Steel Manufacturing Industry & Schneider Electric

92 

Loading....

Loading....

Loading....

Loading....

Loading....

Full text

(1)

Steel Manufacturing Industry

& Schneider Electric

Company introduction

Selected references

Selected references

- Iron Making

- Energy Management

April 2012

(2)

Index

Schneider Electric at a glance

Schneider Electric at a glance

Schneider Electric in Mining, Minerals and Metals

Schneider Electric in Steel Manufacturing

Selected Schneider Electric References – Iron Making

Selected Schneider Electric References – Energy Management

(3)

Schneider Electric – the global specialist

in energy management

in energy management

Balanced geographies

– FY 2011sales

billion € sales

(last twelve months) North

America

23%

Western Europe

32%

of sales in new economies

(last twelve months)

23% Asia Pacific 27% Rest of World 18%

people in 100+ countries

Diversified end markets

– FY 2011 sales

of sales devoted to R&D

Utilities & Infrastructure 24% Industrial & machines 22% Data centres 16%

Non-residential buildings 29%

of sales devoted to R&D

(4)

Our Business driver: to help customers

to deal with their major Concerns

to deal with their major Concerns

How to increase the safety of my personnel?

How to increase the safety of my personnel?

How to comply with sustainable development

(environmental impact)?

(environmental impact)?

How to maximize my output and its benefits

(revenues and margin)?

(revenues and margin)?

How to optimize my capital expenditure?

How to optimize my operational expenditures?

How to optimize my operational expenditures?

“…Energy is critical to my production but

I need to reduce my CO footprint

Schneider Electric - Industry Business - K. Lachmann - Date 4

(5)

Our

Unique Value

Propositions

Global

presence

International

Global

presence,

International

networking capabilities,

Local

mind-set

A Comprehensive

Production &

A Comprehensive

Production &

Energy Optimization

Offer dedicated

to Mining, Minerals and

Metals

Customers

Customers

Best in Class

products,

Solutions

d

Services

bi d i

and

Services

combined in an

Integrated Architecture

P j t & S

i

Worldwide

Project & Service

capabilities

(6)

Our

Projects and Services

Capabilities

4

Global Projects and Engineering ●

600+

contracts

1

to

50

M€

4

Global Projects and Engineering Centers

Beijing (China), Grenoble (France) Mumbai (India), Nashville (USA)

600+

contracts,

1

to

50

M€ (2011)

●Potential engineering study capacity

500 000+

ho rs/ ear

10+

System Integration Centers close to you

500.000+

hours/year

50+

years experience in &

Australia, Brazil, Canada, China, France, Gulf, India, Indonesia, Mexico, Spain, Turkey, USA, etc.

Projects & Engineering

●Local and Regional Project & Services Organization in

100+

countries

(7)

Index

Schneider Electric at a glance

Schneider Electric at a glance

Schneider Electric in Mining, Minerals and Metals

Schneider Electric in Steel Manufacturing

Selected Schneider Electric References – Iron Making

(8)

Mining, Minerals and

Metals

in Schneider Electric

14 Global Strategic Customers 4 Major Segments

Mining

Steel Cement

Aluminium

Multiple National Strategic Customers A Gl b l T f250 l

Steel Aluminium

Multiple National Strategic Customers A Global Team of 250+ people

Marketing, Sales and Business Support Experts 4 Global Projects and Engineering Centers

China, France, India, USA

10+Automation System Integration Centers

Multiple Local Projects and Services Organization Schneider Electric is present in over 100 countries.

