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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
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ContentsContents
Who are we?
Motivation
The Goal
What is new?
The results
Developed applications : #1~#4
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ProductsProductsWho are we?
Cold Rolled Galvanized Prepainted
TP / TFS Pipe H Beam
CHQ Wire P.E.B CD Bar
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Works & OfficesWorks & OfficesHeadquarters
Inchon Works
Asan Bay Works Pohang Works
Who are we?
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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
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For what and ...?For what and ...?
Motivation
• Improvement of QualityImprovement of Quality
• Low Production CostLow Production Cost
By What and How?
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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
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Improving Process CapabilitiesImproving Process Capabilities
Pre Treatmen
t
Heat Treatme
nt
Zinc Coating
Post Treatme
nt
Inspection
AdherenceMechanical
Property
Coating
Weight
Coating
Amount Grade
The Goal
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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?
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RIMS ArchitectureRIMS Architecture
What is new?
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11stst Stage Development Results Stage Development Results
Tag 820ea (Sensors : 270ea Coil Length Tracking : 550ea)
Development
Retrieval of archived Real-time Data
Coil based data handling (from time based)
Process Book and WEB Environment with VB and ASP
Inquiry 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
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Main TaskMain Task : Real-time Coil : Real-time Coil Inspection Inspection
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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
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Ss
Sm Swts-atm
-a
tw-a
ts-btm
-b
tw-b
ts-cts-m
SENSOR 1
SENSOR 2
SENSOR n
product
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Main ScreenMain ScreenMain Task : Results
Coil Information
Temperature
Tension
Coil Tracking
Coil LengthThickness Width
Winding Length
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EntryEntryMain Task : Results
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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
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WEB versionWEB versionChartChart SheetSheet
Main Task : Results
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Appl. #1 : Retrieval of Appl. #1 : Retrieval of Operation Operation
Data Data
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MenuMenuAppl. #1 : Retrieval of CGL Operation Data
11
22
33
44
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Export to ExcelExport to ExcelAppl. #1 : Retrieval of CGL Operation Data
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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
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FunctionsFunctions
Upper Limit
관리하한선RTDB
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
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Daily Report Sample #`1Daily Report Sample #`1
Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items
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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
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Appl. #3 : Analysis ofAppl. #3 : Analysis of Measuring Measuring
Devices Devices
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Main ScreenMain ScreenMajor Measuring Devices* Thickness Gauge* Furnace Thermometers* Zinc Coating Weight* Tension Meters* Pin Hole Detector
Appl. #3 : Analysis of Measuring Devices
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Furnace TemperatureFurnace Temperature
Appl. #3 : Analysis of Measuring Devices
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Zinc Coating WeightZinc Coating Weight
Appl. #3 : Analysis of Measuring Devices
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TensionTensionAppl. #3 : Analysis of Measuring Devices
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Daily Report – Sensor TroubleDaily Report – Sensor Trouble
Appl. #3 : Analysis of Measuring Devices
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LoggingLogging
Appl. #3 : Analysis of Measuring Devices
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Appl. #4 : Analyzing ZincAppl. #4 : Analyzing Zinc Coating Weight Coating Weight
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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
CoatingCoating
WeightWeight
GaugeGauge
Appl. #4 : Analyzing Zinc Coating Weight`
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Data SourcesData Sources
Air Knife Coating WeightGauge
Laboratory Test
Results
Appl. #4 : Analyzing Zinc Coating Weight`
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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
Appl. #4 : Analyzing Zinc Coating Weight`
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ResultsResultsAppl. #4 : Analyzing Zinc Coating Weight`
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QuestionsQuestions