PROCESS CONTROL COMPUTERS AT

DURGAPUR STEEL PLANT’S

BASIC OXYGEN FURNACES

PROCESS CONTROL COMPUTERS AT

DURGAPUR STEEL PLANT’S

BASIC OXYGEN FURNACES

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

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

OBJECTIVES

AUTOMATION LEVELS 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.

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.

LEVEL I - LEVEL II - LEVEL III COMMUNICATION

CIU (L1) VAX (L2)

VAX (L3)

RS-232

DECNET

NETWORK 90 SUPERLOOP

WSA

(SUPERVISORY)

PCUs

(22)

FIELD

( I/O)

DISPLAYS

SEND COMMANDS TO PLSs

CHANGE SET POINTS, NODE ETC.

OPERATOR -> BULK MATERIAL ADDITION

SMS HARDWARESMS 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)

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)

Har dwar e Posit ion at Steel Mel t ing Shop of Dur gapur Steel Pl ant

Consoles Consoles

23 M LEVEL

THICK ETHERNET CABLE

DESP ATCHER 9M LEVEL SMS PLANN ING CELL

BOF1 – L2 BOF3 -L2

BOF1 – L2 BOF3 – L2 23M PROG RAMMER/ C.P .U. ROOMS B AC K UP TERM IN AL AT L AB

DESP – L2 DESP – L3 TERMIN ALs MIXER – L2

L AB TERMIN ALS DESP – L2 DESP – L3 F I B E R O P T I C C A B L E TO C.C.P . SCR AP YD – L2 BOF2 – L2 Line Driver to L.D.S.

V.A.D . CON TROL ROOM – 9M L.T.S. & LADLE D ESPATCHER (L2 / L3 ) C.C.P .TERMIN ALS

VAD - L2 / VAD - L3

TEEMING BAY L L2

As on 1 st J une 2002

L2VCS01VAX3300

L2BCS03VAX3300

L2BCS02VAX3300

L2BCS01VAX3300

L3SSC02VAX3800

L3SSC01VAX3800

L3SSC01VAX3800

L3SSC03VAX3100

CIU2CIU1 CIU3

L2LAB01

3100

DECROUTER

REPEATER

REP EATERREP EATER

SSS02SSS01SSS04

SSS07SSS05SSS03

SSS06

SUMM ARYNO OF L3 SYSTEMS : 2 (3800) + 1 (3100)

NO OF L2 SYSTEMS : 4 (3300) + 1(3100) TOTAL = 8NO OF SITES/TERMINALS : 11 / 45

NO OF PRINTERS : 16

NO OF DECSERVERS : 8

NO OF REPEATER /ROUTER : 2 / 1

SSS07

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

INFORMATION FLOW BETWEEN DIFFERENT LEVELS AT S.M.S DURGAPUR STEEL PLANT

• 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 ordering

main & 2nd blow calculation, end blow & alloying additions

* 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

* 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

Level 1 to Level 2 Level 2 to Level 1

Level 3 to Level 2

Level 4 to Level 3Level 3 to Level 4Query Reports

M.I.S. Reports

Teeming Reports

Graphic PrintoutsHeat Reports

Level 2 to Level 3

Level 2 System TasksLevel 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

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

Level 3 System TasksLevel 3 System Tasks

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

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

Level 2 ModelsLevel 2 Models

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

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

Process aim calculation

It is a feasibility checkIt reads grades and re-blow patternThe model predicts aim Carbon

