is your best choice for any Level 2 Automation System in steel works for Meltshop, 17.03.2015 1
History Comprehensive Solutions for the Steel Industry Since 1988, ROSIN design and deliver comprehensive automation solutions for the steel industry. Based on their experience, ROSIN developed the automation system which fits into any IT environment (hardware, operating system, data base system) interfaces to all devices in the plant (cranes, PLC, measuring devices, analysers in the laboratory, PC and any other device) is the base for automations in the scrap yard, EAF, LF, caster, in the laboratory; It is also used for emission tracking to detect sources of pollutants for Meltshop, 17.03.2015 2
Slab/Billet Yard In the Steel Plant VD VD VD LF CC EAF SAP Scrap Yard Production Planning supervises and controls the production from the planning of production to the slab or coil yard. for Meltshop, 17.03.2015 3
Good Reasons is the right choice to implement a Level 2 automation in an existing environment. is the ideal replacement for an existing but outdated Level 2. allows for replacement of outdated hardware or operating systems that cannot be maintained anymore. A Level 2 automation can be delivered compliant with any company directives regarding hardware, operating systems and databases. for Meltshop, 17.03.2015 4
Selected Projects Plant Process Automation for the Steel Industry CELSA Compañía Española de Laminación, Castellbisbal, Spain (Slab Tracking System) HKM Hüttenwerke Krupp Mannesmann, Duisburg, Germany (Laboratory Information System) CELSA Compañía Española de Laminación, Castellbisbal, Spain (Meltshop Level 2 Automation) ACB Arcelor Aceria Compacta Bizkaia, Bilbao, Spain (Meltshop Level 2 Automation) TPCO Tianjin Pipe Corporation, China (Laboratory Information System) SSM Siam Strip Mill, Thailand (Meltshop Level 2 Automation) ILVA, ILP, Taranto, Italy (Sublance Automation) Volta Redonda, Brazil (Sublance Automation) NAS North American Stainless, Pittsburgh, USA (OPC Coupling) Stahlwerke Peine Salzgitter, Germany (Automation System for Coil Heating) for Meltshop, 17.03.2015 5
Modules Scrap Yard Scrap inventory, basket charging Meltshop EAF, LF, VD/VOD, Ladle Tracking Laboratory LIMS Continuous Caster Caster Module Slab/Billet Tracking module Environment Emission Tracking for Meltshop, 17.03.2015 6
Process Overview Meltshop Automation A Level 2 supervises the production process in the Meltshop - from the planning of the heats - to the delivery of final products (slabs/coils/bars). All relevant data gathered in production is stored in the data base, forwarded to high-level automation systems, and used for the automatic and manual generation of various types of heat reports Example for Plant Overview Screen for Meltshop, 17.03.2015 7
Process Tracking EAF Meltshop Automation supervises the meltdown process, stores all relevant information in the database and displays real-time data about the current heat: Example for EAF screen delays temperature, material additions, events, analysis, recipes, model predictions... for Meltshop, 17.03.2015 8
Process Tracking LF Meltshop Automation supervises the refining process, stores all relevant information in the database and displays real-time data about the current heat: Example for LF screen energy temperature, material additions, stiring, analysis, recipes, model predictions... for Meltshop, 17.03.2015 9
Ladle Tracking Meltshop Automation records the ladle use, maintenance and repair history, stores all relevant information in the database and displays realtime data about the current ladles in production: last steel grade in ladle temperature, lining material, use duration etc.,... Example for Ladle Tracking screen for Meltshop, 17.03.2015 10
Process Tracking CC Caster Automation supervises the casting process, stores all relevant information in the database and displays real-time data about the current heat: Example for CC screen speed line status, bar formats, current production, planned heats, qualities, predictions The shift managers can plan heats, edit heat data, especially about defect or repaired bars and special status information concerning the casting lines. for Meltshop, 17.03.2015 11
Slab Tracking Caster Automation The customer's demand for quality is ever increasing. helps you to meet these demands more easily. supervises the bars from the tundish onwards. The Slab Tracking module of communicates with the Meltshop module, but can also work standalone. follows the bars from the tundish via the oxicutters, balance, transport table up a slab tagging machine. The tags which are applied to the slabs contain a barcode with detailed information about each bar (heat, quality code, length, weight, casting line, etc...) Example for Slab Tracking screen for Meltshop, 17.03.2015 12
