Advanced technology lowering energy use and improving environmental status

WE DISCOVER POTENTIAL

ECS/ENERSENTRY™ - ENERGY MONITORING

Real-time energy management improves

decision making and increases profits

Current Usage

Pyro

Usage History

06 07 08 09 10 11 12 01 02 03 04 05

21.5kWh/ton

Current Usage

Raw mill

Usage History

06 07 08 09 10 11 12 01 02 03 04 05

16kWh/ton

Current Usage

Cement grinding

Usage History

06 07 08 09 10 11 12 01 02 03 04 05

19.2kWh/ton

Current Usage

Crushing & transport

Usage History

06 07 08 09 10 11 12 01 02 03 04 05

2.3kWh/ton

Current Usage

Packing unit

Usage History

06 07 08 09 10 11 12 01 02 03 04 05

1.1kWh/ton

How am I performing? What is my

strategy?

Energy management

life cycle How do I buy?

How do I control?

How do I optimise?

How can energy expenditure be

reduced?

What evidence is there to support

decisions?

What energy KPIs should be in place?

Are the right monitoring

systems in place?

Is optimal energy management being

achieved?

Designed and engineered with reference to international standards and guidelines for energy management systems, ECS/EnerSentry™ – Energy Monitoring alerts plant managers and operators to energy-saving measures that have multiple environmental and operational advantages.

ISO 50001:2011 – Energy management systemThe ISO standard recognises that efficient energy use helps to save money at the same time as conserving resources and tackling climate change. ISO 50001:2011 is a key driver towards building and implementing optimal energy management systems – a benchmark that allows cement and minerals plants to continuously improve energy performance and sustain significant savings. ECS/EnerSentry – Energy Monitoring is a comprehensive, integrated tool that helps executives, engineers and all levels of staff collectively work towards this goal.

An energy saving solutionECS/EnerSentry – Energy Monitoring is part of the FLSmidth Expert Control and Supervision suite of products focused on the operation and optimisation of processes in cement and minerals plants. It fully operates on the proven ECS™ platform to gather data from a wide range of energy devices and automation systems. The data is then transformed into actionable information, tailor made for a unique energy monitoring purpose. Alarms, events, trends and reports can all be customised for a deeper understanding of plant energy losses and potential savings – all at micro levels in real time. Real-time energy management improves decision-making and improves profits.

Transform energy data into actionable informationECS/EnerSentry – Energy Monitoring supports energy management, energy procurement and production scheduling at operational, management and executive levels.

More than just a data collection tool, ECS/EnerSentry – Energy Monitoring will intelligently gather raw energy and production data and present that data as gainful information to support simple decision-making about energy conservation measures. Designed specifically for cement and minerals process systems and equipment, the system requires minimum setup for maximum results.

Addressing the energy management lifecycle ECS/EnerSentry – Energy Monitoring can help to establish a streamlined approach to

any plant’s energy management lifecycle by addressing these common questions.

Key benefits ■ Energy excellence and cost savings ■ Reliable information drawn from a wide range of energy

devices and automation systems ■ Easier management of electricity expenditure, surcharges

and tariff variations ■ Live substitution for faulty or offset energy devices ■ No need for high-end energy meters and complex

calculations ■ Seamless integration into new or existing hardware and

automation systems ■ High speed data logging – up to one-second intervals ■ Standard or customised reporting configuration and KPIs ■ Auto-generation and scheduling of reports ■ Simple data export into standard formats ■ All information easily accessible from any location ■ Little impact on data storage and system speed ■ Extendable to load shedding

This flexible FLSmidth application specifically helps the cement and minerals industries improve energy performance and reduce

environmental impact.

Improve energy performance

All users have different requirements when visualising and analysing data. With this in mind, ECS/EnerSentry – Energy Monitoring is expertly designed to monitor and extract all relevant data, then present it in a way that is tailored to each user’s needs.

The entire application is designed and engineered with reference to ISO 50001 standards and International Electrotechnical Commission guidelines.

