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HYM 500

Year of release: 2014


Capacity: 500

Lime plant HYM 500


capacity 500 m.t/day

Altitude above sea level: 500 m.t./d.


Absolute min. Temperature - 38,
Absolute max. Temperature + 40,
Design temperature for blower layout: + 40,
Wind load: 0,23 kPa
Snow load 0,8 kPa
Avarage velocity of wind for calculation 3,8 m/s

Above data are subject of confirmation by Client.

Technical Description and Design Data

Type of the Kiln: Double shaft,circular cross-section,parallel flow,regenerative


vertical HYM lime kiln.
Number of shafts: 2
Shaft dimensions: circular cross section of approx. 12,5 m? each.
Production capacity: 500 m.ton/24 hour of burnt lime with a lime stone
grading of 40-80 mm or similar
Fuel: Natural Gas
Number of burner lances: 33 lances in each shaft. (33x2)
Raw Material:
Type : Lime stone
Size : 40 mm to 80 mm
-40 mm max. 1 %
+80 mm max. 1 %
Mechanical strength: 500 kg/cm2 min.
Abrasion index (-.5 mm ): 1% max. (ASTM E-279)

Chemical Properties:

CaCO3: >97%, Fe2 O3: < 0,5%, SiO2: < 0,5%, MgCO3: <1%, Al2O3: <0,5%,
humudity:<1%

All performance parameters stated in this quotation are based on this typical analysis.
Signficiant changes of the lime stones chemical and/or physical properties may result in
accordingly adapted performance parameters.

HYM Kiln Product:


Type: Burnt lime (CaO)
Size: 0-80mm
Bulk weight: approx. 1,0 t/m?
Temperature: 80-120 C
Residual C0: %2 in avarage
Reactivity: T60- value less than 120 seconds (DIN EN 459-2)

Double shaft,circular cross-section,parallel flow,regenerative vertical HYM lime kiln is


designed ( taking lime stone specifications in to consideration) to produce all reactivity
levels of calcium oxide, ranging from soft to medium and hard burnt lime. Ideal
reactivity level could be defined after examination of sample of lime stone .

Consumption Figures:

Lime Stone: 40-80 mm approx.893 ton


Heat consumption: 900 kcal/kg in avarage burnt lime
Power consumption: 35 kwh/ton of burnt lime (lime kiln)
Compressed air: 150 m?/h (lime kiln)
?nstalled power: 1600 kW (lime kiln)

500 m.t/day THE DOUBLE SHAFT, CIRCULAR CROSS-SECTION, PARALLEL FLOW,


REGENERATIVE VERTICAL LIME KILN;

Specification of Materials and Equipments for the HYM Lime Kiln:


1- Kiln

1.1- Kiln shell and steel structure (1 Set)


The kiln shell is mainly composed of 10 to 20 mm mild steel sheets. The function of the
shell is:
- to absorb the inside pressure
- to bear the refractory lining
- to bear the kiln charging system and the kiln top house

The kiln shafts are equipped with access doors for inspection and maintenance
All doors are equipped with a bulb iron in order to avoid opening of the door when the
kiln is pressurised. It is not allowed to open any access door before the kiln has been
shut down and is depressurised.

1.2- Platforms (1 Set) (expended metal)

1.3- Stairs (1 Set) (grating)

1.4- Kiln Service Crane (1 Set)

Hoisting device for repair and maintenace of kiln.

1.5- Supporting structure for kiln top housing

The upper part of the kiln is clad for weather and sound protection. The housing
consists of a bolted steel construction and sound insulation lining. The lower part of the
kiln is not enclosed. The major installations of the kiln are accessible via platforms and
their respective staircases.

1.6- Limestone Weighing Hopper before the skip (with load cells) (1Set)

The skip hopper has a volume of approx 3.5 m3 corresponding to approx. 4500 kg of
limestone.
The lime kiln is charged batch wise by means of a skip hoist. A pre-determined amount
of limestone is prepared in the skip hopper and charged into the skip bucket.

The amount of stone filled into the skip hopper must be limited to 4500 kg otherwise
there is the danger of overflow of the following charging system.

The hopper is over the skip bucket and placed onto weighing cells.