Bar Tagging Caster Automation Example for Slab Tagging screen for Meltshop, 17.03.2015 13
Emission Tracking Measuring Device for Meltshop, 17.03.2015 14
Report Generator Database Long-term Archive pdf and cvs files heat reports daily summaries monthly sumaries. Report Generator for Meltshop, 17.03.2015 15
User Interface Maintain System Users Parameters Configure Mathematical Models MeSOpt Parameters Maintain Basic Data Basic Data (Process Patterns/Delays/Resources) Steel Quality Codes Delays, Resources, Location for final products Plan, Follow and Control the Production Heat Schedule Production Screens for Each Aggregate Plant Overview Maintain Report Information Scrap Input Resources Delays All Events During Heat Produce Reports Heat Reports, Daily and Monthly Summaries Delays Events SAP Review Steel & Slag Analysis Values for Meltshop, 17.03.2015 16
In Local Language The User Interface can be supplied in any language. for Meltshop, 17.03.2015 17
GUI A Distributed System Meltshop Tracker Laboratory Tracker Process models Caster Tracker Monitor Scrap Yard Tracker Database Installation of user interface Installation on Server Computers on PC, Industrial PC, Notebook, Tablet PC In most installations we use two fast servers and a Raid subsystem. for Meltshop, 17.03.2015 18
Implementation Operating Systems and Databases entirely programmed in JAVA is at present used productively under OpenVMS Linux Windows 2000, 2003, 2008, 2012 Server with the following database systems ORACLE Ingres MS SQL Server 2000, 2005, 2008 MySQL for Meltshop, 17.03.2015 19
Universal Data Reader Interfaces of All Types communicates with other production units via TCP-IP or UDP and supports various interface formats: TCP-IP UDP files (XML, CVS, proprietary formats) JDBC CORBA SMS Email WhatsApp... for Meltshop, 17.03.2015 20
Advantages Maximum Security of Investment Compatible to all database systems (JDBC interface required) Can be installed on all operating systems (from JAVA VM 1.4) Runs on any hardware Updates or changes of hardware or database system any time for Meltshop, 17.03.2015 21
Advantages Individual Solutions with All Advantages of a Standard Product Modules can be added as needed : e.g. Slab Tracking, Emission Tracking, Ladle Tracking Supports future integration of process and optimising models New aggregates (e.g. a VD) can be integrated at a later time. for Meltshop, 17.03.2015 22
Advantages Installation on Virtual Systems The Level 2 servers can be virtual systems. runs on these virtual servers without any problems. for Meltshop, 17.03.2015 23
Advantages Minimal Overhead for IT Department Monitor supervises all Level 2 processes: Daily purging of log files Automatic restart of stopped processes Alarm mails to ROSIN and IT department in case of errors Daily backup of database Permanent database maintenance New Releases can be targeted for specific users upgrades can be reversed easily for Meltshop, 17.03.2015 24
The Project Live Examples facilitate creation of Requirement Book In order to facilitate the design process for the Level 2 system, we discuss all functions of the new Level 2 system with the customer, using a test database and a simulated Level 1 to make the demonstration system as realistic as possible. for Meltshop, 17.03.2015 25
The Project Layout of Screens and Reports as Defined by Customer We shall suggest the layout of screens and reports. But the customer decides. for Meltshop, 17.03.2015 26
Commissioning Disturbance of Production during Commissioning is Kept to a Minimum Most of the commissioning is done remotely from our offices. We make tools for offline communication tests available to all partners (L1, Scrap Yard, Caster, Laboratory ). If there is an existing level 1, records all messages during production and uses recorded messages for offline tests for Meltshop, 17.03.2015 27
Commissioning Most of commissioning is done during normal production Message format description in XML allows dynamic creation of message objects. We adapt message formats almost on the fly. Interface description using XML files permits easy modification of all communication parameters. for Meltshop, 17.03.2015 28
In Production Guarantees an Undisturbed Production is robust: 99,9% availability User interface in customer s language Ease of use Remote maintenance 24 hours/365 days hotline available for Meltshop, 17.03.2015 29
In Production Advanced Supervising Functionality Remote supervision and assistance by management possible during production Supervision of several plant installations from one central office possible for Meltshop, 17.03.2015 30