Maintenance of Cement Plant

Institut Cimentier
FAST TRACK
INTRODUCTION
TO ELECTRICAL & CONTROL
SYSTEMS MAINTENANCE
Notes
November 1999
Lafarge Institut Cimentier • Fast Track Part 2/1998 • Maintenance • Electrical Maintenance • 1
1
FAST TRACK
INTRODUCTION
TO ELECTRICAL & CONTROL
SYSTEMS MAINTENANCE
Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 1
2
INTRODUCTION TO ELECTRICAL &
SYSTEMS MAINTENANCE
Course Participants Will:

• Understand Dept Overview & Primary Objective.
• Be Able to Recognize Essential Electrical System
Components.
• Review and Understand Inspection / Test Procedures.
Notes• Understand the Power Triangle & Consumption Costs.
• Be Introduced to Power System Studies / Benefits.
• Be Able to Recognize Inst & Control System Devices.
ELECTRICAL MAINTENANCE
SLD 13:00-xx
“Introduction to Electrical & Control Systems Maintenance”

Welcoming Remarks and introductions. Have participants give a brief intro on their
electrical background. Provide a brief intro to speakers qualifications.
“Introduction to Electrical & Systems Maintenance”

Review the agenda and make a list of what the expectations are of the group. Put a flip chart
on the wall with topics of interest from the group. Ensure that the presentation covers the
desired topics.
Notes
3
Agenda
Morning:
Electrical / Systems Department Overview &
Primary Objective
Essential Electrical System Components
Typically Found in a Cement Plant
Understanding the Power Triangle &
Consumption Costs
Power System Studies / Benefits
Afternoon:
Plant automation
Instrument & Control System Devices
Electrical / Systems Department

Overview & Primary Objective.
Section 1
Notes
SLD 13:00-xx
“Agenda”
“Electrical / Systems Department Overview & Primary Objective - Section 1”

Intro slide to the first section. Note start time.
Notes
TYPICAL PLANT 5
ORGANIZATION Plant Manager
Production
Maintenance
Manager
Electrical System Engineer

responsible
Organization & Workshop

planning responsible
Electricians
6
SUPERVISOR’S RESPONSIBILITIES
PRIMARY OBJECTIVE
• To schedule, plan and execute

all electrical, systems and instrumentation
activities
 operational and maintenance
Noteswith limited interruption to plant’s production
requirements
at the lowest possible cost.
SLD 13:00-xx
“Typical Plant Organization”

Explain how the Exshaw organization is formed. Point out the typical formation in other
plants. Explain how the Electrical Supervisor normally reports directly to the Maintenance
Manager.
“Supervisor’s Responsibilities”
Provide a simple description of the reason for being! You may wish to include a brief
description of a day in the life of an Electrical Supervisor. (optional)
Notes
7
Electrical / Systems Department

Overview & Primary Objective.
of Section 1
Essential Electrical System

Components Typically Found in a
Cement Plant
Inspection & Test Procedures
Section 2
Notes
SLD 13:00-xx
“Electrical Systems / Department Overview & Primary Objective -

The end of Section 1”
End of first section. Note the time.
“Essential Electrical System Components Typically Found in a Cement Plant -

Inspection & Test Procedures - Section 2”
Beginning of the second section. Note the start time.
Notes
9
10
What is the Function of a Generator?
• The foundation of all electrical design is;
• OHM’S LAW, which describes the relationship

between VOLTAGE, CURRENT, and RESISTANCE.
Notes
• Voltage = Current X Resistance
SLD 13:00-xx
Describe the Alpena turbine and generator setup.
“What is the function of a generator?”

Use flip chart to demonstrate the relationships between the parameters. Provide other
equations such as power (P=ExI)
Notes
11
Power!
• When you buy power at home or for the plant, you

buy Watts, Kilowatts, or Megawatts.
• Watt-hours....
• The relationship between VOLTAGE, CURRENT,
and POWER is the following;
• Power(Watts) = Voltage X Current(Amps)
12
Common voltage levels.
• In the house, you have 110 volts or 240 volts.

