REPORT IRON ORE PELLETIZING CONTROL SYSTEM ON THE MATERIAL MATERIAL INDUSTRY INDUS TRY
Writer : Anang Maruf
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DEPARTMENT O% ELECTRICAL AUTOMATION %ACULTY O% &OCATIONAL TECHNOLOGY INSTITUT TE'NOLOGI SEPULUH NOPEM(ER SURA(AYA 2")
CHAPTER I INTRODUCTION
A* t+e ,e-e./01ent /f *iene an, te+n/./g3 +a* ae.erate, t+e effiien3 /f +u1an 4/r5 */ a* t/ fai.itate +u1an 4/r56 T+u*7 t+e /n*e8uene* /f +u1an re*/ure ,e-e./01ent in t+e in,u*tr3 1u*t /ntinue t/ 9e i10r/-e, t/ fit 4it+ t+e ra0i, te+n/./gia. ,e-e./01ent*6 Te+n/./gia. a,-ane* are +araterie, 93 0r/9.e1 */.-ing in in,u*tr3 u*ing aut/1ati/n 1et+/,*6 C/ntr/. an, regu.ati/n an re,ue* ri*5 an, e.i1inate a,-er*e i10at* /n t+e en-ir/n1ent6 In*tru1entati/n7 /ntr/.7 an, aut/1ati/n are -ita. area* /f t+e /ntr/. 0r/e**6 C/ntr/. 1et+/,/./g3 re8uire* a t+/r/ug+ un,er*tan,ing in /r,er t/ 0r/,ue *afe /0erati/n* an, n/t ,a1age t+e en-ir/n1ent6 T+e urrent /ntr/. /r /ntr/. *3*te1 i* 9eginning t/ *+ift in aut/1ati/n /ntr/. *3*te1* t+at re8uire t+e u*e /f /10uter*7 */ t+e +u1an inter-enti/n in /ntr/. i* -er3 *1a..6 W+en /10are, t/ 1anua. 0r/e**ing7 *3*te1* /ntr/..e, 93 /10uter e8ui01ent 4i.. 0r/-i,e 9enefit* in ter1* /f effiien37 *eurit37 an, aura36 T+e a9i.it3 /f /10uter*7 9/t+ +ar,4are an, */ft4are an 9e uti.ie, f/r -ari/u* /ntr/. a00.iati/n*7 *u+ a* te10erature /ntr/.6 T+e /ntr/. *3*te1 +a* a -er3 i10/rtant r/.e in t+e ,e-e./01ent /f *iene an, te+n/./g36
%igure 6 Pe..etiing C/ntr/. S3*te1 Pe..etiing i* a 0r/e** /f agg./1erati/n /r ./tting /nentrate* /f /re* /r 1inera.* t+at are *1//t+7 genera..3 .e** t+an )! ir/n 0arti.e* *+a0e, .i5e 1ar9.e* /r *1a.. 9a.. 4it+ t+e *ie fr/1 ; u0 t/ 2$ 116 Main g/a.* /f 0e..etiing *tage i* f/r1e, /f 0arti.e* 4it+ a *0eifi *ie f/r ea*3 1/-e, t+e -enue an, +a-e 0r/0ertie* t+at an 1eet t+e nee,* /f t+e nature /f t+e e<0eri1ent6 %ine 0arti.e* ten, t/ 9e 1/re ,iffiu.t t/ 9e +an,.e,7 9/t+ 1/-ing fr/1 /ne 0.ae t/ an/t+er7 fr/1 /ne 0r/e** t/ t+e ne*ie, 9a..* 9et4een ; ? 2$ 11
