System migration – Cement plant in Colombia ­optimized by process control system from Siemens

In a cement plant in Nobsa/Colombia, operated by LafargeHolcim Ltd., a new process control system has recently been commissioned after a three-year project duration. The modernization project entailed converting the previous control system to Cemat 8.1 from Siemens. By migrating to the new high-powered process control system, LafargeHolcim has optimized its production potential and so secured the competitive edge of the location.

Of the many factors which determine success for companies in the process industry, failsafe plant performance and process reliability are paramount. Improving these two aspects is also a key focus for LafargeHolcim Ltd., one of the world’s most advanced group in the building materials industry. This prompted the company to opt in favor of process technology from Siemens when modernizing its cement plant in Nobsa/Colombia, as part of an extensive hardware and software upgrade. The existing system has now been migrated to Cemat 8.1, the Siemens process control system designed specifically for the cement industry.

Simple, rapid and reliable

The Cemat process control system from Siemens supports the building materials industry when it comes to optimizing production potential along the entire value chain. Its convenient user interface design allows employees to access all the relevant production data in real time. Operating and integrated diagnostics functions detect possible faults at an early stage and act to reduce unforeseeable downtime. The flexible, scalable and efficient control system Simatic PCS7 provides the technological basis for Cemat.

Thanks to successful cooperation between LafargeHolcim and Siemens, the migration was implemented smoothly within the three-year period by adapting to planned maintenance schedules to achieve minimum downtime. The solution package comprising hardware and software was tested before and after commissioning by experts from LafargeHolcim using the Factory Acceptance Test (FAT), the Site Acceptance Test (SAT) and the Performance and Completion Test for the process control system (PCT). Rigorous testing before commissioning avoided downtime outside the time schedule, subsequent tests confirmed a correct and safe operation of Cemat control system.

Four phases over three years

As migration of the previous system to Cemat was highly complex, it was divided into four phases:

1. Conceptual engineering

2. Raw material preparation, general plant services, preparation of alternative fuels – AFR

3. Cement grinding #1 and clinker press

4. Kiln, raw mill and coal mill

Siemens supplied all the necessary hardware and software for the automation package, a solution tested and approved by LafargeHolcim head­quarters to the most stringent technical quality standards.

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