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End Line Inspection Implementation Tubular Products, Vereeniging, ArcelorMittal, South Africa

End Line Inspection Implementation Tubular Products, Vereeniging, ArcelorMittal, South Africa. Joao Bordalo Senior Architect, MES Demand. Agenda. General Project Objectives Solution System Architecture Implementation Goals & Benefits Achieved Lessons learnt Conclusion

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End Line Inspection Implementation Tubular Products, Vereeniging, ArcelorMittal, South Africa

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  1. End Line Inspection Implementation Tubular Products, Vereeniging, ArcelorMittal, South Africa Joao Bordalo Senior Architect, MES Demand

  2. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  3. GeneralProfile - ArcelorMittal • ArcelorMittal is the world's number one steel company, with 320.000 employees in more than 60 countries. It has led the consolidation of the world steel industry and today ranks as the only truly global steelmaker with an industrial presence in 27 countries. • ArcelorMittal is the leader in all major global markets, including automotive, construction, household appliances and packaging. The Group leads in R&D and technology, holds sizeable captive supplies of raw materials and operates extensive distribution networks. • Its industrial presence in Europe, Asia, Africa and America gives the Group exposure to all the key steel markets, from emerging to mature. ArcelorMittal will be looking to develop positions in the high-growth Chinese and Indian markets.

  4. GeneralMarkets - ArcelorMittal Market position and market share estimates by region* No 1 in EasternEurope and CIS No 1 inWestern Europe No 1 inNorth America No 1 in Africa No 1 in South America Number 1 in 5 regions and 4 continents

  5. GeneralProfile - Tubular Products Division • Tubular Products is in 21 operating locations in 11 countries world wide, headquartered in Luxembourg with a capacity of over 3 mill. Tons. • Automotive with locations in Brampton, Hamilton, London & Woodstock (Canada), Monterrey (Mexico) and Chevillon, Hautmont & Vitry Le Francois (France). Although organized within other Tubular Products units South Africa, Marion, Shelby, and Karvina also manufacture & supply automotive product. • Energy with locations in Aktau (Kazakhstan), Annaba (Algeria), Galati & Roman (Romania), Ostrava (CzechRepublic), Vereeniging (South Africa) and greenfield in Jubail Industrial City (Saudi Arabia) and Calabar (Nigeria). • Mechanical located in Iasi (Romania), Karvina (Czech Republic), Krakow (Poland), LaSalle (Canada), Marion & Shelby (USA) and Temirtau (Kazakhstan).

  6. Canada, Brampton France, Hautmont France, Chevillon France, Vitry Head Office, Luxemborg Canada, Hamilton Czech Republic, Ostrava Canada, Woodstock Canada, London Mexico, Monterrey Romania, Roman Romania, Galati Kazakhstan, Aktau Algeria, Annaba Saudi Arabia, Jubail USA, Pittsburg Business Service Energy South Africa, Vereeniging GeneralMarkets - Tubular Products Division Polan, Krakow Canada, LaSalle Czech Republic, Karvina USA, Shelby USA, Marion Romania, Iasi Kazakhstan, Temirtau Nigeria, Calabar,

  7. GeneralMarkets : Tubular Products ArcelorMittal South Africa Energy Energy Products: • Line Pipes • Seamless (API,EN, ASTM) • Customer base includes Oil & Gas and Engineering companies in America, Asia, Africa & Europe

  8. GeneralWorks Layout - Tubular Products ArcelorMittal South Africa End Line Inspection

  9. General ELI Plant Up Close - Tubular Products ArcelorMittal South Africa Control Desk Reject Table INLET Ultrasonic Machine Alignment & Rotation Rollers

  10. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  11. Project Objectives • Business Objective • API Accreditation for Tubular Products Plant • API: American Petroleum Institute API standards address several key aspects of the oil and gas industry, including exploration and production, refining, fire protection and safety, petroleum measurement and marine transportation. These standards also reference offshore production, drilling, structural pipe, pipeline, health and environmental issues, valves, storage tanks, etc. • Operational Objective • Shorter Project Delivery • Object and Graphical Standards • Standard PLC Tag Naming Convention • Reliable Data Tracking [Integration with Plant MES] • Operator Accountability

