ECS/ControlCenter™

Why ECS /ControlCenter™ ?

Over 40 years of
development
ECS/ControlCenter™ is FLSmidth’s
well-known software platform
for process control solutions.
The platform is continuously
being improved since its initial
versions were launched in the
1970’s.

Many years of development

across multiple platforms and a
comprehensive base of installed
systems have made the ECS
PC Windows 7
control system a frontrunner
in the cement and mineral
PC Windows Vista
industries. ECS/ControlCenter™
sets new standards for
flexibility, reliability, scalability... PC Windows 2003 + XP

PC Windows 2000

PC Windows NT

DEC Alpha Open VMS

DEC VAX Open VMS

HP 1000 A 600

HP A 32K

1975 1980 1985 1990 1995 2000 2005 2010 2015

The migration path of the product’s development strategy assures reliable support of the control system. Today, a typical installation from the early 90’s
can be upgraded to the latest version of MS Windows, without requiring a plant shutdown.
 3

The cost of production losses in the Open and configurable

process industry makes plant Being a platform for control system
availability the most critical factor solutions, ECS/ControlCenter is an
when selecting a control system open environment that fulfils a wide
supplier. ECS/ControlCenter is range of requirements in terms of
therefore designed to be: local regulations, group
• An effective round-the-clock control standardisation and equipment
system. This is proved by the functionality. The configurable
product performance at 600+ environment of the platform with its
cement and mineral plants high degree of flexibility makes for
worldwide. customer satisfaction.
Expert Control and Optimisation Applications
• An efficient control engineering
platform enabling the shortest State-of-the-art
commissioning time for greenfield In step with continuous development
projects as well as upgrade and of hardware and software,
retrofit projects. ECS/ControlCenter is known to utilise
not only the most recent but also the
most reliable technologies in control
Today, the ECS/ControlCenter
system solutions.
platform is supported and integrated
not only by the engineers of FLSmidth
Scalable
in Denmark, but also by various teams
Scalability is a distinguishing
and subsidiaries as well as customers
characteristic of ECS/ControlCenter.
and their associated engineering
An ECS/ControlCenter server can be
companies. This has been made
used to control from a single ECS/ProcessExpert high level control
possible through a sound and reliable
department with only a few hundred
product development strategy as well
I/Os to a full production plant.
as worldwide support and training
The same server concept can be used
services.
to control single production units or
The general characteristics of the
the entire plant with high
ECS/ControlCenter for process
performance. Process departments
automation are the following:
can easily be added one by one to
support a stepwise expansion of
Hardware independent
existing facilities.
ECS/ControlCenter is designed for
easy integration with numerous
hardware products such as process
controllers & MCCs to allow the user
to freely choose the most suitable Laboratory Automation and Quality Assurance Applications (QCX)

suppliers for the specific project. A

configuration with main motors from
one supplier and process controllers Using ECS/ControlCenter as the “host platform”,
assures an integrated system where FLSmidth’s
from another is an example where
“One Source” commitment to complete process
ECS/ControlCenter is highly control and quality assurance throughout the
advantageous as the overall plant is fulfilled. Common operator user interface
integrating system. and smooth data exchange across the products
are inherent properties of this integration.
4

The Building Blocks

 5

Two ECS/ControlCenter servers ECS/ControlCenter consists of several Last but not least, the Security Center
interconnected in a redundant functional “building blocks” that has a number of security-oriented
configuration are necessary for constitute the added-value of the applications to protect the system
complete control and supervision of product for control systems: The I/O against unauthorised access. All these
all departments in large production Center is a very powerful kernel of the functions can be customised to the
plants. The two servers handle the I/O ECS/ControlCenter to handle the specifications of a plant or company
communication with the process, the entire input-output communication regarding behaviour, user-interface,
entire supervision task for all operator with the plant. etc.
stations of the two lines, the internal
data processing, logging and event The Operator Center contains a ECS/ControlCenter customers can also
handling, and any possible number of functions and features for benefit from a wide range of technical
engineering and configuration task efficient control and supervision of the support and services to maximise
for the control systems. plant. The functions within the utilisation of their control system.
Engineering Center make the control
The two servers are simultaneously systems the strongest and most
active in all the control tasks, and flexible platform of its type.
update each other with any
configuration changes that might
occur in each of them. Thus a
shutdown of any of these servers will
not affect the production.

A number of add-on applications for

process and quality control are also
available for integration into the
control system.

ECS Server A ECS Server B

Engineering Room Laboratory
Kiln Shell Scanner Process Optimizer Management Information
(ECS/CemScanner) (ECS/ProcessExpert) System (ECS/PlantGuide) QCX Quality Control Server

Control Room
Plant

Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s Sub PLC´s

Impactmeter SAG Mill

QCX PGNAA
6

Operator Center

As the control room OpStation The OpStation tool bar has several
operators play a key role The OpStation module is the main feature buttons: The motor group
in process control and Human Machine Interface, HMI, of control allows selection, starting or
supervision, easy-to-use the ECS system, allowing process stopping of a group of motors. With
control and supervision through a one click of the mouse, a complete
facilities for fast and
number of mimics. A number of department can be stopped in
reliable monitoring of the
features characterise the accordance with the interlocking
process conditions are major
ECS OpStation: sequence, or through immediate stop
elements in (so-called quick stop). Other buttons
ECS/ControlCenter. • The toolbar of OpStation turns the
handle the alarm supervision tasks for
HMI application into a true
a single object, group, or a complete
all-in-one operator station enabling
department. Alarm statistics, dynamic
highly efficient plant supervision
trends and many other functions are
and control.
available from the OpStation work
• The very fast mimic update time place.
gives the operator a true sense of
control. Several OpStation application
• OpStation is flexible and it is easy to windows can be opened concurrently
engineer and customise the mimics on the same or other monitors, thus
to match the process conditions. permitting supervision and control of
several process departments at once,
or supervision of start-up of a
department from a main process
mimic while initiating all start
commands from another window.

