Process Instrumentation and Analytics

Size: px

Start display at page:

Download "Process Instrumentation and Analytics"

Ira Porter
5 years ago
Views:

1 Process Instrumentation and Analytics Precise process control in tough environments Cement Answers for industry.

2 Precise process control in tough environments Siemens has extensive and in-depth experience of the cement industry s needs. Our process instrumentation and analytics portfolio gives you the precision, integration and automation you need to deliver the best production efficiency, energy optimisation and safety, whether you are modernising existing operations or developing new facilities. Inefficient process control can be very costly in product quality, safety or environmental terms. Partnering with Siemens provides the reassurance of best-in-class products, and the precision, integration and reliability in process automation to help you deliver optimum efficiency and productivity. Our technology provides solutions to the rigours of cement production, where extremes of dust, vapour, temperature and remote locations are common place. Reliability in arduous applications is paramount, and Siemens products are designed to meet the challenge. Reduce downtime and decrease energy costs through: Precise measurement of inventory to keep overages and shortages to a minimum Accurate control of energy intensive machinery to increase the productivity Accurate control of the burning process to keep fuel consumption to a minimum Manage skilled worker shortage and save skilled labour hours with: Quick, easy installation and fast commissioning for workers Low- to no-maintenance products Products that are easy to understand and can be seamlessly integrated into your control system Adhere to environmental regulations and reduce environmental impact by: Continuous emission monitoring (CEM) Accurately monitoring water consumption Keep workers safe by: Installing products that can handle extreme conditions and applications such as remote-mounted transmitters, heavy duty dust-tight enclosures and non-contacting sensors. This reduces the need for contact with instruments in hazardous and remote locations. 2

Our process instrumentation and analytics portfolio gives you the precision, integration and automation

modernising existing operations or developing new facilities.

Partnering with Siemens provides the reassurance of best-in-class products and the precision, integration

Our technology provides solutions to the rigours of cement production where extremes of dust, vapour,

Reliability in arduous applications is paramount and Siemens products are designed to meet the challenge.

shortages to a minimum Accurate control of energy intensive machinery to increase the productivity

shortage and save skilled labour hours with: Quick, easy installation and fast commissioning for workers

your control system Adhere to environmental regulations and reduce environmental impact by: Continuous

products that can handle extreme conditions and applications such as remote-mounted transmitters, heavy

This reduces the need for contact with instruments in hazardous and remote locations.

3 Precise process control in tough environments Siemens has extensive and in-depth experience of the cement industry s needs. Our process instrumentation and analytics portfolio gives you the precision, integration and automation you need to deliver the best production efficiency, energy optimisation and safety, whether you are modernising existing operations or developing new facilities. Inefficient process control can be very costly in product quality, safety or environmental terms. Partnering with Siemens provides the reassurance of best-in-class products and the precision, integration and reliability in process automation to help you deliver optimum efficiency and productivity. Our technology provides solutions to the rigours of cement production where extremes of dust, vapour, temperature and remote locations are common place. Reliability in arduous applications is paramount and Siemens products are designed to meet the challenge. Reduce downtime and decrease energy costs through: Precise measurement of inventory to keep overages and shortages to a minimum Accurate control of energy intensive machinery to increase the productivity Accurate control of the burning process to keep the fuel consumption to a minimum 2 Manage skilled worker shortage and save skilled labour hours with: Quick, easy installation and fast commissioning for workers Low- to no-maintenance products Products that are easy to understand and can be seamlessly integrated into your control system Adhere to environmental regulations and reduce environmental impact by: Continuous emission monitoring (CEM) Accurately monitoring water consumption Keep workers safe by: Installing products that can handle extreme conditions and applications such as remote-mounted transmitters, heavy duty dust-tight enclosures and non-contacting sensors. This reduces the need for contact with instruments in hazardous and remote locations. Solutions to match your needs From raw materials preparation to the finishing mill, we have a process instrumentation and analytic solutions to meet your needs. The following pages provide you with information to select the best device for your application. To find information about all of our application solutions, including process charts, and a comprehensive list of cement applications visit:

