Control and Instrumentation System

for Cement Plants

LARSEN & TOUBRO LIMITED

L&T AUTOMATION
Automation systems for optimal efficiency and productivity
 COST-EFFECTIVE
CONTROL & INSTRUMENTATION SYSTEM
Today’s large capacity (over 2 million tonne per connected to the plant-wide-network using a simple,
annum) cement plants are characterised by capital yet inexpensive twisted pair cable. Either way, cost-
intensive, high efficiency systems. effectiveness is assured.

Today’s Cement Plants are designed for zero The total plant connectivity from Crushing Section
downtime, high-product quality, and better to Packing Section facilitates better integration and
throughput with minimum energy consumed per unit results in reduction in operating costs by
of cement production. synchronising & optimising the operations. Trouble
shooting becomes much easier with availability of
L&T Automation advanced state-of-the-art cement centralised diagnostic information of various control
plant control & instrumentation system a cost and instrumentation equipment connected to the plant
effective solution to help operate the plant to its wide network.
designed parameters in a optimal & efficient manner.
Cost effective Process Controller
Typical cement plant control & instrumentation configuration
system comprises:
‘Hot standby’ Process Controller configuration for
s Powerful ‘Process Controllers’ with remotely Kiln and Cooler has been so far popular. However,
located I/O stations. with increased reliability of Process Controllers,
s Flexible, user-friendly Windows® NT based modern plants have done away with ‘Hot standby’
supervisory colour graphic ‘Operator Station’ configuration and are going in for single Process
system. Controller in these critical sections also.

s High-speed, deterministic ‘plant-wide- ‘Hot Swap’ I/O for plant online

network’ that links the Process Controllers &
Operator Station System and also allows
connectivity with specialised systems such as
Kiln Optimisation, Energy Management, X-ray
Spectrometer, etc. by means of gateways.
Cost-effective remote I/O stations
Process Controllers with remote I/O capabilities help
in locating I/O stations as far away as those in
Crushing Section, Packing Section, etc., to their
respective Process Controllers kept in CCR, using
a single co-axial or fibre optic cable (for distance
more than 4 km), thus saving miles of expensive
control/signal cables and associated costs of cable
laying, testing & maintenance.
Alternately, Process Controllers with I/Os located
at Crusher Section or Packer Section can be
performance
Due to the modular system architecture and ‘Hot
Swap’ design, I/O modules can be replaced, ‘ON
LINE’ without shutting off the power supply or
affecting the other equipment. This avoids a major
shut-down when only one module is to changed thus
contributing to plant productivity.
Software based closed loop control
Precise closed loop control requirements such as
those required in Kiln, Cooler & Raw mill sections
are easily implemented using readymade PID
software functions in Process Controllers. The result
is optimised solutions and close integration which is
in man-hours otherwise difficult when developing
closed loop control strategies with dedicated single

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Automation systems for optimal efficiency and productivity
loop controllers. With precise & accurate third party systems for a cost-effective, yet reliable
programming of closed loop controls for important system integration.
parameters such as Kiln Feed, Draft Temperature,
Coal Usage, Airflow through Cooler, etc., helps in Integration across all levels
stabilising the Kiln faster.
The plant-wide-network being a open architecture
Cost saving in control cables network, connectivity of this network to higher level
packages such as Kiln Optimisation System, Fuzzy
The operators in Central Control Room are now Logic, Energy Management System, MIS
able to set and control various operating parameters application, etc., is possible. This gives flexibility to
of the plant. Thanks to high-speed, deterministic, the user to choose only off the relevant application
token pass, plant-wide-network. It is now possible systems as per the plant requirement, yet interface
to network all the DC/AC drives of the plant with the same to the plant control & instrumentation
Process Controllers, using drive network for system.
exchange of vital data between them, rather than
hard wiring through expensive control cables. Apart Cost effective Windows® NT based
from cost savings in supply & erection of such cables, Operator Station System
it also results in better synchronisation & effective
response to increased process complexity. The Plant information is now available at fingertips with
deterministic & token passing attribute of drive supervisory and colour graphic Operator Station
network contributes greatly in achieving a fast overall System based on Windows® NT.
system response time of less than 2 seconds. This
means plant operators are updated about happenings
in the plant instantly. This high-speed network uses
simple, inexpensive twisted pair cable for
communication, hence is a very cost-effective
solution. Yet, it is geared up for handling high-density,
high-volume plant data over 6500 ft.

Cost Savings in programming Alarm - Manager Page

terminals

With plant-wide-network, there is no need for a

separate programming/engineering terminal / network
for programming any Process Controller connected
to it, as the network can handle both ‘plant data’ &
‘programming data’ with equal efficiency. This avoids
unnecessary expenditure on separate programming
terminal / network.