(Depending on your country’s standards)
• In the neighborhood, electricity is distributed at

high voltage and transformed to medium/low
Notes voltage for end users.
SLD 13:00-xx
“Power”
“Common voltage levels”
Notes
13
Common voltage levels.
• The loads and distance determine the voltage used
• Heavy loads like kilns and mills will be run at 3 to 15

kvolts, and all other motors will be fed at 400/660 V.
This is to limit the current to reasonable levels, lower
than 1000 A (1).
(1): A is the ISO abbreviation for ampere; American seldom use Amps.
14
Why such high-voltage supply?
• Isn’t it more dangerous to have

extreme voltages around the
plant?
• Why bother with different voltage

Notes levels and all that extra
equipment?
SLD 13:00-xx
“Common voltage levels”
“Why such high-voltage supply?”

The intent is to have the group understand the value of multiple voltage levels in the plant.
Ask questions as to why this would be a good or bad situation
Notes
The relationship between voltage and 15
current determines the choice of
voltage.
• The different loads in the plant consume different

amounts of energy at different rates.
• For example, the mill motor consumes about 1 MW
(Megawatt) of energy at any given moment.
• If we fed this motor at 400 volt supply, what would
the current be?
The relationship between voltage 16

and current determines the choice
of voltage.
• The current to the motor would be 1600 amperes,

which would require wires about the size of your
arm!
Notes
• What if we fed it with 4000 volts or 15000 volts?
SLD 13:00-xx
“The relationship between voltage and current determines the choice of voltage”
Get group to calculate the current value. (Power = Voltage x Currentx1.73xcosphi) =1600 A
Redo calculation at 4160 volts. The new value is 240.3 amps
Notes
of voltage.
• At 4160 volts (USA standard voltage), the

current would be 154 amperes, which
requires a wire about the size of your
thumb, which is reasonable.
• If we were to feed it at 13800 volts, the wire

size would be smaller still, which would
make installation even easier.

of voltage.
• Therefore, we now know that voltage supply

levels are driven by mechanical considerations of
wire and equipment size!
• If the entire plant consumes about 15 Megawatts,

Notes does it make sense to feed it at 69 000 volts or
113 000 volts?
SLD 13:00-xx
Review the slide.
Review the slide.
Notes
19
What have we learned?
• The mechanical demands of handling CURRENT

are the driving force behind determining voltage
levels in various areas of the plant.
• Selecting a voltage level depends on the

equipment power consumption.
20
DISTRIBUTION EQUIPMENT
TRANSMISSION LINES
• Power is delivered to
our plants via kilometers
of aerial cable.
• Utility companies install
and maintain this
equipment.
Notes
• In most areas the
reliability is usually very
high.
Lafarge Honduras
SLD 13:00-xx
“What have we learned?”

Review the slide.
“Distribution Equipment”
Also point out that the cable may be underground, under water or overhead.
Notes
21
VOLTAGE LEVELS
AC VOLTAGE LEVELS DC VOLTAGE LEVELS

• Below 120 volts (very low voltage • 24 volts (Low Voltage)
(safety) (auxiliary Voltage) • 125 volts - common (USA)
• 120 / 208 volts - very common
• 750 volts or less - considered low
voltage
• 751 - 24,000 volts (Medium Voltage,
USA) (30 kv in Europe)
• 24,001 and “Up” (High voltage)
• 115,000 and up (very high voltage)
MAJOR COMPONENTS OF A 22
DISTRIBUTION SYSTEM
13.8 kV
2-14, 400/120V
350 M VA UT IL IT Y
SHORT CIRCUIT V 27
CA PACIT Y
50 5IN A
3-500/5 51
2 1
500 M VA
13,800 VO LT
1200 AM P.
3p/600 A
EM ERGE NCY GENE RA T OR 125 E
500 K W
480Y / 277 VOL T 1000 KVA/OA
KE Y 13.8 kV - 480Y / 277V
Z = 5.00%
600 A T
600 A F 1200 AT
1600 AF
100 A T 600 A T 500 A T 200 A T