The skip (weighing) hopper trap is opened by means of a hydraulic cylinder and closed
by means of a counterweight and hydraulic pressure at the cylinder. In case of a total
power failure the trap closes by means of the counterweight only.

Volume: 3,5 m3
Capacity: 4500 kg of limestone
Number of weighing cells: 3

1.7- Skip Group for conveying limestone to the top of kiln

Basic data for the skip

Stone quantity to be transported to the top of the kiln: 893 t/day


Number of burning cycles per day: 100
Stone weight required per burning cycle: 8.93 t
Number of skip run per cycle: 2
Number of skip run per day *) 200
Theoretically calculated weight per skip run: 4.46 t

1 Skip run = Filling of the bucket, run up, emptying of the bucket, run down.
Design data
Skip capacity: 4.5 t per run
Skip bucket volume approx.: 3.0 m3
Speed of the skip bucket: approx. 20 m/min

1.7.1- Skip Winch with Gear Motor and Brake (1 Set)

The skip winch shall be supplied completely pre mounted on a frame, including:
- 1 double wire rope drum
- 1 gear
- 1 electric motor, approx. motor power 3 * 400 VAC, 50 Hz. 37 kW incl. VVVF
- 2 dynamic brakes for power failure.
1 Skip rope
The following safety equipment shall be delivered together with the skip:

- 1 up and 1 down limit switch


- 1 slack rope switch
- 2 ultimate up and ultimate down limit switches.

1.7.2- Skip Bridge and Rope (1 Set)

Steel structure for skip bridge.


The skips framework is resting at a separate foundation located at plant level +0.00
mNN. Additionally the framework is supported by the steel structure of the lime kiln and
by the lime kilns platforms at several points.
1.7.3- Skip Bucket (1 Pcs.)

- Capacity: 4.5 t
- Volume: 3.0 m3
1.8- Limestone Weighing Hopper on top of the kiln (with load cells) (1Set)

The silo on kiln is mounted on the stone hopper platform and placed onto weighing
cells.
Volume: 7.5 m3
Capacity: 11200 kg of limestone
Number of weighing cells: 3

1.9- Discharging Vibrating Feeder of lime stone (1 Pcs.)

The vibration feeder is located directly below the silo on kiln


The vibration feeder has to be adjusted to discharge the requested amount of limestone
in the available time to the reversible conveyor belt.

? length: approx. 1'500 mm


? width: approx. 650 mm
? capacity: approx. 0 100 t/hr
? limestone size: 40 - 80 mm

1.10- Reversal belt conveyor (1 Pcs.)

The reversible belt conveyor distributes the limestone to the rotating buckets.

? length: approx. 4'800 mm


? width: approx. 650 mm
? capacity: approx. 0 - 150 t/hr
? limestone size: 40 - 80 mm

1.11- Rotating Bucket (2 Set)

The rotating buckets serve for charging the kiln.


During charging the rotating bucket are in their upper position. The rotation by gear
motor serves for an even distribution of charged limestone.

To discharging the limestone into the shaft the rotating bucket will be lowered
hydraulically.

1.12- Shaft Closing Trap (2 Set)

The shaft closing trap serves for a safe closing of the shaft. Before charging the kiln the
trap lowers hydraulically to open the shaft
The shaft closing traps are located above the kiln shafts.
The traps open and close the shaft and are moved due to hydraulic cylinders.
Tightness is achieved by means of special silicon rubber seals.

1.13- Level Indicator (2 Set)

The level indicators are installed directly on top of the shafts and are used for
measuring the filling level of the shafts. The level indicators are equipped with hydraulic
rotary drives and probe weights, which continually monitor the stone level.

1.14- Reversing Trap (2 Set)

The reversal traps allow supply of the burning shaft with combustion air, or the waste
gas coming from the regenerative shaft to exit the kiln. For this purpose they are
changing their position by means of hydraulic cylinders.

1.15- Chimney /dust collector Trap (1 Set)

The filter/ chimney trap can be used to feed the waste gas to the filter or, if necessary,
directly to the chimney.
The filter/ chimney trap are installed above the reversal traps on the stone hopper
platform.
The positions "waste gas to chimney" or "waste gas to filter are set by a hydraulic
cylinder.

