Foundation Field Bus Services Engineering Project Pellet Plant ... Typical Flow Sheet of Pellet...
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Foundation Field BusFoundation Field Bus
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Date: 09.07.2010Date: 09.07.2010
Iron & Steel MakingIron & Steel Making
ATAT
TATA STEELTATA STEEL
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Typical Flow Sheet of Pellet Plant
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12.3 10.57% 7.2 5.56% 944.6 10.00%
11 6.8 850.1
12.1 8.26% 7 2.86%
11.1 6.8
963.7 9.93%
868
872.4 0.62%
867
ESP Dust 5.7 TPH
0.5%
809 0.49%
805
8.99%
881.7 8.70%
805
Tons/Hr %
945 97.98%
12.3 1.28% 1260.1 1259.6 8.70%
7.2 0.75% 1150
4.3 0.45%
125.96 140 0 TPH
154
1259.6 8.70%
1150Tons/Hr or
Nm3/Hr
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)
14.5195354 12.55% 881.2 8.70%
804.5
8.70%
2.5 TPH (D)
Dust
3.83% 1101.9 1102.5 0.00%
1102.5
30.00% 330.7 TPH 3.2 TPH (D)
Dust
768.6 TPH
68.72% 757.6 TPH 1.00% 11 TPH
18182.4 TPD
BF Gas 156
Process Water 96
Coal Tar 12
CO Gas 16
Fuels / Utility
Consumption Rate
Kg or Nm3 per ton
of Pellet
6
Lime Stone
Anthracite Coal
Bentonite
Iron Ore Fines
Drying & Grinding
System
1247
2000 Nm3/hr BF Gas
Raw Materials
Process Water
Consumption Rate
Kg/ton of Pellet
< 10 mm Fraction < 10 mm Fraction
Anthracite Coal Lime Stone
16
10
Ground Concentrate Bins
3.9 TPHBentonite
Anthracite Coal
Impact Crusher 1 Impact Crusher 2
< 40 mm Fraction < 40 mm Fraction
Iron Ore Fines
< 10 mm Fraction
Lime Stone
116000 Nm3/hr BF Gas
Induration Roller Screens
72.7 TPH
Mixed Materials Bins
Mixers
Water
Green Pellets over & undersize
Pelletizing Discs
Pelletization Roller
Screens
Screened Hearth Layer
Induration Machine (768
m2)
Evaporation
Loss of Ignition30.8 TPH (D)
76.7 TPH
12000 Nm3/hr CO Gas
220 TPD Coal Tar
Product Pellets Pellet Fines
3 ESPs
Pellet Screening 1 ESP
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Car Dumper
Fines ReclaimerLimestone Bin Coal Bin
Binder Bin
Pelletizing Bins
PelletizingDisks
GreenPellets
Travelling Grate Furnace
Screening
Fired Pellets
Fired PelletsStacker
Fired PelletsStockyard
Pellets for Hearth Layer
Fines
Mixers
Hammer Mill
Iron Ore Bin
Ball Mill
Ground Ore Bin
PELLETIZING PLANT TATA STEEL (JAMSHEDPUR)
Blast Fuirnace
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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
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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.
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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.
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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.
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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.
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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
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Fieldbus Builder FOUNDATION Fieldbus
The FOUNDATION Fieldbus network and application configuration isdone 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
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• 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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Thanks