225 A F 600 A F 600 A F 225 A F
Notes SOL ID
MO T OR
CO NT ROL FUSE D
CE NT E R SAFE T Y
ST AT E
CO NT ROL SWIT CH
480Y / 277V
DIST RIBU T ION

PA NEL
D.C. M OT OR
A.C. M OT OR 208Y / 120V
PA NEL BOAD
45kVA/AA
480 - 208Y / 120V
Z 3.2%
SLD 13:00-xx
“Voltage levels”
Review the slide. Some code may define the levels differently but this is a general rule of
thumb that will get everyone by in a pinch!
“Major components of a distribution system”

Describe the complete single line in detail. Point out the components and discuss their
function. Leads into next slide that describes the symbols in detail.
Notes
23
UNDERSTANDING DIAGRAM SYMBOLS
1. Ground:
2. Lightning arrestor to ground:
3. Disconnect switch:
1 (unit 1)
4. Switchgear power circuit breaker:
5. Voltage transformer:
6. Current transformer W/Turns ratio: 300/5
7. Metering: A Ammeter V Voltmeter

W Wattmeter WHM
Watt-hour meter
PF Power factor meter VAR
Var Meter
8. Motor, lightning arrestor W/Surge capacitor:

Fuse
9. Fused, starter contactor W/Motor: 250
HP
MTR.
Contractor
10. Low voltage (<600 vac) circuit breakers:
24
MAIN SUBSTATION EQUIPMENT
• Incoming High Voltage • Power Transformers

Disconnect (138kV) • Secondary Bus
• Main Breaker • Neutral Grounding
• Current Transformers Resistor
• Potential Transformers • 4160 Volt Switchgear
• Protection relays Assembly
Notes • High Voltage Isolation • Mechanical interlocks
Switches • Safety tools (gloves,...)
• Lighting Arrestors
SLD 13:00-xx
“Understanding diagram symbols”

Review the various components and symbols.
“Main substation equipment”

Intro into the main substation equipment the following slides show each piece of equipment
in detail. Have general discussion on each slide with input from the group as to what they
think each pieces function may be!
Notes
25
Main breakers at the input (Honduras)

26
Notes
SLD 13:00-xx
Point out the major components. Incoming disconnect, bulk oil breaker, potential
transformers, current transformers. Exshaw main 138 kV outdoor substation.
Explain the mechanical components of a power transformer and basic transformer theory.
Go through examples of turns ration calculations. Note cooling fans and lighting arrestors.
Review the oil dielectric system and protective features built into a typical transformer like
fast & slow gas relays, explosion release device, oil level gauges, winding temperature
devices, cooling fans, etc.
Notes
27
MAJOR IN PLANT DISTRIBUTION SYSTEM 28

COMPONENTS & THEIR FUNCTIONS
Medium & Low Voltage

Distribution
current transformers
(Honduras)
Notes
SLD 13:00-xx
Discuss the Basler relay operation and how it automatically changes the taps on the
transformer when the Utility supply voltage fluctuates or the plant loading causes an low
voltage condition.
“Major in plant distribution system components and their functions”
Notes
29
MAJOR IN PLANT DISTRIBUTION SYSTEM
COMPONENTS & THEIR FUNCTIONS
• Switchgear and • Instrument Transformers

Switchboard Assemblies
• Metering
• Transformers
• Motors
• ESP
• Motor Control
• Cables
• Variable Speed Drive
• Metal-Enclosed Busways
• Direct-Current Systems
• Switches
• Capacitors
• Circuit Breakers
• Emergency Systems
• Protective Relays
30
INSPECTION AND TEST PROCEDURES
Switchgear
• Switchgear and Switchboard Assemblies
Notes
Switchboard M.V. 4.16 Kv (Honduras)
SLD 13:00-xx
“Major in plant distribution system components and their functions”

