1. System overview and project background
ABB IndustrialIT system is the latest enterprise automation solution developed on the basis of ABB’s original control system. The system integrates the advantages of traditional DCS and PLC and supports a variety of international fieldbus standards. It is especially suitable for the application of cement industry, which is widely used in the cement industry.
In 2001, Anhui Conch Group set up two 2500 t/d production lines and four 5000 t/d production lines, all using ABB AC800F control system, which has been running well for three years. In 2004, on the basis of this good cooperation, 11 5000 t/d and 10000 t/d production lines were set up on a large scale. All use ABB control systems. In 2005, there will be six more 5000 t/d and 10000 t/d production lines using ABB control systems. This paper focuses on the 2×5000 t/d production line project in Chizhou and introduces the successful application of AC800F system in conch from the technical point of view.
2. DCS control network
The system network is divided into two layers: field control layer and central monitoring layer.
The first layer is the field control layer. ABB S800 remote I/O adopts Profibus DP communication standard to communicate with AC800F controller. The communication rate is as high as 12MB/s and the distance is as far as 1200 meters. Some fieldbus instruments are used in the field, and ProfiBus PA communication standard is adopted to communicate with AC800F controller.
The second layer is the central monitoring layer, which realizes the communication between each controller and operator station and engineer station. Industrial Ethernet based on TCP/IP protocol is adopted. Due to the characteristics of cement industry, the controller and operator stations are scattered, and the distance is far, so the field interference is large, so the communication network adopts the redundant fiber ring network structure. The hub provides dual redundant power supply and dual optical fiber interface, which can connect the cable into a ring. The communication module has built-in redundancy management function. When a fault occurs at any part of the loop, it can automatically switch to another standby line within 30ms, and the fault location can be detected at the same time.
3. DCS process control station
3.1 Feature description of DCS control station
The process control level includes a number of ControlIT control stations to complete various control functions, ControlIT control station is composed of AC800F field bus controller and S800 distributed intelligent I/O station hanging down. AC800F controller is very powerful, equipped with 150MIPS 32-bit supermax RISC processor (reduced instruction system CPU)Intel80960HT25/75, And equipped with large capacity memory (4M FlashEPROM and 4 ~ 16M RAM) and real-time multi-task embedded operating system pSOS+, fully meet the industrial process control to the real-time and reliability of the strict requirements. The control period of the controller can be set according to the control requirements, the fastest can be set to 5ms. I/O module scanning speed is very high, for analog quantity T<20ms, for switching quantity T<5ms. The controller has the function of self – diagnosis based on Web technology and remote diagnosis through Internet.
Each S800 I/O station configured by the ControlIT control station can support 12 I/O cards, I/O cards using photoelectric isolation technology, analog I/O card accuracy is not less than 0.1%(thermal resistance is 0.05%). The AI card can drive the two-wire 24VDC transmitter within the range of 600m, which can directly supply power to the field transmitter. The DO output is isolated by a relay whose output contact capacity is DC24V/5A. S800 I/O adopts modular design, DIN rail installation, due to the space and environmental requirements are not harsh, S800 I/O is especially suitable for installation in scattered occasions, and almost no requirements for signal processing, so that the field instrument and equipment signals can be directly connected to S800 I/O station. As is known to all, the environment in the cement factory is very bad, but these production lines have been running for 3 years, basically no card damage phenomenon.

3.2 DCS Control Station Configuration
In Chizhou project, 5 sets of AC800F controllers are used, which are placed in 4 control rooms. The raw material grinding control room is equipped with 1 set of AC800F control stations, the kiln head control room is equipped with 2 sets of AC800F control stations, the kiln tail control room is equipped with 1 set of AC800F control stations, and the cement grinding station control room is equipped with 1 set of AC800F control stations. Four control rooms are connected to a network through a redundant fiber-optic loop.

