Training Cum Reference Manual On

“EXPERT CONTROL SYSTEM –ECS”

M/s FLSmidth

Mr. R.B.VIJAY Mr. Navin Chaudhary

Mr. J.J.Delvadia

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PREFACE

Following the Guru Sishya Culture, the project Margdarshan is

trying to create a one to one long term relation for knowledge
transfer. This report is a knowledge base that tries to further
strengthen and pass on the gained knowledge to upcoming
young managers. This will further strengthen the relationship
and attachment between Dronas and Arjuns.

This report deals with the basic of “Expert control system” and
application in cement industries. It also takes into account the
various feature, application and interfacing with different make
of PLC.

GOALS OF THE CHAPTER-

AFTER THIS CHAPTER /SESSION ARJUNAS WILL BE ABLE TO –

-UNDERSTAND & UTILISE BASICS & THEORITICAL
CONCEPTS OF “EXPERT CONTROL SYSTEM” -SCADA.
- ABLE TO DEVELOPGRAPHICS
- UNDERSTAND & UTILISE PRACTICAL ASPECTS
RELATED TO SCADA.

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Content

1. What is ECS/SDR SYSTEM

2. Why ECS/SDR SYSTEM

3. ECS / Plant Control – at a Glance

4. System Overview

5. SDR Sub system

6. FLSA Program Philosophy

7. OpStation Feature and Application

8. Graphic display element

9. ECS – PLC Configuration

10. ECS server synchronization

11. System Backup

12.System Restore

13. Client Partner Assignment

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What is ECS/SDR System?

1.ECS is an acronym of Expert Control and Supervision.The ECS/SDR System is a suite of software
packages providing. Advanced MMI (Man Machine Interface) and other process
Control facilities. It is used to monitor and control the industrialPlants (especially cement plants).
2. ECS is the product of FLSmidth Automation used as SCADASystem to monitor and control the
cement plant.
3. It serve as the main platform for all the products of FLSmidthAutomation.
4. The ECS subsystem includes the graphic displays, interface Windows to monitor the process,
start and stop plant. Machinery, configure system and process parameters.

Why ECS/SDR System?

1. The ECS/SDR system facilitates communication with the most Common PLC families. It acts as an
interface between the PLCand Man-Machine-Interface (MMI).
2.It has set of facilities such as data processing, alarmmanagement, event management, data
logging and reportgeneration that are required to complement the services
Provided by a typical PLC control level.

The ECS/SDR system will support the operation of some of thespecialized control packages
belonging to:
– The ECS (Expert Control and Supervision) product family
– The QCX (Quality Control by Computer and X-ray) productFamily

ECS / Plant Control – at a Glance

 HMI based onECS/OpStation

 Process Supervision andControl
 Motor control, set-pointand output control
 Alarm and Event handling
 Point Parameters withstatistical data
 Trend system with longtime historical data
 Report System
 User Access Control
 Dual Language selection

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Applications of ECS Family

Applications of QCS Family

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System Overview

Communication Network:
 Ethernet Network
 TCP/IP Protocol

The Internet Protocol Suite ( commonly known as TCP/IP) is the set of

communications protocols used for the internet and other similar
networks. It is named of the most important protocols in it. The
Transmission Control Protocol and Internet Protocol (IP), which were the
first two networking protocols defined in this standard.
TCP/IP protocol is two layer protocol, one is the physical layer and that is
directly mapped into the application layer.
The speed of the communication between PLC and ECS is very high due to
this protocol.

Single server Configuration:

– Server(s) – contain the master database.

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Server Partners – 2 servers (Server1 & Server2) running intandem

– May be interfacing to different departments (PLCs)

– Share data so each has the exact same data in theirDatabases

Partner Setup Configuration: If one the server fails clients automatically switches to another server
without disconnecting the process, when dual server is configured through the partner setup
configuration.

Client(s) – client1, Client2 & client3:

– Operating System = Microsoft Windows Workstation

– ECS Software
– Obtains process information and issues all commandsthrough its assigned Server(s) (Server 1 or
Server 2)

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Principle of Redundant System:

Redundant network configuration is used for continuous communication between

ECS/SDR and PLC. For Larger ECS system (dual configuration ) Redundant
network configurations are recommended.

