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

MILLING

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

Field control station ( FCS )

INPUT/OUTPUT MODULES

CPU

POWER SUPPLY

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/Os

2596

Voltage input used

200

Current Output used

26

Status input used

- 1545

Status output used

- 680

Thermocouple input

RTD / POT 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 )

KILN DATA (CS 3000)

Data
Kiln inlet temperature

Tag name
41TI01A

Kiln inlet pressure

41PI01

Kiln inlet NOX

41QI01

Kiln inlet O2

41QI02

Kiln inlet CO

41QI03

Kiln Temperatures

44TI01-44TI22

Contd
Data

Tag name

Kiln rotary motor

44KL01

Kiln rotary speed

44SIK01

Kiln rotary current

44IIKL01

Kiln rotary power

44JIKL01

Kiln rotary lubrication pump

44LU01 & 44LU02

Kiln shell cooling blowers

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

Study about DCS

February- phase I

Practical study of DCS

February- phase II

Collecting information
about cement
manufacturing process

March- phase I

Implement DCS in cement

Manufacturing process

March- phase II

Project compilation

April

Project submission

Thank U