1.16- Emergency chimney (1 Set)

If the waste gas filter fails, the kiln is stopped and the exhaust air is conducted to the
emergency chimney by switching the filter/ chimney trap.

1.17- Discharging Tables (4 Set)

The inward and outward movement of the table causes the lime to fall off of the outer
edge of the table.

The discharge tables are located below the kiln shafts and are used to discharge the
burnt lime.

The discharge tables consist of four steel plate segments connected crosswise to each
other. The segments are made up of two steel plates and an intermediate ceramic fibre
plate, which pre- vents the plates from warping due to differences in temperature.

Each pair of segments rests on four rollers, which allows for easy movement and makes
maintenance unnecessary.

Each of the connected two segments is shifted back and forth by hydraulic cylinders,
which causes the lime to fall off of the outer edge of the table.

This type of discharge device ensures a steady vertical movement of the lime in the
shafts.

Two beams are mounted crosswise above the discharge table to cover the gaps
between the segments and to support a conical displacement body used to cover the
center opening

1.18- Burnt lime discharging Traps (2 Pcs.)

The discharge traps are located underneath the lime collecting hoppers of the shafts.

The traps discharge the burnt lime collected in the conical discharge hoppers installed
underneath the shafts during the burning period. For this purpose, the traps are opened
and closed by means of hydraulic cylinders.

Counterweights close the traps in the event of a power failure or a failure of the
hydraulic power unit. The traps can be locked in their upper position by means of a
mechanical locking device (e.g. for maintenance purposes).

1.19- Cooling Hopper for discharged burnt Lime (2 Pcs.)

1.20- Discharging Vibrating Feeders of burnt lime (2 Pcs.)

2 vibrating feeder for discharging of burnt lime at kiln bottom with following
characteristics:
? length: approx. 1'500 mm
? width: approx. 650 mm
? capacity: approx. 0 - 50 t/hr
? quicklime size: 0 - 80 mm

1.21- Air Shock System with air cannons (22 Set)

Air shock blowers for cleaning the kiln cross over channel including:
22 air shock blowers with pressure vessel 100 l, with main and pilot valve,
22 pressure switches for the control of the air shock blowers
The compressed air is released by rapidly opening cylinders through connecting pipes
and heat resistant nozzles.
2- Refractories For HYM Kiln (1 Set)
The lime kiln is operated at high temperatures. Burning zone temperatures, at times,
reach up to 1'100 C. This is why the kiln shafts are completely lined with refractory
materials.

The pre-heating and cooling zones of the kiln are lined with an abrasion-resistant
material and backed by insulating firebricks. The wear lining in the burning zone
consists of magnesite and high- alumina bricks, backed by a lining made of light fire
clay and insulating bricks as well as a ceramic fibre mat. The work lining has a thickness
of 250 mm, while the total thickness of the wall is about 500 mm.

The arrangement of the bricks is simple as shown in the figure be- low. No burner
bridges or devices that may affect the stone/lime while it passes through the kiln have
been installed

- cooling zone

- burning zone

- preheating zone

- connecting channel in the junction of the burning & cooling zone.

2.1 Special Bricks (Supporting arc set) :

- special magnesite bricks for supporting arches

2.2 Basic refractories:

- special magnesite bricks (

- magnesite bricks

- magnesite ramming mass

- magnesite mortar

2.3 Non-Basic refractories and auxiliary mataerials:

- special hard fireclay bricks

- compressed fireclay bricks


- light fireclay bricks

- insulating bricks

- insulating plates

- insulating ramming mass

- fireclay ramming mass

- ceramic fibre mats and plates

- slag wool

- fireclay mortar

2.4 Gunning mass for kiln top shaft section (Option)

Gunning mass for corrosion and noise protection to be installed in the top sections of
the two shafts. Thickness of the protection approx. 100mm.

3. Refractories Lining

Refractory installation shall be made by Client under HYM supervision.

