Summary
The purpose of this visit 'was' commission'ing of' the 'V8 BLX pile 'and' the 'work is' carried out by 'Nisar Ahmed';' 'FLSmidth 'Global Field Services 'ApS'; 'Valby', 'Denmark'. Site Information
Located:Nooriabad, Karachi, Pakistan
Accommodation:Site Hostel
Contact Person at site:Mr. SM Imran, Director (O&P)
Mr. Muhammad Asim, General Manager
E-mail:sm.imran@powercement.pk
m.asim@powercement.pk
Configuration
3.1Updated the all software & hotfixes with latest available on flsadev and installed the SMX on QCX server.
3.2Collected the data from site and filled out the longitudinal pile & reclaimer excel sheets.
3.2Used the BLX engineering tool to create the file solution files.
3.2Imported the all pile & reclaimer solution files into the configuration.
3.3Converted the standard solution file to FLS solution file and imported it into configuration for cross belt ALLScan analyzer.
3.4Checked in the smoke test tool the sample results are started to receive in QCX server.
3.5Connected the following signals with the Siemens PLC addresses and made sure the right values are receiving in QCX server.
3.5.1Blx.PS_Pile.Feeders.Feeder_1.PV
3.5.2Blx.PS_Pile.Feeders.Feeder_1.STS
3.5.3Blx.PS_Pile.Feeders.Feeder_1.WSP
3.5.4Blx.PS_Pile.Feeders.Feeder_2.PV
3.5.5Blx.PS_Pile.Feeders.Feeder_2.STS
3.5.6Blx.PS_Pile.Feeders.Feeder_2.WSP
3.5.7Blx.SMXModel.Stackers.Stacker.Inputs.InPile1
3.5.8Blx.SMXModel.Stackers.Stacker.Inputs.InPile2
3.5.9Blx.SMXModel.Stackers.Stacker.Inputs.Position
3.5.10Blx.SMXModel.Stackers.Stacker.Inputs.STS
3.5.11Blx.SMXModel.Reclaimers.Reclaimer.Inputs.InPile1
3.5.12Blx.SMXModel.Reclaimers.Reclaimer.Inputs.InPile2
3.5.13Blx.SMXModel.Reclaimers.Reclaimer.Inputs.STS
3.2.14Blx.PS_Pile.Feeders.SPTotal
3.5.15Blx.PS_Pile.Feeders.Feeder_1.SP
3.5.16Blx.PS_Pile.Feeders.Feeder_2.SP
3.5.17Blx.PS_Pile.Feeders.Crusher.PV
3.5.18Blx.PS_Pile.Feeders.Crusher.STS
3.5.19Blx.PS_Pile.Status.IOAutomatic
3.5.20Blx.PS_Pile.Status.IOHeartbeat
3.5.21Blx.PS_Pile.Status.IOOK
3.5.22Blx.PS_Pile.Status.IOSelected
3.6Entered Blx.PS_Pile.Feeders.Feeder_1.PV & Blx.PS_Pile.Feeders.Feeder_2.PV signals in the BLX configuration to enable the estimation.
3.7Entered the ALLScan equipment in the BLX online expert configuration to get the sample results into the BLX.
3.8Put the control on V8 for a while and observed how the estimations are working.
PIle Building & BLX Tunning
4.1After getting the good estimation of raw material chemistry; have started building the pile completely with V8 control.
4.2Have built five piles by using V8 control and have done some tuning to get the precise blending results.
4.3Removed the SIM & ALM modulus from targets & constraint configuration.
4.4Put 12 % limit for minimum & 35 % limit for maximum (% of total) on clay feeder.
4.5Start building pile with 30 min elimination time and later increased it to 60 mins to get the pile on target in 4 x 60 = 240 mins.
4.6Changed the aggregation count from 2 to 1 to re-calculate the LSF control result on every sample.
4.7Put 0.50 limit for min & 3.35 limit for max on SiO2 and 0.10 limit for min & 1 for max on Al2O3 & Fe2O3 on the limestone feeder.
4.8Put 40 limit for min & 70 limit for max on SiO2 on the clay feeder.
4.09Pile-1 was made with V8 control and LSF target was 121.
4.10Pile-2 center cut
4.11 Pile-2 SMX model
4.12Pile-1 center cut when reclaiming.
4.13Pile-1 SMX model
4.14Feeders working setpoint & BLX setpoint mimic
4.15Online analyzer mimic
4.16Online analyzer detail mimic
4.17 Stacker production mimic
4.18Pile details mimic
4.19Reclaimer mimic
4.20Sample viewer - sample logging
4.21Pile-1 stacking forecast mimic
4.22Pile-1 reclaiming forecast mimic
4.23Take & saved the ECS configuration & runtime backup on the external backup drive.
Problem Faced
5.1After upgrading the QCX and QCX driver from v8.5 to v8.6 the system was asking to update the license too. Updated the license file with new received file to solve the issue.
5.2During import the reclaimer solution into the configuration it was giving “Blx.RawMaterial.MixPile is already present” error. Checked and changed the material name in recliamer excel sheet and used the new solution files to solve the issue.
5.3During import the reclaimer solution into the configuration it was giving “Blx.PS_Pile.Piles.Pile1/2.ReclaimingCompleted/State is missing” & “Blx.PS_Pile.Piles.Pile1/2.StackingCompleted/State is missing” errors. Checked and changed the pile names in recliamer excel sheet same as wirite in pile sheet and used the new solution files to solve the issue.
5.4After import the BLX pile configuration into the system eight new sample point added into the sample points and the system was asking to update the license too. The 20 numbers of licenses were available for sample points, but it was needed 24. Updated the license file with new received file to increase the numbers of licenses of sample point and material type to 40/40.
5.5During converting the ALLScan cross bely analyser standard solution to FLS solution it was giving an error “ALLScan.RemCTL.RD” is missing. Checked and imported the ALLScanLibrary solution file into the configuration to solve the issue.
5.6 The pile1/2 accounting was getting reset unexpectedly when reclaimer moved from one pile to another pile. I discussed the matter with Mr. Jesper and used the new updated calculator block to solve the issue.
5.7The faceplate of CNA was showing all the time black color & inactive. Used the correct dynamic symbol to solve the issue.
5.8The trend of calculated points LSF, SIM & ALM was not working. It was showing only last two value all the time. Checked and changed the compression deviation from 0.5 to -1 to solve the issue.
5.9The LSF control result value was not working correctly. The “LSF control result” is calculating correct when I was pressing recalculate button and accept but when it was calculating itself on new sample result it was not calculating correctly and was keeping“ LSF control result” lagging all the time behind the “LSF current value”. Checked and changed the compression deviation from 0.5 to -1 of controller values to solve the issue.
Outstanding Issues ¶
6.1Whenever the production stops the “Matlab optimization failed” alarm is logging in the event list. This issue reported back to our office and hopefully will get hotfix soon to solve the issue.
6.2The BLX mill estimator is working fine but in pile estimator when we click on get data it is showing getting data, but it ends with no data. This issue reported back to our office and hopefully will get hotfix soon to solve the issue.
Recommendations
7.1PCL need to dump image backup of QCX server with AOMEI backupper on the external backup drive.