KREBS SMARTCYCLONE™
Krebs SmartCyclone™
System Architecture
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Smart Cyclone Wear Sensors
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Roping Monitor
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Smart Cyclone Node
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Smart Cyclone Contoller
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HMI Computer
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Krebs SmartCyclone™
System Architecture Introduction The KREBS® SmartCyclone™ System introduces electronic sensing and communications to Krebs cyclone separator products. By doing so, it allows the cyclones to actively participate in plant control systems, plant alarm control systems, and in proactive maintenance planning. With a SmartCyclone‐equipped plant, the cyclone sensors can report the functional state of the cyclone by sensing the viscosity/velocity of the slurry flow from each cyclone individually. The sensors can report the status of the pipe and cyclone wear liners, so that liner purchasing and relining operations can be planned with greater control and more in advance. Finally, the sensors can report when a cyclone, or the SmartCyclone system itself, is malfunctioning. Because multiple sensors can be mounted on each cyclone, the individual performance characteristics of each unit can be monitored and adjusted as necessary in real‐time. The SmartCyclone consists of hardware sensing and control units, and an optional control room PC running SmartCyclone software. The unit status, as well as the health of the components and communications, is visible on an LCD display at each cyclone. The SmartCyclone software allows this data to be logged, analyzed, displayed in real‐time in the control room, or anywhere else on the local area network, or worldwide through a VPN. Those signals can be retransmitted to plant DCS, expert systems, or other outside servers. The SmartCyclone control room software is, at its core, OPC/DA 2.0 compliant. It is able, therefore, to participate in industry‐standard control networks, and to communicate with other OPC compliant systems in the exchange of data and status information.
Cyclone Sensing Hardware The SmartCyclone hardware layout is manifold‐centric. Each sensor on a cyclone feeds into a Node unit for that cyclone; each cyclone Node feeds its data to a Controller. The plant’s collection of controllers then interfaces with the dedicated control room PC. Cyclone sensors fall into two categories. Flow sensors monitor the dynamic operating levels of the unit’s underflow and overflow for changes in which might indicate a roping, or potential roping condition, as well as a plugged cyclone. Depending on slurry and other variables, flow sensors can possibly also be mounted on outlet pipes for the manifold, in order to detect large particles exiting to the flotation cells. Wear sensors are typically embedded in the liners of the cyclone’s highest wear areas, and report the slow abrasion of the liner material during operation. The sensor electronics also monitor and report the actual operating hours for a
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System Architecture
cyclone – a non‐essential, but useful bonus. Such wear sensors can also be mounted into the manifold’s outlet pipes if they need to be monitored for wear. Sensors are connected via waterproof cable to their cyclone’s node control box. These boxes are connected, via RS‐485 serial cable, to the manifold controller, where the signal data is accumulated and transmitted, at regular intervals, to the control room PC.
SmartCyclone HMI PC The SmartCyclone HMI computer is the gateway between the hardware and plant operations. It has two network interfaces, one for the dedicated SmartCyclone network, and one for the plant’s network. It is also possible to run the PC independently of any plant network. The software components which can be installed on the PC will allow it to perform all the necessary functions for display, analysis, and alarm management, as well as data reporting and historian functions.
Input Processing from Hardware Input processing occurs using OPC server’s input system using “unsolicited” transmissions from each manifold controller. Each controller must therefore have its own Ethernet (IP) address and communicate via the same dedicated Ethernet network to the control room PC. Data is retrieved from the sensors and hardware components, and accumulated in each manifold controller until a set interval, then the controller sends a block of data to the PC. There, a Windows service intercepts the block, and “unpacks” it into the OPC tags available to all other internal and external users.
