Editorial Message. Sandeep Bhat. Issue 7, Dear Reader,

Transcription

1 Issue 7, 2015 Editoria Message Dear Reader, Today, more than 54% of the word's popuation ives in urban areas, a proportion that is expected to increase to 66% by As per The 2014 revision of the Word Urbanization Prospects by UN's Department of Economic & Socia Affairs (DESA) Popuation Division, the argest urban growth wi take pace in India, China and Nigeria. As a resut, these countries wi face numerous chaenges in meeting the needs of their growing urban popuations, incuding housing, infrastructure, transportation, energy and empoyment, as we as basic services such as education and heath care. Recognizing the importance of sustainabe infrastructure, the Government of India is working on structura poicy changes to provide a big push to the Indian economy. 'Make in India', one of the major nationa initiative that focuses on making India a goba manufacturing hub with the objective to ensure that manufacturing sector which contributes around 15% of the country's GDP is increased to 25% in the next few years. As a resut, the Cement sector is expected to gain arge benefits from this. Today, with a current production capacity of around 366 MT, India is the second argest producer of cement after China in the word. To meet the rise in demand, cement capacity is expected to increase to around 550 MT by FY20. Cement being a commodity item does not aow much premium pricing and thus most manufacturers are price takers in the markets they operate in. In such a scenario, contro over operating expenses is essentia not ony to maintaining cost competitiveness but maximising profitabiity. The major operating cost for cement companies is power and fue. The vintage of a cement pant aso significanty infuences its cost structure. Whie an oder pant enjoys the advantage of ower capita cost, such benefit is usuay offset by higher power and fue costs, significant repair and maintenance expenses, and generay higher manpower expenses. Size is another factor that determines the overa cost structure of a cement pant, as arger pants usuay enjoy better contro over infrastructure and overhead expenses. Taking into consideration these facts, Indian cement manufacturers are setting up arger capacity pants to everage voume handing. From mines to packing, eectrica and automation pays a vita roe in the production of consistent high-quaity cement, caring about environmenta responsibiities, cost effective production and reducing capita empoyed. Automation soutions pay a vita roe in increasing the efficiency and reiabiity of cement production. C&A has been committed to the cement industry since 1975 and continuay deveoped standards for this industry. During the ast 37 years, C&A has deivered successfu process contro systems to various cement pants with tota capacity of 100 MTPA in India and abroad. In this edition of CAnvas, we are featuring a case study on the atest automation system depoyment at Guf Cement Company for Waste Heat Recovery Based power Pant that highights C&A's technica competence and automation expertise. As a eading system integrator, C&A aso offers Eectrica & Automation soution to the Cement industry. Its engineering department, with their industry-specific vaidation procedures, ensures consistenty high quaity soutions in E&I domain. Hope you wi find this issue interesting and informative as aways. Happy Reading!! Sandeep Bhat

2 Industry Trends Waste Heat Recovery and Cyber Security - heping Cement Industry to increase Pant efficiency Cement industry pays a pivota roe in the infrastructure deveopment. With the government giving a boost to arge scae infrastructure deveopment, the cement industry in India is set for a big growth. To meet the rise in demand, cement companies are focusing on adoption of massive modernisation and assimiation of state-of-art technoogy to become energy-efficient and comparabe to the best in the word in a respects, whether it is kin size, technoogy, energy consumption or environmentfriendiness. Faced with the chaenge of efficient use of energy, major payers of the cement industry are adopting best manufacturing practices to optimize energy, natura resource consumption and technoogy. Energy saving varies on a case-to-case basis depending on the actua seection of process and equipment, quaity and consistency of fue, raw materia characteristics, etc. new cement pant, as is the case in some emerging countries. A significant portion of the energy requirement can be sourced through utiisation of waste heat from the pre-heater and cooer. Typicay, cement pants do not have significant ow-temperature heating requirements, so most waste heat recovery projects have been successfu. The amount of waste heat avaiabe for recovery depends on kin system design