AP09: GrafTech International: Taps Cloud Generating Millions($$) in Annual Savings for Customers
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Transcript of AP09: GrafTech International: Taps Cloud Generating Millions($$) in Annual Savings for Customers
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Copyright © 2014 Rockwell Automation, Inc. All Rights
Reserved.
PUBLIC INFORMATION
Taps Cloud Generating Millions($$) in Customer Savings
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Business confidential
GrafTech Customer Conversations
Introductions
2
Andy Messineo Architect Technical Development Manager
Dennis Kenemuth Arch Furnace Productivity System
Global Manager
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Business confidential
Corporate Overview
GrafTech International Ltd. (NYSE: GTI)
• +125 Year Old Company
• Headquartered in Parma, Ohio
• Focus on Graphite & Carbon Material Sciences
• Global Operations with +3000 Employees
• Annual Revenues of +$1B (USD)
• Operate Two Business Segments
• Industrial Materials
• Engineered Solutions
Company Profile Quick Facts
3
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Business confidential
Crude steel production, 1980-2012
MM tonnes
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Business confidential
2012 VS 2013 Production
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Business confidential
Operational Challenges for Steel Makers
7
Translate & simplify
complex data into
bottom line results
Surface hidden
problems
and opportunities
Eliminate waste and
streamline production
flow
Reduce &
control
cost
Increase
productivity
Maintain
uninterrupted
production flow
Achieving Your Business Objectives
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Business confidential 8
With arrival of ArchiTechTM System 4.0, we‟re making it easier than ever to track
and manage your EAF operations data in one place
• Features of 4.0 • An improved design
• ArchiTechTM navigation will be more streamlined and user-friendly with improved graphics and intuitive controls.
• More powerful tools
• We’re introducing all new trending & reporting tools. Information when you need it, the way you want to see it for informed decision making.
• Customizable trends
• You can make changes and publish trends how you like or we’ll do it for you---it’s all up to you.
In-depth EAF analysis on-demand?
ArchiTechTM is a registered trademark of GrafTech USA LLC.
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Business confidential
Real Examples of Results
9
Actual examples – project description & results Est. Annualized
Financial Impact ($)
Power program changes improving refining period performance resulting in 2
minute reduction in power-on time and an additional 1 MWH/heat due to
substantially improved foamy slag
3,000,000
DOE analysis of customer's fume collection system - set 4th hole draw to
55% - reduced power-on time and kWh/ton 210,000
Reduction in energy and electrode consumption 150,000
Increased power (tapped up), reduced electrode breakage 174,000
Reduced electrode breakage, improved productivity and reduce energy
consumption 610,000
ArchiTech data showed an increase in oxygen / burner usage which was
contributing to high electrode consumption. Several recommendations were
made to help reduce oxidation including a power program adjustment
727,500
Significant decrease in electrode consumption (-12%), electrical energy
consumption (-3.5%), and power-on time (-8.2%) 5,250,000
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Business confidential 10
Examples of problems customers solved faster with ArchiTech™ System
• Regulation problems
• Bad water cooled cable
• “B” phase not regulating
• Five percent voltage drop
• Wrong power program loaded
• Loose rollers affecting regulation
• Single phasing and arc instability
• Electrical phase sequence reversed
• LMF Electrodes being dipped for an
entire heat
Sometimes the problem found by the ArchiTechTM system ends
up being the proverbial “needle in a hay stack”
ArchiTechTM System Server Based Alerts
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Business confidential 11
What if you could solve EAF problems faster?
Small, self-contained, scalable, easy to
install and backed up by expert CTS
Size of bread basket and very durable
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Business confidential 12
24/7/365 advanced high-speed EAF
diagnostic, analysis and reporting system
Monitors Energy, Power and Power Quality
Connects to metering VT’s and CT’s
Minimum of 32 samples per cycle
True RMS measurements
Harmonic distortion
Revenue accuracy
What if you could solve EAF problems faster?
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Business confidential 13
What if you could solve EAF problems faster?
Developed to compliment and backup
existing supervisory systems
Easy to scale and customize
More than 10 years of software development in the product
Now on ArchiTechTM System 4.0
PLC data & Communications
Chemical, mechanical, auxiliary signals
Configurable web tools and CSV files
Master and subservient protocols
Serial and Ethernet integration
Email or direct connection
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Business confidential
ArchiTechTM 4.0
Data Collection
14
Microsoft SQL Database • MS SMTP server for data collection
• Custom parser software to insert
data into database
ArchITechTM
ArchiTechTM Hardware • Collects data and sends to server
via Email message
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Business confidential
ArchiTechTM 4.0
Legacy System
15
Microsoft Windows Server • Microsoft IIS
• Non-Encrypted data connection to client
• Microsoft SQL Database
• Microsoft SMTP server for data collection
• ASP.net web site with Customer Login
• On-Site at GrafTech Data Center
Client • Microsoft IE 8 or greater
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Business confidential
ArchiTechTM 4.0
Server Design
16
Microsoft Active Directory • Used for portal login and
security on the portal items Microsoft Active Directory Backup • Used as a backup security server
• Contains custom tools for adding users and customers
Microsoft SQL Database • All furnace data
• All portal data
• SQL Reporting data
• MS SMTP server for data collection
Rockwell Vantage Point • Microsoft IIS
• Microsoft Reporting Services
• SQL Reporting data
• SSL encrypted data connection to client
Client • Microsoft IE 8 or greater
• Microsoft .NET 4.0 or greater
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Business confidential
ArchiTechTM 4.0
Why as Hosted System in the „Cloud‟
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• 100+ Worldwide Installations
• 24 hour availability
• Reliable high speed Internet connection
• 24 hour monitoring
• Managed backups
• Scalability
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Business confidential 18
My ArchiTech™ System Dashboard - Example
In-depth EAF analysis on-demand?
Transforming EAF data into valuable, actionable insights
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Business confidential
ArchiTechTM 4.0
Customer Portal: Today‟s Heats
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Demo St Marys EF #1
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Business confidential
ArchiTechTM 4.0
Customer Portal: Heat Trace
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Demo St Marys EF #1
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Business confidential
ArchiTechTM 4.0
Customer Portal: Heat Trace (cont.)
I
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Business confidential
ArchiTechTM 4.0
Customer Portal: Current Trend
I
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Business confidential 23
Real Time Data Analysis
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Business confidential
ArchiTechTM 4.0
Multi-Site Comparison
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Business confidential
ArchiTechTM 4.0
Alerts Statistics
25
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Business confidential 26
Electrical Imbalances
• Circuit Impedance
• Static VAR
• Regulator Reference
• Valve or Drive
• Mechanical
• Power Program
Electrical imbalances from changes in…
How do you detect unintended changes in your EAF operation?
Quickly detecting and locating the source of electrical imbalances can be challenging
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Business confidential
ArchiTechTM 4.0
• 2 Portal Systems Reviewed
• SAP
• Rockwell
• Requirements
• Database Source of Microsoft SQL
• Highly Customizable Portal Layout
• Login Security
• Static Live Charts
• Dynamic Live Charts
• Excel Reporting
System Evaluation and Selection
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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Questions?