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System Architecture
Internal Data Processing Data points stored in OPC tags can be logged to a SQL database for future analysis. Which data points are logged, and how often, are configurable parameters. A Data Historian and Analysis Console is available for the review of past cyclone performance. With it, data can be compared visually in a large number of different Two‐Dimensional and Three‐Dimensional charts and graphs. Data can also be viewed in its raw format, and copied for export to other programs. Data can be retrieved for one or many sensors, cyclones, hardware units, or manifolds. The time period can be selected, from a few minutes to as long as the system has been in operation, provided there is adequate hard drive space for the data. An Alarm Manager is also available if customized and detailed alarm control is desired from the SmartCyclone HMI computer. A “basic” alarm mode is the default: In the Visual Display Client, the various sensors change colors from green, to yellow, to red, depending on the conditions, and the levels selected during system configuration. Advanced alarm management, comparable to most commercially available products, is an optional feature which can be enabled. Once active, alarm conditions can be set with delays, escalations, or even sequences of conditions. The responses can vary from simple messages to external (email, pager, etc) communications.
Real‐Time Data Display The SmartCyclone Visual Display Client is the primary method of viewing performance and system status information on a real‐time basis. This program can be viewed from the SmartCyclone HMI computer, or from any other Windows PC on the plant’s network which can access the OPC data on the SmartCyclone computer. The Client displays plant‐wide status views with color codes for overall manifold status; a manifold can be selected for individual viewing with a mouse click from this view. Manifold views show individual sensor readings on each cyclone, with colors indicating status and performance. In addition, individual cyclones can be selected, using mouse clicks, to display detailed status information for those readings which are not normally displayed on the manifold view. A rolling graph is displayed, showing manifold flow trends for up to 24 previous hours.
Output to External Systems The SmartCyclone OPC Communication Service can be enabled to output OPC tag values to, for example, a CHIP or PI system, or another OPC capable server. The tags can be individually selected for output, and the names of the tags on the target system can be specified for each tag. Alternately, an external OPC server capable of soliciting communications using OPC/DA can request the tag data from the SmartCyclone HMI computer directly. OPC “Tunneling” programs, such as Matrikon, PI Tunneler, or OPC Mirror (Emerson), have been used to establish secure links to the SmartCyclone computer in order to retrieve data.
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System Architecture
Visual Client Display This and all SmartCyclone information and documentation is Copyright © by FlSmidth Krebs; all rights, including re‐distribution in any form, are expressly reserved. The information contained in this document is proprietary, and may be confidential. The hardware and software systems, protocols, operating, sensing and communications methods used by the system are subject to international patents and trademarks.
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Krebs SmartCyclone™
SMART CYCLONE WEAR SENSORS Sensor Specifications Wear Sensors monitor liner inserts at various locations within the cyclone to provide an accurate measure of the amount of wear and the remaining liner thickness. Wear sensors allow efficient proactive scheduling of maintenance based on quantitative data obtained while the cyclone remains in service. The ability to schedule cyclone maintenance based on actual measured wear data facilitates optimal use of liner capacity and manpower. Wear Sensors are available in a variety of sizes and configurations to meet specific facility requirements to monitor apexes and other wear parts higher up the cyclone. The patented FLSmidth Krebs technology is based on specialized very‐thin printed circuit boards (PCBs) that fit in a flange between two cyclone inserts. The PCB wears away at the same rate as the cyclone inserts, cutting into an array of PCB traces in the process. Electronic readout of the array of PCB traces provides digital determination of current size and wear.
Environmental Waterproof to IP 68. Operating Temperature: ‐20° to +80°C.
Power 12VDC, 20 mA maximum. Power supplied from the Node via a combined power & data cable. Battery‐operated wear sensors that communicate with the Node via ZigBee wireless (802.15.4) will be available in the second half of 2008. Page 5
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Krebs SmartCyclone™
ROPING MONITOR Sensor Specifications The SMC Roping Monitor detects cyclone flow status to provide continuous early warning of sub‐optimal and potentially dangerous flow conditions, such as roping and plugging. Real‐time monitoring of these data (by human operators and/or computerized expert systems) allows flow corrections to be made quickly to maintain separation efficiency and prevent cyclone plugging and costly associated downtime. The roping sensor itself is an ultrasonic detector mounted to the exterior of the splash skirt housing, underneath the apex of each cyclone. During normal cyclone operation underflow hits the splash skirt and generates a diagnostic ultrasonic‐frequency vibration. As the underflow approaches roping it hits progressively lower on the splash skirt and eventually misses the splash skirt altogether. The corresponding changes in ultrasonic signal strength are processed and interpreted by each Node, which outputs data every second proportional to the ultrasonic signal strength, plus a non‐linear Roping Index (RPI) designed to aid recognition and alarming of incipient roping and roping conditions. Specific ultrasonic frequencies must be used to isolate the desired flow noise from other strong vibrations. FLSmidth Krebs Engineers holds a patent on the use of an ultrasonic sensor to measure the onset of hydrocyclone roping conditions ref US 6,983,850 B2. An alternate Roping Monitor location is on the cyclone overflow piping. This alternate location is less sensitive and requires a considerable amount of very large particles in the overflow for roping detection.
