offers for turn-key project - rucem.ru- quarry/mining equipment and its transporting equipment + -...

2500t/d Cement Production Line for Marijskij

Sichuan Calciner Technology Co., Ltd 1

Engineering Construction of 2500t/d Cement Production

Line for Marijskij

Offers for

Turn-Key Project

Sichuan Calciner Technology Co., Ltd

April 8, 2010



Chapter 1 General Instruction

1.1 Project Scale Clinker production per day： 2500t/d（guaranteed value） Clinker production per year: 775000t/a Cement production per year: 998700t/a Including： CEM II/ A-L 42,5 N 199700t/a CEM II/B-L 32,5 N or R 799000t/a

1.2 Cement specification The type and specification of the cements to be produced in the new plant shall be

according to Standard:EN 197-1:2001 Part 1: Composition, specifications and conformity criteria for common cements. 1.3 Cement Types

The cement types are according to the Standard EN 197-1:2001, and shall be the following:

Product Cement type Strength class

Minimum Clinker

content a)

% of total production

CEM II/ A-L 42,5 N 88% 20% Limestone Portland Cement EN 197-1 CEM II/B-L 32,5 N or R 75% 80%

1.4 Cement fineness (reference values)

% Sieve Residue Product [μm] Product Cement type Strength

class 90 63 45 32 CEM II/ A-L 42,5 N - 0.5 2.0 6.0 Limestone Portland

Cement EN 197-1 CEM II/B-L 32,5 N or R 1.0 4.0 11.5 - 1.5 Process

This project employs the new external pre-calciner-the latest dry process technology, displaying the best of the new dry process technology by yielding Portland cement clinker of high quality.

Calcination system runs 310 days annually. Ratio of bag cement to bulk cement is 60%:40%. Bag cement is 50kg per bag. In the actual production, can readjust the proportion based on the clinker conditions, also

it can produce cements according to the market. Advanced and dependable DCS is used to guarantee the stability of production and

operating mode, realizing economical high efficiency and optimization of control, so as to enhance labor productivity.



Chapter 2 SCOPE OF THE WORKS

O means the proposed supply under the scope of the owner S means the proposed supply under the scope of the supplier

No.

Section and Scope

O S Remarks

1 Engineering and Design - Process design for the production line

within the battery limit of the plant +

- Relevant drawings and technical documentation + - Civil engineering and structure design of the plant

within the battery limit of the plant +

- Facilities sources (power, water, etc.) + - Accommodation area and office + - Other Delivery of Supplier’s drawings & technical

documents by air mail to Local airport +

2 Machinery, Equipment and Materials 2.1 Mechanical Equipment - Quarry/mining equipment and its transporting

equipment +

- Equipment for raw materials, fuel and cement carriers or transport means to and from the plant.

+

- Mechanical Equipment for production Limestone crushing and storage + Clay and sandstone crusher and conveying + Iron powder conveying + Raw material prehomogenizing and storage + Raw material proportioning & conveying + Raw material grinding & exhaust gas treatment + Raw meal homogenizing silo + Kiln feeding system + Preheater & precalciner + Kiln + Clinker cooling & conveying + Clinker storage and conveying + l Gypsum crushing and conveying + Cement grinding and transportation + Cement storage and conveying

+

Cement packing + l Coal grinding



No.

Section and Scope

O S Remarks

l Dedusting equipment + - Equipment and Material for auxiliary production l Compressed air station + Water supply and drainage (process line) + Water treatment system (process line) + Laboratory (chemical and physical) + l Workshop (mechanical and electrical

maintenance) +

Transporting vehicles in whole plant + l Weigh bridge + l Lubricant and grease + Initial filling to be provided

by the supplier for the equipment

l Refractory + l Insulation materials + l Grinding media + l Fire fighting equipment + l Security equipment + l Heating and air conditioning system and

ventilation apparatus (process line) +

l Wheel loaders for charging materials to the receiving hopper

+

l Pipeline (for air, water, oil, wire/cable, steam, natural gas, etc.)

+

l Road to plant site + Spare parts before the owner signs the acceptance

certificate +

2.2 Electrical & Automation Equipment General step down substation (over 6 kv) + Sub-transformer station (<= 6 kv) + Local substations in the production line + Electric transmission line outside the plant + Motors + Process control system + Equipment in central control room

+

Lighting equipment and its apparatus as well as the cables

+

Communication system in the production line + In the plant site Wires and Cables + Emergency power source equipment +



No.

Section and Scope

O S Remarks

Spare parts before the owner signs the acceptance

certificate +

2.3 Delivery and Shipment of Supplier’s

Equipment & Materials + From local Port to plant site

2.4 Customs Duty and Customs Declaration

+ For the products from the

supplier

2.5 Transportation in China (incl. insurance therefrom)

+

2.6 Transportation of equipment on ship from China to Local

+

2.7 Transportation in Local (incl. insurance therefrom)

+

3 Civil Engineering Works - Preparation work + Site clearing work + Topography survey + Engineering geological survey + Bench mark + Construction of Quarry of Limestone and Clay + - Temporary work Temporary access roads from the public road/high

way to the site +

Construction of temporary facilities for personnel

from the Supplier

+ Office, Accommodation, Temporary work site. Storage house etc.

Construction of temporary facilities for personnel from Owner

+

The piling construction + In plant site - Flood protection construction + - Concrete work + - Construction work of building and structure + - Roads and drainage in Plant Site + - Gate and Fence +



No.

Section and Scope

O S Remarks

- Sewage Treatment + - Structure for cable + On ground - Office, Guardhouse, Canteen etc. + Ditto - Drainage and sewage Outside plant + - Supervision and supervisors for civil works + - Supervision and supervisors for construction + 4 Erection work - Mechanical erection work + - Electrical erection work + - Supervision and supervisors for erection work + - Temporary work + Construction of temporary facilities for personnel

from Supplier

+ Office, Accommodation, Temporary work site, Storage house etc.

Construction of temporary facilities for personnel from Owner

+

5 Equipment, Tools and Materials for civil

construction and erection work

- Tools + - Testing laboratory for concrete + - Construction equipment and vehicles + Operators/drivers, fuel, and maintenance work + - Earth moving equipment + Excavators, Rollers, Graders

and Bulldozers - Materials for civil and building work + Cement + Reinforcing bar + Sand, gravel and water for mortar and concrete + Scaffolding material and shuttering material + Bricks, tiles and wooden material for civil work

+

Steel structure --- Columns, Roof Truss, Beams, Roof Materials, Griders and Down take pipes, Doors and Windows with Steel or Aluminum and necessary things according to drawings --- Ladders, steps, walkways, handrailings,

+



No.

Section and Scope

O S Remarks

platforms, covers, supports, sidings, rain covers, embedded steels, etc. which essentially form a part of civil work

Finishing materials for building work + Concrete stack and other products and its lining

materials +

Equipment and Tool for erection work + Various cranes and tools, etc. - Materials for erection work + l Oxygen and propane + l Paint and solvent + l Welding electrode + l Insulation materials + l Special materials for erection: + l Normal consumable materials for erection

work +

l Cabling materials and fixtures (support, protection, tube/pipe, fixture, etc. for erection and fixing of the wires and cables)

+

l Gasket, fixing bolt, etc. + l Paint + l other materials for erection work + Vehicles for transportation of manpower of the

supplier +

Vehicles for transportation of manpower of Owner

+

- Water, electric power and fuel for civil

construction and erection work with necessary facilities and accessories

+

6 Test Run & Commissioning - Personnel for test run and commissioning such as

engineers, operators and patrollers +

- Materials for test run, commissioning and production such as raw materials, cement paper bags, fuel, power and other necessary materials

+

Supervision and supervisors for test-run and +



No.

