BASIC DATAPLANTARASMETA CEMENT PLANT, INDIALINEDESIGN DATAMILL1MILL2COAL MILL TYPEBall MillVertical MillCOAL MILL DESIGN CAPACITY1525tph productPOWER CONSUMPTION DESIGN (MILL ONLY)-24.5kWh/tFUEL ANALYSIS - AS PER DESIGNCVNA4300kcal/kg net adbASHNA32.7% adbTOTAL MOISTURENA20(max)% asrINHERENT MOISTURENA3% asrVMNA25.5% adbSNA0.4% adbClNANA% adbHGINA50PRODUCT RESIDUE 90 um1212%COAL MILL MOTOR POWER INSTALLED405365kWCOAL MILL GEARBOX POWERNANAkWTABLE DIAMETER-2mBALL MILL DIAMETER3-mBALL MILL DRYING CHAMBER LENGTH2.8-mBALL MILL GRINDING CHAMBER LENGTH4.4-mSEPARATOR SUPPLIERFLS/L&TLNVTSEPARATOR TYPEStaticLVT typeMILL FILTER AREA TOTAL340.341000m2MILL FILTER AREA ACTIVE (OFFLINE CLEANING)--m2MILL FAN DESIGN VOLUME2460084000m3/hrKiln coal dosing system capacity14tphCalciner coal dosing system capacity20tphNote:adb - air dried basisasr - as received

CURRENT DATAPLANTARASMETA CEMENT PLANT, INDIALINE0CURRENT OPERATIONRAW MEALChloride0.012-0.02%KFUI3 to 4CLINKER CHEMISTRYS = SO30.6 - 0.8%Na2O0.25 - 0.3%K2O1.5 -1.6%Chloride0.020 - 0.025%COAL MILL PERFORMANCEMILL 1MILL 2PRODUCTION1527tph productActual for 2002PRODUCT RESIDUE 90 UM15.825.26%PRODUCT RESIDUE 200 UM1.922.5%MILL POWER ABSORBED371276kWPOWER CONSUMPTION36.026.0kWh/tPRODUCT MOISTURE1.851.14%FUEL 1 PROPORTION100100% total CV inputFUEL 2 PROPORTION00% total CV inputFUEL ANALYSIS - CURRENTFUEL 1FUEL 2CV48884568kcal/kg net adbASH30.3634.06% adbTOTAL MOISTURE--% asrINHERENT MOISTURE1.851.14% asrVM26.1624.77% adbS0.30.3% adbCl0.0150.015% adbHGI6869ALTERNATIVE FUEL NOT THRU MILLS-% cv replacementKILN FEEDRATE VARIATION3.0% tphCOAL FEED RATE VARIATIONS KILN+/- 10% tphCOAL FEED RATE VARIATIONS PC+/- 6% tphBURNER MOMENTUM3.8Nh/GJAXIAL ALIGNMENT OF BURNER20 mm down & 20mm towards feedGAS ANALYSIS RELIABILTYGAS ANALYSIS KILN INLET70 to 80%GAS ANALYSIS PC OUTLET95 to 98%GAS ANALYSIS P/H OUTLET95 to 98%SPLASH BOXES INSTALLEDYesMEAL CURTAIN INSTALLED-BLASTERS ON RISER AND HEARTHYesSILICON CARBIDE ON RISER AND HEARTHNo

SAFETYPLANT NAMEARASMETA CEMENT PLANT,INDIAKILN NUMBERKILN NUMBERKILN NUMBERKILN NUMBER1ANSWERSANSWERSANSWERSANSWERSCOAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION1PREHEATER EXITPreheater gas analysisPreheater exit gas analyser installed (y/n)YESO2 measured (y/n)YESCO measured (y/n)YESService factor of analyser >95% (y/n)YES2COAL MILLCOAL MILL 1COAL MILL 2Coal mill design pressure300700DCS system installed if not what type of control systemYESYESUsing hot gas from cooler,pre-heater or hot gas generatorCOOLER & HOT GAS GENERATORPREHEATER GAScoal mill temperature monitoringcoal mill exit thermocouple installed (y/n)YESYESNormal operating exit temperature 72- 7573 - 77Alarms configured for exit temperatureYESYESFirst alarm level for coal mill exit temperature 8585Second alarm level for coal mill exit temperature 9090inlet thermocouples installed (y/n)YESYESNormal operating Inlet Temperature 550-580300-350Alarms configured for inlet temperatureYESYESFirst alarm level for mill inlet temperature 580350Second alarm level for coal mill inlet temperature -375Temperature controlled by Recirculation damper (y/n)NONOAutomated shutdown for high high coal mill exit temperature (y/n)YESYESOXYGEN LEVEL at filter (%)NONOTramp metal detection