In the past, the advanced process control system of cement enterprises was arranged by external suppliers, which was a "black box" for us: the logic could not be seen, the parameters could not be moved, the effect was not ideal, and we could only wait for the manufacturer to deal with it. Since the beginning of this year, the APC team of the smart factory has been determined to gnaw down this hard bone: the whole team has divided the work, started with the control principle, sorted out and thoroughly understood the functional composition and parameter adjustment logic of the advanced process control one by one, and for the first time, the control logic of this system has become something that we can "speak clearly and change".
Understanding is only the starting point. In May, the APC team entered Jiaoling Branch Line 1 to find out the actual working conditions of the equipment and the operating habits of the operators one by one. Based on this, the decomposition furnace and the raw material mill were determined as the first batch of pilot projects, and the model construction and parameter setting were completed. At the same time, the electromechanical and process engineers and operators were included in the training scope to avoid the cooperation vacuum of "the system is on line, but the people do not keep up with it". In order to keep the bottom line of safety, the team formulated a four-stage gray scale on-line scheme, from only watching but not controlling to suggesting mode to automatic operation, and set exit conditions for each step.
From June to July, the three applications were put into operation one after another, and the operation effect was verified in practice: the standard deviation of the temperature of the calciner reached the advanced level in the industry during the automatic control period of the calciner; the standard deviation of the weight of the 2 # raw mill steady flow bin was reduced by more than half compared with the manual operation, and the material was stopped for several consecutive days, while the material was stopped twice in two days due to the deviation of the bin weight during the same period of manual operation; Compared with the existing control scheme on the same line under the same working condition, the stability of each index of 1 # raw mill is better. In late July, the team went to the 2 # cement mill to complete the process check and step test, paving the way for the next application.
From "using other people's systems" to "changing their own logic and adjusting their own parameters", the core knowledge remains in the team. This young team used half a year to prove that the initiative of the smart factory can only be grasped by their own hands.
The APC team and the central control operator jointly track the system operation in front of the console. The
APC team and the production department of Jiaoling Branch Company reviewed the operation of
2 # raw mill together. The comparison between the manual operation period and the automatic (after setting) control quality showed that the fluctuation range of the weight of the steady flow warehouse and the power of the fixed roll was significantly narrowed
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