«Management Information System.»

Written and processed by Frederik Luitwieler

MANAGEMENT INFORMATION SYSTEM

for the

Cement Factory

HOFUF 4th Extension

1995

Saudia Arabia

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
all decision-makers jointly with this information on their desktop PCs for individual analysis.

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 example, the specific energy consumption of a production plant in kJ/kg is only meaningful when considered together with laboratory data for raw meal and clinker, production quantity, exhaust gas utilisation, and also production stoppages and process malfunctions.
An information system must therefore be capable of selecting individual items of data and information and interrelating them.
Mathematical calculations and statistical analyses must also be freely selectable, so that meaningful results and comparable characteristic values can be abstracted from the data. It must also be possible to present the results as a report, a graphic or a list, as appropriate.
The kiln operator needs detailed information, e.g. tables of measured values over 24 hours. The production manager only needs a summary of the key production figures, and the Works Manager may need only a graphic display of the most important characteristic values. Fig. 1 shows an example of this for the kiln line6.

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.
Data interfaces and data definitions must be standardised so that data from all systems can be uniformly managed and analysed.
Systematic processing of raw data is crucial for consistency of data and of results, and thus ultimately for the quality of an MIS. This is archived by using "plausibility check", and will be illustrated using the example of the treatment of pulse signals for quantity values. For example, resources consumed during no-load operation and during repairs must be counted separately, and must not be allocated to production. It must also be possible at the raw data stage to allocate consumption and production quantities separately to products, product changeover phases and tariff rate periods. It is also necessary to ensure that input pulses are not converted several times in the system, otherwise rounding errors and inconsistent results will arise. On the other hand, pulses from the weightier during calibration must be suppressed completely. Quantity values that are missing or incorrect must be detected and identified, and this information permanently stored with the data. It must also be possible to input information and correct the results manually, but only outgoing from the operator control terminal (COROS). Manual inputs must be identified as such and stored in the database.

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 system configuration is made up by three user terminals and two industrial PC´s, connected via a high speed bus (SINEC H1) and a optical bus to span a greater distance as 500 meter from the plant control system to the administration building at last, see drawing 825-43-127 UB sheet 005 .
All relevant plant data is collected from the plant control system and archived on a file storage media. MIS-Terminals at different locations enable the personal to have access to the archived data.
Generation of report logs is carried out by colour printers and/or black & white printers, connected to the PC´s.

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.
New PC users can also be added to the network while the system is running.

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 .
Information from other parts of the plant, e.g. power plant has to be transferred to one of the Plc’s at SINEC-H1-A, e.g. to be Gateway-PLC. The network controller CP1413, installed in the data processor is prepared, to collect all configured object data from the Plc’s connected to SINEC-H1-A. The data received via the network (SINEC-H1), is controlled by the PC data processor and will be send to an archive on the PC files server. The communication between the PC data processor and the files server is based on a Novell network.
In order to avoid transfer conflicts between the SINEC-H1-A and the Novell network (on SINEC-H1-1A), a bridge is installed to filter the communication.

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.
Each MIS-Terminal makes use of all plant data stored in the files server.

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.
Also it is possible to display the measured values in tables. The contents of the table can be transferred to an ASCII file, which is readable from a great number of standard software packages.

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).
It is also possible to include manually entered information’s before the report is printed out. The system generates automatically a report after each shift, each day (at the end of last shift) and each month (at the end of last shift). The automatic printout of each report kind is switchable between on and off. A request of the current report is possible each time. The reports contain all basis production, consumption, specific and total values, running times, storage capacities.
Also included are maximum-, mean- and minimum of main process values.

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).
The search criterion is a pre definition for the function messages. On request, the collection list is displayed on monitor.
On request, the collection list is printed on printer.
This function is used typically, to detect weak equipment in the plant. Combined with the "Runtime-Information" (Hour-counters) of the machines, the maintenance staff are able to actuate and verify their maintenance programmes.