process control system : cemat v8 update -...

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Process Control System : CEMAT V8 update

Siemens Process Automation Conference (SPACe) 2013, Mumbai, India

2013-06-06

Restricted © Siemens AG 2013 All rights reserved.

Agenda

Q & A

Case Study

What is new in CEMAT V8.0

Introduction to Vertical Minerals 1

2

3

4

2013-06-06


Vertical Minerals serves the Cement and Mining industry

Excavation Transportation Beneficiation

Blending/Grinding

Bulk Material Handling

Clinker/ Grind & Finishing Outbound Transportation

DRIVE SOLUTIONS

ELECTRIFICATION

AUTOMATION

SERVICES

- SOLUTIONS -

covering the whole plant

2013-06-06


Vertical Minerals leverages its domain knowhow to solve your challenges

through Siemens products

Ho

rizo

nta

l (I

DS

)

Vert

ical (T

IA)

Lif

e C

ycle

Serv

ice

s

Domain knowhow in Cement & Mining

2013-06-06


Our portfolio serves end-to-end needs of the Minerals Industry

SIMINE SICEMENT

Converter

Transformer

Control &

Monitoring

Cabinet

Frequency

Converter Motor Gearbox

Perfectly integrated drive system for all power and

performance classes

Unrivaled portfolio from one source

Ensure drive train compatibility

Reliable system performance

Boost plant availability to up to 98% Ho

rizo

nta

l

Integrated Drive Train

Ve

rtic

al

Totally Integrated Automation

Lif

ec

yc

le

A full Lifecycle perspective

Seamless integration into automation

environments from field level to ERP

Drive train integrated into TIA

Intelligent monitoring and control

Integrated tool for engineering, commissioning, and

diagnosis

Cut engineering time by up to 30%

Comprehensive software tools & expert services

from planning to operation, maintenance &

updates

Configuration from coupling to control

Seamless tools from MCAD to comm.

Simulation and optimization

Lower maintenance cost by up to 15%

2013-06-06


Agenda

Q & A

Case Study



2

3

4

2013-06-06


More than

800 CEMAT

installations

since 1976

CEMAT - A success story!

U p g r a d e

1976 1981 1987 1992 1996 2000 2003

Cemat

with

SIMATIC S32

C emat V1.8

- Cemat V2

MIS WIN3.11

LS_C

SIMATIC S5

Cemat V1.6

DISIT

SIMATIC S5

150A/K

Cemat V3

MIS WIN3.11

LS_B

SIMATIC S5

Cemat V4

MIS WIN3.5

NT4.0

SIMATIC S5

SIMATIC S7

Cemat V5

PCS7 V5

SIMATIC S7

Cemat V6

PCS7 V6

SIMATIC S7

2005

Cemat V6.1

2007

Cemat V7

PCS7 V7 SP1

SIMATIC S7

PCS7 V6

SIMATIC S7

2010

Cemat V7.1

PCS7 V7.1 SP1

SIMATIC S7

Cemat V8

2012

PCS7 V8.0

SIMATIC S7

CEMAT® is a control system specifically designed for cement plants and has been

well proven in this harsh environment over many years of service.

2013-06-06



CEMAT - Project Standards developed for cement industry

Code Standard

000 “normal”

001 Minerals

004 Holcim

006 Dyckerhoff

007 Heidelberger Zement

023 Vigier

024 Bushehr

025 Caima

026 Alsen

027 Lafarge

028 Rossi

2013-06-06


Minerals “001” Standard

Key feature clusters

All interlock interconnections

contain Signal State

(i.e. Quality)

Use of feature word

to enable/disable functions

Use of permission word

for individual permissions

Power management

interface

Object browser for

simulation, manual mode,

local mode, PM released

Overall Group / Drive

communication

(PLC to PLC)

Additional manual modes

and Out of Service mode

2013-06-06



Control / Supervision : Group, Route and Selection features

Group-wise change

to Automatic, Manual

and Local possible

Object browser for



Overall Group / Drive

communication

(PLC to PLC)

Group not empty

Information

Interlocks can be

by-passed

Object browser for



Automatic mode and

Out of Service mode

Group control

Route Selection

2013-06-06



Control / Supervision: Intuitive diagnostic tool via Group faceplate

Related objects C_GROUP Object list

2013-06-06



Control / Supervision : Information flow and diagnosis via Group faceplate

Information Flow between objects with diagnosis and interlocks

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Control / Supervision : Alarm & Status list via Group faceplate

status – list alarm – list

2013-06-06



Device Control and Messaging: Unidirectional drive

Manual modes with

different interlocking grades

Automatic mode,

manual mode , local mode

And Out of Service mode

Additional essential

Interlocks (effective also-

in local mode)

Individual mode selection

via OS or via program

Damper with contactor

Feedback supervision and

calibration function

Valve with Contactor

feedback supervision and

simulation function

Object Browser function

Emergency Stop function

Field switch functions

can be configured

individually

http://www.automation.siemens.com/bilddb/picdetails.asp?objID=33226&aktprim=0&nodeID=10007359&foldersopen=-1079-2907-3037-2908-2979-2980-3054-5450-7339-10185-10186-9172-9346-1-2-&jumpto=2&page=28

2013-06-06



Device Control and Messaging: Various Operating Modes offer higher

flexibility

“Automatic” mode

• The control of the function is computed automatically by the block algorithm or from a super ordinate control like Group.

