SOP-Startup Shutdown and Operation of Cement Mills

ANJANI PORTLAND CEMENT LIMTIED
Ref No. OPER/SOP-10 Dept: Operations

Supersedes Nil Page : 01 of 03
01/01.03.20 00/01.03.201 Effective
Version No./Dt. Rev .No ./Dt. Next Review Dt. 28.2.2021 01.03.2018
18 8 Dt.
Title Standard Operating Procedure for startup/shutdown and operation of Cement Mills
1.0 Purpose:
To ensure safe start, stop and operation of Cement Mills.
2.0 Scope:
Cement Mill.
3.0 Responsibility:
H.O.D (Operation)/HOS Grinding (Operation) is responsible for implementation of this SOP.
4.0 Pre requisites

 Check all groups are ready to start.
 Ensure space is available in selected silo.
5. Procedure
Starting or stopping of mills is made by selecting groups in a sequence to avoid the material
accumulation in the system and jamming of the transportation system.
Mill groups will be started as per the following sequence.
 Mill inlet and out gear box system group
 Mill girth gear lubricating system group
 Silo filling group.
 Bag house material conveying group.
 Separator lubrication & Separator groups.
 Mill Fan group.
 Ball Mill material transport group
 Ball Mill vent fan group
 Ball Mill Main drive group
 Mill feed group.
 Water spray group
 Feed Hopper filling group.
All the equipments are stopped in reverse sequence for stopping the mill
To be followed the following operating parameters
Prepared by Reviewed for adequacy and approved by Authorized by

Ref No. OPER/SOP-10 Dept: Operations
Next Review Effective
Version No./Dt. 01/01.03.2018 Rev .No ./Dt. 00/01.03.2018 28.2.2021 01.03.2018
Dt. Dt.
S.NO Operating Parameters Permissible Range

Cement Mill1 Cement Mill 2 Cement Mill-3
1 Cement mill Feed max 32 TPH 32 TPH 100 TPH
2 Mill Sound level % Min-20 % to 30 % Min-20 % to 25 % Min-15 % to 30 %
3 Mill Main Motor 59 to 61amps 60 to 62 amps 220 to 225
4 Mill outlet draught 70 to 85 mmWC 60 to75 mmWC 110 to 150

5 Mill Outlet temperature 80 to 100 O C 80 to 100 O C 105 to 115
6 Bag filter DP 85 to 100 mmWC 80 to 100 35 to 55
7 ID fan amps 135 to 145 100 to 120 37 to 39

8 Residue % on 212 2.8 to 3.2 2.8 to 3.2 2.8 to 3.2
Blains 330 to 340 330 to 340 270 to 280
9 Separator rpm 180 to 200 180 to 200 175 to 190
10 CA fan Damper Open % NA NA 85 to 100
11 Mill Vent Fan 1200 to 1350 900 to 1000 85 to 100

(rpm/Damper open %)
12 Mill separator B.E amps 30 to 40 30 to 35 25 to 30
Sr. Contingency
Reasons Corrective Action
No. Measures
 Reduce feed rate
Mill outlet draught  Excess feed rate
1.  Check and confirm the jam and stop the
high  Mill outlet duct jam
feed
 Excess feed rate  Reduce feed rate
Mill inlet draught
2  Mill inlet duct jam  Check and confirm the jam and stop the
low
feed
 Low feed rate  Increase feed rate
3. Mill Sound level high
Mill outlet  Mill inlet hot air % high  Reduce hot air %
4.
temperature is high  Mill is empty running  Increase feed rate
 Mill inlet hot air % low  Reduce feed rate
Mill outlet
5.  Mill is running with load  Increase hot air %
temperature is low
 Mill feed moisture% high
 Reduce separator rpm
 Input feed size high
6. Residue % is high  Reduce vent fan rpm
 Separator rpm is high

Ref No. OPER/OCP-10 Dept: Operations
Effective
Version No./Dt. 01/01.03.2018 Rev .No ./Dt. 00/01.03.2018 Next Review Dt. 28.2.2021 01.03.2018
Dt.
CCR operator to be record the parameters hourly in APCL / PRO / F-05 or APCL / PRO / F-06
Or APCL / PRO / F-07
 The quality parameters are intimated by the shift chemist or Tester from the QUAS Dept
Safety:
1. Take Line Clearance from Electrical, Mech and Inst dept. before starting the any equipment
Environment:
1. Cement mill ID fan Stack emission are to be maintained below 30mg/Nm3.
 If any abnormal condition, inform Section Incharge/HOD (operation) and follow guidelines and
instructions.
EnMS:
1. Do not run idle running of the equipments
2. Check the clinker and additives hoppers levels are in desired level
3. Inform to CPP people to before start the mill Main drive ,separator fan & Auxiliaries to
get the power in time
4. Do not run unnecessary equipments while in stoppage of the equipment
5. Calculate the power loss across the ID fans if any replaced with VFD
6. Identify the interlocks and implement the same for energy saving opportunities


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ANJANI PORTLAND CEMENT LIMTIED

Ref No. OPER/SOP-10 Dept: Operations

4.0 Pre requisites

To be followed the following operating parameters

Prepared by Reviewed for adequacy and approved by Authorized by

S.NO Operating Parameters Permissible Range

2 Mill Sound level % Min-20 % to 30 % Min-20 % to 25 % Min-15 % to 30 %

3 Mill Main Motor 59 to 61amps 60 to 62 amps 220 to 225

4 Mill outlet draught 70 to 85 mmWC 60 to75 mmWC 110 to 150

7 ID fan amps 135 to 145 100 to 120 37 to 39

Blains 330 to 340 330 to 340 270 to 280

9 Separator rpm 180 to 200 180 to 200 175 to 190

10 CA fan Damper Open % NA NA 85 to 100

11 Mill Vent Fan 1200 to 1350 900 to 1000 85 to 100

Prepared by Reviewed for adequacy and approved by Authorized by

1. Cement mill ID fan Stack emission are to be maintained below 30mg/Nm3.

1. Do not run idle running of the equipments

4. Do not run unnecessary equipments while in stoppage of the equipment

Prepared by Reviewed for adequacy and approved by Authorized by

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