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, 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 co-
engineering. This will make FLSmidth Automation 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/AME

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 to a preventive maintenance 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 Power Power
transformer transformer
systems for a cement factory is needed in order to
ensure that all aspects are incorporated.
Incoming overhead line Incoming overhead line

Medium voltage switchgear Medium voltage switchgear

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
3-winding
reduced substantially. Distribution Distribution
transf. transf.
step-down Step-down Distribution Emergency
transf. transf. transf. Diesel Generator
Distribution
transf.
Distribution Step-down
transf. transf.
Distribution
transformer
G
Emergency
MV Slipring motor~~ ~~ Distribution MV Slipring motor ~~
MV Slipring motor Main Distributi on
MDB MDB MDB Board MDB MDB Board (MDB)

M M M
I I I I I I I
> > Variable Variable > > > >
Variable >
speed speed UPS speed
M M M M M M M
drive drive drive
MCC MCC MCC MCC MCC
Motor Control Center (MCC)
I I I I I I
> > > > > >
M M M M M M
ACE

2
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. The client at this
factory preferred Rockwell CLX PLC
but had recently installed a new cooler
with a Siemens S7 PLC. As the
FLSmidth Automation system is able to
interface with several PLC systems the
investment with S7 was not wasted.

This retrofit job included an upgrade

of the Motor Control Center with
intelligent units on a Devicenet
(Rockwell E3+ modules).

System Example 2:
This configuration drawing is from a retrofit
project with FLS ACE/SYS software 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 Example 3:
This configuration drawing is from a
retrofit project with FLS ACE/SYS
software concept and Schneider
Quantum PLC.

The interface to the MCC is parallel.

ACE

3
Control room layout
The ACE/Woodware system comprise of a range of control room Features
furniture especially designed to modern process control • Independent of hardware
equipment such as computer displays, keyboards and printers • Pleasant “office look”
etc. • Cabinet maker quality
• Electrical adjustable working heights
The furniture is independent of the particular hardware and is • Ventilated cabinets for the PC
well constructed to integrate equipment of different sizes and • Concealed cable ducts
styles.

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 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 the possibility of installing software on the
PC`s.

The top section is designed for binders, manuals and

papers which are needed in the daily operation of the
plant.
ACE

4
Adaptable Control 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 process control system for
cement. The ACE/SYS standard is based on experience gained from
the successful engineering, programming and commissioning of more
than 300 control systems worldwide 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 the object as well as the help function.

It is also possible to open the faceplate by a left double

click on the object.

When opening a PID Loop or an analog point a real

time trend is shown with 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 the following

control tasks:
• Positioner • Group control
• Valve • Route control
• Select point • Uni-directional Motor
• Digital alarm • Bi-directional Motor
• Analog measuring • Change Over Gate
• PID controller
ACE

5
Operator Station
In the ECS series, the ECS/OpStation software program for advanced Human-Machine-Interface (HMI) runs on Microsoft’s Windows
2000 operating system. Integrated in the ECS environment it offers a set of basic process-control functionalities with object-based
drivers to process controllers, process object database, object and event treatment, 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
ECS

6
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, but also for the management and the maintenance department in the ongoing optimization of the production
and improvement of the 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.
ECS

7
FLS Automation`s Engineering Station • Word and textual documents
ECS/SmartStation is an engineering and software tool • Photos of the object
integrating the process control with on-line view to PLC • Interlocking diagram
programs and key electrical documentation. The • Video and Audio documentation
ECS/SmartStation integrates software, program applications • Software for remote support
and support functions, and automatically finds the object in (via modem or Internet)
the database for:
ECS/SmartStation runs in a client/server environment using
• Live process HMI’s from ECS/OpStation standard PC’s with Microsoft’s Windows 2000 operating
• PLC programming software system. It is normally connected to the same plant network as
• CAD/CAM software and key electrical documentation the ECS/OpStation (NT) and the PLC’s.

Benefits derived from ECS/SmartStation

• Device or object focus (example); Click on a motor in the ECS/OpStation
HMI. Select an application on the Toolbar and view on-line the associated
PLC program, the electrical and textual documentation for that specific
object.
• Easy retrieval of any kind of documentation linked to an object i.e. bit maps,
log-book, mechanical drawings and suppliers data.
• Highly efficient trouble-shooting because process ECS/OpStation HMI, PLC
program, electrical and project documentation are integrated into the same
software environment.
• Remote connection offers plant engineers easy assistance from system and
process specialists at technical headquarters, when problems arise and
support is required.
Link to Preventive Maintenance Maximo
ECS

8
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 resulted in the following benefits:

! Improved process stability through continuous, accurate and consistent process evaluation and control 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
Limits operation trends towards the optimum point.
Operator Control

ECS/FuzzyExpert

P1

ECS/FuzzyExpert-
CementMillOptimisation 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, select/de-selct control loops, insert off line
quality measurements, process alarms and event diagnostic.
ECS

9
Cement Plant Simulation
ECS/CEMulator is an advanced cement process simulator that encompasses the extensive knowledge of F.L.Smidth in process
modelling and the long experience of FLSmidth Automation in process simulation.

