Description of technological object
The system is put into operation at Sambirsky Haydite
Plant (Lviv region, Ukraine). Constituents of technological process
of haydite burning are:
- elevator #1 (#2) of finished-products
- mechanism of haydite grading;
- folder gates ##1...6;
- haydite breaker #1 (#2);
- clay opener;
- box transporter;
- batcher #1 (#2) of in-process stock charging;
- batcher of ground limestone;
- burning kiln, main drive of kiln, dust
precipitation chamber, kiln burner, kiln head;
- silo banks #1...6;
- cooler, chambers ##1...3;
- blow fan of burner and cooler;
- transporter #8;
- power supply standby generator;
- drying drum #2;
- main smoke exhauster D-19;
- chain elevator CS-1 (CS-2);
- in-process stock grinder.
Destination of the ACS
Automated control system of haydite burning area and
rotary kiln burner is intended for acquisition, representation and
archiving the information, that permits to operator to carry out
the control for process of haydite burning, for rotary kiln burner.
Also the system is intended for remote control of technological
objects of the kiln.
Structure and functions of the ACS
The developed system is integrated automated system
that is based on programmable logic controller SIMATIC
S7-300 from SIEMENS, distributed I/O modules ET-200
and operator stations, which in a whole perform the functions of
measurement, monitoring, automatic and manual remote control, visualization
and archiving of events and parameters of technological process.
Structure chart of the automated control systems is
shown on figure 1.
Figure 1 - Structure chart of the
ACS of haydite burning area and rotary kiln burner
Lower layer of the system is based on programmable
logic controller Simatic S7-300, that
provides reception of information (digital and analog) about flow
of technological process, state of systems and machinery, values
of measurable parameters. It also performs processing of the information
in accordance with specified program, generation of commands and
information transfer to operator station OS1srv.
PLC Simatic S7-300 is located in control
cabinet C1ctr in operator building,
distributed I/O modules ET-200 are
located in control cabinet C3ctr in
remote plant building near technological
Upper layer of the system consists of 3 operator stations
on basis of personal computers - OS1srv,
OS1srv - operator station, server,
that is located in operator building; OS2cl
and OS3cl - operator stations, clients,
that are located in remote administration building.
Data exchange between OS1srv and OS2cl,
OS3cl is realized via Ethernet
OS1srv performs the data
exchange with Simatic S7-300 via MPI
(Multi Point Interface), visualizes the state of technological equipment
at mnenonic screens, writes the analog values to daily archives
and the discrete data in event log (switching the equipment on/off,
threshold elevations, alarms, operator actions and so on). Analog
archive values are displayed in trend view, the customer can create
and modify trend groups. The databases and custom settings for OS2cl
and OS3cl are generated the same way.
Operator can execute the control of technological process (for example,
switch the equipment on/off) and modify limit values.
OS2cl and OS3cl
are constituent parts of the ACS, only the difference - visualization
and archive reading are performed from server database, which is
located on OS1srv. Operator also can
modify the parameters of technological process, not directly in
PLC, but through OS1srv,
which traces and registers all changes in the system.