The ”group start” mimic shows the motors

of a department divided into functional
groups. The start of a motor group, e.g.
material transport, is a simple 2-step
procedure. 1) Click Select to start 2) Click
on start button to execute start command.
The starting of motors in the group will
now begin according to the start sequence
as defined in the process controller. It is
possible to select a number of motor groups
before the start command is issued, the
program will make sure that the groups are
started in the correct sequence.

In some groups, interlock “dots” are

available to indicate any interlocks that
may prevent the group from starting. In the
event of an interlock problem, the green
dot will turn red. A mouse click on the
problematic interlock can now show the
reason of interlock.
 7

Normally, operator mimics are • Display detailed information in follow a given standard, procedure,
grouped in process diagrams and real-time device function or block behaviour.
group start/stop mimics. The mimics • Display detailed data directly from
may consist of hundreds of static and the process controllers ACESYS
dynamic symbols. The dynamic Based on decades of experience,
• Execute device specific commands
symbols can be simple values, colours FLSmidth has developed the perfect
remotely
and shapes as well as animated standard control system design and
objects. • Enable easy modification of block engineering system for the cement
parameters such as PID settings, and mineral industries.
OpStation software follows a strong etc.
and flexible client/server architecture. The ECS control systems are built
This means that all process control When an object is double clicked, the using FLSmidth’s Adaptable Control
and supervision is actually possible generic faceplate of the object is Engineering SYStem, ACESYS, and
from any PC stations only limited by opened with the specific data from contains a standard library of
the user’s access right. This kind of the device. Provided the user has the programming framework, ECS
flexibility is not only appreciated by necessary rights, the faceplate- database layout, industry specific
the operators, but is extremely enabled commands can be executed device faceplates and mimics.
important for plant engineers and and parameters changed. All changes Included in this system, all device
maintenance staff too. are simultaneously logged by the ECS faceplates are extended with off-line
event system with the name of the Device Simulation capabilities to
Faceplates user and details of the changes. examine program behaviour against
All dynamic objects can be associated The capabilities of faceplates are various conditions of a given device.
with a faceplate model. The purpose clearly related to the underlying Faceplates as well as all other user
of a faceplate is: program. Thus the end-user can easily interfaces are generic. This means that
design customised faceplates to the same interface is used regardless
of the specific process controller.

Advanced faceplates for intelligent devices

8

Alarm system

Efficient alarm handling is vital Alarm System and it provides an overview of the
to maintain a high run factor. The Alarm System is a fundamental overall alarm status in each of the
Therefore a lot of energy has building block for plant monitoring process departments.
been put into the design of the and alarm/event supervision. The
main objective of the system is to When an alarm is annunciated in the
ECS alarm system
provide efficient and clear information Alarm Header, the operator can be
on an alarm condition and thereby guided into the relevant process
assist the operator in finding the mimic for the physical location of the
cause of the alarm. The main device emitting an alarm. All
advantages of the Alarm System are: operator actions to handle the alarms
or other process interventions can be
• The operator’s attention is used
configured to be recorded in the
efficiently by enabling automatic
system with the operator’s
hierarchical suppression of
identification. The complete event
irrelevant alarms.
registration in chronological order
• The operator’s workload is reduced assists users in backtracking of the
by configuring the behaviour of an process history.
alarm according to the required
alarm handling procedure. The Alarm List displays current and
• The operator can easily find the historic events for each department.
location of an alarm as the alarms With a hierarchical structure of the
are structured in accordance with objects, the alarm storage facilitates
the plant structure. easy overview at various level of
details. Furthermore, the alarm list
The Alarm Header announces new offers strong features for searching in
alarms visually and by sound to attract the list.
the operator´s attention. It displays
the alarm last detected by the system

Operator actions upon alarm detection are also recorded as “information”, and categorised as “control” in the alarm list. The list contains “alarms“,
“warnings“ and “information“ in the chronological order.
 9

For example, the alarms can be

filtered according to a given category
(e.g. process or mechanical) or a given
priority. Alarm statistics are computed
continuously for every object in the
system. Consequently, if an operator
observes a certain device emitting an
alarm, a simple click will display the
alarm statistics e.g. in the current
hour, the previous hour or even the
previous shift to find out if the alarm
is persistent.

A powerful feature of the Alarm

System is its ability to be configured
to the characteristics and needs of the
individual plant. Configuring the
alarm system contains a wide range
of possibilities:
• scope of alarm silence / reset
• alarm announcement and logging
• alarm priority sounds and
external horns
• colour coding and categorisation
• automatic alarm printing

Flexible alarm configuration.

