E3-Module 1

Package E3: Automation and instrumentation
The Process Control

System
Equipment and configuration
Basic Functional Objects
Software and Integration
Module 01: Process control and process control equipment

Copyright©: This training material is licensed by FLSmidth to Lafarge Asia Technical Center and must be used
only for training of staff and personnel employed at Lafarge plants in ATC (Asia, ASEAN and China) regions.
Table 1.1: The Process Control System step by step

Fig. 1.2: Typical process control system (PCS) layout at Lafarge plants
Fig. 1.3: Computer integrated manufacturing (CIM)

Fig. 1.4: Example of a PCS architecture in a cement factory

Fig. 1.5: A local PLC (field controller).

Fig. 1.6: Redundancy power supply

• EXCHANGED SIGNALS
• Logic of signals
 Signals exchanged with the PCS will use:
 Positive logic for commands and feedbacks (“0” with no
command; “1” when a command is required)
 Failsafe logic for interlocks, alarms and events (“1” in normal
condition; “0” when an interlock, an alarm or an event is active).
Table 1.7: The plants configuration of logic signals

EXAMPLE OF SIGNALLING TRAFFIC

IN A CEMENT PLANT
Fig. 1.8: The signalling within the PCS (CCR) and the plant
Examples of binary logic levels
Technology Low voltage High voltage Notes
CMOS 0 V to VCC/2 VCC/2 to VCC VCC = supply voltage
TTL 0 V to 0.8 V 2 V to VCC VCC is 4.75 V to 5.25 V
ECL -1.175 V to -VEE .75 V to 0 V VEE is about -5.2 V VCC=Ground
Table 1.9: Examples of binary logic levels.

Fig. 1.10: “Collapsed backbone”

Fig. 1.11: Communication cards

Network access
Cable type Max. length
protocol
Ethernet 10Base2 Coaxial 185 m
10Base5 Coaxial 500 m
10Base-T TP 100 m
10Base-FL multi-mode FO 2 km
10Base-FL single-mode FO 5 km
Fast Ethernet 100Base-TX TP 100 m
100Base-FX FO 412 m
FDDI Multi-mode FO 2 km
Single-mode FO 60 km
CDDI TP 100 m
Table 1.12: Network Bus cabling range for Network access protocol.

Fig. 1.13: “Supervisory control and data acquisition” (SCADA) system.

Fig. 1.14: Network (i.e. Ethernet) Redundancy

Fig. 1.15: A touch-screen panel with mimic display

Fig. 1.16: A mouse-driven PC plant control and data screen

Fig. 1.17: Screen arrangement for the process control system

Fig. 1.18: The standard la Farge display layout

Fig. 1.19: The symbols used for digital operated valve

Figure 1.20: The symbol of a material diverter

Inner part Outer part

Animation Condition
colour colour
Sequence is sleeping and
actuator is in sequential Light grey Dark grey
operating mode
Damper / shutter not in

operation without Trip White Green
failure
Damper / shutter in
operation, closed without White Green
Trip failure
Damper / shutter in
operation, in intermediate White Green
position without Trip failure
Damper / shutter in
operation, open without White Green
Trip failure
Damper / shutter is
blocked by an Interlock White Red
(animated by output IT)
Damper / shutter is
blocked by a Trip failure Red Red
(animated by output FAN)
Fig. 1.21: The damper symbol

Fig. 1.22: The basic motor symbols

Fig. 1.23: The typical motor faceplate as displayed at the CCR

Fig. 1.24: A typical local PLC, here a Siemens S7-400 PLC

Table 1.25: Common programming languages (part 1)

functional,
Prolog, Ericsson concurrent,
Erlang Compilation dynamic, weak 1987
Pascal, CSP distributed, multi-
platform
Interpretation / imperative, stack-
Forth RPN, Assembly typeless 1977
Compilation oriented
APL (Fortran 90), imperative,
static, strong,
Fortran Compilation Algol 68 (Fortran 90), procedural, object- 1957
safe, nominative
C (Fortran 2003) oriented
Interpretation / static, strong,
Haskell Miranda, ML functional, generic 1990
Compilation type inference
Smalltalk, Self, imperative, object-
Io Interpretation dynamic 2002
NewtonScript, Act1 oriented
imperative, object-
Interpretation / C++, Objective-C,
Java oriented, multi- static, strong 1994
JIT compilation C#[2]
platform, generic
imperative, object-
JavaScript Interpretation C, Self, awk, Perl dynamic 1995
oriented, functional
Interpretation,
Lisp λ-calculus functional dynamic, strong 1958
Compilation
procedural,
Interpretation, JIT Python, Icon, Lisp, dynamic,
Lua imperative, 1993
compilation Scheme strong, safe
reflective
functional,
Mathematica Interpretation Lisp, APL dynamic, strong 1986
procedural
imperative, object- static/dynamic
Objective-C Compilation C, Smalltalk 1986
oriented hybrid, strong
object-oriented, static, safe,
Interpretation /
Objective Caml ML, Lisp functional, structural, type 1996
Compilation
imperative, generic inference
static, strong,
imperative, object- safe (but unsafe
Object Pascal Compilation Pascal 1985
oriented allowed),
nominative