Teaming : To avoid that the switch to switch connection becoming a bottleneck

this connection can be by up to four network connections forming a single
team.i.e the capacity of the team is the sum of the capacities of the network
connections

Watch Dog :

The watch dog helps to continuously monitor (polling ) between the ECS system and the
PLC.Any Communication problem will be indicated with the help of color identification.

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The watch Dog user interface is automatically started when a user logs in.A color
indicator is placed in the system tray on the task bar.
Also the information like product installed ,version ,licence information ,installation time
and hot fix installed can be viewed using watch dog

SDR Subsystem

The SDR Subsystem is responsible for:

1) Point Database Update
2) Historical Data Logs
3) Alarm Processing
4) I/O Interface / Processing
5) Internal Calculations

1. Point System:
– Point
– Point Database
– Point ConfigurationParameters
– Point Processing(Treatment)

A point is:
– A storage location in the SDR system representing an I/Osystem point status value
– A SDR system variable
– The result of an internal calculation.

2. Alarm System:During system operation, a specific process condition may cause nuisance
alarms or cause invalid data to be calculated and logged. For example, a motor stop condition may
cause another point to report an alarm condition. During normal operation, alarms must be
processed for this point. For this motor stop condition however the alarms are expected and
notification is not necessary. In addition, the motor stop condition may also cause invalid data to
be used in the point’s report algorithm. In this case, it would be desirable to disable the point’s
event and report algorithms. There are two types of alarm suppression techniques, (1) Point Alarm
and Report suppression and (2) Hierarchical Alarm suppression. Both are point based.
The ECS system enables Point Alarm and Report suppression for individual points by assigning a
parent point. Whenever the parent point status is not normal, alarms or reports for the child point
are disabled. A parent point can be specified for alarm suppression and/or report suppression.
Reports and alarms for individual points can also be permanently suppressed.

– Alarm Limits
– Alarm States
– Alarm Notification
– Alarm Log

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3. Event System:A system event is generated when a user performs a control action. When a
system event is reported, the occurrence is logged into the event log. The log can be reviewed
from the ECS alarm list display. An event log report can also be generated on demand or scheduled
on a periodic basis.

– Control Actions

– Event Log

4. Data Log System:The ECS/SDR Data Log system periodically saves point values and
statistical information to historical data files. The historical data files are organized into two groups
– Trend Value Logs and Statistical Logs. The log files are accessed by other ECS/SDR utilities to
generate point value trend displays, and plant, shift, and production reports

– Value Logs
– Statistical Logs
– Data Analysis, On DemandReports, Scheduled Reports, Trend Displays.

5. I/O Interface:
– Program Philosophy
– Departments
– Motor Groups
– Start Displays
– Database Points

FLSA Program Philosophy:

– Defines methods used to interface with plant operation

– Defines details related toEquipment start-up and shutdownAnalog and digital control
Alarm Processing.
– Uses standard FLSA Subroutines that reside in the PLCProgram and interfaces with common plant
equipment suchas motors, valves, dampers, controllers, etc.

System Parameters:

– System identification and database backup frequency

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Partner SetUp Configuration:

– Workstation Identification
(Server / Client)
– Server Partner Assignment
– Client Server Assignment

Point System Configuration:

–Miscellaneous system parameters (department names, alarm reset actions, event log
configuration, number ofavailable points, point scan frequency, etc.).

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Module 1 – Introduction ECS 7.7.0 – Introduction Course 2007-10-11 1-18

Language Configuration:

– Assigns the language (English, Spanish, French, etc.) usedin display windows

OpStation:

– OpStation is an Application that presents process graphicsTo the SDR System operator

– These graphics are also called pictures, models, mimicDisplays and includes display elements
that are used toMonitor and control the plant operation.

