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FLS Automation_Cement Plant Control

FLS Automation_Cement Plant Control

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01/26/2013

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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. low production cost and minimum investment. such as gas analyses systems. High Voltage Switchgear FLS/PCI Many years experience in designing the electrical systems for a cement factory is needed in order to ensure that all aspects are incorporated. down to smallest transmitter. such as PLC programs. with everything tied together in an object. ECS/Pocess Expert.Introduction FLSmidth Automation`s electrical control and engineering concept is based on FLS/ACE ( Adaptable Control Engineering ) FLS/AME ( 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 Automation is able to design an optimal solution with focus on maximum run time. 3-winding n Distributio n step-down Step-down Distributio Emergency transf. as well as a partner in renovation of existing production lines. Indutherm for measuring temperature on kilns or mills and the well known folaphone for mill control. database. The FLS/AME platform contains all the special measuring equipment for cement. pictures. and it is possible to link to a preventive maintenance system. Diesel Generator transf. This will make FLSmidth Automation the ideal partner both in design of new production lines. The FLS/ECS platform is the platform containing all the optimizing tools specially developed for the cement industry for optimizing the production. transf. Distributio Step-down n transf. transf. The design experience covers all aspects from the incoming feed to the factory. FLS/ACE. FLS/ECS and FLS/AME The FLS/ACE system is the platform for the design of the control system. There is a link from the operator system or the engineering station to everything related to the object. transf. Distributio n transformer G MV Slipring motor~ ~ MDB I > M I > M M MDB ~ ~ M MDB I > M UPS Emergency Distributio n Board I > M MV Slipring motor MDB I > M MDB I > M ~ ~ M MV Slipring motor Main Distributi on Board (MDB) I > M Variable speed drive Variable speed drive Variable speed drive MCC MCC I > M I > M Motor Control Center (MCC) MCC I > M I > M MCC I > M MCC I > M ACE 2 . Power transformer Power transformer Incoming overhead line Medium voltage switchgear Incoming overhead line Medium voltage switchgear Distributio Distributio n n transf. ECS/CemScanner and ECS/Plant Guide. drawings. manuals. The system is object based. transf. from turn key engineering to coengineering.

The interfacing to the MCC is traditional parallel. System Example 3: This configuration drawing is from a retrofit project with FLS ACE/SYS software concept and Schneider Quantum PLC. As the FLSmidth Automation system is able to interface with several PLC systems the investment with S7 was not wasted. The client at this factory preferred Rockwell CLX PLC but had recently installed a new cooler with a Siemens S7 PLC. System Example 2: This configuration drawing is from a retrofit project with FLS ACE/SYS software concept and S7. 3 ACE . The interface to the MCC is parallel. This retrofit job included an upgrade of the Motor Control Center with intelligent units on a Devicenet (Rockwell E3+ modules).FLSmidth Automation Configurations System Example 1: This configuration drawing is from a retrofit project with FLS ACE/SYS software concept and Rockwell Automation CLX PLC. For this installation the client did not want redundant ethernet between the redundant server system and the PLC placed in the MCC rooms.

Features • Independent of hardware • Pleasant “office look” • Cabinet maker quality • Electrical adjustable working heights • Ventilated cabinets for the PC • Concealed cable ducts Center unit The center unit consists of either a plate or a cabinet for separating and supporting the electrical unit for adjusting the height of the table. The cabinet consists of two sections. The furniture is independent of the particular hardware and is well constructed to integrate equipment of different sizes and styles. manuals and papers which are needed in the daily operation of the plant. The cabinet can be locked to ensure that only authorized staff has access and the possibility of installing software on the PC`s. keyboards and printers etc. ACE 4 . The bottom is a ventilated cabinet with filter and room for two PC`s. The top section is designed for binders.Control room layout The ACE/Woodware system comprise of a range of control room furniture especially designed to modern process control equipment such as computer displays.

