ASKARI CEMENT LIMITED WAH, TAXILA

PLANT MAIN MOTORS &

THEIR SAFETIES
Assignment # 3

Arsalan Ahmed
Askari Cement Wah, Taxila

PREAPARED BY:
ARSALAN AHMED
MTE INSTRUMENT& PLC
Submitted to:
SIR. NIAZ HUSSAIN
DM INSTRUMENT & PLC
SIR. MUHAMMAD NADEEM
AM INSTRUMENT & PLC
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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

1 TABLE OF CONTENTS
2 Electrical Motors ................................................................................................................................... 3
3 Working Principle & Applications ......................................................................................................... 3
4 Motor Construction .............................................................................................................................. 4
5 Types of Motors .................................................................................................................................... 5
5.1 AC Motors ..................................................................................................................................... 5
5.2 DC motors ..................................................................................................................................... 5
5.2.1 Permanent Magnet DC Motors ............................................................................................. 5
5.2.2 Series DC Motors................................................................................................................... 5
5.2.3 Shunt DC Motors ................................................................................................................... 6
5.2.4 Compound DC Motors .......................................................................................................... 6
6 Plant Main Motors ................................................................................................................................ 7
6.1 Raw Mill (361) ............................................................................................................................... 7
6.1.1 Raw Mill Motor List & Specs ................................................................................................. 7
6.1.2 Raw Mill Main Drive Safeties & Interlocks ............................................................................ 8
6.2 421 ID Fan (421-FN2-MO1) ........................................................................................................... 9
6.2.1 ID Fan Motor Specs ............................................................................................................... 9
6.2.2 ID Fan Safeties & Interlocks .................................................................................................. 9
6.3 Kiln Main Drive (461-KL1-MO1) .................................................................................................. 10
6.3.1 Main Drive Specifications.................................................................................................... 10
6.3.2 Kiln Main Drive Safeties & Interlock ................................................................................... 10
6.4 Cement Mill (561) ....................................................................................................................... 11
6.4.1 Cement Mill Motors ............................................................................................................ 11
6.4.2 Cement Mill Main Drive Safeties & Interlocks .................................................................... 11

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

PLANT MAIN MOTORS & THEIR SAFETIES

2 ELECTRICAL MOTORS
An electric motor is an electrical machine that converts electrical energy into mechanical energy usually
torque driving some kind of load. This conversion is usually obtained through the generation of a magnetic
field by means of a current flowing into one or more coils. Electric motors can be powered by direct
current (DC) sources, such as from batteries, motor vehicles or rectifiers, or by alternating current (AC)
sources, such as a power grid, inverters or electrical generators. An electric generator is mechanically
identical to an electric motor, but operates in the reverse direction, accepting mechanical energy (such as
from flowing water) and converting this mechanical energy into electrical energy.

3 WORKING PRINCIPLE & APPLICATIONS

Electric motors operate on the principle of electromagnetic induction, the fundamental principle of
electromagnetic motors is based on the mechanical force that acting on the conductor through which
electric current passes and it is located in the magnetic field. The direction of the mechanical force is
perpendicular to the conductor and the magnetic field.

Electric motors have found widespread application in various industrial processes, systems and devices.
These are some of the application fields:

• In industrial processes – motors with highly standardized characteristics and dimensions

• Blowers and special pumps
• Household appliances and devices
• Machine and power tools
• Electric watches – with small motors
• Hybrid vehicles (such as Tesla motor)
• Ship propulsion – motors with high capacity and power
• Pipeline compression
• Pumped-storage applications

All electric motors are powered by two sources. They are mainly powered by direct current (DC) sources
(batteries, rectifiers or motor vehicles), but some are powered by alternating current (AC) sources (power
grid, generators or inverters).

