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Boosting Uptime, Efficiency & Cyber Resilience with FLSmidth Cement’s ECS/ControlCenter 9
Karbala Cement's facility in Iraq faced operational challenges due to an outdated control system that resulted in frequent unplanned shutdowns and a dependence on specialized technicians. Addressing these issues, Lafarge Karbala partnered with FLSmidth Cement to implement the ECS/ControlCenter™ 9, a modern automation platform specifically designed for the cement industry. This solution streamlined diagnostics, enhanced cybersecurity, and empowered operators with intuitive controls, reducing reliance on specialists. The upgrade, which reused existing hardware, led to improved reliability and operational efficiency, eliminating unplanned downtimes and fortifying the plant's security. This transformation laid a solid foundation for sustainable growth at Karbala Cement.
Boosting Uptime, Efficiency & Cyber Resilience with FLSmidth Cement’s ECS/ControlCenter 9
The Challenge: Aging Systems Hindering Performance and Security
At Karbala Cement’s facility in Iraq, an outdated Polcid control system, built on Rockwell RSview with Siemens I/Os on Profibus DP, created significant operational challenges. The plant experienced frequent unplanned shutdowns, which were difficult to diagnose and resolve, leading to costly downtime. Additionally, the system’s complexity meant that even basic troubleshooting required reliance on specialised technicians, slowing down operations. Compounding these issues, the lack of standardised cybersecurity measures left the plant vulnerable to growing digital threats. “The old system was sluggish, prone to failures, and lacked modern security measures. Our team struggled to pinpoint issues quickly,” said Mr. Salah Hassanein, Instrumentation & Projects Lead at Lafarge Karbala Cement.
- Recurrent unplanned downtime with complex, hard-to-trace issues
- Heavy reliance on specialized technicians for routine operations
- Growing cybersecurity risks due to obsolete system
The Solution: A Robust, Cement-Tailored Automation Platform
To address these challenges, Lafarge Karbala partnered with FLSmidth to implement ECS/ControlCenter™ 9, a state-of-the-art automation platform designed specifically for the cement industry. This solution enables rapid trip diagnostics by providing detailed interlock insights directly through faceplates, streamlining issue resolution. It incorporates advanced cybersecurity features, including role-based access, encrypted communications, and a new network architecture, to protect against digital threats. The platform’s intuitive, standardised controls reduce the need for specialist intervention, empowering operators to manage operations efficiently. Additionally, FLSmidth’s ACESYS (Cement Specific) library ensures seamless integration with cement-specific processes, enhancing overall performance.
- Rapid trip diagnostics with detailed interlock insights via faceplates
- Advanced cybersecurity with role-based access, encrypted communications, and a hardened architecture
- Intuitive, standardised controls to minimize specialist dependency
- FLSmidth’s ACESYS library for seamless integration with cement processes
ECS/ControlCenter™ has revolutionized our plant’s performance and security, laying a solid foundation for sustainable growth.
Mr. Salah Hassanein, Instrumentation & Projects Lead at Lafarge Karbala Cement
Engineering Precision: A Seamless, Budget-Friendly Overhaul
The upgrade was meticulously planned to minimize disruption and costs. Existing hardware, such as I/Os and panels, was retained to optimise expenses, while outdated PLCs and communication cards were replaced with modern SIEMENS 1500 Controllers, secure alternatives. The PLC logic was rewritten to ensure standardisation and efficiency, eliminating inconsistencies in the system. By leveraging ECS/ControlCenter’s simulation mode, the team tested and refined operations before deployment, reducing risks during commissioning. “We revamped the tag database, standardised the logic, and bolstered cybersecurity while keeping costs low by reusing hardware. It was a challenging yet highly efficient transformation,” noted Prasath Kumar, Engineering Manager at FLSmidth.
- Reused existing hardware (I/Os and panels) to optimize expenses
- Upgraded PLCs and communication cards to modern, secure standards
- Streamlined PLC logic for consistency and efficiency
- Utilised ECS/ControlCenter’s simulation mode to test and perfect operations pre-launch
User interface for ECS/ControlCenter™ 9 for coolers
The Impact: Enhanced Reliability, Security, and Efficiency
The implementation of ECS/ControlCenter™ 9 has transformed operations at Lafarge Karbala. The plant now experiences no unplanned stoppages, thanks to faster and more effective troubleshooting capabilities. Operators are empowered to handle issues independently, reducing reliance on specialists and improving operational efficiency. The upgraded system also provides robust cybersecurity measures, ensuring the plant is well-protected and future-ready. Furthermore, the use of simulation during commissioning has lowered lifecycle costs by minimising risks. “ECS/ControlCenter™ has revolutionized our plant’s performance and security, laying a solid foundation for sustainable growth,” said Mr. Salah Hassanein.
- No unplanned downtime and faster issue resolution
- Empowered operators, reducing the need for specialist intervention
- Fortified cybersecurity, ensuring future-ready operations
- Lower commissioning time through simulation-driven commissioning
It was a remarkable experience serving Karbala Cement, where I received exceptional support and understanding from the site team, which greatly contributed to the successful commissioning. Karbala Cement recognizes the efforts of Commissioning Specialist Riyaz Abdullah Mohammad for earning well-deserved appreciation
User interface for ECS/ControlCenter™ 9 for kilns
Ready to Modernize Your Plant?
If your plant is grappling with outdated systems or cybersecurity vulnerabilities, FLSmidth’s ECS/ControlCenter™ offers a proven solution to enhance uptime, efficiency, and resilience. Contact us to explore how this platform can transform your operations.
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