10

Hierarchical Alarm
Suppression

Hierarchical Alarm Each group, route or collection of

Suppression objects may contain a “parent object”
Many of the advantages of the Alarm (e.g. mill main motor) controlling the
System to a great extent reflect the alarm suppression of all the member
object structuring in the database. objects. If the parent object is not in
Relating the plant’s physical layout to normal status, the alarms of any other
the operational contribution of the member object will automatically be
devices involved in the plant, a suppressed. In this way, only the
hierarchical structure can be obtained. relevant alarms will reach the
In practical terms, a “plant” consists operator. If desired, the automatic
of “departments” (e.g. mill) that each hierarchical alarm suppression can be
may contain ”groups“ (e.g. mill oil switched off for selective member
pump) that contribute to the main objects.
objective in the department. Groups
can also contain “routes” represent-
ing paths of material transport (e.g.
silo 3 to silo 5).

Plant

Department 1

Group 1
GP1 Route 2
Route 1
Hierarchical object structuring enables hierarchical alarm suppression.
RP1 RP2
P1 P5

P2 P3 P7

P6 P4
P8
P9 P10

Group 2

Department 2

Department ...
 11

Trend System

Trend system • Fast zoom by swiping in horizontal used by the operator to capture the
This module provides graphical (time) and vertical (value) directions desired information in the process.
real-time or historic insight into the • On-demand trend by a single click The trend module can also handle any
process conditions. In on any opject for ad-hoc package combination of analog and digital
ECS/ControlCenter, all values for configuration objects. The trend curve for a digital
analog and digital objects, as well as object represents the operating status
their statistical data are logged Each package allows defining (e.g. run/stop) of the object.
automatically and continuously. The customised scaling and colours for
logging starts automatically at the each trend object. As the spot values are logged
time of creating the object in the continuously, operators can view full
database. real-time trend curves instantaneously
When opening a package, the trends without having to wait for the curve
can be shown in any period only to be built from incoming spot values.
Logged values can be viewed as trend
limited by the data available. Default If desired the user can export the
curves for individual objects or in
time horizon buttons (1 hour, 1 day, values of any selected area to the
packages. A number of features in the
etc.) can be used for easy and quick clipboard to be inserted in other
ECS trend module ensure high
toggling of the trend period. Further- media such as MS-Excel sheets.
flexibility for the operators and
more, the individual scaling value,
engineers:
zoom areas, curve highlighting,
• Extremely fast view of up to 16 individual trend hide/unhide can be
trends
• Temporary changes to the trend
packages e.g. axis limits, to explore
a given condition, without changing
the package default set-up.

Simple zooming with the mouse in details or time.

12

Reporting System

Performance
1: Preheater Exit
Point info Report
2: Preheater Exit
Oxygen
Temperature Preheater Exit
Process
Oxygen [%]

Reporting System
3: Calciner Fue
l Relation 4,50

4: Id Fan Level 4,00

3,50
5: Calciner Tem
perature 3,00

The ECS system continuously logs

2,50

2,00

1,50

1 1,00
2

statistical information for all defined

Date 3 0,50
4
5 0,00

% degC
1 2 3 4 5 6
% 7 8 9 10
1 rpm 11

objects. Information is stored on a

12

Kiln Fuzzy Performance862,9 Economy

13
2,06 degC 14 15 16 17
307 18 19 20 21
60,21 Day 22 23 24 25
2 933,2 26

n
27 28
1,96 29 30

eratio
31
304
60,35
3 945,6

Op
Point info 1,95
307 861,9

hourly, shift, and daily basis. The ECS

4
60,16
949,6
Calciner & Kiln Fuel [t/d] Preheater Exit Tempera
1: Kiln Feed 3,99
323 864,0 325
ture [degC]
58,13
5 756,7
2: Calciner Fuel 2,00 250,000
315 840,6 320
59,55
6 944,1

rt reporting module allows for

3: Kiln Fuel 1,89 868,4 315

epo
312
59,57 310
7 938,7

ce R
200,000 868,5
4: Total Fuel consumption 1,90
309
nth
n
59,67 305

orma
is Mo865,2
8 937,5
5: Calorifics per ton of klinker 2,10
321
59,83 time th

Perf10
300

automatic printing of standard reports

150,000
9 1,69
322 Run 925,5
863,7 295
60,57
933,9 290
1,57 100,000
320 856,9
60,23 285
11 934,4

on a daily or weekly basis. Reports

1 2 3 4 5 1,81 322 op 854,3
pe d
Kiln St
1 2
59,87 3 4 5 6
12 50,000 926,9 1% 857,8 7 8 9 10 11
Date 1,50 12 13 14
322 15 16 17
t info 60,04 18 19 20
21 22 23
Poin 13 945,9 Day 24 25 26
tpd tpd tpd tpd 1,50
kcal/tcl 319 857,8 27 28 29 30

can also be printed on demand. The

31
0,000 59,76
14 945,6
1,57 859,3
Time
1
6243,0 227,041 150,576 ) 377,618 754,0 310 1 60,083 5 7 9 11 13 15 17 19 21 23 25 27 29 31
ime cm nning
Run un T nth ac 15 950,3 Kiln Ru % Date Calc
Kiln 2 ion R6349,9 r (mo 150,112
228,843 378,955 1,64
743,9 304 859,6 31 iner Fuel Relation
1:
uct acto 60,30 [%]
Prod 3 ion R un F 227,329
16 951,3 61,50

reporting module ensures:

6287,4 150,147 377,476 1,84
748,4 310 862,5
2: 61,00
uct 59,69
Prod 4
17 933,9
4574,4 165,082 114,578 279,660 1,90
762,1 310 867,2 60,50
3: 60,08 Total Fuel [t/d]
line60,00
18 931,0 n On
1,61 uctio
863,1 59,50
4:
5 6060,3 217,263 147,662 364,924 750,6 305
60,81 Prod 68%
19 5 950,6 59,00
1,60 859,6

