Transformation And Implementation Of DCS System Of ChongZheng Cement Clinker Production Line

After years of rapid development, China’s cement industry has ranked first for manyyears in cement output all over the world. The continuing development of the cement industryalso promoted the automatically controlled level of the cement industry. So far, theintroduction of DCS to china has been30years of history, many control systems are facingaging hardware, mean time between failures (MTBF) shortened, but it is difficult to find amatching with the original parts and aftermarket systems, The system failures may cause hugelosses in Process Industry such as while the cement industry product line was discontinueddue to the system failures, thereby the system upgrade or replacement is inevitable. Andsystem software made years ago mainly focus on field equipment and some basic automaticstart-stop control, but rarely involves the automatic control loop. It also increased the load onthe operator, the error rate increases when the operator operates, and thus pose a risk to thesystem. Some frequent operations control loop to be controlled automatically is also verynecessary.This article is based on the transformation of the ZiboChongzheng cement clinkerproduction line from Daily output2500t cement to3200t cement. Clinker production line asthe background, The first step was the analysis of the original system problems andunderstanding what the user needs. Details are as follows:(1) Analyze the original system problems and complete the corresponding transformation.Selecting today’s mainstream controllers and corresponding modules. Count the digital andanalog points according to the process equipment site conditions. Count instrumentation’swiring methods, such as two-wire instrument, four-wire and bus instruments. Select theappropriate I/O modules, communication protocol and communication modules, configuringI/O station. Considering the number of relays and the condition wiring and other conditions todesign the control cabinets.(2) The design of the system software, on-site important equipment and relatedtechnology in the software interlock devices, so as to protect the devices, the purpose ofreducing accidents. Monitoring of key parameters, timely warning, some of the equipment tomake a jump stop and other functions automatically to compensate for human monitoring’s not timely. On the part of the circuit, especially the need for manual operation of the circuitfrequently, selected the appropriate algorithm to achieve automatic control purposes. Oneaspect can reduce the burden on the operator, making them more focused on the mostimportant parameters, or the entire system to control, rather than struggling to adjust someparameters work among the various circuits. Secondly, automatic control have a more rapidlyresponse, the control effect can be increased, thereby improving product quality.On-site practical application proves that part of the automatic control loop reduces thelabor intensity, but also improves the control effects, such as control of the cementdecomposing furnace outlet temperature, the decomposition rate was improved. Afterdecomposing furnace outlet temperature stables, the kiln situation becomes stable. Therebythe improving quality of the cement clinker burning brings good effect to the company.