Schneider Electric - Industry Business - K. Lachmann - Date 8

Only some are displayed 50+ years of experience in

(9)

Mining, Minerals and Metals Sales 2011: ~500M€

Laiwu Steel

China

ArcelorMittal (210KT)

France

Electrical Distribution and Process

China

Energy Management System 7M€

Electrical Distribution and Process Control System for Continuous

Annealing (w/ Ansaldo) 7M€

Votorantim

Brazil

Five (5) Cement Plants MV-LV Electrical Distribution and

SNIM / SNC Lavalin (GuelbII)

Mauritania

Movable Substations, Process Control System and Water MV LV Electrical Distribution and

Process Control System 24M€

Control System and Water Management System

20M€ Cliff Natural Resources

Cliff Natural Resources (Bloom Lake II)

Canada

Electrical Distribution and Process Control System for Mine

Vale (Vargem Grande)

Brazil

Movable Substations and Process Control System

19M€ Control System for Mine

(10)

Index

Schneider Electric at a glance

Schneider Electric at a glance

Schneider Electric in Mining, Minerals and Metals

Schneider Electric in Steel Manufacturing

Selected Schneider Electric References – Iron Making

Selected Schneider Electric References – Energy Management

(11)

Steel Manufacturing

Finished Product Production Resources Assets Billets Slabs Coils Others Assets People Raw Material ENERGY Oth Others… Revenue Others… Cost

Our Goal: To Help our Customers

To Produce More with Less…

Our Goal: To Help our Customers…

(12)

Steel Manufacturing

Finished Product Production Resources Assets Billets Slabs Coils Others Assets People Raw Material ENERGY Oth Others… Revenue Others…

Cost Any Optimization of the Overall Steel

Production Process ill O ti i

Our Mission:

To Help Customers

By:

Optimizing The Overall Steel

Production Process

will Optimize the Production

Resources

Schneider Electric - Industry Business - K. Lachmann - Date 12

To Help Customers to Optimize Their

(13)

Steel Manufacturing Optimization

Business

Business

The Profiting from the Steel Business

Operation

The Running of a Steel Plant The Running of a Steel Plant

Production

The Making of Steel (Facilities and Process)

(14)

Steel Manufacturing Optimization

Business

Minimize

Business

The Profiting from the Steel Business

Minimize

Production

Resource Cost

n

Operation

The Running of a Steel Plant

X

=

Minimized

Production

Resource

m

izatio

n

The Running of a Steel Plant

Optimize

Production

Cost Per

Ton

Opti

m

Production

The Making of Steel (Facilities and Process)

Resource

Consumption

Schneider Electric - Industry Business - K. Lachmann - Date 14

Lifecycle

(15)

Our Presence in Steel: 150+ M€ Sales

(2011)

DOUBLE efficiency and save US$3 million annually!

The state-of-the art automation technology facilitates energy The state of the art automation technology facilitates energy management across our enterprise and has provided us with a professional and efficient diagnostics helps us optimise our energy efficiency.”

Mr. Wenyi Wang, Project Manager, LY Steel Mr. Wenyi Wang, Project Manager, LY Steel

Process Automation for Break-Through Steelmaking Process Automation for Break Through Steelmaking

Schneider Electric responsible for Basic Engineering (Process Automation / Energy Distribution) of ULCOS pilot blast furnace with Top Gas Recycling.

(16)

Index

Schneider Electric at a glance

Schneider Electric at a glance

Schneider Electric in Mining, Minerals and Metals

Schneider Electric in Steel Manufacturing

Selected Schneider Electric References – Iron Making

Selected Schneider Electric References – Energy Management

(17)

Blast Furnace Process Automation

OS12

REPORT PRINT ALARM PRINT

Vijeo Citect Clients (OS) OS1

Vijeo Citect Web Server intranet

Office LAN

Ethernet Vijeo Citect WEB client

Ethernet TCP/IP 100Mbit/s

I/O SERVER1

(redundant)

Engineering Station U it P

Vijeo Citect Web Server

Industrial Ethernet 100Mbit/s

(18)

Blast Furnace

(19)

“Blast Furnace #7” Novolipetsk Iron

and Steel Corporation (NLMK)

Russia

and Steel Corporation (NLMK),

●Production Capacity: 3.4 million tonne/year p y y

● free-standing furnace

● modern refractory and cooling solutions

● advanced air supply system for cold air blasting.

