steel manufacturing industry & schneider electric manufacturing industry & schneider...

Steel Manufacturing Industry& Schneider Electric Company introduction

Selected referencesSelected references - Iron Making - Energy Management

April 2012

Index

Schneider Electric at a glanceSchneider Electric at a glance

Schneider Electric in Mining, Minerals and Metals

Schneider Electric in Steel Manufacturing

Selected Schneider Electric References – Iron Making

Selected Schneider Electric References – Energy Management

Schneider Electric - Industry Business - K. Lachmann - Date 2

Schneider Electric – the global specialist in energy managementin energy management

Balanced geographies – FY 2011sales

billion € sales (last twelve months) North

America23%

WesternEurope

32%

of sales in new economies(last twelve months)

23% Asia Pacific

27%Rest of World18%

people in 100+ countries Diversified end markets – FY 2011 sales

of sales devoted to R&D

Utilities & Infrastructure 24%Industrial & machines 22%Data centres 16%

Non-residential buildings 29%


of sales devoted to R&DResidential 9%

Our Business driver: to help customers to deal with their major Concernsto deal with their major Concerns

●How to increase the safety of my personnel?●How to increase the safety of my personnel?●How to comply with sustainable development (environmental impact)?(environmental impact)?●How to maximize my output and its benefits (revenues and margin)?(revenues and margin)?●How to optimize my capital expenditure?●How to optimize my operational expenditures?●How to optimize my operational expenditures?“…Energy is critical to my production but

I need to reduce my CO footprint ”


I need to reduce my CO2 footprint …

Our Unique Value Propositions

● Global presence International● Global presence, Internationalnetworking capabilities, Local mind-set

A Comprehensive Production &●A Comprehensive Production & Energy Optimization Offer dedicated to Mining, Minerals and MetalsCustomersCustomers

● Best in Class products, Solutionsd Services bi d iand Services combined in an

Integrated Architecture

P j t & S i


●Worldwide Project & Servicecapabilities

Our Projects and Services Capabilities

● 4 Global Projects and Engineering ● 600+ contracts 1 to 50 M€● 4 Global Projects and Engineering CentersBeijing (China), Grenoble (France) Mumbai (India), Nashville (USA)

● 600+ contracts, 1 to 50 M€ (2011)

●Potential engineering study capacity 500 000+ ho rs/ ear

● 10+ System Integration Centers close to you

500.000+ hours/year

● 50+ years experience in &Australia, Brazil, Canada, China, France,

Gulf, India, Indonesia, Mexico, Spain, Turkey, USA, etc.

Projects & Engineering

● Local and Regional Project & Services Organization in 100+ countries


Index







Mining, Minerals and Metals in Schneider Electric14 Global Strategic Customers4 Major Segments

Mining

Steel

Cement

Aluminium

Multiple National Strategic CustomersA Gl b l T f 250 l

SteelAluminium

Multiple National Strategic CustomersA Global Team of 250+ peopleMarketing, Sales and Business Support Experts

4 Global Projects and Engineering CentersChina, France, India, USA

10+ Automation System Integration Centers Multiple Local Projects and Services OrganizationSchneider Electric is present in over 100 countries.


Only some are displayed

50+ years of experience in Projects and Engineering

Mining, Minerals and Metals Sales 2011: ~500M€

Laiwu SteelChina

ArcelorMittal (210KT)France

Electrical Distribution and ProcessChinaEnergy Management System

7M€

Electrical Distribution and Process Control System for Continuous

Annealing (w/ Ansaldo)7M€

VotorantimBrazil

Five (5) Cement PlantsMV-LV Electrical Distribution and

SNIM / SNC Lavalin (GuelbII)Mauritania

Movable Substations, Process Control System and WaterMV LV Electrical Distribution and

Process Control System24M€

Control System and Water Management System

20M€

Cliff Natural ResourcesCliff Natural Resources (Bloom Lake II)

