KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO

Transcription

1 KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO

2 PROCESS AUTOMATION SPECIALISTS DRIVING PERFORMANCE Process Engineering Services Level 1 Process Control Systems Level 2 / 3 Solutions

3 Process Engineering Services KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO

4 Process Engineering Services Specialists in Machine Dynamics and Control Our comprehensive set of dynamic mill models is the basis for the delivery of a range of services Control system performance analysis Bespoke controller designs Control system optimisation Mill vibration analysis

5 [Time,EntryGauge] Entry Gauge 0 Entry Gauge ( Microns ) Exit Gauge Reference Exit Gauge Measurement CONTROLLER Entry Gauge Position Reference ROLLING MILL Exit Gauge TRANSPORT DELAY Exit Gauge Measurement MEASUREMENT ExitGauge NEGATIVE BEND SERVO MILL HOUSING MAE WEST BLOCK -VE BEND SERVO DRIVE BACKUP ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK BACKUP ROLL CHOCK OPERATOR ADJUSTMENTS MEASURED PRESSURES MAE WEST BLOCK AFC CORRECTIONS MILL HOUSING +VE BEND SERVO DRIVE POSITIVE BEND SERVO Process Engineering Services BEND CONTROLLER Speed increase 25% Exit Gauge Measurement Gauge improvement > 20% Exit Gauge Reference Exit Gauge ( Microns ) Process Control Audits Gauge Control Flatness Control Productivity We specialise in the optimisation of mill control performance From audits through controller design to full optimisation Model based controller design Model based optimisation Implementation on existing platforms Single stand cold mills Tandem cold mills Hot mills

6 Process Engineering Services Instrumentation design services Range of strokes available Position Transducers Fully tested on our specialised rig and certified Standard optimal product Sony Magnescales Robust & ultra low friction housing design Range of strokes available Fully assembled, tested & certificated Mounting tool provided for long stroke transducers

7 Process Engineering Services Process Training Operator & Technician Level Module 1: Strip Properties and the Mechanics of Rolling Module 2: Rolling Mill Equipment and Operation Module 3: Measurement and Control of Strip Thickness Module 4: Measurement and Control of Strip Flatness optimal optimal Ce rtific ate o f training This is to certify that has successfully completed the 1 day training course: 板形 FLATNESS Introduction to Cold Rolling of Aluminium for Operators THICKNESS Presented by: optimal process technology limited,, January 2006 Course content: Module I: Strip properties and the mechanics of rolling Module II: Rolling equipment and operation Module III: The measurement & control of the strip thickness Module IV: The measurement & control of the strip flatness 厚度 Mattias Andersson John Mason January, 2006 Fully documented Flatness simulation Specialist Process Engineering Introduction to roll bite mechanics Rolling mill dynamics Automatic gauge control Single stand cold mills Foil mills Tandem mills Automatic flatness control Practical simulations using optimal dynamic models Course assessments & certification Gauge simulation

8 Level 1 Process Control Systems Our focus is your process performance Controller design & optimisation using optimal dynamic models Systems platform selection based on customer requirements ABB GE Siemens Single stand cold and foil mill AGC & AFC Full tandem cold mill solutions AGC AFC Interstand tension control Hot rolling mill HGC & AGC KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO

9 [Time,EntryGauge] Entry Gauge 0 Exit Gauge Reference Entry Gauge ( Microns ) Exit Gauge Reference Exit Gauge Measurement CONTROLLER Degrees db Entry Gauge Position Reference ROLLING MILL Exit Gauge TRANSPORT DELAY Exit Gauge Measurement MEASUREMENT ExitGauge Exit Gauge Measurement Exit Gauge ( Microns ) Level 1 Process Control Systems 2 Stand Tandem Mill Process Control Supplied Controls: Mill Stand Controls (HGC) Automatic gauge control (AGC) Interstand tension control (ITC) Mill sequencing Extensive engineering tools Dynamic controller testing Fast fault finding Simple tuning interfaces ABB Systems Platform AC800 PEC Controller 800xA programming Advanced Tuning Techniques Stimulus --> Position Reference Full mill dynamic models Frequency Hz Adapted to fit your mill Outstanding Results Bengt Jansson: Granges Technical Director: The performance of the cold tandem mill is world class! Commissioning and achievement of project target was reached within very short time!

10 Level 1 Process Control Systems 3 Stand Cold Mill Flatness Control Mill widening project to accommodate 14 out can stock New flatness controller required GE Rx7i platform customer requirement Proficy machine edition programming Cimplicity HMI Full AFC solution Air bearing shapemeter interface Roll bend and steer control Spray control Total Process Support Our focus was final delivered product On line system tuned to deliver required off line flatness Full support from optimal from cold mill through to slitter optimize flatness process diagnostics Outstanding Results Tuning Analysis Assessment Top flatness rating from can manufacturers

11 Level 1 Process Control Systems 3 Stand Tandem Mill Process Control Major mill revamp extension from 2 to 3 stands Can stock production GE Rx7i platform customer requirement Total process control solution Mill stand controls Interstand tension control Multi stand AGC AFC Level 2 also supplied by optimal Standard GE Programming Tools Proficy machine edition Cimplicity HMI Extensive Engineering Interfaces Level 2 from optimal Easy to use interfaces for tuning and maintenance Extensive controller testing facilities Designed for process & plant engineers Process Diagnostics Mill Set Up