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Desktop Start menu:
a) Starts the OpStation utility and opens the Top model display
b) Top model display is assigned during OpStation Configuration

Starts the OpStation utility and opens the display associatedWith the selected point or the selected
department

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Menu Commands:
a) Open OpStation displays (pictures)
b) Print OpStation displays
c) Silence and reset alarms
d) Open Alarm List
e) Open Trend displays
f) Start and stop process equipment
h) Access point displays.

Status Bar:
– Department
– Point Code
– Point Description
– Point Value
– Point Status
– I/O Control

Graphic Display Elements

Display Types:
a) Static / Dynamic
Display Element Behaviour:
b) Element reaction to point value and status
c) System reaction to mouse click on element
Display Elements:
d) Common graphic elements

Point Status Table:

Popup Menu Commands

 Picture Back
 Faceplate
 Point Alarm List
 Point List
 Add to Favourite List
 Point Parameters
 Point Configuration

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  ECS Note Pad
 Point Trend

Trend Display:

PID Trend Element Analog In Trend element

Process Interface
Departments:Departments are plant divisions usually defined by operational boundaries. For
example, in a cement plant, the kiln would be one department and clinker handling would be
another. A single PLC can control several departments, but in typical applications, one PLC controls
one department. Points do not belong directly to a department, they belong to a group. A PLC horn
point can be associated with a department. Points are indirectly, through groups, members of
departments.
The maximum number of departments is 100.

a) Motor Groups
b) Motors
c) Gates

Start Display:
a) Groups
b) Devices

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c) Group Status
d) Device Status
e) Interlocks
f) Select Points
g) Local Status

Device Control:

Open Top model Open Graphic Print Graphic

Turn off the audible alarm for the current department.

Reset all alarms for the current department

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 Open the alarm list for the current department

Open the alarm list for the selected point

Open the alarm list for the selected point’s group.

Open the SDR Trend display

Open the SDR Trend display with the selected point assigned to the trend group

Open the SDR Point List

Add the selected point to the favorite points

Open the SDR Point Parameter display for the selected point

Open the SDR Point Configuration display for the selected point

Open the ECS Note Pad and display notes for the selected point

Open the online help file

Motor Faceplate:
a) Right mouse button on Group Status
b) Select Faceplate in popup menu

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Analog Control:
– PID Control:
SP - (Set point) – Desired processvalue set by the operator or providedby another point within
the ECSsystem.

PV - (Process Variable) – Feedbackfrom the process. The actual processvalue being controlled.

Out – (Output) - Output to the devicethat regulates the process value.

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Point Address Configuration

Points
are the cetral part of all communication in th ECS system. All new points are created
in Point Configuration. The setting in Point configuration also defines which type the

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faceplate used in the equipment. The use of Point Configuration is therefore a
central part of this course. Since the points are used for all measurements and all
control there are many different types of points.
Total list of points can be reached by clinking on the list button in above picture.

SDR Alarm header

ECS –PLC Configuration:

1. Creating ECS-PLC Interface
2. PLC Configuration
PLC Interface
The PLC interface enables the ECS/SDR system to interact with the plant. This is done by communicating data
to and from the PLC's. The ECS/SDR system facilitates communication with the most common PLC families.

ECS Server ECS Server

1 Client Client 2
Printers

Teaming

Switch 1 Switch 2

PLC PLC

TCP/IP:

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Scan between check spare links:Specifies how often redundant communication links will be
checked for availability. Specified in units of PLC update periods. Valid entry range: 1 to 100.

Max time no update:The amount of time the ECS system will wait before a point
That doesn’t receive any updates is marked as Not Updated. Valid entry range: 1 to
60 seconds.

Min. time between link switch:This parameter specifies how many seconds must
Pass after a network switch before another switch can be initiated. Valid entry range:
1 to 60 seconds.
Set time in PLC’s: If enabled, the ECS system will set the time in connected
PLC5s. In a dual system the time can be set from MOP1, from MOP2 or from both
Servers.

Block read timeout:This parameter specifies how many seconds must pass after
Close of faceplates before stop of polling. Valid entry range: 2 to 60 seconds.

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Name:The name of the PLC

Active:This checkbox determines whether the communication to the selected PLC will be active or
passive.

