1. APPLICATION OF DISTRIBUTED CONTROL SYSTEM IN CEMENT MANUFACTURING PROCESS FINAL YEAR PROJECT ( FINAL REVIEW)
Group members
J.Antony Arun ( )
A.HariVignesh ( )
R.Mohana subramani ( )
EB-1
Internal guide : Mr.K.Subadeepan ( AP1 / ICE)
External guide: Mrs.S.Sushma (Assistant Manager / Trainee)
YOKOGAWA INDIA LTD.,BANGALORE

2. 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.

3. Cement manufacturing process

4. Contd…….

5. Contd…….

6. Overall Cement manufacturing process
MILLING
PREHEATER
COOLER
GRINDING
CEMENT STORAGE
CLINKER STORAGE
KILN
BLENDING SILO
CRUSHING

7. 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).

8. DCS Overview

9. Field control station ( FCS )
INPUT/OUTPUT MODULES
CPU
POWER SUPPLY

10. 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

11. COMMUNICATION BUS
For redundancy, L2switch is used

12. PROGRAMMING IN DCS In Yokogawa CS3000, we are using Function block
technique for programming

13. INTERLOCKS Three types of interlocks are used Sequence Table
Logic Chart
Calcu Block

14. Contd…

15. 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)

16. TUNING WINDOW

17. Control group

18. Trend window

19. Graphic builder

20. Contd…

21. 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

22. PLANT DATA
Total number of process - 14 Total number of I/O’s Voltage input used Current Output used - 26 Status input used Status output used Thermocouple input - 40 RTD / POT input - 105

23. 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

24. 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 )

25. KILN DATA (CS 3000) Data Tag name
41TI01A 41PI01 41QI01 41QI02 41QI03 44TI01-44TI22
Kiln inlet temperature Kiln inlet pressure Kiln inlet NOX Kiln inlet O2 Kiln inlet CO Kiln Temperatures

26. 44KL01 44SIK01 44IIKL01 44JIKL01 44LU01 & 44LU02 44BL01-44BL15
Contd…
Data
Tag name
Kiln rotary motor Kiln rotary speed Kiln rotary current Kiln rotary power Kiln rotary lubrication pump Kiln shell cooling blowers
44KL01 44SIK01 44IIKL01 44JIKL01 44LU01 & 44LU02 44BL01-44BL15

27. Function block diagram for kiln rotary motor

28. Logic chart for kiln rotary motor

29. Logic chart for kiln rotary motor

30. Function block diagram for kiln speed ctrl

31. Function block diagram for lubrication pump

32. Logic chart for lubrication pump

33. Function block diagram for simple open loops

34. Function block diagram for simple open loops

35. Function block diagram for simple open loops

36. Function block diagram for kiln blowers

37. Function block diagram for kiln blowers

38. Function block diagram for kiln blowers

39. Function block diagram for kiln blowers

40. Logic chart for kiln blowers

41. Logic chart for kiln blowers

42. Kiln Graphic window

43. Controller tuning window

44. 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.

45. 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.

46. 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 . .

47. 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

48. Thank U