/f 0/4,er /nentrate=/re=1inera.*6 T+i* agg./1erati/n re*u.t 0e..et* 5n/4n a* green 0e..et*6 W+i.e in,urati/n i* t+e 0r/e** /f +eating t+e 0r/,ut again*t t+e re*u.t* /f t+e agg./1erati/n /r green 0e..et* in te10erature* /f a9/ut 72"" ,egree* Ce.*iu*6 In,urati/n ,/ne in t+e 5it+en +eater i* a..e, 4it+ in,urat/r6 Pr/,ut /f t+e in,urati/n 0+a*e i* referre, t/ a* 9urnt 0e..et* /r 0e..et fue.6 T+e 1ain 0ur0/*e /f t+e *tage* i* t/ get a 0e..et in,urati/n t+at +a-e 0r/0ertie* *u+ a* t+e e<0eri1ent /f 1e+ania. 0r/0ertie* /r *trengt+ an, t+e nature /f t+e re,uti/n6 T+e *trengt+ re8uire, t/ 4it+*tan, t+e 1e+ania. ./a, /f 0e..et* ,uring a ne
%igure 26 Pe..etiing S+e1ati S3*te1 S+e1ati *tage /f t+e 0r/e** /f 1a5ing 0e..et* an 9e *een in t+e figure 26 T+e 0r/e** *tart* 4it+ t+e 1anufaturing /0erati/n* /f green 0e..et*6 T+i* /0erati/n i* e8ui00e, 4it+ 1i
Air Control Valve
Temperature
Thermocouple
%igure #6 C./*e, L//0 C/ntr/. S3*te1 T+i* ./*e, .//0 *3*te1 9a*e, /n t+e 9./5 ,iagra1 a9/-e 4+ere t+e /ntr/..er i* a te10erature /ntr/. T'!S7 a t//. u*e, t/ rea, te10erature*7 /ntr/. t+e te10erature */ t+at it /rre*0/n,* t/ t+e e<0ete, *0eifiati/n*6 T+e 1ain 0ur0/*e /f /ntr/. i* 1aintaining t+e *ta9i.it3 /f t+e te10erature /n t+e -aria9.e /ntr/. /n e<0en,iture */ t+at t+e /19u*ti/n ga* te10erature +a* 9een *et t/ run /n*tant.36 t+e /ntr/..er /10are* t+e *et 0/int *igna. @in0ut an, 0re*ent -a.ue=/ut0ut *igna. 4it+ t+e *en*/r u*e, i* a t+er1//u0.e *en*/r6
CHAPTER II PROBLEM STATEMENT
Pe..etiing 0r/e** 4i.. 0r/,ue ir/n /re fr/1 t+e +e1ia. /10/un,* t+at are 1i 0r/,ut*6 An3 1i
CHAPTER III RESULT AND DISCUSSION 3.1 Temperature Controller TK C/ntr/..er* are 4i,e.3 u*e, in in,u*tria. /ntr/. *3*te1* t/ a,u*t /r 1aintain ,e*ire, /ut0ut* /f *0eifi 0r/e**e* 4it+in a ,e*ire, range6 Aut/ni* 0r/-i,e* a ,i-er*e range /f +ig+.3 aurate an, re.ia9.e /ntr/..er* f/r i,ea. *3*te1 /ntr/.6
%igure #6 T'! Serie* Te10erature C/ntr/..er*7 u*e, in 4i,e -ariet3 /f in,u*trie*7 i* t+e *tarting an, i10/rtant t//.* f/r t+e /ntr/..ing /f t+e te10erature t/ get ,e*ire, re*u.t* in -ari/u* in,u*trie*6 Aut/ni* Ana./g=Digita.@PID te10erature /ntr/..er*7 /ffer 8ui5 *etu0 an, 0r/-i,e 0rei*e te10erature 1anage1ent an, /ntr/. f/r a -ariet3 /f a00.iati/n* 4+i.e /ffering t+e 9etter 0rie7 ,e*ign an, ea*3 /0erati/n6 T+e3 4i.. 9e t+e ,efinite +/ie f/r 3/ur *ue**fu. /ntr/. in an3 te10erature a00.iati/n*6 Stan,ar, t30e PID te10erature /ntr/..er* T' Serie* rea.ie* 1/re 0/4erfu. /ntr/..ing 4it+ *u0er +ig+>*0ee, *a10.ing 3.e /f $"1* an, "6#F ,i*0.a3>aura36 It *u00/rt* +eating=//.ing *i1u.tane/u* /ntr/.7 aut/1ati=1anua. /ntr/.7 SSR /ut0ut=urrent /ut0ut *e.eta9.e funti/n7 SSRP /ut0ut funti/n an, /11uniati/n funti/n6 In a,,iti/n7 it /-er* ,i-er*e in0ut *en*/r *u00/rt7 1u.ti S& *etting7 +ig+ re*/.uti/n ,i*0.a3 0art an, /10at *ie6
