Concept and Operating Results of a Higher-Level Automation System for the new C-Battery at the U. S. Steel Clairton Plant

AISTech Indianapolis

Stephen Hlavach (IMS), James Zelazny (IMS),

Klaus-Peter Leuchtmann (TKIS), Marcel Schulz (TKIS)

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

2

Coke Plant Automation Overview

3

2

1

0

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

3

PROCESS CONTROL - Level 1 System - Architecture

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

4

PROCESS CONTROL - Level 1 System - Safety PLC‘s

Flex I/O

Hydraulic/Pneumatic

Solenoids

24VDC

Safety I/O

<202>

E-STOPSafety I/O

<211>

Ram VFD(s)

Leveler VFD

Safety I/O

<210>

Travel VFD

1-4

Bypass Interlock PB

Mode Selector Sw.

O/T Magnets

Board "Safe" PB

Board "Resume" PB

De-Board "Safe" PB

De-Board "Resume" PB

E-Stop PBs

Pull Cords

E-Stop PB Ligts

Board "Safe" Lights

De-Board "Safe" Lights

PM1

PLC

Ethernet SAFE BOARDING

ENABLE

SAFE PASSAGE

ENABLE

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

5

PROCESS CONTROL - Level 1 System - HMI

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

6

PROCESS CONTROL - Level 1 System - Coordination

Quench

Car

Start Conveyors

Start Plow

Take SamplesOff Loadout

Fill Rail Cars

C B

atte

ryPro

ven

Sys

tem C

oal

Charg

ing

Car

Push

erM

ach

ine

SS4

&C

oke

Han

dling

Charge Oven

Replace Lids

Travel to CoalTower

Load Coal

Travel to Oven

Clean Oven Top

Pressure Reg

Disconnect

Full Suction

Coke

Tra

nsf

erC

ar

Level Coal

Travel to Oven

Remove Door

Clean Door

Push Coke

Clean Oven Jam

Replace OvenDoor

Open ChuckDoor

Replace Door

Remove Door

Attach Guide

Guide Coke

Retract Guide

Clean Jam

Clean Door

Travel to Oven

Travel to HoldingPosition

Travel Wharf

Dump Coke

Travel to Oven

Catch Coke

Travel to QuenchTower

Quench

"C"

Quen

chTow

er

Quench

Refill QuenchTanks

Refill SprayTanks

Flush Baffles andTrough

Backwash GravelFilters

Close ChuckDoor

Prepare toCharge

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

7

PROCESS CONTROL - Level 1 System – Project Execution

Execution Plan

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

8

PROCESS CONTROL - Level 1 System – Project Execution

First Engineering Submittal

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

9

PROCESS CONTROL - Level 1 System – Project Execution

Second Engineering Submittal

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

10

PROCESS CONTROL - Level 1 System – Project Execution

Factory Acceptance Test

HMI -

Tou

chH

MI -

Tou

chH

MI -

Tou

chHM

I - T

ouch

Co

mm

an

d

Ce

nte

r

Em

g. R

am

Tra

ve

l #2

Co

ntro

l

Sta

tion

s

Ra

m

Leve

l Ba

r

H-R

OO

M I/O

CC

O

CT

C

PM

QC

PLC-I/O

Trvl. 1-2LightsLPPAUX

CC

C

HMI -

Tou

chH

MI -

Tou

chH

MI -

Tou

chHM

I - T

ouch

Co

mm

an

d

Ce

nte

r

Em

g. R

am

Tra

ve

l #2

Co

ntro

l

Sta

tion

s

Ra

m

Leve

l Ba

r

H-R

OO

M I/O

CC

O

CT

C

PM

QC

PLC-I/O

Trvl. 1-2LightsLPPAUX

CC

C

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

11

SUPERVISORY SYSTEM – Level 2 COKEMASTER® Overview

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

12

AutoTherm™-G (on Coke Guide) – Overview

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

13

Pyrometer Box

Optical lens

located at the coke guide

AutoTherm™-G (on Coke Guide) – Installation on Site

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

14

Raw data from AutoTherm™ PLC

PSCS

Oven 72 upper pyrometer

Challange of raw data evaluation:

• Coke temperature is inhomogeneous

• Hot and cold temperatures are mixed

• Temperatures are fluctuating widely

Result of Data Evaluation:

• Data are filtered and averaged

• Profiles are acceptable close to raw data

• Temperature curves are similar to each other ���� AutoTherm™ is beneficial and usefull !

AutoTherm™-G (on Coke Guide) – Evaluation

Oven 72 upper pyrometer

CS PS

Mirrored trend curve to correspond to raw data shown on the left side

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

15

PushSched™ – Pushing and Charging Management

Next Cycle

Next Oven

to Operate

(max. 1 Oven)

CO-PLC

(CCO)

Oven Status

Actual

Oven

Calculated

Schedule

for 5 - Days

Fully Automatic-

Operation

PushSched Operator Station

Display

Oven Status

Scheduling is triggered with each machine signal

Display

Oven No.

Machine PLC

Control and

Scheduling of

Pushing and

Charging

Operation

Scheduling

on Demand

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

16

PushSched™ – Pushing and Charging Management

PushSchedSupervision & Planning

Level 1Battery Instruments

PROvenSupervision

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

17

BatControl™ – Automatic and Continous Heating Calculation

QSurfaceQRawgas

QWastegas

QCoke

QUnderfiring = QRawGas + QCoke + QWastegas + QSurface

QUnderfiring

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

18

BatControl™ – Heating Management

18:00

eCT

GP

CT=18:30h

--29:00 h

--17:00 h

27.00 h

BatControl™ 7 day trend plot

Co

ke

ca

ke

te

mp

era

ture

He

atin

gflu

ete

mp

era

ture

1060

Coke

Temperature

Decrease

Time

Delay

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

19

Ram drive motor &

VVVF-converter

RamForce™ – Monitoring of Pushing Performance

Coking Time

Ovens with extended coking time (“hot”

ovens) are causing higher pushing forces

Measurement of Pushing Force:

• Amperage from the ram drive motor was

controlled by VVVF-converter

• Pushing Force was correlated with the

ram travel distance

• Min, Max and Average Pushing Force are

calculated

Operation Example:

• Change of Pushing sequence created

higher coking times than normal

• Significant differences in the pushing

force between normal ovens and „hot“

ovens could be seen

Ovens with regular coking time (~19h). Maximum current 123 – 133 Amps

Ovens with extended coking time (33h-41h) . Maximum current 151 – 166 Amps

Negative pushing force caused

by proper motion of the pusher

ram while lowering the scorpion

tail

Pushing Force

Concept and Operating Results of a Higher-Level Automation System

for the new C-Battery at the U. S. Steel Clairton Plant

May 2014

20

Summery and Conclusions:

C-Battery instrumentation and machines are controlled by a state-

of-the-art process control system

C-Battery is equipped with special measuring systems to keep

track of battery temperatures and pushing forces

On top of all, a sophisticated process model controls the oven

machines and the battery heating

C-Battery operators have quickly accepted the automation and see

the benefits

C-Battery is up to this date the most modern coke plant in the USA