APPLICATION OF DISTRIBUTED CONTROL SYSTEM IN CEMENT MANUFACTURING PROCESS

INDUSTRIAL TRAINING PROJECT

WORKING SYSTEM IS
DCS ABB-800XA

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.

Overall Cement manufacturing process

PREHEATER MILLING COOLER GRINDING CEMENT STORAGE

CLINKER STORAGE KILN

BLENDING SILO

CRUSHING

OBJECTIVE
Main objective of our project is to control the basic process block of cement manufacturing plant using a single control desk using DCS (ABB-800 XA system) version 5.0.2 SP2.800 XA Limestone crusher and transportation to stocker Raw mill Coal mill Baghouse auxalliries Field transducers Central control room

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

DCS ABB-800XA SYSTEM ARCHITECTURE

DCS ABB-800XA SYSTEM OVERVIEW

ABB-DCS 800 XA Automation system, Version 5.0.2. SP2 .800XA Installed at BJCL is the extended version of ABB which consist the AC800M control module, Aspect and connectivity server, Engineering station, Operating Stations.

AC 800M is a family of rail-mounted modules, consisting of:-

Power Supply CPU-PM864A Communication Module-Profibus (CI854A) and Modbus (CI853). Remote Units-Digital Input Card(DI810),Digital Output Card(DO810),Analog Input Card(AI 810),Analog Output Card(AO810)

Contd

ABB 800XA network is divided into three parts 1. Field Network

Field network consist the data transmission from the field instrument to remote IOs as well as from remote IOs to Controller. Fibre optics communication is major mode of communication for field network. 2. Control Network Control network is basically a communication between controllers and Connectivity server; we use Ethernet cable as a communication media. We are having two connectivity servers and two control network to provide redundant system.

3. Plant Network Plant Network is basically a Domain controlled network where domain definitions are defined in Aspect server and all plant system are connected to this. We are using two Aspect servers to provide redundancy to the process. The plant operation is monitored & controlled in automatic mode by operators from central control room (CCR). There are four operating stations works on high speed Ethernet network and with levels of permission to operate any section of plant from any one of the operator stations

Cont.
Five nos. Process controllers (PM864A), which are located in the CCR. The remote IO panels are located adjacent to MCC room in Load centres.

All motor feeders in the MCC/Drives /Sub control system can be selected in local, Central and Seq. mode. In local mode basically testing of drive from the field is carried out after taking permission from the operator. In central mode drive can be started individually from CCR and also in seq mode as per group sequential interlocks and all sequential interlocks are as per process requirement.
The process, machine safety and upstream/downstream sequential interlocks are applied to the machines as per the Block Interlocking diagram which is supplied from machinery supplier.

The processors of Process controller are having self-diagnostics features to ensure healthy working all times, if any fault and process stop warning appears; it gives advance warning in form of alarm and is audio visual.

800XA software along with controller is having following features: Totalizer, Ratio controlling, PID controlling multi variable control etc. These are the some examples of PID controlling: Cooler fans speed control V/S Fan flow PC firing feed control V/S Cyclone top temperature. Cooler ID fan Speed V/S Kiln Hood Draft Operation of L/S stacker and reclaimer is interfaced through radio link to 800XA and stacking and reclaiming operation are controlled in automatic mode for better blending.

Programmable Controller(PC)
System run by programmable controller works in much a same way : Input sensing devices report machine conditions Output devices respond to commands. Wiring between the machine & the controller provides electric paths from the sensing devices to the controller and from the controller to the output devices

THE FOUR MAJOR SECTIONS IN PROCESS

CONTROLLER:Processor (PM864) Communication Card-Profibus and Modbus Power Supply

Communication Card-Profibus and Modbus

Contd.
PROFIBUS:Profibus is a type of field bus through which remote Input/output as well as Field bus transmitters are connected.

PROFIBUS DP (Decentralized Peripherals) is used to

operate sensors and actuators via a centralized controller in production (factory) automation applications

PROFIBUS PA (Process Automation) is used to monitor

measuring equipment via a process control system in process automation applications PA has a data transmission rate of 31.25 kbit/s.

MODBUS
Modbus is serial link communication to communicate to energy measuring device An open data communication protocol Supplied by many SCADA and HMI software 2 serial transmission modes: ASCII 10 bits RTU (Binary) 11 bits Communication interface RS-232/485 Ethernet (TCP/IP)

SCADA :
Through the help of SCADA the operation of Plant is executed and this is configured with the help of Functional Structure

ALARM AND EVENT COLLECTOR

800 XA SYSTEMS HAS THE PROVISION TO STORE ALARM AND EVENT OF THE PLANT OPERATION

TRENDS ANALYSIS THROUGH DCS

We can plot the trend of Analog process variables and keep its record for 3 months

PROGRAMMING TECHNIQUES

Functional Block Diagram Ladder logic Structured Text Logic

Logic chart for kiln rotary motor

Function block diagram for kiln speed ctrl

Kiln Graphic 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.

Thank U