Transcript PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL PLANT…

PROCESS CONTROL
COMPUTERS AT
DURGAPUR STEEL
PLANT’S
BASIC OXYGEN
FURNACES
OBJECTIVES


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
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HELP REDUCE PROCESSING TIME
MONITOR PROCESS IN REAL-TIME
HELP INCREASE IN PRODUCTIVITY
ACHIEVE ‘C’ / TEMP. HIT RATE %
MANAGEMENT INFORMATION
SYSTEM
ENSURE QUALITY OF PRODUCT
AUTOMATION LEVELS
 LEVEL 0 - FIELD INSTRUMENTS /SENSORS
CAPTURING ANALOG AND DIGITAL DATA.
 LEVEL 1 - BASIC AUTOMATION SYSTEM
HAVING A SUPERLOOP OF TWISTED PAIR
CABLE CONNECTING PCUs, WSAs , CIUs.
 LEVEL 2 - VAX 3300 SYSTEMS ONE FOR
EACH CONVERTER; CONNECTED TO CIUs
OF LEVEL 1 & COLLECT DATA FROM
LEVEL 1 AND PASS SET POINTS.
 LEVEL 3 - VAX 3800 CLUSTER CONNECTED
TO LEVEL 2.
LEVEL I - LEVEL II - LEVEL III
COMMUNICATION
RS-232
CIU (L1)
VAX (L2)
DECNET
VAX (L3)
NETWORK 90 SUPERLOOP
WSA
PCUs
FIELD
(SUPERVISORY)
(22)
( I/O)
 DISPLAYS
 SEND COMMANDS TO PLSs
 CHANGE SET POINTS, NODE ETC.
 OPERATOR -> BULK MATERIAL ADDITION
SMS HARDWARE
 MicroVAX 3800 Cluster - 2 M/Cs called Level 3 Systems
 MicroVAX 3300 Computers - 4 M/Cs , 1 for each Converter and
1 for VAD
 MicroVAX 3100 - for BOF Lab
 Cluster Monitor
 8 Terminal Servers, 2 Repeaters, 500 m Fiber Optic Line
 DEC Router, 45 Terminals and 20+ printers including 1 Laser
printer, 1 Plotter and 1 Line printer
 Connections to Control Room and Blower desks at 9M,
VAD,LDS,LTS, CCP, Mixer Bay, Scrap Yard, Welfare Building,
LAB
 Commissioned by DEMAG (Germany)
Hardware Position at Steel Melting Shop of Durgapur Steel Plant
CIU1
CIU2
CIU3
Consoles
Consoles
L2
VCS01
VAX
3300
L2
BCS03
VAX
3300
L2
BCS02
VAX
3300
L2
BCS01
VAX
3300
L3
SSC02
VAX
3800
L3
SSC01
VAX
3800
L3
SSC03
VAX
3100
23 MLEVEL
THICK ETHERNET CABLE
SSS03
SSS05
SSS07
DECROUTER
REPEATER
DESPATCHER
9M LEVEL
SMS PLANNING CELL
BOF1 – L2
BOF3 -L2
BOF1 – L2
BOF3 – L2
DESP – L2
DESP – L3
DESP – L2
DESP – L3
SSS04
L2
LAB01
3100
SSS02
SSS01
23M PROGRAMMER/ C.P.U. ROOMS
BACKUP TERMINAL AT LAB
MIXER – L2
TERMINALs
LAB TERMINALS
F I B E R O P T I C C A B L E TO C.C.P.
SCRAP YD – L2
REPEATER
BOF2 – L2
Line Driver to L.D.S.