4 Optimal crusher control Ultrasonic continuous level measurement with separated transducer helps maintain plant efficiency by measuring the level of material in crushers. Preferred device: SITRANS LUT400 and XPS transducers Separated controller / transducer protects the electronics from extreme vibration The non-contacting ultrasonic transducer is rugged and fully potted to provide long-term reliability in a harsh environment Sonic Intelligence is standard and is proven to provide superior performance in difficult conditions Raw material conveyor flow monitoring Stack emission monitoring The Gasmet CEMS FTIR measuring system is designed for continuous emission monitoring (CEM) measurements. By use of Fourier Transform Infrared (FTIR) spectroscopic technology it typically monitors H 2 O, CO 2, CO, NO 2, SO 2, HCl, HF, and NH 3 in cement applications. Preferred device: Gasmet CEMS Standardised emission monitoring system which reliably covers all requirements associated with sampling, sample preparation, and gas analysis Contains the Gasmet FTIR gas analyzer, an industrial computer and a sampling system, may be enhanced with an optional Z r O 2 oxygen analyzer and/or a total organic carbon analyzer FIDAMAT 6 Depending on configuration, certified measurements according to European WID and LCPD guidelines as well as compliance to US EPA guidelines are supported The operation of the system is fully automatic and controlled by the Calcmet software Stockpiles Primary crusher Optimal crusher control Screen QUARRY Secundary crusher Raw material conveyor flow monitoring Pre-blending hall RAW MATERIAL PREPARATION Raw material silos Vertical roller mill Level measurement in homogenisation silos Homogenization silo Beltscales are installed throughout the process to monitor the flow of material within the plant and thus control inventory and identify bottle necks. Preferred device: Milltronics MSI beltscale with SIWAREX FTC integrator With the unique modular design, the MUS beltscale is easy to install on every conveyer in the plant Modifications to the existing installations are kept to a minimum which makes it economically viable for retrofits Stand alone integration with BW500 or direct integration into SIMATIC S7 with the SIWAREX FTC card Integration with SIWAREX FTC allows management of all beltscales on site in the Control System and the management of all scales centrally on one HMI Level measurement in homogenization silos Non-contact high power FMCW radar technology measures the material levels in the homogenization silos, unaffected by extreme dust and even in high silos. Process pressure and temperature monitoring It is vital that pressure and temperature in the preheater tower are monitored continuously, not just to maintain product quality but to avoid damage to the production equpiment. Preferred devices: SITRANS P DSIII and SITRANS T Remote mounting capability of the transmitter allows isolation from high temperatures and vibration sources Local display and local programming with pushbuttons, accessible without opening the enclosure Advanced communications and predictive maintenance functions enable optimised maintenance cycles The SITRANS P DSIII has high turn down ratio that allows 1 transmitter to cover a wide range of applications, reducing the variants required The 5 year long stability of the SITRANS P DSIII keeps maintenance intervals to a minimum Preheater tower Electrostatic precipitator ALTERNATIVE FUELS Waste/fuels/ solvents Tires Stack Coal silos Coal silos CLINKER PRODUCTION Stack emission monitoring Filter COAL MILL Coal mill Stack FINISHING MILL / PACKING & SHIPPING Clinker storage Cooling water management for the mill Gypsum silo Dosing of clinker and additives Finishing mill Finished cement silos Finishing mill rejects Level Additives silo Preferred device: SITRANS LR460 Non-contact high power FMCW radar technology Built in relay programmable as additional high level alarm for ultimate back up security Predictive maintenance functions ensure that maintenance demands are kept to a minimum Process Intelligence allows a reliable level measurement on every solids application in the cement industry with a range up to 100 m (328 ft) Continuous kiln gas analysis Process pressure and temperature monitoring Rotary kiln Clinker cooler bed depth Clinker cooler Transportation loading packaging Flow Pressure Temperature Weighing Process protection CGA In-situ Positioning Identification 5 6

