A fully automated

cement storage and dispatch terminal

For: Presentation at the 1994 IEEE Meeting

Seattle, Washington, May 29 - June 2, 1994

By: JOERN KNABBE CARLOS A. GARCIA LUNA

Manager Electrics Direccion Nuevos Projectos

C l , ~ ~ d i Peters
us AG La Cruz Azul SCL
I3 u xtehude, Germany Mexico City, Mexico

0-7803-1766-1/94 $4.00 01994 IEEE 235

Abstract
Three Million Dollars extra for a highly technical advanced computer network in a plain cement
storage and dispatch terminal?

The objective of this paper is to clarify why it makes sense in the technical and economical point
of view to invest this extra money. It describes the new terminal control system for a cement
plant in Mexico.

One data highway connects 6 local area networks via 8 computer gateways to 22 PLCs,
I O personal computers (one abroad), 6 micro computers, 15 printers, 30 additional terminals,
20 intelligent card readers, and other peripherals like truck gates.

The complete operation is centralized in 2 rooms which are monitored by video transmission.
In addition, 5 existing manual bag loading stations have also been integrated into the operation.

INTRODUCTION
There are various services involved in the operation of cement terminals used for storage and
dispatch, and each service has its own individual problems to s o l ~ cFor
. each question one can
find a solution that guarantees the function.

It is not the purpose of this paper to explain a single item or specific problem of an automation
system in cement terminals, but rather wants to show the complexity and the interrelationship
should the unit be intended to be an integrated unit.

ITEMS TO BE INCLUDED
The basic units for each terminal are:
m silos and other buildings
H conveyors, elevators
bag packers
truck loaders
truck scales
H PLCs, voltage supplies

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 The areas specially to be considered are:
material supply
- by conveyors of various types
- by trucks, trains, and other vehicles
material dispatch
- of bulk material or bags
-by trucks, trains, etc.
- including special blended products
plant operation
- handling and control of materials statistics and balance ledger
- monitoring of material flow and power consumption
- computer aided maintenance
- man-machine-interface by a graphic visualization system

It must be mentioned, that in this plant the cement is blended to have the possibility of marketing
different types of cement.

REALIZATION
Overview
The terminal is a collection of various single machines or units. These units can be divided into
two categories:
1, machine based units (or hardware)
2. data processing units (or software).

The machine based units are:

the silos including feeding machines like conveyors
the bulk loading equipment including truck scales and feeding by mobile loaders
the packers to fill cement into bags including bag applier and feeding by bucket elevators
the bag loaders to load bags onto trucks including feeding by belt conveyors.

Although these machines are considered as hardware, they do include software which is
implemented within thc programmablc logic controllcrs or the micro processors, and determines
the function of each machine.

238
The data processing units are:
The overall process control system which uses a graphic process visualization software
system.
The dispatch automatior? system which handles the data for all shipments including also the
shipments from the existing dispatch points used by the cement plant. and that are not part
of this terminal.
The raw material registratio:i system collects data from all rnaterials coming into the cement
plant includiny points outside this terminal such as the quarry.
The computer aided maintenance system is a part of the process visualization system, but it
has more capability than conventional maintenance software.
The software coinponents listed above require hardware which consists of personal
computers, offict. terminals, printers etc.

Machines
The hardware descriptions are short as they are well known to everyone in the cement industry.

Thc cement silos used are the bottom

aerated pneumatic type with an
ins pec 1i on cham be r. ( Fig ir re I )

Feeding of material from the blending

plant t o the silos is handled by belt
conveyors. The distribution on top of
thc silos is accomplished by aeroslide
conveyors. Just by entering the
material source and the destination
silo, thc control system automatically
determines what conveyors, valves.
filters. etc. havc to bc xtivated. Even
the blending recipe is determined
~i~itoniatically according to the desti-
nation o f the cement. The material
l the silo is regularly updated on
l e ~ c in
the opcrator displays.