CanadaElectrical Distribution and Process

Control System for Mine

Vale (Vargem Grande)Brazil

Movable Substations and Process Control System

19M€


Control System for Mine3.5M€ 19M€

Index







Steel Manufacturing

Finished Product

Production Resources

Assets

BilletsSlabsCoils

OthersAssetsPeople

Raw MaterialENERGYOth

Others…

Revenue

Others…

Cost

Our Goal: To Help our Customers

To Produce More with Less…

Our Goal: To Help our Customers…


Grow in a Sustainable Way…

Steel Manufacturing

Finished Product


Assets

BilletsSlabsCoils

OthersAssetsPeople

Raw MaterialENERGYOth

Others…

Revenue

Others…

CostAny Optimization of

the Overall Steel Production Process

ill O ti i

Our Mission: To Help Customers

By: Optimizing The Overall Steel

Production Process

will Optimize the Production

Resources


To Help Customers to Optimize Their


Steel Manufacturing Optimization

BusinessBusinessThe Profiting from the Steel Business

OperationThe Running of a Steel PlantThe Running of a Steel Plant

ProductionThe Making of Steel

(Facilities and Process)


Steel Manufacturing Optimization

Business MinimizeBusinessThe Profiting from the Steel Business

Minimize Production

Resource Cost n

OperationThe Running of a Steel Plant

X =Minimized Production Resource m

izat

ion

The Running of a Steel Plant

Optimize Production

Cost Per Ton O

ptim

ProductionThe Making of Steel(Facilities and Process)

Resource Consumption


LifecyclePrefeasibility Upgrade

Our Presence in Steel: 150+ M€ Sales (2011)

DOUBLE efficiency and save US$3 million annually!

The state-of-the art automation technology facilitates energyThe state of the art automation technology facilitates energy management across our enterprise and has provided us with a professional and efficient diagnostics helps us optimise our energy efficiency.”

Mr. Wenyi Wang, Project Manager, LY SteelMr. Wenyi Wang, Project Manager, LY Steel

Process Automation for Break-Through SteelmakingProcess Automation for Break Through Steelmaking

Schneider Electric responsible for Basic Engineering (Process Automation / Energy Distribution) of ULCOS pilot blast furnace with Top Gas Recycling.


with Top Gas Recycling.

Index







Blast Furnace Process Automation

OS12REPORT PRINTALARM PRINT

Vijeo Citect Clients (OS)OS1

Vijeo Citect Web Server

intranet

Office LANEthernet Vijeo Citect WEB client

Ethernet TCP/IP 100Mbit/sI/O SERVER1(redundant)

EngineeringStation

U it P

Vijeo Citect Web Server

Industrial Ethernet 100Mbit/s

Unity Pro


Raw Material BodyTOP Coaling & InjectionHot Stave Circulating Water

Blast Furnace


“Blast Furnace #7” Novolipetsk Iron and Steel Corporation (NLMK) Russiaand Steel Corporation (NLMK),

●Production Capacity: 3.4 million tonne/year p y y● free-standing furnace ● modern refractory and cooling solutions● advanced air supply system for cold air blasting. ● up-to-date charge make up solution, p g p ,● bell-less top charging, ● pulverized coal injection, ● reliable hydraulic equipment at the foundry, ● multiple process data recorders p p● a top notch automation system ● Sachem expert system

●General contractor Stroitelno-montazhniy Trest NLMK LLC (NLMK’sGeneral contractor Stroitelno montazhniy Trest NLMK LLC (NLMK s Construction and Assembly Unit)

●Metallurgical equipment manufacturer PAUL WURTH


●Hot testing August 2011

“Blast Furnace #7” Novolipetsk Iron and Steel Corporation (NLMK) Russiaand Steel Corporation (NLMK),

●Schneider Electric: main supplier of automation systems and low●Schneider Electric: main supplier of automation systems and low voltage equipment for the production complex

●Scope of Supply (extract)S p S pp y ( )>50 PLC Quantum Hot Standby >30 PLC Quantum, Premium, M340 > 70 000 SCADA tags Vijeo Citect >110 Licenses >180 Control cabinets >400 Control panels

250 IMCC>250 IMCC >75 VSD >15 LV Substation etc


etc.

