ECS CEMulator Manual v7.0.5
ECS CEMulator Manual v7.0.5
ECS CEMulator Manual v7.0.5
CEMulator Configuration
FLSmidth A/S - Automation
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Printing History:
Version CPSV7
Last modified $Modtime:: 9/16/05 8:47a $
Author Torsten Vagn Jensen
Last modified by $Author:: Tvj $
Name of Word File $Workfile:: CpsConfigUi30_English.doc $
Disclaimer:
The information in this document is subject to change without notice and should not be construed as a commitment
by FLSmidth A/S. FLSmidth assumes no responsibility for any errors that may appear in this document.
In no event shall FLSmidth be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall FLSmidth be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.
Options specified and described in the FLSmidth documentation as part of the general description - but initially
neither ordered by the customer nor confirmed by the seller - will not commit the supplier to any further and future
supply and/or installation.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
Glossary of Terms 11
Index 13
Introduction
The configuration tool is used for editing the basic set up of the CEMulator.
This document describes in detail the 10 available configuration tags.
Before changing the settings it will be good to make a backup selecting all CPS checkmarks.
Starting up
When starting the CEMulator Configuration Tool a password box will appear.
Model Names
Changing the model names will affect all user interfaces using the model names. Select a model name in the combo
list and type in the new text and click Apply.
Message Sound
Change the Message Sound used to announce messages in the CPS Instructor and CPS Trainee user interfaces.
Unit Conversion
*** Licensed Utility ***
This utility can convert the units in all process models to fit the local needs. By converting the units, output to the
ECS/Opstation will be converted from predefined engineering units. Definitions in the CPS Instructor menus,
Evaluation and Input Parameters, will also be converted. Whenever the databases are converted the point
configurations are rounded, so avoid converting the same model over and over again. Use instead the
original backup and convert from this.
To alter the conversion definitions and types open the file ‘%FlsaDev%\CpsHome\ConfigDb\CpsUnitConvert.mdb’.
2. Select the Initial Situation that should be deleted and click Delete.
License Info
This tab gives a resume of the CEMulator relevant licenses.
Printing History:
Version CPSV7
Last modified $Modtime:: 9/16/05 10:53a $
Author Torsten Vagn Jensen
Last modified by $Author:: Tvj $
Name of Word File $Workfile:: CpsRunInstUI30_English.doc $
Disclaimer:
The information in this document is subject to change without notice and should not be construed as a commitment
by FLSmidth A/S. FLSmidth assumes no responsibility for any errors that may appear in this document.
In no event shall FLSmidth be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall FLSmidth be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.
Options specified and described in the FLSmidth documentation as part of the general description - but initially
neither ordered by the customer nor confirmed by the seller - will not commit the supplier to any further and future
supply and/or installation.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
CEMulator Specifics 15
The instructors point of view .............................................................................................. 15
Evaluation ............................................................................................................ 15
Disturbances ......................................................................................................... 19
Input Parameters................................................................................................... 34
The trainee point of view .................................................................................................... 43
Evaluation ............................................................................................................ 43
Trouble shooting 45
Reload of PLC Module ....................................................................................................... 45
Upgrading the CEMulator software..................................................................................... 46
Glossary of Terms 71
Index 73
Introduction
The CEMulator or CPS (Cement Process Simulation) Software is designed for simulation of the production process
of cement. The package is primarily intended for operator training, but can also be used to test what if scenarios or
test new control strategies.
The package consists of an Analogue simulation part and a Soft PLC (responsible for interlocking etc.).
The package consists of one or several models of part of a cement plant, such as the grinding process for raw
material, a kiln along with possible preheater system and a cooler...
It is important to note that there is no connection between the distinct models of the plant. Meaning that the result of
a simulation of raw material grinding will have no effect on a subsequent simulation of a kiln system.
The system runs one simulation at a time, and only the instructor can change which part of the process is being
simulated.
The computer hardware configuration of a CEMulator system consists of one PC per trainee. The instructor can have
a separate PC of it can be the same as one of the trainees.
The interface for the trainee is partly the ECS/Opstation and partly a separate CEMulator interface. This manual will
describe the functionality of the CEMulator interface. For a description of the functionality of the ECS/Opstation
refer to (ECSMANUAL). However a description of the evaluation through the ECS/Opstation will be given.
