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Transcript of Dofasco’s Enhanced Monitoring System Vit Vaculik and Adam Smyth OSI PI Users Conference San...
Dofasco’s Enhanced
Monitoring System
Vit Vaculik and Adam SmythOSI PI Users Conference
San FranciscoMay 13, 2003
Vit Vaculik and Adam SmythOSI PI Users Conference
San FranciscoMay 13, 2003
© Dofasco Inc., 2003. All rights reserved. Dofasco Inc. makes no representation or warranty as to the contents of this presentation and shall not be liable to any person in connection with its use.
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
AgendaAgenda
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
AgendaAgenda
Dofasco Hamilton Works
Dofasco Hamilton Works• One of Canada’s largest
fully integrated steel producers
4.8 million tons of steel shipped in 2002 with sales $3.6 billion (Cdn)
7500 employees
1000 in technology areas
• A North American leader in profitability
• One of Canada’s largest fully integrated steel producers
4.8 million tons of steel shipped in 2002 with sales $3.6 billion (Cdn)
7500 employees
1000 in technology areas
• A North American leader in profitability
The ProcessThe Process
LadleLadle
TundishTundish
BendingBending
UnbendingUnbending
RunoutRunout
Caster SOSTMCaster SOSTM
Process
OpportunitiesCaster Stability/Quality Prediction/Breakout Avoidance
DataTemperatures
Cooling Water Data
Stopper Rod Position
Heat Transfer
Negative Strip Time
Etc.
Alarms and Warnings through 2 Stability Indices
Top 5 Influences to the Problem
Trending of Data
Thermal Contour Map
InformationAutomatically Slow Cast Speed
Automatically Disposition Product
Strand Operator Slows Down Cast Speed
Operator Deselects Faulty Signal from the Model
Action
DAT SolutionCaster SOS
Caster SOSTM Concept Caster SOSTM Concept
CASTER SOS
ALARMALARM
ALARM
ALARM
ALARM
Erratic MouldLevel
SEN ChangeRequired
Sensor Failure
Breakouts
Other Events
Good Operation
New RequirementsNew Requirements• Enhanced Visualization of data
• Real-Time display with PI data
• Expand Monitoring System to include Transient Casting Conditions• PI as an integral component
• Enhanced Supporting Analysis Utilities• Analyzes large PI archive data set
• Enhanced Visualization of data• Real-Time display with PI data
• Expand Monitoring System to include Transient Casting Conditions• PI as an integral component
• Enhanced Supporting Analysis Utilities• Analyzes large PI archive data set
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
AgendaAgenda
Thermal MapThermal Map
Thermal MapThermal Map
• Purpose: provide the operators with an enhanced view of the thermocouple data so that it can be used to help diagnose Caster SOSTM alarms
• Purpose: provide the operators with an enhanced view of the thermocouple data so that it can be used to help diagnose Caster SOSTM alarms
Thermal MapThermal Map
ConfigDatabase
Plant Network
PLC & DCS
PI Server PI Server
PI PumpClass
Active X
PI API
EVM Arch
Thermal MAP
OSI PI Servers
Resamp toDistance
Charts
Thermal MapThermal Map
Thermal MapThermal Map
Thermal MapThermal Map
Benefits
• Temporal and spatial visualization of the data
• Operator able to see hot and cold spots in the mould
• Operator able to diagnose Caster SOSTM alarms based on thermal map display
Benefits
• Temporal and spatial visualization of the data
• Operator able to see hot and cold spots in the mould
• Operator able to diagnose Caster SOSTM alarms based on thermal map display
Case Study #1Case Study #1
• Caster SOSTM and Thermal Map identified formation of a sticker in the mould
• Thermal Map not commissioned for the event
• Sticker Breakout Occurred
• Caster SOSTM and Thermal Map identified formation of a sticker in the mould
• Thermal Map not commissioned for the event
• Sticker Breakout Occurred
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
Example 1Example 1
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
AgendaAgenda
Transient Caster MonitoringTransient Caster Monitoring• Start cast
• SEN change
• Tundish fly
• Plate insert
• Start cast
• SEN change
• Tundish fly
• Plate insert
Transient Caster MonitoringTransient Caster Monitoring
Steady State Casting
• 25% of breakouts found to be during start cast operation
• 25% of breakouts found to be during start cast operation
Start Cast MonitoringStart Cast Monitoring
• Purpose: provide the operator with on-line monitoring of the start cast operation giving them a continuous indication of start cast stability
• Purpose: provide the operator with on-line monitoring of the start cast operation giving them a continuous indication of start cast stability
• Inherent characteristics in process data of batch or start-up processes
• Dynamic (non-stationary)
• Auto-correlated
• In a finite duration
• Inherent characteristics in process data of batch or start-up processes
• Dynamic (non-stationary)
• Auto-correlated
• In a finite duration
Nature of Batch/Start-up ProcessesNature of Batch/Start-up Processes
Continuous process Batch/Start-up process
0 500 1000 150060
70
80
90
100
110
120
130
140
150
Observations
Tem
pera
ture
(D
egre
es)
0 500 1000 150060
70
80
90
100
110
120
130
140
150
Observations
Tem
pera
ture
(D
egre
es)
0 1000 2000 3000 4000 5000 6000 7000 8000 9000105
110
115
120
125
130
135
140
145
Observations
Tem
pera
ture
(D
egre
es)
0 1000 2000 3000 4000 5000 6000 7000 8000 9000105
110
115
120
125
130
135
140
145
Observations
Tem
pera
ture
(D
egre
es)
Start Cast MonitoringStart Cast Monitoring
Monitoring Module
Process StateDetermination
Run-timeOperationMonitoring
Start-upMonitoring
Model Set
MPCAModels
Standard PCAModels
.