Figure. 1
Silo design

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 The bulk loading cqiiiprnent is designed to assist the truck drivers in loadin,0 their own trucks.

i
i
I

I
iI
I
I

I
I

Figure 2
Principle of bulk Loading

As seen iinjiLquw2 above, there is presently one loading line per silo, however a second one will
be added in the 1uture.The weigh bridges have a capacity of 60 metric tons. All equipment used
to load trucks is state-of-the-art.
There are two packers
(rotational type with 8
spouts each) for each
silo. (Figure 3)

Figure 3
Principle of bag packer

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The bags are applied mtomatically. To start a packer, the so called “lines” are to be released
within the process control system. (Figure 4 )

Figure 4
Grufic with
,, lines “ shown

This is accomplished the satne way with all other “lines”. The packer is actually put into
operation when an order is issued by the dispatch system. This process is described later in more
detail.

Each silo has 2 packers and 3 auto loaders. ( F i g w c ) 5 )

Figi(w 5
Air tomcitic
truck loader

24 1
 Packers and loaders are designed to handle more than 2200 bags per hour. The design, with
3 loaders, provides time to change trucks during the packinglloading process. This is one area
where unfortunately everything is not fully automated. One operator is used for a line of
3 loaders to position a loader with respect to the truck during full service. In the future, consider-
ation will be given to the possibility of letting the truck driver do it himself like he does with
the mobile loader for the bulk loading.

SUPERVISORY CONTROL AND DATA AQUISITION

The data processing units are the heart of the terminal because they are the real automation
technology. They offer the real savings in plant operation. For basic data processing, units are
referred to:
1. process control system 3. raw material registration
2. dispatch automation 4. computer aided maintenance

Figure 6 Plant with network

242
These units are tied together in a data processing network; the backbone of which is the “arcnet”
local area network (1,AN). (Figure 6)

This is a proven and reliable network system, and will continue working even if connected parts
fail or if just switched off. This feature is common in PLC-networks, but it is not necessarily
common in EDP-systems (e.g. in offices).

The network is served by a database computer, printers and the data back-up unit (which is a
built in streamer). (Figure 7 )The importance of data back-up is critical because the database
system forms the centcr of the data processing system.

m- :. e.# -- Figure 7 Network scheme

Sensitive data are protected by a password hierarchy. Each operator can only see or manipulate
the data allowed by his security clearance authorization.

Process Control System

Each line of the three i l o s contains various programmable logic controllers which are connected
to each other via another local network.

One PLC acts as a 1x1~

coupler to connect the check weigher for the packing machine and the

243
 operating terminal of the automatic bag loader used by the company's operator. The other
operating termina1,which is used by the truck driver, is located two stories below. (Figure 8)
Therefore, it uses a direct intelligent coupler to the main network.

Figure 8
Terrnincrl bcig
loading

The same principle is used for the existing manual bag loading, which is still retained by the
cement p I ant .

In the bulk loading area a computer handles the shipments with the help of truck driver terminals.
Because the truck driver loads his truck single-handedly, a closed circuit television system
monitors the operations i n the central control room. (Figurc. 9 )

244
This helps the drivers align their trucks on the scales.

The graphic process visualization is a MS-DOS based software system. The application software
consists of:
1, Graphics for the display of plant sections defined by the P & I diagram for each silo
line. This includes an overview graphic, 4 flow sheets, a trend, and a bar graph.
2. The statistic program is used to monitor capacity data and deviations utilizing data
from the packer machines.
3. The event, alarm logging, and reports module provide the operator with alarm
and printed records.

Dispatch System
-
The dispatch house at the entrance/exit gates is an important part of the dispatch system.
(Figure IO)

Figure 10
Enirmce / exit gates

Every customer and supplier has to pass these gates to enter and to exit. All kinds of customers
must be taken into consideration:
1. regular customers (frequent clients)
2. infrequent customers (one time clients)
3. haulage contractors
4.company drivers

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 Except for one time clients, each customer has a magnetic card. It serves as a identification
entrance key to the plant, and as data media. (Figure 11)

Magnetic Stripe Standards

ANSI x 4.13-1971
IS0 2894

EMBOSSED
INFORMATION

0.030"Thick

Magnetic Stripe Encoding

ANSI x 4.16-1976
IS0 3554

f I 0.223"