and production, the moisture content of the raw materias, and the amount of heat required for drying in the raw mi system, soid fue system and cement mi. Waste heat recovery can provide up to 30% of a cement pant's overa eectricity needs and offers the foowing advantages: Reduces purchased power consumption (or reduces reiance on captive power pants), which in turn reduces operating costs Mitigates the impact of future eectricity price increases Enhances pant power reiabiity Waste Heat Recovery System The cement industry is currenty focusing on five broad categories: therma and eectrica energy efficiency, co-processing of aternate fues and raw materia, cinker substitution, waste heat recovery for power generation and adoption of new technoogies ike use of bio-fues. In this context, the upcoming pants are considering aternative fue and raw materias (AFR) and waste heat recovery (WHR) system for power generation. It is imperative to make WHR a mandatory requirement for any Improves pant competitive position in the market Lowers pant specific energy consumption, reducing greenhouse gas emissions (based on credit for reduced centra station power generation or reduced fossi-fired captive power generation at the cement pant) A WHR instaation is a reativey compex system with mutipe inter-reated subsystems. The basic package for a steam-based system consists of heat recovery boiers or heat exchangers, steam turbine, gearbox, eectric generator, condenser, steam and condensate piping, ubrication and cooing systems, watertreatment system, eectrica interconnection equipment and contros. Tota instaed cost, which incudes design, engineering, construction and commissioning can significanty vary depending on the scope of pant equipment. Industry is ooking forward to eectrica and automation soutions that wi hep in better power management and waste heat recovery. Automation heps in understanding how much energy each unit is using, thereby reveaing the 'energy wasters' that can be repaced by more efficient systems. Automation aso monitors energy imports, and heps to stay within contractua imits, for exampe, through seectivey switching off non-critica defined parts of the pant. Cyber Security Aside from desire to become energy-efficient, some companies are investing in advanced technoogies to boost manufacturing fexibiity and speed, suppy chain responsiveness, and customer satisfaction. For years, traditiona factories have been operating in isoation and disconnected with corporate business systems, where managers have ony poor visibiity into downtime and quaity probems, and 2

3 where the root causes of inefficiencies are hardy understood or addressed. To get ahead, modern manufacturers are adopting new pant architectures where in pant network converges with goba IT networks. In such a scenario, it is absoutey critica to protect your Contro Network infrastructure, as today, goba cyber attacks are not just restricted to the IT word. More and more process/manufacturing industries are faing prey to various attacks that are designed to crippe the entire organization. Lack of awareness and inabiity to update the process contro systems on reguar basis are the major oop-hoes which act in the favour of the attackers. Apart from financia osses, there can be significant impact to the environment and human ives; such attacks coud aso affect the very existence of the organization in the ong run. Some of the primary causes of ost production eading to financia oss and impact to environment are incorrecty configured firewas, viruses and un-instaed or outdated system patches. To effectivey address security, peope, processes and technoogy must be considered. Advance requirements ike remote monitoring and diagnosis on rea time basis of critica equipments by the OEM, which may happen on the internet, cas for impementation of secure and robust infrastructure for integrating the PCN environment with the Enterprise network. There is a significant difference between the security phiosophies of enterprise IT and Process Contro Network (PCN). The purpose of enterprise security is to protect the data residing in the servers from attack. The purpose of PCN security is to protect the abiity of the faciity to safey and securey operate the automation activities which may consist of systems ike DCS, SCADA, HMIs and equipment ike PLC, RTU and sensors, regardess of what may befa the rest of the network. The use of mainstream operating system environments such as Windows, UNIX, Linux and various open sources systems as we as COTS (commercia off-the-shef) networking components for running PCN appications eave them just as vunerabe as IT systems. However, the appication of mainstream IT security technica soutions may not work as effectivey for automation systems primariy