● up-to-date charge make up solution, p g p ,

● bell-less top charging,

● pulverized coal injection,

● reliable hydraulic equipment at the foundry,

● multiple process data recorders p p

● a top notch automation system

● Sachem expert system

●General contractor Stroitelno-montazhniy Trest NLMK LLC (NLMK’sGeneral contractor Stroitelno montazhniy Trest NLMK LLC (NLMK s Construction and Assembly Unit)

●Metallurgical equipment manufacturer PAUL WURTH

(20)

“Blast Furnace #7” Novolipetsk Iron

and Steel Corporation (NLMK)

Russia

and Steel Corporation (NLMK),

Schneider Electric: main supplier of automation systems and low

Schneider Electric: main supplier of automation systems and low

voltage equipment for the production complex

Scope of Supply (extract)

S p

S pp y (

)

>50 PLC Quantum Hot Standby >30 PLC Quantum, Premium, M340 > 70 000 SCADA tags Vijeo Citect >110 Licenses >180 Control cabinets >400 Control panels 250 IMCC >250 IMCC >75 VSD >15 LV Substation etc

Schneider Electric - Industry Business - K. Lachmann - Date 20

(21)

Techint Ternium Siderar

Revamping Blast Furnace 1

Revamping Blast Furnace 1

Automation scope

• Charging operation • Funace operationp • Stoves & Blast • Gas Cleaning • Fuel oil

• Slag granulation (INBA) • Slag granulation (INBA) • …..

(22)

Techint Ternium Siderar

Revamping Blast Furnace 1

Revamping Blast Furnace 1

Automation scope

Automation scope

●Unity Pro platform with Modicon Quantum HSBY and Modicon Premium configurations

●Ethernet, RIO and MB+ networks

●Ethernet, RIO and MB networks

●90+ drops

Benefits of this solution

Benefits of this solution

●Process improvement with higher performance pf plc scan time

●Integration of Terniums programming standard

●Easy troubleshooting for the maintenance people thanks to advanced

●Easy troubleshooting for the maintenance people thanks to advanced diagnostic tools

●Increased reliability reducing the time required to operate the supervision of the system

Schneider Electric - Industry Business - K. Lachmann - Date 22

(23)

Gerdau SA

Blast Furnace + Sinter + Coke

Blast Furnace + Sinter + Coke

Customer profile

Brazil

Customer profile

●Gerdau Group is the largest producer of long steel in the Americas,

●Mills in Brazil, Argentina, Canada,

●Mills in Brazil, Argentina, Canada, Chile, Colombia, the United States, Peru, Uruguay.

●Holds 40% stake in the Spanish company Sidenor. Currently,

●Gerdau has an installed capacity of 19.1 million metric tons of

steel per year steel per year.

(24)

Gerdau SA

Blast Furnace + Sinter + Coke

Blast Furnace + Sinter + Coke

Project scope

Brazil

Project scope

●Expansion the Acominas steel plant to raise production capcity from 3 to 6 million metric tons in two phases

●First phase:

● To raise capacity from 3 to 4.5 mtpa (duplication of reduction area)

● Three packages: Blast Furnace, Coke Plant and Sinter Plant.

● Scope of supply includes mechanical, electrical, instrumentation and automation items.

●Packages awarded to chinese OEM’s

● CISDI: Blast Furnace

● ACRE: Coke Plant

Schneider Electric - Industry Business - K. Lachmann - Date 24

(25)

Gerdau SA

Blast Furnace + Sinter + Coke

Blast Furnace + Sinter + Coke

●The challenge

Brazil

●The challenge

● Internat. coordination of Schneider Electric subsidiaries, and three different OEMs for different systems

● Provide local support for the OEMs and implement local

t ifi ti t d d d f

customer specifications, standards and preferences

● End User preference for Modicon Quantum PLC’s thanks to previous experience with technical solution and support

●The solution

● Local presence in Brazil: automation technical support, training

● Supply chain coordination in China: Gerdau Acominas local team, Schneider Electrics

l l t i t t d l b ild t k

local system integrator and panel builders network

● Key values for End User and OEM’s:

