Keeping Your Process at the Centre of Everything We Do 1 op - PowerPoint PPT Presentation

Keeping Your Process at the Centre of Everything We Do 1

op optimAl pr process ss technology ltd ltd. Process Automation Specialists DRIVING PERFORMANCE Process Engineering Level 1 Process Services Control Systems Level 2 / 3 Solutions 2

Keeping Your Process at the Centre of Everything We Do Process Engineering Services 3

Process ss Eng Engineering Ser Services Specialists in Machine Dynamics & Control Comprehensive set of dynamic mill models - the basis for the delivery of a range of services Control system performance analysis Bespoke controller designs Control system optimisation Mill vibration analysis 4

Process ss Eng Engineering Ser Services NEGATIVE NEGATIVE BEND SERVO BEND SERVO BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK POSITIVE POSITIVE BEND SERVO BEND SERVO MILL MILL MILL MILL MILL MILL MILL MILL MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MAE WEST MILL MILL MILL MILL MILL MILL MILL MILL HOUSING HOUSING HOUSING HOUSING HOUSING HOUSING HOUSING HOUSING BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK HOUSING HOUSING HOUSING HOUSING HOUSING HOUSING HOUSING HOUSING WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK MEASURED PRESSURES MEASURED PRESSURES -VE BEND -VE BEND +VE BEND +VE BEND SERVO DRIVE SERVO DRIVE SERVO DRIVE SERVO DRIVE BEND CONTROLLER BEND CONTROLLER OPERATOR OPERATOR AFC AFC ADJUSTMENTS ADJUSTMENTS CORRECTIONS CORRECTIONS Speed increase 25% Entry Gauge ( Microns ) [Time,EntryGauge] Entry Gauge Entry Gauge Gauge improvement > 20% Exit Gauge Exit Gauge Measurement ExitGauge Exit Gauge Measurement TRANSPORT DELAY MEASUREMENT 0 Exit Gauge Reference Position Reference Exit Gauge Exit Gauge ( Microns ) Reference Exit Gauge Measurement CONTROLLER ROLLING MILL Process Control Audits Gauge Control Flatness Control Productivity We specialise in the optimisation of mill control performance From mill audits through controller design to full optimisation Model based controller design Model based optimisation Implementation on existing platforms Hot mills Tandem cold mills Single stand cold & foil mills 5

Process ss Eng Engineering Ser Services Instrumentation Design Services Range of strokes available Fully tested on our specialised rig and certified Mill Duty Position Transducers Standard optimAl product Sony Magnescales Robust & ultra low friction housing design Range of strokes available Fully assembled, tested & certificated Mounting tool provided for long stroke transducers 6

Process ss Eng Engineering Ser Services Process Training tim Al tim Al Al Al tim Al tim Al Al Al opti opti opti opti Operator & Technician Level Ce rtific ate o f training This is to certify that 板形 板形 __________________ FLATNESS FLATNESS has successfully completed the 1 day training course: Module 1: Strip Properties and the Mechanics of Rolling Introduction to Cold Rolling of Aluminium Introduction to Cold Rolling of Aluminium Module 2: Rolling Mill Equipment and Operation THICKNESS THICKNESS for Operators for Operators 厚度 厚度 Module 3: Measurement and Control of Strip Thickness Presented by: Presented by: optimAL process technology limited , January 2006 optimAL process technology limited , January 2006 Module 4: Measurement and Control of Strip Flatness Course content: Course content: ➢ Module I: Strip properties and the mechanics of rolling ➢ Module II: Rolling equipment and operation ➢ Module III: The measurement & control of the strip thickness ➢ Module IV: The measurement & control of the strip flatness ____________________ Mattias Andersson ____________________ John Mason ___ January, 2006 Fully documented Course assessments & certification Specialist Process Engineering Introduction to roll bite mechanics Rolling mill dynamics Automatic gauge control Single stand cold mills Foil mills Tandem mills Automatic flatness control Practical simulations using optimAl dynamic models Flatness simulation Gauge simulation 7

Le Level 1 1 Process ss Control Systems Keeping Your Process at the Centre of Everything We Do Level 1 Process Control Systems 8

Le Level 1 1 Process ss Control Systems Our focus is your process performance Controller design & optimisation using optimAl dynamic models Systems platform selection based on customer requirements ABB GE Siemens Single stand cold & foil mill AGC & AFC KEEPING YOUR PROCESS AT THE Full tandem cold mill solutions CENTRE OF EVERYTHING WE DO AGC AFC Interstand tension control Hot rolling mill HGC & AGC 9