installedNONOCoal mill explosion reliefExplosion relief installed on coal mill (y/n)NONOVenting direction inside or outside building ?Position (e.g. on coal mill body in inlet or exit duct etc)Type of protection explosion flap, rupture panelArea of explosion flap, panel (m2)Lifting/ breaking pressure of flap , panelManufacturer of explosion reliefExtra Venting fitted on duct from coal mill to filter (y/n)NONOVenting direction inside or outside building ?3COAL MILL BAG FILTERBag filter design pressure+1500mmwgNA-500mmwgBag filter temperature monitoringInlet thermocouple fitted (y/n)YESYESOutlet thermocouple fitted (y/n)YESYESDifferential temperature monitored and displayed (y/n)YESYESPosition of probes (e.g. in filter or ducts)INLET DUCTINLET DUCTTypical differential temperature First alarm level of differential temperature--Second alarm level of differential temperature2020Does second alarm trigger automatic shutdown (y/n)YESYESTemperature measured in bag filter bottom (y/n)NOYESMaterial discharge temperature of bag filter measured (y/n)YESYESBag filter Gas monitoringBag filter gas exit analyser installed (y/n)NOYESPosition inside filter or in exit duct-EXIT DUCTCO measured (y/n)NOYESO2 measured (y/n)NONONormal operating level of CO ppm-0Normal operating level of O2 %-First alarm level (O2 %)--Second alarm level (O2%)--First alarm level (CO ppm)-0.20%Second alarm level (CO ppm)-0.50%Do the second alarms for CO or O2 trigger an automatic shutdown-YESBag filter level devicesAny level devices installed in bag filter (y/n)YESYESposition of level devicesIN DISCHARGE HOPPERIN DISCHARGE HOPPERAny blockage devices fitted to filter discharge (y/n)NONOBag filter isolationFast acting isolation dampers installed outlet and inlet of filter (y/n)YESYESBag filter Explosion protectionExplosion relief installed on bag filter (y/n)YESYESYESType of protection (self closing doors rupture panels etc)flame front eqipmentflame front eqipmentflame front eqipmentArea of explosion doors, panels (m2)2.04.52Lifting/ breaking pressure of flap , panelNANANumber of explosion doors panels etc--Position of doors panels (side venting etc)INLET DUCTINLET DUCT4PULVERIZED FUEL STORAGEFuel storage design pressureNANAPulverized fuel Storage silo gas monitoringNumber of storage silos11Capacity of silos /s (t)75100CO analyser installed on individual silo/s (y/n)NONOPulverized fuel Storage silo temperature monitoringThermocouples installed in silo/s (y/n)YESYESNumber of measuring points36Position of points ( silo bottom, body, top etc)SILO BODYSILO BODYFirst alarm level9085Second alarm level105100Any other temperature monitoring devices installed (describe)pulverized fuel storage silo/s explosion protectionExplosion relief installed on silos (y/n)NONOType of protection (self closing doors rupture panels etc)Number of explosion doors panels etcArea of explosion flap, panel (m2)Lifting/ breaking pressure of flap , panel5RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)Fire suppression system installed (y/n)NONOTemperature monitoring for hopperNONOExplosion vents installed (y/n)NONOCO monitoring installed (y/n)NONO6OPERATOR TRAININGHave operators had training on fire suppression techniquesnono7DOCUMENTATIONIs there a written