4- Kiln Fuel System (for natural gas)

Main components
Manually operated shut-off valve,
Flow measuring device,
Control valve for natural gas
Safety Shut-off valves ,
Double block shut-off valves for shaft 1,
Double block shut-off valves for shaft 2,
Double block shut-off valves for start-up burner,

Electrical Equipment

Temperature measuring device gas inlet


Pressure measuring instrument gas inlet
Gas VORTEXMETER
Control valve for natural gas ( IP positioner 4-20 mA)
Gas fuel shut off valve (solenoid pilot valve 24VDC)
Gas fuel shut off valve SH1 (solenoid pilot valve 24VDC)
Gas fuel shut off valve SH1 (solenoid pilot valve 24VDC)
Gas fuel shut off valve SH2 (solenoid pilot valve 24VDC)
Gas fuel shut off valve SH2 (solenoid pilot valve 24VDC)
Gas fuel shut off valve start up burner (solenoid pilot valve 24VDC)
Gas fuel shut off valve start up burner (solenoid pilot valve 24VDC)
Pressure switch monitoring natural gas
Pressure switch monitoring air supply
Solenoid valve for venting/cooling pyrometer

The gas reversal and safety rack is designed fail safe. That means that in case of de-
energising the pilot solenoid valves the fuel shut-off valves will close automatically by
spring force. The venting valves between the main shut-off valves will open
automatically by spring force.
In normal kiln operation the manually operated shut-off valve, must be open.
The double block valves open and close cyclically in order to feed fuel gas to the burner
lances at the burning shaft.
The valves control the required gas flow.

These control valves can be set to either automatic or manual mode by the kiln
operator.
The gas flow is measured by means of a vortex meter. The PLC converts the measured
flow using the pressure measuring instrument, and the temperature measuring
instrument, , to a flow expressed as normal flow (0C/1013 mbar base).
Fuel is fed to the burning shaft only during the fuel feeding time FFT.
A filter unit is arranged behind the main shut off valve (50 my).

4.1- Burner lances for natural gas (66 Pcs.) and equipments.(1 Set)

The burner lances are suspended from steel structures covered by protection boxes.
The length of the burner lances depends on the range of stone size to be burnt in the
lime kiln. The horizontal position of each single burner lance is well determined to
achieve an optimal distribution of fuel over the cross section of the shaft.
The burner lances can be changed from the outside of the kiln.
Fuel gas which is supplied by the gas reversal and safety rack arrives at the reversal
valves at a pressure of maximal 4.0 barg.
For each single burner lance two non return valves have been provided. One for fuel
gas and one for lance cooling air. For uniform fuel gas distribution through all lances,
orifices are installed, directly before entering the lance body.
Fuel gas is supplied to the burner lances only during the fuel feed time. During burn out
time and the kiln reversal the reversal valves are automatically closed.
Lance cooling air is provided by means of ring ducts at both kiln shafts. Similar as
above for fuel gas each burner lance is connected to that ring duct. The total amount of
lance cooling air is uniformly distributed by means orifice plates installed close to the
burner lance connection unit .
The inside diameter of the orifice plates must be adjusted to achieve a pressure approx.
400 mbarg at full kiln capacity.

4.1.1- Gas reversal and safety rack. (1 Set)

4.1.1.1- Gas proving system for shaft 1. (1 Set)

4.1.1.2- Gas proving system for shaft 2. (1 Set)

4.2- Start up burner rack. (1 Set)


Gas fuel which is supplied by the gas rack unit arrives at the start-up burner at a
pressure of maximal 3.0 barg. After ignition, the flame conditions are manually
controlled due to manual operated control valves. If the start up flame disappears the
flame indicator will monitor after a few seconds of an adjustable delay time No Flame.
Then the PLC will automatically shut down gas.
Combustion air is provided by means of a combustion air blower.

4.2.1- Start up burner (1 Set)

4.2 - All piping system for Natural Gas (by Client)