because of their deterministic operation; they are not designed for 'patching' since their mission critica appications do not permit a 'reboot' for these upgrades to take effect. The biggest chaenge in making pant automation, protection and contro systems more secure thus reate to human behaviour and organizationa processes. The first step in any security programme shoud be the deveopment of a security poicy a document identifying the overa security goas and objectives and defining what the vauabe assets are that need to be protected. The security poicy is the basis for any technica, procedura, or organizationa security mechanism, yet ceary defined security poicies do not exist for many contro systems today. Creating, communicating, and enforcing a security poicy are management's responsibiity and shoud no onger be negected. After deveoping a security poicy, the next step is to buid in processes to hep estabish and enforce it. These processes, for exampe, woud incude empoyee hiring and eaving, but shoud aso describe incident handing and disaster recovery. Additionay, the security poicy shoud offer a we-documented pan about how to dea with possibe security incidents or breaches and address questions such as what shoud be done, who must be invoved, and how to restore the system. Just as important as having these processes documented is exercising them reguary to ensure they work. Overa, the demand for cyber security, both from technica as we as from process perspectives, wi increase in the near future. Cyber security wi become mandatory requirements in products, systems, soutions, and processes as industry standards are deveoped and reguations are adopted as aw. 3

4 E&A offerings for Cement Pant Integrated E&A Soutions for Cement Industry Today, for a cement pant, consistenty producing high-quaity cement is just not enough as the chaenge ies in achieving continua operationa exceence in terms of reducing input cost, usage of fewer resources and meeting stringent environmenta reguations. A of these cannot be achieved by ony enhancing process contro. It actuay requires technoogicay advanced and innovative soutions. The soutions that the Contro & Automation's (C&A) business unit of L&T Eectrica & Automation offers and heps you effectivey meet the chaenges are buit on over four decades of experience in the cement industry. We offer the right bend of advanced contro technoogy, optima sizing of eectrica equipment and seamess data connectivity from fied instruments to the board-room, which heps users in taking faster decisions / actions to increase overa pant efficiency. From mines to packing pant operations, our subject matter experts with domain knowedge of contro and engineering processes pay a front roe in providing seamess integrated soutions. These are cost effective soutions that improve the reiabiity, avaiabiity, maintainabiity and safety of operations. Our services provide you with the opportunities to maximize production uptime and ower the ife cyce cost. We engage with your project team upfront during pre-bid stage to faciitate the basic engineering and critica specifications. It heps us to deiver tota soutions on-time with minimum cost of ownership. Our end-to-end offerings for Cement Pant incude: Integrated Eectrica & Automation soution for Cement Pants, Grinding Units, Captive Power Pants and Waste Heat Recovery Systems. We undertake turnkey contracts for Design/Engineering, Procurement, Erection and Commissioning of compete Eectrica 4 and Automation system for cement pants. Our Integrated soutions incude Switchyard, Power /Distribution Transformers, MV/LV Switchboards, PF Correction Equipment, MV/LV AC Drives, Pant Instrumentation, DCS, ivisionmax-scada, Pant Surveiance System, Lab Automation, IT Backbone and Pant Information System. Our service incudes Switchyard Design, Faut Leve Cacuation, Preparation of Reay Co-ordination Chart, Cabe/Core Schedue, Instrument Sheets, Loop Diagrams, Earthing Design and Automation Network. We aso provide services such as Erection of Equipment, Statutory Approvas, Integrated Trias and O&M. Integrated Soution for ong conveyer system Today, coastine pants & mines are panned and designed to hande buk materia economicay and reiaby. Therefore, operators are investing in buk materia handing system which incudes conveying, stacking and wagon oading. Each faciity has its own cargo handing capacity and requirement and it, therefore, requires customised soution to avoid materia spiage, equipment damage and dust emission. Our eectrica and automation soution pays a vita roe in improving operation speed, efficiency and safety of these systems. C&A provides seamessy integrated E, C&I system for a faciity comprising conveyors, stacker recaimer, storage yard / sios, truck or wagon oading / unoading incuding wagon tippers. Our taiormade soution optimizes the overa performance, reiabiity and energy efficiency. Our offering: Instrumentation comprising Pu Cord/Bet Sway switches, Bet Weighing system, Bet monitoring system, Sio eve monitoring, Condition Monitoring systems etc. Power Distribution system incuding power & distribution