On demand user viewThe home page is central to navigating between live human-machine interface (HMI) pages that provide any user with an overview of plant energy consumption. Each user can easily configure the information required for their daily monitoring and analysis, including:

■ plant energy performance overview (live KPIs from different reporting periods such as shifts, days, the previous month, or month to date)

■ substation single line diagram ■ process section overview ■ HMI trends for the previous 24-hours or 30-days.

Users can track and monitor the energy performance of the different process sections by reporting specific power consumption and breakups.

Reports, energy performance indicators and trend dataStandard and customised reporting is available to cover the needs of all users, ensuring each area of the plant works at optimal efficiency.

Standard reports included with initial setup are: ■ daily power report (breakups) with kWh, tonnes, run hour,

and specific power-consumption values ■ power factor, power quality and maximum demand reports

for each hour, shift and week, as well as month to date.

All required reports can be produced with just one touch and can be generated in a range of standard formats, including Excel, Word and PDF. Automatic reports can be scheduled for defined times, from every 10 seconds to every minute, hour, shift, day, week or month. They can be sent to a pre-defined common path in the server, where any user who is connected to the plant network can access them.

All reporting tools are accessible through the same portal. For more advanced reporting facilities, a separate ECS/Plant Data Management product is available as an add-on to ECS/ControlCenter™. This can also provide a longer log horizon stored on an external device if necessary.

Inbuilt calculator solversThe system provides energy performance KPIs such as specific power consumption, energy losses, load factors, efficiency, run factors, energy targets and more. Users can set and track the energy KPIs in every aspect of energy conservation measures, such as power, demand and consumption targets, for that day and for the previous day, week, month or month to date.

Trend anything, anytimeAll data is logged automatically and continuously. It can be presented in any combination of trend curves and reports, with data broken down into intervals of only minutes or up to 30 days. Standard installation includes a daily overview of energy, specific power consumption, demand, power factor, and voltage quality trends for the past 30 days. Or summaries can be customised as required.

Data export in several formatsTo simplify data export and support further analysis, the data behind any combination of trend curves can easily be exported in various standard formats.

Alarms and eventsUsers can set dedicated alarms for trouble shooting and proactive energy conservation measures. High and low values can be defined for issues such as maximum demand, power factor, power quality and power disturbance. The Event Historian feature helps analyse various alarms and identify the root cause of problems.

Open solutionThe system is capable of collecting and sharing data seamlessly with any external automation system via OPC software interface.

Energy monitoring system - Home page Electrical distribution diagram - Live monitoring Quick data access via graphical faceplates Energy distribution and per-unit consumption - Live chart

Expertly designed features

System architectureECS/EnerSentry – Energy Monitoring includes all necessary modules to gather, treat and store energy data, as well as to provide alerts, reports, and trends that enable users to visualise the information.

Hardware flexibilityAs a hardware independent solution supplier, FLSmidth has focused on enabling the ECS/EnerSentry – Energy Monitoring platform to communicate with various energy devices, including energy meters and smart relays, through built-in high-performance input/output (I/O) drivers.

I/O communication driversThe high-performance drivers allow for concurrent communication and provide support for redundant nets and CPUs. I/O drivers are ABB, Siemens, Rockwell/Allen-Bradley and Schneider/Modicon. There is strong interoperability due to the OPC-DA server and client platform.

OpStationThe OpStation’s draw-and-configure mimic designer programming allows for live and user-friendly HMI pages to be available to any user at all times. The OpStation also includes standard libraries of energy monitoring symbols, algorithm-based dynamics and structured object-oriented faceplates, which make troubleshooting easy.

Alarms and eventsThe system includes automatic hierarchical alarm suppression, configurable alarm philosophy and full alarm annotation support.

Data loggingECS/EnerSentry – Energy Monitoring can manage continuous logging of all analog process values and of digital status (for example, run/stop, alarm/normal). The time horizons for data logging are easily configurable. Spot data logging has a resolution of up to one second, and communication with the database to store and retrieve logs is rapid thanks to the swinging-door algorithm and SQL database storage.

Trend configurationThe trend configuration is compatible with analog and digital values, and horizontal and vertical zoom. Data export is hassle-free with what you see is what you get (WYSIWYG) programming, ensuring that exports and print-outs depict exactly what is on screen. The user-friendly system has a configurable colour scheme to suit individual or plant needs and makes time horizon selection and on-demand trending of any object easy.