CPU slot number:The number of the slot in the rack where the CPU is placed.

Use Block Alg. Items:When enabled “Read Item” and “Write Item” from Block algorithms are
used instead of “Read Offset”, “Read Bit Number”, Write Offset” and “Write Bit Number”.

Redundant Link:If the PLC is connected to two communication links (two networks -A/B), enable
this checkbox.
Link A Type:Select the type of communication link used for link A.
§ None:No communication link
§ TCP/IP:TCP/IP connection to PLC

Link B Type:Select the type of communication link used for link B. The possible Choices are as
described in the Link A Type field.

Use CN routingif the Controller is present on a remote rack, accessible on Control Net check this
field.

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Poll frequencyDefines how often the ECS system collects data from the PLC. Legalentries: 200 to
60000 milli seconds.

DepartmentThe department name associated with this PLC. Communication alarmsfor the PLC
will be logged in the selected department.

Watchdog periodDetermines how often the ECS system will write a watchdog bit tothe PLC to
indicate that the ECS system is operational. Legal entries: 5 to 3600seconds. If set to 0 the
watchdog function will be disabled.

Watchdog addressthe address of the bit that will be set by the watchdog function.

PLC status pointThe ECS database point will be updated with the status on theactive link for this
PLC. The point must be a B-point with the CLX IO-type, but withno IO addresses assigned. The
conversion algorithm for the point has to be
"Interface Status”. If the status of Link A is Passive and the status of Link B is Polling OK, then the
value Of the PLC status point will be Polling OK, if Link B is selected active.

IP Addr. / Node NameEnter the IP address or the node name for the PLC.

Timeout (milli seconds)the amount of time the ECS system will wait for a reply from the PLC.
Legal entries: 500 to 60000 milli seconds.

Max pending requeststhe maximum number of requests that the ECS system will issue
concurrently to one PLC. Legal entries: 2 to 20.

Link status pointthe value of this point will be the status of the link (Aor B),
Regardless of the link selected as active. Apply a point code of a B-point with the IOtype CLX, but
with no IO addresses assigned. The conversion algorithm for the point has to be "Interface Status".

CN Slot No.The number of the slot in the rack where the Control Net Card is placed.

CN Port No.The number of the port on the Control Net Card. 2 for Channel A and 3 for Channel B.

CN MAC Idthe MAC Id of the Control Net Card in the remote rack.

ECS Server Synchronization:

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a) Required if a ECS Server Partner is down or disconnected fromnetwork for any period of time
b) Must be in the Maintenance Mode.
c) Must be performed from the ECS Server that was down.
d) Select Subsystems to Synchronize: Graphic Files, Log Files, System database and I/O system
database.

Server Synchronization
1) Boot to the maintenance mode and log into “flsamain”.
2) When the Maintenance utility window appears, click on the Datasynchronization Tab.
3) Select the subsystems to synchronize by clicking the associated“Enabled” checkbox.
4) Click on the “Run” soft button to synchronize the enabled subsystems.

System Backup

1) The backup program is accessed from the maintenance utility

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2) Select Maintenance in the desktop Start menu.
3) When the Maintenance window appears, click on the Backup
Tab.
4) Select each item to back up by clicking on its Enabled checkbox.
5) Select the type of backup to be performed (Folder or Tape).
6) Click on the “OK” soft button to start the backup process.

The Backup Utility includes:

 Graphic Files
 Log Files
 Point Database
 System Configuration Files
 Language Database Files

System Restore:
a) From the FLSADEVBACKUP Directory delete the file“RESTORE.LOG”.
b) Maintenance Utility
c) Select Files to Restore
d) Procedure:
1) Restore from tape to folder
2) Restore from folder to system

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User Access Configuration :

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The ECS User Access Control (UAC) Configuration is used to grant access right to
new and exsting users for the ECS system.
System administrators can control access to the points, I/O,log,event and so on
system for an individual user or a group of user.Rights are granted to users either
expilicity ir by groups.

Client Partner Assignment:

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SDR Partner Configuration:
– Required if existing ECS Server is not available
– Select ECS Server
– Low Speed Connection

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