5- Kiln Air Blowers


Rotary piston blowers are installed to supply combustion air, lime cooling air and lance
cooling air to the lime kiln. This blower type supplies constant volumes of air, almost
independent from the pressure drop in the material column in the kiln shafts.
The blowers are mounted in a specially designed sound insulated concrete house with
soundproof doors. The air is aspirated into the blower room through a concrete channel
via silencers and filters.
Aspiration filters as well as suction and pressure silencers are installed on each blower.
Between each blower and the collection air ducts non-return and safety valves are
installed.
Both in the combustion and cooling air ducts to the kiln shafts relief valves are installed
to de-pressurise the kiln during reversal periods.
All blowers with the exception of one combustion air blower and one lime cooling air
blower are driven by AC-motors with fixed speed. One combustion air blower as well as
one lime cooling air blower and one spare for both are driven by variable speed motors
allowing control of the air flow into the kiln depending on production rate and quality
parameters set.
All air is aspirated into the blower house through a concrete channel. To prevent dust
from entering into the blower room an aspiration filter is installed in the concrete
channel.
Furthermore an aspiration silencer is installed in the channel to reduce noise emissions
to the outside to the level set by the relevant authorities during the permission
procedure.

Blowers are sized for 25 % spare capacity, stand by blowers for combustion / lime
cooling air and lance cooling air.

Roots type blowers for the supply of combustion, cooling and lance cooling air.

Motor Voltage: 400 V AC / 50 Hz

All motors connected to inverters are equipped with thermistor protection.

? All the blowers will be supplied completely pre- mounted on frames including each:

- Suction filter
- Inlet silencer
- Blower body
- Coupling or V-Belt
- Motor
- Outlet silencer
- Check valve
- Safety relief valve
- Bellow expansion joint
- Ant vibration mounts

5.1- Combustion Air Blowers ( with motors)


5.1.1- 5 Units Air Blowers at 35 C : each at 6600 m?/h, 400 mbar
1 AC Motor 132 kW, 250-1500 rpm (Frequency converter)
4 AC Motor 110 kW, 1500 rpm

5.1.2- Relief Trap for Combustion air (1 Pcs.)

The combustion air relief trap releases the kiln pressure while it is being opened. When
set to its open position, the trap provides exit to the outside. In doing so, the trap
relieves the kiln and releases the combustion air supplied by the combustion air
blowers. For this purpose, the trap is opened and closed by a hydraulic cylinder.

5.1.3- Air Collecting Duct for Combustion Air (1 Pcs.)


5.1.4- Combustion Air Pipe Lines (1 Set)
5.1.5- Combustion Air Manuel Valve (1 Pcs.)

5.2- Cooling Air Blowers (With Motors)

5.2.1- 3 Units Air Blowers 35 C: each at 7250 m?/h, 350 mbar


1 AC Motor 132 kW, 250-1500 rpm (Frequency converter)
2 AC Motor 110 kW, 1500 rpm

5.2.2- Relief Trap for Burnt Lime Cooling Air (1 Pcs.)

The cooling air relief trap relieves the lower part of the kiln while its being opened.
When set to its open position, i.e. when the exit to the outside is open, the trap vents
the cooling air produced by the blowers outside. For this purpose, the trap is opened
and closed by a hydraulic cylinder.

5.2.3- Air Collecting Duct for Cooling Air (1 Pcs.)

5.2.4- Automatic Dosing Valves for Cooling Air (2 Pcs.)

2 cooling air flow control traps DN 250 with servo drive. 220 VAC, single phase.

5.2.5- Cooling Air Piping

5.3- Lances Cooling Air Blowers (with motors)

5.3.1 - 2 Units Air Blowers at 35 C: each at 4575 m?/h, 600 mbar (one as a stand-by)
2 AC Motor 110 kW, 1500 rpm

5.3.2 - Lances Cooling Air Reversal Valve (2 Pcs. Pneumatic operated)


5.3.3 - Lances Cooling Air Pipe Lines (1 Set)
5.3.4 - Air Collector for Lances Cooling Air on the kiln (2 Pcs.)

5.4- Blower House inlet filter and inlet silencer (1 Pcs.)

5.5- Soundproof steel door for blower house (1 Pcs.)

5.6- Stand-by Air Blower for Cooling air and combustion air and lance cooling air
(with motor and frequency converter) (1 Pcs.)
1 Units Air Blowers at 35 C : each at 7250 m?/h, 400 mbar
1 AC Motor 132 kW, 250-1500 rpm (Frequency converter)

6- Hydraulic System

Complete hydraulic equipment to operate all movable parts of the kiln, such as the kiln
traps in the charging device for limestone, the discharging device for burnt lime air and
waste gas reversal valves, relief valves for combustion and cooling air, etc.