• Meeting the plant floor requirement

6 6079,0 216,642 146,848 363,489 745,4 400,000
304 58,50
5: 4 60,98
20 949,6 58,00
Perfo
7 6118,3 216,0323 145,668 361,700 1,54
736,91: 350,000 860,3
Kiln 304
Feed 60,40 int inf
Po 57,50
8 5785,6 2 206,758 138,604
21
345,362 1,702:
744,1 300,000 per
ker pe 60,76Day 939,7
951,0
o
862,2 57,00
rman
Klin305
ce Re
for routine process performance
1 22 56,50
r
port
1,59
3: D 860,6
9 6145,1 220,735 % 142,920 363,655 737,7
Accum 303 250,000 60,74ay 1 3
urs
6201,6 ho 221,641 75,48145,997
23 1,54
4: ulated 951,0
861,0 5 7 9
Date 10 s
367,639 739,0 300200,000
60,67 Klinke 11 13 15 17
hour ,55 24 1,56 r948,4
per D 860,8 19 21 23

reporting.
5:737,9
11 5863,5 17 209,433 87,46 137,641 347,075 302 150,000
60,74 ay Day 25 27 29 31
23,44
Hours 4500
Produ
25 954,0
1 12 6128,8 23,50218,110 ,66
91143,670 361,779 1,61
735,8 308 859,9 Run Kiln Cl
iln inker
K
ction
100,000 60,17
24,00 ,00 26 955,0 per da
2 13 6152,8 24218,700
92 ,58
145,785 364,485 1,56738,4 309 863,6 Id Fan y [t]
50,00059,81 Level [rpm]
24,00 ,37 27 953,5 4000
17 ,18 1,50 866,5 1200,

• Tracking shift performance using

314 6229,9 222,222 146,597
92 368,819 738,0 307 0
18,19 28 1 0,00059,66 959,6
21,47 Da 1,25 866,6 1000,0
4
15 6242,8 221,989 91,76
145,464 367,452 te 733,7 313 2
1 3 5 7 9 11 13 15
3500
17 19 21 23 25 27 29 31
24,00 59,40
21,33 29 3 945,7
165 6029,9 212,569 83,46
141,757 354,326
1,56
732,5 316 877,8 800,0 Date
tpd 30,0060,29 4
24,00 3000

the dedicated shift reports

8,35 30 1 1,44 936,3
877,7 5 600,0
17 6 5860,0 208,238 72,84
136,639 344,877 733,6 313 tpd
24,00 6243,0 58,26
0,00 ,50
31 2 40 25,00 t 935,7
875,3 400,0
18 7 6185,9,38 221,904 143,23864 365,142 735,8 77 25 00
23 6349,9 Kiln Feed [t/d]
0,00 4077
8 57,88 365,591 3 4147 20,00 200,0
19 6270,8 ,00 222,985 142,606 726,7
6287,4 31
24 8223 2000 30
0,00

• Efficient statistical reporting for

29
9 6228,2 ,67 4 41 0,0 28
143,51156 06 27
20 218,504 362,015 724,6
45 7000,0 15,0012
26
24,00 74,4 24
25
10,36 ,37 5
329 1 23
1500 3
2987 22
10 6181,4 142,850 60 363,173 5
21
23 ,40 220,323 60 732,4
60,3 Mon th tota10
6000,0
l 15,00316
7 19 209 21
11 13
24,00
18 15
Days ,69 6 3957
17 17 19
11 62 30 15
16 21 23

production, maintenance, electrical

22 6242,0 222,482 144,500 366,983 6079 732,9 30 14 25
24,00 ,0 30 19273 1000 13 Date Day 27 29
21,35 7 5000,0
5,00 30 11
12 31
12 65,21 3970 9 10
23 6326,4 225,448
24,00 146,858 372,306 6118733,6
,3 23243 30 7
8
23,22 Max648,71 39 4000,0 5
6
13 3,99
380,285 5785 748,4 323 95
4
24 6333,9 24231,208
,00 149,076 0,00 2
3 500 Calc
ou rs iner Tem
,53 ,6 60,9827 23 1 H perature [deg
13 8 Run
and control staff.
Min 965,74 959,6
25
14
6195,4 227,178
,00 150,564
1,25
377,742 6145,1760,0 300
3778 3000,0
877,8 890,0
uc tion C]
0 Prod
24 58,1331016
19,15 10 67,50 756,7
15 4013 880,0
26 6119,7 23,45
223,160 149,834 372,9946201,6 759,8 2000,0 35029
840,6
22,30Mean 11 1
16 69,341,76 4050 870,0 3
27 6183,9 23,30
220,505 149,421 369,926 5863,5 745,7311
39079 5
24,00Accm12
1000,0
60,03 7
17 70,98 3829 937,1 860,0 9
28 6061,0 24,00
215,932 147,282 363,214 6128,8 747,0 862,9 11
24,00 42907 13
18 13 72,45 4002 0,0 850,0 15
17
29 5871,5 24,00
216,328 142,748,00 359,076 6152,8 762,3 46 1 3 30 ,00 5 7 9 11 13 15 17 19 21 23 25 27 29Da 31 19
2414 910 840,0 te 21
19 72,95 4018 23
30 5776,6 207,147 24 ,00 148,471 ,39 355,618 62 29,9 767,4 Date 25