Techint Ternium Siderar Revamping Blast Furnace 1Revamping Blast Furnace 1

Automation scope• Charging operation • Funace operationp• Stoves & Blast• Gas Cleaning• Fuel oil• Slag granulation (INBA)• Slag granulation (INBA)• …..



●Automation scope●Automation scope●Unity Pro platform with Modicon Quantum HSBY and Modicon Premium

configurations●Ethernet, RIO and MB+ networks●Ethernet, RIO and MB networks ● 90+ drops

●Benefits of this solution●Benefits of this solution●Process improvement with higher performance pf plc scan time ● Integration of Terniums programming standard●Easy troubleshooting for the maintenance people thanks to advanced●Easy troubleshooting for the maintenance people thanks to advanced

diagnostic tools● Increased reliability reducing the time required to operate the supervision of

the system


y

Gerdau SABlast Furnace + Sinter + CokeBlast Furnace + Sinter + Coke

●Customer profile

Brazil

●Customer profile●Gerdau Group is the largest producer

of long steel in the Americas, ●Mills in Brazil, Argentina, Canada,●Mills in Brazil, Argentina, Canada,

Chile, Colombia, the United States, Peru, Uruguay.

●Holds 40% stake in the Spanish company Sidenor. Currently,

●Gerdau has an installed capacity of 19.1 million metric tons of steel per yearsteel per year.



Project scope

Brazil

Project scope

●Expansion the Acominas steel plant to raise production capcity from 3 to 6 million metric tons in two phases

● First phase: ● To raise capacity from 3 to 4.5 mtpa (duplication of reduction area) ● Three packages: Blast Furnace, Coke Plant and Sinter Plant. ● Scope of supply includes mechanical, electrical, instrumentation and automation

items.

●Packages awarded to chinese OEM’s ● CISDI: Blast Furnace● ACRE: Coke Plant


● CIE: Sinter Plant


● The challenge

Brazil

● The challenge● Internat. coordination of Schneider Electric subsidiaries,

and three different OEMs for different systems● Provide local support for the OEMs and implement local

t ifi ti t d d d fcustomer specifications, standards and preferences● End User preference for Modicon Quantum PLC’s

thanks to previous experience with technical solution and support

● The solution● Local presence in Brazil: automation technical support, training● Supply chain coordination in China: Gerdau Acominas local team, Schneider Electrics

l l t i t t d l b ild t klocal system integrator and panel builders network ● Key values for End User and OEM’s:

●international cooperation, ●local support and warranty,


●local support and warranty,●spares availability.

Gerdau Acominas – Blast FurnaceCentral Control

Room

Stockhouse BF Proper BF Top Hot Stove Gas Cleaning Indirect Water To Level 3Servers

PCI

PCIPCIRoom

Schneider Electric - Industry Business - K. Lachmann - Date 26Stockhouse Room BF Proper Room Top Room HS Room Direct Water Room

Circulation Water RoomTRT RoomBF Proper Room


Customer benefits

Brazil

Customer benefits

●OEMs confidence to work with Schneider Electric solutions thanks to the partnership between the end user and Schneider Electric Brazil andthe partnership between the end user and Schneider Electric Brazil and Schneider Eletric China

O t h f A t ti LV d MV k●One stop shop for Automation, LV and MV packages

●The international coordination was key to satisfy the local customer requirements and preferences


EKO-Stahl GmbH EisenhüttenstadtGermanyGermany

●Blast furnace 5A and Sinterplant●Blast furnace 5A and Sinterplant

●Schneider Electric Process Automation20 it M di Q t l t● 20+ units Modicon Quantum plc system

●Vijeo Citect redundant Scada system●Decentralized I/O

C i ti●Communication●Modbus+ ●Ethernet TCP/ IP Communication

/O● ~20.000 I/O points

●Electrical Distribution



Blast furnace 5ABlast furnace 5A



PCI (Pulverized Coal Injection)PCI (Pulverized Coal Injection)