Section and Scope

O S Remarks

commissioning 7 Training - At site + Trainer and lectures + Trainees + Facilities, utilities and office, etc, for training + - Abroad Training + 8 Others - Facilities, utilities and others beyond the plant + - External telephone line + - Vehicles and for shipping sacked cement, bulk

cement +

- Vehicles for transporting limestone, clay up to the unloading hoppers

+

- Vehicles for transporting iron powder and gypsum up to the storage yard

+

Equipment, material, facilities, utilities, etc. for accommodation area and office

+

Any and all others not directly used in production line

+



Chapter 3 Technical Specification

3.1 Process 3.1.1 Process design scale and product varieties Design scale: Use a φ4.0×60m rotary kiln, the kiln inlet takes KSF 2500 5-stage cyclone preheater and calciner system with clinker production capacity of 2500t/d and clinker heat consumption of 3135kJ/kg.cl. Calculated at the annual utilization ratio of 85%, the annual clinker output shall reach 775,000 tons. If calculated at Limestone Portland Cement EN 197-1, annual cement output shall be about 1000,000 tons. At the same time, it can produce cement of different classes depending on local raw materials and market requirements. 3.1.2 Storage of materials

See Table 3-1 for storage method and period of different materials. Storage method and period of different materials Table 3-1

No Materials Storage type Capacity (t) (d)Period Remark

42×196m rectangular pre-blending pile 24070 7.17 1 Limestone/ Marl Φ10×20m dosing silo 1000 8.4h

2 Pure Limestone Φ10×20m dosing silo 1000 8.4h

Shed 35 ( width)×20 (length)m 5000 13.40 3 Clay/Bauxite Φ8×14m dosing silo 500 18.34h

Shed 35 (width)×10m（length） 1800 15 4 Sand

Φ8×14m dosing silo 500 17.51h Shed 35 ( width)×15(length)m 5000 70

5 Iron ore Φ8×14m dosing silo 500 12.5

6 Raw meal 1－Φ15×45m blending silo 7000 1.80

2－Φ22.5×45m clinker silo 42500 17

7 Clinker Φ8×18m dosing silo 700 0.28

to cement

mill Shed 35 (width)×10m（length） 3000 21.9

8 Gypsum Φ8×18m dosing silo 640 4.6

to cement

mill

9 Limestone Φ8×18m dosing silo 700 1.13 to

cement mill

10 Cement 4－Φ12×36m cement silo 4×5000 5.96d 3.1.3 List of main equipment



List of main equipment Table 3-2

№ Project Technical performance Capacity（t/h） Q’s Remark heavy duty plate feeder norm:B2500×11500 grain size ≤1500 mm Моtоr:75 kW machine weight :136t

400-1200 2

1 Limestone/Marl crushing single-stage hammer crusher

norm： grain size: ≤1500×1200×1200 mm power:2×800 kW machine weight:159t

1200 1

2 Limestone & Marl

pre-blending storage

rectangular pre-blending pile :42×196m side staker：DB1200/24 bridge scraper charger：QG300/38

1200 300

1 1

3 Clay/Bauxite， Iron ore & Gypsum crushing

crusher model no:NPG1210 ротора rotor diameter ×width:φ1280×1015 mm maximum grain size:＜400mm discharge grain size (residue10％):0-30mm material moisture≤13%

60-90 1

mill: Φ4.6×(10+4.0)m feed moisture: ≤5% feed grain size:≤25 mm(95%getting through) moisture: ≤1% discharge grain size: 0.08 mm sieve residue10~12% motor power: 3550 kW

200 1

Сепаратор separator: KZS3000 motor power: 132kW

1

4 Raw mill

System Fan capacity: 320000m3/h peak pressure:7500Pa motor power: 1000kW

1

high temperature fan: capacity:480000m3/h peak pressure:7500Pa motor power: 1400kW

1

Davies & Son brought the technique in from Britain Davidson

5 Kiln inlet

conditioning tower: Φ8.5×36m capacity:480000 m3/h jet capacity: 8.5-26t/h

1



№ Project Technical performance Capacity（t/h） Q’s Remark bag filter capacity:480000m3/h outlet density: ≤30 mg/Nm3

1

brought the technique in

from Germany Lurgi

Fan for waste gas Capacity:480000m3/h peak pressure: 3500Pa motor power: 630kW

1

cyclone pre-heater & pre-calciner system : KSF2535 C1: 2-Φ4700mm C2: 1-Φ6500mm C3: 1-Φ6500mm C4: 1-Φ7100mm C5: 1-Φ7100mm calciner: Φ6300 mm

104.17 1

bag filter capacity:150000m3/h outlet density: ≤30 mg/Nm3

1

6 By pass system fan: capacity:180000m3/h peak pressure:3500Pa motor power: 450kW

1

7 Kiln

rotary kiln: Φ4×60m grade: 3.5% rev: 0.41-4.07r/min motor power: 315kW(DC)

104.17 1

dc speed regulating

8 Kiln outlet clinker cooling

grate cooler： third generation air beam Type:KC2500 grate effective area: 65.54m2 discharge temperature: ambient temperature+65℃

104.17 1

9 Kiln outlet waste gas treatment

bag filter capacity: 380000m3/h outlet density: ≤30mg/Nm3

1

brought the technique in

from Germany Lurgi

cement mill: Ф3.8×13m feed grain size: ≤20 mm product fineness: specific are3400±200 cm2/g motor power: 2800kW

70 2

separator: O-Sepa N1500 motor power: 90kW

55-90 2

10 Cement grinding

bag filter Capacity: 134500m3/h outlet density: ≤30mg/Nm3

2



№ Project Technical performance Capacity（t/h） Q’s Remark blower for waste gas:130000m3/h peak pressure: 7800Pa motor power: 400kW

2

11 Cement packing eight-mouthed rotary packing machine computation fineness: +0.5kg -0.2kg 100 2

50kg/bag or 25kg/bag

12 Coal / petrol coke Coal crusher Type:PCH1010 Power:110kw

160 1

mill : φ3.2X（6.5+2） feed moisture: ≤12 % feed grain size: ≤25mm(95%getting through) discharge moisture : ≤1% discharge fineness: ≤3.5% (0.08mm residue) host motor power: 710Kw

20 1

bag filter （explosion proof） capacity: 55000m3/h outlet density: ≤30mg/Nm3

1

13 Coal grinding

Fan capacity :58000m3/h pressure: 7800Pa motor power: 200kW

1

14 Air compressing station

screw air-boosting compressor discharge capacity: 23m3/min discharge pressure: 0.8MPa motor power: 132kW

6

3.1.4 Simplified description of the process 3.1.4.1 Limestone /Marl crushing and transportation

Trucked to the site from its mine, limestone and marl will be discharged into respective special hoppers and be conveyed into the single stage hammer crusher by two B2500mm heavy apron feeders. Crushed mixtures are conveyed into Limestone/Marl rectangle homogenization storage yard. On line cross analyzer to control chemical composition of raw material from crusher to pre-blending storage, and high grade limestone is directly discharged at an exclusive tipple, and crushed in the single-stage hammer crusher via heavy-duty plate feeder B2300mm. Crushed high quality limestone are conveyed separately into quality limestone silos of raw proportioning system and cement milling silo system by belt conveyers.

3.1.4.2 Limestone /Marl pre-blending & transportation Crushed limestone/Marl is to be stored in sealed rectangle limestone/Marl pre-blending

pile, 42×196m square meter, piled up by side cantilever stacker and reclaimed by bridge-type re-claimer, then conveyed to raw meal proportioning silo through belt.

3.1.4.3 The accessory raw materials crushing and transportation



Gypsum, Iron ore, and Bauxite/Clay is transported by truck, directly discharged at hopper. Iron ore, Bauxite/Clay are conveyed independently into the NPG1210 crusher for crushing by apron feeder. Crushed materials are conveyed into respective proportioning silos by belt conveyers of connecting with proportioning systems.