●international cooperation,

●local support and warranty,

●local support and warranty,

(26)

Gerdau Acominas – Blast Furnace

Central Control Room

Stockhouse BF Proper BF Top Hot Stove Gas Cleaning Indirect Water To Level 3 Servers

PCI

PCI PCI Room

Schneider Electric - Industry Business - K. Lachmann - Date Stockhouse Room BF Proper Room Top Room HS Room Direct Water Room26

Circulation Water Room TRT Room

(27)

Gerdau SA

Blast Furnace + Sinter + Coke

Blast Furnace + Sinter + Coke

Customer benefits

Brazil

Customer benefits

OEMs confidence to work with Schneider Electric solutions thanks to

the partnership between the end user and Schneider Electric Brazil and

the partnership between the end user and Schneider Electric Brazil and

Schneider Eletric China

O

t

h

f

A t

ti

LV

d MV

k

One stop shop for Automation, LV and MV packages

The international coordination was key to satisfy the local customer

requirements and preferences

(28)

EKO-Stahl GmbH Eisenhüttenstadt

Germany

Germany

Blast furnace 5A and Sinterplant

Blast furnace 5A and Sinterplant

Schneider Electric Process Automation

20 it M di Q t l t

●20+ units Modicon Quantum plc system

●Vijeo Citect redundant Scada system

●Decentralized I/O C i ti ●Communication ●Modbus+ ●Ethernet TCP/ IP Communication /O ●~20.000 I/O points

Electrical Distribution

(29)

EKO-Stahl GmbH Eisenhüttenstadt

Germany

Germany

Blast furnace 5A

Blast furnace 5A

(30)

EKO-Stahl GmbH Eisenhüttenstadt

Germany

Germany

PCI (Pulverized Coal Injection)

PCI (Pulverized Coal Injection)

(31)

Bhushan Power & Steel Limited,

Rengali – Blast Furnace + Sinter + Coke

Rengali Blast Furnace + Sinter + Coke

Customer profile

India

Customer profile

●A fully integrated 1.5 Million TPA Steel making Company with turnover of INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in g India

(32)

Bhushan Power & Steel Limited,

Rengali – Blast Furnace + Sinter + Coke

Rengali Blast Furnace + Sinter + Coke

Customer challenges:

India

Customer challenges:

●Completion of System Engineering, Panel designing, Panel manufacturing and Dispatch Based on Mecon Technical Specifications

●Providing necessary support for equipments coming from SSIT for Blast

●Providing necessary support for equipments coming from SSIT for Blast Furnace of capacity 1004m3, Sinter Plant of capacity 104m2, Raw Material Handling Plant, Coke Oven of 0.45MT Capacity

●Completion of job based on availability of site

Project scope:

●Design, Engineering, Manufacturing, Supply, Erection, Testing andDesign, Engineering, Manufacturing, Supply, Erection, Testing and Commissioning

●Programmable Logic Controllers (PLC) & Supervisory Controls and Data Acquisition (SCADA) system, for Raw Material Handling, Coal Preparation.

Schneider Electric - Industry Business - K. Lachmann - Date 32

(33)

Bhushan Power & Steel Limited,

Rengali – Blast Furnace + Sinter + Coke

Rengali Blast Furnace + Sinter + Coke

Schneider Electric Solution:

India

Schneider Electric Solution:

Modicon Quantum Hot Standby PLC System with RIO nodes

Vijeo Citect SCADA for overall process Control & Monitoring

Historical data & various process related reports. Archiving of upto 6

Months period

(34)

Bhushan Power & Steel Limited,

Rengali – Blast Furnace + Sinter + Coke

BF Main Control Room Blower Control Room PCI Room STOCK Control Room

Rengali Blast Furnace + Sinter + Coke

India

COKE SCREEN & QUENCHING

AREA PREPARATION COAL AREA ESP C t l (PLC i id Si t Pl t) RMHP

ESP Control (PLC inside Sinter Plant)

SSIT Scope

BF COOLING WATER

Schneider Electric - Industry Business - K. Lachmann - Date 34

Gas Cleaning Control Room Sinter PLC System SSIT Scope Local Source

(35)

Bhushan Power & Steel Limited,

Rengali – Blast Furnace + Sinter + Coke

Rengali Blast Furnace + Sinter + Coke

Customer Benefits

India

Customer Benefits

Modicon PLCs are the most reliable PLC equipment for industrial

automation

automation.