The following slides will discuss the items identified in detail. We will be looking at the
equipment and identifying the recommended maintenance strategies for each piece of
equipment. Hand out the NETA Maintenance Testing Specifications” document. Have disk
copies available.
“Inspection and test procedures”

Get the group to turn to the page identified and peruse the recommended tests. Have an
individual read out the section on mechanical and then electrical for the first few items only.
This will lead into a discussion on the types of tests and equipment available for testing. The
concept of contracting out the testing service will also be discussed.
Notes
INSPECTION AND TEST 31
PROCEDURES
Transformers
• Dry-Type
• Liquid-Filled
What's wrong ? (Venezuela)
32
ESP!
Advantages Disadvantages
• There are less and • The collection efficiency
less of them left! is very sensitive to
process variations.
• They are very efficient
dust collectors.
• They are mechanically • Costly and labor-
intensive to maintain.
tolerant of temperature
Notes excursions. (Caution!)
• They do not generate • Very difficult to trouble-
shoot!
waste(such as bags).
SLD 13:00-xx
“Inspection and test procedures”

Refer to NETA section for recommended tests.
“ESP!”
Notes
33
ESP Operating Principles!
• All plant personnel need to have an idea of what it

takes for the ESP to function correctly! Teamwork
is critical!
• There are literally hundreds of factors that can

affect ESP operation. Unfortunately, these factors
are often….
34
ESP Operating Requirements!
• Minimized gas velocity through the precip.
• Strength of the electrostatic field.
• Dust characteristics. (size, conductivity, amount)
Notes
• Gas temperature and chemistry.
SLD 13:00-xx
“ESP Operating Principles!”
“ESP Operating Requirements!”
Notes
35
ESP Theory of Operation!
• The ESP collects dust by charging each particle in

the gas stream and then attracting it to collector
plates.
• The particle accumulates a charge by passing

through an electrostatic field and is subsequently
swept out of the gas stream because it tries to
follow the field to the collector plate.
36
ESP Keys to Efficient Operation
• Maximum power input to the fields to maximize

electrostatic field strength.
• Uniform spacing between wires and plates.
• Clean inlet ducts for uniform gas distribution.
Notes
• Minimal in-leakage to preserve temperature of gas
stream
SLD 13:00-xx
“ESP Theory of Operation!”
“ESP Keys to Efficient Operation”
Notes
37
ESP Keys to Efficient Operation
• Minimal buildup on wires or plates and no “snow-

drifts” within any of the fields.
• Adequately strong rapping of the fields
• Adequate withdrawal of precipitated dust from the

collection hoppers.
38
How can I manage my ESP?
• Capture a “snapshot” of all operating parameters

at a time when the process is stable and the ESP
operation is satisfactory. (See example)
• Tracking the numerous parameters on paper will

enable you to better troubleshoot problems by
comparing conditions.
Notes
SLD 13:00-xx
“ESP Keys to Efficient Operation”
“How can I manage my ESP?”
Notes
39
The ESP “Snapshot Sheet”
• Captures all control room data on process and

equipment at that moment.
• Captures the chemistry and physical properties of

ESP dust from each field.
• Captures weather conditions, type of product

being produced, type and mix of fuels, etc.
40
ESP Snapshot
#1 Kiln Snapshot
Friday, 17th November, 1995 7:30AM

