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May 11-14, 2003 2003 OSIsoft Users Conference

Development of Real-time Information Management System(RIMS) to Continuous Galvanizing Line(CGL) at the Asan Bay Works, Dongbu Steel Co., Ltd. May 11-14, 2003 2003 OSIsoft Users Conference. Dongbu Steel Co., Ltd. www.dongbusteel.co.kr. Contents. Who are we? Motivation The Goal

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May 11-14, 2003 2003 OSIsoft Users Conference

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  1. Development of Real-time Information Management System(RIMS) to Continuous Galvanizing Line(CGL) at the Asan Bay Works, Dongbu Steel Co., Ltd. May 11-14, 2003 2003 OSIsoft Users Conference Dongbu Steel Co., Ltd. www.dongbusteel.co.kr

  2. Contents Who are we? Motivation The Goal What is new? The results Developed applications : #1~#4

  3. Who are we? Products Cold Rolled Galvanized Prepainted TP / TFS Pipe H Beam CHQ Wire P.E.B CD Bar

  4. Who are we? Headquarters Works & Offices Inchon Works Pohang Works Asan Bay Works

  5. Motivation 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 capability with lower production cost

  6. Motivation For what and ...? • Improvement of Quality • Low Production Cost By What and How?

  7. Motivation What we need? Data type Large amount of real-time data Unrestricted for operator, maintenance and technical members Application Data reliability Real-time monitoring Challenge On-line storage over 3 years Storage Intranet / Internet Korean Language Accessibility In-house control Analysis tools

  8. The Goal Improving Process Capabilities Zinc Coating Post Treatment Inspection Pre Treatment Heat Treatment Coating Weight Mechanical Property Coating Amount Adherence Grade

  9. What is new? The Legacy system LEVEL 3 Coil Data, Production Result LEVEL 2 RIMS Server LEVEL 1 (PLC, DCS) Real-time Data IRMS SIEMENS TOSHIBA RIMS User Real-time measurement Thickness Temp. Coating Current Tension Pressure ...

  10. What is new? RIMS Architecture

  11. The results 1st Stage Development Results

  12. Main Task : Real-time Coil Inspection

  13. Main Task 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. ? ?

  14. SENSOR 1 SENSOR 2 SENSOR n Sm Sw Ss ts-a product tm-a tw-a ts-b tm-b tw-b ts-c ts-m

  15. Main Task : Results Main Screen Coil Length Winding Length Thickness Coil Tracking Width Coil Information Temperature Tension

  16. Main Task : Results Entry

  17. Main Task : Results Inspection Speed Upper Limit Lower Limit Data Searching Thickness re-scaling 1st product 2nd product 3rd product Process Status Temp. Coating Weight Width Pin Hole

  18. Main Task : Results WEB version Chart Sheet

  19. Appl. #1 : Retrieval of Operation Data

  20. Appl. #1 : Retrieval of CGL Operation Data Menu 1 3 2 4

  21. Appl. #1 : Retrieval of CGL Operation Data Export to Excel

  22. Appl. #2 : Monitoring and Daily Report System - Line Operation and Quality Related Items

  23. Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items Functions Operation Criteria Alarm Measured Value Taking measures Upper Limit RDB RTDB 관리하한선 Lower Limit Time Alarm Report . Daily report via e-mail . At anytime

  24. Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items Daily Report Sample #`1

  25. Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items Daily Report Sample #2 Sheet E-mail

  26. Appl. #3 : Analysis of Measuring Devices

  27. Appl. #3 : Analysis of Measuring Devices Major Measuring Devices * Thickness Gauge * Furnace Thermometers * Zinc Coating Weight * Tension Meters * Pin Hole Detector Main Screen

  28. Appl. #3 : Analysis of Measuring Devices Furnace Temperature

  29. Appl. #3 : Analysis of Measuring Devices Zinc Coating Weight

  30. Appl. #3 : Analysis of Measuring Devices Tension

  31. Appl. #3 : Analysis of Measuring Devices Daily Report – Sensor Trouble

  32. Appl. #3 : Analysis of Measuring Devices Logging

  33. Appl. #4 : Analyzing Zinc Coating Weight

  34. Appl. #4 : Analyzing Zinc Coating Weight` Air Knife Level 1 PLC Level 2 RIMS Coating Weight Gauge . Quality Factor . Set Points Measured Value of Sensors Stored value in RIMS User Lab. test results Level 3 Analysis System Configuration

  35. Appl. #4 : Analyzing Zinc Coating Weight` Data Sources Air Knife Coating Weight Gauge Laboratory Test Results

  36. Appl. #4 : Analyzing Zinc Coating Weight` Analyzing Flow Daily Data Gathering Statistical Analysis per Coil Long-term Data Analysis Yes C/W OK? Data Archiving No Analyzing C/W in Rolling Direction Analysis Data Feedback Laboratory Test Result Tuning

  37. Appl. #4 : Analyzing Zinc Coating Weight` Results

  38. Questions

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