“Manual” mode

• The function is controlled by the operator - completely interlocked - only protection interlocks are active - only essential interlocks - non interlocked (only protection Interlock general)

“Local” mode

• The function is computed by the device directly. (local switch) - only essential interlocks

“Out of service” (Maintenance) mode

• The function is stopped • All values go to safe position or last used value depending on the

function block. • All messages are suppressed

2013-06-06



Device Control and Messaging: High flexibility ‘Feature Parameter’&‘OS

Permission’

Local Settings

Manual settings

OS Permission Feature Parameter

2013-06-06



Device Control and Messaging: Measured values

Automatic mode

And Out of Service

mode

Individual mode

selection via OS

or via program

Measured values

can be linked to

the drives

Enhanced online

curve selection

Forcing PV

Out to “0” possible

2013-06-06



Device Control and Messaging: Annunciations

Automatic mode

And Out of Service

mode

Individual mode

selection via OS

or via program

Annunciations

and PROFB can be

linked to the drives

2013-06-06



Device Control and Messaging: Process feedback

Automatic mode

And Out of Service

mode

Individual mode

selection via OS

or via program

New Process

feedback block PROFB

Annunciations

and PROFB can be

linked to the drives

2013-06-06



Device Control and Messaging: TREND

With right mouse click on the unit the new Online Trend window

will be shown. Storage of Curve Group

2013-06-06



Device Control and Messaging: Single click TREND feature

Show selected Online Trends Right mouse

click on Symbol

Show Archive Curve in a big dialog

2013-06-06



Device Control and Messaging: Alarm & Message List

New Alarm control with extended functionality

Selection input dialog

Toolbar window

Alarm & Message List

2013-06-06



Device Control and Messaging: Object Browser Functions

The Object browser can be called from the OS Client to display all objects according to selection:

All Objects within one PLC being in Manual Mode in Local Mode out of Service

with simulation

All Objects within one PLC having a note assigned to

Via mouse-click onto the object in the browser list each object can be opened

2013-06-06



Device Control and Messaging: Required information at single click !

Diagnostic

Obj. list

Alarm list

Info dialog Info. Dialog

Maintenance

2013-06-06


Agenda

Q & A

Case Study



2

3

4

2013-06-06


CEMAT enables streamlined cement production at Wonder Cement

• 6500 TPD Greenfield

Integrated Cement Plant

• Location: Nimbahera,

Rajasthan

• Status: Commissioned in

2013

Plant details

• Complete integrated solution for:

• Process optimization system for

mills and kilns

Customer needs

Drives Intelligent MCC

Lab System Energy meters

Profibus - PA Sub-control system

• PCS7 suite based on CEMAT is the overarching solution

• Redundant PA Ring for reliable and deterministic

communication

• Messaging & E-mail facility to enable constant monitoring

• KCS & MCS based on CEMAT for process optimization

Solution description & configuration

• Proven engineering solution based on CEMAT

• Special design blocks for Cement coming out of Siemens’s

deep domain knowhow

• Homogeneous integration on one single platform results in

reduced operational and maintenance costs

Customer benefits

System configuration

ES OS OS-Servers AS IO

3 8 1 11 8000

+Pro. PA iMCC EMS/MIS Drives/SCS MFM/Rel.

250 1100+ Yes 85 Yes

Unique

2013-06-06


PA Ring and iMCC drive availability, reliability and flexibility in the plant

• State of the art technology with redundant deterministic

communication

• Redundancy ensures availability of system

• IP66 for Spur JB results in low maintenance

• Seamless integration into control system

PA Ring

• Proven technology for Motor control.

• Centralized engineering/access/control.

• Rugged system.

• Freely parameterized

• Seamless integration into control system

iMCC

2013-06-06


Agenda

Q & A

Case Study



2

3

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2013-06-06


We welcome your questions!

2013-06-06


Thank you for being patient participants!

2013-06-06


Contact détails

Dwajan BSG

Siemens Limited

Industry Sector

SAS RC-IN I-DT LD VSS-M

Kalwa Works, P.O. Box 85, Thane-Belapur Road,

Thane- 400 601 (Maharashtra), INDIA

Phone: +91-(022)-3326 5138

Fax: +91-(022)-27643727

Mobile: +91- 9619484026

E-mail: bsg.dwajan @siemens.com

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