(QCX Blendexpert Software Manual)

.
QCX Blend Expert Software Manual

V8, QCX 4190/4191
Instruction English
Plant Name: Beni Suef Cement
Contract Number: 2871777259-164X
Created by: TORJ

Approved by: DISK-IN
Approved date: JUNE 2017
Doc. No.: 80048000 - 1.0

1 Installation Manuals
1.1 QCX Blend Expert - Installation Manual 1
2 Reference Manuals
2.1 QCX Blend Expert - Mill - Reference Manual 2
3 User Manuals
3.1 QCX Blend Expert - Mill - User Manual 3
GOE Beni Suef
Egypt
Line 01 & Line 02
Order No. 2871777259
Project No.
QCX 4190 AUS &
QCX 4191 BLX
QCX Blend Expert

Software Manual
Version 8.0
Document No :
80048000
FLSmidth A/S
Vigerslev Alle 77
DK-2500 Valby
Copenhagen
Denmark
Phone: +45 36 18 10 00
Telefax: +45 36 44 11 46
TAB
TAB
QCX/BlendExpert
Installation Manual
www.flsmidth.com/automation
csc@flsmidth.com
Version V8.0
Last modified 2016-02-23
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.
Copyright © FLSmidth A/S. All rights reserved.
QCX/BlendExpert V8.0 2
Table of Contents
1. Introduction 4
1.1 Purpose 4
1.2 Intended audience 4
1.3 How to use this manual 4
1.4 Installation overview 4
2. Before Installation 5
2.1 Hardware requirements 5
2.2 Software requirements 5
3. Installation Procedure 6
3.1 Pre-installation of QCX/BlendExpert 6
3.2 Installation of QCX/BlendExpert 6
3.3 Installation of the Workplace 6
4. Un-installation procedure 7
4.1 Un-install Workplace 7
4.2 Un-install QCX/BlendExpert 7
1. Introduction
1.1 Purpose
This document describes the procedure used to install the QCX/BlendExpert
product. When completing the instructions in this manual, the system will be
ready for configuration.
This manual refers to QCX/BlendExpert version 8.0.
1.2 Intended audience

This manual is relevant for FLSmidth engineers, system engineers, or plant
maintenance staffs who are in charge of a system installation on site with no
access to the FLSmidth Production Team facilities.
1.3 How to use this manual

The first part explains the necessary software, hardware and any other
prerequisites for the installation.
Hereafter, a number of sections describe the detailed procedure to be followed for
a given installation step.
All the steps of this manual must be followed exactly in the order they
are explained and guided. Deviations from these instructions may have
various consequences on the following installation steps or system
performance after installation.
After each major installation step, a verification step is requested in each

procedure. This verification is meant as a milestone to maximize a healthy
installation throughout the process. In case the verification steps have not been
confirmed, i.e. the installation has not been successful, please contact FLSmidth
Customer Service Center for further assistance.
Please contact FLSmidth Customer Service Center csc@flsmidth.com or

your associated FLSmidth project engineering office for further
assistance on the installation procedure.
1.4 Installation overview

The following is an overview (in the order of execution) of tasks to be performed
using this manual:
1. Installing QCX/BlendExpert
2. Before Installation
2.1 Hardware requirements

Minimum hardware requirements are:
 Intel Xeon Processor E5-1607 v2 (Quad Core, 3.0 GHz,10 MB)
 16GB RAM.
 200GB hard disk, SAS at 15,000 Rpm.
2.2 Software requirements

1) The system must be configured according to the “Core/OS Configuration
manual” for the used Operating System.
2) FLS Core V8.8 or higher must be installed according to the “ECS & QCX -
installation manual”.
3) FLS QCX Basis V8.2 or higher must be installed according to the “QCX Basic –
Installation manual”.
a) Additional FLS QCX products might be required, depending on installation.
Please install them according to the installation manuals.
4) QCX/BendExpert installation CD V8.0.
3. Installation Procedure
3.1 Pre-installation of QCX/BlendExpert

Install the MATLAB® Compiler Runtime V8.2 from the file:
 “matlab_R2013b_win32_installer.exe" on the installation media.
3.2 Installation of QCX/BlendExpert

 Open the “FLS Discovery Configuration” and select the “Cluster” tab.
 Depress the “Maintenance” button, if the system is not already in
maintenance mode.
 Execute Fls.QcxBlx.Install.msi from the installation media and install the
features (select by default):
o Fls QcxBlx Base product
o Fls QcxBlx Mill product
 If OnLineExpert is required, please select the feature:
o Fls QcxBlx OnLineExpert product
 Open the “FLS Discovery Configuration” and select the “Cluster” tab.
 Depress the “Operational” button.
3.3 Installation of the Workplace

On a standalone system the Workplace is started using a local path in the
browser:
1. http://localhost/flsmidth
2. Depress the “Workplace” Tab
3. Depress the “Install FLSmidth Workplace” button.
The workplace will now be installed and started.
On a remote client the Workplace is started using the application server name
(where the QCX/BlendExpert is installed) in the browser
1. http://<App. Server name>/flsmidth
From here proceed as for the standalone system.
After installation one can find a shortcut to the Workplace in the start menu under
“All Programs” -> “FLSmidth”. From here one can launch the Workplace. By right
clicking one can: “Pin to Taskbar”, “Pin to Start Menu” or send it to the Desktop
by selecting “Send to” -> “Desktop (create shortcut)”.
4. Un-installation procedure
4.1 Un-install Workplace

1. Close any existing FLSmidth Workplaces. Double press FLSmidth Workplace
<App. Server> in “Program and Features” in the “Control Panel” and select
'Yes' to un-install.
2. Select Remove the application from this computer and press OK.
Note: please note that the workplace can be installed in several instances from
different application servers.
4.2 Un-install QCX/BlendExpert

1. Open the “FLS Discovery Configuration” and select the “Cluster” tab.
2. Depress the “Maintenance” button, if the system is not already in maintenance
mode.
3. In the “Control Panel” open "Program and Features". In the list double click on
the “FLSmidth QCX/BlendExpert 8.0" entity and select 'Yes' to un-install.
TAB
TAB
Mill
Reference Manual
csc@flsmidth.com
Version QCX/BlendExpert V8.0
Disclaimer:
In no event shall FLSmidth be liable for direct, indirect, special, incidental or consequential
this document.
Mill QCX/BlendExpert V8.0 2

Table of Contents
1. Introduction 5
1.1 Purpose 5
2. Concept and terms 6

2.1 HMI 6
2.2 Operation-Mode 6
2.3 Maintenance-Mode 6
3. Access Control Claims 7

3.1 Access control claims 7
4. Configuring QCX/BlendExpert 8
4.1 Introduction to the QCX/BlendExpert configuration 8
4.2 Open Mill subproduct configuration window 8
4.3 Modify Controller 8
4.4 Modify DataItem 9
4.5 Modify Estimator 9
4.6 Modify MillManager 10
4.7 Modify RawMaterial 11
4.8 Modify Feeder 11
4.9 Modify Mill 11
4.10 Modify Sampler 12
4.11 Modify SurgeBin 13
4.12 Modify Delay 13
4.13 Modify Silo 14
4.14 Modify Splitter 15
5. User Access Control 16

5.1 The user access principles 16
5.2 User access for HMI elements 16
5.3 User access for faceplates 16
5.4 The Controller Faceplate 16
5.5 The Feeder Faceplate 17
5.6 The Sampler Faceplate 17
5.7 The User access for the QCX/BlendExpert Toolbar. 18
6. Report Card KPI 18

6.1 BLX OEE 18
6.2 Availability 18
6.3 Performance 18
6.4 Quality 18
6.5 Operation 19
6.6 KPI setup 19
7. Related Manuals 22
7.1 Related Manuals 22

1. Introduction
1.1 Purpose
The purpose of the Mill subproduct changes in core configuration is to handle the
configuration changes of the QCX/BlendExpert product not already described in
the user manual. The Mill subproduct changes in the core configuration only
contain configuration-properties that can be changed in Maintenance-Mode. Mill
subproduct configuration-properties that are available in the HMI, can be changed
in Operation-Mode, so these are thus not described in this document.

This manual is relevant for the engineer/administrator of the system. The focus of
the manual is therefore on configuration and maintenance of the system, rather
than the use or commissioning of the system.