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

4 MOTOR CONSTRUCTION
The main components of a typical electric motor are:

• Rotor – The moving part of the motor. It turns the shaft to transfer the mechanical power.
• Stator – The stationary part, which has windings or permanent magnets.
• Air gap – It is the space between stator and rotor.
• Windings – Wires that are wrapped around the iron magnetic core.

Figure 1 Motor Components

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

5 TYPES OF MOTORS
Electric motors can operate on three different principles: magnetic (the most common), electrostatic and
piezoelectric. Based on the type of electricity for their work, they can be divided into two categories:

5.1 AC MOTORS
AC motors operates on Alternating current, single phase or three Phase. AC motors can be divided into
two types.

• Synchronous Motors
• Asynchronous (Induction) Motors

A.C. electrical motors, and are driven by alternating current, for e.g. the synchronous motor, which always
runs at synchronous speed. Here the rotor is an electromagnet which is magnetically locked with stator
rotating magnetic field and rotates with it. The speed of motors is given by
𝑓
𝑁𝑠 = 120 ⁄𝑃

Ns - Synchronous speed

f - Frequency of AC Supply

P - No. of Poles

And induction motors rotor run on slightly less speed then synchronous speed. Difference between
synchronous and actual speed is called slip & is given by.
𝑁𝑠 − 𝑁
𝑆𝑙𝑖𝑝 =
𝑁𝑠
Ns – Synchronous speed

N – Rotor Speed

5.2 DC MOTORS
Use direct current for operation. They differ in how the windings are connected, as well as by their
characteristics. There are four main types of DC motors.

5.2.1 Permanent Magnet DC Motors

The permanent magnet motor uses a permanent magnet to create field flux. This type of DC motor
provides great starting torque and has good speed regulation, but torque is limited so they are typically
found on low horsepower applications.

5.2.2 Series DC Motors

In a series DC motor, the field is wound with a few turns of a large wire carrying the full armature current.
Typically, series DC motors create a large amount of starting torque, but cannot regulate speed and can
even be damaged by running with no load. These limitations mean that they are not a good option for
variable speed drive applications.

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

5.2.3 Shunt DC Motors

In shunt DC motors the field is connected in parallel (shunt) with the armature windings. These motors
offer great speed regulation due to the fact that the shunt field can be excited separately from the
armature windings, which also offers simplified reversing controls.

5.2.4 Compound DC Motors

Compound DC motors, like shunt DC motors, have a separately excited shunt field. Compound DC motors
have good starting torque but may experience control problems in variable speed drive applications.

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

6 PLANT MAIN MOTORS

6.1 RAW MILL (361)

There are different type & rating of motors in raw mill area which collectively consume 5 MW. List of
motors is given below.

6.1.1 Raw Mill Motor List & Specs

Sr. Operating
Motor Tag Description Type Rating RPM Manufacturer
No. Voltage
3ø
361-RM1- Raw mill Main
1 Induction 6.3KV 2290KW 993 ABB
MO1 Motor
Motor
3ø
361-FN1- Raw mill Fan
2 Induction 6.3KV 25KW 992 ABB
MO1 Motor
Motor
311-BC4- Belt conveyor DC
3 415V 68KW 1800 ABB
MO1 Motor Motor

