Introduction FLSmidth Automation`s electrical control and engineering concept is based on FLS / ACE( Adaptable Control Engineering ) FLS / AM E( Advance Measurement Equipment ) FLS / ECS( Expert Control System ) FLS / PCI ( Power Control Integration) By combining our systems with our knowledge in the cement industry and our supplier independence FLSmidth Aut omation is able to design an optimal solution w ith focus on maximum run t ime, low production cost and minimum investment . The design experience covers all aspects from the incoming feed to the factory, down to smallest transmitter, from turn key engineering to coengineering. This will make FLSmidt h Aut omation the ideal partner both in design of new production lines, as well as a partner in renovation of existing production lines. FLS/ ACE, FLS/ ECS and FLS/ AM E The FLS/ACE system is the platform for the design of the control system. The system is object based, with everything tied together in an object. There is a link from the operator system or the engineering station to everything related to the object, such as PLC programs, drawings, manuals, database, pictures, and it is possible to link t o a preventive maint enance system. The FLS/ECS platform is the platform containing all the optimizing tools specially developed for the cement industry for optimizing the production; ECS/Pocess Expert, ECS/CemScanner and ECS/Plant Guide. The FLS/AME platform contains all the special measuring equipment for cement, such as gas analyses systems, Indutherm for measuring temperature on kilns or mills and the well known folaphone for mill control.
High Voltage Switchgear
FLS/PCI Many years experience in designing the electrical systems for a cement factory is needed in order t o ensure that all aspects are incorporated. By only having one responsible for designing the electrical system all the way from the incoming feed to the last transmitter the risk of mistakes is reduced substantially.
Power transformer
Power transformer
Incoming overhead line
Incoming overhead line
Medium voltage switchgear
Medium voltage switchgear
3-winding step-down Step-down Distr ibuti on Emergency transf. transf. DieselGenerator transf.
Distr ibution Distr ibution transf. transf.
Distr ibution transf.
Distr ibution Step-down transf. transf.
Distr ibution transformer
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FLSmidt h Auto mation Conf iguratio ns
System Examp le 1: This configuration drawing is from a retrofit project with FLS ACE/SYS software concept and Rockwell Aut omation CLX PLC. The client at this factory preferred Rockwell CLX PLC but had recently installed a new cooler with a Siemens S7 PLC. As the FLSmidth Aut omation system is able to interface with several PLC systems the investment wit h S7 wasnot wasted. This retrof it job included an upgrade of the Motor Control Center with intelligent units on a Devicenet (Rockwell E3+ modules).
System Examp le 2: This configuration drawing is from a retrofit project w ith FLSACE/SYSsoftw are concept and S7. The interfacing to the MCC is traditional parallel. For this installation the client did not want redundant ethernet between the redundant server system and the PLC placed in the MCC rooms.
System Examp le 3: This configuration drawing is from a retrof it project wit h FLS ACE/SYS software concept and Schneider Quant um PLC. The interface to t he MCC is parallel.
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Cont rol room l ayout The ACE/Woodware system comprise of a range of control room furniture especially designed to modern process control equipment such as computer displays, keyboards and printers etc.
Features • Independent of hardware • Pleasant “ office look” • Cabinet maker quality • Electrical adjustable working heights
The furniture is independent of the particular hardware and is well constructed to integrate equipment of different sizes and styles.
• Ventilated cabinets for the PC • Concealed cable ducts
Center u nit The center unit consists of either a plate or a cabinet for separating and support ing the electrical unit for adjusting the height of t he table. The cabinet consists of two sections. The bottom is a ventilated cabinet with filter and room for two PC`s. The cabinet can be locked to ensure that only authorized staff has access and t he possibilit y of installing soft ware on t he PC`s. The top section is designed for binders, manuals and papers which are needed in the daily operation of the plant.
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Adapt able Cont rol Engineering System ACE/SYS Standard is an acronym for Adaptable Control Engineering SYStem. It is a Programmable Logic Controller (PLC) programming standard, defining control objects, data and program structures needed to implement an efficient PLC-based processcontrol system f or cement. The ACE/SYS standard is based on experience gained from the successful engineering, programming and commissioning of more than 300 control systems worldw ide in cement factories. Right click on the selected object will bring the menu down, a left click on the faceplate line will open the faceplate. From the faceplate it is also possible to open the diagnostic for t he object aswell as the help function. It is also possible to open t he faceplate by a left double click on the object. When opening a PID Loop or an analog point a real time trend is shown wit h a scan time of one second.
The ACE/SYS is designed for the followering PLC Systems; Rockwell Type CLX, Siemens type S7, Schneider Quantum, and ABB Controllers IT. Object blocks are standard in the system, and there is a group of faceplates related to each object. A tool box exist for special functions. A block examples in the tool box is for instance PLC to PLC communication. The system is very flexible and easily adapted to the individual needs of the factory.
