Flow Diagram - نگهداری و تعمیرات بهره ......Flow Diagram, Equipment identification numbering system 39971-02-2.1 The information transmitted by this document is

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Flow Diagram

Equipment identification numbering system Process control and measurement identification numbers and symbols

Instruction Manual

Approved date: 2006-10-25

Created by: AlH

Approved by: JLL

Doc. No. 39971–02-2.1

Flow Diagram, Equipment identification numbering system 39971-02-2.1

The information transmitted by this document is the proprietary and confidential property of FLSmidth And may not be duplicated, disclosed or utilized without written consent from FLSmidth. 2/23

List of contents:

Page: 1 General information.............................................................................. 3

1.1 Reference to standard: ................................................................................... 3 1.2 General notes: .............................................................................................. 3

2 Equipment Number............................................................................... 4 2.1 Plant department number ............................................................................... 4 2.2 Equipment number ........................................................................................ 5 2.3 Structure of equipment number....................................................................... 5 2.4 Position on flow diagram................................................................................. 5 2.5 Package of equipment .................................................................................... 5

3 Tag Number ........................................................................................ 6 3.1 Tag number .................................................................................................. 6 3.2 Structure of tag number ................................................................................. 6 3.3 Position on flow diagram................................................................................. 6

4 Signal Number..................................................................................... 7 4.1 Signal number............................................................................................... 7 4.2 Structure of signal number ............................................................................. 7 4.3 Example ....................................................................................................... 8 4.4 Position on flow diagram................................................................................. 8

5 Flow diagram, instrumentation ............................................................... 9 5.1 Symbols in connection with measuring points .............................................. 9 5.2 Instrumentation Level ...................................................................................10 5.3 Instrument lines ...........................................................................................10 5.4 Code for types of measurement and function ...................................................10 5.5 Control loops................................................................................................10 5.6 Examples.....................................................................................................11

6 List of equipment codes .......................................................................12 7 Table of unit codes ..............................................................................20 8 Signal identification letters ...................................................................21 9 Signal type ........................................................................................22 10 Signal code for motor control ................................................................23



1 General information 1.1 Reference to standard:

This instruction manual is based on the principles outlined in IEC 61346 with respect to structure and reference.

1.2 General notes:

In order to plan, build, operate and maintain a cement plant or a part hereof,

it is important to be able to decompose the cement plant into process areas,

process areas into plant departments, plant departments into equipment, etc.

and then designate these plant parts in a structured and unambiguous

manner for the purpose of identification and references.

A flow diagram is a diagram using symbols to illustrate the process sequence

in a process area or a part hereof.

The flow diagram indicates the instrumentation and the control loops with

sufficient information to enable qualified personnel to understand the means

of measurement and control of the process.

The present instruction manual describes the structure and meaning of the

relevant numbers used for designation of departments, equipment, tags,

units, signals and signal functions.



2 Equipment Number

2.1 Plant department number

A plant department designates a part of the total plant, e.g. storage or a mill

department.

5 1

3 2

1 3

Process area

Function

Production unit

Plant department No.

The first character represents the process area. The following digits are used:

0. General

1. Raw material handling

2. Additive and coal handling

3. Raw meal production

4. Clinker production

5. Cement grinding

6. Cement storing and dispatch

7. Utilities

8. Electrical equipment departments

9. Service departments

The second character represents the designation or function within each process

area (Crushing, storage, transport, etc.).

The third character represents the production unit. Example: Cement mill 1 and

cement mill 2 will have plant department nos. 531 and 532 (5 for Cement grinding,

3 for Mill and, respectively, 1 and 2 for Mill 1 and Mill 2).



2.2 Equipment number

The equipment number is used to give an unambiguous identification of any

equipment. The equipment number consists of a plant department number and

an equipment code with sequence number. The equipment number system is

used on flow diagram.

2.3 Structure of equipment number

An equipment No. consists of a plant department No., an equipment code and

a sequence number, as illustrated below

31

2

2

13

R4

M5

16

07

Plant department No.

Equipment code

Equipment sequence No.Equipment

08

Equipment No.

The first 3 characters (1st to 3rd) represent the plant department number (this

case raw mill department)

The next 2 characters (4th and 5th) represent the equipment code, (raw mill).

As defined in section 6.

The last 3 characters (6th to 8th) represent the sequence number. The

sequence numbers are usually following the process flow

2.4 Position on flow diagram

The equipment number is indicated next to the relevant equipment

2.5 Package of equipment

On the flow diagram there may exist a group of equipment surrounded by a

dashed box line. This package of equipment is tagged as one equipment number in

Bold inside one of the corners of the surrounding box. This equipment number is used

as reference to other documentation.



