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PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL PLANT’S BASIC OXYGEN FURNACES

PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL PLANT’S BASIC OXYGEN FURNACES. OBJECTIVES. 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.

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PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL PLANT’S BASIC OXYGEN FURNACES

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  1. PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL PLANT’SBASIC OXYGEN FURNACES

  2. OBJECTIVES • 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

  3. 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.

  4. LEVEL I - LEVEL II - LEVEL III COMMUNICATION RS-232 DECNET VAX (L3) VAX (L2) CIU (L1) NETWORK 90 SUPERLOOP WSA (SUPERVISORY) PCUs (22) FIELD ( I/O) • DISPLAYS • SEND COMMANDS TO PLSs • CHANGE SET POINTS, NODE ETC. • OPERATOR -> BULK MATERIAL ADDITION

  5. 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)

  6. 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

  7. 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 • Mode of converter operation • Set point passing for o2 and bulk materials after metallurgical calculations like : • * Process aim, hot metal orderingmain & 2nd blow calculation, end blow & alloying additions Teeming Reports Heat Reports Level 3 to Level 2 Graphic Printouts Level 2 to Level 3 * Heat Number * Heat Data * Heat Status * Steel/Hot Metal/Slag Analysis * CCP/LTS, Teeming Data * Scrap Yard/ Mixer Data • Schedule/Plan for the day • Ladle details • Grade Specifications / Definitions • Actual Steel Grades Query Reports M.I.S. Reports Level 4 to Level 3 Level 3 to Level 4 * Heat Number * Teeming /CCP Cast Data * Heat Data * Steel/H.Metal/Slag Analysis Data * Backlog details of the above, if any. • Schedule Data • Actual grades of cast from laboratory Level 4 terminal

  8. 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

  9. Level 3 System Tasks • Heat Tracking • Ladle Tracking • Shop Scheduling • Grade definitions • Data Transfer to PPCS • Database Upkeep • Software development

  10. Level 2

  11. Level 2 Models • Process Aim calculation • Hot Metal /Scrap Ordering • Blowing Calculation • 2nd Blow Calculation • Reblow Calculation • Alloying Calculation • Feedback Calculation

  12. 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

  13. PIC 60 DISPLAY PROCESS AIM CALCULATION 15-JAN-03 11:16:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631 PETRO COKE N

  14. 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

  15. PIC 61 DISPLAY HOT METAL AND SCRAP ORDERING CALCULATION 15-JAN-03 11:20:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631

  16. 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

  17. PIC 62 DISPLAY MAIN BLOW CALCULATION 15-JAN-03 11:38:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631

  18. 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

  19. PIC 63 DISPLAY SECOND BLOW AND REBLOW CALCULATION 15-JAN-03 11:38:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631 ACTUAL PROCESS STATUS MAIN BLOWING 2 NUM OF REBLOWS 0

  20. Offline alloying calculation • Done before Tap Start • This model advices three different combinations of alloys • C , SiMn, FeSi, FeMn are calculated

  21. PIC 66 DISPLAY OFFLINE ALLOYING ADVICE 15-JAN-03 12:09:23 HEAT NO.: 02311369 CHARGE ID : 23631 EXP. STEEL WT.: 127.0 LADLE ANALYSIS : C Mn Si P S C LOSS AIM: 0.200 0.600 0.080 0.040 0.030 10.00 ACTUAL 0.028 0.012 0.050 0.005 0.031 COST (1) – RS 30902.0 COST (2) – RS 0.0 COST (3) – RS 38566.2 ELEMENT C SI-FESI MN-FEMN SI-SIMN MN-SIMN YIELD : 45 65 85 65 85

  22. 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

  23. Level 3

  24. Level 3 Models • Heat Tracking In Shop • Heat Scheduling • Ladle Tracking • Ladle Overview • Data Storage • Data Transfer To Level 4 PPC System

  25. Production status of steel shop • Shows the status of last 10 heats • One can know the heat number, status, area, start / end times.

  26. DIALOG 23 DISPLAY PRODUCTION STATUS STEEL SHOP 01-JAN-03 10:19:51 HEAT NO. CHID LDL ST CONVERTER TRANS SECONDARY TRANS CASTING 02110767 22951 14 CE BOF–1 04:36 TEA-06:00 05:18 06:51 02310768 22952 08 CE BOF-3 05:02 TEA-4 07:09 05:45 07:50 02110769 22949 18 CE BOF-1 05:21 LTS-2 06:42 CCM-1 06:51 06:15 06:44 08:12 02310770 22939 17 CE BOF-3 05:47 LTS-1 06:53 CCM-2 07:03 05:45 07:00 09:00 02110771 22942 02 HS BOF-1 06:17 02310772 22943 01 BS BOF-1 05:55

  27. Heat schedule • Shows the planning of the shop • Heat status, grade, route code • Start / end time of different areas

  28. PIC 5O DISPLAY HEAT SCHEDULE - SSC 01-JAN-03 10:27:24 BDVLCT

  29. 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

  30. PIC 99/1 (2) LADLE STATUS 01-JAN-03 10:27:24 VAD BOF –1 BOF - 2 BOF - 3 HEAT AND LADLE > SCHED. END > NEXT PROC. AREA > NUMBER ST VD HM IN USE 4 AT LPB 15 8 EXT MT 1 6 INJ PARK 04 06 11 13 21 25 TEA - 4 TEA- 3 TEA–2 TEA - 1 DRYER TEA –5 PARK 05 19 26 CSTF 07 08 14

  31. 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

  32. PIC 72 DISPLAY STEEL LADLE OVERVIEW 01-JAN-03 10:27:24

  33. Level 3 To Level 4 Data Flow L E V E L 3 L E V E L 4 HEATDATA CASTDATA ANALYSIS DATA GRADE LIST BILLET DATA

  34. Level 4

  35. Level 4 PPC Modules • Production and Planning • Commercial Module • Data Warehousing and Shipping • Manufacturing Module • Quality Assurance Module

  36. Thank You

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