The first part is a brief description of the concepts and terms involved in the
system. The understanding of these concepts and terms are crucial in the efficient
use of the following sections.
Hereafter, a number of sections describe the procedure to be followed by the user
to perform a specific task e.g. (“find configuration of….”). These descriptions are
setup in a step-by-step structure.

2. Concept and terms
2.1 HMI
The graphical user interface of the QCX/BlendExpert application.
2.2 Operation-Mode
This is when QCX/BlendExpert is online and fully activated.
2.3 Maintenance-Mode
This is when QCX/BlendExpert is taken offline due to maintenance. In order to
change properties described in this document, it is necessary to be in
Maintenance-Mode.
2.4 Homogeneity
The homogeneity is a parameter used to set the aggressiveness of the raw
material estimates. This is a not editable value defined in the Fls.QcxBlxCommon
solution.
2.5 Message type

The message type is used for relaying messages while using the manual control
action acceptance. This is a not editable value defined in the Fls.QcxBlxCommon
solution.
2.6 PlantSection
The plant section holds the plant section specific configuration for
QCX/BlendExpert. The base of this is not editable and defined in the plant section
specific solution generate by the engineering tool
2.7 Reserved items

Reserved Data Item, Reserved Preparation and Reserved Procedure is part of the
setup to ensure that the sample specific data can be generated and logged
correctly. These are parts of the site specific backup generated by the
engineering tool or the Fls.QcxBlxCommon solution.
2.8 SuccessorSubsection
The successor subsection defines the unit flowsheet and should not manually be
altered. This is not editable and defined in the plant section specific solution
generate by the engineering tool.

3. Access Control Claims
3.1 Access control claims

All access control claims for the Mill system are defined under the subproduct
name Fls.QcxBlx.Mill:
Name Description
GeneralConfig Required in order to configure the Mill system

4. Configuring QCX/BlendExpert
4.1 Introduction to the QCX/BlendExpert configuration
Please note: the QCX/BlendExpert system will always be pre-configured by a

Solution constructed according to installed equipment.
If it becomes necessary to add/change/remove properties in the solution the user

should be aware that all properties described in this document must be modified
in Maintenance-Mode.
There exist many additional properties that can be changed in Operation-Mode,
but these are not described in this manual. Please find those described in the user
manual.
4.2 Open Mill subproduct configuration window

To configure QCX/BlendExpert, first do as follows:
1. Select System in the navigation pane under Workplace
2. Press Configuration in the Configuration group.
3. Expand the QCX/BlendExpert product-node.
4. Expand the Mill subproduct-node.
4.3 Modify Controller

From the Mill subproduct-node, proceed as follows:
1. Select the Controller entity-node.
2. For this node, the following modifiable properties are of interest:
Property Description
MinTotalRawMaterial A double datatype describing the minimum
amount of raw material in tons, which must
pass through the sampler, before a control
action will be triggered.
MinRuntimeMM An integer datatype describing the minimum
number of minutes, that the process must
have been running, before a control action
can be triggered.
RecalculateTimeOutMM An integer datatype describing the maximum
number of minutes which is allowed to pass
after the latest control action, before a new
control action is forced.
ControlledSubsectionId The tag designation reference of the
subsection which is controlled. If the silo is
selected here the control will run in Silo
mode, while any other sub section will result
in Mix mode control. These control types are
described in the user manual. Mark the last

in the process before the silo of type merger
or mill for mix mode to ensure correct
update of core values.
IsLossFree A marked checkbox denotes the Controller is
loss free and an unmarked checkbox denotes
that it is not loss free.
MinCtrlActCoeff The minimum control action coefficient is the
minimum effect a control action can have if
in silo mode. A low number here will allow
aggressive control actions.
SetPointDeviationTolerance The set point deviation tolerance is used to
evaluate if the set points are accurate
enough. If not the set points are recalculated
until within limits. If this is set too small it
will influence performance.
GaugeSensitivity Defines the dead band for the feeder gauge
to be within limits. There should be no
reason to change this from the default value.
3. When done modifying, press Save Changes button in the configuration
toolbar.
4.4 Modify DataItem

1. Select the DataItem entity-node.
DisplayOrder An integer datatype. When the DataItem is
displayed in a list, this number is used to
determine the position of the DataItem in the list.
All list orderings are ascending, meaning that the
DataItem with the smallest number is displayed
first.
LOICoefficient A double datatype. The loss of ignition coefficient
describes the loss factor of a DataItem’s material
weight, when the pure input chemical compound is
turned into an output chemical compound.
Example:
The chemical compound CaO can have a
LOICoefficient=0.786.
This means that when the pure input chemical
compound “CaCO3” is ignited in order to produce
“CaO” then a loss of CO2 is also released. The
relationship in weight between the two output
chemical compounds are then:
(CaO:CO2) → (1 : 0.786)
toolbar.

4.5 Modify Estimator
1. Select the Estimator entity-node.
MadAlarmFactor A double datatype used to tune when both the
low/high “BlxMill.Estimator.SamplerMadLimit”-
alarm should be raised.
The low-alarm for

“BlxMill.Estimator.SamplerMadLimit” will be raised
when:
𝑂𝑥𝑖𝑑𝑒𝑀𝑎𝑑𝑉𝑎𝑙𝑢𝑒 <‒ (𝑀𝑎𝑑𝐴𝑙𝑎𝑟𝑚𝐹𝑎𝑐𝑡𝑜𝑟 ∗ 𝑂𝑥𝑖𝑑𝑒𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑𝐷𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛)
The high-alarm for

“BlxMill.Estimator.SamplerMadLimit” will be raised
when:
𝑂𝑥𝑖𝑑𝑒𝑀𝑎𝑑𝑉𝑎𝑙𝑢𝑒 > 𝑀𝑎𝑑𝐴𝑙𝑎𝑟𝑚𝐹𝑎𝑐𝑡𝑜𝑟 ∗ 𝑂𝑥𝑖𝑑𝑒𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑𝐷𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛
OxideLimitReachedCo An integer describing the number of times a

unter specific oxide in a continuous streak of taken
samples can pass its OxideLimit, before the
low/high “BlxMill.Estimator.SamplerOxideLimit”-
alarm is raised.
Thus, if e.g. the “OxideLimitReachedCounter=3”,
the following holds:
The low-alarm for “BlxMill.Estimator.
SamplerOxideLimit” will be raised when the same
oxide has passed its low-limit for 3 consecutive
samples.
The high-alarm for “BlxMill.Estimator.
SamplerOxideLimit” will be raised when the same
oxide has passed its high-limit for 3 consecutive
samples.
toolbar.
4.6 Modify MillManager

1. Select the MillManager entity-node.
LoggingHorizonDD An integer describing the number of days that
historic logging data is persisted. This will set the
limitation for the Estimator tuning first data, a high

number will however increase database size.
EstMaxSampleAgeHH An integer describing the maximum number of
hours, which is allowed to pass, before a sample is
disregarded.
EstRefSamplerCount An integer describing the number of the reference
samples one can change status/chemistry on. The
number is counted from newest reference sample.
E.g. a number of 2 means that one can only
change the two most recent reference samples.
SimulationIntervalSS Simulation interval for the accounting. Changes in
this will have effect on performance and the values
should therefore be kept at the default value
StateLoggingFrqMM The frequency of logging the state should not be
changed as it will have an impact on the
performance. Keep this value at default value.
IOHalt Operator inserted value used to switch to
QCX/BlendExpert halt mode for configuration
changes.
toolbar.
4.7 Modify RawMaterial

1. Select the RawMaterial entity-node.
IsIgnited A marked checkbox denotes the RawMaterial is
ignited and an unmarked checkbox denotes that it
is not ignited.
SamplePointId The tag designation reference of the sample point.
A sample point for the RawMaterial describes the
places where samples are introduced or collected
for the RawMaterial.
toolbar.
4.8 Modify Feeder

1. Expand the Subsection entity-node.
2. Expand any data-node instance in the list placed under the Subsection
entity-node, that contains a property SubsectionType=Merger
3. Expand the Merger entity-node.
4. Expand any data-node instance in the list placed under the Merger entity-
node.
5. Select the Feeder entity-node.