Programming any Process Controller connected on

the network from any of the Operator Station System Graphic Mimic Page
is now a reality. Redundancy in the plant-wide-
Cost-effectiveness & user-friendliness is the hallmark
network is available as an inexpensive option for
of such a system. A standard system is realised with
increasing the reliability of data transmission. A
commonly available, standard, non-proprietary
standard bridge ‘gateway’ enables connectivity to
hardware platforms as Operator Stations. Besides

L&T AUTOMATION
Automation systems for optimal efficiency and productivity
high resolution, object oriented graphic mimics with normally required to be done during commissioning
tag-based parameter display, the system has a or otherwise, from any of the Operator Stations.
powerful ‘Alarm-Manager’ to highlight any
abnormality in the process in real-time, irrespective Connectivity through Ethernet TCI/IP to other
whether the concerned section mimic is displayed application system is available using the built-in Net
or not. DDE facility.
Embedded trends, as a part of graphic mimic, Over 500 levels of security guards are available for
enables viewing of parameter trends along with the protection against tampering or unauthorised
associated section graphic display. operation of the plant. There is no additional cost
Cost effective flexibility involved for connecting third party Process
Controllers to such a flexible system, as Multi-
With such flexible system, making modification or Process Controller ‘protocol’ is again ‘built-in’.
changes ‘On-line’ does not call for either a separate
programming network or a separate development Such flexible and cost-effective system can make
package. Thus, saving additional expenditure. The life of cement plant personnel at all levels, much
system lends itself easily to ‘on-line’ changes, easier.

L&T AUTOMATION
Automation systems for optimal efficiency and productivity
 K iln O ptim isatio n X R F /X R D
(3 rd P a rty S o ftw a r e)
S p ectro m ete r

E th e rn et 

O pera to r s tation

P lan t-wide-netw ork

P C R I/ N N N
S P O O O O
N N N N N N
P
S
C
P
U
RI/
O
DRR
N
O
M
N
O
M
N
O
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Process Con troller U D RR M M E
Process Con troller P
S
C
P
R I/
O
D RR
O O O Process Con troller P
S
C
P
R I/
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D RR
O O O Process Con troller
U M M E U M M E
for Cru sh er section for Raw Mill section for Klin section for Coo ler section

D rive netw ork

D rive netw ork D rive netw ork

A C drive s fo r R aw M ill sectio n D C drive fo r Klin se ction A C drive fo r Co oler se c tio n

R I/O R I/O R I/O R I/O

N etw ork N etw ork N etw ork N etw ork

R I/O s tation s R I/O s tation s Typic al Ins trum en ts R I/O s tation s R I/O s tation s
fo r C ru she r fo r R a w M ill co nn ec ted to the I/O station s fo r K lin fo r C o ole r

To o th er To o th er To o th er To o th er
R I/O S tation s R I/O S tation s R I/O S tation s R I/O S tation s

C ru sh er R aw M ill
C ooler
K lin

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Automation systems for optimal efficiency and productivity
 S erv er

G atew ay

P lan t-w id e-n etw o rk

P C R I/ N N N
S P O O O O
U D RR M M E
Process Con troller P
S
C
P
U
RI/
O
DRR
N
O
M
N
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M
N
O
E
Process Con troller P
S
C
P
RI/
O
DRR
N
O
M
N
O
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N
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Process Con troller
U
for Coal M ill section for Cement Mil section for Packin g section

D rive netw ork D rive netw ork D rive netw ork

A C drive s fo r C o al M ill s ectio n A C driv es fo r C em en t M ill section A C driv es fo r P ack in g s ectio n

R I/O R I/O R I/O

N etw ork N etw ork N etw ork

R I/O s ta tion s R I/O s ta tion s R I/O s ta tion s

fo r C o al M ill fo r C em en tl M ill fo r P a ckin g P la nt

To o th er To o th er To o th er
R I/O S tation s R I/O S tation s R I/O S tation s

P acking
P lan t
C linke r C em ent
stire M ill

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Automation systems for optimal efficiency and productivity
 LARSEN & TOUBRO LIMITED
P.O. Box 8119 Post Bag 5247
Mumbai 400 051 Chennai 600 002
Tel : 6401232 Tel. : 8522141
Fax : 6401312 Fax : 8520769
P.O. Box 7025 P.O. Box 619
New Delhi 110 002 Calcutta 700 071
Tel. : 3721830 Tel. : 2422301
Fax : 3713802 Fax : 2421025

L&T AUTOMATION
Automation systems for optimal efficiency and productivity