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Pebble Lime Kiln Preheater

Systems Seminar
Control System Description
Evolution Of Controls
Preheater Lime Kiln

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Evolution of Preheater lime Plant Control

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Developing Your Controls
Instrumentation & Controls

• Control System Design


- Process & Instrumentation Diagrams
• Control Loops, PID Control
• Instrumentation

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Control System Description
ISA Instrument Identification Name Chart

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Control System Description
ISA Instrument Identification Symbols

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Control System Description
ISA Instrument Identification Symbols

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Control System Description
Overview

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Control System Description Link To Drawing
Stack O2/CO Analyzer

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Control System Description Link To Drawing
Stone Bin and Preheater Exhaust

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Control System Description
Preheater Even Modules

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Control System Description
Preheater Odd Modules

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Control System Description
Hydraulic Power Unit

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Control System Description
Kiln, Drawing

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Control System Description
Cooler

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Control System Description
Cooler Discharge

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Graphics - Overview

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Graphics - Baghouse

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Graphics - Preheater Control

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Graphics - Kiln

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Graphics - Cooler

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Graphics - Burner

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Control System Description
KILN #1 PID STATUS and PID CONTOLLER

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Control System Description
Motor Control

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Controls Explanation
Instrumentation & Controls

• Control System Design


- Process & Instrumentation Diagrams
• Control Loops, PID Control
• Instrumentation

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What Is A Loop? What Is A PID?

• A loop is an automatic controller to help the process and operators


• A PID is a type of loop controller that has been accepted as the
industry standard for decades.
• The original loop was the governor on a steam engine, 1919

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Explain PID

• P – Proportional (Gain)
• I – Integral
• D – Derivative

The output of PID controllers will change in response to a change in


measurement or set-point.
Proportional Control produces the control output proportional to the current error. Although P-controller provides
stability of the process variable with good speed of response, there will always be an error between the set
point and actual process variable.
Integral Control integrates the error term over a period of time until the error becomes zero. Typically Integral is
never used alone, PI is the most common control.
Derivative Control sees how fast process variable changes per unit of time and produce the output proportional
to the rate of change. The derivative output is equal to the rate of change of error multiplied by a derivative
constant. The D-controller is used when the processor variable starts to change at a high rate of speed.

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Trended Loop

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PID Tuning

• Settings
- Forward / Reverse
- PID Settings
- Options
• PV Tracking
• Cascade
• Bias
• Get The Right Parameters
- Software
- Experience
- Luck

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Instruments
Instrumentation & Controls

• Control System Design


- Process & Instrumentation Diagrams
• Control Loops, PID Control
• Instrumentation

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Instruments

• Use Instruments For The Environment


- Nema4/4x, Watertight
• Use Name Brand
- Rosemount, Allen Bradley, Endress Hauser, IFM, etc.
• Use “Smart” Devices – If Needed
- Programmable, Communication, Self Diagnostics
• Use “Networked” Devices
- DeviceNet, EthernetIP, Wireless

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Instruments

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Instruments - Microwave Cooler Level Sensor

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Instruments - Cooler Air Flow Measurement

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Instruments Kiln Exit Temperature

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Instruments - Firing Hood Temp Thermocouple

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Instruments - Preheater Outlet Temp Odd &
Even

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Instruments - Preheater Module Temperature

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Instruments - Preheater Inlet Thermocouple

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Instruments - Baghouse Tempering Damper

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Instruments - Cooler Feeders

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Instruments - Cooler Feeder Vibration

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Instruments - Inward and Outward T/Cs

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Instruments - Stack CO and O2 Analyzer

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Instruments - Stack CO and O2 Analyzer

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Instruments - Stack CO and O2 Analyzer

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