5 Continuous kiln gas analysis Extractive measurement at the kiln inlet enables an accurate picture of the kiln gas composition, and allows detailed assessment of burner control, fuel requirements and product quality. Preferred device: Set FLK Stable kiln control safeguards product quality and prevents the emission of toxic materials into the environment Synthetic liquid coolant allows the sample gas to remain above its acid dew point, avoiding the need for further treatment Proven oval probe design coupled with an emergency retraction mechanism ensures reliable long-term operation Clinker cooler bed depth Reliable level measurement of the clinker bed depth allows accurate control of the clinker cooler, which results in a more stable cooling process. Next to a more consistent clinker quality, this also has a positive influence on the operation of the kiln and the fuel consumption. Preferred device: SITRANS LR GHz radar transmitter provides reliable and accurate measurement through extreme dust and high temperatures found in the enclosed cooler space Very narrow 4 beam angle allows the radar to be mounted on a tall standpipe away from extreme temperatures No additional forced cooling is required, reducing maintenance and simplifying the installation A quick start wizard and process intelligence ensure easy commissioning and reliable operation under the most difficult circumstances Dosing of clinker and additives Weighfeeders precisely control the clinker feed in proportion with the additive materials, even in harsh environments with abrasive materials. Preferred device: SITRANS WW300 weighfeeder Rugged, durable design for heavy-duty applications, available in open or enclosed construction with a design rate of up to 800 t / h Fast installation, easy to clean and an easy to replace endless belt keeps the maintenance downtime to an absolute minimum The accuracy of +/ 0.5 % allows precise dosing and ratio control of raw material The BW500 integrator has 2 PID controllers and all communication possibilities for seamless integration in every control system Direct integration in SIMATIC S7 with the SIWAREX FTC module Finishing mill rejects A compact and accurate impact flowmeter monitors the finishing mill rejects, so that the mill settings can be adjusted. Reducing over-grinding has a direct impact on the energy consumption. Preferred device: SITRANS WF330 solids flowmeter Sensing element is mounted outside the process, keeping the maintenance to an absolute minimum. Standard version can measure from 0.2 to 40 t / h, however larger versions are available to handle flow rates up to 300 t / h Typically, installations achieve an accuracy of +/-1 %. SF500 integrator has 2 PID controllers and all communication possibilities for seamless integration in every control system Cooling water management for the mill Electromagnetic flowmeters accurately control the use of cooling water for the mills, in order to comply with the environmental regulations. Preferred device: SITRANS F M MAG 3100 High accuracy of 0.2 % ±1 mm/s Available in sizes from DN15 to DN 2000 (½ to 78 ) Various communication protocols allow easy integration in any automation system Electronics can be mounted with the sensor or remote Approved for hazardous areas 7

A comprehensive portfolio for all applications Siemens process instrumentation has a

This overview shows the entire spectrum of our process instrumentation and analytics

Level Whether you are measuring liquids, slurries or bulk solids, Siemens provides the

Regardless of the application, we provide the optimum solution, whether the technology is

One of our product highlights is the SITRANS LR560, which is the ideal solution for level

Weighing The comprehensive Siemens weighing portfolio includes beltscales, weighfeeders,

Our SIWAREX PLC-based weighing electronics also allow direct integration into the Siemens

Milltronics MSI beltscales are the preferred solution for raw material flow monitoring on

Flow Our flowmeters meet the toughest challenges and are available for a wide variety of