●No failures in the continuous site operations.

●Quantum PLC running under Dusty Environment

Vijeo Citect SCADA helps in logging of various process related events

& alarms. Historical trends for analyzing various process parameters

(36)

Techint Ternium Siderar

Revamping Blast Furnace 1

Revamping Blast Furnace 1

Customer profile

Argentina

Customer profile

●Manufacturer of flat and long steel products

●Production centers in Argentina, Mexico, Colombia, Guatemala and the United States

●One of the leading steel companies in Latin America and largest argentinian steel company hot rolled, cold rolled, hot dip galvanized,

electro-galvanized, prepainted and tinplate steel g , p p p sheet products

Project objective

Project objective

●Expand production capacity to reach 4 mtpa

●Improve iron quality for easier processing in downstream facilities

Schneider Electric - Industry Business - K. Lachmann - Date 36

(37)

Cosipa – Blast Furnace Upgrade

B il

Companhia Siderúrgica Paulista (Cosipa) is a member company of the

Brazil

Companhia Siderúrgica Paulista (Cosipa) is a member company of the

Usiminas System, Latin America’s biggest flat steel complex

Producer of uncoated flat steels

Producer of uncoated flat steels

for a wide variety of industries

(38)

Cosipa – Blast Furnace Upgrade

B il

Migration of Blast Furnace #1

Brazil

Migration of Blast Furnace #1

Existing automation system

●Entirely based on 584 Modicon controllers

●Entirely based on 584 Modicon controllers

●Close to critical status for maintenance and spares parts / components availability

Challenge

●Modernizing the system during the blast furnace regular maintenance

●A safe modernization procedure

●A safe modernization procedure

– Critical equipment importance for the whole plant – No acceptance of delays

(39)

Cosipa – Blast Furnace Upgrade

B il

Schneider Electric Solution – a Smooth and Safe upgrade path

Brazil

Schneider Electric Solution – a Smooth and Safe upgrade path

Hardware

●New powerful Modicon Quantum automation platform

●New powerful Modicon Quantum automation platform

●Keep the existing I/O systems (200 Series - Controller 584), to reduce re-wiring system, save time

●Preserves past investment through Modicon Quantums system with

●Preserves past investment through Modicon Quantums system with possibility to mix additional racks with the modern I/O modules

Software

Software

●Re-use existing software - a simple operation to upload and download for the new CPUs

●Upload procedure from the old controller to the new platform allowed to pre-Upload procedure from the old controller to the new platform allowed to pre test all the variables and software prior to comission

(40)

Cosipa – Blast Furnace Upgrade

B il REDE COSIPA PCI ETHERNET NOTE BOOK MANUTENÇÃO Brazil PROCESSO

SERVIDOR PROCESSO SUPERVISÃO

Ç

REDE MODBUS PLUS

MODICON QUANTUM REDUNDANTE PC MANUTENÇÃO MODICON TSX QUANTUM REGENERADORES CARREGAMENTO O CARREGAMENTO S MÓDULOS DE E/S CONTROLADOR 584

Schneider Electric - Industry Business - K. Lachmann - Date 40

NORTE SUL

Variáveis Analógicas do Regenerador

(41)

Cosipa – Blast Furnace Upgrade

B il

Migration of Blast Furnace #1 – Step 2

Brazil

Migration of Blast Furnace #1 Step 2

Upgrade of I/O system during regular maintenance period

Schneider Electric Solution

●Re-use and migration of previous software

●Support of current CPUs (from the first upgrade) with simple upgrade easily

●Support of current CPUs (from the first upgrade) with simple upgrade easily migrated to new versions (if required) and support of any additional modules (networks)