RPH 80.5 DC KiloVolts AC Amps AC volts DC mA Sparkrate
Kiln Amps 267.2 #1 precip inlet section 36-37 peak 40 peak 330 peak 200 peak
Dilution damper 0 26-27 min 30 min 250 min 125 min
ID fan speed 384.5 #1 precip center section 24-28 peak Below 20 180 peak 80 peak 120
ID fan amps 33.1 20 min 130 min 20 min
Feed/Speed 38 #1 precip outlet section 28.5 peak 42-43 200-220 330 peak
Opacity 3 25 min (steady) (steady) (steady) 150 min
Precip inlet 739.9
Coal mill amps 171.6 #2 precip inlet section 47 peak 25-30 350 peak 220 peak 56
Coal tons 2 25 min 220 min 120 min
Coke tons 3 #2 precip center section 28 peak 75 peak 280 peak 500 peak 48
Gas Mcfh 1.4 21 min 40 min 220 min 350 min
Hood press. -0.07 #2 precip outlet section 33 steady 71 steady 280 steady 440 steady 0
Kiln exit temp. 929.2
Chain "A" temp 1648.8
Dust elev. % 34.7
Schenk feeder 30.8
Notes
Mod. valve %
Thermox
40.5
1.6/O2 and .055/CO
Servomex 1.73/O2 and .17/CO Temp damper 0
Cooler drive spm 8.4 Baghouse temp. 219/219/200
Cooler amps 5.4 Baghouse damper % 30.5
Sec air temp 1630.6 Baghouse fan 44.8
1st comp press 7.1 Clean cycle on
2nd comp. press. 6.3 Multiclone fan amps 0.1
3rd comp. press. 6.1 Isol. damper open
4th comp. press. 6 Multiclone fan damper % 0
SLD 13:00-xx
“The ESP “Snapshot Sheet””
“ESP Snapshot”
Discuss the details of a precip operating under ideal conditions. Give examples of poor
conditions and problems found like air in-leakage.
Notes
41
Cables
• Low-Voltage, 600 V Max
• Medium-Voltage, 69 kV Max
• High-Voltage
42
INSPECTION AND
TEST PROCEDURES
Switches
• Low-Voltage
• Medium-Voltage, Metal-
Enclosed
• High- and Medium-Voltage,
Open
• Vacuum Switches
Notes • SF6 Switches
Typical L.V. unit 32 amp 440 V (Venezuela)
SLD 13:00-xx
“Inspection and Test Procedures”

Refer to NETA section for details.

Refer to NETA specs.
Notes
43
INSPECTION AND
TEST PROCEDURES
Circuit Breakers
• Low-Voltage
• Medium Voltage
• High Voltage
• Air
• Oil
• Vacuum
• SF6
Typical L.V. unit 32 amp 440 V (Venezuela)

44
Protective Relays
• Over current
• Voltage
• Differential
• Motor Protection
• Power
Notes
SLD 13:00-xx

Refer to NETA spec. Talk about the different types of breakers available on the market.

Notes
45
Metering
• Analog
• Digital
Testing windings isolation (Venezuela)
46
Motors
• AC Motors
• DC Motors
Notes
Kiln DC motor (Venezuela)
SLD 13:00-xx

Refer to NETA spec.

Refer to NETA specs. Talk about the fundamental differences between an AC vs DC motor
in terms of their construction.
Notes
47
DC motor (Italy)
48
HOW AND WHY DO MOTORS FAIL
A.C. Motors Synchronous Motors

• Windings can short out • Field rings - Locks rotor to
• Motor overloaded - Overheating stator
• Excessive Starts - Protection • Field shorts and grounds
• Bearings • Testing for grounds
• Rotor Imbalance. • Bearings - Sleeve
• Eccentricity • Field failure
• Unstable operating conditions
D.C. Motors • Stator coils can short out
Notes • Sometimes coils can be
• How do commutators wear?
bypassed
• Commutator flashover
• DC Field Tests
• Bearings
• Field failure - Shorted turns
SLD 13:00-xx
“How and why do motors fail”

Review slide.
Notes
49
STANDARD VS HIGH EFFICIENCY
% efficiency
100
95
High efficiency
90
85 Standard efficiency
80
75
70
1 5 10 25 50 100 200
Horsepower
50
Motor Control
• Motor Starters
Low-Voltage
Medium-Voltage
• Motor Control Centers

Low-Voltage
Medium-Voltage
Notes
SLD 13:00-xx
“Standard vs High Efficiency”

General discussion on the differences between the standard vs High Eff design. Talk about
the ability of a repair shop to be able to fix a HE motor.
“inspection and Test Procedures”

Notes
51
A.C. MOTOR CONTROL DIAGRAM
Motor windings for replacement (Venezuela)
52
INSPECTION AND
TEST PROCEDURES
Variable Speed Drives
Notes
frequency converter (Turkey)
SLD 13:00-xx
“A.C. Motor Control Diagram”

Explain how the wiring diagram relates to the schematic diagram. Explain how a motion
detector or pull cord is connected in the field.