C, shell, awk, sed, functional, object-

Perl Interpretation dynamic 1987
Lisp oriented, procedural
imperative, object-
PHP Interpretation Perl, C dynamic, weak 1995
oriented
imperative, object-
Interpretation / ABC, C, Perl, Modula- dynamic (duck),
Python oriented, functional, 1991
JIT compilation 3 strong
aspect-oriented
imperative, object-
Smalltalk,Perl,Python, dynamic (duck),
Ruby Interpretation oriented, functional, 1995
Lisp strong
aspect-oriented
static, strong,
Interpretation / object-oriented,
Scala Java partial type 2003
Compilation functional, generic
inference
Interpretation /
Scheme Lisp, Algol 60 functional dynamic 1975
Compilation
object-oriented,
functional, dynamic,
Smalltalk JIT compilation Sketchpad, Simula concurrent, event- strong, safe, 1971
driven, imperative, duck
declarative
static/dynamic
hybrid,
component-oriented,
Visual Basic Compilation QuickBASIC weak/strong 1991
event-driven
hybrid, safe,
nominative
object-oriented,
Visual Basic .NET JIT compilation Visual Basic static, strong 2001
event-driven

Back-
Can be Can be Can be
ground Priority Sound Printable
sorted broadcast stored
colour
Message White 3 Soft Yes Yes No Yes
Warning Yellow 2 Normal Yes Yes No Yes
Trip Red 1 Loud Yes Yes Yes Yes
Status Message Sound

Not acknowledged Blinking On
Acknowledged Steady Off
Table 1.26: Message and alarm attributes

Fig. 1.27: The faceplate PID regulator (sample)

Fig. 1.28: The control loop parameter and limit setting faceplate
Fig. 1.29: The graphical display showing the trend curves and the min./max. setpoints
Fig. 1.30: The trend curves of an analogue PID controller

Fig. 1.31. The procedure of authorisation of software changes and up-dating

Code Description Start-up Shutdown

314 S01 Dust removal 1 7
314 S02 Kiln fans 2 6
314 S03 ………. ………. ……….
316 S04 ………. ………. ……….
315 S05 ………. ………. ……….
………. ………. ………. ……….
Table 1.32: General description of the process control principles.

SSI SPI Remarks

Interlock No. 1
Interlock No. 2
Table 1.33: A list sequence interlocks.

Fig. 1.34: Sequence flowsheet

Code Description Start Stop Essent. Emerg. Remarks

step step drive power
316LU07MT10 Kiln main gear Start if
1 1 Y N
lubrication pump 1 selected
316LU07MT20 Kiln main gear Start if
1 1 Y N
lubrication pump 2 selected
316LU07VA30 Kiln main gear Start if
valve 1 2 Y N selected oil
pump
Table 1.35: Example of a list of D/Ds

DSI DPI DSQI Remarks

Interlock No. 1
Interlock No. 2
Table 1.36: A list of D/D interlocks

Fig. 1.37: Process variability via setpoint

Fig. 1.38: Process variable and setpoint in the control loop

Fig. 1.39: Integral action.

Fig. 1.40: Derivative action.

Fig. 1.41: A block diagram of a very simple control system

Fig. 1.42: A block diagram for a “closed loop system”

Fig. 1.43: A PID controlled variable frequency drive.

Fig. 1.44: A block diagram for a PID controlled variable frequency drive

Fig. 1.45: “P” and “I” ‘s influence on the output.