IOSetPoint Link to the IO Set Point value. Not set for
disturbance feeders.
IOWorkingSetpoint Link to the Working set point value. Not set for
disturbance feeders.
IOProcessValue Link to the IO process value
IOSelectedForControl Link to IO to select the feeder for control. Not
set for disturbance feeders.
IORawMaterialSelection The tag designation reference identifying the
raw material that is currently used in the
feeder. This is only to be configured for feeders
with more than one raw material assigned.
MaxCapacity A double datatype describing the maximum
capacity of the feeder in tons/hour.
MinCapacity A double datatype describing the minimum
capacity of the feeder in tons/hour.
IsDisturbance Defines if the feeder is a disturbance feeder.
Disturbance feeders are not getting set point
uptates.
StarvationThresholdSS
NominalRawMaterialRate
DisplayOrder The display order is used for trending limits and
displaying the feeders in the correct order.
Change of this may change the controller
values.
toolbar.
4.9 Modify Mill

entity-node, that contains a property SubsectionType=Mill
3. Select the Mill entity-node.
IOMassFlow The tag designation reference of the mass flow.
5. Continue by expanding the just selected Mill entity-node.
6. Expand any data-node instance in the list placed under the Mill entity-
node.
7. Select the DynamicFirstOrder entity-node if it exists (depends on the
type if the mill).

TimeConstantSS An integer datatype (must be positive) that
denotes the value of the filter time constant, in
seconds, used in the loss pass filter equation that
controls a dynamic first-order simulated mill. This
can be translated as the retention time in the mill
for each raw material.
toolbar.
4.10 Modify Sampler

entity-node, that contains a property SubsectionType=Sampler
3. Select the Sampler entity-node.
MADWeight An integer datatype describing the amount of
smoothing we want to apply to the results of the
accounting calculation.
If the results of the accounting calculation are very
volatile, having large positive and/or negative
oscillations within a short amount of time, we want
to filter out these. Independently of the
MADWeight, the accounting calculations will still go
towards the same result, so the MADWeight does
not affect the long term result of the accounting
calculation.
A value of “10” means that the wave peak of any
oscillation is reduced to 10%
IslossFree A checkbox describing whether or not the sampler
is done after being ignited or not. The ignition will
evaporate any LOI left in the sample resulting in
larger oxide concentrations. When marked, sample
is considered loss included.
NormalSampleTimeIn An integer datatype describing the normal period
tervalMM of time, in minutes, for which the sampler should
receive new samples. When no incoming samples
for the given sampler has been received in more
than 150% of given time, an alarm will be raised.
When NormalSampleTimeIntervalMM is given no
value, then no alarms will be raised when there is
a late/missing sample.
toolbar.

4.11 Modify SurgeBin
entity-node, that contains a property SubsectionType=SurgeBin
3. Select the SurgeBin entity-node.
SurgeBinCapacity The maximum mass capacity of the SurgeBin in
tons.
NOTE: This property must be populated for a
SurgeBin entity-node.
IOWeight The tag designation reference identifying the
SurgeBin’s measured weight signal coming from
the external system. The value of the incoming
signal is expected to be in tons.
IOMassFlow The tag designation reference identifying the
SurgeBin’s measured output mass flow signal
coming from the external system. The value of the
incoming signal is expected to be in tons/hour.
toolbar.

4.12 Modify Delay
entity-node, that contains a property SubsectionType=Delay
3. Select the Delay entity-node.
Length A double datatype describing the total length of
the delay in meters.
IOVelocity The tag designation reference of the velocity,
describing how many meters/second the material
on the delay is transported.
The value of IOVelocity is variable and can thus
change from one tick to the next.
This value will only be used when the FixedVelocity
column is null.
FixedVelocity A double datatype, describing how many
meters/second the material on the delay is
transported.
The FixedVelocity is a constant and cannot vary
from one tick to the next.
When the FixedVelocity is given a value, it
overrides any value from IOVelocity.
toolbar.
4.13 Modify Silo

entity-node, that contains a property SubsectionType=Silo
3. Select the Silo entity-node.
BlendingPart The ContinuousSilo’s BlendingPart constant in
Tons. This is used to calculate the oxide
concentrations and is the basis for silo mode
control actions.
NOTE: This property must be populated if the Silo
entity-node has the property value
SiloType=ContinuousSilo, and otherwise this
property should be null.
BatchCapacity The maximum mass capacity of the BatchSilo in
tons.

SiloType=BatchSilo, and otherwise this property
should be null.
IOEmptyBatch The tag designation reference identifying the
BatchSilo’s empty batch signal coming from the
external system. The BatchSilo is only emptied
when the value that IOEmptyBatch references, is
changed from “false → true”. Thus to empty the
BatchSilo once again later, it is first necessary for
the referenced value to change back to “false”,
and then again when it is changed to “true”
another BatchSilo emptying will occur.
should be null.
SamplePointId The sample point that will receive a composition
sample, when the batch silo is emptied.
NOTE: This property should only be populated if
the Silo entity-node has the property value
should be null.
toolbar.
4.14 Modify Splitter

entity-node, that contains a property SubsectionType=Splitter
3. Select the Splitter entity-node.
IOSplitterRatio The splitter ratio is a fraction in the interval [0;1]
describing the percent vise distribution of material
going out of the splitters two material output
streams.
The IOSplitterRatio is the tag designation
reference of the splitter ratio, when the fraction
comes from the external system.
The value of IOSplitterRatio is variable and can
thus change from one tick to the next.
When the IOSplitterRatio is given a value, it
overrides the value of the FixedSplitterRatio.
FixedSplitterRatio FixedSplitterRatio is a double datatype. The
splitter ratio is a fraction in the interval [0;1]
describing the percent vise distribution of material

going out of the splitters two material output
streams.
A FixedSplitterRatio of “0,35” means that 35% of
the material is placed in the primary output steam,
while 65% is placed in the secondary output
stream.
The FixedSplitterRatio is a constant and cannot
vary from one tick to the next.
toolbar.
4.15 Modify Trendable output

2. In the right data gird select the appropriate subsection.
3. Select the TrendAbleOutput tab.
For all trend able outputs the following fields must be set to:
 Compression: -1
 DataType: 1 (double)
 PiecewiseConstant: True (checked)
 TimeSeries: True (checked)
When the SubsectionType is: Delay or Merger

The following fields could only be set to:
 Algorithm: Null.
TrendAbleOutputType DataItem StdDevObsNoId PrimarySplit

[In ton per hour] Non Derived items Null Null
[Unitless] Derived items Null Null
[Total in ton per hour] Null Null Null
[In Percent Dry] Non Derived items Null Null
When the SubsectionType is: Mill

 Algorithm:
o For TrendAbleOutputType = [Status]:
Fls.Core.Value.BlxStateAlgorithm]
o Else: Null.


[In Percent Dry] Null Null Null
[Status] Null Null Null

When the SubsectionType is: Sampler
 The Algorithm:
o For TrendAbleOutputType = [State]:
[Fls.Core.Value.BlxSamplerStateAlgorithm]
o For TrendAbleOutputType = [MAD in Percent]:
[Fls.Core.Value.BlxMADAlgorithm]
o For TrendAbleOutputType = [Oxide Limit]:
[Fls.Core.Value.BlxOxideLimitAlgorithm]
o Else: Null

[In ton] Non Derived items Null Null
[MAD in Percent] Only Oxides Null Null
[Status] Null Null Null
[Total in ton] Null Null Null
[Unitless] Derived items or Any Null
Oxides
[Oxide Limit] Only Oxides Null Null
When the SubsectionType is: Silo


[In percent dry] Non derived items Null Null
[In ton] Non derived items Null Null
[Total in ton] Null Null Null
When the SubsectionType is: SurgeBin


When the SubsectionType is: Splitter
[In ton per hour] Non Derived items Null True/False
[Unitless] Derived items Null True/False
[Total in ton per hour] Null Null True/False
[In Percent Dry] Non Derived items Null True/False

5. User Access Control
5.1 The user access principles

When a user logs in to the portal a number of configurable claims are assigned to
the user. Either based on the user id or the user group(s) the user is a member
of. How to configure this is described in the related manuals section.
These claims are used to control what various users have access to do in the
portal.
For Qcx/BlendExpert, user access is divided into three areas:
1. The user access for HMI elements
2. The user access for faceplates.
3. The user access for the QCX/BlendExpert Toolbar.
5.2 User access for HMI elements

