ABB application of PLC in the lime kiln monitoring system

Abstract: This paper introduces the application of lime kiln application ABB AC500 lime kiln application ABB ABB PLC in the monitoring system of lime kiln. In addition to the data acquisition and processing of field instruments, PLC is also used to complete the automatic control of machinery and equipment in the field. In addition, the industrial control configuration software iFIX as a standard human machine interface (HMI) is used to monitor the dynamic process of industrial production

 

Keywords: PLC lime kiln process monitoring iFIX configuration software

 

Abstract: In this paper, we discuss the application of ABB AC500 PLC in the process monitoring and control for limekiln production. The PLC is mainly utilized for collecting process data as well as realizing auto-controlling of field mechanism. In addition, iFIX configuration software with a Human man-Machine Interface (HMI) is used to monitor the dynamical industrial process.  Keywords: PLC; Limekiln; Process Monitoring and Control; iFIX configuration software .

 

Introduction

 

Active lime is an essential material in the steel industry. In recent years, the rapid development of China's iron and steel industry, the steel industry has a considerable demand for active lime, lime quality directly affects the quality of steel, therefore, the use of advanced automatic control system to improve the production and quality of steel, it is very important.

 

The PLC (programmable controller) is designed for industrial environment applications and design of industrial control computer, has become the most widely used in the electrical control system, it can not only achieve complex logic control, but also to complete a variety of sequential or timed closed-loop control functions, and strong anti-interference ability, reliability, stability, small size, can be in bad environment for long time, and programming is simple, easy maintenance, and equipped with all kinds of communication interface and module processing, can be easily connected.

 

1. Lime kiln monitoring system overview

 

The raw material of the production of lime kiln is the stone (Shi Huishi), and the product is the raw material. Adding limestone and coke in the kiln inlet, calcined into lime, output to the finished product bin. Control system is mainly composed of the limestone and coke transport system, feeding system, weighing system, material system, cloth calcination system, air cooling circulation system, combustion supporting air circulation system, waste gas dedusting circulating system, finished out of kiln, transportation system. And request in the main control room can print the report, show the kiln temperature, the operating status of the system, the motor running current, etc..

 

New lime kiln process design advanced, high degree of automation, all the equipment with the machine next to the manual, the main control room of the manual, the main control room of the three control mode, and have the equipment fault diagnosis and alarm function.

 

According to the requirements of the users and process design, the process monitoring of the production of lime kiln adopts the typical two stage monitoring method: production management level and field control level. PC (IPC) as the main (Human-Machine), as the main ABB (Interface), for the production management level, to complete the lower machine monitoring, production operation management, mainly for the operation personnel; the lower machine iscomposed of AC500 series PLC, to complete the production process of data acquisition and process control.

 

(1) production management

 

For production operators, the operating conditions of various devices are displayed on the HMI monitor screen, and the production process is controlled by HMI. According to the production conditions, the main control room and the main control room can be selected manually, and the main control room automatically works. When the production of abnormal, the HMI display alarm information. To store, manage and produce all kinds of data in production.

(2) the field control level

 

The production process, which is composed of programmable controller, intelligent I/O processor and various templates, is based on measurement and control level. Complete the production site of a lot of pressure, temperature, flow of the collection and processing, the production process control. Automatic control system through by vibrating, feeding and screening, hopper lifting machine, electronic weighing hopper, single bucket elevator to the carriage out of the feeding machine, unloading gate, vibrating feeder structure of shaft kiln screening, feeding, automatic control feeding system of unloading, the raw material screening, feeding and unloading the automation of the material. In the lime shaft kiln closed type material process to ensure the must be to ensure that the unloading feed gate only one at the same time in the open state. By adjusting the air pressure, cooling air pressure PID, to achieve constant pressure control requirements.

 

According to the above control requirements, we will describe in detail the hardware and software configuration of the monitoring system for the lime kiln process.

 

2. System hardware configuration

 

In order to meet the control requirements of the lime kiln process monitoring and control system, we use the ABB AC500 series of programmable controller, AC500 uses a modular design.

 

(1)    Advantech industrial control computer (IPC), operating system to Windows 2000 professional, the Pentium IV processor, 2.66GHz frequency, 256M memory, 80g hard disk

 

(2) CPU module: ABB AC500 series programmable controller CPU has PM571, PM581, PM591 three different levels, the system uses PM581, CPU on: LCD display, a set of operating buttons, an SD card expansion port and two integrated serial communication port, CPU bottom board integrated Ethernet interface, and retain the CS31 communication interface, with AC31 series PLC compatibility good features.

 

(3) the local expansion module: ABB 16 channel AI523 analog input module 2, 8 input /8 output channel AX522 analog input / output module 1, DX531 switch input / output module (can be set) 4.

 

(4) distributed extension: DC551 ABB remote expansion module 1, with CS31 interface, and 8 DC 24V switch input, 16 DC 24V can be set up the input / output, DX531 switch input / output module 2, DC523 switch output module 1.

 

(5) power supply module: CP-S ABB power supply, input AC85-264V/ output DC24V, 10A, 5A 1, individually installed.