percentage and the temperature of liquid steel at the end of blow

PIC 60 DISPLAY PROCESS AIM CALCULATION 15-JAN-03 11:16:24

HEAT NO. 02311369 STEEL GRADE R16 AXLE STEELCHARGE ID 23631 PETRO COKE N

LADLE DATA

STEEL LADLE NO 15

USE LOCAL LADLE DATA N

EMPTY LADLE 0

WALL LIFE 75

BOTTOM LIFE 23

PREHEATING DUR 0

LADLE SKULL WT 0.00

BLOW. PATTERN NO. 751

BOT. STIR PAT NO. 19

ORDERED STEEL WT 122.00

PRESET ADDITIONS 0

NUM BATCHES [ ½ ] 1

KILLED STEEL Y

ADDITIONS

FeSi 200

Al 50

SiMn 1650

FeMn 0

Carbon 450

DESULPHURIZER 0

SYNTHETIC SLAG 0

ALL OTHERS 0

TOTAL 2350

C CONTENTS

C AIM EOB 0.080

C AIM LDL 0.200

TAPPING DATA

MAX SiMn 1700

TAP TMP LOSS 9

EXP TAP DUR 9

WAIT TIME 5

TAP CORR INP -60

TEMPERATURES

AIM TMP EOB 1674

AIM TMP LDL 1630

AIM TMP CAST 1563

Hot metal and scrap ordering calculation

Hot metal, scrap or iron ore can be fixed

Mixer and ladle number are a mustBulk materials are calculatedDownload order to mixer and scrap

yard bayBasicity can be adjusted

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

HOT METAL DATA

MIXER NO 2

HM LDL NO 06

HM EXP TMP 1269

HM ORDER WT 125.00

HM DEM WT 125.00

HM ACTUAL WT 0.00

DESLAGGED (Y/N) N

EXP ANALYSIS END OF BLOW

C Mn P S

IMS 0.178 0.062 0.042 0.035

EOB 0.080 0.040 0.021 0.035

CONVERTER AIM DATA

INT-DESL DUR 0

INT-MEAS DUR 5

INT-STOP

EXP TMP 1674

EXP C-CONTENT 0.178

BLOWING END

AIM TMP EOB 1703

C AIM EOB 0.080

P MAX EOB 0.032

AIM BASICITY 3.0

S MAX EOB 0.100

DEM IRON ORE 0

DEM % BAUXITE 0.00

SCRAP DATA

MENU NO 7

TRIM TYPE S00003

BOX NO

ORDER WT 9.11

DEM WT 0.00

ACTUAL WT 0.00

ADDITION DATA

LIME 9469

DOLOMITE 2000

IRON ORE 224

LIMESTONE

Mn ORE

FLUOSPAR

Main blow calculation

Done after start of heatActual 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

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

CONVERTER AIM DATA

INT – STOP

EXP. TMP 1673

BLOWING END

AIM TMP EOB 1674

C AIM EOB 0.080

AIM BASICITY 3.0

DEM % BAUXITE 0.00

PROCESS DATA

BLOW. PAT NO. 751

BOT STIR PAT NO. 19

DEM O2 FLOW 430

LANCE HT 165

EXP BATH WT 126.99

HOT METAL DATA LDL NO : 06

ORDER WT 125.00

ACT WT 130.00

ACT TMP/TIME 1211 / 11:20

CHARGING TIME 11:11

BATH ANALYSIS

C Mn P S

IMS 0.157 0.048 0.026 0.035

EOB 0.080 0.031 0.014 0.036

SLAG ANALYSIS

FeO CaO MgO SiO2

IMS 18.27 48.95 4.87 16.59

EOB 23.79 45.43 4.53 15.43

SCRAP DATA BOX NO

CODE : S00003 ORDER WT 9107 Kg

ACT 10000 Kg

MODEL ADVICES

O2 AMOUNT 6045

LIME 9863

DOLOMITE 2000

IRON ORE 252

MN ORE

FLUOSPAR

BAUXITE

LIMESTONE

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 valuesRe-blow is necessary if percentage of