Sand is transported by truck, directly discharged at an hopper. Then conveyed by belt to the raw proportioning system Sand silo

3.1.4.5 Raw material proportioning & transportation Raw meal proportioning shall employ five silos, and weigh belt of frequency control

type. HG Limestone, Limestone/Marl’s is of Φ8m steel plate, while Bauxite/Clay, sand and iron powder proportioning silo is of Φ6m steel plate.

3.1.4.6.Raw mill & waste gas treatment at kiln inlet After meeting the requirements of grindability test, raw meal shall enter into

Φ4.6×(10+4.0)m tube mil. When raw mill is on: after through conditioning tower treatment, waste gas discharged

from pre-heater shall be blown to raw mill by high temperature fan and discharged by the system fan, then dedusted and cleaned by the bag filter at kiln inlet, finally released via chimney into the atmosphere by kiln inlet blower.

When raw mill is off: after through conditioning tower treatment, waste air discharged from pre-heater shall be blown to kiln inlet the bag filter at kiln inlet, finally released via chimney into the atmosphere by waste fan.

Parts of the kiln inlet waste gas will be sent to the coal mill for drying heat of pulverized coal preparation, during the waste gas treatment, being required to design a minor bin for dust storage of during waste gas treatment, which will be conveyed into the pre-heater of kiln inlet or the raw meal homogenization silo via the measuring appliance at the bottom of the bin.

3.1.4.9 Kiln by pass system The 35% of waste gas comes out from the pre-heater will be sent into the bypass bag

filter for dedusting by the temperature fan of the bypass snorting system, dedusted gases are dispersed into the atmosphere via the bypass exhaust fan and the stack. The dust which collected by the bag filter will be conveyed into the bypass minor bin. Materials in the bypass bin will be trucked by the bulk trucking system at the bottom of bin.

3.1.4.7 Raw meal blending silo & kiln inlet feeding Raw meal from raw mill is to be stored in silo IBAU of φ15m, impact flow meter shall

be employed at kiln feeding, and raw meal is to be carried into pre-heater system by two set belt elevator.

3.1.4.8 Pre-heater & pre-calciner system Kiln inlet employs single line five stage cyclone pre-heater and KSF calciner. 3.1.4.9 Rotary kiln & kiln outlet After pre-calcining processing, raw meal is calcined into clinker in rotary kiln of

Φ4×60m, with thermal consumption as 750kCal/kg-cl. High temperature clinker from rotary kiln is to be cooled sharply by cold air blown in below from grid plate in grate cooler. The temperature of clinker from grate cooler is ambient temperature + 65 , cooled and crushed ℃clinker is to taken to clinker silo by bucket chain conveyor.

Part of high temperature exhaust gas from cooler shall become secondary air; part shall become combustion air in calciner via tertiary air duct; the residual waste gas proceeds heat exchanging through the air heat exchanger and dedusting through the bag filter at kiln outlet, being dispersed into the atmosphere through the exhaust fan and the stack at kiln outlet. Fine ash from the air heat exchanger and the bag filter shall be carried to clinker silo via bucket chain conveyor.

In order to meet the need of clinker calcining, heavy oil or coke are used as standby system in designing,there are 2-Φ16m heavy oil tank in the plant. When lacking of coal, it



can supply heavy oil to meet the need of clinker calcining for kiln outlet and kiln inlet calciner.

3.1.4.10 Clinker storage & clinker bulking Clinker storage adopts two Φ22.5×45m silos, and truck bulking should be found at either

side of it, which also serve for transportation of reject. Clinker from silo bottom is carried to, then stored and proportioned in cement mill proportioning silo by belt conveyor. Reject is carried and stored in the free field in the east of the site by truck, and taken to cement mill proportioning silo along a trench by belt conveyor.

3.1.4.11 Petcoke /coal crushing and feeding system Raw coal and petcoke into the site is to be unloaded from the truck to the open pile.

Later crushered by PCH1010 , the crushed raw coal is conveyed into the raw coal bin by the belt conveyer。

3.1.4.12Coal grinding & pulverized coal weighing Raw coal will be fed intoφ3.2×（6.5+2）m air swept ball mill for drying and grinding. Hot

gas comes from waste gas of kiln system. Pulverised coal was separated through the separator, coarse dusts return into the head of the mill for grinding again, fine dusts will be collected by the special high-concentration explosion-proof bag filter, pulverized coal enters into two bins (one for calciner, the other for kiln). Rotor scale of Pfister weighing shall be used in coal dosing.

3.1.4.13 Cement Material feeding silos Cement mixtures are conveyed by different belt conveyers for clinker, quality

limestone and gypsum into respective proportioning silos. And then be conveyed into cement mill system by belt conveyers.

3.1.4.14 Cement mill Cement mill is adopted two sets of Φ3.8×13m closed circled ball mill system, and highly

efficiency separator O-Sepa N1500. Single mill capacity is 70t/h .. 3.1.4.15 Cement storage Cement from cement mill system is stored in four Φ12m cement silo. Cement is carried

to packing system and bulk system from the silo bottom. 3.1.4.16 Cement packing Cement from cement storage bottom is lifted by the elevator, enters into cement packing

system. Packing machine shall employs two sets rotary packer with 8 mouths, and bagged

cement are transported by belt conveyor to bag cement storage and truck self-car loader system..

3.1.4.17 Compressor air station There are two compressor air stations in the plant, that is, 6 sets of screw air-boosting

compressor in all of 23m3/min as displacement and the pressure is 0.8Mpa. One air compressor station is set below the kiln pre-heater frame, the other which is below the proportioning silo of cement mill shop can meet the demands of every pneumatic valve, kiln pre-heater block-up, measuring device and pulsed bag dust collector and so on.

3.1.4.18 Central lab There is one central lab (located in central control room), discharging of the normal

chemical analysis and physical tests of raw materials carried in or out site, fuels, semi-finished or finished products guarantees the product quality at each stage, and is a headquarter for regulating, managing and supervising over cement quality.



3.2 Electrical and automation plan 3.2.1 Electrical 3.2.1.1 Power source The main power supply voltage level 15kV of the project will be led in the main

substation in 2 loops, and the capacity of source will be no less than 20000kVA. In order to maintain the class 1 power supply system in site, we shall use a diesel

generator as the emergency supply, which is for kiln auxiliary drive, grate cooler fan, fire pump and emergency lighting, mill auxiliary drive, and so on. The rated capacity of the diesel generator is 500kW.

3.2.1.2 Power Supply Level Site leading-in voltage： 15 kV MV distribution voltage： 6.3 kV MV voltage motor consumption： 6.3 kV LV distribution voltage： 0.4 kV LV motor consumption： 0.38 kV General lighting voltage 0.22 kV Inspection lighting voltage： 36V

3.2.1.3 Technical economical index for power supply system over site power capacity： 21364kW power capacity of mid voltage 10kV： 13680kW power capacity of low voltage 0.4kV： 7684kW over site computation of active load 16023kW factor after compensation power： 0.92 general power consumption of one ton cement： 98.0kW.h/t annual overall electrical consumption 9800×104kWh

3.2.1.4 Power supply system A main substation 15kV/6.3kV will be designed and constructed in site. This substation

shall radiately supply to Electrical Room (abbr. ER) for limestone crushing, ER for raw mill and kiln inlet, ER for kiln outlet and coal mill, ER for cement mill, and Substation for living area with 6.3kV voltage level. Transformers capacity of the main substation are suggested to be no less than 20000kVA in total.

In these four electrical rooms indicated above are MV switchgears house, 6.3/0.4kV transformer houses and LV switchgears house and so on. Besides there are 4 substations, they are Substation for raw material proportioning, Substation for cement packaging, Substation for slag drying, and Substation for living area. The power supply 6.3kV of each substation is just led in from the nearby electrical room.