SSS07
SSS06
V.A.D. CONTROL ROOM – 9M
L.T.S. &
LADLE DESPATCHER (L2 / L3)
SUMMARY
VAD - L2 / VAD - L3
TEEMING BAY
C.C.P.TERMINALS
L
NO OF L3 SYSTEMS
: 2 (3800) + 1 (3100)
NO OF L2 SYSTEMS
NO OF SITES/TERMINALS
: 4 (3300) + 1(3100)
TOTAL = 8
: 11 / 45
NO OF PRINTERS
: 16
NO OF DECSERVERS
: 8
L2
NO OF REPEATER /ROUTER : 2 / 1
As on 1st June 2002
SYSTEM SOFTWARE
 OPEN VMS 5.5-2
 VAX FORTRAN, DECNET, DECFORMS, GKS, TCP/IP,
ORACLE RDB, VOLSHAD, CLUSTER MONITOR
 MODAS ( Case Tool )
APPLICATION SOFTWARE
 DIALOG BASED & BACKGROUND PROGRAMS
 L II CONVERTER SPECIFIC SOFTWARE
 L II TEE,CCP,LTS,VAD SPECIFIC SOFTWARE
 L III ( Scheduling, Tracking )
 L II TO L III AND L III TO LIV COMMUNICATION S/W
INFORMATION FLOW BETWEEN DIFFERENT
LEVELS AT S.M.S DURGAPUR STEEL PLANT
Level 1 to Level 2
Level 2 to Level 1
• Heat status e.g., HS,BS,TS,TE
• Each heat’s data like bulk material
addition, temps, lance position. Co/co2 at
tap end
• Converter activities as seen in event log
• Set point passing for o2 and bulk
materials after metallurgical calculations
like :
* Process aim, hot metal ordering
main & 2nd blow calculation, end
blow & alloying additions
• Mode of converter operation
Teeming Reports
Graphic Printouts
Heat Reports
Level 2 to Level 3
* Heat Number
* Heat Data * Heat Status
Level 3 to Level 2
•Schedule/Plan for the day
* Steel/Hot Metal/Slag Analysis
•Ladle details
* CCP/LTS, Teeming Data
•Grade Specifications / Definitions
* Scrap Yard/ Mixer Data
•Actual Steel Grades
M.I.S. Reports
Query Reports
Level 4 to Level 3
Level 3 to Level 4
* Heat Number * Teeming /CCP Cast Data
•Schedule Data
* Heat Data * Steel/H.Metal/Slag Analysis Data
•Actual grades of cast from
laboratory Level 4 terminal
* Backlog details of the above, if any.
Level 2 System Tasks
 Heat Number Generation
 Metallurgical Calculations
 Heat status monitoring
 Select Mode of operation
 Analysis data entry from Lab
 Event log generation
 Data transfer <-> Level 3 Systems
Level 3 System Tasks
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Heat Tracking
Ladle Tracking
Shop Scheduling
Grade definitions
Data Transfer to PPCS
Database Upkeep
Software development
Level 2 Models
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Process Aim calculation
Hot Metal /Scrap Ordering
Blowing Calculation
2nd Blow Calculation
Reblow Calculation
Alloying Calculation
Feedback Calculation
Process aim calculation
It is a feasibility check
It reads grades and re-blow
pattern
The model predicts aim Carbon
percentage and the
temperature of liquid steel at
the end of blow
PIC 60
DISPLAY
HEAT NO. 02311369
CHARGE ID 23631
PROCESS AIM CALCULATION
STEEL GRADE R16
PETRO COKE N
LADLE DATA
STEEL LADLE NO
15
USE LOCAL LADLE DATA N
EMPTY LADLE
0
WALL LIFE
75
BOTTOM LIFE
23
PREHEATING DUR
0
LADLE SKULL WT
0.00
BLOW. PATTERN NO.
BOT. STIR PAT NO.
ORDERED STEEL WT
751
19
122.00
15-JAN-03 11:16:24
AXLE STEEL
ADDITIONS
FeSi
Al
SiMn
FeMn
Carbon
C CONTENTS
200
50
1650
0
450
DESULPHURIZER
0
SYNTHETIC SLAG
0
C AIM EOB
C AIM LDL
0.080
0.200
TAPPING DATA
MAX SiMn
TAP TMP LOSS
EXP TAP DUR
WAIT TIME
TAP CORR INP
1700
9
9
5
-60
TEMPERATURES
ALL OTHERS
PRESET ADDITIONS
NUM BATCHES [ ½ ]
KILLED STEEL
0
1
Y
TOTAL
0
2350
AIM TMP EOB
AIM TMP LDL
AIM TMP CAST
1674
1630
1563
Hot metal and scrap
ordering calculation
Hot metal, scrap or iron ore can
be fixed
Mixer and ladle number are a
must
Bulk materials are calculated
Download order to mixer and
scrap yard bay
Basicity can be adjusted
PIC 61
DISPLAY
HEAT NO. 02311369
CHARGE ID 23631
HOT METAL AND SCRAP ORDERING CALCULATION
STEEL GRADE R16
AXLE
STEEL
CONVERTER AIM DATA
INT-DESL DUR
0
INT-MEAS DUR
5
INT-STOP
EXP TMP
1674
EXP C-CONTENT
0.178
BLOWING END
AIM TMP EOB
1703
C AIM EOB
0.080
P MAX EOB
0.032
AIM BASICITY
3.0
S MAX EOB
0.100
DEM IRON ORE
0
DEM % BAUXITE
0.00
HOT METAL DATA
MIXER NO
HM LDL NO
HM EXP TMP
HM ORDER WT
HM DEM WT
HM ACTUAL WT
DESLAGGED (Y/N)
2
06
1269
125.00
125.00
0.00
N
EXP ANALYSIS END OF
BLOW
C
Mn
P
S
IMS 0.178 0.062 0.042 0.035
EOB 0.080 0.040 0.021 0.035
15-JAN-03 11:20:24
SCRAP DATA
MENU NO
TRIM TYPE
BOX NO
ORDER WT
DEM WT
ACTUAL WT
7
S00003
9.11
0.00
0.00
ADDITION DATA
LIME
9469
DOLOMITE
2000
IRON ORE
224
LIMESTONE
Mn ORE
FLUOSPAR
Main blow calculation
Done after start of heat
Actual hot metal weight and
temperatures are given as input
to the model
Model advices oxygen amount
to be blown ( 1st blow )
It also outputs expected steel
composition at endpoint and
slag weight
PIC 62
DISPLAY
HEAT NO. 02311369
CHARGE ID 23631
CONVERTER AIM DATA
INT – STOP
EXP. TMP
1673
BLOWING END
AIM TMP EOB
1674
C AIM EOB
0.080
AIM BASICITY
3.0
DEM % BAUXITE 0.00
PROCESS DATA
BLOW. PAT NO.