ACESYS covers the following control tasks: • Positioner • Valve • Select point • Digital alarm • Analog measuring • PID controller • Group control • Route control • Uni-directional Motor • Bi-directional Motor • Change Over Gate 5 ACE . The ACE/SYS standard is based on experience gained from the successful engineering. and ABB Controllers IT. Rockwell Type CLX. Siemens type S7. A tool box exist for special functions. data and program structures needed to implement an efficient PLC-based process control system for cement. Schneider Quantum. From the faceplate it is also possible to open the diagnostic for the object as well as the help function. The system is very flexible and easily adapted to the individual needs of the factory. a left click on the faceplate line will open the faceplate. The ACE/SYS is designed for the followering PLC Systems. Right click on the selected object will bring the menu down. It is also possible to open the faceplate by a left double click on the object. defining control objects. and there is a group of faceplates related to each object. A block examples in the tool box is for instance PLC to PLC communication. It is a Programmable Logic Controller (PLC) programming standard.Adaptable Control Engineering System ACE/SYS Standard is an acronym for Adaptable Control Engineering SYStem. Object blocks are standard in the system. programming and commissioning of more than 300 control systems worldwide in cement factories. When opening a PID Loop or an analog point a real time trend is shown with a scan time of one second.

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. object and event treatment. process object database. Integrated in the ECS environment it offers a set of basic process-control functionalities with object-based drivers to process controllers. all objects has one Faceplate for a measuring point ECS 6 . the ECS/OpStation software program for advanced Human-Machine-Interface (HMI) runs on Microsoft’s Windows 2000 operating system. Note pad for the object. and data logging and trending.Operator Station In the ECS series.

The alarm filtering facility is a powerful tool in analysing the errors. If the assembling of the number of trends are to be used several times. The alarm reporting system is developed to satisfy both the operator in his daily work. 7 ECS .Operator station Trend and Alarm System The trend and alarm handling in the ECS/Opstation system is a very powerful and easy to use tool both for the operator in the daily operation of the plant. Each time a new measuring point is selected and the trend icon is activated. and the management for analysing the production performance. the measuring point is added to the trend. it is possible to save it as one of the 250 trend packages available in the system. and thereby improving the run factor. but also for the management and the maintenance department in the ongoing optimization of the production and improvement of the run factor. It is possible to add 8 measuring trends into one chart.

• Remote connection offers plant engineers easy assistance from system and process specialists at technical headquarters.FLS Automation`s Engineering Station ECS/SmartStation is an engineering and software tool integrating the process control with on-line view to PLC programs and key electrical documentation. It is normally connected to the same plant network as the ECS/OpStation (NT) and the PLC’s. electrical and project documentation are integrated into the same software environment. Select an application on the Toolbar and view on-line the associated PLC program. • Easy retrieval of any kind of documentation linked to an object i. the electrical and textual documentation for that specific object. program applications and support functions. log-book. when problems arise and support is required. mechanical drawings and suppliers data. bit maps. • Highly efficient trouble-shooting because process ECS/OpStation HMI. PLC program. The ECS/SmartStation integrates software. Benefits derived from ECS/SmartStation • Device or object focus (example). and automatically finds the object in the database for: • Live process HMI’s from ECS/OpStation • PLC programming software • CAD/CAM software and key electrical documentation • • • • • Word and textual documents Photos of the object Interlocking diagram Video and Audio documentation Software 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. Click on a motor in the ECS/OpStation HMI.e. Link to Preventive Maintenance Maximo ECS 8 .

insert off line quality measurements. more uniform end-product quality Better utilization of human. process alarms and event diagnostic. Around 200 systems have been installed worldwide since the ECS/ FuzzyExpert system was introduced in the late 70's. select/de-selct control loops. 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/PlantControl HMI enabling operators fast and easy access to control performance measures and trends. accurate and consistent process evaluation and control actions Rapid control and suppression of process upsets Lower operating costs through energy and maintenance savings Better. 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. capital and material resources Minimized emissions and environmental effects Release of operators from routine control actions P2 Optimum operation point Limits Operator Control ECS/FuzzyExpert The ECS/FuzzyExpert system aims at forcing the operation trends towards the optimum point. Initially. ECS/FuzzyExpert has resulted in the following benefits: ! ! ! ! ! ! ! Improved process stability through continuous. 9 ECS .High-level Control FLSmidth Automation has long been acknowledged as being the pioneer of using Fuzzy Logic techniques for high level process control.