The interface for the instructor is mainly the CPS/Instructor interface. This has in addition to the functionalities of
the trainee interface functionality for controlling the current simulation session.
Here the basic functionalities (those present on both trainee and instructor interfaces) will be described and the more
detailed functionality of the instructor interface will be dealt with in a separate section.
It can occur during reboot that the Soft Plc encounter errors during load of the PLC Module. If this happens you can
reload the PLC Module to that slot by doing as described in the Trouble Shooting – Reload of PLC Module chapter.
A PLC slot is faulted if it looks as slot 1 in the Soft PLC below or if the ‘BAT’ and ‘OK’ indicator lamps are red.
In the two following sections a step through of the CEMulator interface will be given. The first one is seen from the
point of view of the instructor and the second one from the point of view of the trainee. The options in the interface
accessible to both will be described twice.
It is possible to change the password. After Clicking 'OK', the following interface will appear:
After a possible change of model the instructor should now select which saved situation the trainees has to start
from, or the Trainee can be allowed to select a situation. A list of training session types is available and the instructor
or trainee should now chose one.
The instructor can furthermore insert values in the following fields (active depending on session type):
Trainee – Name of the trainee (or default trainee name)
Instructor – Name of the instructor (or default instructor name)
Tutorial Description – Change the describing text for the tutorial
Passed Penalty – Max allowed penalty for passed statement in evaluation reports.
Observation Mode – When on the actions done while recording the tutorial will be activated.
There are two views available in the Main window; Training Session Info and Message Center.
The Training Session Info contains information’s on the running session. The instructor can modify the settings
during the session to fit the recorded tutorial or standard session.
Show Input Parameter dialog, a detailed description is found in the Input Parameter chapter.
Help functionality
When pressing Save the following dialog will appear
If the instructor select continue the simulation will proceed, if the instructor select save, the save session dialog will
appear. If Stop is selected the current simulation will stop and the CEMulator will reset it self to the initial state,
where the instructor can either change model or select a starting situation. The default selected starting situation will
always be the last situation saved.
Selecting the Pause bottom will simply halt the CEMulator at the current state, and the main window will how have
the following appearance:
Sending a message while paused will be recorded as a paused message action. This type of event can also be created
later on in the Tutorial Editor Tool.
All actions regarding disturbances, input parameters, evaluation and session speed will be recorded when recording
or editing tutorials.
From here it is possible the restart the simulation or save the situation.
This shows the current and the new possible values to change the speed to. Changes are effectuated by ‘Apply’.
This concludes the list of basic function available to the instructor from the CEMulator.
The two selections below will be available when starting the CEMualtor.
The trainees main CEMulator interface will start in a Ready situation, and the Trainee now can click to start
the simulation (unless the instructor have already started the simulation). The interface for selecting a saved situation
to start from has the following appearance. A list of training session types is available and the instructor or trainee
should now chose one.
There are two views available in the Main window; Training Session Info and Message Center.
The Training Session Info contains information’s on the running session.
In the message center the trainee can send messages and read received messages. Lab. Reports from sampled
measurements will also be send to the Message Center. Whenever a new message is available a notify sound will be
played.
Here the trainee can keep track of the total time since simulation was started (Simulated Time) and the status of the
simulation (Simulator Status) this should under ‘normal circumstances’ be ‘Running’. Also the time since the last
update came from the simulation can be seen (Time Since Last Update). The background colour of this will change
depending on how long its been since last update. There are three categories.
Green background The update time is low and no special measures have to be taken.
Yellow background Warning level the update time is a bit high, no further changes to set points should be
applied.
Help functionality
When pressing Save the following dialog will appear
Here the name and description of the saved situation is entered. The instructor and trainee names are taken from the
main window. After save is finished the simulation continues as before.
If the trainee presses Stop a warning will appear prompting the trainee to either continue with the present simulation,
save the present situation or really stop the simulation.
If the trainee select continue the simulation will proceed, if the trainee select save, the save session dialog will
appear. If Stop is selected the current simulation will stop and the CEMulator will reset it self to the initial state,
where the trainee can select a starting situation. The default selected starting situation will always be the last
situation saved.
