New digital solutions lift performance at Lafarge Emirates Cement
Attention!! to Download Most Important Books in Cement industry reviewed from more than two thousands people + Manuals and notes from big Cement Companies like F L S , Holcim Lafarge , Cemex , + Excel sheets for calculations process Click here Now
The cement plant at Fujairah, UAE, needed to keep up with the rapid advances in industrial automation hardware and software. They decided to equip their team with the best digitalisation tools available in the industry – control and monitoring system upgrades from FLSmidth.
The United Arab Emirates (UAE) is currently experiencing one of the fastest growing and active construction markets worldwide, driven by a strong property market, thriving tourism sector and increasing investor interest.
Lafarge Emirates Cement plant (LEC), a member of the LafargeHolcim Group, is making a significant contribution to the building materials and construction sector in the UAE. The plant can produce up to 3.2 million tonnes of cement per year. To keep up with the rapid advances in industrial automation hardware and software, LEC commissioned FLSmidth to upgrade its ageing version 7 (V7) Plant Control system (ECS™) and ECS/PlantGuide® reporting systems (PLG) to the latest version 8 (V8) product.
Keeping up with demand
LEC realised that the control and monitoring systems needed to meet the ever-growing demands of a wide range of users, from the control room operators to process engineers, the production team and management teams. All of these users interact with plant automation system data to make decisions that ultimately benefit the profitability of the plant operation.
LEC decided to equip its team with the best digitalisation tools available in the industry by investing in control system upgrades for its cement plant at Fujairah, UAE.
Our digital systems had successfully supported the plant site for over ten years, building a strong and effective relationship that reassured LEC we could be trusted to deliver the upgrade solutions.
A collaborative approach
FLSmidth offices came together to collaborate, plan, engineer and execute these upgrade solutions from Valby in Denmark, Brno in the Czech Republic, Chennai in India and Bethlehem in the USA.
Each of these offices played a significant role in shaping the upgrade by sharing their knowledge and resources. The project was initiated in the Denmark office. The hardware system was built in the Czech Republic. And the system engineering took place in America and India by the V8-Global Upgrade Team, who are experts in handling version 7 to version 8 upgrade projects.
“It was big challenge for us to deliver the upgrade project online without stopping or disturbing plant operation”, says Sherif Salah, Project Manager at LEC. ”
A successful transition
Mr. Hasmukh Patel (Manager – Process Applications, Systems & Technologies) from the FLSmidth USA office attributes the seamless transition to the new system to the meticulous planning and scheduling of engineering and site commissioning activities by the control systems teams of FLSmidth and LEC.
The V8 system explained
The ECS/ControlCenter system provides a process automation platform with dual redundant servers collecting I/O data from the PLC (motors, drives, field instruments, process values, etc.). It provides HMI/SCADA functionality for operator supervision and control of all departments in large production facilities at cement and mineral plants.
This system also includes machine control directly at the machine. Users connect to a portal workplace to view or operate specific departments or equipment using operator display screens, trends, alarms and reporting tools.
User access rights can be configured to control what information is made available.