5 transformers, MV and LV power distribution Motors and Variabe Speed Drives for ong conveyor contro Automation system with redundancy at various eve servers, data network, controers, power suppies and IO network for maximum pant avaiabiity Automatic operation and visuaisation of entire faciity from Contro Room using SCADA patform Lifecyce Services incuding system upgrades and ong term AMC contracts Energy Saving Drives and Sip Power Recovery Systems (SPRS): Energy Saving Drives are used in appications ranging from sma fans and pumps to the arge Mi drives and compressors. With recent advancements in IGBT devices, VFD technoogy can now address Medium Votage and, therefore, directy operate Medium Votage motors resuting in energy saving of arger magnitude and reduction of eectrica assets ike transformers and associated switchgear. We offer a compact design with Smart Harmonics Technoogy which ensures a very ow THD, without the need for additiona fiters. C&A continues to be a dominant payer in SPRS for over three decades. With our new technoogy, we bring SPRS with IGBT based Inverter and Active Front End (AFE) which overcomes the egacy probem of poor power factor, whie providing energy saving. G-Vertor SPRS is now avaiabe for speed contro of Sip ring motors up to 5 MW. Power Management System Cement pants need eectrica power which is sourced from utiities, captive power pants and renewabe energy systems. The emphasis is on efficient use of a such power sources aong with effective management of oads, power quaity and assets. To achieve this, one needs an integrated and comprehensive power management system which can meet current and future requirements. C&A provides compete Power Management Soution for a cost effective and efficient energy utiization by maintaining continuous and reiabe power, avoiding penaty in case maximum demand is exceeded, improving power quaity, reducing maintenance cost and thus increasing profitabiity in terms of ower production costs. For some industries, energy costs constitute as much as 20-30% of their tota operating costs and hence even a sma improvement in operationa efficiency can have a dramatic impact on its bottom ine. L&T's ivisionmax provides comprehensive information on optimization potentias and utiization parameters to be correated with KPIs viz., energy efficiency, production rates, process efficiency, power quaity, asset optimization and further supports the decision-making process with up-to-date information. It enabes cear overview of the eectrica network and provides means for monitoring and managing oad. Tight integration of a subsystems ensures system stabiity and heps avoid system coapse. It incorporates a the features of high-end eectrica SCADA system. The features incude: Rea Time Contro, L o a d Shedding, Aarm, Event & Reporting, Synchronization & Load Sharing, Energy Accounting,Power Quaity Monitoring, A s s e t M a n a g e m e n t, L o a d F o re c a s t i n g, E c o n o m i c D i s p a t c h, Avaiabiity Based Tariff (ABT) functionaity, Renewabe Integration. Asset Management & Optimization Soution (AMOS) C&A offers Asset Management & Optimization System (AMOS) for managing the asset ife cyce through a poo of appication and product experts.the systems vary from simpe Drives & Automation to arge E,C&I instaations in Power, Infrastructure, Oi & Gas, Cement, Port and Nucear sectors. The services resut in improvement in the pant avaiabiity and productivity and, thereby, maximise asset sweating. Our services start right from the project impementation stage and are avaiabe ti the end of ife cyce and beyond through optimized migration pans. Our Service Modues cover: Spares Management Remote Monitoring & Assistance Annua Maintenance Contracts Operation & Maintenance Services Energy Audits Training Services Post site hand-over, our engagement with you goes up manifod. We undertake comprehensive O&M of your pant's E&I assets. In the event of technoogica advancements, we provide suitabe upgrade soutions with minima cost of ownership. Cyber Security With over three decades of experience in technoogy improvements and changes in the industry needs as we as processes, C&A today is we equipped to offer its expertise in securing an organization from cyberattacks for an uninterrupted growth in a highy competitive economy. C&A everages on its own experience to secure your information assets and infrastructure to avoid business disruption and achieve