Selecting the Pause bottom will simply halt the CEMulator at the current state, and the main window will how have
the following appearance:
This concludes the list of basic function available to the Trainee from the CEMulator.
The evaluation possibilities for the Trainee is described in the Evaluation Chapter.
Evaluation
Purpose
The Session Evaluation is a tool for:
Rate the performance of an Operator/Trainee
Accustom the Trainee to follow specific objectives when operating the plant.
Identify areas where more training is needed.
Overview
The Session Evaluation Functionality provides a quantitative measure of the performance of the operator. The
evaluation will depend on the initial conditions (the saved situation) of the simulation and on the number and nature
of the disturbances imposed by the Instructor.
The evaluation returns a Score or Total Penalty, which is a numeric figure that the Trainee should try to minimize.
The session is evaluated by continuously supervising a number of SDR/points, relating their values to predefined
objectives. For each objective a penalty figure will be calculated. The Total Penalty is calculated as a weighted sum
of the objective penalties.
Limitations
The evaluation score will depend heavily on the initial conditions of the simulation and on the imposed disturbances.
Thus, evaluation sessions can only be compared if run under identical conditions:
Same initial conditions (saved situation)
Same number, time and magnitude of the imposed disturbances (Tutorial)
The total penalty is a performance figure rather than a qualitative assessment of the performance. It is important that
the result is discussed in detail between the Instructor and the Trainee. To assist in this discussion, the instructor
could use information from the detailed penalty figures and from the trend curves/alarms lists from the ECS system.
Mathematical description
This section describes the terminology and structure of the session evaluation functionality. This includes the
mathematical algorithms used to calculate the penalties. Although understanding the mathematics is not necessary to
be able to use the session evaluation, it is recommended to read the short description of the calculation types in Table
1.
The idea behind the session evaluation is to see how the trainee performs with respect to a number of objectives. An
objective could be to minimize the heat consumption in the kiln, to keep free lime equal to 1.3%, etc.
Total Penalty
+ + +
Objective 2.2
Objective 2.1 Objective 2.m
Type of
calculation
Point in
Target Value
calculation
How to use it
When Clicking the Evaluation button in the Main CEMulator Interface the following window appears. This is
the summary of the Evaluation, and for display purposes only.
Here is shown an example of keeping the oxygen content in the Smoke Chamber blow a limit value or Target. For
this type of evaluation objective it is possible to change both the gain and the target value on the right hand side. For
each individual entry the objective is listed and the calculation method as listed in Table 1.
Disturbances
The disturbances’ functions make it possible for the instructor to expose the trainee to situations, which cannot be
created as real life training experiments. This is done as explained in detail below, by changing artificially the values
of some especially chosen parameters.
When clicking the button the main disturbance window will appear. The appearance of this window will be
different pending on which model is active in the simulation. First a description of the points that are always present
regardless of the model will be given, and then the specific disturbances for the individual models are described.
Controller Failure
The Controllers in model system can fail with an artificial offset in the measurement value. The offset can be either
positive or negative. The way to clear this disturbance is to put the controller back in normal operation.
The last general disturbance point will be motor failures. This point is only included if the simulation model includes
a Soft PLC. An example of this disturbance is shown below. Here the instructor can trigger a MCC Ready fault for
The rest of the disturbances will be different depending on which model is being simulated. These disturbances are
given in the following sections.
Evaluation
The Trainees way to look at the evaluation is through a ECS/Opstation picture. Here the trainee can see how he/she
is doing at the present moment and they can through the normal trend program see how well they have been doing
the in past. It is not possible for the trainee to change any of the weighting for the penalties neither for the groups nor
for the individual penalties. However it is possible to see the weighting, in order to get an overview of what the
instructor considers important and what is not as important in the present session.
The main evaluation picture is
2. A popup window will prompt it is desired to remove the module. Click on ‘Ok’.
Some times the Soft Plc fails in removing the PLC Module. In this case an error message will pop up advising to
reboot and remove again. If this happens ignore the reboot part and run through step 1 and 2 once more.
3. To reload the PLC module in the Soft PLC slot right click on the now empty slot and select ‘Create’.
5. Select ‘Use the Configuration…’ and Check ‘Load Saved Controller…’. Then click ‘Next >’.
6. In the next two windows the default settings shall be used, so just click ‘Next >’ and ‘Finish’ in those.
Appendix A: Start Up
Procedures
Session 1: Ignition
:o) Now is a good time to make the first save of the session progress.