751
BOT STIR PAT NO. 19
DEM O2 FLOW
430
LANCE HT
165
EXP BATH WT
126.99
MAIN BLOW CALCULATION
STEEL GRADE R16 AXLE STEEL
15-JAN-03 11:38:24
HOT METAL DATA LDL NO : 06
ORDER WT
125.00
ACT WT
130.00
ACT TMP/TIME
1211 / 11:20
CHARGING TIME
11:11
SCRAP DATA BOX NO
CODE : S00003
ORDER WT
9107 Kg
ACT
10000 Kg
BATH ANALYSIS
C
Mn
P
S
IMS
0.157 0.048 0.026 0.035
EOB
0.080 0.031 0.014 0.036
MODEL ADVICES
O2 AMOUNT
6045
LIME
9863
DOLOMITE
2000
IRON ORE
252
MN ORE
FLUOSPAR
BAUXITE
LIMESTONE
SLAG ANALYSIS
FeO
CaO
MgO SiO2
IMS 18.27 48.95 4.87
16.59
EOB 23.79 45.43 4.53
15.43
Second / Re-blow
calculation
After taking sample and temperature
during first blow, this calculation can
be done
Model advices oxygen amount and
bulk material additions/coolants
Expected end values
Re-blow is necessary if percentage
of Carbon is too high, slag is too
viscous
PIC 63
DISPLAY
HEAT NO. 02311369
CHARGE ID 23631
SECOND BLOW AND REBLOW CALCULATION
STEEL GRADE R16 AXLE STEEL
ACTUAL PROCESS STATUS MAIN BLOWING 2
15-JAN-03 11:38:24
NUM OF REBLOWS 0
CONVERTER AIM DATA
AIM TMP EOB
1674
C AIM EOB
0.080
P MAX
0.032
S MAX
0.100
DEV. LANCE H T
-10
ORE MAX
0
LIMESTONE MAX
0
PREV. ADD ADVICE ACT
LIME
9863 11275
DOLOMITE
2000
894
IRON ORE
252
1716
MN ORE
FLUOSPAR
BAUXITE
LIMESTONE
OXYGEN PU
MEASURED DATA
TMP EXP
TMP ACT
TMP TAKEN
PREV. BLOWING PERIOD
ANALYSIS DATA
ADVICE ACT
LANCE HT
165
0
O2 AMOUNT 6045 6084
C
PRE 0.157
ACT 0.090
NXT 0.050
NEXT BLOWING PERIOD
TMP EXP
1674
LANCE HT
155
O2 AMMOUNT
200
IRON ORE
0
LIMESTONE
0
BAUXITE
0
MN ORE
0
QUICK TAPPING [Y/N]
MN
0.048
0.080
0.070
P
0.026
0.035
0.029
S
0.035
0.040
0.039
N
FE TOTAL IN SLAG
14 %
1674
1660
TECTIP C
SAMPLE CODE
SAMPLE TAKEN
Offline alloying
calculation
Done before Tap Start
This model advices three
different combinations of alloys
C , SiMn, FeSi, FeMn are
calculated
PIC 66
DISPLAY
OFFLINE ALLOYING ADVICE
HEAT NO.: 02311369
15-JAN-03 12:09:23
CHARGE ID : 23631
EXP. STEEL WT.: 127.0
LADLE ANALYSIS :
C
Mn
Si
P
S
AIM:
0.200
0.600
0.080
0.040
0.030
ACTUAL
0.028
0.012
0.050
0.005
0.031
RESULT 1
RESULT 2
1056
SiMn
0
SiMn
1289
FeMn
345
FeMn
0
FeMn
213
Coke
611
Coke
0
Coke
447
COST (2) – RS 0.0
ELEMENT
C
SI-FESI
YIELD :
45
65
MN-FEMN
85
10.00
RESULT 3
SiMn
COST (1) – RS 30902.0
C LOSS
COST (3) – RS 38566.2
SI-SIMN
MN-SIMN
65
85
Level II VCS System
This system is significant after tap
end
This system has data entry and
monitoring screens for
 LADLE TREATMENT STATION
 CONTINIOUS CASTING PLANT
 TEEMING BAYS
 LADLE DESPATCHER
 PRODUCTION DATA ENTRY SCREENS OF
TEEMING AND CONTINIOUS CASTING PLANT
Level 3 Models
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Heat Tracking In Shop
Heat Scheduling
Ladle Tracking
Ladle Overview
Data Storage
Data Transfer To Level 4 PPC
System
Production status of
steel shop
Shows the status of last 10
heats
One can know the heat number,
status, area, start / end times.
