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Group members J.Antony Arun (9908007008) A.HariVignesh (9908007025) R.Mohana subramani (9908007047) EB-1
Internal guide : Mr.K.Subadeepan ( AP1 / ICE)
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.
Contd.
Contd.
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
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
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
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 Total number of I/Os - 14 2596
200
26
- 1545 - 680 40
- 105
DCS configuration
DCS configuration mainly depends on total number of I/Os and speed of the process We should use minimum of 20% spare philosophy with the total number of I/Os
KILN
In this process, powdered form of preheated blended raw material is introduced as input Heating the raw mix to sintering temperature ( up to 1450C )
Tag name
41TI01A
41PI01
41QI01 41QI02 41QI03 44TI01-44TI22
Contd
Data
Kiln rotary motor Kiln rotary speed
Tag name
44KL01 44SIK01
44IIKL01
44JIKL01 44LU01 & 44LU02 44BL01-44BL15
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 Study about DCS Practical study of DCS Collecting information about cement manufacturing process
March- phase I
Thank U