3 Tag Number 3.1 Tag number

The tag number is used to give an unambiguous identification of any equipment

including its individual units. The tag number is composed of an equipment number,

as described in section 2 and a unit code with sequence number. The tag number

system is in particular used in electrical documentation and on flow diagram.

3.2 Structure of tag number

The tag No. is made up of two sections, the equipment No. and a unit code with

sequence number, as illustrated below.

3 1

2 2

1 3

R 4

M

5

1 6

0 7

0 8

N

9

Tag No.

Equipment No.

Unit code

Unit sequence No. Unit

0 10

1 11

The first 8 characters (1st to 8th) represent the equipment number.

The next 3 characters (9th to 11th) represent the unit code and unit sequence

number, as defined in section 7. Counting sequence is:01 to 99, hereafter A0 … A9,

B0…B9 etc.


Normally, the tag number is not shown in its entirety on the flow diagram.

The equipment No. is indicated next to or inside the relevant equipment. The unit

code with sequence number is normally indicated in the lower half of the measuring

circle or next to the unit.

To obtain the entire tag number from the flow diagram, it will be necessary to

combine the sub-parts (equipment No. & unit code with sequence number).



4 Signal Number

4.1 Signal number

A signal number is a combination of letters and digits for designation of the

measuring point (Tag No.), the measuring type and the signal type with the

sequence number.

The signal number system is used in electrical documentation and on flow

diagram.

4.2 Structure of signal number

The signal No. is built up of two sections, the tag No. and a signal code with a

sequence number, as illustrated below.

1 11

T 12

0 13

Signal No.

Type of measurement

Type of signal

Signal sequence number

2 2

1 3

R 4

M 5

1 6

0 7

0 8

N 9

0 10

Tag No.

14 1

Signal code

3 1

The first 11 characters (1st to 11th) represent the tag number

The last 3 characters (12th to 14th) represent the signal code, the type of

measurement, and the type of signal with sequence number.

12th character: Type of measurement.

A letter designates the type of measurement. See section 8 - Signal

identification letters.

For example, letter T indicates that the measurement is a temperature

measurement.

13th character: Type of signal.

The digit indicates the type of signal used for the particular measurement.

See section 9: Signal type.



Section 10: explaining Signal codes for motor control. Note: Motor control signals

are not shown on flow diagram, but in signal list only.

14th character: Signal sequence number.

The sequence number indicates the signal sequence for several identical types of

measurements on the same unit.

4.3 Example

1 11

T 12

0 13

Temperature measurement, sec. 8

Analog input, section 9

Signal sequence number 1

2 2

1 3

R 4

M 5

1 6

0 7

0 8

N 9

0 10

Raw mill department

Raw Mill Section 6

Raw Mill, sequence no, 100

Transmitter, section 7

Sequence number 01

First transmitter (Unit) related to the Raw Mill

14 1 3

1


The unit code with sequence number, and type of measurement/signal with

sequence number, is indicated in the lower half of the instrumentation circle on the

flow diagram. In case the equipment number and unit number are already defined

on the flow diagram, they will be individually represented; if not, the equipment

number will precede the circle.

In case of identical units on equipment, indication is provided only in the first

circle, which is preceded by the numbers of the identical units.

The unit sequence number will then be sequential from 1 to the last numbers.

See section 5.6 for examples.



5 Flow diagram, instrumentation

5.1 Symbols in connection with measuring points

On a Flow diagram the measuring points are marked with at least one circle.

A horizontal line through the centre of the circle indicates the accessibility of

the measurement/function.

A horizontal solid line indicates that the measurement / function are directly accessible to an operator in the central control system.

A double horizontal solid line indicates that the measurement/function is accessible at a sub control system.

In case of a simultaneous indication in the central control system and on a sub control system, a circle with a horizontal solid line is added. For example, a subset of signals from a hot gas generator (typically interface signals only) will be shown in the central control system.

A horizontal dashed line indicates that the measurement/function is not directly accessible to an operator. Often there is no physical signal, but, for example, an internal calculation.

Circles without a horizontal line mean that the measurement is indicated locally only. For example, a pressure gauge. Such circles are normally not used on a flow diagram.

It is noteworthy that the ISA-standard specifies different symbols depending

on the control system employed, however, only the circles shown above are

used. Unless otherwise specified, the use of symbols for discrete indication

will be used.



5.2 Instrumentation Level

The level of instrumentation shown on the flow diagram is limited to show

instrumentation and control loops in the field. Signals from switchgears etc. are not

shown on flow diagram.

