The KCS cement plant in Turkey is located in the town of Pazardjik, Kahramanmaras province, southeastern Turkey. It was completed and put into operation in 2008.There is a new dry clinker production line with an actual output of 4,250 t/d and an actual output of 4,550 t/d, which is the residual heat of waste gas generated during the production process of the new dry process cement kiln,To save energy, reduce environmental heat pollution, and further reduce production costs, KCS Cement Company of Turkey used the waste heat of the cement kiln to build a two-furnace and one-machine, 9MW offshore heat power station.

According to the experience and requirements of KCS, the power station adopts DCS control system to realize: data acquisition; analog quantity control; production report, operation record, accident occurrence and processing record, parameter curve printing; equipment sequence control, interlock and protection; Adjust process parameters such as drum water level, condenser water level, drain tank water level, deaerator tank water level, deaerator working pressure, etc.; integrate various other control devices to meet the requirements of various operating conditions of the power plant.

System Configuration

1） Process control system

-- 1 engineering station, 3 operator stations, 1 report and WEB service station

-- Turbine control cabinet 3 sides, boiler control cabinet 2 sides

-- Controller PM902F-pair, I0 module S800 collects about 1300 points

2 ) Power monitoring system

-- Generator protection screen 1 side, including generator protection REG650

-- Manual and automatic synchronization screen 1 side, including automatic synchronizing device SYN5201 

-- 2 lines of contact line and 2 sets of transformer protection, 10 sets of 615 series protection

3 ) High and low voltage switchgear

-- 10 high-voltage cabinets of KYN28 type, circuit breakers adopt VD4

-- Low-voltage cabinet 20 MSN type, components use ABB

-- 82 low-voltage distribution boxes, components using ABB

System Structure

-- A total of one engineering station and three operator stations are set up in the system layer, all of which are dual-screen display, one report and WEB service station, large-screen LCD TV wall display

-- The communication layer uses two Ethernet switches to form two independent star networks to achieve dual network communication redundancy

-- Protection of power supply and distribution systems and other intelligent devices to realize data access with DCS system via WXD216 communication management machine and AC500

-- The three-sided steam turbine control cabinet is placed in the main control room, and the two boiler control cabinets are placed in the low-voltage power distribution room under the furnace. The boiler control cabinet communicates with the redundant controller PM902F of the main control room through the optical fiber

-- Two boiler control cabinets use ProfibusDP to communicate with the original Siemens and ABB DCS systems for data exchange

-- Other systems such as water system and inverter also use ProfibusDP to access this DCS system