procedure in case of fire or suspected fire on the coal mill systemYESYESAre there any written procedures covering general house keeping in coal grinding areaAny formal training attend (with suppliers Atc etc)8SYSTEM GENERALIs there a cleaning schedule for the coal plant area (y/n)YESYESHave earthing straps been installed and tested on all conveying pipes (y/n)NONOIs there any horizontal ducting in the systemNONO9FIRE SUPPRESSION SYSTEMDate installedManufacturerType of suppression usedCO2 (gas)YESYESCO2 (liquid & gas)N2NOYESStorage capacity--Storage in bulk or bottlesIN BOTTLESIN BOTTLESRefill delivery time from time of order (hrs)In case of CO2 the delivery time is approx one week and for N2 it is within a daysDeliver capacity (M3/hr)--Available discharge areas (coal mill, filter, silos others etc)-SILOAny alternative or secondary system usedNONOAutomatic raw meal blanket system installedNONOAny explosion suppression system fitted ( dry powder or other)NONOWhat areas have explosion the suppression system installed10No such type of historyFirst time in the year 1995 and second time in the year 2001, bag filter of coal mill 2 got fire and all the bags got burnt.If there is a history of fires or explosions please give frequency with comment11DESIGN PRESSURE SHOCK RESISTANCE OF ITEMS OF PLANT IF KNOWNPressure shock resistance (bar) (absolute)Pressure shock resistance (bar) (absolute)Pressure shock resistance (bar) (absolute)Pressure shock resistance (bar) (absolute)Coarse feed valve into coal millNANAHot gas duct upstream of the millNANADucting to the filterNANAGas duct to the fanNANAExhaust gas fanNANAscrew conveyor from filterNANAFine coal silo 1NANAFine coal silo 2NANASilo dedusting filterNANASilo dedusting filterNANAfeeder from pulverized fuel silo/sNANAConveying pipeline to the main burnerNANAConveying pipeline to the calciner burnerNANADRYER ANSWERSDRYER ANSWERSDRYER ANSWERSDRYER ANSWERS12DRYER IF INSTALLEDInlet temperature measured (y/n)NOOutlet temperature measured (y/n)YESHIGH LEVEL ALARM FOR INLET TEMPERATURE-HIGH HIGH ALARM FOR INLET TEMPERATURE-HIGH ALARM FOR EXIT TEMPERATURE700HIGH HIGH ALARM FOR EXIT TEMPERATURE AND AUTOMATED SHUTDOWN CONFIGUREDYES13DRYER MILL BAG FILTERBAG FILTER EXIT ANALYSERO2 MEASURED (Y/N)CO MEASURED (Y/N)INLET TEMPERATURE MEASUREMENTOUTLET TEMPERATURE MEASUREMENTHIGH DIFFERENTIAL TEMPERATURE ALARMHIGH HIGH DIFFERENTIAL TEMPERATURE ALARM AND AUTOMATIC SHUTDOWNFAST ACTING DAMPERS INSTALLED ON INLET AND OUTLET OF FILTERFIRE SUPPRESSION SYSTEM INSTALLEDCO2EXPLOSION RELIEF INSTALLEDADDITIONAL INFORMATION AND COMMENTS

ANSWERS TO THIS QUESTIONNAIRE SHOULD BE ACCURATE AND SPECIFIC please add any comments you might feel of help at the end of the questionnaire. If there is an area where the answer is not know please state not known. Note cells are auto formated yes = green no = red

Completion target date 10th October 2003utpals01:THERMOCOUPLE AT MILL CYCLONE OUTLET.utpals01:INCASE OF MILL STOP CONDITION I.e WHEN ONLY BAGFILTER IS RUNNING CONDITION.ramesh02:DESIGN MILL OUT LET PRESSURE IN mm wg.ramesh02:mill out let pressure in mm wg.ramesh02:In present operating condition recirculated air is not getting use (mill out let temp.)ramesh02:Same as in mill one case.