ACESYS covers th e fo ll ow in g control tasks: • • • • • •
Positioner Valve Select point Digital alarm Analog measuring PID controller
• • • • •
Group control Route control Uni-directional Mot or Bi-directional Mot or Change Over Gate
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Operator Stat ion In the ECS series, the ECS/OpStation software program for advanced Human-Machine-Interface (HMI) runs on Microsoft’s Windows 2000 operating system. Int egrated in t he ECS environment it offers a set of basic process-control f unctionalities wit h object-based drivers to process controllers, process object database, object and event t reatment, and data logging and trending. ECS/OpStation’s object-based control structure enables access to all related supervision information and control commands with a simple right -button mouse-click on any mimic object.
Note pad for the object, all objects has one
Faceplate for a measuring point
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Operator stat ion Trend and Alarm System The trend and alarm handling in the ECS/Opstation system is a very powerf ul and easy to use tool bot h for t he operator in the daily operation of the plant, but also f or the management and the maintenance department in t he ongoing optimization of the production and improvement of t he run factor.
Each time a new measuring point is selected and the trend icon is activated, the measuring point is added to the trend. It is possible to add 8 measuring trends into one chart. If the assembling of the number of trends are to be used several times, it is possible to save it as one of the 250 trend packages available in the system.
The alarm reporting system is developed to satisfy both the operator in his daily work, and the management for analysing the production performance. The alarm filtering facility is a powerful tool in analysing the errors, and thereby improving the run factor.
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FLS Autom atio n`s Engin eering St atio n
• Word and textual documents
ECS/SmartStation is an engineering and software tool integrating the process control with on-line view to PLC programs and key electrical documentation. The ECS/SmartStation integrates software, program applications and support f unctions, and automatically finds the object in the database for:
• Photos of the object
• Live process HMI’s from ECS/OpStation • PLC programming soft ware • CAD/CAM soft ware and key electrical documentation
• Interlocking diagram • Video and Audio documentation • Softw are for remote support (via modem or Internet) ECS/SmartStation runs in a client/server environment using standard PC’s with Microsoft’s Windows 2000 operating system. It is normally connected t o t he same plant netw ork as the ECS/OpStation (NT) and the PLC’s.
Benefit s derived f rom ECS/Smart St atio n •
Device or or object focus focus (example); (example); Click on on a motor motor ininthe theECS/OpStation ECS/OpStation HMI. Select an application on t he Toolbar and view on-line the associated PLC program, the electrical and textual documentation for that specific object.
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Easy retrieval of any kind of documentation linked to an object i.e. bit maps, log-book, mechanical drawings and suppliers data.
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Highly eff icient trouble-shooting because process ECS/OpStation HMI, PLC program, electrical and project documentation are integrated into the same software environment.
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Remote connection off ers plant engineers easy assistance from system and process specialists at technical headquarters, when problems arise and support is required. Link to Preventive Maintenance Maximo
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High-level Control FLSmidth Automation has long been acknowledged as being the pioneer of using Fuzzy Logic techniques for high level process control. Around 200 systems have been installed worldwide since the ECS/ FuzzyExpert system was introduced in the late 70's. Initially, the ECS/FuzzyExpert system was mainly used for kiln control but in the recent years a number of installations for mill and cooler control has also been successfully commissioned bt FLSmidth Automation Using high-level advanced process control, ECS/FuzzyExpert has result ed in the follow ing benefits: ! ! ! ! ! ! !
Improved process stability t hrough continuous, accurate and consistent process evaluation and cont rol actions Rapid control and suppression of process upsets Lower operating costs through energy and maintenance savings Better, more uniform end-product quality Better utilization of human, capital and material resources Minimized emissions and environmental effects Release of operators from routine control actions
P2 Optimum operation point
The ECS/FuzzyExpert system aims at forcing the operation trends towards the optimum point.
Limits Operator Control
ECS/FuzzyExpert
P1
ECS/FuzzyExpertCementMillOptimisation has typically resulted in: ] 3-8% increase in production ] 3-8% reduction in specific
power consumption ] 10-20% reduction in standard
deviations of product quality
The operator interface of ECS/FuzzyExpert-CementMillOptimisation system is based on the proven concept of ECS/PlantCont rol HM I enabling operators fast and easy access to control performance measures and trends, select/de-selct control loops, insert off line quality measurements, processalarms and event diagnostic.
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Cement Plant Simul ati on ECS/CEMulator is an advanced cement process simulator that encompasses the extensive know ledge of F.L.Smidth in process modelling and the long experience of FLSmidt h Aut omation in process simulation. With a vast amount of functions and features in ECS/CEMulator, the product aims at ! ! ! ! !