Keep a surplus of O2 in the kiln inlet by adjusting the ID-Damper position. The surplus of O2 in the kiln should be
kept between 2% and 4%.
Continue heating of the pyro system while keeping an eye on the O2 level and the vacuum at kiln inlet.
:o) To skip some waiting time the simulation speed can now be set to 10 times real time using the CEMulator
interface.
When the cyclone 5 exit temp to reach 800 oC the pyro system will be ready for feed. Be careful to keep the cyclone
1 exit temp below 450 oC. If the cyclone 1 exit temp rises to above 450 oC an interlock will shut down the ID-Fan
and burner.
1. During heat up, start the following groups in the cooler department; 1,5,6 and 13 (2 starts needed).
:o) Now is also a good time to save your session, so that you won't have to redo this part of the simulation once
more, should the simulation time out. The session can be continued from your current state or the next session save
can be loaded.
:o) If you continue from your current state go back to real time simulation. To get back to real time simulation set
the simulation speed back to 1.
To ready the kiln system for feed it will be necessary to start the cooler department.
1. Select cooler group 7-11 and start all of the cooler fans.
:o) Wait for the update time to stay between 0 and 1 second before continuing with the next step.
:o) In normal kiln operation the Kiln Speed is not regulated until well formed clinker are formed in the burning zone.
But due to the nature of the simulated model the procedure differs sligthly on this point.
11. Increase the through-draugh by opening the damper in front of the Id-Fan to 100 % and increase the ID-Fan
speed. Hold the temperature after the cyclone preheater under 400 Deg C.
12. Regulate the through-draught and the oil supply so that there is 5-10 % more oil supplied than with normal
production of that level (~820-860 kCal/kg Clinker). Always increase the draught before increasing the oil
supply to avoid the formation of carbon monoxide (CO).
13. To keep a steady temperature at the top of the preheater tower change the water controller mode to
Automatic.
:o) To avoid having to redo all of the changes once more if the simulation should get instable, it is a good idea to
save the simulation session now. The session can be continued from your current state or the next session save can
be loaded.
The kiln start up is divided in four simulation sessions where operators can train in each of the four specific intervals
of a start up that each session represents. The operator can also train on all sessions continuous without having to
restore prefabricated FLSA sessions.
Session 1: Ignition
:o) Now is a good time to make the first save of the session progress.
Keep a surplus of O2 in the kiln inlet by adjusting the ID-Damper position. The surplus of O2 in the kiln should be
kept between 2% and 4%.
Continue heating of the pyro system while keeping an eye on the O2 level and the vacuum at kiln inlet.
:o) To skip some waiting time the simulation speed can now be set to 10 times real time using the CEMulator
interface.
:o) Now is also a good time to save your session, so that you won't have to redo this part of the simulation once
more, should the simulation time out. The session can be continued from your current state or the next session save
can be loaded.
:o) If you continue from your current state go back to real time simulation. To get back to real time simulation set
the simulation speed back to 1.
To ready the kiln system for feed it will be necessary to start the cooler department.
1. Select cooler group 7-11 and start all of the cooler fans.
:o) Wait for the update time to stay between 0 and 1 second before continuing with the next step.
:o) In normal kiln operation the Kiln Speed is not regulated until well formed clinker are formed in the burning zone.
But due to the nature of the simulated model the procedure differs sligthly on this point.
12. Increase the through-draugh by opening the damper in front of the Id-Fan to 100 % and increase the ID-Fan
speed. Hold the temperature after the cyclone preheater under 400 Deg C.
:o) To avoid having to redo all of the changes once more if the simulation should get instable, it is a good idea to
save the simulation session now. The session can be continued from your current state or the next session save can
be loaded.
1. To start the coal feed to the calciner a surplus of Oxygen at kiln inlet of 5% is needed, so adjust the Id-Fan
speed to achieve this.
The kiln start up is divided in four simulation sessions where operators can train in each of the four specific intervals
of a start up that each session represents. The operator can also train on all sessions continuous without having to
restore prefabricated FLSA sessions.
