Centralized Control System for Cement Plant

Centralised Control System for Cement Plant is a control system with multiple Siemens PLC CPUs, each CPU has its own control station called Field Control Station (FCS). There are 3 FCS altogether communicating each other and sharing data through Ethernet communication system as defined in its sharing Data Block (DB). Each FCS has multiple I/O cards (Digital Input, Digital Output, Analog Input, Analog Output) and CPU.
Cement plant has different manufacturing stages, first one is Limestone Crusher which is getting controlled by FCS named FCS01, second is Raw Mill Grinding (RMG) for grinding limestone with different impurities and its using FCS02. Third stage 5 is Kiln system for burning the grinded feed to make the Clinker (Cement) and its using FCS03. Each FCS is at some meter distance from each other. All the FCS are communicating through Ethernet and fibre optics communication. It can share any data up to 400 bytes at a time. In this project I am sharing 20 bytes to demonstrate the communication. Some of the data are binary control signal and some of them are analogue parameters, PLCs will take decision depends on the data they receive from other
PLC.
Due to unavailability of physical PLC, I am simulating my project on Siemens simulator, here I have used Siemens PLC CPU S7 -400 CPUs with each FCS and each FCS has 32 input DI card, 32 output DO card and different AI/AO card with respect to the requirement. I have used Simatic Step7 to program the multiple PLCs and using WinCC to design mimic on the screen. I have made one screen with multiple tabs to access particular FCS data. Operator who is sitting in Common Control Room (CCR) can see all the data (Analog, Digital) in the CCR.
Each Motor circuit has multiple parameters and control signals that operator can see in CCR and can give start/stop command to any motor from the mimic in the CCR. These control signals come from the electrical cabinets to the PLC and I have designed the PLC in a way that if all control signals fulfil its condition then PLC with accept operator command or else PLC will notify operator about any particular signal missing or not available. After taking command, if any control signal malfunctioned then PLC will trip the motor and will generate an alarm to notify operator why it happened.
This control system is also logging all the analogue parameters for nearly up to 3 months and if operator wanted to see any analogue parameters activity can see by going into the trend
window and there, operator needs to put the particular date and time to see the graphical representation. This system also logs all the alarms for up to 1000 alarms and if operator want then he can go in alarm list and see how many times alarm occurred and even he can search any particular alarm in the list with alarm number.