Physical and Environmental Sealed stainless‐steel housing, 2.7” long, 1.8” diameter. Weight = 1.0 lb. Waterproof to IP 68 (intermittent immersion). Operating Temperature: ‐20° to +80°C.
Power 24VDC, 20 mA maximum. Power supplied from the Node via a combined power & data cable.
Scaling and Calibration The absolute intensity of the ultrasonic signal for optimal underflow can vary significantly from one installation to another based on parameters such as cyclone size and configuration. At any one installation the ultrasonic signal for normal flow can vary over time with changes in flow rate, feed stock, etc. For these reasons each Node includes configuration functions to optimize the scaling of the ultrasonic signal. Both manual and automatic scaling options are available from the front panel of each Node. In addition, a single command at the Controller can be used to initiate simultaneous automatic scaling of all Nodes and sensors on that manifold. Page 6
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Krebs SmartCyclone™
SMART CYCLONE NODE Hardware Specification Every cyclone in the SMC system is assigned a dedicated Node to collect and process data from the sensors installed on that cyclone. Every 5 seconds each Node communicates its data to the Controller on its data Bus. Depending on the type of sensor, Nodes provide power, data acquisition, data processing, and configuration/optimization. Sensor‐to‐Node communication can be either cabled or wireless, with up to 6 sensors (of various types) per Node.
Physical Gray ABS molded box, UL94‐HB flammability rating, factory sealed. Dimensions with steel mounting plate: 9.0” tall, 4.8” wide, 2.6” deep. Two mounting holes for ¼” (6mm) bolts, top and bottom on vertical centerline, 8.0” hole spacing. Weight = 1.5 lbs.
Environmental NEMA 4X / IP 65. Operating Temperature: ‐20° to +60°C. Storage Temperature: ‐40° to +80°C
Input Power 24VDC isolated power supplied through Bus cable, 0.2 Amp maximum.
Bus Communications Proprietary Krebs data protocol running on an RS‐485 multidrop network with 15KV ESD and transient protection. Shielded DeviceNet cables connect the Controller with up to 16 Nodes on a manifold, one Node per cyclone. The Bus uses daisy‐chain geometry to minimize cable runs around the manifold.
Controls Three tactile dome switches on the front overlay provide entry and navigation for Node configuration mode. This mode allows the setting of Node address (1‐16) as well as customization and optimization of all sensors connected to that Node. The Node remains attached to the Bus throughout configuration, and does not interfere with normal operation of other Nodes.
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Smart Cyclone Node
Data Display A backlit LCD on the face of each Node provides a continuous display of the status and output of all sensors connected to that Node. This LCD also displays configuration menus when the Node is in configuration mode.
Firmware Proprietary FLS Krebs firmware can be field‐upgraded using built‐in bootload capability.
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Krebs SmartCyclone™
Smart Cyclone Controller Hardware Specification The Smart Cyclone™ Controller powers and controls the digital communications Bus for all SMC sensors and components on a manifold. Every 5 seconds the Controller collects and compiles sensor data from the Node assigned to each cyclone, and communicates that data via Ethernet to the SMC Computer located in the control room.
Physical Gray powder‐coated steel enclosure with hinged door and latch. Overall dimensions: 11.5” tall, 8.2” wide, 4.9” deep. Four mounting holes for ¼” (6mm) bolts, arranged in rectangular pattern: 10.75” vertical spacing, 6.0” horizontal spacing. Weight = 9 lbs
Environmental NEMA 4X / IP 66. Operating Temperature: ‐20° to +60°C. Storage Temperature: ‐40° to +80°C
Input Power Required from Mains 100‐240 VAC, 50/60 Hz, single phase, 1.7 Amp maximum. Input protection via internal fuse. AC power (hot, neutral, and earth ground) is hardwired to the Controller at installation, through a waterproof ¾”conduit hub on the enclosure bottom.