Benefits:

●Migration in a record time according to the user requirements (during the scheduled maintenance period)

●A safe migration strategy with a stepwise approach

●Open doors for immediate benefits: Ethernet communications new software

●Open doors for immediate benefits: Ethernet communications, new software functionalities

(42)

Shagang Group

Blast Furnace 5800m

3

Blast Furnace 5800m

China

(43)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

Stove Automation Project

The customer:

India

The customer:

●Situated at a distance of 158 km from Calcutta

●With the successful commissioning of the modernized units, DSP is all set to produce modernized units, DSP is all set to produce

●2.088 million tones of hot metal,

●1.8 million tones of crude steel

●1 586 million tones of saleable steel annually

●1.586 million tones of saleable steel annually

(44)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

Stove Automation Project

Customer challenges:

India

Customer challenges:

●Delivery and installation of the equipment within the shortest possible time with Zero defect

●Commissioning of the system within the Capital Repair period of the Blast

●Commissioning of the system within the Capital Repair period of the Blast Furnace ( 45 days)

●Heating of the Stoves with efficient Techno economics, possible due to monitoring and controlling features of PLC and SCADA

●Good interfacing with operation personnel for incorporation of required monitoring & control features as per the process requirement

●Various, Critical PID Loop controls for the entire process, integrated & t ll d b i l

controlled by a single processor

(45)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

Stove Automation Project

Project scope:

India

Project scope:

●Design, Engineering, Manufacturing, Supply, Erection, Testing and

Commissioning of Programmable Logic Controllers (PLC) & Supervisory Controls and Data Acquisition (SCADA) system, for achieving Blast Furnace q ( ) y g #4 Stove Automation

Project requirements:

j

q

●This is a 1200MT/Day Blast Furnace

●The failure rate of the running TOSDIC DCS has increased and therefore M/s. DSP was looking for an alternative automation system

(46)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

Stove Automation Project

Schneider Electric Solution

India

Schneider Electric Solution

Stove Automation achieved by the following equipments:

●Quantum Hot Standby PLC System with RIO nodes

●Quantum Hot Standby PLC System with RIO nodes

●Standby Premium PLC system (13Nos.) for various PID Control Loops

●Magelis TSD for Control & Monitoring of these Premium PLC

●Citect SCADA for overall process Control & Monitoring

●Citect SCADA for overall process Control & Monitoring

●Flow, Temperature and Pressure parameters from field being monitored and trended continuously. Historical data & various process related reports.

Archiving of up to 6 Months period

System Redundancy at every level

(47)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

Stove Automation Project

India

Ethernet Switch TCP/IP 10/100Mbps

Stand Alone Premium

Primar y

Secondary

Stand Alone Premium CPU 1 to 8 on

Ethernet XBT-G 1 to 8

on Ethernet y

(48)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

India

Stove Automation Project

(49)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

India

(50)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

Stove Automation Project

India

(51)

Durgapur Steel Plant - Blast Furnace # 4,

Stove Automation Project

Stove Automation Project

Customer Benefits

India

Customer Benefits

Modicon Quantum / Premium PLCs are the most reliable PLC

equipment for industrial automation.

q p

●No failures in the continuous site operations of over a year.

●Quantum / Premium PLC running under high Ambient Temperature & Dusty Environment.

Citect SCADA helps in logging of various process related events &

alarms. Historical trends for analyzing various process parameters.