Bhushan Power & Steel Limited, Rengali – Blast Furnace + Sinter + CokeRengali Blast Furnace + Sinter + Coke

●Customer profile

India

●Customer profile●A fully integrated 1.5 Million TPA Steel making Company with turnover of

INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in gIndia



●Customer challenges:

India

●Customer challenges: ●Completion of System Engineering, Panel designing, Panel manufacturing

and Dispatch Based on Mecon Technical Specifications ●Providing necessary support for equipments coming from SSIT for Blast●Providing necessary support for equipments coming from SSIT for Blast

Furnace of capacity 1004m3, Sinter Plant of capacity 104m2, Raw Material Handling Plant, Coke Oven of 0.45MT Capacity

●Completion of job based on availability of site

●Project scope:●Design, Engineering, Manufacturing, Supply, Erection, Testing andDesign, Engineering, Manufacturing, Supply, Erection, Testing and

Commissioning ●Programmable Logic Controllers (PLC) & Supervisory Controls and Data

Acquisition (SCADA) system, for Raw Material Handling, Coal Preparation.


Coke Screening, BF Ventilation, ESP & SMS Ventilation Systems.


Schneider Electric Solution:

India

Schneider Electric Solution:

●Modicon Quantum Hot Standby PLC System with RIO nodes

●Vijeo Citect SCADA for overall process Control & Monitoring

●Historical data & various process related reports. Archiving of upto 6 Months period

●Fiber Optic networking & Data Communication in the entire Steel Plant.


Bhushan Power & Steel Limited, Rengali – Blast Furnace + Sinter + Coke

BF Main Control Room Blower Control Room PCI Room STOCK Control Room

Rengali Blast Furnace + Sinter + CokeIndia

COKE SCREEN & QUENCHING AREA

COAL PREPARATION

AREAESP C t l (PLC i id Si t Pl t) RMHPESP Control (PLC inside Sinter Plant)

SSIT Scope

BF COOLING WATER


Gas Cleaning Control Room

Sinter PLC System

SSIT ScopeLocal Source


Customer Benefits

India

Customer Benefits

●Modicon PLCs are the most reliable PLC equipment for industrial automationautomation.

●No failures in the continuous site operations.●Quantum PLC running under Dusty Environment

●Vijeo Citect SCADA helps in logging of various process related events & alarms. Historical trends for analyzing various process parameters

●The overall steel plant’s data available on the network.



●Customer profile

Argentina

●Customer profile●Manufacturer of flat and long steel products●Production centers in Argentina, Mexico,

Colombia, Guatemala and the United States ●One of the leading steel companies in Latin

America and largest argentinian steel company hot rolled, cold rolled, hot dip galvanized, electro-galvanized, prepainted and tinplate steel g , p p psheet products

Project objective●Project objective ●Expand production capacity to reach 4 mtpa● Improve iron quality for easier processing in downstream

facilities


facilities

Cosipa – Blast Furnace UpgradeB il

●Companhia Siderúrgica Paulista (Cosipa) is a member company of the

Brazil

●Companhia Siderúrgica Paulista (Cosipa) is a member company of the Usiminas System, Latin America’s biggest flat steel complex

●Producer of uncoated flat steels●Producer of uncoated flat steels for a wide variety of industries



Migration of Blast Furnace #1

Brazil

Migration of Blast Furnace #1

●Existing automation system●Entirely based on 584 Modicon controllers●Entirely based on 584 Modicon controllers●Close to critical status for maintenance and

spares parts / components availability

●Challenge●Modernizing the system during the blast furnace regular maintenance●A safe modernization procedure●A safe modernization procedure

