Foundation Field Bus
Iron & Steel Making AT TATA STEEL Date: 09.07.2010
Typical Flow Sheet of
< 40 mm Fraction 12.3 10.57% < 40 mm Fraction 7.2 5.56% < 10 mm Fraction 944.6 10.00% Anthracite Coal 11 Lime Stone 6.8 Iron Ore Fines 850.1 Impact Crusher 1 Impact Crusher 2 116000 Nm3/hr BF Gas < 10 mm Fraction 12.1 8.26% < 10 mm Fraction 7 2.86% Anthracite Coal 11.1 Lime Stone 6.8 Drying & Grinding System 963.7 9.93% 868 872.4 0.62% 867 2000 Nm3/hr BF Gas Bentonite 0.5% 3.9 TPH Ground Concentrate Bins ESP Dust 809 0.49% 805 5.7 TPH Process Water 72.7 TPH 8.99% Mixers Raw Materials Iron Ore Fines Lime Stone Anthracite Coal Bentonite Fuels / Utility Coal Tar 12 CO Gas 16 BF Gas 156 Process Water 96 Consumption Rate Kg/ton of Pellet 1247 16 10 6 Consumption Rate Kg or Nm3 per ton of Pellet 881.7 8.70% 805 Tons/Hr % 945 97.98% Mixed Materials Bins 12.3 1.28% 1260.1 1259.6 8.70% 7.2 0.75% 1150 4.3 0.45% 125.96 140 0 TPH Pelletizing Discs 154 1259.6 Water 8.70% 1150 Tons/Hr or Nm3/Hr Green Pellets over & undersize 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) Induration Roller Screens 14.5195354 12.55% 881.2 8.70% 76.7 TPH 804.5 Evaporation 8.70% Loss of Ignition 12000 Nm3/hr CO Gas 220 TPD Coal Tar 30.8 TPH (D) Pelletization Roller Screens Induration Machine (768 m2) 2.5 TPH (D) Dust 3.83% 1101.9 1102.5 0.00% 1102.5 30.00% 330.7 TPH 3.2 TPH (D) Pellet Screening Screened Hearth Layer Dust 768.6 TPH 3 ESPs 1 ESP 68.72% 757.6 TPH 1.00% 11 TPH Product Pellets Pellet Fines 18182.4 TPD
PELLETIZING PLANT TATA STEEL (JAMSHEDPUR) Engineering Project Limestone Bin Coal Bin Car Dumper Fines Reclaimer Iron Ore Bin Hammer Mill Ball Mill Binder Bin Ground Ore Bin Pelletizing Bins Mixers Pelletizing Disks Green Pellets Travelling Grate Furnace Pellets for Hearth Layer Screening Blast Fuirnace Fired Pellets Stacker Fired Pellets Fired Pellets Stockyard Fines
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 is done 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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