Complex equipment, forming a sub system, such as heat generators, hydraulic

drives, lubrication stations etc. are symbolized by a solid line box. All devices

contained within the line box are designated according to the equipment number

and the number of instrumentation circles is limited to show interface signals only.

Normally, primary elements for measurements are not shown on flow diagram. In

instances where enhancement of the level of clarity is needed, primary elements

will be shown.

For example, the noise microphone on a ball mill.

5.3 Instrument lines

The following instrument lines are used in connection with the circles:

1) From process to circle and mechanical connection.

2) Electrical connection.

5.4 Code for types of measurement and function

In the upper half of each circle there are a number of letters indicating the type of

measurement (pressure, temperature, etc.) and the function (indication, alarm,

etc.).For explanatory key to letters, see section 8. If the number of letters

required to describe a measurement exceeds 6, two (or more) circles abutting one

another will be used or they are inter-connected by a solid line. The signal code of

the measuring point is indicated only in the lower half of the first circle.

5.5 Control loops

When a measurement is used in a control loop, the controlling part (the controller)

is indicated by an independent circle. This circle normally abuts the circle for the

measuring point. From the controller circle there is a dashed line, with an arrow

pointing at the unit to be controlled.



5.6 Examples

TIN01T01

Temperature, Indication

(Temperature read on indicator, or screen display)

TRN01T01

Temperature, Recording

(Temperature recorded on recorder, or screen display)

TAHD01T41

Temperature, Alarm, High

TALHN01T01

Temperature, Alarm, Low, High

IIM01I01

Current, Indication

(E.g. current measurement on motor for belt conveyor)

LALD01L41

Level, Alarm, Low (E.g. in oil tank)

TR

N01T01

TC

Temperature, Controller,

(In connection with a temperature measurement)

541BC01

IIM01I01

Current, Indication

The associated equipment No. precedes the circle if the equipment No. is not already defined on the flow diagram.

6 off

TIN01T01

Temperature, Indication

The designation "6 off" indicates that there are 6 identical units, with unit numbers from N01 to N06.



6 List of equipment codes The equipment code is character number 4 and 5.

The term - General - behind an equipment name means that this list also contains

more specific types of the same kind of equipment, see below.

The General equipment name is only used, if there is no specific name for the

equipment.

To avoid any confusion in interpretations of the number "0" and the letter "O", the

letter "O” will not be used for coding.

Electrical measuring equipment such as level indicators, load cells, belt scales,

metal detectors etc. will not have an equipment number, but a unit code + a

sequence number.

The electrical measurement equipment may where appropriate be shown on the flow

diagram as a symbol.

Code Designation

AC Apron conveyor AD Auxiliary drive AE Aeration system for bins/silos AF Apron feeder AG Agitator AL Air lift / pneumatic elevator AM Gas analyser Dust Analyser AN Neutron analyser XR - X-Ray Analyser AR Air receiver AS Air slide / Fluxoslide AT Aerated material trap AU Air conditioning unit AV Alleviator AW Apron Weigh feeder

BA Bin activator BB Barge BC Belt conveyor BD Bag deflector BE Bucket elevator BF Bag filter / fabric filter BI Bin / hopper



BK Bulk loading device / Fluxo filling BL Blower / rotary blower BM Ball mill / tube mill BN Bag cleaner BQ Blasting equipment / shock-blaster BR Boiler BU Burner BV Butterfly valve / shut-off valve BX Bin extractor

CA Crane CB Cables CC Clinker cooler CE Combustion engine CG Centrifuge CH Chute / hopper - General FB - Feed Bin FY - Feed Hopper CI Calciner CK Plant clock System equipment CL Cooler - General CC - Clinker cooler CQ - Cement cooler EC - Evaporation cooler GQ - Grate cooler RK - Rotary cooler CM Cable installation material CN Cyclone CP Compressor CQ Cement cooler CR Crusher - General DC - Drier crusher GC - Gyratory crusher HC - Hammer crusher IM - Impact crusher JC - Jaw crusher MQ - Mobile crusher RB - Roller breaker RC - Roller crusher CS Control System equipment CT Conditioning tower CU Communication equipment CV Chain conveyor

DA Damper -General DV - Disc Valve FV - Flap Valve / Tipping Valve LD - Louvre Damper FG - Flow Control Gate



SD - Shut-off Damper TV - Throttle Valve

DB Deep-bucket conveyor DC Drier crusher DE Dedusting equipment - General BF - Bag filter EP - Electrostatic precipitator GF - Gravel bed filter DG Distribution-, Dividing-, Splitter-, Bottom-, Change over-gate DI Air distributor DM Dome DQ Dosing equipment - General FG - Flow control gate FM - Flowmeter for bulk material WF - Weigh belt feeder DR Drier DU Ducting DV Disc valve