Report configurationThe reporting configuration includes built-in standard reports with variable time horizon selection, including shift-based time horizon selection. The detailed statistical value reporting includes automatic report value suppression to protect sensitive data.

SecurityFLSmidth is vigilant about system security to protect data, users and operations. ECS/EnerSentry – Energy Monitoring provides full redundancy support with built-in user access control, secure on-the-fly user login, and user action/event logging.

Software foundationThe software is built with dual server redundancy for continuous reliability, while the client/server architecture ensures fast operation. Updates and extensions can easily be managed thanks to the click-once client deployment and the hierarchical and object orientated programming.

Operational components ■ Operator station ■ Reports configurator and viewer ■ Calculator engine ■ Trends ■ Alarms/events ■ Workplace ■ ECS V8 server (plant control system server or

stand-alone server) ■ Data acquisition system – FLSmidth ECS/ControlCenter

(native I/O drivers) ■ Programmable logic controller (PLC) ■ Data highways ■ External automation systems ■ Energy meters ■ Relays

Advanced automation technology

ECS/EnerSentry - Energy Monitoring provided essential support to the energy management, reporting and auditing process at a South Asian cement plant. The plant is operated as a joint venture between a local infrastructure organisation and a leading international diversified building materials group.

Engineering and commissioning time: 10 daysTime of commissioning: Second quarter 2017

Quick configurationECS/EnerSentry – Energy Monitoring setup and configuration is quick and easy. Users can gather data from all energy devices and benefit from enhanced energy management in a matter of days, with minimal investment and payback time.

The standard solution package bundles all required components, including predefined mimics, standard report templates, and HMI trends, among others. Other predefined components include the different reporting energy parameters across the plant process sections, such as power, tonnes, specific power consumption, power factor and demand at various periods. All that is required of the user is to map the respective tags for each piece of equipment and application.

Ongoing remote supportThe ECS/EnerSentry – Energy Monitoring system is delivered with Go2FLS, the FLSmidth solution for remote support and engineering. If there is a need, FLSmidth engineers will connect remotely to the system to implement any necessary configurations for rapid resolution. The only requirement is an internet connection to the system.

Customer support servicesFLSmidth offers a wide range of services to help integrate ECS/EnerSentry – Energy Monitoring into any plant. A tailored package can be provided with the best possible combination of initial and ongoing training and support to ensure the highest return on service – that means maximum satisfaction from performance, utilisation and productivity.

PlantLine™ service agreementA service agreement is a prudent investment that gives top priority to emergency assistance. FLSmidth can provide on- and off-site support through service visits, telephone and remote connection. The result is reduced callout cost, reduced system downtime and optimal plant performance.

The customer originally investigated a legacy standalone energy monitoring system, which included high-end hardware, complicated architecture and a cumbersome software and reporting system – a proposal that ultimately missed the synergy between existing control system infrastructure and process knowledge. Instead, plant managers chose ECS/EnerSentry - Energy Monitoring with an upfront saving of 60% on total investment plus better value for ongoing operations and maintenance. In only a short time, the plant reported an improved understanding of energy status, gaps and potential savings, as well as enhanced insight for quick problem-solving and troubleshooting.

Competitor proposal:

■ Standalone dual server ■ 2 x industrial computers requiring relevant

accessories and licenses ■ 50 x high-end energy meters mounted in electrical panels ■ 5 x data highways for interfacing energy meters

with the industrial computers ■ Separate analog modules to communicate energy

meter data to the existing plant control system ■ 15-minute datalogging intervals

ECS/EnerSentry - Energy Monitoring:

■ Simple add-on application for the existing plant control system – ECS/ControlCenter™ V8 process control system

■ 1 x workstation-grade PC ■ 50 x basic energy meters ■ 1-second datalogging intervals

Easy to set up, configure and use

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Copyright © 2017 FLSmidth. ALL RIGHTS RESERVED. FLSmidth, ECS/EnerSentry™”, ECS™, ECS/ControlCenter™ and PlantLine™ are trademarks of FLSmidth. 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. C

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