VolynCement, part of Buzzi Unicem’s Dyckerhoff group, operates a 2Mta cement works in

Zdolbunov in the Rivne region, Ukraine. The project for Volyn Cement’s new

process control system was awarded to Votum Ltd. The Ukraine-based system integrator and official partner of Siemens, Germany, was responsible for the design, delivery, engineering and commissioning of the new Simatic Process Control System 7 (PCS7). The PCS7 represents the implementation of Siemens’ ‘Total Integrated Automation’ concept and includes Cemat, an open, flexible and fully-scalable process control system which combines information and diagnostic tools, specifically developed for the cement industry. Figure 1 shows the structure of the automated control system (ACS) employed at VolynCement.

PCS7 (version 7.1) is a two-level system that carries out the following tasks:• control of the process parameters and the state units. Data are displayed on client stations and transferred to the plant’s server.

• management of equipment and measurement of process variables• warning and alarm functions with fault localisation and mapping shown on client stations, as well as the transmission of messages to upper management• diagnosis of pre-emergency and emergency situations• logging and archiving • preparation of reports.

System characteristicsAs previously noted, the system’s functions are distributed between two levels. The lower level includes the signals from the sensors, actuator control, warning alarms, protection and local magement. Meanwhile, the top level enables process visualisation, control, recording, archiving, remote management and the collaboration units in groups.

IStaying in controlby Votum Ltd, Ukraine

UKRAINE PROJECT

OCTOBER 2014 INTERNATIONAL CEMENT REVIEW

VolynCement control room staff now have a better overview of cement plant operations and are able to take action quickly and efficiently

Dyckerhoff-owned VolynCement OJSC recently installed a new control system at its cement works in Zdolbunov, western Ukraine. Supplied by Votum Ltd, the new system is expected to provide long-term benefits as staff are able to better monitor the plant and take effective action when required, thereby avoiding costly unscheduled shutdowns.

Figure 1: structure of automated control system

©Copyright Tradeship Publications Ltd 2014

UKRAINE PROJECT

INETRNATIONAL CEMENT REVIEW OCTOBER 2014

Process BusThe lower level, Process Bus is a management station automation system (controller SIMATIC S7-400) connected to a Profibus network which includes decentralised peripheral stations ET200M, ET200S, variable-frequency converter, flowmeter and other equipment.

Terminal BusMeanwhile, the upper-level, Terminal Bus is based on servers with a redundant function (Siemens Rack PC), industrial-scale computers (clients) with two monitors on each and an engineering station.

The OS Server offers station management and process visualisation rather than direct process control.

Currently a WinnCC system collects data, archives, and records alarms and values. Communication with the controller is carried out via a SR1613 communication processor.

The OS Client is an operating unit with two monitors designed to control and monitor the process. It receives control process data from the OS Server and transmits information back to this server.

The engineering station is designed to develop control programs and visualisation (Step7, WinCC). It supports communication with the programmable controller and server but is not intended for direct process control.

The Process Bus and Terminal Bus are connected via an optical ring Fast Ethernet (1Gb) topology with the help of Siemen’s Scalance 308-1 network equipment.

Comprehensive plant control The new process control system covers all key parts of the cement production process, with each department controlled by PLC Simatic S7-400 modular process controllers.

Slurry preparation and laboratoryThe ACS controls the grinding mills, vertical and horizontal basins, pumps, flowmeters and slurry transport.

The new process control system covers key plant equipment such as the cement mill (above) and the kilns (right)

The plant’s TSV-3200 separator is controlled by a PLC S7-400 modular process controller as is each individual plant department

©Copyright Tradeship Publications Ltd 2014

Moreover, it stabilises the chemical and physical characteristics of the raw mixture that is fed into the kiln, helping to normalise the formation of clinker.

The system operates via an algorithm that calculates the value of all raw materials (including clinker additives, coal ash and slag additions in kiln) and the percentage of oxides in the raw sludge, which must meet the performance requirements defined in the lime saturation factor (LSF), silica ratio (SR) and alumina ratio (AR).

Coal millSince the commissioning of the new ACS, Volyn Cement has been able to substitute 93 per cent of its natural gas usage with coal dust.

Kilns 4, 5 and 6 In the kiln, the ACS controls the main motor, burner, electrostatic filter and transporters, positively impacting kiln

operations. With the help of a flowmeter and frequency converters, accurate dosing of raw meal components has resulted in improved kiln operations.

In addition, the time between kiln repairs has increased by 1.5 times.

Cement mills 4 and 9 plus separatorA TSV-3200 separator is connected to the plant’s FM4 and FM9 ball mills. It consists of an additional air duct system,

fan and cyclone which are switched between the mills’ outlet and the existing process air systems of the mill fans and filters (aspiration). Transport systems bring material from the mill outlets to the separator and move separator reject material to the mill inlets, as well as convey the finished materials to pneumatic transport.

In terms of the cement mills at the works, Volyn Cement now benefits from lower energy costs.

ACS implementationDuring ACS implementation Votum assessed the different parts of the plant in terms of automation requirements and then recommended a suitable ACS. In addition, the company developed the ACS, a general functional specification (GFS), a detailed functional specification (DFS), and software for the PLC and the operator stations. Votum also designed the sensor and consumer lists, P&ID – piping and instrumentation diagram, electric circuits, cabling track, manuals and all other documentation required for a smooth system operation.

Following the purchase, production and delivery of all equipment needed for the automated systems, Votum supervised the installation and commissioning of the new equipment as well as provided training.

