ABB Case Studies System 800xA at Indian Cement Plants

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	System 800xA at Indian Cement Plants ABB

System 800xA at Indian Cement Plants

ABB

Technology Category	Automation & Control - Distributed Control Systems Automation & Control - Human Machine Interface (HMI) Sensors - Gas Sensors
Applicable Industries	Cement
Applicable Functions	Discrete Manufacturing
Use Cases	Process Control & Optimization
Challenge	Chettinad Cement recognized that further efficiencies could be achieved in its cement manufacturing process. It looked to investing in comprehensive operational and control technologies to manage and derive productivity and energy efficiency gains from the assets on Line 2, their second plant in India. Read More
About Customer	Chettinad Cement as part of Chettinad Group is a major supplier of cement in southern India. Read More
Customer Name	Chettinad Cement Read More
Solution	Chettinad upgraded Line 2 control system to ABB System 800xA, including the latest human machine interface. Drives, motors and transmitters were also employed to ensure safety operation and optimal performance. ABB gas analyzer was used to monitor product quality and nitrogen oxides (NOx), sulfur oxides (SOx) and other gas components compliance. The Knowledge Manager solution was used to manage production and quality. Read More Log in to view content
Data Collected	Asset Performance, Device Diagnostic Status, Energy Cost Per Unit, Process Procedure, Production Efficiency Read More Log in to view content
Contents

Technology Category

Automation & Control - Distributed Control Systems

Automation & Control - Human Machine Interface (HMI)

Sensors - Gas Sensors

Applicable Industries

Cement

Applicable Functions

Discrete Manufacturing

Use Cases

Process Control & Optimization

Challenge

Chettinad Cement recognized that further efficiencies could be achieved in its cement manufacturing process. It looked to investing in comprehensive operational and control technologies to manage and derive productivity and energy efficiency gains from the assets on Line 2, their second plant in India.

About Customer

Chettinad Cement as part of Chettinad Group is a major supplier of cement in southern India.

Customer Name

Chettinad Cement

Solution

Chettinad upgraded Line 2 control system to ABB System 800xA, including the latest human machine interface. Drives, motors and transmitters were also employed to ensure safety operation and optimal performance. ABB gas analyzer was used to monitor product quality and nitrogen oxides (NOx), sulfur oxides (SOx) and other gas components compliance. The Knowledge Manager solution was used to manage production and quality.

Data Collected

Asset Performance, Device Diagnostic Status, Energy Cost Per Unit, Process Procedure, Production Efficiency

Impact #1	[Cost Reduction - Production] The energy efficiency of production processes was improved, reducing production costs.
Impact #2	[Efficiency Improvement - Installation] Technicians are able to query instruments remotely during commissioning to confirm device functionality.
Impact #3	[Efficiency Improvement - Maintenance] Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.

Impact #1

[Cost Reduction - Production]
The energy efficiency of production processes was improved, reducing production costs.

Impact #2

[Efficiency Improvement - Installation]
Technicians are able to query instruments remotely during commissioning to confirm device functionality.

Impact #3

[Efficiency Improvement - Maintenance]
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.

Benefit #1	Energy consumption was reduced by 10% due to the system upgrade.

Benefit #1

Energy consumption was reduced by 10% due to the system upgrade.

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Overview

System 800xA at Indian Cement Plants

Operational Impact

Quantitative Benefit