The supply of the hydraulic equipment comprises:


6.1 Hydraulic power pack

The hydraulic power pack will be supplied completely pre-mounted on a frame including
the following main equipment:

? hydraulic oil tank: capacity approx. 600 l

? 3 hydraulic pumps (one as a standby): operating pressure 100 bar, capacity


approx.100 l/min.
? 3 motors for hydraulic oil pumps, 18.5 kW each

? circulating pump 1.1 kW with oil cooler 0.37 kW

? double oil return filter

? 1 suction oil filter

? 1 oil tank heater 3 kW

? all auxiliary equipment necessary to operate the power pack

Instrumentation

- Level switch min. in oil tank


- Level switch min. min. in oil tank
- Temperature probe in oil tank
- Pressure switch min. in main supply line
- Difference pressure switch at return oil filter
- Limit switches for open indication at suction lines of main pumps
- Limit switch for open indication at main return line

6.2 Solenoid valve blocks

All solenoid valves necessary to operate the hydraulic cylinders are installed on several
blocks built into covers. The hydraulic blocks will be installed on different levels of the
kiln nearby the hydraulic cylinders in order to keep the pipe work as short as possible.
The number of hydraulic valve stands will be determined during the detail design stage.

6.3 Hydraulic cylinders

All hydraulic cylinders necessary to operate the kiln traps including:

? 4 Cylinders for discharge tables


? 2 Cylinders for discharge traps

? 1 Cylinder for combustion air relief trap

? 1 Cylinder for cooling air relief trap

? 2 Cylinders for combustion air / waste gas reversal traps

? 1 Cylinder for filter / chimney reversal traps

? 1 Cylinders for charging skip hopper trap

? 4 Cylinders for shaft closing traps

? 2 Cylinders for rotary hopper

? 2 Hydraulic actuators for level indicator

6.4 Installation accessories


One lot of hydraulic oil pipes, fittings, flexible hoses, pipe supports and shut-off valves
complete to install the pipe work from the power pack to the hydraulic blocks and the
cylinders.

All piping and fittings will be in C-Steel, screed type fittings.

7- Jet Pulse Bag Filter For Kiln (Waste gas dust cleaning system)

A suction type bag house filter is installed to reduce the dust content of the waste
gases leaving the kiln to a level compatible with environmental requirements.

The waste gas filter collects the dust in the exhaust air.

The fan draws the exhaust air through the waste gas filter. The filter bags are cleaned
with compressed air.
The filter dust is collected in a conical hopper underneath the body of the bag house
filter. A screw conveyor discharges the filter dust to a rotary valve in to a dust silo.
If the temperature of the exhaust gas is too high, quench air is fed in to avoid filter
damages.
If the waste gas filter fails, the kiln is stopped and the exhaust air is conducted to the
emergency chimney by switching the filter/ chimney trap.

The unit runs PLC controlled. No manipulation by the operator is required. Settings can
be made in the visualization system.

Max. Waste gas volume: 106 250 m?/h at 160 C


Waste gas temperature: 60-120C
Filter area: 1350 m?
Dust load in raw waste gas: 5-10 g/m?
Dust load in clean gas: less than 10 mg/m?
Bags: ? 160 mm x 3600 mm total 750 pcs.

7.1- Filter Steel Structure shell and collecting cone (2 Set)


7.2- Filter Bags (1 Set)
7.3- Filter Pipe Lines (1 Set)
7.4- Filter Fan (1 Pcs.)
7.6- Main Kiln Funnel Filter Fan Exit (1 Pcs.)
7.7- Proportional Controlled Dosing Valve for fresh Air (1 Pcs.)
7.8- Filter Screw Conveyor (3 Pcs.)
7.9- Rotary Valve (2 Pcs.)
7.10- Dust Silo (1Pcs.)
7.11- Rotary Valve (1 Pcs.)
7.12- Hydraulic Slide Valve (1 Pcs.)