reguatory compiance in the changing threat andscape. We offer proven methodoogy to hep our customers put up an in-depth defence and compiance to goba security standards. Our team of experts work in cose co-ordination with customers in order to ensure that a gaps are identified for the necessary critica infrastructure. This ensures data protection, compiance to mandatory requirements as we as ensuring that industry best practices are impemented. Our services incude: Assess the Cyber Security Risk Study Organization's Security Standard and map it with Goba Standards Formuate Audit approach Prepare assessment checkist / tempates Assessment / Discovery of compiance of Assets Pubish Gap / Compiance Anaysis Report Prepare remedia pan Evergreen Compiance Conduct training & awareness programmes 5

6 Case Study E,C&I Soutions from L&T C&A heps GCC enhance WHRS operation About Customer: Guf Cement Company (GCC) is a eading cement producer in the United Arab Emirates. Based in Ras A Khaimah with an instaed annua production capacity of 2.5 miion tons cement and 1.3 miion tons cinker. GCC is eading regiona cement exporter in the United Arab Emirates. GCC Ras A Khaimah (U.A.E.) operates 2 cement kins the first one of 4100tpd capacity & the second one of 7500tpd capacity. The Need Eectrica energy is a significant contributor to the cost of manufacture of cement. In its endeavour to remain competitive, the cement industry remains pre-occupied with figuring out measures to reduce energy consumption or the cost of energy. Since the unit cost of captive generation turns out to be we beow that of grid power, most cement pants prefer to set-up a captive power pant. As an additiona measure, severa cement pants have invested in power generation based on the recovery of heat from kin & cooer exhaust gases, which woud otherwise have been vented to the atmosphere; so caed Waste Heat Recovery Systems (WHRS). To meet its eectrica energy needs and reduce demand on the grid suppy or captive power, GCC decided to invest in Waste Heater to the substation, and from the instrumentation and fied devices to the distributed contro system, across the entire deivery chain. This invoved detai ayout engineering pertaining to eectrica equipments, cabe trays, ighting fixtures & earthing & ightning protection system based on the existing pant ayout & the GA drawings of the various pant structures, i.e. STG buiding, boier structures, eectrica rooms On the eectrica side, L&T-C&A designed, engineered, suppied Recover system which coud aso bring down the burning of fossi Generator Power Transformer, MV switchboards, LV Power fues. The GCC required advanced WHRS in order to quicky and Switchgear and protection system to ensure reiabe and efficienty reduce greenhouse gas emissions and attracts CDM uninterrupted power suppy from and to the power grid. benefits. During design and panning stage, the space avaiabiity on site As a consequence, GCC contracted ThyssenKrupp Industries India was a major chaenge. The situation was chaenging, due to this Pvt. Ltd (TKII) to set-up a 35.5MW Waste Heat Recovery based being a brown-fied project, L&T was responsibe to ensure the Power Pant utiizing waste heat from the preheaters & cooers of accommodation of equipments in existing avaiabe space. The both kins and exhaust gas from a gas turbine operating in open responsibiity was aso to ensure modification in existing cyce. switchboards to faciitate interface with the existing power TKII in turn entrusted L&T Contro & Automation (C&A) the responsibiity for design, suppy, erection supervision, testing & distribution system, understand existing as we as new oad, P&IDs commissioning of the Eectrica, Contro & Instrumentation System and pant Lay out. for WHRS. However L&T-C&A team adopted innovative engineering The Soution L&T-C&A was responsibe for a compete design, engineering, procurement, suppy, supervision of instaation and commissioning of Eectrica Power Distribution System, Instrumentation & Contro and DCS system for the WHRS Auxiiaries. The scope of suppy incuded a the eectrica, contro and instrumentation equipments from the eectrica baance of pant 6 strategies to overcome these chaenges, and ensured instaation of equipment did not constrain in any way. In addition to the eectrica package, L&T-L&T-C&A was aso responsibe for compete design/sizing of a Distributed Contro System (DCS), deveopment of appication software to contro & monitor the entire WHRS operation. L&T-C&A provided DCS to maximize WHRS efficiency and reiabiity through the automation, integration and optimization of

