APPLICATION OF DISTRIBUTED CONTROL SYSTEMIN CEMENT MANUFACTURING PROCESS

FINAL YEAR PROJECT ( FINAL REVIEW)

Group members

J.Antony Arun (9908007008)

A.HariVignesh (9908007025)

R.Mohana subramani (9908007047)

EB-1

Internal guide : Mr.K.Subadeepan ( AP1 / ICE)

External guide: Mrs.S.Sushma (Assistant Manager / Trainee) YOKOGAWA INDIA LTD.,BANGALORE

ABSTRACT

In modern days, infrastructure plays a vital role, so high efficiency in cement manufacturing is required.

Computer based automation is the best technique for the above function.

The controlling is done best using the Distributed control system concept.

DCS is faster, reliable and has many helpful features to its credit.

It enables you to manage the process as a complete system, with control over the interrelationship of the various subsystems.

Cement manufacturing process

Contd…….

Contd…….

Overall Cement manufacturing process

CRUSHING

GRINDING

BLENDING SILO

PREHEATER

KILN

COOLER

CLINKER STORAGE

MILLING

CEMENT STORAGE

OBJECTIVE

Main objective of our project is to control the KILN of cement manufacturing plant using a single control desk.

The project is aimed at controlling various parameters involved in a kiln of cement manufacturing Process Industry, using DCS (CS3000 of the centum series – a proprietary product of YOKOGAWA).

DCS Overview

Field control station ( FCS )

POWER SUPPLYCPUINPUT/OUTPUT MODULES

Human interface station ( HIS )

HIS is mainly used for operation and monitoring purposes

It displays process variables, control parameters, and alarms

Users can quickly grasp the operating status of the plant

COMMUNICATION BUS

For redundancy, L2switch is used

PROGRAMMING IN DCS

In Yokogawa CS3000, we are using Function block

technique for programming

INTERLOCKS

Three types of interlocks are used

Sequence Table

Logic Chart

Calcu Block

Contd…

Operation and monitoring windows

There are two types of Operation and monitoring windows

provided by the HIS.

System Windows

(i.e, System Message Window, Instrument Faceplate Window, Tuning Window, Process Report Window, Historical Report Window, Navigator Window, System Alarm Window, Process Alarm Window)

User-defined Windows

(i.e, Control Group Window, Trend Window, Graphic Window, Overview Window)

TUNING WINDOW

Control group

Trend window

Graphic builder

Contd…

DCS in cement manufacturing process

Safe operation of plant

Increased flexibility

Redundancy & High performance capability

Improved accessibility of plant data to engineering &

management personals

Historical storage and retrieval system

PLANT DATA

Total number of process - 14

Total number of I/O’s - 2596

Voltage input used - 200

Current Output used - 26

Status input used - 1545

Status output used - 680

Thermocouple input - 40

RTD / POT input - 105

DCS configuration

DCS configuration mainly depends on total number of

I/O’s and speed of the process

We should use minimum of 20% spare philosophy with

the total number of I/O’s

KILN

In this process, powdered form of preheated blended raw material is introduced as input

Heating the raw mix to sintering temperature ( up to 1450°C )

KILN DATA (CS 3000)

Data

Kiln inlet temperature

Kiln inlet pressure

Kiln inlet NOX

Kiln inlet O2

Kiln inlet CO

Kiln Temperatures

Tag name

41TI01A

41PI01

41QI01

41QI02

41QI03

44TI01-44TI22

Contd…

Data

Kiln rotary motor

Kiln rotary speed

Kiln rotary current

Kiln rotary power

Kiln rotary lubrication pump

Kiln shell cooling blowers

Tag name

44KL01

44SIK01

44IIKL01

44JIKL01

44LU01 & 44LU02

44BL01-44BL15

Function block diagram for kiln rotary motor

Logic chart for kiln rotary motor

Logic chart for kiln rotary motor

Function block diagram for kiln speed ctrl

Function block diagram for lubrication pump

Logic chart for lubrication pump

Function block diagram for simple open loops

Function block diagram for simple open loops

Function block diagram for simple open loops

Function block diagram for kiln blowers

Function block diagram for kiln blowers

Function block diagram for kiln blowers

Function block diagram for kiln blowers

Logic chart for kiln blowers

Logic chart for kiln blowers

Kiln Graphic window

Controller tuning window

CONCLUSION

The DCS with its prominent advantages over conventional systems has become indispensable equipment in the field of industrial automation. It has enhanced plant safety and also user friendliness in operation thereby reducing human errors. Due to these reasons the production rate has increased around 20%.

The controlling of cement manufacturing plant critical parameters using DCS thus has led to achievement of greater output at the rate of standard cost.

REFERENCE

D. M. STEELMAN, “Distributed cememt plant control The intelligent approach” IEEE transactions on industry applicatlons, vol. ia 8, no. 2, niarch/april 1982.

TIM WALKER, PROJECT MANAGER, “An open DCS solution for cement process control” Control systems international,Inc Prepared for the 1996 IEEE/PCA cement industry committee, 38th Annual Technical Conference.

MOIN SHAIKH, “Cementing the relationship between DCS and PLC “A review of emerging trends in plant control systems” , Siemens Energy & Automation, lnc.

Chemical engineering department “Distributed control system”, KING SAUD UNIVERSITY ,2002.

Contd…

YOKOGAWA CS-3000 R3 Engineering manual . Process Control Systems, by F.G. SHINSKEY . Fundamentals Of Industrial Instrumentation & Process

Control, by WILLIAM C. DUNN . Chemical Process Control , by GEORGE

STEPHANOPOULOS. Industrial Instrumentation, by K. KRISHNAMURTHY

, S.VIJAYACHITRA, K.KRISHNASWAMY . www.yokogawa.co.in . www.wikipedia.com.

Work plan

January

February- phase I

February- phase II

March- phase I

March- phase II

April

Study about DCS

Practical study of DCS

Collecting information

about cement

manufacturing process

Implement DCS in cement

Manufacturing process

Project compilation

Project submission

Thank U