Session 1: Ignition
Keep a surplus of O2 in the kiln inlet by adjusting the ID-Damper position. The smoke gas analyses at the kiln inlet
should show a O2 content of 8-12% at the start of the heating up process. The Oxygen percentage under heating falls
to 3-4% just before the kiln feed is introduced.
Continue heating of the pyro system while keeping an eye on the O2 level and the vacuum at kiln inlet.
:o) To skip some waiting time the simulation speed can now be set to 10 times real time using the CEMulator
interface.
:o) Now is also a good time to save your session, so that you won't have to redo this part of the simulation once
more, should the simulation time out. The session can be continued from your current state or the next session save
can be loaded.
:o) If you continue from your current state go back to real time simulation. To get back to real time simulation set
the simulation speed back to 1.
To ready the kiln system for feed it will be necessary to start the cooler department.
1. Select cooler group 7-11 and start all of the cooler fans.
:o) Wait for the update time to stay between 0 and 1 second before continuing with the next step.
:o) In normal kiln operation the Kiln Speed is not regulated until well formed clinker are formed in the burning zone.
But due to the nature of the simulated model the procedure differs sligthly on this point.
:o) To avoid having to redo all of the changes once more if the simulation should get instable, it is a good idea to
save the simulation session now. The session can be continued from your current state or the next session save can
be loaded.
Session 1: Ignition
Keep a surplus of O2 in the kiln inlet by adjusting the ID-Damper position. The smoke gas analyses at the kiln inlet
should show a O2 content of 8-12% at the start of the heating up process. The Oxygen percentage under heating falls
to 3-4% just before the kiln feed is introduced.
Continue heating of the pyro system while keeping an eye on the O2 level and the vacuum at kiln inlet.
:o) To skip some waiting time the simulation speed can now be set to 10 times real time using the CEMulator
interface.
When the cyclone 4 exit temp reaches 350 oC and the heating up program is completed, the kiln will be ready to
recieve feed. An other indicator that can be used is the temperature at the top of the lowesat/final stage cyclone. If
this temperature is higher than 700 oC the kiln is ready to recieve feed. Be careful to keep the cyclone 1 exit temp
below 450 oC. If the cyclone 1 exit temp rises to above 450 oC an interlock will shut down the ID-Fan and burner.
1. After 6 hour (Process time) heating up begin to slowly increase the fuel with 0.1 t/h every 2nd hour.
:o)Thus simulating with a speed of 10, six minutes in the classroom corresponds to 1 hour process time.
:o) Now is also a good time to save your session, so that you won't have to redo this part of the simulation once
more, should the simulation time out. The session can be continued from your current state or the next session save
can be loaded.
:o) If you continue from your current state go back to real time simulation. To get back to real time simulation set
the simulation speed back to 1.
Increase production stepwise to 100 % while regulating the through draught so that there is 5-10% more kiln fuel
supplied than with normal production of the same amount. Always increase the draught before increasing the fuel
supply to avoid the formation of carbon monoxide (CO).
During the start-up the oxygen level after the preheater should be 3-5% and at the kiln inlet the oxygen content
should not be higher than 3%.
To ensure well-burned clinker it is important that the raw meal temperature in burning zone is sufficient high. The
burning zone temperature can be monitored by the kiln moment, thus a high kiln moment means melt in the burning
zone.
During the next two hours the through draught, the raw meal feed rate, fuel supply and kiln speed are gradually
increased, at the same time it must be ascertained that the resulting clinker is well burnt. The temperature in the
fourth lowest cyclone stage should be approximately 820 oC, this will ensure a calcination grade of approx. 75%.
1. Start auxiliary groups in raw mill department: Sealing Air Fan, Oil Heating, Roller lubrication, gear
lubrication and hydraulic unit.
