End Line Inspection Implementation Tubular Products, Vereeniging, ArcelorMittal, South Africa

Joao Bordalo Senior Architect, MES Demand

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

General Profile - ArcelorMittal

► ArcelorMittal is the world's number one steel company, with

320.000 employees in more than 60 countries

. It has led the consolidation of the world steel industry and today ranks as the only truly global steelmaker with an industrial presence in 27 countries.

► ArcelorMittal is the networks.

leader in all major global markets

, including automotive, construction, household appliances and packaging. The Group leads in R&D and technology, holds sizeable captive supplies of raw materials and operates extensive distribution ► Its industrial presence in the Group exposure to all the key steel markets, from emerging to mature. ArcelorMittal will be looking to develop positions in the high growth

Chinese

and

Europe

,

Asia Indian markets.

,

Africa

and

America

gives 3

General Markets - ArcelorMittal

Market position and market share estimates by region*

No 1 in North America

23% 77%

No 1 in Western Europe

74% 26%

No 1 in Eastern Europe and CIS

11% 89%

No 1 in Africa No 1 in South America

24% 76% 53% 47% Number 1 in 5 regions and 4 continents

General Profile - Tubular Products Division ► Tubular Products is in 21 operating locations in

11 countries

world wide,

headquartered in Luxembourg

with a capacity of over 3 mill. Tons.

►

Automotive

product.

with locations in Brampton, Hamilton, London & Woodstock (Canada), Monterrey (Mexico) and Chevillon, Hautmont & Vitry Le Francois (France). Although organized within other Tubular Products units South Africa, Marion, Shelby, and Karvina also manufacture & supply automotive ►

Energy

with locations in Aktau (Kazakhstan), Annaba (Algeria), Galati & Roman (Romania), Ostrava (Czech Republic),

Vereeniging (South Africa)

and greenfield in Jubail Industrial City (Saudi Arabia) and Calabar (Nigeria).

►

Mechanical

located in Iasi (Romania), Karvina (Czech Republic), Krakow (Poland), LaSalle (Canada), Marion & Shelby (USA) and Temirtau (Kazakhstan).

5

General Markets - Tubular Products Division Canada, Brampton Canada, Hamilton Canada, Woodstock Canada, LaSalle Canada, London USA, Shelby USA, Marion Mexico, Monterrey

Head Office, Luxemborg

France, Hautmont France, Chevillon Czech Republic, Ostrava France, Vitry Polan, Krakow Czech Republic, Karvina Romania, Iasi

USA, Pittsburg Business Service

Nigeria, Calabar,

South Africa, Vereeniging

6

Energy

Kazakhstan, Temirtau Romania, Roman Romania, Galati Kazakhstan, Aktau Algeria, Annaba

Saudi Arabia, Jubail

General Markets : Tubular Products ArcelorMittal South Africa Energy

Energy Products:

► ► ► Line Pipes Seamless (API,EN, ASTM) Customer base includes Oil & Gas and Engineering companies in America, Asia , Africa & Europe 7

General Works Layout - Tubular Products ArcelorMittal South Africa

End Line Inspection

General ELI Plant Up Close - Tubular Products ArcelorMittal South Africa Control Desk Reject Table INLET Alignment & Rotation Rollers Ultrasonic Machine

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Project Objectives

► Business Objective ▪ API Accreditation for Tubular Products Plant ▪

API: American Petroleum Institute

API standards address several key aspects of the oil and gas industry, including exploration and production, refining, fire protection and safety, petroleum measurement and marine transportation. These standards also reference offshore production, drilling, structural pipe, pipeline, health and environmental issues, valves, storage tanks, etc. ► Operational Objective ▪ Shorter Project Delivery ▪ Object and Graphical Standards ▪ ▪ ▪ Standard PLC Tag Naming Convention Reliable Data Tracking [Integration with Plant MES] Operator Accountability

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Solution

► ► ► ► Existing WONDERWARE Install base: ▪ Wonderware Historian [5000 tags] ▪ Active Factory 9.2