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

6.1.2 Raw Mill Main Drive Safeties & Interlocks

Raw Mill Main Motor Safeties & Interlock

Signal Limits Tripping

Sr. No Tag/Name Description Unit Remarks
Type H2 H1 L1 L2 Point
i Emergency Stop of Plant Plant Running DI Plant Trip Mill Stop_Roller Up cmd
First Roller Up then After 30 sec
ii 421_FN2_M01 ID Fan Must be Running DI ID Fan Stop or Roller up Position after mill
stop
2 Raw Mill Main Motor
i 361_LQ2_PZ1 Press. Thrust Bearing AI 100 100 30 24 Bar L2 Gear Lubrication
ii 361_LQ2_PZ2 Press. Thrust Bearing AI 100 100 30 24 Bar L2 Gear Lubrication
iii 361_LQ2_PZ3 Press. Thrust Bearing AI 100 100 30 24 Bar L2 Gear Lubrication
iv 361_LQ2_PZ4 Press. Thrust Bearing AI 100 100 30 24 Bar L2 Gear Lubrication
v 361_RM1_TZ7 RM thrust Bearing AI 85 75 20 20 Celsius H2
vi 361_RM1_PL1 Low Press. Thrust Bearing DI Low Press. After 2 Sec Delay
vii 361_RM1_PL2 Low Press. Thrust Bearing DI Low Press. After 2 Sec Delay
viii 361_RM1_PL3 Low Press. Thrust Bearing DI Low Press. After 2 Sec Delay
ix 361_RM1_PL4 Low Press. Thrust Bearing DI Low Press. After 2 Sec Delay
x 361_RM1_PL5 Low Press. Thrust Bearing DI Low Press. After 2 Sec Delay
xi 361_RM1_PL6 Low Press. Thrust Bearing DI Low Press. After 2 Sec Delay
xii 361_RM1_PL7 Low Press. Thrust Bearing DI Low Press. After 2 Sec Delay
xiii 361_LQ1_LL1 Low Oil Tank Level DI Low Level Lubricatoin Unit Oil Tank
xiv 361_LQ2_M01.Out.Run Lubrication Unit Pump DI Motor Stop Motor Runing
3 Raw Mill Main Motor Starter
i 361_1R1_ZX1 Starter Positon Open DI Unit Alarm MCC Starter
ii 361_RM1_UA1 Raw Mill Starter Unit Alarm DI Unit Alarm Electrical Signal
iii 361_1R1_UA1 Starter Unit Alarm DI Unit Alarm MCC Starter
Raw Mill Main Motor Oil
4
Lubrication
i 361_LQ1_M05 Feed Pump DI Out Auto 5 Min delay
ii 391_FN1_M01A Raw Mill Fan DI Motor Run Run
iii 391_FN1_UU1/UU2 Raw Mill fan Starter Unit Alarm DI Starter
iv 361_SR1_M01.run Seperator Motor Running DI Starter
5 Raw Mill Main Motor Bearing
i 361_FN1_M01 Sealing Air Fan DI Running Sealing Fan Stop
Give Roller Up cmd & BC1 stop
ii 361_FN1_PZ1 Sealing Air Pressure AI 200 200 18 15 mbar L2 cmd after 30 sec or roller up
limit stop mill
iii 361_RM1_TZ3 RM Motor Bearing Temp AI 100 90 0 0 Celsius H2
iv 361_RM1_TZ4 RM Motor Winding Temp AI 140 110 0 0 Celsius H2
v 361_RM1_TZ5 RM Motor Cooling AI 100 90 0 0 Celsius H2 Removed from Location
on H1 Roller Up/on H2 Motor
vi 361_RM1_AZ1 Raw Mill Vib AI 5 4 0 0 mm/s H1
Trip
vii 361_LQ2_TZ2 Inlet Oil Temp Maag Gear AI 49 47 28 27 Celsius H2
viii 361_LQ2_TZ8 outlet Oil Temp Maag Gear AI 60 56 20 20 Celsius H2
on H1 Roller Up/on H2 Motor
ix 361_LQ2_AZ1 Maag Gear Vibration AI 6 4 0 0 mm/s H1
Trip
x 361_LQ2_M01.Run Lubrication Unit Pump DI Motor Stop Mill stop & Roller Up cmd
6 Hydraulic System Fault
i 361_HS1_M01. Out Run In running Condition DI Motor Stop After 5 Sec mill Stop
ii 361_HS1_LL2 Oil Tank Level Low DI Low Level Raw Mill Trip
iii 361_HS1_TZ1 hydraulic Oil Temp 70 50 15 2 Celsius L1
iv 361_HS1_ZX1 Oil Valve Pos open DI Valve Close Must Open
7 Gear Lubrication Fault
i 361_LQ2_LL1 Oil Tank Level DI Low Level
ii 361_LQ2_M01.Out Run Oil Lubrication Unit Motor DI Motor Stop Running
Operate on the command of
iii 351-GA1 GA1 Must be in Auto DI Manual
metal detector