Carbon is too high, slag is too viscous

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

CONVERTER AIM DATA

AIM TMP EOB 1674

C AIM EOB 0.080

P MAX 0.032

S MAX 0.100

DEV. LANCE H T -10

ORE MAX 0

LIMESTONE MAX 0

PREV. ADD ADVICE ACT

LIME 9863 11275

DOLOMITE 2000 894

IRON ORE 252 1716

MN ORE

FLUOSPAR

BAUXITE

LIMESTONE

OXYGEN PU

MEASURED DATA

TMP EXP 1674

TMP ACT 1660

TMP TAKEN

TECTIP C

SAMPLE CODE

SAMPLE TAKEN

PREV. BLOWING PERIOD

ADVICE ACT

LANCE HT 165 0

O2 AMOUNT 6045 6084

QUICK TAPPING [Y/N] N

ANALYSIS DATA

C MN P S

PRE 0.157 0.048 0.026 0.035

ACT 0.090 0.080 0.035 0.040

NXT 0.050 0.070 0.029 0.039

FE TOTAL IN SLAG 14 %

NEXT BLOWING PERIOD

TMP EXP 1674

LANCE HT 155

O2 AMMOUNT 200

IRON ORE 0

LIMESTONE 0

BAUXITE 0

MN ORE 0

Offline alloying calculation

Done before Tap Start

This model advices three different combinations of alloys

C , SiMn, FeSi, FeMn are calculated

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

RESULT 1 RESULT 2 RESULT 3

SiMn 1056 SiMn 0 SiMn 1289

FeMn 345 FeMn 0 FeMn 213

Coke 611 Coke 0 Coke 447

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

Level II VCS System

This system is significant after tap endThis system has data entry and

monitoring screens forLADLE TREATMENT STATIONCONTINIOUS CASTING PLANTTEEMING BAYSLADLE DESPATCHERPRODUCTION DATA ENTRY SCREENS OF TEEMING

AND CONTINIOUS CASTING PLANT

Level 3 ModelsLevel 3 Models

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

System

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

System

Production status of steel shop

Shows the status of last 10 heats

One can know the heat number, status, area, start / end times.

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

Heat schedule

Shows the planning of the shop

Heat status, grade, route code

Start / end time of different areas

NO

ST HEAT NO CARG

ID

GRADE

CODE

HEAT START

TAP.

END

2. MET

STAR

2.MET

END

CAST CAST ROUTE

START END CODE

1 CE 02110771 22942 107482S 06:25 07:26 08:48 09:15 100001

2 CE 02310772 22943 107482S 06:30 07:45 08:09 08:11 08:31 10:04 300003

3 CS 02310774 22963 XCHEPA 07:57 09:19 09:42 09:43 09:44 10:05 300110

4 BS 02210773 22966 ASP1241 0730 200220

5 1786415 300004

6 ASP3110 200003

7 107482S 100110

8 XCHEPA 300002

9 107482S 200220

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

BDVLCT

Ladle tracking and Ladle data

Shows a map like view of positions of ladles in the entire steel shop

Ladle placement times are capturedTemperatures/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

10776

00:00

TEA-4

10755

00:00

LTS-1

17

=

02

=

PIC 99/1 (2) LADLE STATUS 01-JAN-03 10:27:24

HEAT AND LADLE >

SCHED. END >

NEXT PROC. AREA >

VAD BOF –1 BOF - 2 BOF - 3

TEA - 4 TEA- 3

TEA–2 TEA - 1

TEA –5

INJ

PARK 04 06 11 13 21 25

PARK 05 19 26

CSTF 07 08 14

NUMBER ST VD HM

IN USE 4

AT LPB 15 8

EXT MT 1 6

DRYER

Ladle overviewShows 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

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

LDL

STATUS LOC LD BT IN ON PP WB CURRENT BEGIN

HEAT

01 - M DN LR6 NEW NEW NEW NEW NEW NEW SHEL. RPR

02 C O PP DE2 20 20 20 4 15 20

03 C O PH LH3 18 NEW 0 0 0 NEW TO MAKE 01-JAN

04:07

04 C O US CC2 4 4 4 4 2 4 02310774

05 C O US CC1 27 9 9 3 4 9 02110775

06 - M DN LR2 0 0 0 0 0 0 F/D -> DBS

07 C O PH CSF 17 17 17 3 9 17

08 - M DN BCP 0 0 0 0 0 0 FOR CEM

09 C O PP DE3 15 15 15 15 13 18

Level 3 To Level 4 Data Flow

L

E

V

E

L

3

L

E

V

E

L

4

HEATDATA CASTDAT

A ANALYSIS DATA

GRADE LIST

BILLET DATA

Level 4 PPC ModulesLevel 4 PPC Modules

Production and Planning Commercial Module Data Warehousing and

Shipping Manufacturing Module Quality Assurance Module

Production and Planning Commercial Module Data Warehousing and

Shipping Manufacturing Module Quality Assurance Module