6 A comprehensive portfolio for all applications Siemens process instrumentation has a comprehensive, proven product portfolio suitable for arduous environments. This overview shows the entire spectrum of our process instrumentation and analytics portfolio for the cement industry. Level Whether you are measuring liquids, slurries or bulk solids, Siemens provides the right level measuring technology for both continuous and point level measurements. Regardless of the application, we provide the optimum solution, whether the technology is radar, ultrasonic, capacitance, electromechanical or hydrostatic pressure. One of our product highlights is the SITRANS LR560, which is the ideal solution for level measurement in cement silos and dusty environments. Weighing The comprehensive Siemens weighing portfolio includes beltscales, weighfeeders, solids flowmeters and static weighing. Our SIWAREX PLC-based weighing electronics also allow direct integration into the Siemens range of PLCs, providing unparalleled flexibility and ease of use. Milltronics MSI beltscales are the preferred solution for raw material flow monitoring on the conveyor. Flow Our flowmeters meet the toughest challenges and are available for a wide variety of applications. Highly accurate and reliable, they measure and monitor flow rates of liquids with varying consistencies. Technologies include electromagnetic, ultrasonic, coriolis and vortex. Pressure Siemens offers a comprehensive range of solutions for pressure measurement relative, differential and absolute. The outstanding accuracy, robustness and ease-of-use make these instruments the preferred choice. 8

Temperature Siemens temperature measurement devices offer you a comprehensive solution.

sensors to match all common applications.

specifically developed for the demands of the cement industry.

systems, while our motion sensor range ensures that mechanical conveying systems

on-board diagnostic functions and minimum loss of process air by only using air when

This enables operators to gain cost effective and accurate control over typical

Gas analysis Siemens offers a comprehensive range of products and systems for process

7 Temperature Siemens temperature measurement devices offer you a comprehensive solution. They are designed to support all common RTDs, thermocouples, resistance and millivolt-sensors. The range covers head, rail and field transmitters and includes industry specific sensors to match all common applications. Process protection A wide range of rugged and reliable process protection devices, specifically developed for the demands of the cement industry. SITRANS AS100 acoustic sensors help operators detect blockages in pneumatic conveying systems, while our motion sensor range ensures that mechanical conveying systems maintain their set speed informing operators in the case of breakdown or failure and helping to increase availability. Positioner The electro-pneumatic valve positioner SIPART PS2 offers easy integration, on-board diagnostic functions and minimum loss of process air by only using air when required. This enables operators to gain cost effective and accurate control over typical applications. Gas analysis Siemens offers a comprehensive range of products and systems for process analytics. It includes continuous gas analysers for stand-alone and system solutions. The FLK-Probe is the specialised device for extractive measurement at the cement kiln inlet. Identification Siemens RFID systems identify safely, quickly and efficiently and are resistant to dusty environments. RFID access control systems support the management of the truck traffic flow through the facility and can significantly improve the efficiency in truck weighing and truck loading operations. 9

Just click on Selection by Industry. Scan to explore the PIA Life Cycle Portal Subject to change without prior notice Order No.: E20001-A240-P780-X-7600 Dispo 27900 2150/47941 MI.SC.IM.XXXX.52.3.

8 Find out more: Learn more about our process instrumentation products for your industry in the PIA Life Cycle Portal, the tool for engineering, ordering, installation and operation. Just click on Selection by Industry. Scan to explore the PIA Life Cycle Portal Subject to change without prior notice Order No.: E20001-A240-P780-X-7600 Dispo /47941 MI.SC.IM.XXXX WS Printed in Germany Siemens AG 2013 The information provided in this brochure contains me re ly general descriptions or characteristics of per for m ance which in case of ac tual use do not always ap ply as described or which may change as a result of fur ther de ve lopment of the pro ducts. An obligation to provide the respective characteristics shall only exist if ex pressly agreed in the terms of contract. All product designations may be trademarks or product na mes of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners. More information: Follow us on: Siemens AG Industry Sector Sensors and Communication KARLSRUHE GERMANY

Process Instrumentation and Analytics

Process Instrumentation and Analytics Providing process control in tough environments Aggregates Answers for industry. Providing process control in tough environments Siemens has extensive and in-depth