Level 1 Le 1 Process ss Control Systems 2 Stand Tandem Mill Process Control Supplied Controls Mill Stand Controls (HGC) Automatic Gauge Control (AGC) Interstand Tension Control (ITC) Mill sequencing Extensive engineering tools Dynamic controller testing ABB Systems Platform Fast fault finding AC800 PEC Controller Simple tuning interfaces 800xA programming Outstanding Results Advanced Tuning Techniques Bengt Jansson: Granges Technical Entry Gauge Director: ( Microns ) [Time,EntryGauge] Entry Gauge Entry Gauge The performance of Exit Gauge Exit Gauge Measurement ExitGauge Exit Gauge Measurement TRANSPORT DELAY MEASUREMENT Stimulus --> Position Reference the cold tandem mill is 0 Exit Gauge Reference 5 Exit Gauge Position Reference Exit Gauge ( Microns ) Reference Exit Gauge Measurement CONTROLLER 0 world class ! dB -5 ROLLING MILL Commissioning and -10 -15 -1 0 1 10 10 10 achievement of 150 project target was 100 Degrees 50 • Full mill dynamic models reached within very 0 short time ! -50 -1 0 1 • Adapted to fit your mill 10 10 10 Frequency Hz 10

Le Level 1 1 Process ss Control systems 3 Stand Cold Tandem Mill Flatness Control Mill widening project – to accommodate 14 out can stock New flatness controller required GE Rx7i platform – customer requirement Proficy machine edition programming Cimplicity HMI Full AFC solution Air bearing shapemeter interface Roll bend and steer control Spray control Total Process Support Outstanding Results Our focus was final delivered product On line system tuned to deliver required off line flatness Full support from optimAl from cold mill through to slitter optiMize flatness process diagnostics Top flatness rating from can manufacturers Tuning Analysis Assessment 11

Le Level 1 1 Process ss Control Systems 3 Stand Cold Tandem Mill Process Control Major mill revamp – extension from 2 to 3 stands Can stock production GE Rx7i platform – customer requirement Total process control solution Mill stand controls Interstand tension control Multi stand AGC AFC Standard GE Programming Tools Level 2 also supplied by optimAl Proficy machine edition Cimplicity HMI Extensive Engineering Interfaces Level 2 from optimAl Easy to use interfaces for tuning and maintenance Process Diagnostics Mill Set Up Extensive controller testing facilities Designed for process & plant engineers 12

Level 1 Le 1 Process ss Control Systems 1 + 1 Hot Line – HGC / AGC Reversing breakdown hot mill Twin coiler finishing hot mill Supplied Controls: Gap referencing for screwdown and hydraulic cylinders Hydraulic Gap Control Automatic Gauge Control Gaugemeter ABB Systems Platform Smith predictor feedback AC800 PEC Controller Spray Control 800xA programming Outstanding Results Fully Integrated Approach High productivity Level 2 supplied by optimAl High Accuracy Fully integrated project with drives supplier Common hardware and software platform Close co-operation on complete line sequencing 13

Keeping Your Process at the Centre of Everything We Do Level 2 / 3 Solutions 14

Le Level 2 2 / 3 3 Sol Solutions MES MES Machine Setup Process Diagnostics Reporting Plant Production System Interfaces ERP Scheduling Coil Storage Suite of Level 2 & 3 systems from machine setup through to ERP interfacing 15

Level 2 Le 2 / 3 3 Sol Solutions Automatic Process Diagnostics for Metals Rolling & Processing Casting Furnaces Hot Mills Cold Mills Foil Mills Levelling Lines Coating Lines Slitting Lines Testing Automatic tracking of material & machine performance throughout the entire process Casting Finishing ✓ Reduced scrap Production $ ✓ Increased yield ¥ Plant Management & Supervision ✓ Increased productivity ROI € ✓ Fast detection of process problems ✓ Material and machine performance tracking Process Engineering & Quality Control Delivering real payback ✓ Better use of valued process engineering resources 16

Le Level 2 2 / 3 3 Sol Solutions Cold & Foil Hot Slitting Advanced Machine Set Up Systems (AMSU) Rolling Finishing Fixed and Adaptive Setup Systems Same core system configured for specific machines Hot rolling lines Single stand and tandem cold mills Slitting lines Highly configurable Setup management Interfacing to control systems Interfacing to plant scheduling systems Multiple language support 17