EC Evaporation cooler EE Electronic ear / Folaphone EG Emergency diesel-generator GE - Generator with internal combustion engine EH Electric hoist EI Electrical Installation equipment EJ Expansion joint EL Elevator (person / goods) EP Electrostatic precipitator ER Electric room ES Expert Control equipment EV Explosion vent EW Extraction wheel EX Explosion gate

FA Flowmeter for gas FB Feed bin FC Field control equipment FD Feeder - General AF - Apron Feeder FW - Wobbler feeder KF - Kiln Feeder RF - Rotary feeder / Air sluice TF - Table feeder SF - Screw feeder VF - Vibrating feeder WF - Weigh belt feeder FE Fire extinguisher FF Fuel filter



FG Flow Control Gate FH Fuel heater FI Fire protection equipment - General FE - Fire Extinguisher FM Flow-meter for Bulk Material FN Fan FP Fuel pump FS Filter cake press FT Fuel tank FU Filter (air, oil, water) FV Flap valve / tipping valve FW Wobbler feeder FY Feed hopper

GA Gate - General DG – Distribution-,Dividing-,Splitter-,Bottom-,Change over gate FG - Flow control gate NG - Needle gate PG - Proportioning gate RG - Rod gate SE - Sector gate SG - Shut-off gate GC Gyrator crusher GE Generator with internal combustion engine GF Gravel bed filter GM Grinding medium GN Grounding equipment GP Gas pump GQ Grate cooler GR Grinding aid system GS Grease system GX Gunnax

HC Hammer crusher HD Hydraulic drive HE Heat exchanger HG Hot gas generator / heat generator HI Hoist HP Hopper - General FY - Feed hopper HR Hot disc reactor HT Hydraulic thrust unit / hydraulic jack HV High Voltage system HY Hydraulic system

IG Industrial gun IJ Injection system IM Impact crusher IN Insulation IP Instrumentation equipment



IS Inlet seal IT Injector tee

JC Jaw crusher JB Junction box / mixing vessel

KB Kiln Base KF Kiln feeder KH Kiln Hood KL Kiln KR Kiln riser KS Kiln scanner equipment

LB Lump breaker LD Louvre damper LG Lighting System LM Loading machine LN Lightning equipment LQ Lubrication equipment LS Load spout LV Low Voltage equipment MC Multi cyclone MD Main drive MI Management Information system ML Mill - General BM - Ball mill RM - Roller mill MM Moisting and mixing machine MQ Mobile crusher MS Magnetic separator / Magnet MV Medium Voltage equipment MW Material deflector MX Mixer - General PW - Paddle wheel SB - Silo blending equipment

NG Needle gate NR Noise reducer / silencer

PA Palletizer

PB Pneumatic rock breaker PC Pneumatic conveyor PD Power distribution / distribution boards PE Pelletizer PG Proportioning gate PH Pre-heater PI Piping PL Pipeline PM Packing machine PN Pneumatic hammer PP Pneumatic pump / screw pump



PQ Pressurising equipment (El.Rooms) PR Pre-calciner PT Pneumatic transport by pressure vessel PU Pump - General

FP - Fuel pump GP - Gas pump PP - Pneumatic pump SJ - Sump pump SP - Slurry pump WP - Water pump

PW Paddle wheel

QC QCX system / Chemical control

RB Roller breaker RC Roller crusher RE Reclaimer - General RF Rotary feeder / air sluice RG Rod gate RI Rotary indicator RK Rotary cooler RL Rotary Scale RM Roller mill / vertical mill RS Rotary screen RT Lining, refractory RP Roller press

SA Slurry agitator SB Silo blending equipment SC Screw conveyor SD Shut-off-, Hoisting- or slide- damper SE Sector gate SF Screw feeder SG Shut-off gate SH Ship SI Silo SJ Sump pump SK Stack SL Scale - General SM Sampler SN Screen - General RS - Rotary screen VS - Vibrating screen SP Slurry pump SQ Silo discharge equipment SR Separator SS Steel structures (for maintenance) ST Stacker - General SU Sluice - General FV - Flap valve RF - Rotary feeder / air sluice SV Steam boiler



SX Spillage conveyor SY Scrubber SZ Sizer for mill balls

TA Transformer TC Telescopic chute TE Television equipment TF Table feeder TH Thruster TI Tipper TK Tank TR Tripper TV Throttle valve

