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DESIGN OF DISTRIBUTED CONTROL SYSTEM FOR AUTOMATION OF CALCINATION UNIT FOR ALUMAR BRAZIL EXPANSION PROJECT


Under The Guidance Of
Mrs. Anita Tapadia
Lead Engineer
GES-HPS
Honeywell Automation India Limited
Mr. G. Saravanakumar
Senior Lecturer
Dept. of Instrumentation and control, MIT, Manipal

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•
NEED FOR THE PROJECT
• Alumar is a smelter located in São Luis, Maranhão, Brazil.
• It is involved in extracting Aluminium from Bauxite and refining it by Bayer’s process.
• At present the capacity of Alumar smelter is 2 MTPY. Alumar wants to modify its control system (TPS) for more tags so as to increase its production to 3.5 MTPY.
• Honeywell automation has been hired by Alumar to provide the required solution for modifying, upgrading and reconfiguring the existing TPS( Total Plant Solution).



OBJECTIVES
• P&ID TAKE OFF
• P&ID SHEET
• HPM(HIGH-PERFORMANCE PROCESS MANAGER)


GENERAL DESCRIPTION
• The High-Performance Process Manager (HPM) is designed to provide flexible and powerful process scanning and control capabilities.
• It uses a powerful multiprocessor architecture with separate microprocessors dedicated to perform specific tasks.
• HPM ARCHITECTURE
• As depicted in Figure 1-1, the HPM consists of the High-PerformanceProcess Manager Module (HPMM) and the I/O Subsystem.
• The HPMM consists of a Communication Processor and Modem, I/O Link Interface Processor, and Control Processor.
• The Communication Processor is optimized to provide High-Performance network communications, handling such functions as network data access and peer-to-peer communications.
• The Control Processor is the HPM resource dedicated to executing regulatory, logic, and sequence functions, including a powerful user programming facility.
• The I/O Link Interface Processor is the interface to the I/O Subsystem.
• The I/O Subsystem consists of a redundant I/O Link and the I/O Processors. These I/O Processors handle all field I/O for both data acquisition and control functions.
• The I/O Processors, for example, provide such functions as engineering unit conversion and alarm limit checking independent of the HPMM.
• All control operations are performed within the HPMM, with all data acquisition being performed in I/O Processors.
• The process engineer has complete flexibility of choice, within the maximum HPM design limits, in the assignment of point types and control strategies.

CONTROL FUNCTIONS
• The HPM provides a variety of control tools that can be customized to address a wide range of process automation needs. Functions from I/O scanning, through regulatory and logic control to more advanced control can be easily implemented through the HPM.
• The HPM toolbox includes a sophisticated regulatory control package, fully integrated interlock logic functions, and an advanced process engineer-oriented Control Language (CL/HPM).
• CL/HPM is an enhanced version of the Control Language implemented by Honeywell in the Multifunction Controller, Process Manager, and Application Module.
• This language facility includes the sequence structures needed to handle batch or hybrid applications as well as the computational capability needed for some continuous control tasks.

COMMON FUNCTIONS
• The HPM provides a configurable parameter called PNTFORM (Point Form) that allows the user to define which points are to be used as the primary operator interface for point data.
• The PNTFORM parameter provides the user with two choices for point form: "Full" and "Component.
• Points that are configured as having "Full" point form include alarm-related parameters and sometimes, some other miscellaneous parameters. This information is needed when the point is to be used as the primary operator interface to the point's data.
• Points that are configured as having "Component" point form should be used for points that provide inputs to the "Full" point, and also for those points that handle the outputs from the "Full" points.
• POWER APPLICATION BUILDER

PURPOSE AND SYSTEM REQUIREMENT
• The Power Application Builder is an open systems application by Honeywell’s Power Generation Business Center (PGBC).
• This application is a tool designed to increase the productivity of designing and maintaining Honeywell APM, HPM logic drawings within a Power Plant.
• This application runs on an Intel Pentium based PC running Windows 95/98/NT 4.0.
• It utilizes a Microsoft Access Relational Database Management System (RDBMS).
• During the design of the plant control logic, the application provides forward building capabilities to allow the user to create logic drawings on his/her PC, print the drawings, and write the drawings into EB files.
• After design and start-up of the power plant, the application has backbuilding capabilities to allow the plant engineers/technicians to easily keep the plant drawings up to date with the actual APM, HPM configuration as well as a comparison tools to list any changes from prior project files.
• SAMA DRAWING
• TPS SYSTEM

GENERAL DESCRIPTION
• The Total Plant Solution (TPS) system is Honeywell’s open plant automation system.
• It includes our robust, secure distributed control capabilities, as well as advanced applications like multivariable control, batch control, and optimization, plant-wide history, and information management capabilities in one unified system.

FEATURES
• TPS ARCHITECTURE

COMPONENTS
• Global User Station (GUS)
• Process History Database (PHD) historian and real-time database
• Application nodes including the Application Processing Platform (APP)
• TPS Builder
• TPS Network (TPN)
• Smart field devices
• NATIVE WINDOW
• HMI GRAPHICS

• CONCLUSION
• We were able to create the EB files required to upgrade the existing DCS so that new tags i.e sensors, indicaters and controllers can also be accommodated and lead to increased productivity of ALUMAR refinery. Thus we can conclude as follows:
• 1. P&ID take off –The loops were identified.
• 2. The identified loops were implemented in HPM (High-Performance Process Manager) Power Application Builder.
• 3.HPM System was configured for testing (DCS) .
• 4. Control strategies were tested and implemented.
• 5. HMI graphics were build.

• REFERENCES
1. Control Functions in the System—System Control Functions, SW09-501 in the Implementation/Startup & Reconfiguration - 2 binder.
2. Control Functions in the CM50S—Refer to the publications in the Implementation/CM50S binders.
3. Control Functions in the Application Module—Application Module Control Functions, AM09-502 in the Implementation/Application Module - 1 binder.
4. Definitions of the HPM Parameters—High-Performance Process Manager
Parameter Reference Dictionary, HP09-640 in the Implementation/High-
PerformanceProcess Manager - 2 binder.
5. Configuration, Redundancy, Failover information—Engineer's Reference
Manual SW09-605 in the Implementation/Startup & Reconfiguration - 2 binder.
6. Control Language—Control Language/High-PerformanceProcess Manager
Reference Manual, HP27-510 in the Implementation/High-PerformanceProcess
Manager - 2 binder.
7. Serial Interface Communications—APM/HPM Serial Interface Options,
OP01-501 in the Implementation/PM/APM/HPM Optional Devices binder.