The user access for HMI elements is used to control a given HMI element
(enabled, visible etc.) on the HMI. Each HMI element may be adjusted as desired.
Two HMI user claims have been defined to be used in Qcx/BlendExpert context,
namely:
 Fls.QcxBlx.Operators
 Fls.QcxBlx.Engineers
The claim [Fls.QcxBlx.Operators] is by default assigned to the user group:
Operators
The claim [Fls.QcxBlx. Engineers] is by default assigned to the user group:
Engineers
Please referrer to appropriate documentation of how to use them in the HMI
editor.
5.3 User access for faceplates

The user access for faceplates is used to control which parts of a faceplate could
be edited, based on the claims provided. Which specific parts of a faceplate a user
can get access to, are predefined and cannot be changed. Only which user are
allowed to do so, can be changed.
There are three faceplates with user access:
 The Controller Faceplate
 The Feeder Faceplate
 The Sampler Faceplate
5.4 The Controller Faceplate

The controller faceplate contains the following predefined claims, which are by
default only assigned to users belonging to the Engineering User group:

 ChangeEliminationTime: Controls if the Change Elimination Time can be
adjusted from the Control configuration faceplate.
 ChangeAutoAcceptSetpoints: Controls if the “Auto Accept Setpoints
changes” can be adjusted.
 AddRemoveChangeRecipes: Controls if the possible to add, remove or
change recipes for the controller.
 AddRemoveChangeTargets: Controls if the possible to add, remove or
change targets for a recipe for the controller. This claim is only active if
the AddRemoveChangeRecipes claim is not activated.
 ChangeTargetParameterForTargets: Controls if the possible to adjust the
target values only in the targets grid for a recipe for the controller. This
claim is only active if the AddRemoveChangeRecipes or
AddRemoveChangeTargets claim is not available.
 AddRemoveChangeConstraints: Controls if the possible to add, remove or
change constraints for a recipe for the controller. This claim is only active
if the AddRemoveChangeRecipes claim is not available.
 AddRemoveChangeRawmaterials: Controls if the possible to add, remove
or change raw materials for a recipe for the controller. This claim is only
active if the AddRemoveChangeRecipes claim is not available.
 ChangeMinMaxOfTotalForRawmaterials: Controls if the possible to adjust
the minimum and maximum values only of the raw materials for a recipe
for the controller. This claim is only active if the
AddRemoveChangeRecipes or AddRemoveChangeRawmaterials claim is
not activated.
5.5 The Feeder Faceplate

The feeder faceplate contains the following predefined claims, which are by
default only assigned to users belonging to the Engineering User group:
 ChangeFeederParameters: Controls if “Feeder starvation alarm limit” and

the “Recalculate on starvation” could be adjusted.
 ChangeFeederDetailsParameters: Controls if the “Moisture” value and

“New sample weight” value and the values in the columns: “Default %”,
“Mini %” and “Max %” in the oxide grid could be adjusted. Additionally it
enables the two buttons: “Use current as default” and “Reset estimates”.
 ChangeRawmaterialAnalysis: Controls if the “Moisture” value and the

values in the column: “Default %” in the oxide grid could be adjusted.
Additionally it enables the button: “Reset estimates”. This claim is only
active if the ChangeFeederDetailsParameters claim is not Active.
5.6 The Sampler Faceplate

The sampler faceplate contains the following predefined claim, which is by default
only assigned to users belonging to the Engineering User group:
 ChangeSamplerParameters: Controls if values on the faceplate can be

adjusted by the user.

5.7 The User access for the QCX/BlendExpert Toolbar.
The QCX/BlendExpert Toolbar contains the following predefined claims, which are
by default only assigned to users belonging to the Engineering User group:
 ChangeControllerTuning: Controls if the controller tuning icon in the

toolbar is enabled. Please be aware that this claim will also provide
capabilities to adjust all parameters for the controller.
 ChangeEstimatorTuning: Controls if the estimator tuning icon in the

toolbar is enabled. Please be aware that this claim will also provide
capabilities to adjust all raw material and sampler parameters.

6. Report Card KPI
The BLX is the high level control system responsible for mixing the raw materials
in Cement production.
The BLX Mill analysis result is the main focus in the V8 report card. The BLX Mill
report results in 4 KPI values where 3 of those will be base for the OEE.
6.1 Availability
The calculation of BLX Availability is calculated in the aggregation report;
Availability = (Time in automatic / Mill Operation Time) * 100 %
Mill Operation Time is the In Production status, while the Time in automatic is
based on the controller aggregated status
6.2 Operation
The Operation KPI is how much time the equipment has been running;
Operation = (Mill Operating Time / 24 hours) * 100 %
6.3 KPI setup

The KPI report setup will be part of the engineering solution. So this section is
more for information.
6.3.1 The configuration of the solver programs to make KPI values.

The solver programs are:
 HeartbeatMonitor
o Used to monitor if a given plant section in QCX BlendExpert is in
operation, by monitoring the heartbeat pulse of the plant section. If no
heartbeat has been received within the last minute, the output is set to
an integer value of: 0 (zero) and no status bits are set. When at least
one heartbeat has been received within the last minute, the output is
set to an integer value of: 1 and operating status bit set.
o One needs to create one instance of this solver program per plant
section. The solver instance parameters must be set as:
 [Compression]: -1 or 0.
 [TimeSeries]: True
 [DataType]: Binary
 [GraphicalLow]: -1
 [GraphicalHigh]: 2
 [PiecewiseConstant]: True
o One input need to be specified per instance:
 HEARTBEAT: Should be linked to the core values aspect of the
IOHeartbeat of the plant section instance. If no I/O Heartbeat
exists, one needs to create one (e.g. a solver instance of
[OPERATOR INSERTED] of the double).

 ControlStatusToOperational
o Used to create operating values for three KPI values, based mainly on
the plant sections controller state (Ready, Ok and Automatic). So one
needs to create three instances of this solver program per plant
section: one for Ready, one for Ok and one for Automatic. The solver
parameters must be set:
 [Compression]: -1 or 0.
 [TimeSeries]: True
 [DataType]: Binary
 [GraphicalLow]: -1
 [GraphicalHigh]: 2
 [PiecewiseConstant]: True
o The output of each instance is set to an integer value of: 1 and
operating status bit set when the controller state is higher than the
specified level and the operating status bit of HeartbeatMonitor
instance for the plantsection is set. Else the output it is set an integer
value of: 0 (zero) and no status bits set.
o Three inputs needs to be specified per instance:
 CONTROLLERSTATUS: Should be linked to the core values
aspect of the controller status for the plant section.
 LEVEL: An integer constant. Should be 1 for the Ready KPI, 2
for the ok KPI, and 3 for the Automatic KPI.
 HEARTBEATMONITORSTATE: Should be linked to the core state
aspect of the output of the heartbeat monitor instance for the
plant section.
6.3.2 The configuration of a report to make KPI values for a plant section.
The solution contains report layout name: QcxBlxKPI
For each plant section a KPI report must be made. In the Reporting configuration.
The fields need to be set as follows:
 Name: The KPI report name for a plant section
 DescriptionId: The description for the KPI report for a plant section.
 ReportLayoutId: [QcxBlxKPI]
 DateTimeEntry: [Start date]
Once the report has been created, move to the [Report Configuration] and setup
each report as follows:
Add a [Value Day Report] Report query and create four samplings:
1) The IORunState for the mill in the plant section. Set the field as follows:
 Tag: The tag of the IORunState for the mill for the plant section.
 Label: MILL
 Category: [Operation Time]
 Total: [None]

2) The solver instance for the Operation Ready KPI for the plant section. Set the
field as follows:
 Tag: The Ready KPI tag.
 Label: RDY
 Total: [None]
3) The solver instance for the Operation Ok KPI for the plant section. Set the
field as follows:
 Tag: The Ok KPI tag.
 Label: OK
 Total: [None]
4) The solver instance for the Operation Automatic KPI for the plant section. Set
the field as follows:
 Tag: The Auto KPI tag.
 Label: AUTO
 Total: [None]

7. Related Manuals
7.1 Related Manuals

The “QCX/BlendExpert – Mill - User Manual” describes how to use the
QCX/BlendExpert application.
The “ECS & QCX Core – Hmi Reference Manual” describes how to use the HHI
editor.
The “ECS & QCX Core – Access Control Reference Manual” describes how to
configure users, user groups and claims.

TAB
TAB
Mill
User Manual
csc@flsmidth.com
Version QCX/BlendExpert V8.0
Disclaimer:
In no event shall FLSmidth be liable for direct, indirect, special, incidental, or consequential
this document.

