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CSP Production Scheduling and Information System Using Web-browser Technology
Jose L. de la Riva, Senior Automation Engineer, HYLSA,S.A. de C.V. Fernando Martinez,Vice-President, AMI GE Automatización, S. de R.L.
The system implemented at HYLSA includes a Database Server and application Web Server(Internet Browser). Production schedules can be monitored and modified on a real timebasis. Production and information can be browsed via the internet.
INTRODUCTION.
HYLSA upgraded recently its CSP plant (orSecond Phase) by installing a second MeltDown Furnace, a second Ladle MetallurgyFurnace, a second Caster and a secondTunnel Furnace Heating and Shuttlesection. These improvements increasedthe capacity to 1.5 MTPY.From startup, or first phase, CSP Plant hashad comprehensive automation facilitiescovering Automation Levels.Level 1 – Basic AutomationLevel 2 – Process ControlLevel 3 – Production CoordinationLevel 4 – Production Planning
Figure 1 shows the Automation Equipmentarrangement in CSP Plant.
Level 1 and 2 were included as part of scope of supply of main processequipment under supplier specifications.Level 3 was specified by HYLSA andcontracted to a software developmentoriented supplier. Level 4 was handled ina particular way, since HYLSA already hadin operation a Production Control System,developed in house which schedules andtrack material for process lines from MeltShop and Hot Strip Mill # 1 (ingot based)trough Cold Mills and Batch Annealing.MIS group modified that system in orderto accommodate scheduling and trackingfor Hot Strip Mill # 2 (CSP) which suppliesmaterial in parallel with existing Hot StripMill # 1.Phase 2 operation has imposedrequirements that demanded flexible yetspeedy interaction with Level 3 by facingchanges to scheduling caused by tightcoordination in operation between CSPMelt Shop and Mill.
PRODUCTION PLANNING ANDSCHEDULING.
Production Planning and Scheduling isbased on Shop Orders, which are coilproduction batches (built from CustomerOrders) required from CSP Plantconsidering Melt Shop, Caster and Millconstraints.Shop Orders once in CSP Plant aremanaged by a Level 3 function, ProductionCoordination System.
 
Shop Orders requires from CSP Plant whatto produce but Operating personnel decidewhen to produce it considering operatingconstraints in a weekly basis.Once in production, Shop Orders results inreferences to Level 2 Process ControlSystems and actual production is sentback to Level 4 Production PlanningSystem for coil tracking in next processinglines.
Fig. 2 shows the Production Coordination modelused.
Figure 2. Production Coordination Model.
DATA COLLECTION
Modern steel processing plants are basedon high performance yet cost effectiveautomation equipment. This kind of devices allow CSP personnel to have datalogging and transmission to externalmassive storage systems at no additionalcost at all. CSP Plant benefits by collectinga big amount of data that let not just toproduce detailed production reports butalso to log pertinent data about productquality and process behavior that helpprocess and maintenance engineers toimprove plant operation.Currently a high-speed network is used tointerconnect automation equipment. AData Base Server stores more than 25Giga Bytes of information for 1 year,where more than 80% of this capacity isfor quality and process data. Figure 2shows Equipment involved in Level 3functions.State of the art hardware, software anddigital communications based on industryaccepted platforms and standards arebeing used.
Fig. 2 Level 3 Network Configuration
INFORMATION AND INTRANET
Collected data is used for severalpurposes:• Production Reports• Quality Reports• Product and Process HistoryProduction and Quality reports areaccessed trough Intranet while History isaccessed by process engineers usingstandard data base retrieve software.An Intranet Server is installed in order toallow access to CSP Plant data by usingstandard Web Browser, the same oneused to access Internet.This data access method results in a moreeasy way to deploy, maintain, set up anduse of CSP Plant information since
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