– Critical equipment importance for the whole plant – No acceptance of delays



Schneider Electric Solution – a Smooth and Safe upgrade path

Brazil

Schneider Electric Solution – a Smooth and Safe upgrade path

●Hardware●New powerful Modicon Quantum automation platform●New powerful Modicon Quantum automation platform●Keep the existing I/O systems (200 Series - Controller 584), to reduce re-

wiring system, save time●Preserves past investment through Modicon Quantums system with●Preserves past investment through Modicon Quantums system with

possibility to mix additional racks with the modern I/O modules

●Software●Software●Re-use existing software - a simple operation to upload and download for

the new CPUs●Upload procedure from the old controller to the new platform allowed to pre-


Upload procedure from the old controller to the new platform allowed to pretest all the variables and software prior to comission


REDE COSIPAPCI

ETHERNETNOTE BOOK

MANUTENÇÃO

Brazil

PROCESSOSERVIDOR PROCESSO SUPERVISÃO

Ç

REDE MODBUS PLUS

MODICON

QUANTUMREDUNDANTE

PC MANUTENÇÃO

MODICONTSX QUANTUM

REGENERADORES CARREGAMENTOO

CARREGAMENTOS

MÓDULOS DE E/SCONTROLADOR 584


NORTE SUL

Variáveis Analógicas do Regenerador

(Phase 1)


Migration of Blast Furnace #1 – Step 2

Brazil

Migration of Blast Furnace #1 Step 2

●Upgrade of I/O system during regular maintenance period

●Schneider Electric Solution ●Re-use and migration of previous software ●Support of current CPUs (from the first upgrade) with simple upgrade easily●Support of current CPUs (from the first upgrade) with simple upgrade easily

migrated to new versions (if required) and support of any additional modules (networks)

●Benefits:●Migration in a record time according to the user requirements (during the

scheduled maintenance period)●A safe migration strategy with a stepwise approach●Open doors for immediate benefits: Ethernet communications new software


●Open doors for immediate benefits: Ethernet communications, new software functionalities

Shagang Group Blast Furnace 5800m3Blast Furnace 5800m China


Durgapur Steel Plant - Blast Furnace # 4, Stove Automation ProjectStove Automation Project

●The customer:

India

●The customer:●Situated at a distance of 158 km from Calcutta ●With the successful commissioning of the

modernized units, DSP is all set to producemodernized units, DSP is all set to produce ●2.088 million tones of hot metal, ●1.8 million tones of crude steel ●1 586 million tones of saleable steel annually●1.586 million tones of saleable steel annually

●1200MT/Day Blast Furnace



●Customer challenges:

India

●Customer challenges: ●Delivery and installation of the equipment within the shortest possible time

with Zero defect●Commissioning of the system within the Capital Repair period of the Blast●Commissioning of the system within the Capital Repair period of the Blast

Furnace ( 45 days)●Heating of the Stoves with efficient Techno economics, possible due to

monitoring and controlling features of PLC and SCADA●Good interfacing with operation personnel for incorporation of required

monitoring & control features as per the process requirement●Various, Critical PID Loop controls for the entire process, integrated &

t ll d b i lcontrolled by a single processor



●Project scope:

India

●Project scope:●Design, Engineering, Manufacturing, Supply, Erection, Testing and

Commissioning of Programmable Logic Controllers (PLC) & Supervisory Controls and Data Acquisition (SCADA) system, for achieving Blast Furnace q ( ) y g#4 Stove Automation

●Project requirements:j q● This is a 1200MT/Day Blast Furnace● The failure rate of the running TOSDIC DCS has increased and therefore

M/s. DSP was looking for an alternative automation system● A DCS equivalent solution



Schneider Electric Solution

India

Schneider Electric Solution

●Stove Automation achieved by the following equipments:●Quantum Hot Standby PLC System with RIO nodes●Quantum Hot Standby PLC System with RIO nodes●Standby Premium PLC system (13Nos.) for various PID Control Loops●Magelis TSD for Control & Monitoring of these Premium PLC●Citect SCADA for overall process Control & Monitoring●Citect SCADA for overall process Control & Monitoring● Flow, Temperature and Pressure parameters from field being monitored and

trended continuously. Historical data & various process related reports. Archiving of up to 6 Months period