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 dEi = Yset − Y dt H = ∑ x ⋅ ∫ C Pi (T )dT Tref T The operator can be evaluated against predefined weighted. a number of realistic process disturbance and changes in dynamic characteristics can be introduced. ECS 10 .Smidth in process modelling and the long experience of FLSmidth Automation in process simulation. Increasing operator skills in reaching pre-defined production quantity and quality targets. Thus systematic training of operators in a cement production plant has a direct impact on. Process Model Soft PLC implementation ECS/CEMulator operator interface has exactly the same look’n feel as the real ECS/PlantControl including alarm. the digital I/O part of the process (PLC sequence control) is also fully simulated using a Soft 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. trend.L.target values of the process control performance. In addition. Operator skill evaluations. Increasing operators skills in interaction with and optimal utilisation of a modern control system. The process models are based on comprehensive and complex mathematical descriptions of the physical. chemical and thermodynamic relations that characterize the cement production process. not only plant safety and environment protection but also the overall plant economy. During this transition. the product aims at ! ! ! ! ! Process operator training in an absolute realistic environment. Enabling process engineers and designers in testing their ideas before practical implementations A typical pay-time of an ECS/CEMulator investment can be justified by the savings in a production stop/waste of one shift in a middle size cement plant of 3000tpd.Cement Plant Simulation ECS/CEMulator is an advanced cement process simulator that encompasses the extensive knowledge of F. With a vast amount of functions and features in ECS/CEMulator.

Today's plants are typically supported by several computer systems linked together by a Local. solution is called ECS/PlantGuide. 11 ECS . regardless of physical location. and has the capacity to store large amount of data. The aim of ECS/PlantGuide 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. MIS. SQL. MS-Access. The ECS/PlantGuide server makes process data available to any client that has a requirement. o has been developed based on the Microsoft SQL server database. This means that important requirements to a MIS database are storage capacity. The data archiving facility of SQL server allows the user to store and retrieve data for a period of several years. The SQL server database has the flexibility to store both process and lab data in a readily accessible format. T meet these requirements the ECS/PlantGuide server database .Management Information System FLSmidth Automation's Management Infomation System. HTML ect.g. In addition. Wide Area or Satellite Network. The purpose of the ECS/PlantGuide system is to be a "Data Warehouse" and to integrate and archive all relevant plant data (process. flexibility data availability and security. ECS/PlantGuide has the following features in order to fulfill the above mentioned objectives: ! ! ! ! Advanced trending and reporting capabilities Possibility of designing special reports for Special mimic diagrams form the factory level Data export to various formats e. chemical analysis and cement dispatch data) into one single dedicated database.

high speed fiber link to a dedicated Fiber Optic Link Interface (FOLI) in the CemScanner PC. medium and long term time spans. the CemMicro-II. ECS 12 . Historical data are saved in a set of user configurable short. The use of the ECS/CemScanner will result in: ! ! ! ! ! Increased kiln availability Lower refractory consumption Fewer stops Reduced thermal consumption Ability to plan overhauls An advanced. 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.Kiln Shell Temperature 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 has since then proven to be the most effective tool. The operator interface of the system is specially designed for easy access to all the functions and features used in daily operations. processing system with distributed intelligence. The next two pages outline some of the software features in displaying both actual and historic kiln shell temperature distribution as well as calculated brick and coating thickness. Set up parameters and diagnostic information is exchanged between the modules by means of an industry standard robust LonWorks network ensuring maximum data reliability. A click on the history button from the toolbar turns the actual operation window into a history data view. constitutes the back bone of the system.

Indutherm II The FLSAutomation Indutherm II system is designed for temperature measurement in a rotary kiln or cement mill. The system is developed for applications in the cement industry. easy to install • Minimum maintenance Folaphone The FLSAutomation - Folaphone system is designed for monitoring and supervision of the material charge in a ball mill. for better control of the kiln or cement mill. Features • Online and continuous temperature measurement • Wireless transmission • Simple system. easy installation 13 AME .Special Instruments The FLSAutomation Advance Measurement Equipment (FLS/AME) contains several special instruments for instrumentation in the cement industry. The instruments are: Induterm II. The system provides useful temperature information. Folaphone and Gas analysis equipment. Features • Online and continues control of the filling charge of material • Minimum maintenance • Simply system.

