May 11-14, 2003 2003 OSIsoft Users Conference

DONGBU STEEL2003 OSIsoft Users Conference2003 OSIsoft Users Conference 1

Development of Real-time Information Management Development of Real-time Information Management System(RIMS) to Continuous Galvanizing Line(CGL) at System(RIMS) to Continuous Galvanizing Line(CGL) at

the Asan Bay Works, Dongbu Steel Co., Ltd.the Asan Bay Works, Dongbu Steel Co., Ltd.

May 11-14, 2003May 11-14, 20032003 OSIsoft Users Conference2003 OSIsoft Users Conference

Dongbu Steel Co., Ltd.Dongbu Steel Co., Ltd.

www.dongbusteel.co.kr


ContentsContents Who are we? Motivation The Goal What is new? The results Developed applications : #1~#4


ProductsProductsWho are we?

Cold Rolled Galvanized Prepainted

TP / TFS Pipe H Beam

CHQ Wire P.E.B CD Bar


Works & OfficesWorks & OfficesHeadquarters

Inchon Works

Asan Bay Works Pohang Works

Who are we?


What does the CGL (Continuous Galvanizing Line) make?What does the CGL (Continuous Galvanizing Line) make?By utilizing the “sacrifice anode effects” of zinc layer over steel

it gives steel the corrosion resistance capabilitywith lower production cost

Motivation


For what and ...?For what and ...?Motivation

• Improvement of QualityImprovement of Quality• Low Production CostLow Production Cost

By What and How?


What we need?What we need?Motivation

Challenge

Data type

Application

Data reliability

Storage

Accessibility

Analysis tools

Large amount of real-time data

Unrestricted for operator, maintenance and technical members

Real-time monitoring

On-line storage over 3 years

Intranet / InternetKorean Language

In-house control


Improving Process CapabilitiesImproving Process Capabilities

Pre Treatmen

t

Heat Treatme

nt

Zinc Coating

Post Treatme

nt

Inspection

AdherenceMechanicalProperty

Coating Weight

Coating Amount Grade

The Goal


The Legacy systemThe Legacy systemLEVEL 3

LEVEL 2

Thickness Temp. Coating Current Tension Pressure ...

IRMS SIEMENS TOSHIBA

Real-time measurement

Coil Data, Production Result

LEVEL 1 (PLC, DCS)

RIMSUser

Real-time Data

RIMSServer

What is new?


RIMS ArchitectureRIMS ArchitectureWhat is new?


11stst Stage Development Results Stage Development Results

Tag 820ea (Sensors : 270ea Coil Length Tracking : 550ea)

Development

Retrieval of archived Real-time DataCoil based data handling (from time based)Process Book and WEB Environment with VB and ASPInquiry and Analyzing of Production Coils

System Access Process Book and WEB with ASP

OS Windows 2000

Service

Process Book with Application Program Real-time Coil Inspection, Inquiry – 1 screens 6 charts Real-time Trend Data chart - 10 screens with 93 charts

WEB with ASP The same as Process Book Inquiry and Analyzing of Production Coils 10 screen with 108 charts

The results

12

Main TaskMain Task : Real-time Coil : Real-time Coil Inspection Inspection


Customers are expecting no-defects.Customers are expecting no-defects.On every point,what is the history?Thickness, Pre-treatment, Heat treatment, Bath temp., Coating amount,Roll force, Elongation, Amount of oil etc.

? ?

Main Task


Ss

Sm Swts-atm

-a

tw-a

ts-btm

-b

tw-b

ts-cts-m

SENSOR 1

SENSOR 2

SENSOR n

product


Main ScreenMain ScreenMain Task : Results

Coil Information

Temperature

Tension

Coil TrackingCoil LengthThickness Width

Winding Length


EntryEntryMain Task : Results


InspectionInspectionMain Task : Results

1st product2nd product 3rd product

Upper Limit Lower Limit

Speed

Thickness

Temp. Coating Weight

Pin HoleWidth

Process Status

Data Searching

re-scaling


WEB versionWEB versionChartChart SheetSheet

Main Task : Results

19

Appl. #1 : Retrieval of Appl. #1 : Retrieval of Operation Operation

Data Data


MenuMenuAppl. #1 : Retrieval of CGL Operation Data

11

22

33

44


Export to ExcelExport to ExcelAppl. #1 : Retrieval of CGL Operation Data

22

Appl. #2 : Monitoring and Daily RAppl. #2 : Monitoring and Daily Report System - Line Operation aneport System - Line Operation an

d Quality Related Itemsd Quality Related Items


FunctionsFunctions

Upper Limit

관리하한선 RTDB

Taking measures

Report. Daily report via e-mail. At anytime

Alarm

Alarm

MeasuredValue

Time

Operation Criteria

RDB

Lower Limit

Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items


Daily Report Sample #`1Daily Report Sample #`1Appl. #2 : On line monitoring and Daily Report System

for Line operation and Quality related items


Daily Report Sample #2Daily Report Sample #2

SheetSheet

E-mailE-mail

Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items

26

Appl. #3 : Analysis ofAppl. #3 : Analysis of Measuring Measuring

Devices Devices


Main ScreenMain ScreenMajor Measuring Devices* Thickness Gauge* Furnace Thermometers* Zinc Coating Weight* Tension Meters* Pin Hole Detector

Appl. #3 : Analysis of Measuring Devices


Furnace TemperatureFurnace Temperature

Appl. #3 : Analysis of Measuring Devices


Zinc Coating WeightZinc Coating WeightAppl. #3 : Analysis of Measuring Devices


TensionTensionAppl. #3 : Analysis of Measuring Devices


Daily Report – Sensor TroubleDaily Report – Sensor TroubleAppl. #3 : Analysis of Measuring Devices


LoggingLoggingAppl. #3 : Analysis of Measuring Devices

33

Appl. #4 : Analyzing ZincAppl. #4 : Analyzing Zinc Coating Weight Coating Weight


Analysis System ConfigurationAnalysis System Configuration

Level 1 PLCLevel 1 PLCLevel 2Level 2 RIMSRIMS

UserUserLevel 3Level 3

. Quality Factor. Set Points

Measured Value of Sensors

Stored value in RIMS

Lab. test results

Air KnifeAir Knife

CoatingCoatingWeightWeightGaugeGauge

Appl. #4 : Analyzing Zinc Coating Weight`


Data SourcesData Sources

Air Knife Coating WeightGauge

Laboratory Test

Results



Analyzing FlowAnalyzing FlowStatistical

Analysis per Coil

AnalyzingC/W in Rolling

Direction

C/W OK?

DailyData

Gathering

Data Archiving

DataFeedback

Long-termData

Analysis

Yes

No

LaboratoryTest Result

Analysis

Tuning



ResultsResultsAppl. #4 : Analyzing Zinc Coating Weight`


QuestionsQuestions

Documents

May 11-14, 2003 2003 OSIsoft Users Conference