Card Data Format

Recording Density Character Configuration Information

(bits per inch) (includinq Parity Bit) Content

79 alphanumeric character

107 numeric character

Figure I1
Magnetic cczrd

Automatic access control: The access control system is divided into two possible procedures:
1. The frequent clients who have a credit account, identify themselves by means of
magnetic cards at the entrance and can pass through the gate with a "long-term card".
The computer checks the clients balance and displays the latest quantity loaded by the
same driver /vehicle on a monitor which is easily accessible to the driver. If the same
quantity is requested again, the driver can confirm this by a function key, or he can
order another quantity and type of cement at the terminal. If the credit is not sufficient

246
 (below a certain value), the client will be asked to proceed to a special parking lot in
order to request the accounting department, in the dispatch office, to clarify the
situation with their company. As soon as the matter has been clarified, the stored credit
will be extended by the accounting department. The quantity ordered, type of cement
and the loading station are displayed and have to be confirmed by the driver. By this
confirmation the order is recorded in the computer and the gate is opened.
2. Those clients who come for the first time or who come very seldom must use the road
next to the dispatch office CO they can contact the accounting department. They will
have to pay i n advance by cash or some other type of payment. Then they will receive
a magnetic c;ird which can only be used once. Accounting informs the client where
to load the product and opens the gate after the following order data was been entered
as a shipping order into the computer:
client number
vehicle number
driver name
cement tvpe
quantity
bulk or bags
loading system

Trucks are directed to their loading stations by different color signs and their color coded
magnetic cards, which is the same color as the designated loading station. Each driver controls
the loading of his truck.

Drivers identify themselves by their magnetic card and are directed by the display of the data
station. The magnetic card remains i n the rcading device during the loading process. The
computer checks to determine whether the ordered cement type is available at the loading point.
If they differ, the driver will be informed that he is at the wrong loading point. If they corre-
spond, the vehicle number. cement type and cement quantity will be displayed. This data must be
confirmed by the driver,whereupon the tare weight of the correctly positioned vehicle is taken.

If the data differs, the driver must call the accounting department at the plant’s entrance for
clarification.

After the tare weight is taken. which is displayed on the monitor, and the confirmation by the
driver, the loading spout can be coupled to the vehicle and loaded.

Once loading is finished. the data is reconfirmed by the driver and will be transferred to the EDP
computer when the magnetic card is removed.

A so called safety prlnter records the dispatch data for each truck scale in the weigh house and/or
in the central control room.

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 Loading of bag material:

For the new automatic loaders (9 stations), the client identifies himself by inserting his magnetic
card in the reading device of the assigned loading station or the next vacant station with the
required cement type. The magnetic card remains in the reading device during the loading
process.

The computer checks to determine that the type ordered corresponds to the loading points; if not,
this will be shown on the driver’s display (bottom).

If the type ordered is available at the loading point the following data, which was entered into the
computer at the plant’s entrance, is displayed:
vehicle number
m cement type
cementhag quantity
This display must be confirmed by the driver.

On the loader’s operator display, the following data is released for entry in the loading control by
the operator,
a bag quantity
loading type. piles (rows) x layers
and the loading process is started.

After loading the bag quantity ordered, confirmation is requested on the drivers terminal.

The driver enters his confirmation and the loading data is transferred to the EDP computer when
the magnetic card is removed.

For the existing 5 manual loading stations the client identifies himself by inserting the magnetic
card in the reading device.

The plant personncl load the vchicle and record the data via dialogue communication through the
data station. This data is transferred to the EDP computer after acknowledgement by means of a
function key.

All clients drive to the plants exit and identify themselves by inserting the magnetic card in data
station. The data stored during loading will be automatically integrated and all calculations
required will be made.

248
The results are indicnttd to the client on a display. The frequent client\ nfill rcceivc information
on the display reg;irdiiig their credit (tatus so the driver c;m inior-rii h i \ comp;in>.

The displayed data is c.onfirnicd by the clriver and ~i bill of' I:idinp is printed. Ttic biil 0 1 lading in
qiiadruplicate, (original paper with 3 copies) is signed by the cirivcr-.7'n.o copies XY cllawn ofl'
and the two remaining copies are returned or put into a mail 1)os. :I list of the isyiied bills of
lading is simultaneou5ly printed in the daily report.

