Application of DCS in Cement Manufacturing Process

APPLICATION OF DISTRIBUTED CONTROL SYSTEM IN 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 MILLING

PREHEATER

COOLER GRINDING CEMENT STORAGE

CLINKER STORAGE KILN

BLENDING SILO

CRUSHING

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 ) INPUT/OUTPUT MODULES

CPU

POWER SUPPLY

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

-

RTD / POT input

- 105

40

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

Tag name 41TI01A

Kiln inlet pressure

41PI01

Kiln inlet NOX

41QI01

Kiln inlet O2

41QI02

Kiln inlet CO

41QI03

Kiln Temperatures

44TI01-44TI22

Contd… Data

Tag name

Kiln rotary motor

44KL01

Kiln rotary speed

44SIK01

Kiln rotary current

44IIKL01

Kiln rotary power

44JIKL01

Kiln rotary lubrication pump

44LU01 & 44LU02

Kiln shell cooling blowers

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

Study about DCS

 February- phase I

Practical study of DCS

 February- phase II

Collecting information about cement manufacturing process

 March- phase I

Implement DCS in cement Manufacturing process

 March- phase II

Project compilation

 April

Project submission

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