This section is reserved in the NETA spec.
Notes
53
Direct-Current Systems
• Batteries
• Chargers
54
Capacitors
Notes
What's wrong ? (Turkey)
SLD 13:00-xx
Refer to NEAT specs.
Refer to NEAT spec.
Notes
55
Capacitors
• Used for Power Factor

Correction
• Increases Voltage Levels
• Maintains a Charge After
Being De-energized
56
Emergency Systems
• Engine Generator
• Automatic Transfer Switches
• Uninterruptible Power Systems
Notes
SLD 13:00-xx
“Capacitors”
Hi-lite the danger associated with charge after power removed.
Refer to NETA spec.
Notes
57
UPS Systems
• Has a DC battery pack that provides power during

a short power outage.
• Load does not see power bump.
• Time limited dependent upon size of connected
load.
• Used to maintain Process computers and critical
devices during power excursions.
58
Essential Electrical System

Components Typically Found in a
Cement Plant
Notes
End of Section 2
SLD 13:00-xx
“UPS Systems”
Review slide. Describe event that took place at Exshaw when main system failed on LCAIV.
“Essential Electrical System components Typically Found in a Cement Plant -

End of Section 2”
Notes
59
Understanding the Power Triangle

& Consumption Costs
Section 3
60
POWER FACTOR CORRECTION
C
“ Ph a n to m ” p ow er 3 50 7 k v a r
A
kV
15
46
=
er
ow
tp
en
ar
pp
E
F
A
.6 5P
 =0 815 kvar afte r
correction
 = 0.96 PF
A
Notes “True” power = 3000 kW B
2692 kvar of
corrective
capac itors
SLD 13:00-xx
“Understanding the Power Triangle & Consumption Costs - Section 3”
“Power Factor Correction”

Power factor is defined as the ratio of useful working current to total current in the line. Since power is the
product of current and voltage, the power factor can also be described as a ratio of real power to apparent
power and be expressed as: power factor = kW/kVA. Although it is often expressed in percent, power factor is
actually a ratio and is better expressed as a decimal when used in formulas and table. This relationship is
shown in the accompanying vector diagram.
Unlike purely resistive loads, induction loads (such as motors, transformers, industrial furnaces, or lamp
ballasts) require a reactive or magnetizing current. The reactive current provides only the electromagnetic field
needed for operating the device. The magnetizing current, which does not perform any work or advance the
kWh meter, is also called wattles, non-usable, or phantom current. The quantity of reactive component is
expressed in kilo-volt ampere reactive (kvar).
Referring back to the vector diagram, note that line AB represents the working or “true” power, and line BC
represents the “phantom” power reactive component, known as kvar. This quadrature component results in a
phase displacement between the true power requirement of the load (kW) and the apparent power (kVA), line
AC. Power factor is the cosine of the angle of displacement (Ø0), typically called the phase angle. Ø0 equals
the product of kW divided by kVA.
As shown in the accompanying diagram, with a load of 3000kW and 3507 kvar of inductive reactance, a
facility would have 0.65 pF at 480V, 3 phase. Since 1kvar of capacitors cancels 1kvar of the inductive
reactance component of the “apparent power” (kVA), the use of a capacitive reactance of 2692kvar (line BD)
would cancel all but 815kvar of the inductive reactance (line BE). The result would be 3109kVA of apparent
power and a 0.96 PF (line AE).
Most electric utilities assess a penalty for low PF. In some locations, the penalty is only nominal; while in
other locations, the utility’s PF penalty can account for a substantial portion of the electric bill. The amount of
penalty, the basis on which it is levied, the facility’s present PF, and the expenditure necessary to obtain PF
improvement must all be considered to determine whether a project will be economical.
In some cases, customers who do not maintain a minimum of .90 PF — PF — are penalized by increased kW
demand charges. For example, if a power company has a requirement that an average PF of 0.95 or greater
must be maintained, the customer’s billing demand is increased if his PF is less than the required amount, as
follows:
Measured kW x 0.95/Actual PF = Billing kW.
Obviously, a proportional increase in the billing demand results. This increase in demand multiplied by the
demand charge becomes the PF penalty. And for even small facilities with relatively low demand, this can add
up to thousands of dollars a year.
Notes
61
Skills to be Acquired!
Exercise # 1
1) How to calculate power consumption.
2) How to calculate and justify power savings.
62
Calculating Power Consumption,
the Easy Way!
Some points of reference:
• 1 Horsepower = 746 watts