Process operator t raining in an absolut e realistic environment, Increasing operator skills in reaching pre-defined production quant ity and qualit y targets, Operator skill evaluations, Increasing operators skills in interaction with and optimal utilisation of a modern control system. Enabling process engineers and designers in testing t heir ideas before practical implement ations
A typical pay-time of an ECS/CEMulator investment can be justif ied by the savings in a production stop/w aste of one shift in a middle size cement plant of 3000t pd. Thus systematic training of operators in a cement production plant has a direct impact on, not only plant safety and environment protection but also the overall plant economy.
The process models are based on comprehensive and complex mathematical descriptions of the physical, chemical and thermodynamic relations that characterize the cement production process. In addition, t he digit al I/O part of the process (PLC sequence control) is also fully simulated using a Sof t PLC system with the entire I/O control including interlockings The combination of analog and digital simulation capabilities covers the process operation entirely from stand-still to full production state. During this transition, a number of realistic process disturbance and changes in dynamic characteristics can be introduced.
Operator Training: • Normal Operation Control • Handling Upset Conditions • Quality Control • New Control System
Engineering Platform: • High-level Control Strategy Test • Test Before Process Modifications • Test Material and Fuel
ECS/PlantControlSDR (Operator HMI)
Process Dynamics
Digital I/O
∂wai ∂(vwai ) =− + fwb − c j wai ∂t ∂ x dE i = Y set − Y dt
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The operator can be evaluated against pre- defined weighted- target values of the process control performance.
Process Model
Soft PLC implementation
ECS/CEMulator operator interface has exactly the same look’n feel as the real ECS/PlantControl including alarm, trend,
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Management Informati on System FLSmidth Aut omation's Management Inf omation System, MIS, solution is called ECS/PlantGuide. The purpose of the ECS/PlantGuide system is to be a " Data Warehouse" and to int egrate and archive all relevant plant data (process, chemical analysis and cement dispatch data) int o one single dedicated database. Today's plants are typically supported by several computer systems linked together by a Local, Wide Area or Satellite Network. The ECS/PlantGuide server makes process data available to any client that has a requirement, regardless of physical location. The aim of ECS/Plant Guide is to ! !
Enable a user-frindly access to the key plant data for management use Ensure consistency and reliability of data for management use
The main focus of a MIS system is data storage and general data availability. This means that important requirements to a MIS database are storage capacity, flexibility, data availability and security. To meet these requirements the ECS/PlantGuide server dat abase has been developed based on the Microsoft SQL server database. The SQL server database has the flexibility to store both process and lab data in a readily accessible format, and has the capacity to store large amount of data. The data archiving facility of SQL server allow s the user to store and retrieve data for a period of several years. In addition, ECS/PlantGuide has the following features in order t o fulfill t he above mentioned objectives: ! ! ! !
Advanced trending and reporting capabilit ies Possibilit y of designing special reports for Special mimic diagrams form the factory level Data export to various formats e.g. MS-Access, SQL, HTML ect.
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Kiln Shell Temper atu re Scanner The ECS/CemScanner is a system for online measurement of the kiln shell temperature. The principle of using infrared line scanners to measure the kiln shell temperature was introduced by FLSmidth Automation in the mid 80' s and hassince then proven to be the most effective tool. The use of the ECS/CemScanner will result in: ! ! ! ! !
Increased kiln availability Lower refractory consumption Fewer stops Reduced thermal consumption Abilit y to plan overhauls
An advanced, processing system with distributed intelligence, the CemMicro-II, constitutes the back bone of the system. The Scanner Front-end Interface (SFI) receives the temperature measurements from the scanner head and the kiln position from the Kiln Position Encoder (KPE) as well as kiln and tyres rotation pulses and transmits the measurements via an optical, high speed fiber link to a dedicated Fiber Optic Link Int erface (FOLI) in the CemScanner PC. Set up parameters and diagnostic information is exchanged betw een t he modules by means of an industry standard robust LonWorks netw ork ensuring maximum data reliabilit y.
The operato r int erface of t he system is specially designed f or easy access t o all t he fu nction s and f eatures used in dail y operations. The next t w o pages out line some of t he soft w are features in displaying bot h actual and historic kiln shell temp eratur e dist ribu t ion as w ell as calculat ed brick and coati ng t hickness.
A click on the history butt on from the toolbar t urns the actual operation window into a history data view. Historical data are saved in a set of user configurable short, medium and long term time spans.
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Special Inst rument s The FLSAutomation Advance Measurement Equipment (FLS/AME) contains several special instruments for instrumentation in the cement industry. The instruments are: Indut erm II, Folaphone and Gas analysis equipment .
