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Copyright AIST Reprinted with Permission. Presented at the 2013 Iron and Steel Technology Conference and Exposition (AISTech 2013). Coke is one of the base materials for any integrated steel mill production. Coke quality and properties affect the blast furnace operation and, as a result, plant performance is directly impacted. The control characteristics of coke plants combine process control with machine interlocking coordination, in a distributed automation and supervision architecture.
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Dave HrehaApplication Engineer
Schneider Electric
Advanced Supervision System for Coke Plants
Dave McWilliamsEngineering Manager
Integrated Mill Systems
Automation Characteristics of Coke PlantsOverview
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
Automation Characteristics of Coke PlantsSupervision System Characteristics
Graphical interface that allows production and operations to 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 logic controller (PLC), drives, and network status Process and production tuning Maintenance and troubleshooting
Case: The ChallengeProject and user requirements
New control system for a coke plant with a supervision system that could manage a complex environment: Several operators and maintenance personnel scattered over
thousands of acres Maintenance required to support a large process campus with limited
resources while minimizing downtime Data sharing between all process areas to ensure continuous
operation 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
Case: The ChallengeSystem complexity
Case: Proposed SolutionNew automation / supervision 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
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
Case: Proposed SolutionThe architecture
Case: Proposed SolutionHigh availability supervision system concept
No single point of failure8 paths for plant control
Case: Proposed SolutionDevelopment and testing
Systematic approach for development / engineering
Template creation Consistency / Methodology Constant dialog with user
Design document submittals Customer assistance
Exhaustive testing before start-up
Case: Proposed SolutionMain User Environment
Case: Proposed SolutionExample: Operator Screens
Live data information Permissive screens Calibration screens Setup Fault Trends
Case: Proposed SolutionExample: Maintenance Screens
Overview Setup Speed Drives Fault Communication Status Alarms
ConclusionState of the art 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
Thank You
Dave HrehaApplication Engineer
Schneider Electric
Dave McWilliamsEngineering Manager
Integrated Mill Systems
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