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.

HC800

HC800

HC800

HC800

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.