safety-Example questionnairePLANT NAMEANYWHEREKILN NUMBERK9ANSWERSCOAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION1PREHEATER EXITPreheater gas analysisPreheater exit gas analyser installed (y/n)NOO2 measured (y/n)NOCO measured (y/n)NOService factor of analyser >95% (y/n)NO2COAL MILLCoal mill design pressure (bar)10bar (absolute)DCS system installed if not what type of control systemYESUsing hot gas from cooler,pre-heater or hot gas generatorP/HEATERcoal mill temperature monitoringcoal mill exit thermocouple installed (y/n)YESNormal operating exit temperature 65cAlarms configured for exit temperatureYESFirst alarm level for coal mill exit temperature 75cSecond alarm level for coal mill exit temperature 90cinlet thermocouples installed (y/n)YESNormal operating Inlet Temperature 220cAlarms configured for inlet temperatureYESFirst alarm level for mill inlet temperature 240cSecond alarm level for coal mill exit temperature 255cTemperature controlled by Recirculation damper (y/n)YESAutomated shutdown for high high coal mill exit temperature (y/n)YESOXYGEN LEVEL at filter (%)14%Tramp metal detection installedNOCoal mill explosion reliefExplosion relief installed on coal mill (y/n)NOVenting direction inside or outside building ?outsidePosition (e.g. on coal mill body in inlet or exit duct etc)on exit duct after coal millType of protection explosion flap, rupture paneleplosion doorArea of explosion flap, panel (m2)8m2Lifting/ breaking pressure of flap , panel4barManufacturer of explosion reliefThorwesternExtra Venting fitted on duct from coal mill to filter (y/n)YESVenting direction inside or outside building ?outside3COAL MILL BAG FILTERBag filter design pressure4 (bar) (absolute)Bag filter temperature monitoringInlet thermocouple fitted (y/n)YESOutlet thermocouple fitted (y/n)YESDifferential temperature monitored and displayed (y/n)YESPosition of probes (e.g. in filter or ducts)in ducts before & afterTypical differential temperature 5cFirst alarm level of differential temperature10cSecond alarm level of differential temperature12cDoes second alarm trigger automatic shutdown (y/n)YESTemperature measured in bag filter bottom (y/n)yesMaterial discharge temperature of bag filter measured (y/n)yesBag filter Gas monitoringBag filter gas exit analyser installed (y/n)NOPosition inside filter or in exit ductinside filterCO measured (y/n)NOO2 measured (y/n)NONormal operating level of CO ppmNONormal operating level of O2 %NOFirst alarm level (O2 %)NOSecond alarm level (O2%)NOFirst alarm level (CO ppm)NOSecond alarm level (CO ppm)NODo the second alarms for CO or O2 trigger an automatic shutdownNOBag filter level devicesAny level devices installed in bag filter (y/n)yesposition of level devicesdischarge hopperAny blockage devices fitted to filter discharge (y/n)noBag filter isolationFast acting isolation dampers installed outlet and inlet of filter (y/n)YESBag filter Explosion protectionExplosion relief installed on bag filter (y/n)YESType of protection (self closing doors rupture panels etc)self colossing doorsArea of explosion doors, panels (m2)15m2Lifting/ breaking pressure of flap , panel0.4barNumber of explosion doors panels etc10Position of doors panels (side venting etc)side venting4PULVERIZED FUEL STORAGEFuel storage design pressure10bar (absolute)Pulverized fuel Storage silo gas monitoringNumber of storage silos2Capacity of silos /s (t)35tCO analyser installed on individual silo/s (y/n)YESPulverized fuel Storage silo temperature monitoringThermocouples installed in silo/s (y/n)YESNumber of measuring points20Position of points ( silo bottom, body, top etc)silo bottom to mid pointFirst alarm level60Second alarm