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
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Application of DCS in Cement Manufacturing Process
FINAL YEAR PROJECT – APPLICATION OF DCS IN CEMENT MANUFACTURING PROCESS Main objective of our project is to control the overall function of cement manufacturing plant using a single control desk. The project is aimed at controlling various parameters involved in a cement manufacturing Process Industry, using DCS (CS3000 of the centum series – a proprietary product of YOKOGAWA). DCS is used because of its increased flexibility, redundancy and high performance capability. DCS ensures accurate process condition and this in turn means better plant performance
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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 )
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