With a vast amount of functions and features in ECS/CEMulator, the product aims at

! Process operator training in an absolute realistic environment,

! Increasing operator skills in reaching pre-defined production quantity and quality 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 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. 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 Operator Training: Engineering Platform:
physical, chemical and thermodynamic relations • Normal Operation Control • High-level Control Strategy Test
• Handling Upset Conditions • Test Before Process
that characterize the cement production process.
• Quality Control Modifications
In addition, the digital I/O part of the process (PLC • New Control System • Test Material and Fuel
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 ECS/PlantControlSDR
(Operator HMI)
process operation entirely from stand-still to
full production state. During this transition, a
number of realistic process disturbance and Process Dynamics Digital I/O
changes in dynamic characteristics can be
introduced.
∂wai ∂ (vwai )
=− + fwb − c j wai
∂t ∂x
dEi
= Yset − Y
dt
T
H = ∑ x ⋅ ∫ C Pi (T )dT
Tref

Process Model Soft PLC implementation

The operator can be evaluated against pre-
defined weighted- target values of the process
control performance.

ECS/CEMulator operator interface has

exactly the same look’n feel as the real
ECS/PlantControl including alarm, trend,
ECS

10
Management Information System
FLSmidth Automation's Management Infomation System, MIS, solution is called ECS/PlantGuide. The purpose of the ECS/PlantGuide
system is to be a "Data Warehouse" and to integrate and archive all relevant plant data (process, chemical analysis and cement
dispatch data) into 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/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. 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 database
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
allows the user to store and retrieve data for a period of several years.

In addition, 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.g. MS-Access, SQL, HTML ect.

ECS

11
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 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, 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 Interface (FOLI) in the CemScanner PC. Set up parameters and
diagnostic information is exchanged between the modules by means of
an industry standard robust LonWorks network ensuring maximum
data reliability.

The operator interface of the system is specially designed for easy access to all the functions and features used in daily
operations. 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.

A click on the history button from the toolbar turns 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.
ECS

12
Special Instruments
The FLSAutomation Advance Measurement Equipment (FLS/AME) contains several special instruments for instrumentation in the
cement industry. The instruments are: Induterm 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 - 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
AME

13
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 fully owned company FLS Airloq.

FLS Airloq 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
with 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 throughput 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 FLS Airloq EP protection system.

The Coal Mill Department needs various

analysing results for safety and process control. If
necessary the equipment is capable of scanning
several measuring points from one system.
AME

14
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.

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
plants 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:
The configuration of the CEM equipment must reflect the legislation enforced by
• Reduce fuel cost the local authorities or a specific production approval for a given plant. In
• Reduce emission determining the best configuration for a specific country/plant, We can provide you
• Burn waste with the most suitable solution by not being dependent on any specific sub-
• Obtain waste disposal fee income supplier.

D-R 290 AW
D-R 290 AW

DURAG
D-R 290 AW

06.4
STO MOD + --

CEM calculation and reporting system. Optional integration

into FLSmidth Automation ECS control system packages for FLS Airloq

full data integration and safety. Please see separate ECS detailst
for CEM reporting 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 the 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 for easy installation on site GASloq CUBE
AME

15
Power Concept Integration
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 power to the factory to the smallest transmitter. FLSAutomation is specializing in cement, the
specialists are able to advise in new and retrofit projects either to replace or repair the system. FLSAutomation is hardware
independed, we are always able to design and supply the best and most economical solution.

Main substation
installation, an installation
at a new factory

High Voltage Complete one line

Switchgear
power design including
the ground protection,
Power Power harmonic, cable, cable
transformer transformer
routing, and substation
design including
Incoming overhead line Incoming overhead line
necessary relay settings.
Medium voltage switchgear Medium voltage switchgear

3-winding
Distribution Distribution step-down Step-down Distribution Emergency Distribution Distribution Step-down Distribution
transf. transf. transf. transf. transf. Diesel Generator transf. transf. transf. transformer
G
Emergency
MV Slipring motor~~ ~~ Distribution MV Slipring motor ~~
MV Slipring motor Main Distribution
MDB MDB MDB Board MDB MDB Board (MDB)

M M M
I I I I I I I
> > Variable Variable > > > >
Variable >
speed speed UPS speed
M M M M M M M
drive drive drive
MCC MCC MCC MCC MCC
Motor Control Center (MCC)
I I I I I I
> > > > > >
M M M M M M

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
PCI

16
Motor Control Center (MCC)
Retrofit projects always require a decision whether to replace or repair the MCC. If the decision is to replace, always remember that
old cables, which have been subject to heat for 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 after 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 to
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.
PCI

17