3.2.1.5 Distribution wire & laying mode YJV-10kV XLPE insulated power cable is supplied to connection of high–tension motor

and electrical room, and in each electrical room, and YJV-1kV XLPE insulated power cable is used in LV distribution wire. Control cables adopt KVV full-plastic shielded cable.

Cables and control cables connecting plant site general step-down substation and each electrical room power are laid through cable bridges or cable trench. As for inside and among workshops, it is laid along bridge, poling and trench.

3.2.1.6 Electric drive HV and LV winding motors are controlled by liquid resistance starters. Inverters as

starters, controllers and regulators in AC motors are applied in separator of raw mill and cement mill, and heavy-duty feeder for limestone crushing; DC speeder is employed by motor of the main conveyor at kiln. The LV squirrel cage asynchronous motor is started in full



voltage, and use soft starter when in difficulties. 3.2.1.7 Control level and control mode DCS is exclusively the controller in central control room, and in-place toolbox is fixed

nearby (see the attached drawing). Winding rotors of high and low tension are controlled under liquid resistance starters; AC squirrel cage asynchronous motor which needs speeder employs frequency controller; DC speeder is employed by motor of the main conveyor at kiln. Cage motor, which is difficult to start up as its capacity is 10% more than this system’s capacity, shall adopt soft starter. The other cage motors all started up by full pressure. 10kV motor circuit has three-phase active watt-hour meter and ammeter, and LV motors over 30kW also need ammeters, as for the other dc motors, it is left to the consideration of technical department.

3.2.1.8 Electrical metering and watt-hour computation Special CT,PT metering cabinet of 0.2 fineness is used at 10kV inlet wire side. For the

convenience of computation on internal cost, 10kV motor computes at each circuit. And add quantifiers at inlet-wire cabinet in every workshop.

3.2.1.9 Relay protection 3.2.1.9.1Transformer protection in workshop substation: fast-trip protection, over current,

overload protection, transformers no less than 400kVA are under the protection of gas, temperature and pressure.

3.2.1.9.2 10kV motor protection: fast-trip protection, over current, overload protection, LV, thermal protection, limiting on number of starts and locked-rotor

3.2.1.9.3 Protection on capacitor: over current, over tension and LV protection without or with time limit

3.2.1.9.4 10kV busbar protection ：Timed and limited fast-trip protection 3.2.1.9.5 10kV wire protection: fast-trip, over current and single phase grounding

protection. 3.2.1.10 Lighting High pressure sodium lamps lighten up the site road, while fluorescence lamps are used

in lads and electrical rooms in workshops. And in huge workshops use optical mixing lamps. Dustproof lamps are used in workshops where dust hazard is severe. Coal grinding system uses lamps and switches of anti-explosion.

3.2.1.11 lighting proof and earthing Structures and erections which are no less than 15 m should be under lighting protection.

Air termination conductor and lighting rod shall work together. Φ12 round bar is used in ground wire and down lead, earthing device uses hot-dip zinc

flat steel Structures and erections which are no less than 15 m is applied with lighting protections

with down leads of steel bars. And weld the bar with the embedded parts when 1 meter from the ground for future connection with connection device or metering use. Column bars, ring girder bars and foundation bas in structures and erections should be welded together firmly.

3.2.1.11.2 Earthing 10kV system excludes earthing work, while system 380V has TN－C－S earthing

system. Earthing work of each item is only indoors available, however, location and direction of leading-in network need drawing out. Outdoor part is left to the consideration of the general layout.

One earth electrode network overall site： site earth electrode metwork： Include electrical earthing, lighting protection earthing

and apparatus earthing in workshop.Earthing resistance is 1Ω. Central control room is connected with the general earth electrode network. Any

requirements of DCS device manufacturer should be followed



Earthing device includes only horizontal earth termination system overall site. 3.2.2 Production automation 3.2.2.1 Principles and proposals Aiming to fulfill the technical requirements of modern cement production line and

guarantee the stable operation of technical equipments, stabilify technical parameters and product quality, save power and enhance running rate of production line, we adopt leading technology for this project, which is dependable in performance, based on PLC and host computer (which shortened to be control system). The control system controls the main production line as supervisor, operator and branch charger combined, able to enhance the stability and maintainability of electrical equipments so as to realize the modernization in control, monitoring and operation. In limestone crushing and packing departments, PLC on-site control base and operation station are employed as master, supervisor and operator, who signal the central control room through high-speed communication network. Managerial staff can at any time see into the actual productions in a modern way.

3.2.2.2 Configurations of computer control system The system consists of local control station, high-speed communication network and

operator station. The controller covers the whole production line from raw materials pre-blending pile to shipments. There is central control room. And supervisor system chooses the way of client/ sever. Based on the general layout of production line, the high-speed communication network (key network) is star type network structure. The network must have excellently speedy communication and communicating protocol with fine developing quality, and the network communication protocol agrees on Ethernet (TCP/IP). Optic fibers are used as medium to enable a stable and easy maintain communication network for control system.

MV switchgear of all ERs and main substation are under the protection of microcomputer. And when necessary, the microcomputer protection device can send the operating parameters and protected data through communication network to the monitor of CCR.

A 15kVA UPS is fixed in CCR for the needs of CCR operator station to deny data loss of production line when power off.

3.2.2.3 Local Control Station (abbr. LCS) Local Control Station is in charge of sequence logical control on motor, field data

collecting and monitoring over data in technical processes and automatic regulation on processing circuit, realizing data communication with other operator computers and controller computers via communication network. A 5kVA UPS should be fixed for each Local Control Station. The covering range of each LCS is:

LCS No. 1 is at E.R For Limestone Crushing, covering limestone crushing and transport, limestone pre-blending and transport, and accessory raw materials crushing and transport..

LCS No. 2 is at Substation for Raw material Proportioning, covering raw material proportioning silo and transport, accessory raw materials pre-blending and transport, and. circulation water pumps room and water treatment.

LCS No. 3 is at E.R for raw mill & kiln inlet, covering raw mill and exhaust gas treatment, raw meal blending silo and kiln inlet feeding, kiln inlet pre-heater and pre-calciner system, kiln;

LCS No. 4 is at kiln outlet electrical room, covering kiln outlet, clinker cooling and transport, clinker storage and transport, Raw coal crushing and transport.

LCS No. 5 is at E.R for cement mill, covering clinker silo bottom, cement proportioning, cement mill, cement silo top and Gypsum crushing and transport.

LCS No. 6 is at Substation for cement packaging room, covering cement silo bottom, cement packing and products silo and bulk cement lorry.

LCS No. 7 is at coal mill distribution room, covering Coal Mill system, Coal



Preblending Shed & Transportation. 3.2.2.4 Operator Station (abbr. OS) There are 6 operator stations, 1 programming computer (be auxiliary server when on)

and 1 server. They are operator stations separately for raw materials system, raw mill system, preheater system, kiln system, and cement mill system.

Main functions of operator computers： manifest dynamic state of technical equipment and technical processes represented by

technical parameters； operation panel for on and off of technical device group and single machine and manifest

working state of equipments ； operation panel for technical parameters and grouped manifestation of technical

parameters ； manifest the curve of instant and historical trend of technical parameters； detailed manifestation of regulating circuit and readjustment of parameters； general manifestation of alarming system in technical state and relative details； alarming report and printed technical parameters report ； when the production line alarm, it can display and record relative parameters and give

out dealing tips； Manifestation of the state of controller system。 3.2.2.5 Application software Application software of control system is an essential software which encourage

performance of Local Control Stations, operator computers and manager computer, and we should develop and debug basing on the characteristics knowing of production line, equipments, system controlling software and hardware。

(1) Functions of logical control program All motors, motorized valve, electromagnetic valve and so on are controlled by

keyboards and mice based on information from technical processes and operation panel on the screen of operation computer. We should via Local Control Station to carry out the selection of group device, and its on-off of logical interlocking, on-off of single-machine, emergency shutdown and break down resetting.

