PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL PLANTS BASIC OXYGEN FURNACES

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PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL
PLANTSBASIC OXYGEN FURNACES
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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

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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.

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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 -gt BULK MATERIAL ADDITION

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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)

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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

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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 heats 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 ordering main
  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

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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 lt-gt Level 3 Systems

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Level 3 System Tasks

• Heat Tracking
• Ladle Tracking
• Shop Scheduling
• Grade definitions
• Data Transfer to PPCS
• Database Upkeep
• Software development

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Level 2
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Level 2 Models

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

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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

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PIC 60 DISPLAY
PROCESS AIM CALCULATION
15-JAN-03 111624
HEAT NO. 02311369 STEEL
GRADE R16 AXLE STEEL
CHARGE ID 23631 PETRO
COKE N
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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

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PIC 61 DISPLAY HOT METAL AND SCRAP
ORDERING CALCULATION 15-JAN-03 112024
HEAT NO. 02311369
STEEL GRADE R16 AXLE STEEL
CHARGE ID 23631
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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

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PIC 62 DISPLAY
MAIN BLOW CALCULATION
15-JAN-03 113824
HEAT NO. 02311369 STEEL
GRADE R16 AXLE STEEL
CHARGE ID 23631
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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

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PIC 63 DISPLAY SECOND BLOW AND
REBLOW CALCULATION 15-JAN-03
113824
HEAT NO. 02311369
STEEL GRADE R16 AXLE STEEL
CHARGE ID 23631 ACTUAL PROCESS
STATUS MAIN BLOWING 2 NUM OF REBLOWS 0
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Offline alloying calculation

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

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PIC 66 DISPLAY
OFFLINE ALLOYING ADVICE
15-JAN-03 120923
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 0.0
50 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
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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

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Level 3
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Level 3 Models

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

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Production status of steel shop

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

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DIALOG 23 DISPLAY PRODUCTION STATUS STEEL SHOP
01-JAN-03 101951 HEAT NO.
CHID LDL ST
CONVERTER TRANS SECONDARY TRANS
CASTING 02110767 22951 14
CE BOF1 0436

TEA-0600
0518 0651
02310768 22952 08
CE BOF-3 0502
TEA-4 0709
0545

0750 02110769 22949
18 CE BOF-1 0521
LTS-2 0642 CCM-1 0651

0615
0644
0812 02310770 22939
17 CE BOF-3 0547 LTS-1
0653 CCM-2 0703
0545
0700
0900 02110771
22942 02 HS BOF-1 0617
02310772 22943 01
BS BOF-1 0555
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Heat schedule

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

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PIC 5O DISPLAY
HEAT SCHEDULE - SSC
01-JAN-03 102724
BDVLCT
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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

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PIC 99/1 (2)
LADLE STATUS
01-JAN-03
102724
VAD
BOF 1
BOF - 2
BOF - 3
HEAT AND LADLE gt SCHED. END
gt NEXT PROC. AREA gt
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
TEA2
TEA - 1
DRYER
TEA 5
PARK 05 19 26
CSTF 07 08 14
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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

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PIC 72 DISPLAY
STEEL LADLE OVERVIEW
01-JAN-03 102724
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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
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Level 4
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Level 4 PPC Modules

• Production and Planning
• Commercial Module
• Data Warehousing and Shipping
• Manufacturing Module
• Quality Assurance Module

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Thank You