level75Any other temperature monitoring devices installed (describe)thermocouple in silo toppulverized fuel storage silo/s explosion protectionExplosion relief installed on silos (y/n)YESType of protection (self closing doors rupture panels etc)Number of explosion doors panels etcself closing doorsArea of explosion flap, panel (m2)2.4 M2Lifting/ breaking pressure of flap , panel4 bar5RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)Fire suppression system installed (y/n)NOTemperature monitoring for hopperYESExplosion vents installed (y/n)YESCO monitoring installed (y/n)NO6OPERATOR TRAININGHave operators had training on fire suppression techniquesNO7DOCUMENTATIONIs there a written procedure in case of fire or suspected fire on the coal mill systemNOAre there any written procedures covering general house keeping in coal grinding areaNOAny formal training attend (with suppliers Atc etc)NO8SYSTEM GENERALIs there a cleaning schedule for the coal plant area (y/n)yesHave earthing straps been installed and tested on all conveying pipes (y/n)NOIs there any horizontal ducting in the system1 meter to filter9FIRE SUPPRESSION SYSTEMDate installed1995ManufacturerChemitronType of suppression usedCO2 (gas)yesCO2 (liquid & gas)N2Storage capacity kg5000kgStorage in bulk or bottlesbulkRefill delivery time from time of order (hrs)24 hoursDeliver capacity (M3/hr)1200M3/hrAvailable discharge areas (coal mill, filter, silos others etc)coal mill, filter, silosAny alternative or secondary system usedNOAutomatic raw meal blanket system installedNOAny explosion suppression system fitted ( dry powder or other)dry powderWhat areas have explosion the suppression system installedsilos only10one fire in 1995 during commissioning. Since then only small fires in silo which have been containedIf there is a history of fires or explosions please give frequency with comment11DESIGN PRESSURE SHOCK RESISTANCE OF ITEMS OF PLANT IF KNOWNPressure shock resistance (bar) (absolute)Coarse feed valve into coal mill8barHot gas duct upstream of the mill3barDucting to the filter8barGas duct to the fan1.4barExhaust gas fan1.4barscrew conveyor from filter4barFine coal silo 14barFine coal silo 24barSilo dedusting filter10barSilo dedusting filter10barfeeder from pulverized fuel silo/s10barConveying pipeline to the main burner10barConveying pipeline to the calciner burner10barDRYER ANSWERS12DRYER IF INSTALLEDInlet temperature measured (y/n)YESOutlet temperature measured (y/n)YESHIGH LEVEL ALARM FOR INLET TEMPERATUREYESHIGH HIGH ALARM FOR INLET TEMPERATUREYESHIGH ALARM FOR EXIT TEMPERATUREYESHIGH HIGH ALARM FOR EXIT TEMPERATURE AND AUTOMATED SHUTDOWN CONFIGUREDYES13DRYER MILL BAG FILTERBAG FILTER EXIT ANALYSERNOO2 MEASURED (Y/N)NOCO MEASURED (Y/N)NOINLET TEMPERATURE MEASUREMENTYESOUTLET TEMPERATURE MEASUREMENTYESHIGH DIFFERENTIAL TEMPERATURE ALARMYESHIGH HIGH DIFFERENTIAL TEMPERATURE ALARM AND AUTOMATIC SHUTDOWNYESFAST ACTING DAMPERS INSTALLED ON INLET AND OUTLET OF FILTERYESFIRE SUPPRESSION SYSTEM INSTALLEDNOCO2NOEXPLOSION RELIEF INSTALLEDYESADDITIONAL INFORMATION AND COMMENTSadditional information might be that the bag fiter access is restricted when coal mill is in operation or that the plant run raw meal through the system before it is shut down for major repairswe often get a few small smouldering rejects from the mill but these do no cause a problem

ANSWERS TO THIS QUESTIONNAIRE SHOULD BE ACCURATE AND SPECIFIC please add any comments you might feel of help at the end of the questionnaire. If there is an area where the answer is not know please state not known. Note cells are auto formated yes = green no = red.

Completion target date 10th October 2003