(2) Functions of process control software It carries out the checkout, display and alarming concerning the temperature, pressure,

runoff, valve opening, materials level, gas components, speed current flow and so on at technical production line, and records and regulates some important parameters. The main circuits able to auto-regulate parameters in technical processes are as following：

Regulate the capacity of each proportioning scale based on the pressure difference at in- and outlet of raw ill; adjust proportioning scale, based on the ratio of the raw meal components.

Adjust the valve opening, based on the inlet temperature at raw mill. Adjust blower valve opening, based on the negative pressure at raw mill inlet. Adjust the front valve opening of system blower, based on Adjust the discharging valve opening at blending silo bottom, based on the weight of

regulator silo. Adjust the feeding valve opening at kiln, based on runoff of raw meal. Adjust the returning water valve opening at conditioning tower system, based on the gas

moisture at the tower inlet when raw meal is off . Adjust high temperature fan rev at kiln inlet, based on the negative pressure at pre-heater

outlet. Adjust the feed quantity of gas of coal powder to calciner ,based on inlet temperature of



C5 cyclone. Adjust the chief blower valve opening at coal mill, based on the negative pressure at coal

mill inlet. Adjust the cold-air valve opening at kiln inlet, based on the air temperature at coal mill

outlet. Adjust blower valve opening at kiln outlet, based on the negative pressure at coal mill

outlet. Adjust the grate speed of grate cooler, based on the pressure in grate cooler housing. Adjust blower valve opening of grate cooler, based on the air input of fan in each grate

housing. (3) Monitor software of operator computer Programming suitable operating window for this production line and collecting relative

parameters at each controller computers should base on the supervisor software of system, see its chief functions at chapters about operator computers.

(4) Software for plant management It provides records of historical data, which includes data record, alarms records,

operation records. By historical data records and its powerful capacity in data analyzing, we can draw out information concerning daily output and power and natural gas consumption, and more over those monthly in every workshop, which shall lent scientific basis to total output soaring and total produce cost reducing. Through mathematical statistics function of it, which can analyze historical data, and give out warning to potential dangers in quality, managerial and technical staff can skip off the development stage of quality program. And they can see into the warning and operation records after accidents at production line.

Control system has special on-site button for inspectors, which can effectively have the inspectors be on duty in time. The software can count up the numbers of running time, starts and accidents of each technical equipment, thereby we are enabled to cut down accidents by changing them within maintenance period when equipments send out warnings for being overdue It also enables managerial staff around the world to visit the data of plant through website. No matter in the office, home or hotel room, the managerial staff can get the production data as easy as a phone call via this software, which also encourage phone calls. Management in site has been greatly simplified by these functions of this software.

3.2.2.6 Location of special apparatus (1)Quality control system for raw meal: to stabilize raw meal quality and guarantee the

qualification of raw meal rate, we shall employ a monitor system QCX to optimize raw meal quality control. It consists of sampling device, multielement fluorescence spectrum analyzer, computer, external equipment and relative software. The raw meal quality monitor system communicates the control system with data through the communication network

(2) Employing infrared scanner for temperature measurement of kiln enables operator at CCR computer directly to know the kiln temperature, the distribution of attached clinker, thickness of refractory brick and also can analyze temperature curves to prevent damages to kiln from falling of refractory brick during production, so as to reduce repair of refractory brick. It consists of infrared scanner system for temperature measurement, computer, external equipment and relative software.

(3) Kiln inlet EP entrance demands a CO gas analyzer, O2,CO analyzers are set at outlet of C1 cyclone of pre-heater， CO analyzer at outlet of coal mill EP. Gas analyzer consists of sampling probe, back-flushing cabinet, pre-treatment and analyzer cabinet.

(4)It will be easy to be handled by CCR by providing industrial television monitors to raw materials pre-blending pile, raw mill proportioning station, cement mill proportioning station, kiln outlet and grate cooler

3.2.2.7Choosing of primary on-the-spot apparatus



Choose hot resistance amored Pt100 and K type armored thermal couple for temperature apparatus.

Transducers of temperature and pressure choose products imported or brought in. Ultrasonic material level meters and radar level meters and capacitance level switch

should be selected differently according to their different duties. 3.2.2.8 Choosing of cable Cable connecting primary detecting element, transducer and on-spot-spot controller

computers is shielded and sleeved copper multi-conductor cable. Copper conductor cable KVV is applied in communication and switching signals. Thermal couple to temperature transducer is connected with shielded and sleeved compensation conductor of high temperature.

Connection cable and communication cable are supplied together with equipments in each control system.

3.2.2.9 Cable laying Cable between primary element and on-the-spot controller computer is laid by poling in

ground and along cable bridge. Cable in control room is laid down in the heightened floor, while the key communication cable runs along outdoor cable bridge.

3.2.2.10 Electrical grounding protection Заземляющая защита The grounding system is import to the anti-jamming capacity of the automatic facility,

each on-the-spot controller computer and CCR computer system are supplied with grounding device. Shielded layer of signal cable at the side of the distributing head is connected with the shielded grounding end

3.2.2.11 Apparatus repair During the repairs of CCR indoor apparatus, it is used to complete the daily maintenance

and repairs of the control system. 3.2.2.12 There should be a fire alarm device.

3.2.2.13 On-site communication 3.2.2.13.1 On-site administration and scheduling telephone network are made up with

200 small digital program controlled exchanges, and 10 pairs among which are connected with the city telephone network. And the central exchange is located in the CCR building. Another 5 telephones are used as direct connectors for important departments with the outside.

3.2.2.13.2 Power communication including a city connector and a interphone makes up the power communication net between in-site general step-down substation and city telephone network in a way of being backup to each other. 3.3 Water Supply & Drainage

3.3.1 Design considerations, coverage and principles (1)Design considerations: water consumption of each workshop on the cement

production line is provided by the processing department. And documents of water supply & drainage supplied by the owner, Design Codes for Cement Plant （GB50295-1999）and relative concerned national design codes and standards of water supply & drainage.

(2)Design coverage: including the water supply & drainage system for domestic, production and fire fighting uses (covering circulation water system, spray water system of raw mill and conditioning tower), sewage treatment etc.

(3)Design principles: it should comply with nation design codes concerned, to meet the water demands of the processing equipment, under the principle of “save on water, make the most of the source”.

3.3.2 Water Supply 3.3.2. 1water Source



Pipe wells are planned to take the underground water to the domestic, production and fire-fighting uses. The owner shall be responsible for the water quality and quantity demanded in domestic,production and fire fighting.

3.3.2.2 Water consumption （water supply & drainage system plan） total production consumption in plant： 6710.0m3/d including :consumption in circulation： 6060.0m3/d once through consumption： 600.0m3/d consumption in auxiliary shops： 50.0m3/d backwater in circulation： 5900.0m3/d makeup in circulation： 160.0m3/d efficiency of circulation water： 97.4% makeup for fire-fighting： 216.0m3/d domestic consumption： 100.0m3/d watering consumption： 96.0m3/d Drawn from what have been mentioned, the makeup water for production and domestic

system is 1006.0m3/d (fire fighting water is excluded) 3.3.3 Source Supply The unforeseen water consumption accounts for 20% of the total consumption, and the

usual consumption is 1006.0×1.2=1207.0m3/d. and it is 1214.0+216.0=1423.0m3/d when the fire fighting water is considered.

3.3..4 Water quality and pressure Quality:for circulation in production:turbidity ≤20mg/l, carbonate hardness（measured by

CaCO3）is 80∼250mg/L, water temperature ∠32°C, PH=6.5~8.5; domestic water should meet the national Hygienic Standard for Dringking Water （GB5749-2006）.