2. In the dust transport department start groups: Dust transport, Dust measuring and EP filter heating.
3. Start EP Fan group and Cooling tower group
4. Start ID Fan and Kiln group
5. Open Id-Damper to 100 %
6. Open the exhaust damper to 80-100 %
7. Switch EP fan and Inlet Temperature controllers in auto.
8. Start kiln rectifiers and rapping
9. Allow all fans to settle to fully running.
10. Start Elevator and transport to elevator groups in the Raw mill Department
11. Start Water Injection group.
12. Open gates to let hot gas to the mill (gates on Raw mill mimic 02)
13. Start Mill fan and separator group.
14. Switch the Cyclone Differential Pressure controller in auto.
15. Wait until pressures are settled
16. Select Grinding mode and start the material circulation and mill motor groups.
17. Adjust manual input to feed to approximately 200-220 t/h.
18. Start the mill feed group- wait until the actual mill feed has reached its set point and pressures are settled.
(Dp over the mill should be approximately 30-34 mbar)
Close the water flow from the water controller manually and keep a temperature of 80-85 oC. If the temperature gets
below 80 oC with no water injection, the Inlet temperature controller in dust transport needs to be adjusted up to get
the drying effect.
19. Increase manual feed set point to approximately (80% of full production ~290 t/h)- wait until dp over mill is
~42-46mbar, Alternative skip this point but this results in the smoothest startup.
20. Switch mill feed controller into auto.
21. Switch water controller in auto.
The following procedure can be used to bring down the mill for planned stops.
1. Set Inlet temp controller to 190 oC to avoid interlocking the EP fan during shutdown.
2. Switch Feed Control to manual and set the set point to ~220 t/h, wait until set point is reached and dp in the
mill is ~30-35 mbar.
3. Switch water controller in manual and set outman to ~20 m3/h.
4. Switch cyclone control in manual and adjust damper position to keep inlet pressure to the mill at least 2-4
mbar.
5. Stop Mill feed group, wait until al is stopped.
6. Stop mill motor group, this will also lift rollers.
7. Stop Material circulation group
8. Stop mill fan and separator group
9. Close the guillotine dampers on mimic 2.
10. Close the mill damper (Diff Press Controller) and wait for the damper to be app 1%.
11. Stop transport to elevator and Elevator groups.
12. Stop the remaining auxiliary groups in the Mill department.
:o) If the kiln is continuously running the stop sequence should end here. If not then continue, but remember to ask
the instructor to switch the kiln gas temperature to 190 oC or less to avoid interlocking of the EP-fan.
13. Stop Kiln Rectifier in dust transport.
14. Switch EP fan and inlet temp. controllers in manual.
15. Stop the ID-fan and cooling Tower Groups.
16. Stop the EP fan group.
17. Close the ID-Fan and EP fan dampers.
The following procedure will start the coal mill when hot gases are available from the kiln, alternative procedures
have to be followed if the mill is heated up with the aid of the heat generator.
1. Start the groups for Transport to Coal Mill Silo. And the auxiliary groups:
2. Bagfilter Heating, Oil Heating, and Roller lubrication
3. Start the sealing Air fan group, and adjust the exit gas damper (just before the stack fan) to fully open
(100%)
4. Set water controller to 50 % (still in manual)
Printing History:
Version CPSV7
Last modified $Modtime:: 9/16/05 10:14a $
Author Torsten Vagn Jensen
Last modified by $Author:: Tvj $
Name of Word File $Workfile:: CpsPointAccessUI30_English.doc $
Disclaimer:
The information in this document is subject to change without notice and should not be construed as a commitment
by FLSmidth A/S. FLSmidth assumes no responsibility for any errors that may appear in this document.
In no event shall FLSmidth be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall FLSmidth be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.
Options specified and described in the FLSmidth documentation as part of the general description - but initially
neither ordered by the customer nor confirmed by the seller - will not commit the supplier to any further and future
supply and/or installation.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
Glossary of Terms 5
Index 7
Introduction
This user interface enables the trainee or instructor to change values or states for motors, set points and controllers
that are not linked to any CEMulator point.
When the session is started it is advised to click refresh to update the tables.
Select one ore more motors from the list and click stop or start to simulate the motor states.
:o) As there is no interlocking or sequence control in this way of starting and stopping motors it is advised to use
caution.
Select a set point and insert a new value in the New Value box. Click Apply to send the change.
:o) There is no validity check in this User Interface so choose set point values with care.
Select the controller you need to adjust. Switch mode (manual/automatic) by clicking on the ‘Switch mode’ button.
When a controller is in Automatic mode the _SPA can be changed, while the _SPA value can be changed while in
Manual.