Various critical control elements for the process, integrated to a single

p

,

g

g

Quantum System, thus reducing the Operational & Maintenance

(52)

JSW, Toranagallu

BOF Converter Upgrade

India

BOF Converter Upgrade

The customer:

India

The customer:

●JSW Steel Ltd. is among the largest Indian Steel Companies

●today with capacity of 7.8 MT

● most modern eco friendly steel plants

● most modern, eco-friendly steel plants with the latest technologies for both upstream & downstream processes

The Challenges:

●Replace Honeywell TDS 3000 DCS System

●Replace Honeywell TDS 3000 DCS System

(53)

JSW, Toranagallu

BOF Converter Upgrade

India

SERVER A SERVER B SERVER C SERVER D BMCS ENGG GCP ENGG CONV ENGG

BOF Converter Upgrade

India

ETH SW 1 ETH SW 2 ks CONVERTER PLC GCP PLC BMCS/FACS PLC Un ity Fast L in ijeo Ci tect wi th

TOTAL 5 DROPS TOTAL 10 DROPS TOTAL 3 DROPS

tum U n it y & V i Quan t

(54)

Converter Process

India India

(55)

Gas Cleaning and Cooling Plant

India India

(56)

Bulk Material Charging System

India India

(57)

Blast Furnace

(58)

Bhushan Power & Steel

Blast Furnace Cooling & Slag Handling

Blast Furnace Cooling & Slag Handling

The customer:

India

The customer:

●A fully integrated 1.5 Million TPA Steel making Company with turnover of INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in g India

(59)

Bhushan Power & Steel

Blast Furnace Cooling & Slag Handling

(60)
(61)
(62)
(63)
(64)
(65)

Automation reference list

(extract)

Blast furnaces

Blast furnaces

(66)

Process automation references

Extract steel reference list

(revision 2009, China)

Application area

Application area

●Sinterplant ●Blast Furnace

Process automation

●Modicon plc and/or

Schneider Electric - Industry Business - K. Lachmann - Date 66

(67)

Blast Furnace

Oxygen Plant

(68)

DSP-SAIL - Oxygen Plant

The customer:

India

The customer:

●Situated at a distance of 158 km from Calcutta

●With the successful commissioning of the modernized units, DSP is all set to produce 2.088 million tones of hot metal, 1.8 million tones of crude steel to produce 2.088 million tones of hot metal, 1.8 million tones of crude steel and 1.586 million tones of saleable steel annually

Challenge

●Upgrading 80 MOD30 standalone controller to Quantum Unity HSBYUpgrading 80 MOD30 standalone controller to Quantum Unity HSBY

Solution

●Vijeo Citect SCADA Servers with Unity Fast Links

● Configuring 60 PIDs & 15 Manual Loaders

● Configuring 60 PIDs. & 15 Manual Loaders

(69)

DSP-SAIL - Oxygen Plant

India Automation Architecture Architecture TYPE DI DO AI AO TOTAL TOTAL 192 288 368 136 984

(70)

DSP-SAIL - Oxygen Plant

India Example Operator Operator Screen

(71)

DSP-SAIL - Oxygen Plant

India Example Operator Operator Screen

(72)

Bayi Iron & Steel Co., Ltd

Oxygen Plant

Oxygen Plant

Customer Profile

Customer Profile

●Subsidiary of Baosteel Group with steel capacity of 7 mtpa

●Fully integrated from mining, ore dressing, sintering, coking, iron-making, steel-making to steel rolling

●Manufacturer of long products, flat products and tubular products

Project scope

●Control of Air Separation Plant (40000Nm3/h)

Automation scope

U it P l tf ith M di Q t d Q t HSBY

●Unity Pro platform with Modicon Quantum and Quantum HSBY configurations

●Ethernet-network, redundant fiber rings

●Vijeo Citect Scada, Client/Server, redundant servers

Schneider Electric - Industry Business - K. Lachmann - Date 72

Vijeo Citect Scada, Client/Server, redundant servers

(73)

Bayi Iron & Steel Co., Ltd

Oxygen Plant

Oxygen Plant

Crude Argon

Example Operator Operator Screen

(74)

Bayi Iron & Steel Co., Ltd

Oxygen Plant

Oxygen Plant

Main Tower System

Example Operator Operator Screen

(75)

Bayi Iron & Steel Co., Ltd

Oxygen Plant

Oxygen Plant

Liquid Oxygen Tank

Example Operator Operator Screen

(76)

Bayi Iron & Steel Co., Ltd

Oxygen Plant

Oxygen Plant

Precooling of Air Oxygen Turbocompressor

Recycled water Molecular Sieves

(77)
(78)

