Supervision System for Coke Plants -...
Transcript of Supervision System for Coke Plants -...
![Page 1: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/1.jpg)
Supervision System for Coke Plants
AIST Cokemaking TC & ACCCI Mesh Jt Meeting September 2013 Steve Hlavach General Manager Dave McWilliams Engineering Manager Jeff Mason VP Sales & Marketing
Integrated Mill Systems
![Page 2: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/2.jpg)
In order to meet the supervisory system challenges outlined by the user, Integrated Mill Systems (IMS) presented a superior alternative from the initial specification which required supplying a specific vendor supervisory/HMI package. The customer’s input was vital in order to validate the IMS supervisory system solution with respect to the specification
requirements.
Current process requirements provide a level of flexibility and a path for future. At this stage it became apparent that the user requirements could not be met using the supervisory system/HMI
![Page 3: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/3.jpg)
The specified system originally required two separate communication networks and associated screen development for local and global systems. This would require extensive mapping, hardware, and two different HMI hardware platforms.
Global communication was also sought to provide several benefits to the customer’s maintenance processes and functions.
![Page 4: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/4.jpg)
Maintain process area operational capabilities, even when a communication loss occurs.
Disconnect caused by segmented coordination by production staff of their respective processes
Operation stations must continue process operations even in the event of subsystem failures
For each modification to a given machine screen, all other machines would have to be individually changed.
![Page 5: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/5.jpg)
Automation characteristics of coke plants
Combination of process control (battery systems) with machine interlocking coordination (pusher machines, coal charging, transfer cars, quench cars),
Distributed automation and supervision architecture
High degree of redundancy, allowing critical operations to be performed even when other systems fail
Manage multiple technologies working together
![Page 6: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/6.jpg)
The system design and staging was done at the IMS facility to reduce startup time and eliminate any potential errors, resulting in a faster customer’s ROI.
A powerful template for large production systems
independent of the manufacturing process A platform which is scalable to customer needs
without costly redesign and extensive programming A faster review cycle with the customer which results
in accelerated installation time
![Page 7: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/7.jpg)
Supervision System Characteristics
Graphical interface that allows production and operations oversee the coke system:
System overview and parameters Real-time information processing Process trends Automatic and manual operation of coke machines Alarms and fault detection Programmable controller, drives, and network hubs. Process and production tuning Maintenance and troubleshooting
![Page 8: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/8.jpg)
System complexity
![Page 9: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/9.jpg)
New SCADA solution
Scalable,' view-anywhere’ supervisory control and maintenance system:
Scalability to meet current system requirements with a designed-in capability for easy expansion to meet current and developing production needs
Redundant global servers communicating with global process and client servers throughout the production campus
![Page 10: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/10.jpg)
Use of wireless and fiber optic communications to reduce cost and ensure network survivability
‘View-anywhere’ supervision stations capable of acting as a maintenance or operator terminal for any process area
Continuous power backup system capabilities to reduce impact of downtime or outages
![Page 11: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/11.jpg)
![Page 12: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/12.jpg)
High availability supervision
system concept
![Page 13: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/13.jpg)
Development and testing
Systematic development engineering
Template creation
Methodology
Constant dialog with user
Design documents submittals
Exhaustive testing before startup
![Page 14: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/14.jpg)
![Page 15: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/15.jpg)
Example: Operator Screens
Live data information
Permissive screens
Calibration screens
Setup
Fault
Trends
![Page 16: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/16.jpg)
Example: Maintenance Screens
Overview
Setup
Drives Fault
Communication
Alarms
![Page 17: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/17.jpg)
Leading edge supervision system
Advanced supervisory system which reduced
development and startup time: Multiple redundancy allowing a safer and continuous
operation A powerful template for large production systems
independent of the manufacturing process A platform which is scalable to customer needs
without costly redesign and extensive programming A faster review cycle with the customer which results
in accelerated installation time
![Page 18: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/18.jpg)
In summary, the scope of the project had to address the following:
Several operators and maintenance personnel scattered over hundreds of acres of a facility
Maintenance required to support a large process campus with limited resources, minimizing downtime
Data sharing between all process areas to ensure continuous operation.
![Page 19: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/19.jpg)
• Coke Oven Machine Lubeck 153
![Page 20: Supervision System for Coke Plants - …mscdn.metalandsteel.com/documents/business/7988/fb775b3d-7afb-4… · Supervision System for Coke Plants ... Leading edge supervision system](https://reader031.fdocuments.net/reader031/viewer/2022030806/5b14ef9c7f8b9a66508ce305/html5/thumbnails/20.jpg)
THANK YOU FOR YOUR INTEREST IN OUR PRESENTATION