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