PB Integral Integral Derivative

Loop type Valve type
% min/rep rep/min min
0.005 to Linear or modified
Flow 50 to 500 20 to 200 None
0.05 percentage
0.005 to Linear or modified
Liquid pressure 50 to 500 20 to 200 None
0.05 percentage
Gas pressure 1 to 50 0.1 to 50 0.02 to 10 0.02 to 0.1 Linear
Linear or modified
Liquid level 1 to 50 1 to 100 0.1 to 1 0.01 to 0.05
percentage
Temperature 2 to 100 0.2 to 50 0.02 to 5 0.1 to 20 Equal percentage
Chromatograph 100 to 2000 10 to 120 0.008 to 0.1 0.1 to 20 Linear
Table 1.46: An example of basic setting ranges for the most common control loops.

Fig. 1.47: General Function Block Model

Fig. 1.48: Function block FB_control loop

Fig. 1.49: The basic function block

Fig. 1.50: Function block data and event flows

For the input/output

definition please refer to
the la Farge standards,
Process control system,
Basic Functional
Objects, Page
32,33,34,35,36.
Fig. 1.51: The la Farge basic Motor one direction function block

Fig. 1.52: The general motor face plate

1.5.2 LUCIE
•LUCIE is an expert system developed by Lafarge

and accepted as BEST PRACTICE for operating
departments at Lafarge plants.
•LUCIE needs information with good availability and
accuracy for operating the departments. This expert
system communicates with the PCS via an OPC
server.
•The following tables show the communication of
LUCIE at the cement plant.

Kiln communication:
Burning zone sensors Signal (fieldbus or analogue)

For complete
Kiln torque / A From VSD
tabel refer to
NOx signal From gas analyser the la Farge
Burning zone temperature Pyrometer standards!
Secondary air temperature (optional) Thermocouple or pyrometer
Back end temperature (optional) Thermocouple
Preparation sensors Signal (fieldbus or analogue)
Cyclone gas temperatures Thermocouple

Cyclone material temperatures (optional) Thermocouple
Chain gas temperature (optional) Thermocouple
Electrostatic precipitator Signal (fieldbus or analogue)
Dust collector inlet temperature (optional) Thermocouple or Pt100

Precalciner temperature (optional) Thermocouple or Pt100
Cyclone temperatures (optional) Thermocouple
Table 1.53: Kiln communication by the LUCIE system sample

• 1.5.3 QMC - Lafarge Quality Mix Control
• The QMC programme is a multi-strategy programme for:

• * maintaining any process at optimum conditions,
• * identifying the root cause of instabilities,
• * monitoring equipment, sensors and control applications,
• * evaluating alternatives for optimization,
• * migrating models and data to real-time application,
• * integrating models with economics,
• * graphically pinpointing and removing bad data,
• * data filtering, smoothing and 100+ transforms,
• * analyzing pipe and flow element systems,
• * rating, sizing or developing equipment specifications,
• * providing statistical analysis,
• * monitoring SPC variables,
• * tuning, configuring and optimizing multivariable control loops,
• * measuring unit stability quality, safety, reliability, profit,
• * and much more.

#: Pcs. Description Part and/or Pos no.

1 Process Control System 841.CS011
2 1 Ethernet PLC-5/80 controller 100K word SRAM 1785-L80E
3 1 I/O CHASSIS ASSEMBLY, 8 SLOT 1771-A2B
4 1 PLC-5 ETHERNET INTERFACE MODULE 1785-ENET
5 2 Power Supply, slot (one slot), 8A, 220V AC 1771-P6S
6 1 1771 I/O CHASSIS CABLE FOR 1771-P4S, 6S
POWER SPLY, 3.58 FT/1.09 M 1771-CT
7 25 FLEX 48 VDC INPUT MD 1794-IC16
8 10 FLEX 48 VDC OUTPUT MDL 1794-OC16
9 6 ANALOG INPUT MODULE, 12 BIT, 8 POINT 1794-IE8
10 4 Analog Output MODULE, 12 BIT, 4 POINT 1794-OE4
11 50 Terminal Base 3-wire 1794-TB3T
12 10 Devicenet adapter with 24V DC power supply 1794-ADN
13 8 85-264 VAC IN/24 VDC out 1 A power supply 1794-PS1
14 1 MODBUS CARD for PLC5, PROSOFT 3100-MCM
15 2 MASTER MODULE FOR POWERMONITOR 1403-MM05A
, 120/240V AC 50/60 HZ
16 2 COMMUNICATION MODULE FOR 1403-NDNET
POWERMONITOR, (DeviceNet)
17 2 DISPLAY UNIT FOR POWERMONITOR, 1403-DMA
120/240V AC 50/60 MZ OR 125/250V D
18 2 2x3 M F link for power monitor 1403-CF003
19 2 2-CHANNEL DEVICENET SCANNER MODULE 1771-SDN
20 4 Power TAB for DEVICENET 1485-T-P2T5-T5
21 1 8 Port TAB for DEVICENET 1485-P-P8T5-T5
22 8 2 Port TAB for DEVICENET 1485-P-P25T-T5
23 1 Accessories Kit for DEVICENET 1485-Acc Kit
24 8 Terminator for DEVICENET 1485-A-C2
25 1 RSNETWORX FOR DEVICENET 9357-DNETL3
26 1 DEVICENET RS232 Adapter 1770-KFD
27 1 PROBE CABLE FOR 1770KFD 1787-PCABL
28 2 DEVICENET CLASS II 24VDC Power Supply 1787-DNPS
29 2 RT2 -TX/FX 943658002
30 1 Wall mounted patchbox with 12 ST-simplex holes 88648886
and 2 cable
31 2 Fiber Optic Patch cable ST-SC 62,5/12um Duplex 88701586
32 10 Single Media Adapter for Cotrolnet 1794-ACN15
33 50 Flex I/O terminal base, 3 wire 1794-TB3
34 8 Flex I/O 85-264 VAC to 24 VDC 1.3A Power 1794-PS13
Supply
Table 1.59: A typical spare part list for the automation system (part 1)

