
connected to one side of the sensing element and the single lead to the other side. The resistance in
the two closest wires should be matched as close as possible, this will cause the lead resistance to
cancel themselves. The color code for a three wire RTD is two red wires and one white.
Four Wire RTD : A four wire RTD is the most accurate method to measure an
RTD. It is primarily used in laboratories and is seldom seen in an industrial
application. A four wire RTD circuit removes the effect of mismatched
resistances on the lead wires. A constant current is passed through external wires while wires
closest to the RTD element measure the voltage drop across the RTD element. The color code for a
four wire RTD is usually two red wires and two white
wires.

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Thermocouple
Thermocouple used in plant is K type and made up of two dissimilar metals called Alumel and
Chromel
Working Principle
Thermocouple works on the principle of Seed back Effect
Seedback effect tells that when we connect two dissimilar metals with each other ,there is a hot
junction at both metals meetup ends and at open it is called cold junction, so at the hot junction we
provide temperature and in result of it gives the mVolt output

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the range of these thermocouple is from 200°C to +1260°C / -328°F to +2300°F
Temperature Range:
•Thermocouple grade wire, −454° to 2,300°F (−270 to 1,260°C)
•Extension grade wire, −32° to 392°F (0 to 200°C)
•Melting Point, 2550°F (1400°C)
Accuracy(whichever is greater):
•Standard: ± 2.2C% or ±.75%
•Special Limits of Error: ± 1.1C or 0.4% -
Thermocouple is installed in Cyclones of Pre heater which near from Klin due to high
temperature they are preferable

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DCS DEPARTMENT:
PLC(Programmable Logic Controller)
Programmable Logic Controllers (PLCs), also referred to as programmable controllers, are in the
computer family. They are used in commercial and industrial applications. A PLC monitors inputs,
makes decisions based on its program, and controls outputs to automate a process or machine.
PLCs consist of input modules or points, a Central Processing Unit (CPU), and output modules or
points. An input accepts a variety of digital or analog signals from various field devices
(sensors) and converts them into a logic signal that can be used by the CPU. The CPU makes
decisions and executes control instructions based on program instructions in memory. Output
modules convert control instructions from the CPU into a digital or analog signal that can be used
to control various field devices (actuators). A programming device is used to input the desired
instructions. These instructions determine what the PLC will do for a specific input. An operator
interface device allows process information to be displayed and new control parameters to be
entered.
Pushbuttons (sensors), in this simple example, connected to PLC inputs, can be used to start and
stop a motor connected to a PLC through a motor starter (actuator).
Substation:
Siemens PLC Order No. & Specifications:
SIMATIC S7-400
CPU MODULE card no: 412-2
order no: 412-2XG00-0AB0

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Order Code: 422-1B200-0AA0
DI Module card no: DU 16xUC120/230V
Order Code: 421-1FH20-0AA0
AI Module card no: 16*13Bit
Order Code: 431-0HH00-0AB0
PS Module card no: 407-10A
Order Code no: 407-0KA02-0AA0
External Module card no: IM 461-0
Order Code: 461-0AA01-0AA0

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Raw Mill Proportionator(RMP):
Siemens PLC Order No. & Specifications:
SIMATIC S7-200
CPU Card no: 224
SIMATIC S7-200 CPUs
CPU for higher communication and computing requirements - The high-performance CPU for
complex tasks that require speed and special communication capabilities
CPU for simple drive tasks - The CPU 224 version for convenient implementation of simple drive
tasks – with two interfaces, two analog inputs and one analog output, as well as two 100-kHz pulse
outputs and two high-speed 200-kHz counters.

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Feature
CPU 221 CPU 222
CPU 224
CPU 224XP
CPU 224XPsi
CPU 226
A Independent hardware
counters
4 4 6 6
Independent alarm inputs 4 4 4 4
Pulse outputs 2 2 2 2
Time interrupts 1 to 250 ms 1 to 250 ms 1 to 250 ms 1 to 250 ms
Real-time clock optional optional integrated integrated
Binary processing speed 0,22 μs 0,22 μs 0,22 μs 0,22 μ
EM Module card no: 231 A14*12BIT
Order Code: 231-0HC22-0XA0
Weigh Feeder:
Siemens PLC Order No. & Specifications:
SIMATIC S7-200
EM Module card no: 232 A14*12BIT
Order Code: 232-0HC22-0XA0
CPU Module card no: 224
Order Code: 224-0HC22-0XA0

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KILN(MASTER) & PREHEATER(SLAVE) AREA:
Siemens PLC Order No. & Specifications:
SIMATIC S7-400
RACK 1
DI (Digital Input module) card:
Order no: 421-1FH20-0AA0
QTY: 13
DO(Digital IOutput module) card:
Order no: 421-1FH20-0AA0
QTY: 4
Digital I/p:16*UC 120/230V
Digital O/p: 32*DC 24V/0.5V
IM (Interface Module) Card:
IM 461-0
Order code:460-0AA01-0AB0
Rack2
AI(Analoge Input Module) Card:
Order code: 421-0HH00-0AB0
QTY: 8
AO(Analoge Output Module) Card:
Order code: 432-1HFC0-0AB0
QTY: 4

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Analog I/p: 16
Analog o/p: 8
Order code:
IM (Interface Module) Card:
IM 461-1
Order code:461-0AA01-0AB0
Cement Mill (Weigh Feeder )AREA:
Siemens PLC Order No. & Specifications:
SIMATIC S7-200
CPU 224
Order no: 214-1AD23-0XB0
QTY : 4
EM 232
Order no: 231-0HB22-0XA0
QTY : 4
Analog O/p: 24
EM 231
Order no: 231-0HC22-0XA0
QTY : 4
Analog O/p: 24
Controller TD-200:
Siemens S7 TD-200
Order No : 6ES7272-0AA30-0YA0
QTY: 2

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PACKER AREA:
Siemens PLC Order No. & Specifications:
SIMATIC S7-300
Rack1
CPU 314
Order code: 314-1AG14-0AB0
QTY: 1
DI (Digital Input module) card:
Order no: 321-1BL0-0AA0
QTY: 2
DO(Digital IOutput module) card:
Order no: 322-1BL00-0AA0
QTY: 1
Digital I/p:32*DC 24V
Digital O/p: 32*DC 24V/0.5V
Rack2
AO(Analoge Output Module) Card:
Order code: 332-5HB01-0AB0
QTY: 1
Analog I/p: 0
Analog o/p: 2
Order code:

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