  12. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  13. Solution • Existing WONDERWARE Install base:- • Wonderware Historian [5000 tags] • Active Factory 9.2 • INTOUCH 10 • ARCHESTRA 3.0 • Existing Portal [ProcessNet] • Visualization • Existing Reporting tools utilized • MS Reporting Services • Additional Requirements for solution • Consulting [Adopted WONDERWARE’s Best Practices BMA] • Training [ARCHESTRA and INTOUCH’] • Implementation [Functional Specification, Project Schedule, Commissioning] • Time Frame of 12 weeks

  14. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  15. Author Workstations ERP Plant IS Expert System Historian Model Software DB Server Intranet Server Engineering ”SCADA” / MES “SCADA” PLC / DCS / SSS Sensors/ Field Devices Intelligent Devices System ArchitectureConcept Network Topology SAP R/3 MES Plant Centric Information System Process Control

  16. Process Control Information System : Key Data Application Server GUI AOS Downstream Reporting Services Server ELI SCADA IDE TP EWS PLC - ABB PLC - ABB PLC - ABB System Architecture- TP ELI Plant System Topology - Plant Information Network Tubular Pipes Information System Router WAN Control Information Network TP Wonderware Historan Control Network Standard ArchestrA ELI

  17. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  18. ImplementationSchedule • Operational Specification Written and Approved by line Management (1x week) • Setting up the environment: WW Historian, ARCHESTRA, MES Database, IO Servers and IP assignments (2x Week) • Consulting with WONDERWARE. Setting of standards and best practices. (1x week) • Development of ARCHESTRA environment (scripts etc) using INTOUCH objects, deployment (3x weeks) • Development of Information object in ARCHESTRA (1x week) • Commissioning (3x weeks) • 11 weeks total

  19. ImplementationARCHESTRA: BMA $UserDefined $B_Userdefined $M_Limits $M_Limit_Switch $M_Proxy $A_ELI_Proxy Base Object Derivation Standard Base Master Application

  20. ImplementationARCHESTRA: Deployment / Plant Model

  21. ImplementationARCHESTRA: Data Handling

  22. ImplementationData Flow

  23. ImplementationAnimation of End Line Inspection Plant Alignment Rolls 2A Rotation Rolls 1 Alignment Rolls 2B Alignment Rolls 1 Rotation Rolls 2 INLET Scale UT UT

  24. ImplementationSCADA: Plant Overview

  25. ImplementationSCADA:ELI Overview

  26. ImplementationSCADA : Drive Status

  27. ImplementationSCADA: Manual Override

  28. ImplementationARCHESTRA: MESINFO Object

  29. ImplementationMES GUI

  30. ImplementationDatabase Schema

  31. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  32. Goals & Benefits Achieved • Reduced Engineering Costs on system expansion or duplication • This project has been shown that ArchestrA can be a vertical as well as a horizontal tool for integration • Standardised Environment :- great stepping stone for future automation • Contribution To Plant Operations due To Accreditation: • 80 % of normal throughput • 88 000 Ton (Budget 2008) • 130 Million Rand (Budget 2008)

  33. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  34. Lessons Learnt • Hardware and Software (OS) requirements for SYSTEM PLATFORM • Networking Environment • Stand-Alone Server for the Development Environment (IDE) • Deploy redundancy [Our Future Plan] • For optimum performance use stored procedures • Use a SQL connection for every object writing to the Database • Consult with WONDERWARE to ensure that standards and best practices are employed • Training is essential

  35. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  36. BUSINESS SYSTEMS AUTOMATION SYSTEMS DATABASES ArchestrA Conclusion • Process Control Information Systems are a company strategic asset, it needs reliable and flexible systems that can populate the databases correctly • ArchestrA is a powerful system technology that supports our company strategy as outlined above

  37. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  38. Acknowledgements Acknowledgements Cobus Muller - General Manager, Tubular Products Frikkie Fourie - Systems Engineer [TPSA] Hannes van Wyk - Senior Engineer Mechanical [TPSA] Marius Swanepoel - SNR Analyst MES DEMAND Vereeniging, IM Roche Bester - Senior Engineer Metallurgy [TPSA] Andries Wentzel - Electrical Technicians [TPSA] Willie Essendrup - Electrical Technicians [TPSA] Wimpie Lubbe - Electrical Technicians [TPSA] Markus van de Merwe - WONDERWARE SA Regional Manager Jos Peters - WONDERWARE SA Technical Consultant

  39. Agenda • General • Project Objectives • Solution • System Architecture • Implementation • Goals & Benefits Achieved • Lessons learnt • Conclusion • Acknowledgements • Questions

  40. Questions ? ? ? ? ? ? ?

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