SAT: Our experience with Holcim proves that process stability depends on the proper design of the on-site installations

Specifics surrounding automation in the cement sector, are connected primarily to two conditions; the continuous operation of installations and the aggressive environment (dust, thermal overloading and vibrations). In this context, the projects of the Bulgarian engineering company Systems Automation Technologies – SAT for Holcim factories in Germany and Bulgaria, highlight the practicality of engineering solutions in the field. Holcim factories operate 24 hours nonstop, in which the rotary kilns maintain a temperature of 1450°C, with pauses outside of scheduled repairs being out of the question. We examine how new control systems are implemented given such a production schedule—and the details of on-site engineering—through SAT’s projects in Beckum and Beli Izvor.

During the reconstruction of cooling installations and clinker transport at the factory in Beckum, SAT works with the German equipment producer IKN. The project encompasses the engineering and commissioning of a new rotary cooler, a hot-air heat recovery ventilation system, and mechanical conveying lines. Due to the kiln's continuous operation, a prolonged shutdown of the feed system is not an option; consequently, the transition to the new control system must be carried out concurrently with ongoing operations.

During modernization of the installation for powder-based materials at the Holcim Bulgaria factory, situated near the Beli Izvor village, the hardware challenge involves the complete replacement of medium- and low-voltage equipment. SAT designs and manufactures low-voltage distribution boards, as well as specialized MCC and PLC panels.

Due to mounting and caballing on site requires time, engineers have decided to shorten the start-up period by cleaning up the software outside the factory. Before the panels are delivered to the site, the control system undergoes a phase of preliminary computer simulations and Factory Acceptance Tests (FAT) at the company's manufacturing facility.

By constructing a virtual model of the production process, the reactions of PLC controllers can be tested for different load conditions and critical modes. Preparing in such a manner minimizes software errors before mounting, which allows on-site commissioning to be completed within a matter of months, without disrupting the plant's round-the-clock schedule.

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