If customised reporting is needed,

19 50927 27
25,00
830,0
20 15
OpHrs 74,20 4068 29
23,43 6242,8 31
31 ,00 54995 820,0140000 Clinke
21 16 24 75,34 4077 r Ac
24,00 6029,9 20 ,00 cumul 30
31

24,00 59072 Calories

1
per
2
ton
3
of
4
clinker
5 ated 28
29
22 17 76 ,38 3937
6 7 8 9 10 11 12 [t]
25
26
27

dedicated MS-Excel add-ins can be

24,00 ,005860,0
63009 15,00 120000 13 14 15
16 17 18
22
23
24
19 20 21
24 21
77,33
18 20Day 22 23 24
23 3827 19 25 26 27
28 29 30
,00 61 18

24
Month total
24
19
85
24,00 ,9 ,90
7640
780,0
66836 10 ,00
14
15
16
17 31

24,0030 6230,000
39 100000 12
13 Date
1570,53,8
Days 30 30 30,0 7087 11
770,0 5,00

provided to develop plant specific

25 20 ,36 5 9 10
7695
40 7
8
24,00 6228,2 6
15,01 7497760,0 4
5
26 21 406773,60 0 0,00 280000
3
ctor
24,00 6181,4 0 1 n Fa
Max 6349,9 231,208 150,576 0,0
380,285 767,4 ,08 79037 tio n Ru
27 22 4036 71 750,0 uc
Prod

report layouts. Furthermore, in other

24,00 6242,0
Min 4574,4 165,082 114,578 0,00
279,660 724,6 83074 60000
28 23 4076 68,68 740,0
,356326
09-07-2010 11:21 23 ,4 0,0 0 87150
29 24 4131
24,00
6333,9 730,0 40000
Mean 6077,6 217,724 30 25 144,388 362,112 743,0 91281
Titan Saloni
cases of specific requirements for data
4136
Accm 2631
6195,4
10863,356
4046
22288,7 95417
720,0
200,0
0 ki
6119,7 10 000
99463 tal 710,0
27
th to 90,00
Mon10345930 700,0
3996
5
extraction from the data logging
6183,9
28 80,00
4038 0
6061,0 30 1074 1 3 5 7 9 70,0011 13 15 17 19 21 23 25 27 29 31
OpHrs 29 97 31
5871,5 30 3958 1
60,00 3 Date 28
29 30
111455 5 26 27
30 Days 50,00

system, the desired data may be easily

3834 7 24 25
5776,6 ,0052 9 23
2411 ,00 11 21 22
31 37 89 40 13 19 20
24,0072 15 18
0,0 0 ,00 17 16 17

2005
11 9061 30 19 te
Max Date13 14
15
Da 21
18,19 20,00

April
11 12 23

retrieved by use of the ActiveX

9 10 25
Min 8 27
10,00 6 7 29
16,18 4 5 31
68,68 7000,0 0,00 3
Kiln Fe
1 2
23,44 ed pe
r day
Days Mean [t]
Month

Max
30
cm
Ac 30
to
30
tal 60 00 ,0
1 interface provided.
09-07-2010 10:52 Min
6349,9 488,5
4
Titan Saloniki 5000,0 3
4147
711,5
1 ine
4574,4 n Onl
OpHr
s
uctio
2987 Pr40od
67,90
00,0
Mean unning
6077,6 Kiln R
30,96
Accm 3969 ped
niki
3000,0
KilnStop
119061
Salo
Titan
1190611,
13
2000,0
OpHr
s
1000,0

0,0
:15
1011
7-20 1
09-0 3
5
7
9
11
13
15
17
19
Date 21
23
25
09-07- 27
2010 29
11:19 31

Titan
Salon
iki

2
 13

On-the-fly
language change
ECS/ControlCenter can be supplied in
a variety of languages (English,
Spanish, French, Italian, Russian,
Chinese etc.). The system language is
based on a dual language
configuration, a “default“ and a
“local” user selected language.
Furthermore, an on-the-fly language
change feature enables changing the
system language between the two
languages at any of the ECS stations.
For installations where system
support and services are carried out
by a technical center in another
country, this capability ensures that:
• The support engineer’s language
can be enabled on-the-fly and at
the PC station of the engineer,
without any interruption or
language changes for the other
operator stations.

Language Editor

Add new...

In addition to the standard library of

supported languages, the system has
also a new-language-builder feature Configure...

that enables system integrators and

Use!
engineers to extend the standard
library with additional languages.
14

I /O Center

All the ECS supported As a hardware independent solution The following highlights the technical
communication drivers can run supplier FLSmidth has historically aspects of the communication drivers:
at the same time. This means, focused on enabling the ECS platform
for example, that a plant with to communicate with various types of Communication
a step-by-step upgrade project
process controllers through its built-in redundancy
high-performance I/O drivers. High data availability is achieved by
will benefit from one unified
supporting redundant links to the
operator interface regardless of
process controllers. If a process
the underlying process With the capabilities of the ECS I/O
controller is equipped with multiple
controller type. Center, users are guaranteed a
communication cards, the
number of benefits:
communication drivers allow for
• High degree of scalability assures automatic switching between the
the ability to extend the automation communication lines in the case of
solution using the same ECS server network or communication card
system. failure.
• Flexible supplier selection if the user
has according to local conditions, Communication efficiency
past experience, etc. The ECS communication drivers can
• Step-by-step control system read and write entire blocks of data
upgrade from one supplier to for a given device. Using proper
another, with ECS as one uniform programming principles, such as the
control room environment during ECS/ACESYS standard library for the
the upgrade phases. cement and mineral industries, each
object can be identified with only one
• Backward compatibility enabling
ECS point (tag) and associated with
migration paths to minimise
its data block. While the point value
hardware, software and
and status is frequently polled for
engineering expenses in future
continuous operator visualisation, the
upgrades.
data block is only polled upon request,
 15

e.g. faceplate view. This strong

architecture of the communication
drivers creates unmatched efficiency
and scalability for large-scale control
systems.