• P = E*I
Notes
SLD 13:00-xx
“Skills to be acquired!”
“Calculating Power Consumption, the Easy Way!”
Notes
63
Question #1
1) Calculate the total power consumption in

kWh’s of a 200 kW Fuller Pump motor
rated at 600 volts, that only runs 85% of
the time?
Note: Assume a 90 % load Factor;

a 94.7% efficiency.
64
Answer #1
1) 200 kW x .9 (Load Factor) = 190 kW

0.947 (Efficiency)
2) 190 kW x (365 d X 24 hrs ) x 0.85 = 1,414,740 kWh
Notes
SLD 13:00-xx
“Question #1”
“Answer # 1”
Notes
65
Question # 2
2) What does it cost to operate this pump

for one year if the average cost of
power is USD 0.04 per kWh?
66
Answer # 2
2) 1,414,740 kWh x 0.04 =

USD 56,590 per year
Notes
SLD 13:00-xx
“Question #2”
“Answer # 2”
Notes
67
Section 4
68
POWER SYSTEMS STUDIES
• Short Circuit
• Co-ordination & selectivity
• Load Flow
• Stability (if generators)
• Voltage Transients
• Motor Starting
Notes
• Harmonic Analysis
• Ground Mat
SLD 13:00-xx
“Power System Studies - Benefits - Section 4”
“Power Systems Studies”
Notes
69
SHORT CIRCUIT STUDY
• Verify Protective
Device Ratings
• Calculate Fault
Currents
• Calculate Remote
Voltage and Current
Levels
70
CO-ORDINATION
• Verify Power Fuse

Ratings
• Relay Settings
• Breaker Setting
• Transformer Ratios
Notes
• Equipment Damage
Curves
SLD 13:00-xx
Notes
71
LOAD FLOW
• Determine Overloads
• Optimize Voltage
Levels
• Accurately Size
Capacitors
• Detect Problem
Voltages
72
EQUIPMENT EVALUATION
• An equipment evaluation
study shall be performed to
determine the adequacy of
circuit breakers, controllers,
surge arrestors, busways,
switches, and fuses by
tabulating and comparing the
Notes short-circuit ratings of these
devices with the maximum
short-circuit momentary and
interrupting duties.
SLD 13:00-xx
Notes
73
HARMONIC ANALYSIS
4,000
• Adjustable frequency
drives, electrostatic 2,000
precipitators, computers
and SCR controlled -0.000
devices all generate

harmonics that may be -2.000
harmful to a distribution
system. Filtering may be -4,000
used in order to minimize 0 5 10 15 20 25 30 35

their effects. Time (MSec)
74
Maintenance files must

include all these informations
as built diagrams and
calculations
Notes
Maintenance files (Venezuela)

