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DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING

DISTRIBUTED CONTROL SYSTEM APPLICATION IN CEMENT INDUSTRY


GUIDE Dr. U Ramachandraiah, M, Tech, MBA, PhD. Professor BY Electronics & Instrumentation Department S.VIJAY KUMAR - 0001236002 School of Electrical Sciences Hindustan Institute of Technology and Science, Hindustan University, Padur, Chennai.603 103 Cell No.9884195179

BASIC OF DCS
DCS (Distributed Control System) is a computerized control system used to control the production line in the industry. Why DCS System is required? While a product (Food, medicine, Oil..etc) passing through many stages in the factory before it reaches it's final so the product can be sold out, during those stages it requires a kind of control in order to adjust the quality of it. However, to adjust the quality it is required to control many physical quantities such as pressure, Temperature..etc. Further more, in some dangerous applications such as petrochemical factories and nuclear reactors the control will much critical, However, losing the control may lead to an explosion of the plant. What does DCS System consists of? DCS System consists minimum of the following components. 1. Field Control station (FCS): It consists of input/output modules, CPU and communication bus. 2. Operator station: It is basically human interface machine with monitor, the operator man can view the process in the plant and check if any alarm is presents and he can change any setting, print reports..etc. 3. Engineering station: It is used to configure all input & output and drawing and any things required to be monitored on Operator station

GENERAL BLOCK DIAGRAM

Process Automation structure:

Control and information structure

Level 0- It can be treated as the elementary field devices and sensors


which represent the state of the process. These can typically be switches indicating the position of the dampers, gates or temperature values of the gases, etc. Level 1-It can be treated as the nodes collecting the above mentioned field information, grouping the minto related areas and taking logical actions based on this information. This is traditionally based on input / output (I/O) cards, the processor (CPU) and the basic visualization displays like the operator stations (OS), CCTV systems etc. Level 2-It is a combination of more involved process operations related to Human Machine Interfaces(HMIs) which are typically the more advanced operator stations, remote clients, reporting packages , interfaces to process model based controls etc. Level 3-It is the Management Execution Systems (MES) level where the systems will support decision making for optimizing the operations integrating the information from quality systems and also taking into consideration the constraints in plant capacity, raw material availability and economic parameters. Level 4-It is considered as the Enterprise Resource Planning (ERP) level involving business and financial decision making systems. These systems can be seamlessly integrated with the abovementioned plant process control levels by the use OF ERP connectors.

MODEL PLANT INFO

BLOCK DIAGRAM

RAW MATERIAL
The fundamental chemical compounds to produce cement clinker are: Lime (CaO) Silica (SiO2) Alumina (Al2O3) Iron Oxide (Fe2O3)

TEMENT MANUFACTURING PROCESS


THE CEMENT MANUFACTURING PROCESS

quarry

dumper loader

Quarry face

1. BLASTING

2. TRANSPORT

crushing conveyor

storage at the plant

3. CRUSHING & TRANSPORTATION


1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted from the quarry. 2. TRANSPORT : The raw materials are loaded into a dumper. 3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are transported to the plant by conveyor. The plant stores the materials before they are homogenized.

storage at the plant conveyor

Raw mill Raw mix

preheating

1. RAW GRINDING

kiln cooling clinker

2. BURNING
1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix. 2. BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can be as hot as 2000 C. The raw mix burns at 1500 C producing clinker which, when it leaves the kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to make cement.

THESS

Grinding, storage, packing, dispatch


Gypsum and the secondary additives are added to the clinker. clinker storage

Finish grinding

silos

1. GRINDING

dispatch bags

2. STORAGE, PACKING, DISPATCH


1.GRINDING : The clinker and the gypsum are very finely ground giving a pure cement. Other secondary additives and cementitious materials can also be added to make a blended cement. 2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in bulk or in bags to its final destination.

Communication networks
Communication networks provide ability to connect the managing and the managed, communicate with each other among the engineer station, operator stations and process stations, the communication networks is partitioned into two layers-system networks and networks. System networks complete the communication functions among the engineer station, operator station and the controller of the process communication protocol station. of this layer is TCP/IP. Every unit in this network has address. The medium of this network is optical Field bus networks complete the communication functions between controller and I/O modules in each process station. The communication protocol of this layer is pro bus. The medium of this network is

conclusion
since accomplishing the application to the vertical system we continue to use modules to implement the network in other subsystems because this kind of system can meet the product requirements and obtain the best price/performance ratio. On the whole the implementation of the system marks a great achievement in the automation and management in our company.

THANK YOU

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