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Application of DCS in Cement Manufacturing Process
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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
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 SUPPLY CPU INPUT/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
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