Post on 12-Aug-2015
transcript
Concept and Operating Results of a Higher-Level Automation System for the new C-Battery at the U. S. Steel Clairton Plant
AISTech Indianapolis
Stephen Hlavach (IMS), James Zelazny (IMS),
Klaus-Peter Leuchtmann (TKIS), Marcel Schulz (TKIS)
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
2
Coke Plant Automation Overview
3
2
1
0
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
3
PROCESS CONTROL - Level 1 System - Architecture
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
4
PROCESS CONTROL - Level 1 System - Safety PLC‘s
Flex I/O
Hydraulic/Pneumatic
Solenoids
24VDC
Safety I/O
<202>
E-STOPSafety I/O
<211>
Ram VFD(s)
Leveler VFD
Safety I/O
<210>
Travel VFD
1-4
Bypass Interlock PB
Mode Selector Sw.
O/T Magnets
Board "Safe" PB
Board "Resume" PB
De-Board "Safe" PB
De-Board "Resume" PB
E-Stop PBs
Pull Cords
E-Stop PB Ligts
Board "Safe" Lights
De-Board "Safe" Lights
PM1
PLC
Ethernet SAFE BOARDING
ENABLE
SAFE PASSAGE
ENABLE
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
5
PROCESS CONTROL - Level 1 System - HMI
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
6
PROCESS CONTROL - Level 1 System - Coordination
Quench
Car
Start Conveyors
Start Plow
Take SamplesOff Loadout
Fill Rail Cars
C B
atte
ryPro
ven
Sys
tem C
oal
Charg
ing
Car
Push
erM
ach
ine
SS4
&C
oke
Han
dling
Charge Oven
Replace Lids
Travel to CoalTower
Load Coal
Travel to Oven
Clean Oven Top
Pressure Reg
Disconnect
Full Suction
Coke
Tra
nsf
erC
ar
Level Coal
Travel to Oven
Remove Door
Clean Door
Push Coke
Clean Oven Jam
Replace OvenDoor
Open ChuckDoor
Replace Door
Remove Door
Attach Guide
Guide Coke
Retract Guide
Clean Jam
Clean Door
Travel to Oven
Travel to HoldingPosition
Travel Wharf
Dump Coke
Travel to Oven
Catch Coke
Travel to QuenchTower
Quench
"C"
Quen
chTow
er
Quench
Refill QuenchTanks
Refill SprayTanks
Flush Baffles andTrough
Backwash GravelFilters
Close ChuckDoor
Prepare toCharge
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
7
PROCESS CONTROL - Level 1 System – Project Execution
Execution Plan
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
8
PROCESS CONTROL - Level 1 System – Project Execution
First Engineering Submittal
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
9
PROCESS CONTROL - Level 1 System – Project Execution
Second Engineering Submittal
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
10
PROCESS CONTROL - Level 1 System – Project Execution
Factory Acceptance Test
HMI -
Tou
chH
MI -
Tou
chH
MI -
Tou
chHM
I - T
ouch
Co
mm
an
d
Ce
nte
r
Em
g. R
am
Tra
ve
l #2
Co
ntro
l
Sta
tion
s
Ra
m
Leve
l Ba
r
H-R
OO
M I/O
CC
O
CT
C
PM
QC
PLC-I/O
Trvl. 1-2LightsLPPAUX
CC
C
HMI -
Tou
chH
MI -
Tou
chH
MI -
Tou
chHM
I - T
ouch
Co
mm
an
d
Ce
nte
r
Em
g. R
am
Tra
ve
l #2
Co
ntro
l
Sta
tion
s
Ra
m
Leve
l Ba
r
H-R
OO
M I/O
CC
O
CT
C
PM
QC
PLC-I/O
Trvl. 1-2LightsLPPAUX
CC
C
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
11
SUPERVISORY SYSTEM – Level 2 COKEMASTER® Overview
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
12
AutoTherm™-G (on Coke Guide) – Overview
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
13
Pyrometer Box
Optical lens
located at the coke guide
AutoTherm™-G (on Coke Guide) – Installation on Site
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
14
Raw data from AutoTherm™ PLC
PSCS
Oven 72 upper pyrometer
Challange of raw data evaluation:
• Coke temperature is inhomogeneous
• Hot and cold temperatures are mixed
• Temperatures are fluctuating widely
Result of Data Evaluation:
• Data are filtered and averaged
• Profiles are acceptable close to raw data
• Temperature curves are similar to each other ���� AutoTherm™ is beneficial and usefull !
AutoTherm™-G (on Coke Guide) – Evaluation
Oven 72 upper pyrometer
CS PS
Mirrored trend curve to correspond to raw data shown on the left side
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
15
PushSched™ – Pushing and Charging Management
Next Cycle
Next Oven
to Operate
(max. 1 Oven)
CO-PLC
(CCO)
Oven Status
Actual
Oven
Calculated
Schedule
for 5 - Days
Fully Automatic-
Operation
PushSched Operator Station
Display
Oven Status
Scheduling is triggered with each machine signal
Display
Oven No.
Machine PLC
Control and
Scheduling of
Pushing and
Charging
Operation
Scheduling
on Demand
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
16
PushSched™ – Pushing and Charging Management
PushSchedSupervision & Planning
Level 1Battery Instruments
PROvenSupervision
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
17
BatControl™ – Automatic and Continous Heating Calculation
QSurfaceQRawgas
QWastegas
QCoke
QUnderfiring = QRawGas + QCoke + QWastegas + QSurface
QUnderfiring
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
18
BatControl™ – Heating Management
18:00
eCT
GP
CT=18:30h
--29:00 h
--17:00 h
27.00 h
BatControl™ 7 day trend plot
Co
ke
ca
ke
te
mp
era
ture
He
atin
gflu
ete
mp
era
ture
1060
Coke
Temperature
Decrease
Time
Delay
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
19
Ram drive motor &
VVVF-converter
RamForce™ – Monitoring of Pushing Performance
Coking Time
Ovens with extended coking time (“hot”
ovens) are causing higher pushing forces
Measurement of Pushing Force:
• Amperage from the ram drive motor was
controlled by VVVF-converter
• Pushing Force was correlated with the
ram travel distance
• Min, Max and Average Pushing Force are
calculated
Operation Example:
• Change of Pushing sequence created
higher coking times than normal
• Significant differences in the pushing
force between normal ovens and „hot“
ovens could be seen
Ovens with regular coking time (~19h). Maximum current 123 – 133 Amps
Ovens with extended coking time (33h-41h) . Maximum current 151 – 166 Amps
Negative pushing force caused
by proper motion of the pusher
ram while lowering the scorpion
tail
Pushing Force
Concept and Operating Results of a Higher-Level Automation System
for the new C-Battery at the U. S. Steel Clairton Plant
May 2014
20
Summery and Conclusions:
C-Battery instrumentation and machines are controlled by a state-
of-the-art process control system
C-Battery is equipped with special measuring systems to keep
track of battery temperatures and pushing forces
On top of all, a sophisticated process model controls the oven
machines and the battery heating
C-Battery operators have quickly accepted the automation and see
the benefits
C-Battery is up to this date the most modern coke plant in the USA