Table of Contents
1. Introduction 4
1.1 Purpose 4
2. Concept and terms 5

2.1 HMI 5
2.2 Mimic 5
2.3 Button navigation 5
2.4 Matrix Navigation 5
2.5 Accounting 5
2.6 Estimator 5
2.7 Controller 5
2.8 Degree of freedom 6
2.9 Run Status 6
2.10 Constraint 6
2.11 Target 6
2.12 Set Point 6
3. Scenario overview 7
3.1 Select Scenario 7
3.2 Change Plant Section 8
3.3 Change Sub scenario 8
4. Using the Monitor sub scenario 8

4.1 Getting the overview 8
4.2 Looking at feeder collection status 9
4.3 Looking at feeder details 10
4.4 Changing Feeder Configuration 11
4.5 Looking at sample status 12
4.6 Looking at sampler details 13
4.7 Changing sampler configuration 14
4.8 Looking at estimation status 15
4.9 Looking at mill status 16
4.10 Looking at silo status 17
4.11 Looking at controller details 18
4.12 Recalculating Set points (Manual set point acceptance) 19
4.13 Configuring controller 21
5. Control Sub Scenario 25
6. Estimator Sub Scenario 26
7. Manual Accepted Control Actions 28
8. Related Manuals 29
8.1 Related Manuals 29

1. Introduction
Static toolbar Sub scenario toolbar
Navigation View Active Sub Scenario area
1.1 Purpose
The purpose of the BlendExpert user interfaces is to monitor, diagnose and tune
the performance of the BlendExpert control.

This manual is relevant for the daily users of the system such as laboratory
operators. Furthermore the manual is relevant for the engineer/administrator of
the system. The focus of the manual is therefore on monitoring, diagnosing and
tuning of the system.

The first part is a brief description of the concepts and terms involved in the
system. The understanding of these concepts and terms is crucial for the efficient
use of the following sections.
Subsequently, a number of sections describe the procedure to be followed by the
user to perform a specific task e.g. (“find configuration of….”). These descriptions
are set up in a step-by-step structure.

2. Concept and terms
2.1 HMI
HMI is an abbreviation for ‘Human-Machine Interface’; the apparatus or device
which presents process data to a human operator.
2.2 Mimic
This is the operator interface presented on the HMI and the target for the mimic
editor.
2.3 Button navigation

Navigate to another mimic by pressing a button in the current mimic. The button
typically has a text to indicate which mimic it will navigate to.
2.4 Matrix Navigation

Matrix Navigation is another way of navigation between mimics. The top mimic
will in this case be the first mimic the scenario opens. Each matrix level has a set
of mimics representing a plant section. First row will only contain the overview
mimic while second row contains status mimics and third row and down details.
2.5 Accounting
The QCX/BlendExpert product keeps account of the process at any time. The
accounting will always be up to date based on Process inputs, like feeder flows
and run state of equipment, and the latest oxide estimation base. This way oxide
concentrations and flows can be monitored and trended at key points of the
process. Sometimes the user can experience jumps in the accounting trends, this
is normally due to an update of the estimates resulting in an updated accounting.
2.6 Estimator
Every time a new lab or on stream sample is registered in QCX the estimator
updates the estimated values of the oxides based on deviation of the new sample
and the current accounting. The estimator is a key as a too slow reacting
estimator will result in a slower reacting controller. More details of the Estimator
can be read in the chapter describing the Estimator Sub Scenario.
2.7 Controller
The controller will calculate new feeder set points, based on current accounting,
whenever a control action is required. This will normally be whenever a new lab
or on stream sample arrives, but can also be requested manually or by a timer.
Automatically triggered control actions can either be accepted automatically
(recommended) or require manual acceptance.
In QCX/BlendExpert there are two different controller modes:
 Silo Mode – Where the controller will find a mix of raw materials that
result in a mix of the silo obtaining constraints and targets. The mix will be
obtained after the Elimination time of the silo control.

 Mix mode – Where the controller will find a mix of materials that obtains
constraints and targets.
2.8 Degree of freedom

The Degrees Of Freedom is a widely used term and in QCX/BlendExpert it’s used
in the control area describing how much room the controller have to do the
required control actions. In the area of raw material mixing it is a matter of if it is
possible to obtain a number of targets and constraints with the number off
feeders that can be controlled. The Degree of Freedom therefore gives an
indication of the number of constraints and targets we can hope to meet. As we
have a summation to 100% of our set points the Degree of Freedom will always
have a maximum of number of feeders minus one. Hope it makes sense that we
cannot control any chemical targets or constraints if we only have one raw
material. When a feeder goes into limitation, starvation or it’s deselected we lose
one degree of freedom. So with 6 feeders, where 3 is in limitation we only have 2
degree of freedom resulting in a possible control of 2 targets and constraints.
2.9 Run Status

This element shows the setup for a digital point which could be a running signal
for a motor. These signals can be used in some of the process units like in
Feeders, Samplers and Mills.
2.10 Constraint
The Constraints in QCX/BlendExpert are defined as high priority objectives that
should be obtained before considering the targets. A constraint can either be
relative or absolute:
 Relative constraints are connected to a target on the same oxide or
module and will follow the target value as it changes
 Absolute constraints do not require a target and the values inserted
on these are the absolute values constraining.
Constraints are defined in a prioritized list and lowest priority will be excluded
first based on the degree of freedom.
2.11 Target
The controller will after obtaining as many constraints as possible focus on the
targets. As these have weights the control action will based on an optimization
decide set points that results in the mix or silo content closest to the targets.
2.12 Feeder Gauge

The feeder gauge gives a graphical overview of the feeder control status. The flag
on the side indicates if the feeder is running (green flag), deselected (Yellow Flag)
or in limits (Warning box). The gauge bar represents the feeder capacity span
where the controller constraints have been marked in.

The following indications are shown on the Gauge:
1. Lower delta limit from last control action. Only visible if the feeder has a
delta limit within the feeder’s capacity.
2. Last Set point. The set point used before this set point was accepted.
3. Current Set point.
4. Higher delta limit from last control action. Only visible if the feeder has a
delta limit within the feeder’s capacity.
5. Minimum of total in %. The relative minimum set in the active recipe.
6. Maximum of total in %. The relative maximum set in the active recipe.
2.13 Set Point

A set point in QCX/BlendExpert is the controller output to the process control.
These set points are used to define the mix of the controllable feeders and will
always sum up to 100%. There are some values that are presented and
comparable with a set point.
Value Description
WSP WSP is an abbreviation for Working Set Point and

refers to the set point value read directly from the
PLC. This point is the same as the point where the
operator is changing the set point value of an feeder
SP SP is the abbreviation for Set Point and means the

value sent to an actuator by the operator or a high
level control. Once this set point has been accepted
by the PLC it will be overwriting the Working Set
Point.
CPV CPV is the abbreviation for Calculated Process Value

and means the Process Value relative in percent
calculated based on the PV values.
PV PV is the abbreviation for Process Value and means

the process value for the given feeder in mass flow
(t/h).
PVO PVO is the abbreviation for Process Value Offset and

describes the accumulated offset of the feeder over
time. A value not close to 0 is an indication that the
feeder control is not working correctly in the PLC.