Typical figures for emissions from natural gas fired HYM kiln,

Nox [ mg/m3n,tr] : <100


CO [ mg/m3n,tr] : <100
KW [ mg/m3n,tr] : <2
SO2 [ mg/m3n,tr] : <20

8. Electric and Automation


8.1 Electric control switch board (MCC),

Power voltage: 3 * 400 VAC 50 Hz (L1 / L2 / L3 + PEN)


Control voltage:

Motors: 220 VAC Solenoid valves: 220 VAC PLC inputs/outputs: 24 VDC
8.1.1 The main incoming section comprising:

1 Power cable connection for 3 phase & PEN


1 Main power switch, size approx. 2000 A according to motors, with manual resetting
1 Low voltage / phase failure protection (adjustable type to be used)
1 Three phase voltmeter with switch 0 - 500 V
1 Ampere meter with three phase switch
1 Power meter with pulse output for PLC connection
1 Control power transformer
1 Connection to copper bus bar (supply of the motor output sections)
1 Bus bar system and motor outputs

8.1.2 The motor output section for DOL motors comprising:


Fuses or automatic fuses, circuit breakers, motor protection devices,
motor contactors and auxiliary relays for all motors. All fuse circuit breakers are
connected to the copper bus bar installed on the top of the switchboard.
Number of motor feeders as per Motor list.

Equipment for each AC motor:


- Fuse or automatic fuse, circuit breaker for motor protection
- Motor contactor for direct start.
- Control power fuse circuit breaker 220 VAC 50 Hz
- Auxiliary control relay

The following signals shall be pre-wired in the switchboard ready to be connected to


PLC:
- Control and power circuit ready (fuse ready)
- Local selector switch in position "AUTO" (auto ready)
- Run signal (run)

For each motor or motor group one local control panel is provided, equipped with:

- Emergency stop / push button


- Selector key switch with auto / 0 / local position
- Start / stop push button

Motor operation:

- AUTO mode: Motor can be started automatically by PLC only.


- 0 or off: Motor is stopped
- LOCAL mode: Motor can be started locally, by-passing the PLC.
8.2 Inverter Panel for the Air Blower, Skip and Filter fan.

VVVF electrical switchboard (Frequency Converters Switchboards)

The switchboard will include all frequency converters (blowers, filter fan and skip) of
the HYM Kiln.

Power voltage: 3 * 400 VAC , 50 Hz. Control voltage : 220 VAC,


50 Hz / 24 VDC Degree of protection: IP 21,
Colour: Ral 7032
The VVV F electrical switchboard will be complete with

1 main power switch 1600 A

1 three phase voltmeter with switch,

1 control power transformers.

The VVVF electrical switchboard have to be tested and parameterized in the workshop
before delivery to plant site. All required data from / to PLC S7-400 will be sent by L2
Bus (Speed set point / feedback signal, output current, start/stop signals, on, off ,fault,
etc. ).

The powers of the motors indicated in the list are preliminary, and may be subject of
revision during the detail design.

8.3 Local control panel

All local control panels equipped with AUTO / LOCAL mode selector, emergency stop
and start push button. LCP will be connected to MCC.

8.4 Control system (PLC) for the lime kiln and kiln auxiliary equipment

8.4.1 PLC - S7 400 Control Cabinet

The S7 400 cabinet will be complete with:

1 central rack UR1, complete with

1 Power supply 230VAC / 24 VDC

1 CPU 414-2DP with relevant Ram and Flash-eprom module,


1 Industrial Ethernet interface card CP 443-1

1 Sinec L2 interface module CP 443-5 and relevant Link Module

1 lot of I/ O modules ( analogue and digital ) inserted into central and expansion racks
as well as in the remote I/O stations.
The S7 400 as well as the remote I/Os in the Filed will be supplied on the following
basis of I/O signals:
required 20% spare total installed quantity

* digital inputs : 300 60 360 384


* digital outputs: 100 20 120 124
* analogue inputs : 40 6 46 48
* analogue outputs: 5 1 6 8

8.4.2 Remote I/O Stations for kiln


In order to save electrical installation cost, remote I/O stations Type SIMATIC ET 200M
will be installed.

Number of Remote Stations: 4


Location: - Kiln top
- Kiln discharge platform
- Kiln channel platform
Each station will be supplied completely pre-wired in protection boxes, including:

- Power supply 24 VDC


- Profibus DP connection
- I/O Modules as required
- Interface relays
- Terminals ready to connect the Power supply as well as filed signal cables.
- All necessary Bus signal cables and connectors to remote I/O stations.