No additional I/O server

Unlike some other control systems,
the communication drivers of the ECS
I/O Center are executed in the same
ECS server as the operator HMI.
Therefore, regardless of the control
system size, number of process
controllers, etc., only one dual ECS
server is necessary for a complete and
secured control system engine. Fewer
servers means less software
engineering, complexity and
maintenance. And most important –
Higher avalability!.

Third party independence

All I/O Center communication drivers
run without the use of any third party
software or hardware components.
This independence ensures best
performance and high supportability.

The communication drivers can be configured through engineering utilities dedicated for each driver. Polling frequency, timeouts, network type (ethernet
and serial) are some of the configurable items for each driver. Also a number of diagnostic facilities provide assistance for supervision and tuning of
the driver performance. Polling time statistics, read and write errors, operation status, individual communication link load and performance, data
communication maps to optimise function block layout are some of the diagnostic features in the communication drivers.
16

Security Redundant Control

The availability of the control system is

Center clearly of high importance to ensure

continuous production. For this
purpose, the ECS/ControlCenter
servers can be configured to operate
as a redundant system. In a redundant
configuration, 2 servers will be on-line
A professional control system simultaneously, each performing the
must be equipped with functions same task. Therefore, a redundant
and facilities that ensure high configuration allows:
security and protection of • Uninterrupted process operation,
the control system against tolerating the shut-down of a
unforeseen events. control server for any reason (e.g.
software upgrade and mainte-
The Security Center is a suite of nance). This is possible as one ECS
functions to accomplish the high server is fully sufficient to operate
priority requirements for control the entire plant.
system security.
In a redundant server set, all on-line
engineering and changes of param-
eters, and mimics are automatically
transferred between the ECS servers.

User Access Control

The control system is the heart of the
process control function and it is
highly important that changes to the
system configuration and parameters
may only be performed by authorised
 17

staff. The built-in User Access Control wrong scaling factor or PID controller Remote access
of ECS/ControlCenter ensures: parameter can just perform the Remote access to the control system is
• High protection of control system modification by logging into the very often an efficient way of
configurations against unauthorised nearest operator station with his/her distributing information. This capabil-
persons. own ID. This flexibility is possible as ity is both important for support
the UAC controls the access privileges engineers as well as production and
regardless of user location. plant-floor managers. At the same
Using the built-in facilities of the UAC
system, the system engineer can time, this kind of remote connection
create groups of users such as shift On-the-fly must be secured for unauthorised
operators, chief operators, electrical user registration access to the control network.
engineers and system engineers with In coordination with the UAC system, ECS/ControlCenter offers:
certain rights and privileges according the ECS system login enables tight • An efficient combination of high
to the area of responsibilities and control and registration of users. The security and easy remote access to
skills. The scope of these rights can be user access through ECS login user information in the control
selected at a number of detailing ensures: system.
levels such as changes to database • Automatic user-action recording
parameters, PID controller tuning, and attribution for back-tracking in Using advanced firewall and other
process set-point changes, etc. Once a the historical events in the process network security techniques, the
group is defined, associated members and control system. control network can be isolated from
can be assigned as individual users of the office or other user-LAN networks.
the system. System operators and engineers can Remote users will then have access to
use the on-the-fly ECS login system to the control network through the
Together with the client/server register themselves, without any supported “Terminal Clients” without
architecture of the ECS system, the windows logout. In many other any additional software installation on
UAC enables a high degree of control systems, the lack of a dedi- their PC. The User Access Control
flexibility for the users to use any cated login facility is often a major system will handle the privileges for a
connected ECS station to perform reason for operators to use the same given remote user.
their task. This means that the control username for all users.
system engineer who is faced with a The on-the-fly ECS login also facili-
problem in a certain area, e.g. a tates registration of new users in an
easy way.
18

Engineering Optionally, in addition to the

described standard services, FLSmidth

Center offers a highly project-oriented

engineering station that integrates
plant/project information into project
engineering tools on one PC called
ECS/SmartStation. The added-value of
the integrated engineering stations is
ECS/ControlCenter offers highly visible in troubleshooting and
engineering, configuration and maintenance tasks of a control and
diagnostic facilities at various electrical nature.
levels. ECS/SmartStation may result in:
• Improved efficiency in
A number of these tasks, such as troubleshooting as the relevant
changes to the server database, information is centralised in one
mimic updates, alarm handling single location.
algorithms, data conversion • Fast and easy information access
algorithms, and communication through the integrated framework
performance tuning are to the project engineering tools.
performed directly on the server • Flexibility in accessing information
stations. ECS/SmartStation is as the engineering station can be
a powerful extension of these supplied with various types of
facilities. remote and wireless access
solutions.
 19