（1）Pressure: Water pressure for production: and that at the conduit inlets in the workshop is 0.25∼0.30Mpa, domestic water pressure should be no less than 0.3MPa, fire water pressure: it employs temporary high pressured fire water system, the quantity and quality will meet the fire fighting demands when there is a fire.

3.3.5 Water supply system （1） Circulation water supply system for production In order to save on water and sufficient exploration on water, cooling water equipment in

each workshop employs pressured backwater circulation system. When the backwater is low in temperature, it directly joins the circulation water reservoir (two of V=300m3 ),when it is high in temperature, it shall be carried to the cooling tower （one set of GBNL3-350）by the residual pressure in the network of pipes, then the cooled water flows back to the circulation reservoir, and via the circulation water pump (three sets of 2G200WFB-A，Q=160.0m3/h，H=55m，N=55kW，two for use, the other standby)sent to the circulation water supply pipe network to cool down each equipment in the production shop. Bypass hydrotreating facilities are set for assuring the water quality, part of the pressured backwater directly enter a set of automatic steel filter (SQ1-20，Q=20m3/h),then a set of comprehensive water treater (WD-300A1.0ZH-F-AC) and other equipment, which serve as an antiscale and sterilizer and preservative and suspended material remover in the circulation water. Thereby it can stabilize the water quality. The loss of circulation water is made up by the water source. （2） Domestic, fire water supply system This system consists of pressure tank, fire pump (2G200WFB-Bdtype, Q=144m3/h

H=55m ), domestic pump （2G125WFB-E type,Q=70m3/h H=52m ）, which jointly supply



the plant with domestic, production and fire water. Three-hour fire water is storage in the domestic, fire water reservoir （V=1000m3）, which will serve only when there is a fire.

Outdoor hydrants as designed are set on two sides of road, nearing the cross road, and the maximum interspace is 120m. the main conduits set with hydrants should be no less than DN100 in diameter.

The pressure should be forced up by a special fore pump for the watering at the conditioning tower.

3.3.6 Drainage syste 3.3.6.1Waste water from the production Q=48.0m3/d, is drained to the domestic sewage

treating system, for it containts little grease and without other harmful matters. 3.3.6.2 Q=135.0m3/d。Domestic sewage Q=135.0m3/d 3.3.6.3Sewage treatment The domestic sewage (as slurry and fecal sewage) and production waste water: due to

they have exceeded the national standards in BOD5、COD、SS etc, class2 biochemical treatment is needed. As designed after the pre-treated at the cesspool, the sewage will experience the sewage treating station (WSZ-10 Q=10.0m3/h with a set of sewage treating equipment) and are discharged after meet the class 1 standard of national Integrated Washwater Discharge Standard (GB8978-1996)



Chapter 4 GUARANTEE 4.1 GENERAL

Contractor guarantees that the equipment proposed to be supplied for the project under this contract, whether furnished by the Contractor, its vendors or other parties, shall meet the performances stated herein. The guarantee values are to be understood on dry basis of the material.

If during the execution of the performance test of the respective equipment, the guarantee value is reached, the test is regarded as successful. In case this value is not reached. The measuring tolerances of 3% shall be applied.

All performance tests shall be carried out during the test period as specified herein. During the tests all important data necessary to establish the performance shall be recorded in logs, at least once per hour. The performance shall be calculated as an average over the entire duration of the tests.

From the date of commissioning and performance tests, all correlative machines and equipment shall be operated and serviced by qualified staff from the Contractor and Owner.

We also can follow owner’s requiment whin the negotiation for contract.

4.2 TEST PROCEDURE The test procedure shall be submitted by the Contractor and mutually agreed between the

Owner and the Contractor prior to the tests. Equipment required for conducting the performance tests shall be arranged by the

Contractor. 4.2.1 CAPACITY The capacities of the various equipment will be determined by weighing the resultant

product either continuously by means of the weighing equipment of the department or means of weigh bridges in the plant and using trucks.

4.2.2 POWER CONSUMPTION The power consumption of medium and low voltage consumption will be measured at

the appropriate kwh meter at motor control centres. 4.2.3 FUEL CONSUMPTION The fuel consumption for clinker manufacturing will be measured by the calibrated

counter of the fuel dosing equipment. 4.2.4 HEAT VALUE OF FUEL The heat value of the fuel must above 5500kCal/kg, and this value will be determined by

the local neutral authority of the Owner’s choice and supplier to have a sample for his own checking. Measurement of heat value of the fuel shall be carried out three times during the test period of the respective department. 4.3 GUARANTEES:

Table 3-1 1. Limestone Crushing

Performance guarantee

1.1 When the equipment performance is normal, the average production of crusher: ≥1200t/h 90%≤25mm covering the following equipment: one apron feeder and one crusher



Prerequisite to guarantee

1.2 The performance guarantee shall be based on the following conditions: 1)limestone Bond index: 10~13kWh/t 2)limestone feed size≤1000mm, natural gradation

2 Raw Material Grinding


2.1

The average raw meal production: ≥200 t/h The average raw meal fineness: ≤14% (residue on 90μm square mesh sieve) The average raw meal moisture: ≤1% Power consumption per ton of raw meal: 23 kWh/t, covering: main drive of ball mill, mill separator, mill fan


2.2 1) The raw meal shall be proportioned with limestone, clay and iron ore 2) Limestone particle size≤25mm 3) Grindability index of limestone in roller mill: 10~13 kWh/t

3 Clinker Burning


3.1

1)Clinker production:≥2,500t/d 2)Specific heat consumption of clinker:3135 kJ/kg-cl 3)Free CaO in clinker: average f-CaO in clinker≤1.5% 4)Clinker temperature: The average temperature of clinker out of the cooler is ambient temperature plus 65 .℃


3.2

The performance guarantee shall be based on the following conditions: Lime saturation factor of clinker: KH=0.90±0.02 Silica modulus: SM=2.7±0.1 Alumina modulus: IM=1.6±0.1 Cl- content: Cl-≤0.015% (based on specific clinker) Calorific Value of Coal: ≥5500kCal/kg Volatiles of coal: ≥20%

4 Fuel Grinding


4.1 Average production: ≥20t/h Average fineness: ≤8% (residue on 80 μm square mesh sieve) Average moisture: ≤1%


4.2 The guarantee will be based on the following conditions: Raw coal grain size ≤25 mm Raw coal grindability index for roller mill: HGI=100 (medium) The moisture of coal: ≤12%



5 Dedusting 5.1 Main equipment specification

Performance guarantee 5.2 For EP: Dust content of emitted gas: ≤50 mg/Nm3

For Bag filter: ≤30 mg/Nm3

Prerequisite to guarantee 5.3 The measuring of dust content in emitted gas must be made on the basis of normal production of

every section, normal equipment operation, and good equipment performance. 6 Cement Grinding


6.1 The average production: ≥2×70 t/h The average fineness: ≤3200 cm2/g Power consumption per ton of cement:32kWh/t, covering: mill main drive, mill separator, mill fans

Prerequisite to guarantee 6.2 1) The cement mix shall be proportioned with Clinker, Gypsum and limestone

2) Additive particle size≤25mm 7 Cement

Performance guarantee 7.1 Power consumption per ton of cement: 98 kWh/t,

Prerequisite to guarantee 7.2 Production line from crushing to cement packing.



Chapter 5 Design and Technical Documents

5.1 Project design

5.1.1 Project Design Instruction

5.1.2 Drawings

1） factory general plan；

2） workshop floor plan（including plan and section drawing）；

3） workshop arrangement plan；

4） process sheets；

5） distribution system chart of switching station；

6） load arrangement chart of whole factory；

7） roboticized instrument flow sheets；

8） drawing of computer control system；

9） feedwater and drainage system drawing.

