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Written and processed by Frederik Luitwieler
for the
Cement Factory
1995 1. Requirements A Management information system (MIS) must
satisfy the following requirements: it must be of modular construction and
capable of being updated, it must be capable of functional extension, and
it must be easy for the user himself to adapt to meet his needs. It must
therefore be flexible. A management information system must enable
comprehensive analysis of all the data and information’s from the process,
from the production, from the quality, and from the plant itself. Following
table lists the data and information’s which an information system has to
capture, manage and analyse. a) measured values b) levels in silos c) quantities consumed d) production quantities e) power consumption (process and non process)
f) material movements from stores to bins
and dispatch g) running times h) repair times i) alarm messages j) control room arrangements k) switching operations changes to: set point
values, limit values l) predetermined set point m) values silo allocations n) laboratory data o) emission data Data which cannot be captured electronically
are input via input masks and archived, processed and analysed in the same
way as data captured automatically. The operator can produce his own input masks,
and exchange them between inside MIS-database and an outside database via
an interface. The information needed to produce management
reports includes consumption and production figures, power consumption, level
of material in the silo and material movements, reading and running times,
and possibly also plant downtime. Warning and alarm signals and all switching
operations by the production controls are needed for the process operating
reports. It is also essential to capture all set point adjustments, limit
value changes and all silo and path switching. Laboratory data, predetermined set point values
must be fed into the information system for quality control and production
monitoring. The functions of an information system can
be briefly summarised as follows: It must be capture and file data and information
from all plant sections and systems in an integrated manner, and present
2. Individual analysis Data and information’s have to be related
to each other. It must be possible to analyse them jointly so that they can
be meaningfully interpreted. For HOFUF 4th Extension be brought in CEMAT-MIS.
CEMAT-MIS runs on standard PCs (386 or higher) and uses MS-Windows and NOVEll
NetWare. The several reports to be created by EXCEL 5. CEMAT-MIS condenses data to provide meaningful
information. The network display, for example, enables
a rapid assessment to be made of how the current kiln production characteristic
values compare with the nominal values. The kiln actual values can be compared
with various benchmark values, the best figures achieved, or the last month's
averages. MIS data collection is based on the CEMCASE
object configuration works. Entering the objects for the plant control (S5-programmes,
COROS), also the data collection for MIS is decided. On the other hand, all signals, generated
from external systems (PYROEXPERT , MILLEXPERT and ROMIX) will be send to
CEMAT-Plc’s, converted into CEMAT-structure, and by that way will be available
as object for MIS. Production data from the existing plant, which
have to be incorporated into the MIS-reports, are established as CEMAT objects.
3. Design for a Management Information
System with a secure future An information system is an infrastructure
system and must, like an energy supply system, be carefully planned for the
long term, and systematically implemented. It is also important that standard
hardware and software products are used, and that an open communication network
is selected so that external systems can also feed their data into the information
system. Plausibility checks of this
type are also necessary for measured values and for messages. It is for example
necessary to ensure that the process control system produces only one fault
message in the event of a plant malfunction, and not two or more. Picture, MIS test equipment 4. Structure of the CEMAT-MIS A CEMAT-MIS system consists of networked PCs
carrying out their function in parallel as a co-ordinated system. The PC group includes PC´s for different
tasks: - one PC for data processing - one PC for data storage (file server) with
more as two gigabytes memory - three INFO-PC´s (MIS-Terminals)
one in the COP office and two in the administration building. The PC for data processing and the server
share one monitor (high resolution) and keyboard. A streamer is inserted in the server PC to
secure the system data on demand. Each MIS-Terminal has a monitor (high resolution),
a keyboard and a mouse. Four printers are available for the three
workstations: two black/white printers and two colour printers. The CEMAT-MIS memory capacities and expansion
values scoped as following: Measured values 4000 Quantity values 10000 Running times 2000 Alarm/operating messages 100000 Maintenance messages 10000 Archive capacity 1 year 1 year User PC´s limited only by the NOVELL
network licence (10-50) The CEMAT-MIS databases are self-expanding
without reprogramming or reconfiguration; new measuring points or additional
counter inputs can be connected without interrupting the process. 5. Hardware and software configuration 5.1 PC Dada processor The PC data processor is capable to communicate
with all Plc’s, connected to the data bus SINEC-H1-A . 5.2 PC Files server The data accessed from the Plc’s under the
control of the data processor are archived on the files server. This archive
is the database for the MIS system. It includes the actual and historical
plant data. 5.3 MIS-Terminals The users interface to the MIS is the MIS-Terminal.
Each MIS-Terminal offers the same possibilities of interfacing with the MIS-programmes
and the plant data. By way of forming workgroups and users within groups,
the access to MIS-functions can be assigned to restricted number and level
of users. As each MIS-user has to "log in" with his password, hiss access
rights will be checked and only authorised user may have access to their
dedicated MIS-functions and data. 6. Location of installation 6.1 MIS-data processor and MIS-files server
The data processor and the files server will
be installed in a control cabinet, located in the office 205 of the COP building.
The monitor, keyboard and monitor switch will be put on a desk besides the
cabinet. 6.2 Production Monitoring The MIS-Terminal for the responsible engineer
for production monitoring will be installed in the office 205 of the COP-building,
together with the MIS-data-processor and MIS-files server. 6.3 Plant Manager The MIS-Terminal for the Plant Manager will
be installed in Plant Manager’s office in the administration building.
6.4 General Works Manager The MIS-Terminal for the General Works Manager
will be installed in the General Works Manager’s office in the administration
building. 7. Functions 7.1 Production Monitoring and Trending By use of the graphic-function available with
EXCEL, plant overview displays are prepared, to indicate: a) plant status (operational parts and main
material routing) b) main process values c) main production values The goal of this function is not an operational
type of display, but an informational type of display for the production-,
plant- or works-manager to get an overview on the general process and production
situation. 7.2 Trend Data Evaluation The stored data (measured values, consumption
counters) can be displayed in curve pictures (value over time). The time
is delectable from actual to historical, limited to approximate 3 days back.
For each curve picture a collection up to 6 curves be able to created. For
the measured value an evaluation (average, correlation etc.) is possible.
7.3 Production Reports The production reports are generated by using
the EXCEL tool. It is easy to modify titles and contents of a report (see
MIS-GUIDE to this theme). 7.4 Fault Statistics For pre selected messages the frequency of
new coming messages is controlled and stored. It is possible to generate
collections of information’s by search criteria (message class, alarm class,
location, object, time range). |