UP Un-interruptible power supply, UPS US Outlet seal

VA Valve - General BV - Butterfly Valve DV - Disc valve FV - Flap valve / Tipping Valve TV - Throttle valve VB - Non-return valve VM - Valve Motorised VV - Valve 2 or 3-way VX - Valve - Magnetically operated VB Non-return valve VC Vibrating conveyor VE Ventury VF Vibrating feeder VI Vibrator VL Vacuum filter for slurry VM Valve, Motorised VN Vacuum cleaner VR Valve rack VS Vibrating screen VV Valve, 2 or 3-way VU Ventilation unit VX Valve, Magnetically operated

WB Weigh bridge WC After-cooler WF Weigh belt feeder WI Water injection WP Water pump WS Micromist lubricator WT Water treatment installation

XA Auxiliary equipment CH - Chutes



- Foundation bolts - Heat shields - Bypass mixing chamber

- Pipes, gas - Pipes, water - Pipes, compressed air - Pipes, oil - Pipes IN - Insulation - Tools - Supports - Platforms - Quarry equipment EJ - Expansion joints RT - Lining, Refractory

- Container XC Compressor system XF Fuel system XG General services (Turn key) Laboratory Furniture Work shop Main store Service buildings XK Kiln Feed XM Mechanical accessories - Lubricants - Hydraulic oil - Guards - Shims - Repair paint - Welding materials - Bolts - Safety signs

- Auxiliary steel XR X-ray Analyser XS Scrubber system XW Water system



7 Table of unit codes

The unit code is character number 9

Meaning Example

A Assembled units Sub control systems, local control panels

B Sensor / Transducers Primary elements such as: Pt100, tacho-generator and load cells

C Capacitors

D Binary elements Motion detectors, prx.sw., relay parts, micro switches, press. sw.

E Miscellaneous Heating element/lighting

F Protective units Fuses and similar parts

G Generator Emergency generator, ups

H Signal equipment Siren for start warning, lamp

I Internal Internal points in control

K Relay/contactor

L Reactor

M Motor

N Transmitters Pressure and temperature

O Free

P Measuring/test Instrument/recorder

Q Power switch

R Resistor Starter for SR-motor

S Switch, manually Wire stop, emergency stop

T Transformer

U Modulator Frequency converter and thyristor drive

V Semi-conductor

W Transmission unit Busbar

X Terminal Y Electrically-operated

actuators Motor operated dampers and solenoid valves

Z Adapting equipment Coaxial connection



8 Signal identification letters The signal identification letter is character number 12.

Meaning of letters in signals concerning type and function of measurements

First letter Following letters type of measurement addition reading

function

output

function

addition

A Analysis

(%O2, %CO, %CO2, dust, etc.)

alarm

B Flame control

C Motor/ Device control controller

D Free differential

E Voltage (V) prim. element

F Flow (t/h, m3/h etc.) ratio

G

H Manual operation high

I Current (A) indication

J Power (kW)

K Time (s)

L Level (%, m) indication low

M Metal detection mean

N Folaphone, noise

O Free

P Pressure

(kp/cm2, bar, mm H2O)

Q Quantity (m3, t, number)

summation

R Radiation recording

S Speed (m/s, r/min) safety switch

T Temperature (°C) transmitter

U Multi-variable multi-function

V Vibration valve, damper

W Weight (t), force

X Miscellaneous

Y Event calculation

Z Position (%) controller



9 Signal type

The signal type is character number 13. The type of signal for the relevant measurement conforms to the table below.

13th Character Signal Type

0 Analogue Input - any analogue Input Signal

1 Set point signal

2 Analogue Output

3 Digital Output, any digital output & ref.

4 Digital Input, e.g. motor ready & ref. section

5 Digital Input resulting from local operator

intervention

(e.g. local start, ref. section 10)

6 Digital Input confirming an action commanded by the control system (e.g. motor running ref. section 10)

7 Digital Input - any digital input & ref. section

8 Digital Input - any digital input

9 Free



10 Signal code for motor control

The signal code is character number 12 to 14.

Meaning Signal code Notes

Command 1 (forward or open) C31 1, 2

Command 2 (reverse or close) C32 2

Motor ready C41 1, 2

Local start 1 (forward or open) C51 1, 2

Local start 2 (reverse or close) C52 2

Return signal 1 (forward or open) C61 1, 2

Return signal 2 (reverse or close) C62 2

Notes:

1) minimum requirements of simple motor starter 2) minimum requirements of reversible motor starter

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Flow Diagram - نگهداری و تعمیرات بهره ......Flow Diagram, Equipment identification numbering system 39971-02-2.1 The information transmitted by this document is