●System Redundancy at every level



India

Ethernet Switch TCP/IP 10/100Mbps

Stand Alone Premium

Primary

Secondary

Stand Alone Premium CPU 1 to 8 on EthernetXBT-G 1 to 8

on Ethernet

y


Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project

India

Stove Automation Project



India



Customer Benefits

India

Customer Benefits

●Modicon Quantum / Premium PLCs are the most reliable PLC equipment for industrial automation. q p●No failures in the continuous site operations of over a year.●Quantum / Premium PLC running under high Ambient Temperature & Dusty

Environment.●Citect SCADA helps in logging of various process related events &

alarms. Historical trends for analyzing various process parameters.●Various critical control elements for the process, integrated to a single p , g g

Quantum System, thus reducing the Operational & Maintenance downtime.


JSW, Toranagallu BOF Converter Upgrade IndiaBOF Converter Upgrade

●The customer:

India

●The customer:● JSW Steel Ltd. is among the largest Indian Steel Companies ● today with capacity of 7.8 MT ● most modern eco friendly steel plants● most modern, eco-friendly steel plants

with the latest technologies for both upstream & downstream processes

●The Challenges:●Replace Honeywell TDS 3000 DCS System●Replace Honeywell TDS 3000 DCS System


JSW, Toranagallu BOF Converter Upgrade India

SERVER A SERVER B SERVER C SERVER D BMCS ENGG GCP ENGG CONV ENGG BOF Converter Upgrade India

ETH SW 1 ETH SW 2

ks

CONVERTER PLC GCP PLC BMCS/FACS PLC

Uni

ty F

ast L

inije

o C

itect

with

TOTAL 5 DROPS TOTAL 10 DROPS TOTAL 3 DROPS

tum

Uni

ty &

Vi

Schneider Electric - Industry Business - K. Lachmann - Date 53TYPE DI DO AI AO RTD TOTALTOTAL 2080 1152 280 104 64 3680

Qua

nt

Converter ProcessIndiaIndia


Gas Cleaning and Cooling PlantIndiaIndia


Bulk Material Charging SystemIndiaIndia


Blast Furnace Cooling & Slag Handling


Bhushan Power & SteelBlast Furnace Cooling & Slag HandlingBlast Furnace Cooling & Slag Handling

●The customer:

India

●The customer:●A fully integrated 1.5 Million TPA Steel making Company with turnover of



Bhushan Power & SteelBlast Furnace Cooling & Slag HandlingBlast Furnace Cooling & Slag Handling India


Automation reference list (extract)

●Blast furnaces●Blast furnaces

●Sinter plants


Process automation references

Extract steel reference list (revision 2009, China)

●Application area●Application area●Sinterplant●Blast Furnace

●Process automation ●Modicon plc

and/or


●Vijeo Citect Scada

Blast FurnaceOxygen Plant


DSP-SAIL - Oxygen Plant

●The customer:

India

●The customer:●Situated at a distance of 158 km from Calcutta ●With the successful commissioning of the modernized units, DSP is all set

to produce 2.088 million tones of hot metal, 1.8 million tones of crude steelto produce 2.088 million tones of hot metal, 1.8 million tones of crude steel and 1.586 million tones of saleable steel annually

●Challenge●Upgrading 80 MOD30 standalone controller to Quantum Unity HSBYUpgrading 80 MOD30 standalone controller to Quantum Unity HSBY

●Solution●Vijeo Citect SCADA Servers with Unity Fast Links● Configuring 60 PIDs & 15 Manual Loaders● Configuring 60 PIDs. & 15 Manual Loaders


DSP-SAIL - Oxygen PlantIndia

Automation ArchitectureArchitecture


TYPE DI DO AI AO TOTALTOTAL 192 288 368 136 984


ExampleOperatorOperatorScreen


Bayi Iron & Steel Co., Ltd Oxygen PlantOxygen Plant

●Customer Profile●Customer Profile●Subsidiary of Baosteel Group with steel capacity of 7 mtpa● Fully integrated from mining, ore dressing, sintering, coking, iron-making,

steel-making to steel rolling ●Manufacturer of long products, flat products and tubular products