8.4.3 LAN cables

All relevant Siemens L2 DP and Industrial Ethernet cables according to the following
description:

Simatic L2 DP Bus cables complete with relevant connectors in order to connect the
PLC S7 400 Cabinet with frequency converters and the remote I/O Stations.
Simatic Industrial Ethernet bus cables complete with relevant connectors in order to
connect the PLC S7 400 Cabinet with the MMIs (Man machine Interface) stations. The
topology of this BUS will be ring type in order to increase the availability of the entire
system in case of a break of an cable.

8.5 Visualisation system (MMI)

Supervision Station ( MMI ) including:

1 x Office PCs, (Latest release) each complete with:


1 x Monitor 20 TEF
1 x Printers

Nr. 1 Development & Runtime Win CC SW Package


The operating system will be MS-Windows.
The supply will be complete with all relevant connecting cables and relevant
transceiver.
The kiln and the material handling can be controlled from the MMI station.

8.6 PLC programming PC

Nr. 1 PLC Programming PC Laptop including Step 7 software package

8.7 Field Instruments / Field sensors / Junction boxes

1 lot of field instruments including:

- Temperature sensors
- Pressure Transmitters
- Level sensors
- Scales for dolomite stone
- Flow measuring devices
- Flame safety guard
- Kiln Trap limit switches

All sensors where possible will be connected to the AI-modules in the remote I/O
stations or transmitters installed in the PLC cabinet if necessary.

The number and type of measuring sensors included the scope of supply are shown in
the Instrument list.
Supplier may be changed and replaced by equivalent - if necessary - during the final
design.

8.8 Electric Cables (Field cabling) and cable trays (by Client)

Complete cabling of the kiln and its ancillary equipment including local motor isolator if
required and all necessary mounting material such as cable trays. Quantity as
required.

9. Know-how, Licence and Engineering;

9.1 Supply of Know-how


For the construction, commissioning and operation of the HYM kiln.
9.2 Engineering service;
- Layout drawing showing the placement of the kiln as well as the arrangement of the
auxiliary equipment such as bower house, control room, hydraulic station and dust
cleaning equipment.
- General foundation drawing for the kiln with load indications to enable a local
contractor to design and build the foundations for the HYM kiln.
- General drawing of the blower house with load indications to enable a local contractor
to design and build the blower house
- General assembly drawings for the complete steel structure of the kiln from the
limestone hopper on top of the kiln to the discharge feeder underneath the kiln.
- Erection drawing for the brick lining and refractory brick list with brick drawings and
indication of chemical and physical properties of required refractory material.
- Installation layout drawing for all auxiliary equipment (blowers, hydraulic equipment,
firing equipment, as well as electric, measuring and control equipment.)
- All erection drawings of kiln plant.
- Schematic drawings of hydraulic, iring, electric, measuring and control system.
- Manuals for commissioning, operation and maintenance of the complete kiln plant.

9.3 Software for control system;


Programme for all control, alarm and monitoring functions of the electronic control
system and the visualisation system.

9.4 Supervision of erection of kiln;


Delegation of experienced personnel for supervision of the erection work of the kiln and
its ancillary equipment.

9.5 Supervision of Commissioning


Delegation of experienced personnel for supervision of the commissioning work of the
kiln and its ancillary equipment.

9.6 Terms of Supply, Planning

9.6.1 Foundation drawing for Kiln 2 months from Due Date


9.6.2 Blower house drawing 3 months from Due Date
9.6.3 Supply of drawings for steel structure
- 25 % of steel weight 4 months from Due Date
- 50 % of steel weight 6 months from Due Date
- 25 % of steel weight 10 months from Due Date

9.6.4 Supply of drawings for refractory lining 8 months from Due Date
9.6.6 All technical documentation except manuals 12 months from Due Date
9.6.7 Materials and Equipment 8 months from Due Date
Ex-Works delivery starts 4 months from Due Date
Ex-Works delivery completed 12 months from Due Date
9.6.8 Manuals 10 months from Due Date
9.6.9 Commissioning approx. 14 - 16 months from Due