5.1.3 Equipment Table

1） process equipment table；

2） electric automation equipment table；

3） feedwater and drainage equipment table;

4） layout equipment table;

5） spare parts table；

6） table of mainframe equipment lubricant.

5.2 Design of construction drawing

5.2.1 Process Specialty

1） manufacture drawing of process non-standard structural element，including：

stuff pipe, stuff hopper and accessory① ；

ven② tilation pipe and accessory；

hot air pipe and accessory③ ；



dust collecting ventilation pipe and accessory④ ；

process examine and repair flat and accessory. ⑤

2） general equipment order data, including：

belt bucket elevator① ；

air chute② ；

rubber belt convey③ or（except special instance）；

screw conveyor④ ；

en masse conveyor or chain type conveyor.⑤

3） process pipe and equipment thermal insulation，including：

insulating material table① ；

compound drawing of fire② -proof material，masonry drawing，brick type drawing；

sys③ tem（or workshop）thermal insulation sketch map；

unitive description process pipe and equipment thermal insulation construction.④

4） whole factory production process pipe

arrangement layout① （plan, drawing of section and enlargement） , table of

equipment and stuff；

table of equipment and stuff② ；

air③ -compressor station and pipe line.

5.2.2 Electric and Automation Specialty

5.2.2.1 Switching Station

1） high-voltage distribution system chart；

2） high-voltage control theory chart；

3） table of pipe line；

4） layout of electric equipment；

5） layout of grounding installation；

6） equipment table and stuff table.

5.2.2.2 Electric

1） feed circuit schedule；

2） distribution system chart;

3） control theory chart；

4） non-standard control box layout；



5） exterior wiring diagram（table）；

6） drive line layout drawing（including bridge and frame layout）；

7） grounding installation layout；


5.2.2.3 Automation

1） Automation Design Instruction；

2） instrument flow chart；

3） exterior wiring diagram；

4） chart of power supply system；

5） chart of wiring and pipe laying；


5.2.2.4 Illumination

1） distribution system drawing；

2） illumination layout；

3） lightning device layout；

4） equipment table。

5.2.2.5 Computer Control System

1） table of input volume dot order on switch；

2） table of output volume dot on switch；

3） table analogue volume input dot order；

4） table analogue volume output dot order；

5） power supply system drawing

6） computer system grounding drawing.

5.2.2.6 Grounding Line of Factory Region

5.2.3 General Drawing Conveyance Specialty

1） table of General drawing conveyance equipment;

2） region position drawing;

3） pipe line compositive drawing；

4） earthwork project drawing；

5） vertical design drawing；

6） civil engineer drawing；



7） storage yard layout；

5.2.4 Water Supply-drainage Discipline

5.2.4.1 Source and Water Conveying Project

1） layout；

2） distributing pipe system drawing;

3） water delivery pipeline layout and longitudinal section；


5.2.4.2 All Kinds of Pumping Stations in Factory Region，Water Supply Processing Yard

1） layout；

2） distributing pipe system drawing；


5.2.4.3 Fire-fighting System

1） layout；

2） outdoor water-supply pipe net；

3） fire-extinguishing chemical and pipe network planar and system drawing;


5.2.5 Structure and architecture discipline

5.2.5.1 Structure

1） plan；

2） girder, board, mast and basic detail drawing；

3） reinforcement drawing；

4） steel structure construction detail drawing；

5） unitive description of structure construction；

5.2.5.2 Architecture

1） plan, elevation drawing and section drawing of buildings；

2） schedule of door , window and ladder;

3） crunode detail drawing of door , window and ladder；

4） unitive description of civil building construction；

5.2.6 Heating Ventilation Specialty （ventilation, air-condition, boiler room, etc.）

1） layout, section drawing and enlargement drawing；

2） system drawing；



equipment table and stuff table.



Chapter 6 Training

6.1 General

Seller will provide training as per Owner’s decision. a) The Seller will designate his skilled and qualified personnel who are competent in

their area of specialty on the modern cement plants. The Seller will give the technical instructions and training to the Owner's technical personnel and explain all the technical problems within the scope of the Contract.

b) The Owner's technical personnel will be trained in China in the cement plant similar capacity to the Contract plant to enable the Owner's technical personnel to understand and master the technology, operation, inspection and all necessary analysis, etc.

c) The Seller will submit the preliminary training program to the Owner for his comments 3 (three) months before the training starts.1 (one) month before the start of the training, the final training program shall be fixed by both parties through consultation according to actual requirements of the Owner's personnel.

d) Before the training starts, the Seller shall explain in detail to the Owner's personnel the operating regulations and other precautions for work.

e) The Seller shall take necessary measures to ensure the security of the Owner's personnel during their stay in China.

f) The training fee is included in the total value of the Contract. It includes the training charges, all inland travel charges in China and boarding and lodging.

g) The training is carried in China, the Owner's technical personnel shall observe China's laws and regulations and the rules of the training institution.

6.2 Objective of training

This training is for the production and the technical department’s personnel of the Owner. Objective of the training is to provide a realization of the structure and maintenance of the equipment for the cement clinker production line equipment encompassing the cement process, the equipment operation, the structure and maintenance, etc. Training shall cover all facets of plant and machinery including electrical equipment, control & automatic equipment, laboratory and quality control.

6.3 Training methodology

Proposed training methodology is based on two pronged approach as follows: • “Off Site” Training: familiarizing the personnel with the similar machinery. This is

proposed to be achieved by imparting theoretical training (in class room mode) followed by participative visits to “under erection/commissioning/trouble shooting” of the similar installations to a friendly cement factory.

• “On Site” Training: Enhancing the theoretical knowledge by actual hand-on experience on installation, commissioning and trouble shooting of the machinery and systems for the project. This is proposed to be achieved by imparting “On Site” training during erection and commissioning of the Riyadh cement plant.



After the theoretical training, trainees should acquire some knowledge and skills such as: • The characteristic and the usage for the main equipment; • Operation parameter and implementation; • The step to the start and closure; • Automatic equipment and in chain-like system; • Security guide.

6.4 The place of training

Training place shall be based on type of training i.e for “Off Site” place of training will be in China and for “On Site” mainly in SECIL – LOBITO cement plant.

6.5 “Off site” training

6.5.1 Organization The training person will be divided into five groups as follows: • First group : The person for Mechanical device attendant • Second group : The person for Production and operator • Third group : The person for Electricity attendant • Fourth group : The person for Automation attendant • Fifth group : The person for quality control personnel

table 6-1 Function Description

Process and Mechanical

Number: 5 persons Including: Process engineer, the process operator, the scene daily management for producing and technical personnel and the newly recruited personnel;

Electrical Number: 5 Persons Including: Electrical engineer, the daily management for electrical and maintenance technical personnel and the newly recruited personnel;

Control and Automation

Number: 10 Persons Including: Automation engineer, the technical person for management and maintenance to the instrument. Computer application software engineer, computer hardware engineer and the newly recruited personnel

Maintenance Number: 10 Persons Including: Mechanical engineer, the technical person for equipment maintenance and the newly recruited personnel;.

Quality Control

Number: 5 Persons Including: Quality control engineer, laboratory lab technician and the newly recruited personnel

Total 35 Persons 6.5.2 Class Room Training

table 6-2 Training Need Coverage



The theoretical training for the main equipment operation, structure maintenance (8 hour class)

1) The project technical process, process unit specification model and disposition characteristic 2) The production operation control process parameter, the order for the process line start and stop, the interconnection relations 3) The safety guide for main equipment operational and production management 4) The main engine structure, maintenance keys etc 5) Raw material control, mixture and homogenization.