3. Scenario overview
Static toolbar Sub scenario toolbar
Navigation View Active Sub Scenario area
3.1 Select Scenario

In the Navigation View select Product->QCX/BlendExpert->Mill
3.2 Change Plant Section

In the combo box ‘Plant Section’ chose the plant section the user wish to focus
on.
3.3 Change Sub scenario

There are 3 sub scenarios in under the Mill scenario they can be accessed using
the 3 buttons in the static toolbar:
1. Monitor (Default) – Open the monitor scenario for the selected plant
section
2. Control – Open the control tuning scenario for the selected plant section
3. Estimator – Open the estimator tuning scenario for the selected plant
section

4. Using the Monitor sub
scenario
The purpose of the Monitor sub scenario is to monitor and diagnose the
performance of the QCX/BlendExpert mill application. From the top it is possible
to detect deviations and dig into the reasons for those by matrix or button
navigation.
4.1 Getting the overview
The overview is located on the only mimic in the top of the HMI matrix and will be
the default one to open when switching to the Monitor scenario or changing Plant
Section. Normally the operator will ensure that there are no problems and that
we have stable control from this overview. The following things will normally be
verified by the operator:
1. Process status is visible in the boxes where process status is available.
This could be a collection of feeders, a mill, a sampler or any other parts
of the configuration that contains a status.
2. Controller status will publish the following
 Process status – If there is production or not.
 BLX Control Indicates the level of control
 BLX Ready
 BLX Selected
 BLX OK (Ready and Selected)
 BLX Heartbeat
 BLX Automatic (used by CCR)
 Constraints in percentage indicate how many of the constraints the
controller is able to obtain.
3. Estimation Status
 TBD when developed
4. Common KPI’s like Last 24 hour standard deviation on a lab module.
5. Some key trends to verify that we have a stable control and production

1
2 3
Figure illustrating principal placement of the areas described above. The

orientation may differ a bit from installation to installation.
4.2 Looking at feeder collection status

The feeder collection status can either be accessed by the HMI matrix or by
clicking in the field surrounding the feeder selection icon on the overview screen.
On this mimic the user can observe:
1. Status overview for each feeder detailing
 Selection indicator – is the feeder selected for control.
 Run mode – Feeder motor running
 Status indicator – Status of feeder
 SP – Set Point calculated by BLX
 WSP – Working Set Point used in process
 CPV – Process Value in percent
 PV – Process Value in t/h
 PVO – Process Value Offset in t/h
 Feeder Gauge – Described under Concepts and Terms
2. Trend illustrating key values history of feeder

1 2 1 2
1 2 1 2

orientation may differ a bit from installation to installation. This example is
illustrating a 4 feeder collection.
4.3 Looking at feeder details

The feeder details can either be accessed by the HMI matrix or by clicking in the
field surrounding the feeder section icon on the feeder collection screen. On this
mimic the user can observe:
1. Status for the feeder
 Configuration icon – see next chapter for details
 Selection indicator
 Run mode
 Status indicator
 SP – Set Point calculated by BLX
 PV – Process Value in t/h
 Feeder Gauge – Described under Concepts and Terms
2. Alarm list for active alarms of the feeder.
3. Trend illustrating set point tracking
 MinLimit – Minimum relative limit for feeder
 MaxLimit – Maximum relative limit for feeder
4. Trend illustrating Raw Material Composition
 Trend current estimated raw material composition for the key
oxides

1 2

4.4 Changing Feeder Configuration

Changing the feeder configuration should only be done if tuning is required or if a
feeder have changed raw material. Examples of when tuning can be required is if
the user know that the raw material have changed composition or moisture level
or if there are problems in the estimator finding a solution to the samples taken.
The feeder configuration faceplate can be opened from the feeder details mimic.
Using the faceplate key settings related to starvation and raw material estimate
can be changed. The settings can be changed using the following steps:
1. Starvation settings can be changed in this area
 If the controller should recalculate set points when deviation is
activated and deactivated
 The starvation limit relative to Working Set Point
2. Raw material selection
 If more than one raw material exists the user can change between
the raw materials here. This way we can edit in raw materials not
currently in the feeder.
 The currently used raw material will be marked by an icon, while
the remaining raw materials will be marked by an icon.
3. Common raw material settings can be changed here
 Moisture of raw material in %.
 New sample weight in %. In the case that raw material samples are
taken this is the weight it will be update with compared to the
current estimate.
 Homogeneity (read only). Informs about the homogeneity setting
for the raw material. High homogeneity means small changes are
expected in the raw materials.
4. Advanced raw material settings can be changed here
 In Oxides the limits and current estimates can be changed

 Default value for each oxide is used for start guess when
estimates are reset.
 Min and Max values for each oxide estimate can be set. If no
value is inserted the min value will be 0% while the value
for inserted max is 100%.
 Use current as default to overwrite the default values with
the values the estimator currently uses.
 Reset Estimates will overwrite the Current estimates with
the Default value.
 Data under Modules is based on the current estimates.
5. The user can either Ok or Cancel the changes made. Upon Ok the
configuration changes is committed.
xxx yyy zzz 2
Figure illustrating principal placement of the areas described above.
4.5 Looking at sample status

The sampler status can either be accessed by the HMI matrix or by clicking in the
field surrounding the sampler icon on the overview screen. On this mimic the user
can observe:
1. Status of the sampler
 Sampler status indicator
 Total Sample mass indicating the total mass that has passed the
sample since last sample was taken.
2. Trend area where main modules are trended. Each trend have the
following points
 Measured – Module calculated based on Sampler measured oxides
 Corrected – Module calculated based on QCX/BlendExpert re-
estimated oxides
 Standard deviation – Standard deviation of the module based on
the measured oxides

1

4.6 Looking at sampler details

The feeder details can either be accessed by the HMI matrix or by clicking in the
field surrounding the sampler section icon on the sampler status mimic. On this
mimic the user can observe:
1. Status of the sampler
 Sampler configuration icon . Described in next chapter
 Sampler status indicator
 Total Sample mass indicating the total mass that has passed the
sample since last sample was taken.
2. Alarm list for active alarms of the feeder.
3. Trend illustrating Estimated oxides
 The corrected oxides presented after re-estimation.
4. Trend illustrating Oxide samples
 The Measured oxides from the sampler
5. Trend illustrating Model Analysis Deviation
 MAD is the filtered error between the measured and corrected
analysis.
6. Trend illustrating Standard Deviation
 Standard deviation for each measured oxide.

1 2
3 4
5 6

4.7 Changing sampler configuration

Sampler configuration should only be changed if there is a need for a change.
Changes in common settings can be done if there is a need for example if there
are small samples or many production stops which results in too much noise in
the system. These can also be altered if it turns out that the current settings
filters out too many samples. Standard deviations should only be changed if the
sampler results in too much noise in the estimates or if the estimator is too slow
in reaction.
The sampler configuration faceplate can be opened from the sampler details
mimic. Using the faceplate key settings related to common sample settings and
standard deviation on oxides. The settings can be changed using the following
steps:
1. Common settings can be changed in this area
 Discard estimation on production stop – Discards a sample if there
has been one or more production stops during the sample period
 Discard estimation if sample represent less than in ton. Discard a
sample if the passing material during the sample period is less than
the number entered.
 Normal sample interval in minutes – defines the normal sample
interval. If no samples have appeared since 1.5 times the normal
sample interval the sampler status will change indicating missing
samples.
2. Standard deviations for the sampler can be changed in this area
 For each oxide the standard deviation of the sampler can be
inserted.
3. The user can either Ok or Cancel the changes made. Upon Ok the
configuration changes is committed.

1

4.8 Looking at estimation status

The estimation status can be accessed by the HMI matrix. On this mimic the user
can observe:
1. The estimation status details for each of the plant’s samplers. Each
column in this area describes a sampler (always 1-2 samplers for a
single plant) and either its related OxideLimits or MADLimits. Thus in
context to this, each row describes an oxide and its current
OxideLimits and MADLimits for each of the plant’s samplers.
 The individual OxideLimit bar and status can show 3 different
colors:
 Green: For a specific sampler, the given oxide’s value is
within its low/high-boundary set by the oxide’s OxideLimit.
 Yellow: The given oxide is locked and is not part of the
estimation on the respective sampler.
 Red: For a specific sampler, the given oxide’s value is out of
the low/high-boundary set by the oxide’s OxideLimit.
 The individual MADLimit bar and status can show 2 different colors:
 Green: For a specific sampler, the given oxide’s MAD-value
is within its low/high-boundary set by the oxide’s MADLimit.
 Red: For a specific sampler, the given oxide’s MAD-value is
out of the low/high-boundary set by the oxide’s MADLimit.
2. The overall estimation status, which depends on the estimation status
details, is summed up here.
3. Trend illustrating the oxide values of the plant’s first sampler.
4. Trend illustrating the oxide values of the plant’s potential secondary
sampler.
5. Trend illustrating the oxide MAD-values of the plant’s first sampler.
6. Trend illustrating the oxide MAD-values of the plant’s potential
secondary sampler.

2
3 5
4 6

4.9 Looking at mill status

The mill status can either be accessed by the HMI matrix or by clicking in the field
surrounding the mill icon on the overview screen. On this mimic the user can
observe:
1. Status of the mill
a. Mill status indicator
b. Production – The current production of the mill.
2. Trend illustrating production level
3. Trend illustrating modules out of the mill
a. The key modules based on simulated oxide content out of the mill.

