foundation field bus services engineering project pellet plant ... typical flow sheet of pellet...

Electrical Technology GroupElectrical Technology Group

Shared ServicesShared Services

Engineering Project Engineering Project

Pellet PlantPellet Plant

Foundation Field BusFoundation Field Bus





Date: 09.07.2010Date: 09.07.2010

Iron & Steel MakingIron & Steel Making

ATAT

TATA STEELTATA STEEL

Typical Flow Sheet of Pellet Plant





12.3 10.57% 7.2 5.56% 944.6 10.00%

11 6.8 850.1

12.1 8.26% 7 2.86%

11.1 6.8

963.7 9.93%

868

872.4 0.62%

867

ESP Dust 5.7 TPH

0.5%

809 0.49%

805

8.99%

881.7 8.70%

805

Tons/Hr %

945 97.98%

12.3 1.28% 1260.1 1259.6 8.70%

7.2 0.75% 1150

4.3 0.45%

125.96 140 0 TPH

154

1259.6 8.70%

1150Tons/Hr or

Nm3/Hr

9.2 251.9 TPH (W)

12000 230.9 TPH (D)

118000 20.00% 1007.7 8.70%

72.7 920

Green Pellet under size

126.5 TPH (W)

115.5 TPH (D)

14.5195354 12.55% 881.2 8.70%

804.5

8.70%

2.5 TPH (D)

Dust

3.83% 1101.9 1102.5 0.00%

1102.5

30.00% 330.7 TPH 3.2 TPH (D)

Dust

768.6 TPH

68.72% 757.6 TPH 1.00% 11 TPH

18182.4 TPD

BF Gas 156

Process Water 96

Coal Tar 12

CO Gas 16

Fuels / Utility

Consumption Rate

Kg or Nm3 per ton

of Pellet

6

Lime Stone

Anthracite Coal

Bentonite

Iron Ore Fines

Drying & Grinding

System

1247

2000 Nm3/hr BF Gas

Raw Materials

Process Water

Consumption Rate

Kg/ton of Pellet

< 10 mm Fraction < 10 mm Fraction

Anthracite Coal Lime Stone

16

10

Ground Concentrate Bins

3.9 TPHBentonite

Anthracite Coal

Impact Crusher 1 Impact Crusher 2

< 40 mm Fraction < 40 mm Fraction

Iron Ore Fines

< 10 mm Fraction

Lime Stone

116000 Nm3/hr BF Gas

Induration Roller Screens

72.7 TPH

Mixed Materials Bins

Mixers

Water

Green Pellets over & undersize

Pelletizing Discs

Pelletization Roller

Screens

Screened Hearth Layer

Induration Machine (768

m2)

Evaporation

Loss of Ignition30.8 TPH (D)

76.7 TPH

12000 Nm3/hr CO Gas

220 TPD Coal Tar

Product Pellets Pellet Fines

3 ESPs

Pellet Screening 1 ESP





Car Dumper

Fines ReclaimerLimestone Bin Coal Bin

Binder Bin

Pelletizing Bins

PelletizingDisks

GreenPellets

Travelling Grate Furnace

Screening

Fired Pellets

Fired PelletsStacker

Fired PelletsStockyard

Pellets for Hearth Layer

Fines

Mixers

Hammer Mill

Iron Ore Bin

Ball Mill

Ground Ore Bin

PELLETIZING PLANT TATA STEEL (JAMSHEDPUR)

Blast Fuirnace





FOUNDATION fieldbus was originally intended as a replacement for the 4-20 mA standard.

Foundation Fieldbus is an all-digital, serial, two-way communications system that serves as the base-level network in a plant or factory automation environment

A typical fieldbus segment consists of the following components.H1 - fieldbus interface card FPS - Fieldbus Power Supply and Signal Conditioner PS - Bulk power (Vdc) to Fieldbus Power Supply T - Terminator And fieldbus devices, (e.g. transmitters, transducers, etc





INTRODUCTION

FOUNDATION Fieldbus (FF) is a fieldbus protocol based on

international standards and designed for applications in the manufacturing industry, process automation and

buildings automation. The guidelines for this fieldbus standard are published by the Fieldbus Foundation.





FF defines two communication profiles, H1 and HSE. The H1 profile, with a transmission rate of 31.25 kilobits per second,

is preferably used for direct communication between field

devices in one link (H1 link). The HSE profile, which is based on standard Ethernet and typically features a transmission

rate of 100 megabits per second, serves first and foremost as a powerful backbone for the connection between H1 links. The devices that are already available on the market and support the HSE profile are FF linking devices. They serve as

a gateway between the field devices on the H1 links and the

HSE backbone. Device Management FOUNDATION Fieldbus supports the ABB Linking Device LD 800HSE.





In an 800xA environment a FOUNDATION Fieldbus network (FF network) is linked with the IEC 61131 controller via a

FOUNDATION Fieldbus HSE communication interface

module CI860 in the AC 800M; this module is installed as an HSE host on the powerful HSE subnet.





ADVANTAGES:

FOUNDATION Fieldbus provides an open standard for process automation applications and is supported by all the major control and automation product manufacturers. It consists of a low-speed bus (H1) designed for the interconnection of “field” equipment such as sensors, actuators, and I/O, and a high-speed bus (HSE, High Speed Ethernet) allowing optimization of network design and integration of high speed controllers (such as PLC or DCS), H1 subsystems (via linking devices), data servers and workstations. FOUNDATION Fieldbus provides built-in capability to distribute the control application across the network.





Device Management FOUNDATION Fieldbus consists of a set of software components for efficient planning, commissioning, and maintaining of field devices within ABB’s Industrial IT 800xA system.

The main components are:

• Fieldbus Builder FOUNDATION Fieldbus

• OPC Server FOUNDATION Fieldbus

• Device Library Wizard

• Device Type Objects





Fieldbus Builder FOUNDATION Fieldbus

The FOUNDATION Fieldbus network and application configuration isdone by the Fieldbus Builder FOUNDATION Fieldbus. It acts as an integrated application within the Industrial IT 800xA environment. The main tasks are:

• Managing the FOUNDATION Fieldbus network

• Creating FF Applications running on H1 links





• Parameterization of field devices

• Generation of H1 schedules and configuration data for Link Active Scheduler (LAS)

• Managing device and function block libraries (this includes expanding the set of devices which are available as device type objects via import of Device Description files and Capabilities files)

• Download and commissioning

• Network and device diagnosis

• Configuration of OPC Server FOUNDATION Fieldbus





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