Management Information System

ECS/ PlantGuide

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Boost performance with accurate data ECS/PlantGuide from FLSmidth

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The only management information system designed specifically for the cement and minerals industry to convert plant data into value adding management information

Managers and engineers in cement and minerals plants have long been using process and quality control systems to access data and analyse plant performance. But every manager in a modern cement or minerals plant – whether a plant manager, production manager, electrical manager or maintenance manager – needs very specific information to ensure their area of the plant works at optimal efficiency. The range of data required varies immensely. It may be weekly product quality reports, data on energy consumption after the addition of certain materials, statistics on crucial

equipment failures or plant-wide emissions reports. And for managers and engineers to be able to make accurate decisions, they need to access both real-time data and historical reports covering six months or more.

Better and faster data collection with ECS/PlantGuide ECS/PlantGuide is an advanced information management system designed to make accessing and analysing production information in cement and minerals plants fast and efficient. A scalable solution, it allows managers and engineers to analyse

both historical and real-time process information, and generate reports in standard and custom formats. ECS/PlantGuide provides extremely accurate data to each manager or engineer in the format they need – so they can make better informed decisions.

What is ECS/PlantGuide? ECS/PlantGuide is part of the ECS (Expert Control and Supervision) suite from FLSmidth, a suite of products focused on the operation and optimisation of processes in cement and minerals plants. ECS/PlantGuide gathers data from

plant control systems and allows plant personnel to view the data they need in the form they require. Operating from a central database, ECS/PlantGuide makes critical plant data available to the people who need it, such as plant managers, production managers, electrical managers and maintenance engineers.

The benefits of using ECS/PlantGuide

The data can be customised to suit the exact needs of each user – and the entire system can be tailored to give each plant specific features such as customised reports and automatic scheduled reports.

• Move data efficiently from the plant floor to the control room for better data analysis and reporting

• Avoid human errors and time waste through automatic, immediate and accurate data collection from all levels and units of the production line • Enable asset management through centralised and safe data storage for historical analysis and documentation of crucial information

• Provide plant managers, operators and engineers with the specific information they need, regardless of their location.

Why choose ESC/PlantGuide? • Save time by accessing all plant data from one place • Ensure all essential information is in the right place • Improve plant performance and monitor KPIs • Improve product quality • Lower operating and energy costs • Increase plant productivity • Reduce unscheduled downtime

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One touch and automatic reporting Avoiding human errors and time waste by automatic, immediate and accurate data collection from all levels and units of the production line.

With ECS/PlantGuide, plant managers and engineers can produce all the standard reports they need with just one touch. Reports can be generated in standard formats, such as Microsoft Office Excel, and the reports can be customised to suit the needs of each plant. The system even allows for automate reports that are produced automatically at a set time. Reports include:

Historical reports Historical reports can be viewed as graphical charts or through simple process mimics – and they enable managers and engineers to view historical data from most plant processes. Any number of data points can be retrieved from the ECS/PlantGuide database to show all the details related to that data point (spot and statistical values).

Alarm analysis

Data accuracy and availability Unlike other information management systems, ECS/PlantGuide collects data concurrently from both servers using a dual system. It constantly analyses the data on both servers and chooses the most accurate. If one server fails, ECS/PlantGuide will automatically get data from the other server. And if ECS/PlantGuide goes offline, even for an extended period, the built-in ‘catch-up’ ensures no data is lost.

Best practice and KPI analysis ECS/PlantGuide enables users to set and track KPIs in every aspect of the production process, such as energy and fuel consumption targets, for the past day, week, month or year. This makes it simpler to identify and transfer best practices among production lines. And because users can also track performance in real-time, it’s possible to continually adjust production performance to improve plant efficiency and product quality.

Data export in any format Fully integrated with administrative software and applications, ECS/PlantGuide includes a variety of standard data export options. Users can export any type of raw data, as well as pre-treated data, to any location in the network. Data can be exported in all standard formats, including SQL, XML and CSV – and it can also be integrated into other ERP systems, such as SAP.

Emission analysis with ECS/StackGuide As regulation in the cement and minerals industries increases, producers are required to document that their operations meet emission requirements. ECS/StackGuide is designed to make this easier. ECS/StackGuide is an advanced emission analysis system that integrates fully into ECS/PlantGuide and is configured to support standard cement and minerals regulatory requirements. It enables cement and minerals producers to quickly and effectively create emission reports in industry-standard formats.