1

4.10 Looking at silo status

The silo status can either be accessed by the HMI matrix or by clicking in the field
surrounding the silo icon on the overview screen. On this mimic the user can
observe:
7. Status of the silo
 Key modules based on accounting results
 Silo level - If available
8. Trend illustrating modules in the silo
 If we run in silo mode we will trend both module and target for the
module. If in mix mode only module will be trended.

1

4.11 Looking at controller details

The controller details can either be accessed by the HMI matrix or by clicking in
the field surrounding the controller status on the overview mimic. If
QCX/BlendExpert is running in silo mode control the mimic will be placed under
the silo status mimic while it will be placed under the mill in mix mode control. On
this mimic the user can observe:
1. Trend illustrating main module
 Trending target, accounting and sample measured.
2. [Optional]Recipe selection
 If multiple recipes are available in the setup, the recipe can be
changed here by using the combo box.
 As accounting only updates in a certain interval (default 5 seconds)
the text string indicating the current recipe name will follow a bit
later than the combo box.
3. From the Interaction area the user can.
 Recalculate – Recalculates set points and pop up a faceplate for
acceptance of the new set points. The pop up is described in a later
chapter
 Reset Silo – Reset the silo content. Should only be done if the silo
has been emptied or in the case where targets or constraints have
been changed drastically.
 Configure – A faceplate will pop up where the user can configure
the parameters of the controller. The pop up is described in a later
chapter.
4. Feeders section can be used to select the feeders for control and
observe the status of the feeders. For each feeder the user can:
 Select/deselect feeder for control
 See the name of the current raw material in the feeder
 See the feeder gauge and status of the feeder
 See the currently used QCX/BlendExpert set points

 See the QCX/BlendExpert set points from the last control action.
This can be used to see if the controller makes large set point
changes.
5. In the Targets area the user can observe
 Name of the target
 Target – See target value for the controller to meet
 Current – current accounting value for the target
 Result – the outcome of the control action. In silo mode this is the
value that the current value will meet after the elimination time if
no changes are made to set points or estimates. In Mix mode this
is the value that we will eventually meet if no changes are made to
set points or estimates. In normal conditions for silo mode control
these will not be meet as a new set of estimates normally are
injected before the elimination time period is gone.
 Trend – Get a trend of the three values above
6. In the Constraints area the user can observe which constraints have
been fulfilled during the currently used control action.
 The constraints are listed in the prioritizes order
 Green checkmark means constraint fulfilled
 Red Cross means constraint not fulfilled.
7. Alarm list for active alarms of the controller.
2
1
3
4 5
6

4.12 Recalculating Set points (Manual set point acceptance)

Recalculation of set points can be done whenever the user has made changes to
targets or constraints or if the user has changed the selection of feeders. It can
also be used for first time set points calculation while the process is stopped. In
other words recalculate set points can always be triggered.
This pop up will also be used when control actions are accepted manually.
Recalculation of set points can be triggered from the controller details. Observing
the result on the screen the user can either accept or reject the new set points.

In the unlike event that the controller cannot calculate new set points an error list
will pop up and inform the user about the reason for the failed control action.
When the controller has calculated a successful control action, the following can
be observed and interacted:
1. Common information area
 Active recipe – the user can see the recipe that is base for the
control action
 Calculation time – tells the user when the calculation is done.
2. Feeders section informs about the control action changes to the
feeders. For each feeder the user can observe:
 If the feeder is enabled for control.
 The name based on the current raw material in the feeder
 The feeder gauge and status of the feeder
 The new calculated QCX/BlendExpert set point.
 The QCX/BlendExpert set point from the last control action. This
can be used to see if the controller makes large set point changes.
3. In the Constraints area the user can observe which constraints have
been fulfilled by the new control action.
 The constraints are listed in the prioritizes order
 Green checkmark means constraint fulfilled
 Red Cross means constraint not fulfilled.
4. In the message area the user will get messages like if the controller
has altered relative limits due to feeder capacity limitations.
5. In the Targets area the user can observe
 Name of the target
 Target – the set target for the controller to meet
 Current – accounting value for the target
 Result – the outcome of the control action. In silo mode this is the
value that the current value will meet after the elimination time if
no changes are made to set points or estimates. In Mix mode this
is the value that we will eventually meet if no changes are made to
set points or estimates. In normal conditions for silo mode control
these will not be meet as a new set of estimates normally are
injected before the elimination time period expires.
6. The user can either Accept or Reject the control action.
 Upon Accept the new set points are committed. If a control action
has been committed since the recalculate button where pressed a
warning will appear to allow the user to overwrite or keep the more
resent control action.
 Upon Reject the control action is rejected and there is no update of
the set points.

1
2 3
4 5
4.13 Configuring controller

Controller configuration should only be changed if there is a need for it. The
normal changes done here are changes to targets and in some cases a change of
feeder relative limits. When these are changed the controller may be hit by
limitations and changes in the controller configuration should therefore always be
followed by a recalculation of set points to validate the changes made.
The controller configuration faceplate can be opened from the controller details.
The settings can be changed using the following steps:
1. From the base settings area the user can
 Control point (read only) – Defines the point of control if it’s a silo
the control will run in silo mode else it will be mix mode control.
 Analytical Basis (read only) – If the controller runs loss free or loss
included control.
 Elimination time in minutes (only silo mode) – Set the elimination
time in minutes for the control action. A decrease of the elimination
time results in a more aggressive control while increase will make
the control smoother.
 Auto Accept set point changes – When selected sample triggered
set points calculations will automatically be accepted. If deselected
a message will pop up every time a new set of set points is ready
for acceptance. This is described under Manual Acceptance of set
points.
2. Recipe selection and addition
 If more than one recipe exists the user can change between the
recipes here. This way the recipes not currently in use can be
edited.
 The currently used recipe will be marked by an icon.
 The selected recipe can be edited by clicking
 Change Name

 Change selection mask – the enumerator used to select the
recipe.
 The selected recipe can be deleted by clicking
 A new recipe can be added by clicking
 Define Name
 Define selection mask – the enumerator used to select the
recipe.
3. Define the control settings for the raw materials allowed to be used in
the selected recipe
 The selected raw material can be deleted by clicking
 A new raw material can be added by clicking
 Name – The name of the raw material and what feeder it is
assigned to. All controllable feeders must have at least one raw
material present in a recipe.
 Cost – Relative cost from 0 to 10. A high cost will result in a
minimization of that feeder if targets and constraints allow it. This
can be used if the user has more degree of freedom than required
by targets and constraints.
 Change Weight – will add a penalty for changes on a feeder at the
cost of target. This can be used if some feeders are known to give
disturbances to the process if they are changed too much.
 Minimum [% of Total] – minimum relative set point allowed for a
control action. Limitation of raw materials can result in a loss of
degree of freedom and thereby loss of targets and constraints.
 Maximum [% of Total] – maximum relative set point allowed for a
control action. Limitation of raw materials can result in a loss of
degree of freedom and thereby loss of targets and constraints.
 Maximum change [%] – maximum change in one control action,
when the user later compare Set Point with Last Set Point this
difference will be the max in positive and negative change
direction. Limitations like this can result in loss of degree of
freedom in the controller.
4. Add/remove targets and change current weight and target value
 A new target can be appended to the end of the target list by
clicking . This will be based on the static target list defined for
the plant section.
 The last target in the list deleted by clicking
 Display order – Is the display order of the target. This number will
be used in all presentations and are defined in the plant section
static target list.
 Item – Based on the plant section specific static target list the
name of the Item for the target are displayed
 Target – The controller target for a given item can be defined here.
 Weight – The target weight can be set here. This will be used to
weigh the controller result where the optimal solution would be to
hit targets spot on. If two targets have same weight it means that
it is equally bad for the system if the deviation is 1 absolute value
in the controller result. So remember that smaller absolute target
values will require higher weight than larger values to get the same
relative importance.
5. Change and prioritize constraints can be done in this section
 A new constraint can be appended to the end of the constrain list
by clicking .
 The selected constraint in the list deleted by clicking