Indutherm II The FLSAutomation Indutherm II system is designed for temperature measurement in a rotary kiln or cement mill. The system provides useful temperature information, for better control of the kiln or cement mill. Features • Online and continuous temperature measurement • Wireless transmission • Simple system, easy to install • Minimum maintenance
Folaphone
The
FLSAutomation
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Folaphone
system is designed for monitoring and supervision of the material charge in a ball mill. The system is developed for applications in the cement industry. Features
• Online and continues control of the filling charge of material • Minimum maintenance • Simply system, easy installation
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Gas Analysis - Process optimization FLSmidth Automation supplies gas analysis equipment giving large production benefits, lower emission, and a safer working environment. All sampling equipment solutions are supplied by our f ully owned company FLSAirloq. FLSAirloq is specialised in gas analysis for process and emission purposes. As part of the FLS Group more than 40 years of experience is collected in servicing the cement industry. The supply is based on state-of-the-art analysis equipment wit h integrated process know-how. • • • • • •
Our standard applications are: Kiln inlet Calciner Preheater Stack Emission Coal mill department
Other applications are available on request. We are typically measuring gas analysis componts as: O2, CO, NOx, SO2, CH4, VOC, NH3, HF, HCl, Dust, Flow and Temperature. FLSmidth Automation believes that high quality and ease of operation and maintenance are the key factors for successful analysing equipment. The kiln inlet being the most demanding application on a cement plant therefore sets the high hardware standard for all applications offered.
The Kiln Inlet equipment is the most important gas analysis system for kiln process control. Through this analysis, the burning input and production t hroughput are optimised
The preheater analysis system only has to save the EP once to justify the investment and is, in connection with the plant safety, compulsory. This application is equipped with the unique FLSAirloq EPprot ection system.
The Coal Mill Department needs various analysing result s for safety and process control. If necessary the equipment is capable of scanning several measuring point s from one system.
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Gas Analysis Emission measurement and Reporting Traditionally Continuous Emission Monitoring (CEM) on cement plants has been limited to dust monit oring in order to fulfill legislational demands set by the local authorities. Due to an increasing number of demands on protection of the environment, cement plants must now deal with even greater reductions on emission values and the reporting of these. On the other hand plant s are investing in CEM systems in order to burn waste, obtain ISO 14000 certification or adapt to the Cement Sustainability Initiative. Given these possibilities the benefits of the CEM system are: • • • •
Reduce fuel cost Reduce emission Burn waste Obtain waste disposal fee income
The configuration of the CEM equipment must reflect the legislation enforced by the local authorities or a specific production approval for a given plant. In determining t he best conf iguration for a specific country/plant, We can provide you with the most suitable solut ion by not being dependent on any specific sub- supplier.
W W A A 0 9 0 9 2 2 R R - D D
DURAG D-R290 AW
06.4 S OT M O D +
CEM calculation and reporting system. Optional integration int o FLSmidth Automation ECS control system packages for full data int egration and safety. Please see separate ECSdetailst for CEM report ing
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FLS Airloq
FLS Airloq 180
For sampling, preparation and cleaning of the gas used for analysis highly specialised components must be used. Corrosion is avoided by using heated components or corrosion resistence material. For any of t he systems the kiln inlet process gas sets the standard as the most corrosive. The system can be installed in a electrical cabinet GASLoq 1200 or in a pre- sampled housing f or easy installation on site GASloq CUBE
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Pow er Concept Integr ati on The Power Concept Integration, PCI, is the FLSmidth Automations concept in power design. The concept covers the complete range of electrical engineering from the incoming pow er to t he factory to the smallest t ransmitter. FLSAutomation is specializing in cement, t he specialists are able to advise in new and retrof it projects either to replace or repair the system. FLSAut omation is hardware independed, we are always able to design and supply t he best and most economical solut ion. Main substation installation, an installation at a new factory
Complete one line power design including the ground protection, harmonic, cable, cable routing, and substation design including necessary relay settings.
High Voltage Switchgear
Power transformer
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Incoming overhead line
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As the electrical bill is increasing every year, the saving by optimizing the drives in the factory are becoming more and more important. Replacing old drives to more modern frequence drive often have a return of investment which is
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M ot or Contro l Center (MCC) Retrof it projects always require a decision whether to replace or repair the MCC. If t he decision is to replace, always remember that old cables, which have been subject t o heat f or many years can be damaged during disconnection, bending and reinstallation to the new MCC. Normally the MCC can be upgrated with new intelligent interface and contactors for less than 50% of new a MCC.
The Motor Control Centre Before repair and replacement of components
The Motor Control Centre After repair and replacement of components
The MCC aft er the repair and replacement of components. There was a demand for better power reporting, Power monitors where installed on all MCC`s enabling the plant t o monitor the power consumption much better. The upgrade time on the MCC was approximately one week for each department. The number of PLC input / output were reduced due to / I O` s on the intelligent units.
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