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Process alarms warn an operator when a process begins to reach a critical level. However, a lack of data often means that alarms go off to early – and operators then have to decide which alarms are critical and which are non-critical. ECS/PlantGuide analyses all the process values for limit violations and draws statistical conclusions for the process department. Armed with this overview, operators can make adjustments to the PLC program and control system to reduce the number of non-critical process alarms – and gain a better overview of plant processes.

With continual production line surveillance, ECS/PlantGuide enables manager and engineers to identify the main causes of process downtime. ECS/PlantGuide automatically collects data on each downtime incident and enables the operator to classify each episode. The operator can then analyse the causes, frequency and duration of downtime – and use the information to adjust processes, replace equipment before it fails and reduce future stoppages.

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• Daily Production Reports • Monthly Production and Quality Reports • Emissions Reports • Plant Power Consumption Reports • Down Time Analyses

Downtime analysis

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ECS/PlantGuide Web Access all information anywhere in the plant ECS/PlantGuide Web enables plant managers and engineers to view information from ECS/PlantGuide in a standard web browser on any PC in the plant’s office network. An integrated add-on to the ECS/PlantGuide system, users get access to all the plant and production information they need, without the need to install any additional software on office PCs. ECS/PlantGuide Web gives plant managers and engineers access to both real-time and historical plant data in the ECS/PlantGuide database anywhere in the plant.

ECS/PlantGuide Enterprise All information is delivered across a secure network, and operators and engineers can view the data using a standard web browser, such as Internet Explorer. • Access historical and real-time reports from any computer in the plant’s office network • Analyse  trend graphs in real-time • View real-time process graphics • P re-define user access so each engineer or manager has access to the information they need

Better collaboration and improved productivity ECS/PlantGuide Web gives people anywhere in the plant access to real-time data – and the information can be tailored to ensure that each person gets the data they need, when they need it. This improves collaboration across the organisation, and enables maintenance staff to complete fixes, upgrades and other tasks from any configured PC on the plant’s computer network.

Enterprise-wide visibility in one online environment Any cement or minerals plant creates a huge amount of critical data which can be used to improve processes and production efficiency. But this information is often only available to people working in the plant itself. Using a secure network, ECS/PlantGuide Enterprise makes that information available to managers and engineers, regardless of their location. Ideal for companies with multiple plants, ECS/PlantGuide Enterprise can be integrated into the ECS/PlantGuide system to give Technical Centre staff enterprise-wide operational visibility.

Managers and engineers see data from multiple plants in one online environment, eliminating the need to manually transfer information. ECS/PlantGuide Enterprise provides accurate production, quality and environmental data in real-time – so a company can benchmark the performance of all its plants and optimise performance across the board, all from one place.

How does it work? ECS/PlantGuide Enterprise gathers data from multiple plants using a secure internet connection or a virtual private network (VPN) The data is transferred to the Technical Centre, where managers and engineers can access data and reports in standard formats, including real-time process graphics, historical reports and alarm analyses Users can generate enterprise-wide or single plant reports with just one click ECS/PlantGuide can be integrated with environmental systems to produce combined enterprise-wide environmental reports quickly and easily.

What can managers do with ECS/PlantGuide Enterprise? • Benchmark between business units • Get an overview of stock and resources • Improve environmental compliance • Monitor corporate KPIs • Improve bottom-line performance with enterprise-wide procedures

What can technical experts do with ECS/PlantGuide Enterprise? • Remove plant bottlenecks • Utilise best operation practices • Data mine process departments • Improve specific power and energy consumption • Improve overall equipment efficiency • Reduce stoppages

Project Centre Denmark FLSmidth A/S Vigerslev Allé 77 DK-2500 Valby Copenhagen Tel: +45 3618 1000 Fax: +45 3630 1820 E-mail: [email protected]

Project Centre USA FLSmidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6010 Fax: +1 610-264-6170 E-mail: [email protected]

Project Centre India FLSmidth Private Limited FLSmidth House 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai, Chennai) Tamil Nadu – 603 103 Tel: +91-44-4748 1000 Fax: +91-44-2747 0301 E-mail: [email protected]

www.flsmidth.com /ecs

CM 05-11 800-104-ENG V1

Our 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 any time. Please contact us for specific information or data that may relate to your interest.