 Change the priority of the selected constraint up in the list by
clicking
 Change the priority of the selected constraint down in the list by
clicking
 Priority – The priority starts from highest priority 1 to lower when
going down in the list. The QCX/BlendExpert controller will always
try to solve the control problem with all constraints fulfilled. If this
is not possible lowest priority constraint is taken out of the
constraint objective and so forth.
 Item – Select the Item for which the constraint should fulfill. It is
allowed to have more than one constraint for the same item, but
remember that the constraint must loosen up as we go up in
priority.
 Type - there are two types of constraints available select the
desired one from the drop down box.
 Interval – this type defines a fixed interval for the
constraint.
 Relative – this type defines the relative interval for the
constraint compared to the corresponding target. This
requires that the same Item is defined in the target list.
 Minimum – Constraint minimum value for the Interval type. In the
Relative type it is added to the current target, whilst it in the
Relative case must be zero or negative.
 Maximum - Constraint maximum value for the Interval type. In the
Relative type it is added to the current target, whilst it in the
Relative case must be zero or positive. The Maximum must be
larger or equal to the Minimum. In case Maximum is Equal to
Minimum we have an equal constraint, where the value must hit a
fixed target or specific constraint value.
6. The user can either Ok or Cancel the control configuration changes.
Remember to refresh HMI after adding or removing recipees
 Upon Ok the new controller configuration is committed. This
configuration will be used next time a control action is calculated.
Upon big changes it is a good idea to request a manual control
action. Remember to refresh the portal after Adding or removing
recipes to ensure an update of the recipe selector.
 Upon Cancel the controller configuration changes is discarded.

1
xxx yyy zzz 2
4 5
Figure illustrating principal placement of the areas described above.

5. Control Sub Scenario
1. 4. 6.
2.
3.
5.
The Control sub scenario is used to tune the controller based on a control action
in the past. The steps used to tune the controller will be:
1. Select the sample where the tuning should focus
 In Pop up filter on sample time and sample point and select the
sample in focus from the list to the right.
2. Observe the control action in regards to.
 Feeder, target and constraints results.
3. Change the configuration for the active recipe during the control
action.
4. Click on the calculate button to use the altered configuration in a
new control action calculation.
5. Observe and compare new control action with the old one.
6. Commit the changes will commit the configuration changes and change
the recipe used at the sample time. Next time a control action is
calculated the new settings will be used.

6. Estimator Sub Scenario
2. 7. 8. 9.
1.
111 222 333 3. 111 222 5.
4. 6.
8. 8.
The estimator sub scenario is used to tune the estimator. This will normally be
used during commissioning phase or when a periodical service is done. In some
cases where the estimator is hitting limits or has a bad performance it is a good
idea to retune using the estimator sub scenario.
The steps used to tune the controller will be:
1. Select a period for the data to tune the estimator on.
2. Click the get data icon in the toolbar to get the data from the
database
3. In the tab selection the user can choose the raw material that needs
tuning or the user wish to monitor
4. Change the properties in Settings. Here the user can change:
 Moisture of raw material in %.
 Homogeneity - Set the homogeneity setting for the raw material.
High homogeneity means little changes are expected in the raw
materials.
 Estimation enabling for each oxide is used to define if the oxide
should be estimated or always keep the default.
 Default value for each oxide is used for start guess when estimates
are reset.
 Min and Max values for each oxide estimate can be set. If no value
is inserted the min value will be 0% while the value for inserted
max is 100%.

 Oxide delta Y axis is used for the representation in the plot area in
this scenario. If no value are inserted the trends will auto scale.
Can be used to set same delta range for all oxides for numerical
comparable trends.
5. Select sampler to tune or monitor.
6. Observe the accumulated fit or change the properties in Settings. Here
the user can:
 Observe the accumulated fit for the sampler. Defines how well the
estimates fit the sampler oxide standard deviation.
 Discard estimation on production stop – Discards a sample if there
has been one or more production stops during the sample period
 Discard estimation if sample represent less than in ton. Discard a
sample if the passing material during the sample period is less than
the number entered.
 Max change in oxide per sample in % defines how much an oxide
can change based on a sample from this sampler.
 Change Standard deviations for each oxide in the sampler. A lower
standard deviation means that we trust the sample results more
and make a more tight estimation.
 Under Fit Result Weight the weight of the fit of that oxide is
defined. These weights are used to calculate the total fit factor. A
high weight is advised for the important oxides while oxides of
lesser importance should have low weights.
 Oxide delta Y axis is used for the representation in the plot area in
Can be used to set same delta range for all oxides for numerical
comparable trends.
 Module delta Y axis is used for the representation in the plot area in
7. Click Calculate to estimate using the new settings.

8. Observe the results in the graphs using the filters in the toolbar to
evaluate the results
 Will filter in or out the current result. This is the online results of
the Estimator using the current configuration. The results are both
in the raw material estimates and the sample result.
 Will filter in or out the new result. This is the estimated results
of the Estimator using the new settings. The results are both in the
raw material estimates and the sample result.
 Will filter in or out the sample results. The results are only in the
sample result.
 Use area 3 and 5 to browse the trend views for raw materials and
samplers
 Double click on any trend to expand the trend and track the
results.
 Also observe the Accumulated Fit in area 6. The fit should be as
close to 0 as possible. High fit indicates that the estimates describe
the sampler noise too loose, while low fit indicates a tight fit. This
can be changed by changing the homogeneity of the raw materials
or the standard deviation of the samplers.
9. Commit the changes will commit the configuration and change the
estimation behavior from now.

7. Manual Accepted Control
Actions
There should be really good reasons to use Manual Accepted Control Actions, but
if the QCX/BlendExpert is set up to do this the user will have a Workplace
notification with the new control action. Follow the steps below when a new
manual control action arrives:
1. Click on the message symbol blinking in the upper right of the
workplace.
2. Follow the descriptions in the chapter describing “Recalculating Set
points (Manual set point acceptance)”

8. Related Manuals
8.1 Related Manuals

ECS & QCX Core – Trend - User Manual
ECS & QCX Core – HMI - User Manual
ECS & QCX Core – Workplace - User Manual
ECS & QCX Core – Event Historian User Manual
QCX Basis – Sample Viewer – User Manual

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QCX Blend Expert Software Manual

Plant Name: Beni Suef Cement

Contract Number: 2871777259-164X

Created by: TORJ

Doc. No.: 80048000 - 1.0

QCX Blend Expert

Last modified 2016-02-23

Copyright © FLSmidth A/S. All rights reserved.

1.2 Intended audience

1.3 How to use this manual

After each major installation step, a verification step is requested in each

Please contact FLSmidth Customer Service Center csc@flsmidth.com or

1.4 Installation overview

2.1 Hardware requirements

2.2 Software requirements

3.1 Pre-installation of QCX/BlendExpert

3.2 Installation of QCX/BlendExpert

3.3 Installation of the Workplace

4.1 Un-install Workplace

4.2 Un-install QCX/BlendExpert

Version QCX/BlendExpert V8.0

Last modified 2016-02-25

Copyright © FLSmidth A/S. All rights reserved.

Mill QCX/BlendExpert V8.0 2

2. Concept and terms 6

3. Access Control Claims 7

5. User Access Control 16

6. Report Card KPI 18

Mill QCX/BlendExpert V8.0 3

1.2 Intended audience

1.3 How to use this manual

Mill QCX/BlendExpert V8.0 4

2.5 Message type

2.7 Reserved items

Mill QCX/BlendExpert V8.0 5

3.1 Access control claims

Mill QCX/BlendExpert V8.0 6

4.1 Introduction to the QCX/BlendExpert configuration

Please note: the QCX/BlendExpert system will always be pre-configured by a

If it becomes necessary to add/change/remove properties in the solution the user

4.2 Open Mill subproduct configuration window

4.3 Modify Controller

Mill QCX/BlendExpert V8.0 7

4.4 Modify DataItem

Mill QCX/BlendExpert V8.0 8

The low-alarm for

The high-alarm for

OxideLimitReachedCo An integer describing the number of times a

4.6 Modify MillManager

Mill QCX/BlendExpert V8.0 9

4.7 Modify RawMaterial

4.8 Modify Feeder

Mill QCX/BlendExpert V8.0 10

4.9 Modify Mill

Mill QCX/BlendExpert V8.0 11

4.10 Modify Sampler

Mill QCX/BlendExpert V8.0 12

Mill QCX/BlendExpert V8.0 13

4.13 Modify Silo

Mill QCX/BlendExpert V8.0 14

4.14 Modify Splitter

Mill QCX/BlendExpert V8.0 15