ff ELSMIDTH Plant Services Division INTERNATIONAL CEMENT PRODUCTION SEMINAR LECTURE 13.4 INSTRUMENTATION FOR CEMENT PLANTSHIE LSMIDTH vrennsrionat cement prooucrion seminarfA RLSMIDTH wremnanona. cement provuction seminar INSTRUMENTATION FOR CEMENT PLANTS, 1. INTRODUCTION |A modern control system interacts with the cement machinery and process as shown on Sketch L From the measuring equipment inthe plant comes a huge amount of information reflecting the condition of the machinery and the process. The control system sorts and treats the ‘information, analyses it and takes action ether directly or indiectly through an operator. {All actions and adjustments wil be given as commands to 2 number of actuators placed in the plant [Even the most advanced control system will not be able to handle is job if the information ‘rom the plant are not reliable, or if the actuators fall to execute the commands. Therefore it is important to select the proper actuator and instrumentation equipment, to place it corectly and to maintain it propery, as i's the control systems eyes and hands. 2, MEASURING PRINCIPLES “Measuring equipment can be divided into two groups: Directly Indicating Instrumen + which are locally, on pipes and tubes, placed indicating instruments. The instruments are typically thermometers, manometers and flow meters ‘Signal Forming Instruments “+ which ereae a signal which is an expression forthe measuring value and which can be transmited 1 a contol system for further processing (Only electrical signal forming instruments will be dealt within this peper since directly indicating instruments are not able to communicate with 2 contro system and since pneumatic and hydraulic measuring signals are normally not used in centralised control systems for cement plant.FB ELSMIDTH ivrerwanonat cement proouction seuinan Avypics! measuring circuit is shown in Sketch 2 ‘The measuring. circuit consists of three parts: sensovtransducer, transmitter end a nsmission system, ‘Sensor!Transducer + is adevioe which measures a physical value ie. a temperature ora pressure, and converts the information to an equivalent electrical value. Transmitter + isa device which handles the electrical value from a sensortransducer and converts it toa standardised signal suited for transmission to a contol system. ‘The signal from the transmitter is direct function of the physical measuring. value, ‘therefore the transmitter will offen include compensation and linearization functions. Transmission System + isthe device which brings the information from the tensmitter tothe control system. ‘Two methods can be used, parallel and serial transmission. Parallel transmission means that the signal fom the transmitter i sent 0 the control system via a dedicated measuring cable. “The measuring cable is normally shielded and with twisted pair to protect the measuring signal against electrical and magnetic noise. ‘The signal level can be 0-5 V ,0-10 V ,0-20 mA,t-20 mA, but the use of Wo wire ‘transmitters using 4-20 mA has become increasingly more common,HE ELSMIDTH wrennsriona. cement paooucrion seminar ‘The principle for the two wire transmitter is shown in Sketch 3, and has the following advantages: + Variations inthe impedance inthe transmission fine (Eins. due to temperature variations) will not influence the measuring vale, + Power supply of the transmiter wil take place through the basic current 4 mA from, the control system, + Cable saving. + Automatic detection of a broken wire. Serial transmission means tat signals from more transmitters are send to the control system fon @ common transmission cable, (Gee Sketch 4). Serial transmission demands a transmission unit after the transmitter to convert the 4-20 mA signal to digital code {In the same way a special input port inthe contol system is necessary. ‘Today transducers with buill-in transmission units based on a micro-processor are available ‘onthe market, bt the use in the cement plants are not yet common ‘The reasons for this i partly the relatively low numberof process measurements combined with te large size of @ cement plan, and partly the high price of the equipment, 3. ACTUATING PRINCIPLES “Two typee of actuators are available, On - Off devices and continuous type devices. ‘Sketch $ shows atypical On ~ Off device. When the contol system wants to turn the device fo, it sends an open command, and when it wants to tum it off, it wil send a close command, ‘The command will normally be electrical signals 24 V de, 48 V de, 110 V ac or 220 V ac. ‘Sketch 6 shows a typical continuous device. The control system will sexd 2 command signal ex. 4-20 mA to diect the actuator to the desired postion or speed.HE ELSMIDTH renusmona. cement prooucrion seminar 4, WHAT TO MEASURE AND CONTROL te measure and contol is normally established by the machinery supplier and is shown ‘onan instrumentation flow sheet. A flow sheet for a cement mill is showin in Sketch 7. Each measuring point is identifed by a circle containing information seferting 10 its ‘priton, function and tag name. The principles forthe instrumentation flow sheet (or Pipe & Instrument diagram) were introduced by TSA (Instrument Society of America) but have now ‘been adopted by IEC and other major standards. Sketch 8 shows how the information for 2 measuring point is build up. In the upper half ofthe circle are a number of characters which indicate the function of the measuring point ‘Sketch 9 shows the identification able according to ISA-standsr. ‘The circle may be divided by: + Aborizonal diameter, which indicates that the information for the measure point is available forthe operator in the central control room. + Addashed horizontal diameter which indicates that te instrumentation is avaiable inside a control pane! + No diameter indicates that the instrumentation is mounted locally Inthe lower half ofthe circle is the Tag~name forthe measuring point. If measuring point is astocisted with a contoller, the controller is given its own crcl, drawn adjacent t the measuring point circle, and a dotted line Js drawn between the controller's circle andthe actuator.FS FLSMIDTH wrenwanona. cement prooucrion seman 5. HOWTO MEASURE 1. Temperature Temperature can be measured by three different methods: Thermo resistor, thermocouple or optical pyrometer. ‘Thermo resistor I a resistor witha well defined relation between the resistance andthe temperature, ‘The thermo resistor is normally made from platinum and has the resistance 100 Obm at 0 eg.C.(P* 100) ‘The thermo resistor is used inthe ow end of the temperature range, (upto 500 deg.C), and can in most cases be connected directly to the control equipment. As the signal from a thermo resistor is very small it is recommended to place a transmitter next to the sensor if the distance to the contol equipment is more than approx. 50 m. ‘Thermocouple A thermocouple consists of two threads of different metale or alloys, where the one end, the measuring point, is soldered together. If the measuring point and the free ends have @ } Controtter fe Sketch 13SOLID FLOW METER I 1 ! ! 1 1 1 1 1 | eae —L_ comma. t+ 7] SUE? T/H SKETCH 14MAX-MIN LEVEL + CAPACITIVE SENSOR + VIBRATION SENSOR CONTINUOUS ae + ELECTRO-MECHANICAL, ULTRASONIC + WEIGHINGSILO PILOT MATERIAL, MAX. INDICATOR SKETCH 15MATERIAL MAX. INDICATOR vere sonic. TRingenree /Rsceiver SKETCH 154 meas ror ve vere sae @AS MONITORING UNIT PRE CONDITIONING UNIT SKETCH 17POSITION SPEED VIBRATIONS FLOW + GAS + OL + WATER ELECTRICAL VALUES‘SPECIAL MEASUREMENTS + LIVE RING MIGRATION + KILN POSITION ANGULAR HORIZONTAL + INDUTHERM. + FOLOPHONE,SHETCH 18J LIL <_|> »| uit Loe oss Transmission Demodulator Sketch 19MILL. FOLAPHONE MICROPHONE, A TRANSMITTER covet Se SKETCH 201. PROCESS MEASUREMENTS: + SUPERVISION + CONTROL + OPTIMISATION + REPORTING + PLANNING 2. PROTECTION MEASUREMENTS PROTECTION OF PERSONNEL PROTECTION OF MACHINERY INTERLOCKING ALARM 3. wit 22 yak we, Ry Sen CONSUMPTION Ge + CONDITION ~ cas bead POWER MANAGEMENT —ENVIRONMENTAL CONDITIONS LOCATION 9 ae IM ya oar a + CORRECT MEASUREMENT + ACCESSIBILITY s SOT ae Mawrenance = Ue jot yor o SERVICE a, + SPARE PARTS g peed + TECHNICAL ASSISTANCE“y) te ve ha =P Wwe 2 We i