●Project scope●Control of Air Separation Plant (40000Nm3/h)

●Automation scopeU it P l tf ith M di Q t d Q t HSBY●Unity Pro platform with Modicon Quantum and Quantum HSBY configurations

●Ethernet-network, redundant fiber rings●Vijeo Citect Scada, Client/Server, redundant servers


Vijeo Citect Scada, Client/Server, redundant servers●Engineering Tool Unity Application Generator


Crude Argon




Main Tower System




Liquid Oxygen Tank



Bayi Iron & Steel Co., Ltd Oxygen PlantOxygen PlantPrecooling of Air Oxygen Turbocompressor

Recycled water Molecular Sieves


Raw Material Handling Plant


Bhushan Power & Steel

●The customer:

India

●The customer:●A fully integrated 1.5 Million TPA Steel making Company with turnover of



Bhushan Power & SteelRaw Material Preparation PlantRaw Material Preparation Plant India


Index







TangsteelTangsteelChinaChina

TangSteel: Energy Management SystemExecuted by Project and Services Schneider Electric ChinaExecuted by Project and Services Schneider Electric China

●Customer profile●Customer profile● One of top 10 iron & steel sites in China ● Production capacity: 18M tons per year● 22 energy types

●Customer Challenge ● Regulation compliance ● Reporting mandate● Competitive cost pressures

●Schneider Electric Solution

Key production equipment:• coking (6)

( )●Schneider Electric Solution● Energy audit● Power monitoring● Energy Management System

• sintering (4)• blast furnace (4)• converter (7)• refining furnace (6)• casting (10)


Energy Management System● Platform for the future

casting (10)• heating furnace (10)• rolling (9)

TangSteel: Energy Management SystemLevel 3 functionsLevel 3 functions


TangSteel: Energy Management SystemOverview of project scopeOverview of project scope

● 22 types of W.A.G.E.Syp●Measurement management (power meter)

● Hierarchy (enterprise, plant and sector)● Duration (hours, day, week, month and year)● Categories

Measuring Management● Categories

●Data acquisition (PLC, networking equipment and SCADA)● Areas● Different energy system● Existing measurement database ERP

ManagementData

AcquisitionMonitoring & ● Existing measurement, database, ERP

●Monitoring and control (SCADA)● Information management (Ampla)

● Hierarchy (enterprise, plant and sector) ● Duration (shift day week month and year)

Control Information

Management● Duration (shift, day, week, month and year), ● Every energy usage efficiency

●Energy decision making (Ampla)● KPI & the performance target

M t t i t

Decision Making


● Management report point

TangSteel: Energy Management SystemProject ArchitectureProject Architecture

●20 operator clientsp●Servers including

Ampla, storage etc. ●80 k points data●80 k points data

integration●Backbone network

link to 10 areaslink to 10 areas●10 set redundant

I/O servers●70 sets M340●70 sets M340●1800 sets power

meters


TangSteel: Energy Management SystemIn real lifeIn real life


TangSteel: Energy Management SystemCustomer BenefitsCustomer Benefits

●One open and integrated Energy Management System (EMS)●One open and integrated Energy Management System (EMS) connected energy production to business system (SAP)

●Establish one consistent energy management process based on new●Establish one consistent energy management process based on new EMS system

●Satisfy key management needs with below system capability●Satisfy key management needs with below system capability●Analyze Energy Consumption by Process Segments or Work Center● Identify Key Energy Events with Production Context

Identify Key Energy Consumption Equipments● Identify Key Energy Consumption Equipments●Allocate Energy Cost to Process Segments with real energy data●Energy Cost Variance according to unit price change

E C t l i f h b t h d ti


●Energy Cost analysis for each batch production

Make the most of your energy

Schneider ElectricSchneider ElectricKlaus LACHMANNSteel Solutions Director

Phone: +49 (0) 2102 / 404 ext. 9368Mobile: +49 (0) 172 / 211 94 87


( )Email: [email protected]

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