Air Control Valve Oil
%igure !6 Wiring Diagra1 S3*te1
%igure ! i* t+e 4iring in t+e /ntr/. T'!S te10erature a**/iate, 4it+ */1e /f t+e /t+er /10/nent*6 On T'!S t+e 0in a**/iate, 4it+ t+e SCM>US(;I t+at *er-e* a* a .iai*/n 9et4een T'!S t/ t+e /10uter */ t+at t+e ,ata fr/1 t+e *en*/r* an 9e *ent t/ t+e /10uter6 T'!S g/t *u00.3 22" &AC $" H u*ing t+e 0.ug t+r/ug+ t+e 0in* $ an, /n T'!S6 W+i.e7 t+e atuat/r* u*e, a te10erature /ntr/. -a.-e 4+i+ i* /nnete, t/ 0in* # an, !6 T+e t+er1//u0.e i* /nnete, /n 0in an, 26 S/7 t+e te10erature ,ata an 9e a8ui*ite, fr/1 T'!6 !.3 DA" Ma#ter So$t%are
%igure $6 DA Ma*ter S/ft4are In t+e u*e /f DA 1a*ter */ft4are a9/-e 4e 1u*t 1a5e t+e fir*t /nfigurati/n 9et4een t+e +ar,4are 4it+ t+e */ft4are u*e,6 T+en /nnet an, *anning t+e DA 1a*ter t//.9ar6 T/ 9e a9.e t/ a**ign -a.ue* an, *et -a.ue* Para1eter* an 9e +ange, ,iret.3 t+r/ug+ t+e e8ui01ent /r t+r/ug+ */ft4are6 C+ange* -ia t+e e8ui01ent i* ,/ne 93 g/ing t/ t+e Para1eter 1enu @Pre** M/,e 9utt/n # *e/n,*7 t+en +ange t+e ,e*ire, 0ara1eter*6 C+ange* t+r/ug+ t+e */ft4are an 9e ,/ne 93 +anging t+e ite1* in t+e Pr/0ert3 *u9>4in,/46 !. ON&O'' Mo(e Mea#urement T+i* gra0+ 9e./47 *+/4* t+e te10erature *igna. u*ing ON=O%% 1/,e6
%igure 6 ON=O%% Gra0+i Data In t+e a9/-e *3*te1 t+ere i* ON>O%% C/ntr/. 4+ere t/ u*e t+e *3*te1 93 Pre** M/,e f/r # *e/n,* /n T'!S7 Se.et PAr #7 0re** M/,e7 *e.et Unit +ange t/ B C7 Pre** M/,e7 +//*e />ft t/ *et Heating 1/,e = C//.ing *4it+ t/ Heating 1/,e6 Se.et PAr #7 0re** M/,e7 g/ t/ C>n, t/ +ange t+e *etting t30e7 *e.et ON = O%%7 Pre** M/,e7 t+en PAr 27 *e.et HHYS @Heating H3*tere*i* 4it+ a -a.ue /f 26 Gra0+ In %igure *+/4* a re*0/n*e re*e19.ing a re*0/n*e gra0+ /f /r,er 7 9ut /n t+e gra0+ 4+en it rea+e* a 0re,eter1ine, *et 0/int /f #2 BC t+e .a10 @t+e ti1e> /ntr/..e, 1e,iu1 4i.. ,ie7 an, 4+en t+e te10erature +a* ,r/00e, t/ # BC T+e .a10 4i.. *ti.. ,ie unti. t+e ne4 te10erature #"BC 9a5 .ig+t 4i.. .ig+t u06 T+i* +a00en* 9eau*e t+e -a.ue /f +3*tere*i* t+at +a* 9een gi-en7 after t+e te10erature rea+e* #" BC it 4i.. 9e 4ar1e, u0 again unti. t+e /ntr/..er t/ ,etet t+e te10erature /f #2 BC an, t+e .ig+t 4i.. ,ie again6 In ON = O%% /ntr/..er 4i.. /ntinue t/ ,/ */ an 9e *ai, in t+i* *3*te1 0r/,ue a /ntr/. t+at i* fiMDJ i* *et a* PID7 it i* ,i*0.a3e,6 If err/r OPENJ /ur* ,uring aut/ tuning7 it *t/0* t+i* /0erati/n aut/1atia..36T/ *t/0 aut/ tuning7 +ange t+e *et a* O%%6 @It 1aintain* P7 I7 D -a.ue* /f 9ef/re aut/ tuning6
Aut/>tuning *tart=*t/0 *etting : K Aut/>tuning aut/1atia..3 *t/re* PID ti1e /n*tant* u0/n ter1inati/n6 T+e*e PID ti1e /n*tant* an t+en 9e 1/,ifie, 93 t+e u*er t/ *uit t+eir u*age en-ir/n1ent6 K W+en aut/>tuning i* in 0r/gre**7 t+e AT in,iat/r ./ate, /n t+e fr/nt /f t+e /ntr/..er f.a*+e* in *e6 inter-a.*6 W+en aut/>tuning fini*+e*7 t+e AT in,iat/r aut/1atia..3 g/e* /ff an, t+e aut/>tuning 0ara1eter 4i.. return t/ O%%6 K W+en aut/>tuning i* in 0r/gre** an, ,igita. in0ut 5e3 DI>'J i* STOP @*4it+ing RUN=STOP /r AT@aut/>tuning RUN=STOP i* *et7 an, ,igita. in0ut ter1ina. funti/n DI>7 DI>2J i* STOP @*4it+ing RUN=STOP /r MAN@AUTO=MANUAL /ntr/. *e.eti/n7 aut/> tuning 4i.. 9e aut/1atia..3 en,e,7 if /nerne, DI i* in0utte, /r a *en*/r ,i*/nneti/n err/r /ur*6 @Re*t/re, t+e PID u*e, 0ri/r t/ t+e aut/>tuning *e**i/n In t+i* e<0eri1ent7 4e u*e aut/>tunning t/ get t+e -a.ue /f PID /ntr/..er6 An, +ere i* t+e -a.ue : HeatingPr/0/r*i/na. (an, HeatingIntegra. Ti1e Heating Deri-ati/n Ti1e
# BC !" $
Ta9.e 6 PID -a.ue ,ata
T+i* gra0+ 9e./47 *+/4* t+e te10erature *igna. 9ef/re u*ing aut/>tuning PID6
%igure )6 PID Gra0+i Data
T+i* gra0+ 9e./47 *+/4* t+e te10erature *igna. 9ef/re after ati-e t+e aut/>tuning PID6
%igure ;6 Aut/ Tunning PID Gra0+i Data
After ati-ating t+e aut/ tuning PID7 t+e PID /f ,ata /9taine, a* f/../4*6 HeatingPr/0/r*i/na. (an, HeatingIntegra. Ti1e Heating Deri-ati/n Ti1e
BC 2# $