Printing History:
Version CPSV7
Last modified $Modtime:: 9/16/05 3:44p $
Author Torsten Vagn Jensen
Last modified by $Author:: Tvj $
Name of Word File $Workfile:: CpsDevSimLinkUI30_English.doc $
Disclaimer:
The information in this document is subject to change without notice and should not be construed as a commitment
by FLSmidth A/S. FLSmidth assumes no responsibility for any errors that may appear in this document.
In no event shall FLSmidth be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall FLSmidth be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.
Options specified and described in the FLSmidth documentation as part of the general description - but initially
neither ordered by the customer nor confirmed by the seller - will not commit the supplier to any further and future
supply and/or installation.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
Appendix A 7
Mimics From Classroom simulation...................................................................................... 7
Duodan Raw Mill (1) .............................................................................................. 8
Duodan Raw Mill (2) .............................................................................................. 9
Duodan Raw Mill (3) ............................................................................................ 10
ILC Kiln - Coolax (1) ........................................................................................... 11
ILC Kiln - Coolax (2) ........................................................................................... 12
ILC Kiln – Coolax (3)........................................................................................... 13
ILC Kiln - SF (1) .................................................................................................. 14
ILC Kiln - SF (2) .................................................................................................. 15
SP Kiln – Folax (1) ............................................................................................... 16
SP Kiln – Folax (2) ............................................................................................... 17
SP Kiln – Unax..................................................................................................... 18
Vertical Raw Mill (1)............................................................................................ 19
Vertical Raw Mill (2)............................................................................................ 20
Vertical Raw Mill (3)............................................................................................ 21
Vertical Raw Mill (4)............................................................................................ 22
Cement Mill (1) .................................................................................................... 23
Cement Mill (2) .................................................................................................... 24
Cement Mill (3) .................................................................................................... 25
Cement Mill – Open (1) ........................................................................................ 26
Cement Mill – Open (2) ........................................................................................ 27
Cement Mill – Open (3) ........................................................................................ 28
Atox Coal Mill...................................................................................................... 29
Glossary of Terms 31
Index 33
Introduction
The sole purpose of the Device Simulation Linking user interface is to link the CEMulator to an existing ECS
database. This is aimed at ECS/CEMulator Live installations only.
The linking is eased by a set of filters making the decisions during linking easier. First off the entire ECS database is
sorted, so that only linkable points will be present in the ECS part of the window. Engineering units sort the
CEMulator variables so a filtered list of possible variables will be updated for linking.
Unit Adjustments
Unit adjustment is necessary only if there is a red box around the ‘Unit Match’ button in the ‘Link Status’ Box.
To get to the ‘Unit Configuration’ UI click either on the button or go to the menu bar and click on ‘Unit
Configuration’
It is of great importance that the ‘ECS Unit’ and ‘CPS Unit’ fits each other Even if the text differs from the two. If a
unit is connected incorrect then select the unit and click ‘Cut’.
Selecting the ECS unit in the upper list and the CPS unit in the lower list and clicking ‘Connect’ can connect ECS
Units that are not connected with a CEMulator unit. If the unit is not present in the ‘CPS Unit’ list, then a new unit
definition can be added by clicking ‘Add New’
When all units are linked click the ‘Ok’ button to return to the main UI.
Algorithm Filters
If a point you need to link does not exist in the ECS list then you will need to change the filter. Open the filter in the
toolbar and select ‘Filter Algorithms’
Basically the A-Points will always be filtered by ‘Linear input’, ‘PID Manual output’ and ‘Operator Inserted’ but as
the filtering is done by algorithm text it might be needed in to click the ‘Update’ button to get the right texts if the
language is not English.
Linking of Points
Opening the Device simulation Linking tool will take some time due to waiting time in loading and filtering points
and information. The linking will always be done to the active CEMulator model. To change the CEMulator model
use the ‘CPS Instructor’ UI. In the top of the Link UI is a status bar informing of active model and the status of the
CEMulator.
The status bar is updated dynamically so that whenever status or model name is changed the Linking UI will update
correspondingly.
The UI is split in two parts one with ECS link information and one with CPS link information.