The magnetic cards from frequent clients \\fill bc I-ctur-tied.Tlie ni;igtictic c m l s l'r-om onc time
clicnts will be retainctl a i d can be uscd q i i i i . I n both c:iscs thc gatc v,fill bc opened. The gates
are controllccl by intluition loops. at thc identification point I'or olcning m d bchind for closing.

I n addition to the a.111 bills of lading, thc folIo\vinc docunicnt\ :inti iccoitI\ :ix pr-ociiiccd:

card number
cl ient/fi n al c U s L on1e r/tl i s t r i bu tor
carrier/name of' the driver
or cl er n it in be r
date
time of arrival
beginning loading time
end of loading

v eh i c le n LI ni bc i'

All bills of lading ;lie illit into a data bank and arc acccs(ib1e for- oiic inoritti.

The printing is auton1:itically xtuatcd after insertion OT magnctic cnr-ti by the tlri\,cr or by
dialogue request from the bill of lacl~ngdata bank.

After printing and isii'ing o f the bill of lx!ing. the in\,oiccs t\.ill h~printccl t1.c in\,oicc printcr
in 3 copies inclucliii;: iiic I'ollowing (lata:
sa c I icnt/adcl rcss/n i 111 1be 1' EI yros'; \vc>i?li[
II order number &
I net wciylil
date n1ess:rgc
time of arrival LI pricc
E beginning loading time ciiscomt

249
 U end of loading U value added tax

U vehicle number total amount

H cement types conditions of paymenthype

H quantities bonus registration

U tare weight

A third printer prints daily reports (statistics).

a) system capacity derived from: b) daily report of bills of lading

U capacity of the mills (weighing data) identification
silo levels quantitykement typehime
H total dispatch

c) capacity data of the bulk loading d) capacity data of the packers

w tons per day tons per day

number of vehicles number of bags
H loading time

e) capacity data of the loaders f) manual loading/station

H operator number of bags
H number of bags H shift personnel
number of trucks

Data base storage and maintenance: All primary data and the actual data are stored in data bases.
The primary data is registered and maintained on two screens in the dixpatch office. Actual data
is primarly recorded at the local data stations and will be supplemented on the two screens in the
central control rooin if required. For input and maintenance of the data base. menu controlled
operating dialogues are made available by the central EDP computer. The dialogue language is
Spanish.

Actual data files are maintained locally for 1 month. After this period the earliest data will be
cancelled.

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Data Acauisition and Registration
Registration of raw materials and cement (hand bag loading) is handled at the main gate for the
process data management.

Two additional truck scales are located at the entrance/exit of the terminal f o r registration of
supply material. They are located at the outside and are equipped with a barrier. a display, a card
reader, and a printer.

These scales offer the possibility of checking the weight of loaded bags of cement. The following
procedures are possible and will be processed by the related software:
1. Material supply delivered by trucks
The truck drivers will have a corresponding magnetic card. They drive with their
loaded truck onto the scale, identify themselves with the card, and will receive a
printed ticket after the gross weight of the truck has been determined.
After unloading the material. they drive onto the scale at the exit, identify themselves
again and will get a printout of the net weight which is calculated by the personal
computer from gross and tare weights.
This net weight is recorded in the database, and will be made available to the
accounting department in daily, weekly, or monthly printouts.

2. Check weighing of bags at dispatch

The dribers who already have a magnetic card can drice directly onto the scale. After
identification, the tare weight of the truck is recorded i n the computer system. After
loading the bags (automatic or manual), they drive onto the scale at the exit and receive
a bill of lading.
The net weight is calculated by the difference bctwcen grow weight and the tare
weight. The net weight can be used for checking of quantities loaded, and the
result/deviaition will be printed on the bill of lading.
One time clients who are using this check weight, must drive into a waiting lane and
report to the dispatch house. They will be given a magnetic card, and the remaining
sequence i \ the same as with the other clients; with the exception that the magnetic
card will bc taken back at the exit.

3. Material 5iipply by belt conveyor

A belt sculc is installed on the belt coming from the quarry and connected to the
computer cystem. All data will be collected and can be displayed in the accounting
departmcnt .