Ta9.e 26 Aut/ Tunning PID -a.ue ,ata In t+e /ntr/..er u*ing PID it an /10are 9et4een /ntr/..e, -aria9.e* 4it+ *et 0/int -a.ue* an, gi-e /ntr/. ati/n t/ /rret *et 0/int ,e-iati/n t/ er/6 T+i* /ntr/..er +a* t+ree /10/nent* ea+ /f 4+i+ +a* it* /4n r/.e7 t+e fir*t P @Pr/0/rti/na. t/ ae.erate t+e *tart fr/1 t+e initia. te10erature t/ #$ BC7 t+en I @integra. 5ee0 t+e te10erature 4+en it rea+e* #$ BC */ t+at n/ inrea*e /r ,erea*e /ur*7 an, 4+i+ T+e .a*t D @,eri-ati-e funti/n 5ee0* t+e te10erature /f #$ BC ,uring t+e 0r/e**6 Wit+ t+i* /ntr/..er t+en t+e re8uire, te10erature 4i.. re1ain /n*tant7 a.t+/ug+ n/ +ange* 4i.. n/t 9e t// .arge fr/1 t+e ,e*ire, te10erature6 S/ f/r t+e u*e /f t+i* /ntr/..er i* *uita9.e in t+e in,u*tr3 9eau*e it an 0r/-i,e *ta9i.it3 at t+e ,e*ire, te10erature6
CHAPTER * CONCLUSION
T+e /ntr/. *3*te1 @/ntr/. *3*te1 +a* a -er3 i10/rtant r/.e in t+e ,e-e./01ent /f *iene an, te+n/./g36 One /f t+e t//.* /f t+e aut/ in,u*tr3 i* t+e Te10erature C/ntr/..er6 Aut/ni* Te10erature C/ntr/..er i* a t//. t+at an /ntr/. t+e te10erature t/ /ntr/. t+e //.er = +eater in a/r,ane 4it+ t+e ru.e* a* ,e*ire,6 Aut/ni* Te10erature C/ntr/..er an 0r/e** +ange* in a19ient te10erature an 9e 1ea*ure, an, ,etete,6 One t30e /f Aut/ni* te10erature /ntr/..er i* T'! *erie*6 It +e.0* u* t/ /ntr/. t+e te10erature aut/1atia..3 an, ea*i.36 Stan,ar, t30e PID te10erature /ntr/..er* T' Serie* rea.ie* 1/re 0/4erfu. /ntr/..ing 4it+ *u0er +ig+>*0ee, *a10.ing 3.e6 Aut/ tuning 1ea*ure* t+e /ntr/. *u9et* t+er1a. +arateri*ti* an, t+er1a. re*0/n*e rate7 an, t+en ,eter1ine* t+e nee**ar3 PID ti1e /n*tant 6 Aut/>tuning aut/1atia..3 *t/re* PID ti1e /n*tant* u0/n ter1inati/n6 T+e*e PID ti1e /n*tant* an t+en 9e 1/,ifie, 93 t+e u*er t/ *uit t+eir u*age en-ir/n1ent6 PID /ntr/. i* u*efu. t/ 1ini1ie /-er*+//t6 PID /ntr/. 4i.. 1aintain t+e /ut0ut te10erature t/ 5ee0 it in a/r,ane 4it+ a 0re,eter1ine, .i1it -a.ue6 De0en,ing /n t+e ON = O%% /ntr/..er t+at +a* /n.3 2 /n,iti/n* /ff an, /n7 */ t+e gra0+ t+at /1e* 4it+ t+i* /ntr/..er 4i.. /ntinue t/ ri*e an, fa.. 4it+ t+e te10erature ,ifferene a/r,ing t/ t+e gi-en +3*tere*i* -a.ue6 U*ing a PID /ntr/..er7 /ut0ut te10erature /9taine, 4i.. rea+ *tea,3 *tate 1/re ra0i,.3 an, 4/u., 9e in a *ta9.e /n,iti/n6
RE'ERENCES •
U*er Manua. T' Serie* Hig+ Aura3 Stan,art Te10erature C/ntr/..er
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Data*+eet T' Serie* Aut/ni* Sen*/r* C/ntr/..er
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4446aut/ni*6/1
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