.
.
Data AcquisitionModule
ProcessHistoricalDatabase
ModelDevelopment
Module
ContinuousCaster
Process
Sensors
Operators and HMI Computer Monitoring Module
Process StateDetermination
Run-timeOperationMonitoring
Start-upMonitoring
Model Set
MPCAModels
Standard PCAModels
.
.
.
Data AcquisitionModule
ProcessHistoricalDatabase
ModelDevelopment
Module
ContinuousCaster
Process
Sensors
Operators and HMI Computer
Monitoring Module
Process StateDetermination
Run-timeOperationMonitoring
Start-upMonitoring
Model Set
MPCAModels
Standard PCAModels
.
.
.
Data AcquisitionModule
ProcessHistoricalDatabase
ModelDevelopment
Module
ContinuousCaster
Process
Sensors
Operators and HMI Computer Monitoring Module
Process StateDetermination
Run-timeOperationMonitoring
Start-upMonitoring
Model Set
MPCAModels
Standard PCAModels
.
.
.
Data AcquisitionModule
ProcessHistoricalDatabase
ModelDevelopment
Module
ContinuousCaster
Process
Sensors
Operators and HMI Computer
Start Cast MonitoringStart Cast Monitoring
Cast Speed
State
Steady
Start-up
Idle
Pre-Start-up
Case Study #2Case Study #2
• System in background testing
• System alarms at the end of start cast
• Mould thermocouples abnormally inverted at end of start cast (abnormal)
• Could have lead to start cast breakout
• System in background testing
• System alarms at the end of start cast
• Mould thermocouples abnormally inverted at end of start cast (abnormal)
• Could have lead to start cast breakout
Thermocouples begin to invert
Alarming
State switches from start-cast to run-time
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
• Introduction
• Caster SOSTM and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
AgendaAgenda
Performance Monitor of Process AlarmsPerformance Monitor of Process Alarms
• Purpose: Analysis tool that can be used to statistically analyze PI data
• Purpose: Analysis tool that can be used to statistically analyze PI data
Performance Monitor of Process AlarmsPerformance Monitor of Process AlarmsFeatures• User selects PI tags, start/end time/interval
for the investigation
• Advanced condition based data retrieving and analysis (complex queries can be setup with and/or logic operators)
• Develops generic report
• Analysis can be scheduled to run periodically
Features• User selects PI tags, start/end time/interval
for the investigation
• Advanced condition based data retrieving and analysis (complex queries can be setup with and/or logic operators)
• Develops generic report
• Analysis can be scheduled to run periodically
Performance Monitor of Process AlarmsPerformance Monitor of Process Alarms
Example 3Example 3
Example 3Example 3
Performance Monitor of Process AlarmsPerformance Monitor of Process Alarms
Performance Monitor of Process AlarmsPerformance Monitor of Process Alarms
Performance Monitor of Process AlarmsPerformance Monitor of Process Alarms
Performance Monitor of Process AlarmsPerformance Monitor of Process AlarmsBenefits
• Other tools (E.g. Data link for Excel) limited by the amount of data that can be analyzed at once
• Enables what/if scenarios to be performed in seconds
• Support the monitoring system
• determine alarming thresholds
Benefits
• Other tools (E.g. Data link for Excel) limited by the amount of data that can be analyzed at once
• Enables what/if scenarios to be performed in seconds
• Support the monitoring system
• determine alarming thresholds
• Introduction
• Caster SOS and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
• Introduction
• Caster SOS and New Requirements
• System Enhancements
• Visualization
• Expanded Monitoring
• Historical Support Utilities
• Summary
AgendaAgenda
Enhancing the SOS system with PIEnhancing the SOS system with PI• Improved data visualization in real
time
• HMI for transient monitoring
• Supporting tools for historical data analysis
• Improved data visualization in real time
• HMI for transient monitoring
• Supporting tools for historical data analysis
Caster SOSTMCaster SOSTM
Process
OpportunitiesCaster Stability/Quality Prediction/Breakout Avoidance
DataTemperatures
Cooling Water Data
Stopper Rod Position
Heat Transfer
Negative Strip Time
Etc.
Alarms and Warnings through 2 Stability Indices
Top 5 Influences to the Problem
Trending of Data
Thermal Contour Map
InformationAutomatically Slow Cast Speed
Automatically Disposition Product
Strand Operator Slows Down Cast Speed
Operator Deselects Faulty Signal from the Model
Action
DAT SolutionCaster SOS
Process Monitoring FrameworkProcess Monitoring Framework
OpportunitiesQuality/Throughput/Safety
Process
Data
DAT Solution
Information
Action
• Not just limited to caster monitoring
• Applicable in most industries
• Not just limited to caster monitoring
• Applicable in most industries
Batch AnnealBatch Anneal
Process
OpportunitiesConsistent Heating
DataTemperatures
Fuel Rates
Coil Size
Recipe
Etc.
Information
Action
DAT Solution
Paper MachinePaper Machine
Process
OpportunitiesSheetbreak Prevention
DataSpeeds
Drive Currents
Material Properties
Tensions
Etc.
Information
Action
DAT Solution
SummarySummary• Comprehensive
Monitoring Solution
• Utilizes OSIsoft technology
• Internal Development
• Solid Results
• Growth Potential
• Comprehensive Monitoring Solution
• Utilizes OSIsoft technology
• Internal Development
• Solid Results
• Growth Potential
Questions?
Vit [email protected] ext. 2992
Vit [email protected] ext. 2992
Adam [email protected] ext. 3317
Adam [email protected] ext. 3317
Web Sitehttp://dat.dofasco.ca
Web Sitehttp://dat.dofasco.ca