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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.
PREHEATER
COOLER
GRINDING
CEMENT STORAGE
CLINKER STORAGE
KILN
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
CPU
POWER SUPPLY
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
- 14
2596
200
26
- 1545
- 680
Thermocouple input
- 105
40
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
Kiln inlet O2
41QI02
Kiln inlet CO
41QI03
Kiln Temperatures
44TI01-44TI22
Contd
Data
Tag name
44KL01
44SIK01
44IIKL01
44JIKL01
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%.
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
Collecting information
about cement
manufacturing process
March- phase I
March- phase II
Project compilation
April
Project submission
Thank U