Bhushan Power & Steel

The customer:

India

The customer:

●A fully integrated 1.5 Million TPA Steel making Company with turnover of INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in g India

(79)

Bhushan Power & Steel

Raw Material Preparation Plant

(80)
(81)
(82)
(83)

Bhushan Power & Steel

Raw Material Preparation Plant

Raw Material Preparation Plant

India

Example Operator Operator Screen

(84)

Index

Schneider Electric at a glance

Schneider Electric at a glance

Schneider Electric in Mining, Minerals and Metals

Schneider Electric in Steel Manufacturing

Selected Schneider Electric References – Iron Making

Selected Schneider Electric References – Energy Management

(85)

Tangsteel

Tangsteel

China

China

(86)

TangSteel: Energy Management System

Executed by Project and Services Schneider Electric China Executed by Project and Services Schneider Electric China

● Customer profile

● Customer profile

● One of top 10 iron & steel sites in China

● Production capacity: 18M tons per year

● 22 energy types

● Customer Challenge

● Regulation compliance

● Reporting mandate

● Competitive cost pressures

● Schneider Electric Solution

Key production equipment:

• coking (6) ( )

●Schneider Electric Solution

● Energy audit

● Power monitoring

Energy Management System

• sintering (4) • blast furnace (4) • converter (7)

• refining furnace (6) • casting (10)

Schneider Electric - Industry Business - K. Lachmann - Date 86

Energy Management System ● Platform for the future

casting (10)

• heating furnace (10) • rolling (9)

(87)

TangSteel: Energy Management System

Level 3 functions Level 3 functions

(88)

TangSteel: Energy Management System

Overview of project scope Overview of project scope

●22 types of W.A.G.E.Syp

●Measurement management (power meter)

● Hierarchy (enterprise, plant and sector)

● Duration (hours, day, week, month and year)

● Categories

Measuring

Management

● Categories

●Data acquisition (PLC, networking equipment and SCADA)

● Areas

● Different energy system

● Existing measurement database ERP

Management

Data

Acquisition

Monitoring &

● Existing measurement, database, ERP

●Monitoring and control (SCADA)

●Information management (Ampla)

● Hierarchy (enterprise, plant and sector)

● Duration (shift day week month and year)

Control

Information

Management

● Duration (shift, day, week, month and year),

● Every energy usage efficiency

●Energy decision making (Ampla)

● KPI & the performance target

M t t i t

Decision

Making

Schneider Electric - Industry Business - K. Lachmann - Date 88

(89)

TangSteel: Energy Management System

Project Architecture Project Architecture

20 operator clients

p

Servers including

Ampla, storage etc.

80 k points data

80 k points data

integration

Backbone network

link to 10 areas

link to 10 areas

10 set redundant

I/O servers

70 sets M340

70 sets M340

1800 sets power

meters

(90)

TangSteel: Energy Management System

In real life In real life

(91)

TangSteel: Energy Management System

Customer Benefits Customer Benefits

One open and integrated Energy Management System (EMS)

One open and integrated Energy Management System (EMS)

connected energy production to business system (SAP)

Establish one consistent energy management process based on new

Establish one consistent energy management process based on new

EMS system

Satisfy key management needs with below system capability

Satisfy key management needs with below system capability

●Analyze Energy Consumption by Process Segments or Work Center

●Identify Key Energy Events with Production Context Identify Key Energy Consumption Equipments

●Identify Key Energy Consumption Equipments

●Allocate Energy Cost to Process Segments with real energy data

●Energy Cost Variance according to unit price change E C t l i f h b t h d ti

(92)

Make the most of your

energy

Schneider Electric Schneider Electric Klaus LACHMANN

Steel Solutions Director

Phone: +49 (0) 2102 / 404 ext. 9368 Mobile: +49 (0) 172 / 211 94 87

Schneider Electric - Industry Business - K. Lachmann - Date 92 ( )

Figure

Updating...

References

Updating...

Related subjects :