· The raw mill control station is placed in the raw mill control room, and a set of AC800F controller is adopted, which is equipped with two Profibus modules:
– 1 S800 local I/O control for raw mill and waste gas treatment, total 6 S800IO stations, 3 for line 1 # and 3 for line 2 #.
– 1 for raw material allocation S800 remote I/O control, connecting 2 remote IO stations, 1 for line 1 #, 1 for line 2 #, in addition to the interface of Siemens S7300;
· The kiln head control station is placed in the kiln head control room and equipped with a set of AC800F controller, which is equipped with two Profibus modules:
– 1 for kiln head/clinker storage processing S800 local I/O control, a total of 6 S800IO stations, line 1 # and line 2 # 3 IO stations;
– 1 for remote S800 I/O control for pulverized coal preparation, connecting 5 remote IO stations, 3 for line 1, 2 for line 2, in addition to connecting Siemens S7300 PLC;
– Kiln end control station is placed in the kiln end control room, equipped with a set of AC800F controller, the controller is equipped with a Profibus module, which is used for the local I/O control of S800 in kiln/kiln end/homogenizing warehouse bottom treatment. Line 1 # and line 2 # have 3 IO stations.
· The cement mill control station is placed in the kiln head control room, equipped with a set of AC800F controller, which is equipped with two Profibus modules:
– 1 for interfacing with Siemens S7300.
– One local I/O for cement mill and two S800IO stations are configured.

3.3 Configuration of mine and wharf control system
· Siemens S7-300 PLC is used in both wharf part of mine, which is divided into four stations, namely limestone crushing control station, raw material conveying control station, wharf control station and clinker conveying control station, and communicates with DCS.
– The controller of limestone crushing control station and wharf control station is CPU314, and the controller of raw material conveying control station and clinker conveying control station is CPU315-2DP. Profibus DP protocol can be adopted to communicate with AC800F DCS system;
– CP 343-5 Communication processor uses the Profibus FMS protocol to communicate with the CPU of the corresponding control station.
– Optical fiber is selected as the communication medium between the control stations and is connected by a pair of optical fiber coupler;
– Limestone crushing control station and clinker transfer control station are equipped with touch screen devices, while raw material transfer and wharf control station are equipped with 1 OS station and WinCC monitoring software;
· In addition, the PLC used in Tongling Project is AB’s PLC5, and Modbus standard is adopted for communication between PLC and DCS. Communication is also convenient.

4. Operation management level
Operation management level mainly includes OperateIT operation station, EngineerIT engineer station, data gateway, management computer and the corresponding software, but also includes printers, all kinds of operating stations and other auxiliary equipment.
EngineerIT is used for system software configuration (support online configuration) and debugging and operation. It does not need permanent access to the system. The operation station can also double as the engineer station (need to log in according to the engineer permission). The software on EngineerIT engineer station ControlBuilderF completes the configuration and debugging of process level, operation level and even fieldbus instrument.
The system uses a global database, variables in the system to achieve sharing, the global database is fully installed to the process level, does not use the server/client scheme, to avoid server failure caused by data exchange task paralysis. Any variable update in the global database can be entered only once, and the variable check is system-wide. The programming language is fully compatible with the graphic programming language standard IEC 1131-3. FBD, LD, IL, SFC, ST and other modes can be selected according to the actual control requirements. The system has a large number of standard function blocks and function subroutines. For example, the adjustment block has standard, ratio, step, 2 bit, 3 bit and other function blocks for users to choose according to the actual situation. The function block programming adopts the form of parameter table, and the language is oriented to the language of instrument engineer. At the same time, the system also provides user-defined interfaces to develop special functional blocks according to user requirements. The system has the functions of selecting part, modifying part and all down-loading. The software can be programmed offline, modify parameters online, modified parameters with automatic backup function can be restored. The software can be debugging online, can be single step running, tracking, simulation debugging.
The task of the operation station is production monitoring, that is, comprehensive monitoring of all information from the process control level, monitoring, alarm, trend generation, record, print out and manual intervention operations (send commands, modify parameters, etc.). The operator station uses Ethernet to communicate with the process station and other equipment. Since the system database is global, the data and images can be fully shared between the operator stations.
Operator station supports a series of standard predefined display: such as general appearance display, circuit and each process position number panel display (panel can also be customized according to the special requirements of users), control group display, trend display, alarm display, process signal record and operation record list (realize real-time recording and real-time printing of various operations) display, the number of graphics without software restrictions, Picture data update time is less than 1 second, can be defined by programming software.
Operating station and engineer station hardware are DELL PC, operating system Windows2000. The console is used to place operations management level devices.
Step 5 Summarize
Practice has proved that ABB AC800F system has been successfully applied in more than ten production lines of Conch. In 2004, several 5000 and 10000t/d lines of Conch were also successfully put into operation, and were awarded the 2004 annual excellent control project by China Instrumentation Society.

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