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

6.2 421 ID FAN (421-FN2-MO1)

6.2.1 ID Fan Motor Specs

Sr. Operating
Motor Tag Description Type Rating RPM Manufacturer
No. Voltage
3ø
421-FN2- 690V
1 ID Fan Induction 2100KW 994 Siemens
MO1 (Delta)
Motor

6.2.2 ID Fan Safeties & Interlocks

Kiln Main Drive (461-KL1-MO1)

Limits Tripping
Sr. No. Tag/Name Description Signal Type Unit Remarks
H2 H1 L1 L2 Point
No Run
1 461_KL1_M01.OUT.RUN Motor Run DI 20 SEC DELAY
Signal
2 461_LQ1_UF1 Spraying Lubrication Unit Fault DI Unit Fault 2 HR
3 461_LQ1_KILN_TRIP Spraying Lubrication Trip Signal DI On Fault
4 461_KL1_TZ6 Kiln Motor Winding AI 125 100 0 0 H2 5 SEC DELAY
5 461_KD1_ZX1 Kiln Barring Motor (Limit Switch) DI Barring In Trip at barring Pos.
6 461_KL1_ZM1 Pos Kiln Trip 15mm (up) DI 15 mm >15mm Thrust Device
7 461_KL1_ZM4 Pos Kiln Trip 15mm (Down) DI 15 mm >15mm Thrust Device
8 461_KL1_UY1 MV Switch Gear Stop DI Electrical MV Panel
No Run
9 461_LQ1_M01.OUT.RUN Lubrication Unit Running Alarm DI
Signal

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

6.3 KILN MAIN DRIVE (461-KL1-MO1)

6.3.1 Main Drive Specifications

Sr. Operating
Motor Tag Description Type Rating RPM Manufacturer
No. Voltage
3ø
461-KL1- 690V
1 Kiln Main Drive Induction 690KW 1491 Siemens
Mo1 (Delta)
Motor

6.3.2 Kiln Main Drive Safeties & Interlock

Kiln Main Drive (461-KL1-MO1)

Limits Tripping
Sr. No. Tag/Name Description Signal Type Unit Remarks
H2 H1 L1 L2 Point
No Run
1 461_KL1_M01.OUT.RUN Motor Run DI 20 SEC DELAY
Signal
2 461_LQ1_UF1 Spraying Lubrication Unit Fault DI Unit Fault 2 HR
3 461_LQ1_KILN_TRIP Spraying Lubrication Trip Signal DI On Fault
4 461_KL1_TZ6 Kiln Motor Winding AI 125 100 0 0 H2 5 SEC DELAY
5 461_KD1_ZX1 Kiln Barring Motor (Limit Switch) DI Barring In Trip at barring Pos.
6 461_KL1_ZM1 Pos Kiln Trip 15mm (up) DI 15 mm >15mm Thrust Device
7 461_KL1_ZM4 Pos Kiln Trip 15mm (Down) DI 15 mm >15mm Thrust Device
8 461_KL1_UY1 MV Switch Gear Stop DI Electrical MV Panel
No Run
9 461_LQ1_M01.OUT.RUN Lubrication Unit Running Alarm DI
Signal

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 PLANT MAIN MOTORS & THEIR SAFETIES | Arsalan Ahmed