ConclusionSince its commissioning in 2012, the new process control system has delivered plant-wide benefits. The system’s ability to control operating modes and enable plant personnel to carry out routine mainte-nance on time has helped prevent the failure of equipment. Remote WebServer-based monitoring has also served the plant well as specialists in other locations can view real-time plant operation conditions.

Moreover, the system has not only reduced equipment downtime but also improved quality control, eliminating human error. With this increased reliability, the plant has been able to reduce the number of operator and service personnel.For system operators, it has brought improved working conditions, including a new air-conditioned control room.

In addition, material flows are better accounted for and with all data included in the MES plant system, overall efficiency at the works has increased.

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UKRAINE PROJECT

OCTOBER 2014 INTERNATIONAL CEMENT REVIEW

Votum scope of supplyVotum Ltd supplied the following ACS equipment to VolynCement :

• cabinets with PLC – S7-416-3 from Siemens• cabinets with distributed control – ET200M, ET200S with I/O-modules from Siemens for connect digital and analogue input/output signals• operator station, server – Rack IPC547C from Siemens• motor control centre (MCC)• low-voltage main distribution (LVD)• transformer GEAFOL 2000 kVA, 6kV• flowmeters Sitrans F• frequency converter FC Sinamics for motor• cables and cables rack.

Volyn Cement’s new motor control centre

Since its commissioning in 2012,

the new process control system has

delivered plant-wide benefits. The

system’s ability to control operating

modes and enable plant personnel

to carry out routine maintenance on

time has helped prevent the failure

of equipment.

©Copyright Tradeship Publications Ltd 2014

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BUILDING BULLETIN

1

Contents

page no

Boral acquisitions

Two quarries and a concrete plant 2

Eurozone monthly output falls

Construction activity down 1.1% 2

UK construction outlook

Two further years of decline forecast 2

Japan rebuilding costs

Reconstruction estimated at US$152bn 2

US construction spending down

Dramatic falls seen in May

3

MENA long-term growth

Forecast for contractors positive 3

Summit's spending spree

Six acquisitions made in the US 3

Weinerberger approval

Roof-tile takeover given green light 3

UK quarry reserve shortages

Lack of consents impacting industry 4

SIG first-half improvements

Good progress in Continental Europe 4

Cemex ready-mix investment

UK plant replaced and modernised 4

Poland construction forecast

Sector to see 11% growth YoY 4

LSR brick project

Financing received for new plant 4

Saudi limestone deal

Arabian Cement signs contract 4

Outlook for global building materials

THE OUTLOOK FOR the global building materials industry remains varied with strong growth in

most emerging countries, a likely recovery in West European and Australian markets and a

challenging outlook in the US and some North African markets. Pricing also remains a key

issue in most markets, according to an informative new report from JP Morgan Cazenove.

The analysts remain cautious on exposure to US construction spending. Growing macro-

economic concerns, a depressed housing market, little incremental demand for commercial

space and uncertainty on federal funding for highways are among its concerns. However,

US$5/t price increases announced in April are noted as succeeding in some local markets.

A recovery in Western Europe is expected this year on the back of strong growth in

residential markets in France and Germany. Due to austerity measures announced by most

countries, the report expects infrastructure spending to remain flat or to post a slight decline

compared to last year. Uncertainty about the macro-economic situation in peripheral Europe

remains a concern, but its outlook on Central and Northern Europe remains positive. Similarly,

Eastern European construction markets should show a fast paced improvement with most

companies reporting strong trading conditions in the region, led by Poland and Russia.

JP Morgan Cazenove also expects continued growth in Asian demand this year. While

the Australian market appears to be seeing slight improvements, growth in China, India

and Indonesia remains strong and it expects growth in these markets to

remain robust

longer term because of rapid urbanisation and infrastructure/housing needs for a growing

population base. However, pricing volatility remains inevitable as unpredictable volume

demand combines with significant investments in new capacity.

A positive outlook on Sub-Saharan Africa and a cautious outlook for Middle East and North

Africa due to political uncertainty in the region is noted in the report . Furthermore, higher

energy and labour costs are likely to put margins under pressure this year. On the other hand,

markets in Sub-Saharan Africa continue to grow driven by residential and infrastructural

demand in-line with a typical emerging market.

Finally, in Latin America, housebuilding growth continues in Mexico and Brazil. Cement

volumes were up 11.5 per cent YoY in Brazil in June so volumes seem to continue to perform

well. Pricing versus cost increases will be a similar issue here to the rest of the world.

Lafarge sells Australian gypsum operations

LAFARGE HAS AGREED the sale of its Australian gypsum operation to Knauf for 1200m. This

business generated an EBITDA of 13m in 2010 and is the third plasterboard producer in

Australia, with two plants.

The two bigger producers in Australia are CSR, using the Gyproc name in Australia that

elsewhere belongs to St-Gobain, and Boral. The Australian government would not let two of

the three domestic producers merge and the deal with Knaaf should allow Boral to acquire

the remaining half of Lafarge’s gypsum interests in Asia. The deal with Lafarge is expected to

be completed in late summer or early autumn.

This follows news from earlier in July that Lafarge is in

talks with the Etex Group for the

sale of its European and South American Gypsum assets at an enterprise value of 1bn.

Under this proposed agreement, Lafarge would receive net cash proceeds of approximately

850m and in addition would receive a 20 per cent interest in the new partnership, which

would combine the European and South American Gypsum activities of both groups.

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