Fig. 1.60: The entrance page of the la Farge standards



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Package E3: Automation and instrumentation

The Process Control

Basic Functional Objects

Software and Integration

Module 01: Process control and process control equipment

Table 1.1: The Process Control System step by step

Module 01: Process control and process control equipment

Fig. 1.3: Computer integrated manufacturing (CIM)

Module 01: Process control and process control equipment

Fig. 1.4: Example of a PCS architecture in a cement factory

Fig. 1.5: A local PLC (field controller).

Fig. 1.6: Redundancy power supply

Module 01: Process control and process control equipment

Table 1.7: The plants configuration of logic signals

Module 01: Process control and process control equipment

EXAMPLE OF SIGNALLING TRAFFIC

Examples of binary logic levels

Technology Low voltage High voltage Notes

CMOS 0 V to VCC/2 VCC/2 to VCC VCC = supply voltage

TTL 0 V to 0.8 V 2 V to VCC VCC is 4.75 V to 5.25 V

ECL -1.175 V to -VEE .75 V to 0 V VEE is about -5.2 V VCC=Ground

Table 1.9: Examples of binary logic levels.

Module 01: Process control and process control equipment

Fig. 1.10: “Collapsed backbone”

Module 01: Process control and process control equipment

Fig. 1.11: Communication cards

Module 01: Process control and process control equipment

10Base5 Coaxial 500 m

Fast Ethernet 100Base-TX TP 100 m

Module 01: Process control and process control equipment

Fig. 1.13: “Supervisory control and data acquisition” (SCADA) system.

Fig. 1.14: Network (i.e. Ethernet) Redundancy

Fig. 1.15: A touch-screen panel with mimic display

Module 01: Process control and process control equipment

Fig. 1.16: A mouse-driven PC plant control and data screen

Fig. 1.17: Screen arrangement for the process control system

Module 01: Process control and process control equipment

Fig. 1.18: The standard la Farge display layout

Fig. 1.19: The symbols used for digital operated valve

Module 01: Process control and process control equipment

Figure 1.20: The symbol of a material diverter

Inner part Outer part

Damper / shutter not in

Fig. 1.21: The damper symbol

Fig. 1.22: The basic motor symbols

Module 01: Process control and process control equipment

Fig. 1.23: The typical motor faceplate as displayed at the CCR

Module 01: Process control and process control equipment

Fig. 1.24: A typical local PLC, here a Siemens S7-400 PLC

Module 01: Process control and process control equipment

Table 1.25: Common programming languages (part 1)

Table 1.25: Common programming languages (part 2)

Module 01: Process control and process control equipment

C, shell, awk, sed, functional, object-

Table 1.25: Common programming languages (part 3)

Module 01: Process control and process control equipment

Status Message Sound

Table 1.26: Message and alarm attributes

Module 01: Process control and process control equipment

Fig. 1.27: The faceplate PID regulator (sample)

Fig. 1.30: The trend curves of an analogue PID controller

Fig. 1.31. The procedure of authorisation of software changes and up-dating

Module 01: Process control and process control equipment

Code Description Start-up Shutdown