lower emission. If necessary the equipment is capable of scanning several measuring points from one system. HCl. CH4. and a safer working environment. the burning input and production throughput are optimised The preheater analysis system only has to save the EP once to justify the investment and is. VOC. NOx. As part of the FLS Group more than 40 years of experience is collected in servicing the cement industry. HF. Flow and Temperature. SO2. The kiln inlet being the most demanding application on a cement plant therefore sets the high hardware standard for all applications offered. Dust. The supply is based on state-of-the-art analysis equipment with integrated process know-how. FLSmidth Automation believes that high quality and ease of operation and maintenance are the key factors for successful analysing equipment. We are typically measuring gas analysis componts as: O2. This application is equipped with the unique FLS Airloq EP protection system. AME 14 . • Our standard applications are: • Kiln inlet • Calciner • Preheater • Stack Emission • Coal mill department Other applications are available on request. CO.Gas Analysis . The Kiln Inlet equipment is the most important gas analysis system for kiln process control. FLS Airloq is specialised in gas analysis for process and emission purposes. All sampling equipment solutions are supplied by our fully owned company FLS Airloq.Process optimization FLSmidth Automation supplies gas analysis equipment giving large production benefits. The Coal Mill Department needs various analysing results for safety and process control. NH3. in connection with the plant safety. compulsory. Through this analysis.

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. Please see separate ECS detailst for CEM reporting 180 FLS Airloq FLS Airloq For sampling. preparation and cleaning of the gas used for analysis highly specialised components must be used. In determining the best configuration for a specific country/plant. 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.4 STO MOD + -- CEM calculation and reporting system. We can provide you with the most suitable solution by not being dependent on any specific subsupplier. obtain ISO 14000 certification or adapt to the Cement Sustainability Initiative. D-R 290 AW D-R 290 AW DURAG D-R 290 AW 06. The system can be installed in a electrical cabinet GASLoq 1200 or in a presampled housing for easy installation on site GASloq CUBE 15 AME .Gas Analysis Emission measurement and Reporting Traditionally Continuous Emission Monitoring (CEM) on cement plants has been limited to dust monitoring in order to fulfill legislational demands set by the local authorities. For any of the systems the kiln inlet process gas sets the standard as the most corrosive. On the other hand plants are investing in CEM systems in order to burn waste. Optional integration into FLSmidth Automation ECS control system packages for full data integration and safety. Corrosion is avoided by using heated components or corrosion resistence material.

an installation at a new factory High Voltage Switchgear Power transformer Power transformer Incoming overhead line Medium voltage switchgear Incoming overhead line Medium voltage switchgear Complete one line power design including the ground protection. transf. transf. harmonic. Distribution Distribution transf. cable routing. The concept covers the complete range of electrical engineering from the incoming power to the factory to the smallest transmitter. we are always able to design and supply the best and most economical solution. Diesel Generator Distribution Step-down transf. 3-winding step-down Step-down Distribution transf. is the FLSmidth Automations concept in power design. Distribution transformer G MV Slipring motor~ ~ MDB I > M I > M M MDB ~~ M MDB I > M UPS Emergency Distribution Board I > M MV Slipring motor MDB I > M MDB I > M ~~ M MV Slipring motor Main Distribution Board (MDB) I > M Variable speed drive Variable speed drive Variable speed drive MCC MCC I > M I > M Motor Control Center (MCC) MCC I > M I > M MCC I > M MCC I > M As the electrical bill is increasing every year. the saving by optimizing the drives in the factory are becoming more and more important. the specialists are able to advise in new and retrofit projects either to replace or repair the system. transf.Power Concept Integration The Power Concept Integration. Distribution Emergency transf. transf. Replacing old drives to more modern frequence drive often have a return of investment which is PCI 16 . FLSAutomation is hardware independed. cable. PCI. and substation design including necessary relay settings. Main substation installation. FLSAutomation is specializing in cement.

bending and reinstallation to the new MCC. Power monitors where installed on all MCC`s enabling the plant to monitor the power consumption much better. The Motor Control Centre Before repair and replacement of components The Motor Control Centre After repair and replacement of components The MCC after the repair and replacement of components. which have been subject to heat for many years can be damaged during disconnection. 17 PCI . The number of PLC input/output were reduced due to I/O`s on the intelligent units.Motor Control Center (MCC) Retrofit projects always require a decision whether to replace or repair the MCC. always remember that old cables. The upgrade time on the MCC was approximately one week for each department. If the decision is to replace. Normally the MCC can be upgrated with new intelligent interface and contactors for less than 50% of new a MCC. There was a demand for better power reporting.

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