Output Power to Bus Electrically isolated and regulated 24.0VDC power, 3.3 Amp. Built‐in overload protection, thermal shutdown protection, and short‐circuit protection.
Bus Communications Proprietary Krebs data protocol running on an RS‐485 multidrop network with 15KV ESD and transient protection. Shielded DeviceNet cables with IP 67 MIN quick disconnect connectors connect the Controller with up to 16 Nodes on a manifold, one Node per cyclone. The Bus uses daisy‐chain geometry to minimize cable runs around the manifold.
Network Communications (to control room) The Controller (on the plant floor) communicates with the SMC Computer (in the control room) via wired Ethernet. Standard Cat5e cable enters the Controller through a waterproof ¾” conduit hub on the enclosure bottom, and plugs into an RJ45 jack. Wireless Ethernet (802.11.b/g) is optional.
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Smart Cyclone Controller
Controls Inside the Controller enclosure there are two controls: 1. A Bus power toggle switch allows powering down the entire 24VDC Bus for maintenance, without disconnecting AC power. 2. A Roping Calibration push‐button initiates simultaneous automatic scaling of all Roping Sensors on all Nodes
Data Display A backlit LCD on the Controller face provides a continuous display of all the Nodes currently connected and communicating on the Bus.
Firmware Proprietary FLS Krebs firmware can be field‐upgraded using built‐in bootload capability.
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Krebs SmartCyclone™
HMI Computer Overview Document The KREBS® SmartCyclone™ computer provides the only point of contact between the SmartCyclone hardware on the plant floor, and the operators, engineers, and plant control systems. The computer used for this purpose must be dedicated to only SmartCyclone processing, and can serve no other purposes. The console of the computer can be used to view the system’s function and status using the Visual Display Client and the optional Alarm Manager, and to perform basic troubleshooting and control functions of the SmartCyclone system. The HMI computer can also communicate with other computers on the plant network, either to run SmartCyclone applications such as the Visual Display Client, or System Historian and Analysis Console, or to communicate status and performance data to other servers, such as expert systems and DCS. If these functions are desired, the HMI computer must be connected to the plant’s network. Such functions are, of course, entirely optional, as the HMI computer can function as the sole and only display and control unit for the Krebs SmartCyclone system.
Computer Brand and Physical Size • • • •
No specific brand or manufacturer of computer is required or recommended The computer can be rack‐mounted or free‐standing The computer should be equipped with enough fans to provide highly efficient cooling for all components As the system will be functioning at all times, a reliable system is required, and a system with redundant or backup components is preferred.
Power Supply • • •
A 450 watt system power supply is the minimum recommended for this system Redundant power supplies are preferred The system should be supplied only with electrically filtered pure sine wave power at the voltage and frequency specified by the computer’s manufacturer
Processor •
Dual or Quad Core processors are preferred if the HMI computer is receiving data from 6 or more controllers, or if the machine will be used for System Historian functions. A single core processor is acceptable for smaller installations, or if the machine will only pass data through to other plant
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HMI Computer
systems. The Smart Cyclone software will operate transparently across multiple processors, if present in the computer Sixty‐four (64) bit only processors are NOT supported. 64 bit processors with 32‐bit operating modes ARE supported. This is a system limitation for the OPC services, and not a SmartCyclone software limitation. It is possible that this requirement may be removed in a later version
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Examples of processors not recommended • • • •
Intel Celeron processors are not recommended Intel “M” series Mobile processors are not recommended AMD Sempron processors are not recommended AMD Turion series Mobile processors are not recommended
Memory and Disk Storage • • • • •
1 GB RAM minimum, 2GB preferred 250 GB hard drive minimum Redundant or RAID hard drives are preferred (SCSI is not necessary) DVD or CD ROM drive 512MB USB Flash Drive (constantly attached to the computer)
Network •
2 network interface cards (gigabit)
Operating System Software •
Microsoft Windows XP Professional 32 bit, Service Pack 2 or later
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