ECS/SmartStation offers fully ECS/SmartStation is configured as an

integrated drawing and document ECS Client. This means that all ECS
look up facilities for any object in the Client programs such as the live
database. In this way the user obtains OpStation HMI, the mimic editor,
a fast overview of all the available point configuration and engineering
documentation, electrical drawings, programs can be activated from the
etc. for a given object. The built-in ECS/SmartStation. The point code of
viewer for various software products a selected object in OpStation is
enables viewing of the document automatically transferred to
content. The documents can be ECS/SmartStation where a cross-
edited/updated using the relevant reference database holds the linking
editor package. information of the PLC program,
drawings and documentation for the
The built-in document viewer can be object.
used on various file types such as doc,
pdf, dwg, dxf, vsd, mpeg, avi, jpg and ECS/SmartStation includes facilities to
bmp. set up the rules, and even possibilities
to scan documents and drawings for
ECS/SmartStation provides an open object related information and
environment that allows integration thereby adding them automatically to
of a wide range of tools for control the object drawing database.
engineering and project
documentation. The system can easily ECS/SmartStation can be combined
be adapted to the preferences of the with wireless technologies enabling
users. supervision of the process in the field,
thus facilitating troubleshooting and
optimisation.

One click automatically takes the engineer

from the object mimic to the exact position
of its PLC program or electrical diagram.
20

System
Customisation

In order to meet the functional

requirements of the individual
end-users as well as technical
centers for group customisation,
ECS/ControlCenter includes
powerful features for a wide
range of system customisation.
Using these features, global
customers have been able to
develop their own standards of
the product.

From object-oriented design environment...

...to customised plant mimics.

 21

System Customisation Example: Mimic Editor

As described in previous sections, the All operator mimics as well as
building blocks, Operator Center, I/O faceplates in an OpStation system can
Center, Engineering Center, and be edited and modified by the user. In
Security Center all have their own all standard supplies, the built-in
individual customisation capabilities. mimic editor can be used to maintain
Examples of areas where the the existing mimics as well as for
behaviour of ECS/ControlCenter can creating new mimics. The editor is
be defined by the users are: based on object-oriented principles,
• Time resolution of logged value meaning that a change of an object,
e.g. motor symbol, will be visible in all
• Storage capacity (time duration) for
instances of the object in all process
logged values
mimics without any computer re-boot.
• Communication methods to the In order to facilitate the mimic design,
process controllers the editor contains a number of
• Alarm announcement and logging model libraries for both static and
behaviour dynamic symbols. Thus introducing a
• Actions to happen in process new symbol, e.g. a new fan in a
controller upon an alarm reset mimic is just a matter of dragging the
symbol into the work space and
• Detailed properties of value display
associating it to a database point. As
for analog and digital objects
the new fan is just similar to other
• The degree of complexity in
existing fans (with similar point
operator mimics.
configuration), its behaviour is now
completely defined in colour,
The important aspect of all the above faceplate pop-up, commands etc.
customisations is that no single line of
programming is required to obtain The object-oriented concept is a
them. “Parameterisation” is the crucial element in engineering and
keyword in customisation of maintenance cost. Using the powerful
ECS/ControlCenter behaviour. This mimic designer, standards for a given
aspect is crucial to facilitate corporate group can easily be
backward compatibility and thereby implemented and maintained by the
easier system upgrades. technical centers or system
engineering companies.
22

Project
Execution

FLSmidth has extensive experience in including preventive maintenance

handling large projects all over the visits, 24/7 hotline, remote support,
world. The project execution and site and remote engineering assistance. In
activities are clearly defined in the order to ensure optimum runtime of
ISO9000 certified quality the systems over decades of software
management system which focuses evolution, FLSmidth also offers
on delivering ‘On Cost - On Time - On complete software migration
Spec’. Typically the Project Execution agreements. As part of the mission to
is divided in 3 phases: be a recognized technology leader
and competence centre FLSmidth
1) System Design and Engineering
offer several managerial, engineering
phase includes collection of
and consultancy services, including
information, development of project
feasibility and optimization studies.
specific drawings and diagrams,
network design, configuration of ECS
software, PLC programming and Contract Management
Project Management
production of control panels. Project
A dedicated project manager is
engineering in FLSmidth is handled in
assigned to coordinate all internal and
a high-end engineering tool, Metis, to
external activities through the entire
ensure the highest level of quality and
life time of the project. This person is
consistency. The engineering is
the main contact for the client
verified by a factory acceptance test.
counterpart. At an early stage in the
project, the project manager provides
2) Commissioning and Optimization
a detailed project plan, indicating the
phase involves on-site services by
individual phases and all key
FLSmidth and sub-supplier personnel
deadlines, project meetings etc.
for bringing the delivered equipment
and software into correct operation.
Site management
The installation and commissioning
On larger and more complex projects,
activities are typically joint activities
a site manager is appointed to assist
with the goal of a smooth and rapid
the project manager, representing
start-up. It is essential that dedicated
both FLSmidth and all sub-suppliers.
end-user personnel are appointed to
His role is to prioritize daily work in
follow these activities as they will be
order to optimize overall project
tasked with the future support of the
progress, organize onsite tasks and
system. Depending on the magnitude
hold project meetings with client to
of the actual project, commissioning
coordinate common activities.
can require a few days or several
months’ activity.

