DeviceNet in a cement plant
Source: ODVA
Incorporating motor management as part of a total control system upgrade helped Lafarge Corporation's cement plant in Alpena, Mich., reduce installation time, improve kiln operations and obtain greater diagnostic and preventive maintenance capabilities. Lafarge is a worldwide supplier of building materials such as cement, concrete and aggregate used in virtually all forms of construction -- from sidewalks and schools to highways and high-rises. The Alpena plant is the company's largest cement-producing facility, generating approximately 2.5 million tons per year. Five large rotary kilns operate 24 hours a day and, except for an annual maintenance shutdown, run every day of the year. Approximately 500 motors, varying in size from one half to 450 horsepower, run various kiln functions. The loss of a critical motor could shut a kiln down and dramatically impact the plant's productivity and its profitability – especially since the five kilns average more than 9 500 tons of clinker a week.
To maintain the operational integrity of these motors, Lafarge installed Rockwell Automation SMP-3 Smart Motors Protectors as a cost-effective solution that would deliver the required information -- beyond run, start and stop commands – to actually manage each motor. According to Jim Grochowski, systems engineer at the Lafarge plant, the previous motor control centers were vintage 1960 models and were becoming prone to mechanical failures. "Since the motor control centers were in need of upgrading, the SMP-3 overload relays integrated with DeviceNet network communications seemed like the best solution," Grochowski said. "We now have advanced diagnostic capability and added intelligence to this area of the plant."