The theoretical training for electrical systems and installations (8 hour class)

1) The power distribution structural drawing for distribution network of the project. The load calculations and system studies of the distribution network 2) Power distribution station, electricity room, division for the transformer substation; 3) Electrical machinery drives, the electrical transmission, the electrical control of the project 4) Electrical equipment disposition and characteristic; 5) Earth network and earthing systems

Control and Automation training (8 hour class)

1) Plant distributed control system network structure drawing, hardware, disposition characteristic; 2) Plant measuring appliances, control flow, model control loop; 3) Plant instrument arrangement including special-purpose detector set 4) Computer software’s and the general introduction to various software applications used in the plant

These class hour arrangements are flexible, the main basis is the reception of the trainee personnel's understanding and degree of adjustment to perform .

6.5.3 Field Installation Visits “Off site” training shall be carried out at a similar installation in a cement plant in Syria

or China. This part of the “off site” training will be carried out as an participative “hands-on” real life field situations and shall be imparted by the process of organizing visits to the installations of the similar main equipment. These visits shall be arranged along with equipment service engineers. During the training, the service engineer shall explain the installation process and debugging solutions. Main focus of this training shall be to enable trainee achieve and grasp the familiarity with equipment and common problems associated with installation and commissioning of the machinery. Trainee will obtain the knowledge enhancement vis-à-vis equipment & installation covering the following:

• The main point of equipment installation; • The design feature of the equipment; • The knowledge of equipment routine maintenance, service, maintenance. Focus of this training is to know well the equipment proposed to be installed for the

project, the process and the preparation for the test run work. Training time: First period is 1 Month; Second period is 2 Months 6. 5.4 Training Plant

table 6-3 System Content Class Room

Quality control 1) Principle of instrument. 2) Usage and maintains of the instrument 3) Debugging of the instrument 4) Trouble shooting of the instrument

8 Class hours Theoretical training by the technical personnel followed by case studies from service engineers .



System Content Class Room Cooler system 1) Daily inspection, maintenance

2) System disposition 3) Installation and debugging 4) Trouble elimination

2 Days Theoretical training by the technical personnel followed by case studies from service engineers .

Vertical & ball mill

1) Correct usage of the equipment 2) Equipment maintenance 3) General trouble elimination

2 Day Theoretical training by the technical personnel followed by case studies from service engineers .

Package Machine

1) Correct usage of the equipment 2) Equipment maintenance 3) General trouble elimination.


Fluorescence analyzer


8 class hours Theoretical training by the technical personnel followed by case studies from service engineers .

Industrial TV system



Main transformer

1) Principle and structure 2) Technological process and testing method 3) Routine maintenance

8 Class hours Theoretical training followed by case studies from service engineers .

6.3 KV Switch cabinet

1) Principle and structure 2) Technological process and testing method 3) Routine maintenance and maintain. 4) Trouble shooting

8 Class hours Theoretical training by the technical personnel followed by case studies from service engineers .

Relay protection 1) Principle and structure 2) Testing method 3) Routine maintenance and maintain. 4) Trouble elimination

3 Days theoretical training by the technical personnel followed by case studies from service engineers .

MV frequency changer

1) Principle and structure 2) Debugging 3) Routine maintenance and maintain. 4) Trouble elimination


LV frequency changer

1) Principle and structure 2) Debugging 3) Routine maintenance and maintain. 4) Trouble elimination




System Content Class Room Direct current control panel

1) Principle 2) Debugging 3) Routine maintenance and maintain 4) Trouble elimination


Starter 1) Principle 2) Debugging 3) Routine maintenance trouble shooting


Weighing equipment

1) Principle 2) Debugs and demarcates 3) Routine maintenance and maintain 4) Trouble elimination

5 Days Theoretical training by hhill the technical personnel followed by case studies from serviceengineers .

Gas analyzer 1) Principle 2) Debugs and demarcates 3) Routine maintenance and maintain 4) Trouble elimination


Kiln body scanning

1) Principle 2) Debugs and demarcates 3) Routine maintenance and maintain 4) Trouble elimination.


Dust monitoring 1) Principle 2) Debugs and demarcates 3) Routine maintenance and maintain. 4) Trouble elimination.


Temperature instrument pressure and current instrument

1) Principle 2) Debugs and demarcates 3) Routine maintenance and maintain. 4) Trouble elimination.


Instrument to level of material

1) Principle 2) Debugs and demarcates 3) Routine maintenance and maintain. 4) Trouble elimination.


Vibrating instrument

1) Principle 2) Debugs and demarcates 3) Maintenance. 4) Trouble elimination.


Actuator 1) Principle 2) Debugs and demarcates 3) Routine maintenance and maintain. 4) Trouble elimination.




System Content Class Room Operating system

1) Daily inspection, maintenance 2) Trouble elimination


Note: In addition to Class room design engineer will take trainees to field where he teaches or demonstrate.

6.6 “On site” training

6.6.1 Training Plan table 6- 4

Description Duration Production Processes

3 man x 4 days Instructor. To be covered in 3 sessions. Each session covering (1) Raw & cement grinding , (2) Pyroprocessing and (3) Balance sections

Mechanical General Maintenance 1 man x 5 days Instructor Electrical General Maintenance 1 man 2 days Instructor Automation General Maintenance 1 man x 3 days Instructor Software Programming 1 man x 12 days Instructor Refractory management 1 man x 2 days Instructor Vertical mill 1 man x 2 days Instructor OSEPA separator 1 man x 1 day Instructor Bag filters 1 man x 1 day Instructor Clinker cooler 1 man x 2 days Instructor Process filters 2 man x 1 day Instructor. Two (2) sessions for (1) raw mill/kiln bag

filter and (2) other process bag filters Fans and Blowers 1 man x 0.5 day Instructor Kiln Burner and precalciner burner 1 man x 1 day Instructor Weigh feeders, flow meter, load cell, belt scale & Weigh-bridge

1 man x 2 days Instructor . Including calibration (manual, automatic)

Fuel Handling system 1 man x 1 day Instructor Bucket elevators, chain & pan conveyors

1 man x 0.5 day Instructor

Compressors 1 man x 1 day Instructor Man elevator 1 man x 0.5 day Instructor Rotary packer 1 man x 1 day Instructor Fluid coupling 1 man x 1 day Instructor Variable Speed Drives 1 man x 1 day Instructor MV Switch-gear 1 man x 3 days Instructor . Including MV cells Scanner 1 man x 2 days Instructor Fire fighting detection 1 man x 1 day Instructor



Description Duration Opacity meter 1 man x 1 day Instructor Gas analyzer 1 man x 2 days Instructor

Pyrometer 1 man x 1 days Instructor

6.6.2Training Evaluation After training, the seller will check and evaluate the trained people, the result of examination and

critique will hand to the owner directly, and the seller will offer the suggest name list of the world.



Chapter 7 Biding for Turn-key Project

7.1 Quoted price scope A complete production line of 2500 t/d cement from raw material entering the plant to cement package, comprises electromechanical maintenance, laboratory, centeral control room etc. auxiliary production facilities, comprises equipment supporting, civil work construction, installation, engineering, personnel training, production Commissioning, two years spare parts.

7.2 Quoted excluding scope ⑴ Land purchase； ⑵Overall procedures cost； ⑶All facilities outside the inclosure wall: Owner is responsible for water, road connections to the plant inclosure wall, this quoted price only for facilities within the inclosuring wall.



Price List for turn key project List 7-1

Type № Project and Cost Items Civil project Equipment Erection project Other expenses sum

total investment 5432.42 5096.23 1266.62 2140.22 13935.50

A General plane and transportation project 376.31 41.79 0.16 418.26

0.00

B Plant main production project 4611.45 3801.00 790.33 9202.78

0.00

C Electric and Automation 88.99 665.02 443.34 1197.35

D Water supply and drainage project 43.30 58.03 28.21 129.55

E Auxiliary production and service project 312.36 195.77 4.58 0.00 512.71

F Spare parts 300.00 300.00

G Implements and production furniture costs 34.62 34.62

H Other costs 2140.22 2140.22