12 Level 1 Process Control Systems Hot Line HGC / AGC Reversing breakdown hot mill Twin coiler finishing hot mill Supplied Controls: Gap referencing for screwdown and hydraulic cylinders Hydraulic Gap Control Automatic Gauge Control Gaugemeter Smith predictor feedback Spray Control ABB Systems Platform AC800 PEC Controller 800xA programming Fully Integrated Approach Level 2 supplied by optimal Fully integrated project with drives supplier Common hardware and software platform Close co-operation on complete line sequencing Outstanding Results High productivity High Accuracy

13 Level 2 / 3 Solutions MES MES Machine Setup Process Diagnostics Reporting Plant Production System Interfaces ERP Scheduling Coil Storage Suite of Level 2 & 3 systems from machine setup through to ERP interfacing

14 Level 2 / 3 Solutions Automatic Process Diagnostics for Metals Rolling & Processing Hot Cold Foil Levelling Slitting Coating Rolling Tracking material and machine performance through the whole process Finishing Production Reduced scrap Increased yield $ Plant Management & Supervision Increased productivity Fast detection of process problems ROI Process Engineering & Quality Control Material and machine performance tracking Better use of valued process engineering resources Delivering real payback PLEASE ASK FOR A DEMONSTRATION AT OUR STAND

15 Level 2 / 3 Solutions Wise Alloys optimize System Hot Rolling Cold Rolling Slitting Coating 1 x Reversing Breakdown 1 x Intermediate Breakdown 1 x 4 Stand Finishing 1 x 5 Stand Tandem 2 x 3 Stand Tandem 1 x Single Stand 2 x Edge Slitting & Oiling Production management use the optimize tools on a daily basis. The detailed web based production reports are projected in the morning meeting to identify key production and quality issues and to direct any necessary corrective actions. 1 x Continuous Coating Line optimize generates production reports to assist with tracking performance and identifying equipment issues. We use optimize daily to produce SPC charts using the Group Statistics function. Process and electrical engineers use it for in depth problem analysis. The optimize system has proven to be invaluable for identifying and controlling key process variables at our five stand tandem mill. Joey Bain, Five Stand Mill Superintendent KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO

16 Level 2 / 3 Solutions Thickness Profile Analysis optimize incorporates tools to analyze the performance of key parameters from hot mill profile through cold mill gauge and flatness to coating line thickness and distribution. optimize is fully integrated to the plant quality systems, providing key feedback to the SAP quality module. Gauge Analysis optimal process technology was originally commissioned to replace an existing gauge monitoring tool. The finished product far exceeded expectations when it was implemented back in Since then the system has been expanded to include key process variables, process evaluations, alarms/alerts and trending. The system is dynamic if a variable (analog, digital or virtual signal) is captured it can be displayed and analyzed. Data storage and retrieval is fast and reliable. The real beauty of the optimize system is with a ten minute demo anyone can begin to use the tool effectively to analyze data. Wise Alloys LLC has implemented optimize throughout the plant and relies heavily on it to monitor and maintain product quality. It is an integral part of our Electronic Lot Ticket System and SAP Quality Module. Shelley Wolf, Senior Systems Engineer Wise Alloys LLC

17 Level 2 / 3 Solutions Gränges Shanghai optimize System Hot Rolling Cold Rolling Slitting 1 x Reversing Twin Coiler 1 x 2 Stand Tandem 3 x Single Stand 2 x Heavy Gauge 1 x Light Gauge (Loop) 4 x Light Gauge (Tight) In order to meet their customer s ever higher demands for quality and tighter tolerances Gränges use the optimize suite of applications to track their process and evaluate coil quality. PLANT TO PLANT BENCHMARKING With optimize installed at their plants in Sweden and China, Gränges can use the system to benchmark performance across the whole group and develop best practice. This is a powerful system which can provide us extensive tools for tracking the process, finding and solving process failures. This system improves my work efficiency and I use optimize on a daily basis. It can search and track the coil through the whole process. By using different tools in the system, we can analyse gauge deviation issues and track the root cause. For process follow up, we can select some coils (filter by gauge/ alloy etc. wide range of criteria) produced in a certain period, then use the group statistics tool to monitor the trend and find if there are any problems, such as gauge performance, flatness performance, etc. We also use the alarm mail facility to create process/production alarms. optimize will automatically send alarm s to the related person if any key process values are out of control set point. Maria Dong, Process Department Gränges Shanghai

18 Level 2 / 3 Solutions Hot Cold & Foil Slitting Rolling Advanced Machine Set Up Systems (AMSU) Finishing Fixed and Adaptive Setup Systems Same core system configured for specific machines Hot rolling lines Single stand and tandem cold mills Slitting lines Highly configurable Setup management Interfacing to control systems Interfacing to plant scheduling systems Multiple language support

19 Level 2 / 3 Solutions Cold Mill Adaptive Setup New approach to adaptive set up Lower cost compared to full model based systems Installed systems Single stand cold mill Tandem cold mill Same core system as fixed set up Highly configurable Mix of fixed and adapted set up data Customised Learning Strategies Outstanding Results Learned Rolling Force Learned Roll Bend Before After Developed to fit your process Direct learning from measured data optimal support for integration with your level 1 systems Reduced head end scrap Improved yield Reduced threading time

20 Level 2 / 3 Solutions Hot Line Level 2 Line Tracking & Mill Set Up Reversing breakdown hot mill Twin coiler finishing hot mill Level 2 scope of supply Line tracking Machine tracking Scheduling interface Queue management Fixed setup Automatic Process Diagnostics optimize process diagnostics for hot mills Automated performance monitoring Detailed process analysis tools Web based production reporting Outstanding Results High productivity High Accuracy