3) After-Sales Service phase. Upon

successful client acceptance and
take-over, FLSmidth offers service
agreements to provide the degree of
support desired. These range from
basic troubleshooting and spare part
contracts to full life cycle services
23
24

Support & Support for

ECS/ControlCenter
and gives top priority to emergency
assistance. The customer is supported

Services FLSmidth offers a wide range of

services to help customers in securing
via service visits on site and/or
remotely via hot-line and internet,
their investment in ECS/ControlCenter. ensuring maximum system uptime
The aim of these services is to ensure and optimal plant performance.
maximum customer satisfaction as Furthermore, Migration Agreements
well as product efficiency by improv- ensure continuous operation even if
ing performance, utilisation, and replacement of control system
equipment is required within the next
productivity.
3-5 years. Access to the latest releases
FLSmidth provides the following with service packs, hot-fixes and
services related to ECS/ControlCenter: software upgrades are some of the
• Training Courses ensuring maxi- benefits in these agreements. Delivery
mum utilisation of the product. of software licenses, replacement of
• Service & Migration Agreements to hardware and one major conversion
secure a long-term investment by of software platform during the
enabling beneficial upgrade agreement lifetime of usually 5 years
packages is a typical example of Migration
Agreement package.
• Assistance & Maintenance maximiz-
ing the run factor of the system
With a combined Service & Migration
• Engineering & Consultancy giving
Agreement, the system covered is
the customer access to a wide
kept up-to-date by FLSmidth.
range of experience in control
system engineering.
Remote Services
Remote assistance saves time and
Training travelling costs for specialist visits.
Training plant staff and keeping them Remote Services via modem or
highly qualified is important. Training internet give unique possibilities for
sessions can take place at FLSmidth service from a distance. By allowing
offices worldwide, at integrators’ access to monitor a software applica-
technical office or the end-user tion it is possible to evaluate problems
premises. Based on many years of remotely and even make corrections.
training experience, FLSmidth courses This is done on-line while the system
are divided into Introduction, User, engineer or operator can follow
Specialist and Expert levels. Further- every step.
more, specific courses tailored to
• 24-hour Hotline - offering tele-
meet specific requirements of
phone support with critical issues
engineering companies and technical
• Remote Troubleshooting - offering
centers can also be offered for
on-line support when problems
ECS/ControlCenter.
occur
Having gained some experience with
the product, a follow-up course is • Remote Engineering - offering
normally recommended. These ad-hoc specialist assistance for
brush-up and in-depth training minor engineering tasks
courses give the user the necessary • Remote Software Maintenance
knowledge to fully utilise the product. - keeping software products
updated.
Service & Migration
agreements The services are offered as individual
When the system commissioning and subscriptions in yearly service
warranty period is finished, a Service agreements.
Agreement is a prudent investment
25
26

Software Software Quality

ECS software development is based
In addition, quality assurance of ECS
software is to a great extent based on

Quality on the principle of Agile development.

Agile development is an iterative
automatic software testing
procedures. The procedures allow
process that enables FLSmidth to regression testing that ensures
rapidly respond to customer needs. thorough and consistent quality.
The ECS platform is focused on Automatic regression testing also
customer requirements in the cement makes it possible to test extreme load
and minerals industry. scenarios - instead of testing the
software with a few operators,
ECS is based on standard Microsoft automatic testing can simulate 50 or
technologies, which enables software more operators stressing the system.
openness and reuse. ECS is an open
platform that integrates with Through the use of extensive test
Microsoft products to provide procedures, FLSmidth can ensure the
interfaces to core ECS functions. The highest level of quality to the benefit
ability to build on the open ECS of its customers.
platform enables customers to
produce individual reports, export Software Foundation
data and build custom applications. • Client/server architecture
• Standard faceplate of detailed
FLSmidth is a Microsoft Gold Certified device mimics
Partner. Being a Microsoft Gold
• User-defined faceplate support
Certified partner represents the
highest level of quality and • Standard library of data conversion
competence, and enables FLSmidth to algorithms
always offer software solutions that • User-defined algorithm support
are based on the latest Microsoft • Hierarchical object grouping
technology and platform.
 27

OpStation I/O Center Trend

• Draw-and-configure editor for • ABB • Analog and digital values
process mimics • Siemens • Horizontal/vertical zoom
• Standard libraries of static and • Rockwell/Allen-Bradley • Data grabbing for export
dynamic mimic objects
• Schneider/Modicon • User configurable colour scheme
• Support for object animation
• OPC-DA Server • Package-based trend of groups of
• Object-based drawing of sub- objects
• OPC-DA Client
models for instantiation
• Concurrent communication with • On demand trending of single
different process controller types objects by only a right click
Alarm and Event • Support for redundant link to • Short cuts for easy time horizon
• Automatic hierarchical alarm process controller selection
suppression
• Alarm algorithm selection for group
Data logging Report
or individual objects
• Data logging of both analog and • Automatic value suppression
• Configurable alarm philosophy for reporting
digital objects
• Alarm annotation support • Free time horizon selection
• Automatic data logging upon any
new object creation • Shift-based time horizon selection
Security Center • Configurable time horizon of data • Detailed statistical value reporting
• Full redundancy support logging
• User access control • Spot data logging with a resolution
• On-the-fly user login and up to 1 seconds
registration • Individual logging of statistical data
• User action logging and attribution for hour, shift and day
• Excel add-in for data retrieval
• Available OLE Automation
interfaces for data retrieval
 CM 09-10 800-1-EN V1

Copyright © 2011 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations
or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com /ecs