:o) Samples can be used either as true samples or as a signal delay. A true sample like Free Lime measurement has
high values for interval and prep time, while signal delays has a prep time corresponding to the delay, but a low
interval time. As an example will ‘Sample Prep Time’ = 60 s and ‘Sample Interval’ = 1 s correspond to a one minute
time delay (used in analyzers)
Printing History:
Version CPSV7
Last modified $Modtime:: 9/16/05 10:05a $
Author Torsten Vagn Jensen
Last modified by $Author:: Tvj $
Name of Word File $Workfile:: CpsEvalReportUi30_English.doc $
Disclaimer:
The information in this document is subject to change without notice and should not be construed as a commitment
by FLSmidth A/S. FLSmidth assumes no responsibility for any errors that may appear in this document.
In no event shall FLSmidth be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall FLSmidth be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.
Options specified and described in the FLSmidth documentation as part of the general description - but initially
neither ordered by the customer nor confirmed by the seller - will not commit the supplier to any further and future
supply and/or installation.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
Glossary of Terms 9
Index 11
Introduction
The Evaluation Report user interface is a licensed build on to the CEMulator. The main purpose of the interface is to
give the Instructor a handful of reports to systemize the performance evaluation.
This document will describe the use of the Evaluation Report tool as well as design specifications for customization
of the reports.
Select the model in the combo box and checkmark whether the PLC simulation where active during the logged
session. Click Next and the remaining of the Load Session window will open.
Certificate
To print a certificate based on the certificate master click on Print Certificate. The certificate will be based on the
Session Definition.
Session Plots
The session plots are specific for each model meaning the number of plots and name of these are changing from
model to model. To print the chekmarked session plots click on Print Session Plots.
Session plots can be printed with two common scales:
1. Simulated Time - The simulated seconds (giving a stretch for accelerated simulation)
2. Operator Time - The time stamp from the operators point of view (format HH:MM:SS)
Master Documents
This chapter describes the five master documents used for evaluation reporting. To alter these documents make sure
that the new masters are saved under new filenames and then insert the new file names in the CEMulator
Configuration user interface. The description will not go in depth with how to construct the documents, but only
describe what data will be send to the document and in the Report Plot case how to setup what data to upload and
what sheets will be printed.
Don’t make changes to the masters unless you are:
Familiar with macros in Word
Familiar with bookmarks in Word
Familiar with Charts in Excel
Definition Sheet
The definition sheet must be named ‘Definitions’ for the Evaluation Report program to recognize it.
Printing History:
Version CPSV7
Last modified $Modtime:: 9/16/05 3:51p $
Author Torsten Vagn Jensen
Last modified by $Author:: Tvj $
Name of Word File $Workfile:: CpsTutorialUi30_English.doc $
Disclaimer:
The information in this document is subject to change without notice and should not be construed as a commitment
by FLSmidth A/S. FLSmidth assumes no responsibility for any errors that may appear in this document.
In no event shall FLSmidth be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall FLSmidth be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.
Options specified and described in the FLSmidth documentation as part of the general description - but initially
neither ordered by the customer nor confirmed by the seller - will not commit the supplier to any further and future
supply and/or installation.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
Glossary of Terms 7
Index 9
Introduction
The tutorial editor is used as a tool for altering recorded CEMulator tutorials. In this User Interface it is therefore
only possible to change the value of existing tutorial events and the timing of these. To add extra events the user will
have to record a new tutorial or edit an existing tutorial using the CPS Instructor user interface.
To understand the basic ideas of the tutorial feature in the CEMulator two concepts are important to understand, the
Tutorial concept and the Observation mode concept.
Loading a Tutorial
When starting the Tutorial Editor Tool a password box will appear.
Select the model in the combo box and checkmark whether the PLC simulation where active during the logged
session. Click Next and the remaining of the Load Session window will open.
Editing Tutorial
The Tutorial Editor has two main areas:
1. Session Definition - Basic definition of the session.
2. Event List - List of active instructor events.
Session Definition
Clicking on the Change button can change session Definitions.
Event List
The Event List is a list of actions contained in the Tutorial. Each action are represented by a line parted in four
columns:
1. Type - An icon visualizing the action.
2. Simul Time - Simulated process time in format HH:MM:SS.
3. Sess Time - Session time in format HH:MM:SS.
4. Action Text - Text string describing the action.
From the event list toolbar the following actions can be initiated:
Reset the tutorial event list (will reset all changes made after load)
Adding or reducing time stamp from the selected events in fixed intervals.
Adding or reducing time stamp from the selected events in user defined intervals.