SLD 13:00-xx
“Maintenance files...”
Notes
75
End of Section 4
76
Plant automation
Instrument & Control System Devices
Notes
Operator's control system (Venezuela)
SLD 13:00-xx
“Power System Studies - Benefits - End of Section 4”
“Plant Automation - Instrument & Control System Devices”
Notes
77
Controller's cabinet in electrical room (Venezuela)
78
TYPES OF INSTRUMENTS AND
APPLICATIONS
Temperature Measurement
• Thermocouples couples
• RTD Resistance temperature detector
• Pyrometers
Pressure Measurement
• Gauges indicators
• Measurement using remote mounted
transmitters
Notes
Motion Sensors / Speed Indicators
• Motion Sensors - Milltronics
• Shaft mounted tachometers
SLD 13:00-xx
“Types of instruments and applications”
Notes
79
TYPES OF INSTRUMENTS AND
APPLICATIONS (cont’d)
Electric Actuators
• Types of actuators
Gas Analyzers
• Different types available
• Techniques used
Belt Scales / Load Cells

• Types used
• Strain Gauges
Flow Measurement
• Different types of flow sensors in use today
80
LUCIE
• LUCIE is the name given to the latest generation

of artificial intelligence systems developed by
Lafarge to control kilns, coolers and mills.
• It is a complex collection of conditions and pre-

Notes programmed responses that can be adapted to
each particular kiln or mill system.
SLD 13:00-xx
“Types of instruments and applications” (cont’d)
“LUCIE”
Notes
81
LUCIE
• It is capable of providing optimized operation at a

normal level, but cannot start up or shut down a
system.
• Serves as an extension of the operator’s trade

that eliminates frequent subjective control
changes.
82
Instrument & Control System

Devices
Notes
End of Section 5
SLD 13:00-xx
“LUCIE”
“Instrument & Control System Devices - End of Section 5”
Notes
83
SAFETY AND WORK PRACTICES
SAFETY VIDEO
• Time Permitting
Notes
SLD 13:00-xx
“Safety and Work Practices”
Notes

Maintenance of Cement Plant

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Maintenance of Cement Plant

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Institut Cimentier

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 1

Course Participants Will:

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 2

“Introduction to Electrical & Control Systems Maintenance”

“Introduction to Electrical & Systems Maintenance”

Electrical / Systems Department

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 4

“Electrical / Systems Department Overview & Primary Objective - Section 1”

Electrical System Engineer

Organization & Workshop

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 5

• To schedule, plan and execute

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 6

“Typical Plant Organization”

Electrical / Systems Department

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 7

Essential Electrical System

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 8

“Electrical Systems / Department Overview & Primary Objective -

End of first section. Note the time.

“Essential Electrical System Components Typically Found in a Cement Plant -

Beginning of the second section. Note the start time.

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 9

• The foundation of all electrical design is;

• OHM’S LAW, which describes the relationship

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 10

Describe the Alpena turbine and generator setup.

“What is the function of a generator?”

• When you buy power at home or for the plant, you

• Power(Watts) = Voltage X Current(Amps)

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 11

• In the house, you have 110 volts or 240 volts.

• In the neighborhood, electricity is distributed at

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 12

“Common voltage levels”

• The loads and distance determine the voltage used

• Heavy loads like kilns and mills will be run at 3 to 15

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 13

• Isn’t it more dangerous to have

• Why bother with different voltage

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 14

“Common voltage levels”

“Why such high-voltage supply?”

• The different loads in the plant consume different

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 15

The relationship between voltage 16

• The current to the motor would be 1600 amperes,

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 16

• At 4160 volts (USA standard voltage), the

• If we were to feed it at 13800 volts, the wire

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 17

The relationship between voltage 18

• Therefore, we now know that voltage supply

• If the entire plant consumes about 15 Megawatts,

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 18

• The mechanical demands of handling CURRENT

• Selecting a voltage level depends on the

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 19

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 20

“What have we learned?”

AC VOLTAGE LEVELS DC VOLTAGE LEVELS

Fast Track Block 2 - Week 2 - 1999 / Maintenance / Electrical Maintenance • 21

100 A T 600 A T 500 A T 200 A T