251
 Reliability
There is a certain anxiety concerning electronic units and software programs. Unfortunately this
equipment cannot be repaired by staff people as easily as mechanical machines, but, provisions
can be established in the same way as for mechanical machines. For example, standardized
products that are available all over the world can be used. Units must work independently of each
other in order to avoid failures caused by failures in another unit. In this case, programmable
logic controllers, for a g r o u p h e of the cement terminal, work independently. Computers are
arranged in distributed configurations along functional lines, so they can operate independently
of each other in the plant wide system.

With specific software there are some additional possibilities available:

With todays electronic telecommunication equipment one can transmit data and programs
very easily from one place to another almost anywhere in the world. A “tele-service”
from Germany to Mexico is being used to assist in changes or up-grades to the PLC or
PC software.
Operating the machines automatically with the help of computers, which communicate in the
language of the operator, is important to avoid operational errors. Remember: British english
is different from US english.
Additional reliability is achieved by rcdundant computers outside the central control. In this
cement terminal, both computers in the dispatch office work back to back. In the plant, the
intelligent bus couplers (also called gateways ) are installeci twice. Redundancy means that
two computers exchange data continuously and if one computer should fail the other is
activated via a hot stand-by connection. The other computer takes over immediately and
signals this condition to the central control from where ;I repair or exchange can be initiated.
Each terminal also serves for emergency operation. If the connection to the main network
should fail, up to 50 sets of shipment data can be stored. After reinstalling the network
connection this data is automatically collected and processed. In the worse case. shipments
can be accomplished using paper to note the necessary data. This data must then be keyed
into the computers and used to write the bills, generate balance sheet etc.

RETURN ON INVESTMENT
As the automation lecel of a plant progres\es lroin one schcrne to the next. the plant runs closer
to its true economic optimum. Thus, to effectively compete i n the market, moving a plant from
one level of automation t o ;I higher lcvel, may be economically juctii’ied. Sometimes it may be
even required. As an example, just considering the dispatch system:

252
 Quantities:
total material flow 11300 t/day
1 line equals 1 silo
2 bag packers
3 auto truck loaders
bags (50 kg ea.) 2200 per hour per packer
shipments 1000 per day (=1 per min)
cement types 5 plus special blends

number of data per item:

customers 200 as regular customers
trucks 500 to be handled
blends 30 plus individual recipes
orders 1000 to be processed
cards 5000 to be handled
passwords 5 different levels

Investment (hardware and software) $ 550,000

personnel not required due to dispatch automation

3 truck scales 6
9 auto loaders 6 (6 still there)
special blending load I
manual bag loading 2 (foremen only)
total 15

working time per month: 160 h (holidays deducted)

average wages: $ 2 0 (inclusive incidental expenses)
total wages: $48,000 per month
break even: 11.5 mounth (< 1 year)

253
 CONCLUSION
It has been shown, that handling of more and more data is economically justified.
The reasons are:
1. The technical possibilities are available for a reasonable price.

2. Human resources processing data are becoming more and more expensive.
3. We have learned to use data management and integrated system engineering.

Further extensions to this example are possible:

1. Dispatch of specially blended cement types according to customer specifications
and/or for new applications.
2. Integration of this subsystem into:
w the central control system of the cement plant
central accounting system
new centralized management of maintenance work force and spare parts

A great deal o f thought should be given to the selection of the features required in the system.
During the engineering phase the plan should be adhered to and the temptation to investigate all
possible options must be avoided. Otherwise a situation can arise, as sometimes have occurred
in early days of process control systems, where an attempt was made to record and print every
possible alarm. Such a system would be too complicated, the personnel would not really use it,
and it would be to expensive.

References
S. Hodgson and D. Holden, “Scaling new heights in plant automation”, Chemical
eneineering. pp. 102-108, July 1993.

D. F. Higgins and M. Fischer. “Dispatch automation system in Quassim cement works,

Saudi Arabia”. Zement, Kalk, Gips (ZKG). vol. 4 I , pp. 273-278, June 1988.

H . R o t t c n cl o r I‘ ;I ri d W. K Ii i e se ne r. “Co mpii t e r- ;I i ded d i spat c h ;I11to in nt i on ;it Man ne rsdo rf

cement works. Australia”, Zement, Kalk, Gips (ZKG), vol. 40, pp. 602-609, December
1987.

N. N. ,“Mixing Chamber Silo Discharge”, Claudius Peters AG. Buxtehude, Germany,

E 500, July 1985.

254