DIALOG 23
DISPLAY PRODUCTION STATUS STEEL SHOP
HEAT NO.
CHID
LDL
ST
CONVERTER
02110767
22951
14
CE
BOF–1 04:36
05:18
TEA-06:00
06:51
02310768
22952
08
CE
BOF-3 05:02
05:45
TEA-4 07:09
07:50
02110769
22949
18
CE
BOF-1 05:21
LTS-2 06:42
CCM-1 06:51
06:15
06:44
08:12
LTS-1 06:53
07:00
CCM-2 07:03
09:00
02310770
22939
17
CE
BOF-3 05:47
05:45
02110771
22942
02
HS
BOF-1 06:17
02310772
22943
01
BS
BOF-1 05:55
TRANS
01-JAN-03 10:19:51
SECONDARY TRANS CASTING
Heat schedule
Shows the planning of the shop
Heat status, grade, route code
Start / end time of different
areas
PIC 5O
N ST
O
DISPLAY
HEAT NO
CARG
ID
HEAT SCHEDULE - SSC
GRADE
CODE
HEAT
START
TAP.
END
2. MET
STAR
01-JAN-03 10:27:24
2.MET
END
CAST CAST ROUTE
START END CODE
BDVLCT
1
CE
02110771
22942
107482S
06:25
07:26
2
CE
02310772
22943
107482S
06:30
07:45
08:09
3
CS
02310774
22963
XCHEPA
07:57
09:19
09:42
4
BS
02210773
22966
ASP1241
0730
08:48
09:15 100001
08:11
08:31
10:04 300003
09:43
09:44
10:05 300110
200220
5
1786415
300004
6
ASP3110
200003
7
107482S
100110
8
XCHEPA
300002
9
107482S
200220
Ladle tracking and Ladle data
 Shows a map like view of positions
of ladles in the entire steel shop
 Ladle placement times are captured
 Temperatures/times at various
points like preheating, porous plug
in/out, gate preparation start/end are
captured
 Status, location, last cast end, tap
start, reference details, life of
PP,WB,In,On etcetera
PIC 99/1 (2)
LADLE STATUS
VAD
HEAT AND LADLE
SCHED. END
>
>
NEXT PROC. AREA >
INJ
BOF –1
BOF - 2
10776
00:00
TEA-4
TEA- 3
TEA–2
TEA - 1
BOF - 3
10755
00:00
LTS-1
17
=
TEA - 4
01-JAN-03 10:27:24
NUMBER
02
=
ST VD HM
IN USE
4
AT LPB
15
EXT MT
8
1
6
PARK 04 06 11 13 21 25
DRYER
TEA –5
PARK 05 19 26
CSTF
07 08 14
Ladle overview
Shows the ladle status / position in
the shop
One can know the ladle number,
status, area and time of placement
Current Heat Number attached
with a ladle is displayed
PIC 72
DISPLAY
STEEL LADLE OVERVIEW
01-JAN-03 10:27:24
LD
L
STATUS
LOC
LD
BT
IN
ON
PP
WB
CURRENT
HEAT
01
-
M DN
LR6
NEW
NEW
NEW
NEW
NEW
NEW
SHEL. RPR
02
C
O PP
DE2
20
20
20
4
15
20
03
C
O PH
LH3
18
NEW
0
0
0
NEW
TO MAKE
04
C O US
CC2
4
4
4
4
2
4
02310774
05
C
O US
CC1
27
9
9
3
4
9
02110775
06
-
M DN
LR2
0
0
0
0
0
0
F/D -> DBS
07
C
O PH
CSF
17
17
17
3
9
17
08
-
M DN
BCP
0
0
0
0
0
0
09
C
O PP
DE3
15
15
15
15
13
18
FOR CEM
BEGIN
01-JAN
04:07
Level 3 To Level 4 Data Flow
L
E
V
L
HEATDATA
CASTDATA
E
ANALYSIS DATA
V
E
L
3
E
GRADE LIST
BILLET DATA
L
4
Level 4 PPC Modules
 Production and Planning
 Commercial Module
 Data Warehousing and
Shipping
 Manufacturing Module
 Quality Assurance Module