28.09.2009 | Author / Editor: S. Sezen and A.O. Öziskender / Marcel Dröttboom
Turkey‘s biggest cement production line with its single kiln, put into operation in only 20 months, uses integrated solutions for the complete electrical and automation system. This article illustrates how a smooth production operation was ensured up to service and maintenance in one of the biggest cement plants of Europe.
Currently, Turkey’s cement sector ranks as the third largest in Europe with a production capacity of 42 million tons of clinker and 52.5 million tons of cement. A good deal of that output is being used in Turkey for the construction of new buildings, highways, and tunnels, primarily with the goal of achieving European standards in the pursuit of integration into Europe. But a substantial part is also exported.
Among the cement companies profiting from this steady demand is Çimko, which up to 2006 had a 2.5 percent share of the Turkish cement market with its Adiyaman and Narli cement plants, packaging facilities in Gaziantep and Kilis, and seven ready-mix concrete plants in different locations. To increase its share of the Turkish cement market a main goal of Çimko was to build the most efficient and most advanced cement works of its kind. The location of the new Çimko plant was found in the Kahramanmaras province in south-eastern Turkey. Çimko’s owners, Sanko Group and Cementerie Aldo Barbetti, selected this site to be close to export markets in Asia.
For their new plant Çimko wanted to have a solution that integrates power generation and distribution, drive technology, process control and instrumentation, data management, plant infrastructure and maintenance into one system to gain access to a number of additional possibilities for optimizing plant operation and to ensure high efficiency, reliability and security of investment. To install the entire electrical and automation system, including the electrical equipment and the control system for the material handling facilities of the plant, Çimko selected the Siemens Industry Solutions Division, which provides a line of modularly structured solutions specifically for the cement industry, called Sicement .
Cement works are energy intensive, and their power generation and distribution systems are sometimes exposed to extreme conditions. While at the same time the loads require an extremely wide range of power supplies.
Under peak load, a cement plant the size of Çimko Kahramanmaras will consume between 55 MW and 60 MW of electrical power. The goal was to provide power that is safely distributed and economical, and in the right quantity to every drive and sensor involved in the process. This was accomplished by a power-distribution system that was meticulously designed, manufactured and installed according to power requirements, network conditions and plant-operation conditions.
The high-voltage distribution system consists of mainly four pieces of 154/6.3 kV, 25/31.5 MVA transformers, circuit breakers and disconnect switches with 170 kV, 2000 A, 31.5 kA, current and voltage transformers. For the medium-voltage system, 151 pieces of 12 kV, 31,5 kA switchgears were installed. The high- and medium-voltage switchgears are equipped with multi-protection relays, which enable easy monitoring and control from the process-automation system. In a similar way, the motor control centre system with intelligent control units facilitates control via Profibus-DP communications.
The drives of a cement plant interlink the electrical and the mechanical equipment. Since these components usually come from different suppliers – which was the case at Çimko Kahramanmaras – they have different technical requirements. Tailor-made drives were used to achieve the best drive efficiency with optimum performance. In all, the scope of supply covered not only kiln drives, but also mill, crusher, cooler and exhaust fan drives.
It is crucial to determine the right types and proper options for drive-system elements to meet the mechanical power requirements and the specific needs of the cement process as well as to take advantage of energy-saving possibilities. The scope of the delivered drive systems further illustrates the extent of the Çimko Kahramanmaras plant: 30 sets of 6.3 kV Medium-voltage slipring motors ranging from 355 kW up to 5400 kW and 12 sets of 690 V variable-speed system ranging from 500 kW up to 2700 kW. In order to minimize harmonics speed-control units with 12-pulse technology were selected.
Continuous and stable operation of the kiln system is one of the most important factors for producing clinker that is of consistent quality. For Çimko this means to be able to make a diagnosis in the event of a plant problem and keep downtime to a minimum and to have a way for operators to interlock the drives, dampers, belt conveyors and measuring values from the plant with each other.
For their new plant Çimko selected a process-control system developed for the cement industry, that is based on Simatic PCS-7, a mainstream process control system from Siemens. Because the systems comes pre-configured and is proven over many years, engineering was fast and reliable.
To provide production-specific data for the production planning or management level a Management Information System (MIS) was installed at Çimko Kahramanmaras. This solution supplies real-time information about products, quality and process parameters. All interacting components and processes are linked, which contri-butes toward improving the plant output. Based on process values, messages, data and data entries are archived in an SQL database on a separate computer. Data is stored with protection against manipulation and is independent of Simatic PCS 7.
Thanks to the client/server architecture, all archived data is available for display, evaluation and optimization throughout the entire company. Real-time trend curves, for example, can be viewed on office PCs.
Some of the tasks it helps operators address include drawing up production reports, material balances and statistics; recording long-term developments; identifying problem areas and sources of faults through efficient tools for analysis of the archived alarms and messages; and tracking production.
Instrumentation in a cement plant is vital for accurate and reliable measurement, which in turn brings increases in production, energy savings, as well as better product quality and less pollution thanks to more stable kiln operation. All field transmitters and gas-analyzing equipment for Çimko Kahramanmaras were designed and delivered for the requirements and harsh environmental conditions typical in the cement industry. Siemens’ scope also included the delivery of some special instrumentation systems like the Kiln Shell Scanner, a high-temperature kiln and a cooler-monitoring system. Primary instruments used in this project are:
The scope of the contract also included the cables and cable ways that connect all parts of the plant, as well as the lighting and lightning protection and earthing. Motion sensors have been installed in all cable galleries to allow maximum energy efficiency.
As electrical and automation components are typically installed between the phases that involve civil and mechanical works, a detailed plan was set up to make sure that everything fell into place within an overall schedule of 20 months. A Siemens-wide project management system provided the necessary foundation for these challenges.
During the project-implementation phase, the most important issue was to compress the period for installation, which was possible through good organization. At peak times during electrical installation, just for this part of the project workforce of 250 has been mobilised at the Çimko Kahramanmaras site.
Commissioning started in the middle of October 2007 and temporary acceptance was issued at the end of March 2008. In this period of time that lasted just over five months, technicians and engineers completed the signal checks, carried out the no-load runs and, finally, started up the plant with material to produce clinker. But the job didn’t end with hand-over of the turnkey facility. Maintenance is the key element for high plant availability, reliability and cost efficiency. With a proper and effective maintenance program, operators can be assured that they are extracting the maximum performance from their assets.
The key to success is a pro-active rather than reactive maintenance strategy. With this knowledge in mind, Siemens Turkey has designed a maintenance program for Çimko Kahramanmaras that they will also carry out. The current maintenance contract has a term of three years. A motor and drive-repair workshop at the company’s factory in Istanbul provides rapid support in the case of larger faults or extensive maintenance.
Up to 2006 Çimko had a 2.5 percent share of the Turkish cement market. With completely new manufacturing site put into operation in 2008 Çimko now holds approximately 7 percent of the Turkish market. Designed for a manufacturing capability of 7500 tons of clinker and 10 000 tons of cement per day, Çimko Kahramanmaras is the biggest plant of its kind in Turkey and also one of the biggest in Europe.
Staff at Siemens Turkey took care of the basic and detailed design, integration engineering, installation, testing and commissioning as well as complete project management. Through a fast construction time, a quick return on investment could be guaranteed – the entire electrical and automation system was installed and put into operation within only 20 months.
And with the installation of a detailed pro-active maintenance program the necessary steps have been taken to permit efficient and reliable operation over the entire plant life cycle.
Siemens Industry Solutions
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