Modernization of equipment and software for lime kilns.
Prior to modernization the control system was functioning on basis of the following equipment:
- controllers represented by PCI board installed into PC with CPU S7-416-2 PROFIBUS DP and PROFIBUS DP/MPI (WinAC) functionality;
- outdated computers;
- low-resolution monitors;
- SIEMENS SIMATIC PCS7 V6 software.
The equipment was obsolete and worn-out and hardly repairable due to lack of spare parts and incompatibility of old software PCS7 V6 with modern operational systems. The modernization conducted in 2020 resulted in equipping each kiln with its own master controller SIEMENS CPU 410-5H and operator control station based on industrial PCs SIEMENS (OS1 and OS2).With the view of doing all necessary modifications the engineering station ES one for two kilns was installed that provided for operator station functionality required for “cold replacement”. All equipment is managed by distributed control system SIEMENS SIMATIC PCS7 V9. Operator stations, engineering station and master controller racks were installed into one air-conditioned cabinet. Thin clients connected with system units via net were installed at operator workstations to be used as control devices.
Upgrading of both hardware and software part of lime kiln control systems was conducted within a very short time in the course of scheduled preventive maintenance. Modernization resulted in lime quality improvement and increase in output.