7 the entire pant. The system handes some 400 I/Os for each WHRS it and 600 I/Os for the common system, incuding remote I/Os for cooing water, auxiiary cooing water, cooing towers and other encompasses : pant components. In this project, L&T-C&A The Waste Heat Recovery System PH Boier: Horizonta boier with vertica tubes for L&T-C&A aso impemented Steam & Water Anaysis System (SWAS), covering suppy of 2 boiers for each kin : uniform dust disposa for heat recovery from Sensors & preheater exhaust gases Transmitters for measurement water of eve, temperature, pressure / differentia pressure aong with process hook-up hardware, contro vaves for feed water to condensate fow to the boiers, to provide exact precise measurements of critica parameters and anaysis of steam & water from 24 ocations in the WHRS System. AQC Boier: A vertica boier with horizonta tubes for heat recovery from cooer exhaust gases 1 HRSG for heat recovery from the exhaust gases from a Gas Turbine 1 Steam Turbine of 35.5MW rating The Resut Boier Feedwater & Deaerator system The system was commissioned & synchronized with the grid in Steam s ystem Aug 2013 and is working satisfactoriy. Apart from the monetary Condensate system Water teatment pant hence directy hep conserve fues and reduce overa carbon Cooing water system emissions. The WHRS at GCC is expected to ead directy to a C&A provided an integrated, E,C&I (eectrica, contro and benefit invoved, WHRS is paying vita roe in energy conservation, as GCC do not need any additiona fues to generate eectricity and reduction a tonne of carbon dioxide (CO2) emissions per annum. instrumentation,) soution for the entire project, incuding medium and ow-votage switchgear, motor contro, protection system, inverters, and a state-of-the-art distributed contro system (DCS) WHRS overview screen Power distribution scheme 7

8 Learn Today, Lead Tomorrow The government of India has aready set ambitious targets for increasing the share of manufacturing in GDP to 25% by To accompish this goa, companies are setting up modern manufacturing infrastructure which requires skied workforce. Ironicay, most industries in India are strugging with scarcity of skied abour. Besides academic studies, a speciaised training is aso required to buid necessary skis and knowedge which aows individuas to expand their abiities. To bridge this gap, C&A has auched a Training Academy that offers reevant and adequate training to the youth. It is the first of its kind in India, offering a unique integrated training course for the Automation Industry professionas in technica association with IEEE Bombay section. It is formuated as a comprehensive fu time six-month course, wherein the initia two months comprise cassroom ectures couped with requisite hands on experience on modues ike Drives, PLC, SCADA, Instrumentation, Networking and Project Management. The next two months cover on-the-job training, wherein students are rotated through different departments in C&A ike project software deveopment, testing (on shop-foor) and service centre. To transform graduates into trained Automation professionas, during the ast two months, students are given site exposure and accompany C&A's service team members on visits to project sites. On concusion of the training course, students are awarded certificates, as 'L&T certified Automation Engineer'. C&A aso offers short-term courses arising from the need for industry-ready automation engineers, excusivey aid out by the Training & Pacement officers of engineering coeges. The coeges wanted their third and fina year students to utiize their mid-semester breaks to capitaize on the insights of automation and fet that C&A's Academy had the right patform to serve these needs. The courses are ed by fied-proven and experienced instructors who combine extensive appication and automation knowedge with seasoned training and experience in a hands-on environment. Having successfuy organized five batches in the year , C&A is peased to announce a new batch of 'Integrated Automation Training Course' at its Eectrica & Automation Campus in Navi Mumbai. The Academy is poised to achieve bigger heights with its motto Learn Today, Lead Tomorrow. For detais, contact us at automation.academy@lntebg.com This newsetter is being sent on behaf of Contro & Automation, Eectrica & Automation, Larsen & Toubro, If you wish to unsubscribe, You may aso send an e-mai to: cnamarcomm@lntebg.com. The views expressed in this magazine are not necessariy those of the managment of Larsen & Toubro Limited. The contents of this magzine shoud not be reproduced without written permission from the company. Ony for circuation among the customers and business partners of Larsen & Toubro Group of Companies. CAnvas - Issue 6 CIN No. L99999MH1946PLC Education and training are necessities that open the doors to a gainfu empoyment and enhance an individua's skis and knowedge. This capabiity, in turn, increases productivity and acceerates the economic growth of a country. 7