▪ ▪ INTOUCH 10 ARCHESTRA 3.0

Existing Portal [ProcessNet] ▪ Visualization Existing Reporting tools utilized ▪ MS Reporting Services Additional Requirements for solution ▪ Consulting [Adopted WONDERWARE’s Best Practices BMA] ▪ Training [ARCHESTRA and INTOUCH’] ▪ Implementation [Functional Specification, Project Schedule, Commissioning] ▪ Time Frame of 12 weeks

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

System Architecture Concept Network Topology

SAP R/3

ERP MES DB Server Plant Centric Information System Plant IS Intranet Server ”SCADA” / MES Process Control Historian Expert System Model Software PLC / DCS / SSS Workstations “SCADA” Engineering

System Architecture - TP ELI Plant System Topology -

Plant Information Network

Process Control Information System : Key Data

Control Information Network TP Tubular Pipes Information System AOS Downstream TP EWS Wonderware Historan Control Network ELI Standard ArchestrA Reporting Services Server Application Server GUI ELI SCADA IDE PLC - ABB PLC - ABB PLC - ABB Router WAN

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Implementation Schedule

► ► ► ► ► ► Operational Specification Written and Approved by line Management (1x week) Setting up the environment: WW Historian, ARCHESTRA, MES Database, IO Servers and IP assignments (2x Week) Consulting with WONDERWARE. Setting of standards and best practices. (1x week) Development of ARCHESTRA environment (scripts etc) using INTOUCH objects, deployment (3x weeks) Development of Information object in ARCHESTRA (1x week) Commissioning (3x weeks) 11 weeks total

Implementation ARCHESTRA: BMA

$UserDefined $B_Userdefined $M_Limits $M_Limit_Switch Base Object Derivation Standard Base Master Application $M_Proxy $A_ELI_Proxy

Implementation ARCHESTRA: Deployment / Plant Model

Implementation ARCHESTRA: Data Handling

Implementation Data Flow

Implementation Animation of End Line Inspection Plant

INLET Alignment Rolls 1 Rotation Rolls 1 Alignment Rolls 2A Alignment Rolls 2B Rotation Rolls 2 UT Scale UT

Implementation SCADA: Plant Overview

Implementation SCADA:ELI Overview

Implementation SCADA : Drive Status

Implementation SCADA: Manual Override

Implementation ARCHESTRA: MESINFO Object

Implementation MES GUI

Implementation Database Schema

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Goals & Benefits Achieved

► ► ► ►

Reduced Engineering Costs

on system expansion or duplication

This project

has been shown that ArchestrA can be a

vertical

as well as a

horizontal

tool for integration

Standardised Environment

:- great stepping stone for future automation

Contribution To Plant Operations

due To

Accreditation:

   80 % of normal throughput 88 000 Ton (Budget 2008) 130 Million Rand (Budget 2008)

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Lessons Learnt

► ► Hardware and Software (OS) requirements for SYSTEM PLATFORM Networking Environment ► Stand-Alone Server for the Development Environment (IDE) ► Deploy redundancy [Our Future Plan] ► For optimum performance use stored procedures ► ► Consult with WONDERWARE to ensure that standards and best practices are employed ► Use a SQL connection for every object writing to the Database Training is essential

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Conclusion

► Process Control Information Systems are a company strategic asset, it needs reliable and flexible systems that can populate the databases correctly ► ArchestrA is a powerful system technology that supports our company strategy as outlined above

BUSINESS SYSTEMS AUTOMATION SYSTEMS DATABASES

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Acknowledgements Acknowledgements

Cobus Muller Frikkie Fourie Hannes van Wyk Marius Swanepoel Roche Bester Andries Wentzel Willie Essendrup Wimpie Lubbe Markus van de Merwe Jos Peters - General Manager, Tubular Products - Systems Engineer [TPSA] - Senior Engineer Mechanical [TPSA] - SNR Analyst MES DEMAND Vereeniging, IM - Senior Engineer Metallurgy [TPSA] - Electrical Technicians [TPSA] - Electrical Technicians [TPSA] - Electrical Technicians [TPSA] - WONDERWARE SA Regional Manager - WONDERWARE SA Technical Consultant

Agenda

► ► ► ► ► ► ► ► ► ► General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion Acknowledgements Questions

Questions