6.4 CEMENT MILL (561)

6.4.1 Cement Mill Motors
Cement Mill area has also different motors with different rating and functionality. List is given below.
Sr. Operating
Motor Tag Description Type Rating RPM Manufacturer
No. V/Amps
3ø
561-BM1-
1 Ball Mill Motor Induction 6.3KV 4250KW 596 ABB
MO3
Motor
3ø
561-FN1-
2 Mill Fan Motor Induction 120A 665KW - ABB
MO1
Motor
561-PR1- DC
3 Mill Roller Press - 1400KW 800 ABB
MO1 Motor
561-SC1- Mill Screw DC
4 365A 150KW 1700 ABB
MO1 Conveyor Motor

6.4.2 Cement Mill Main Drive Safeties & Interlocks

Cement Mill Main Drive (561-BM1-MO1)

Sr. Signal Limits

Tag/Name Description Tripping Point Remarks
No. Type L1 L2 H1 H2 Unit
1 IO.AIS._561_BM1_TZ1 Inlet Bearing Temp AI 0 0 94 100 Celsius H2
2 IO.AIS._561_BM1_TZ2 Outlet Bearing Temp AI 0 0 87 95 Celsius H2
3 IO.AIS._561_BM1_TZ3 Material Temp AI 0 0 125 130 Celsius H2
4 IO.AIS._561_BM1_TZ4 Gear Oil AI 0 0 55 65 Celsius H2
5 IO.AIS._561_BM1_TZ5 Gear Bearing AI 0 0 80 85 Celsius H2
6 IO.AIS._561_BM1_TZ6 Motor Winding AI 0 0 130 140 Celsius H2
7 IO.AIS._561_BM1_TZ7 Motor Bearing AI 0 0 115 90 Celsius H2
8 IO.AIS._561_BM1_TZ8 Cool Air Inlet AI 0 0 70 75 Celsius H2
9 IO.AIS._561_BM1_TZ9 Air Outlet AI 0 0 100 110 Celsius H2
10 IO.DIS._561_BM1_AA1 Vibrational Switch DI High
11 IO.DIS._561_BM1_AA2 Vibrational Switch DI High
12 IO.DIS._561_BM1_ZY1 Mill Axial Position DI Not Allign
13 IO.DIS._561_BM1_ZY2 Mill Axial Position DI Not Allign
14 IO.DIS._561_BM1_ZY3 Mill Axial Position DI Not Allign
15 IO.DIS._561_BM1_ZY4 Mill Axial Position DI Not Allign
16 IO.DIS._561_LQ1_CS1.Signal.Value Contamination Switch DI
Cement Mill Main Motor Gear Limit Switch
17 IO.DIS._561_LQ1_ZX1.Signal.Value DI
Oil Suppling open
18 Symetro_vib_10s Symmetro Gear Vibration DI High 10 sec delay before trip
19 IO.AIS._561_BM1_AZ3 Gear Vibration Sensor AI 0 0 2.5 4 mm H2
20 IO.AIS._561_BM1_AZ4 Gear Vibration Sensor AI 0 0 2.5 4 mm H2
21 IO.AIS._561_BM1_AZ5 Gear Vibration Sensor AI 0 0 2.5 4 mm H2
22 IO.AIS._561_BM1_AZ6 Gear Vibration Sensor AI 0 0 2.5 4 mm H2
23 IO._561_GRP14._561_BM1_M15.Out.Rfs Filter Pump DI Not Ready Ready for Start
24 IO._561_GRP14._561_BM1_M16.Out.Rfs Circulation Pump DI Not Ready Ready for Start
25 IO.DIS._561_BM1_MKA.Signal.Value Circuit Breaker Availabilty DI Not Available from MCC
26 IO.DIS._561-BM1_UF3.Signal.Value MV Trolleys IN DI Trolley Not IN Limit Switch
27 IO.DIS._561-BM1_UF2.Signal.Value MV Trolleys IN DI Trolley Not IN Limit Switch
28 IO.DIS._561-BM1_LL8.Signal.Value Oil Splashing Switch DI Low Level Symmetro Gear
29 IO._561_GRP14._561_BM1_M03.Out.Run Contactor (Signal Return) DI Motor Stop Main Motor Out run

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