AP09: GrafTech International: Taps Cloud Generating Millions($$) in Annual Savings for Customers

Copyright © 2014 Rockwell Automation, Inc. All Rights

Reserved.

PUBLIC INFORMATION

Taps Cloud Generating Millions($$) in Customer Savings

Business confidential

GrafTech Customer Conversations

Introductions

2

Andy Messineo Architect Technical Development Manager

Dennis Kenemuth Arch Furnace Productivity System

Global Manager


Corporate Overview

GrafTech International Ltd. (NYSE: GTI)

• +125 Year Old Company

• Headquartered in Parma, Ohio

• Focus on Graphite & Carbon Material Sciences

• Global Operations with +3000 Employees

• Annual Revenues of +$1B (USD)

• Operate Two Business Segments

• Industrial Materials

• Engineered Solutions

Company Profile Quick Facts

3


Crude steel production, 1980-2012

MM tonnes

5


2012 VS 2013 Production

6


Operational Challenges for Steel Makers

7

Translate & simplify

complex data into

bottom line results

Surface hidden

problems

and opportunities

Eliminate waste and

streamline production

flow

Reduce &

control

cost

Increase

productivity

Maintain

uninterrupted

production flow

Achieving Your Business Objectives

Business confidential 8

With arrival of ArchiTechTM System 4.0, we‟re making it easier than ever to track

and manage your EAF operations data in one place

• Features of 4.0 • An improved design

• ArchiTechTM navigation will be more streamlined and user-friendly with improved graphics and intuitive controls.

• More powerful tools

• We’re introducing all new trending & reporting tools. Information when you need it, the way you want to see it for informed decision making.

• Customizable trends

• You can make changes and publish trends how you like or we’ll do it for you---it’s all up to you.

In-depth EAF analysis on-demand?

ArchiTechTM is a registered trademark of GrafTech USA LLC.


Real Examples of Results

9

Actual examples – project description & results Est. Annualized

Financial Impact ($)

Power program changes improving refining period performance resulting in 2

minute reduction in power-on time and an additional 1 MWH/heat due to

substantially improved foamy slag

3,000,000

DOE analysis of customer's fume collection system - set 4th hole draw to

55% - reduced power-on time and kWh/ton 210,000

Reduction in energy and electrode consumption 150,000

Increased power (tapped up), reduced electrode breakage 174,000

Reduced electrode breakage, improved productivity and reduce energy

consumption 610,000

ArchiTech data showed an increase in oxygen / burner usage which was

contributing to high electrode consumption. Several recommendations were

made to help reduce oxidation including a power program adjustment

727,500

Significant decrease in electrode consumption (-12%), electrical energy

consumption (-3.5%), and power-on time (-8.2%) 5,250,000


Examples of problems customers solved faster with ArchiTech™ System

• Regulation problems

• Bad water cooled cable

• “B” phase not regulating

• Five percent voltage drop

• Wrong power program loaded

• Loose rollers affecting regulation

• Single phasing and arc instability

• Electrical phase sequence reversed

• LMF Electrodes being dipped for an

entire heat

Sometimes the problem found by the ArchiTechTM system ends

up being the proverbial “needle in a hay stack”

ArchiTechTM System Server Based Alerts


What if you could solve EAF problems faster?

Small, self-contained, scalable, easy to

install and backed up by expert CTS

Size of bread basket and very durable


24/7/365 advanced high-speed EAF

diagnostic, analysis and reporting system

Monitors Energy, Power and Power Quality

Connects to metering VT’s and CT’s

Minimum of 32 samples per cycle

True RMS measurements

Harmonic distortion

Revenue accuracy




Developed to compliment and backup

existing supervisory systems

Easy to scale and customize

More than 10 years of software development in the product

Now on ArchiTechTM System 4.0

PLC data & Communications

Chemical, mechanical, auxiliary signals

Configurable web tools and CSV files

Master and subservient protocols

Serial and Ethernet integration

Email or direct connection


ArchiTechTM 4.0

Data Collection

14

Microsoft SQL Database • MS SMTP server for data collection

• Custom parser software to insert

data into database

ArchITechTM

ArchiTechTM Hardware • Collects data and sends to server

via Email message


ArchiTechTM 4.0

Legacy System

15

Microsoft Windows Server • Microsoft IIS

• Non-Encrypted data connection to client

• Microsoft SQL Database

• Microsoft SMTP server for data collection

• ASP.net web site with Customer Login

• On-Site at GrafTech Data Center

Client • Microsoft IE 8 or greater


ArchiTechTM 4.0

Server Design

16

Microsoft Active Directory • Used for portal login and

security on the portal items Microsoft Active Directory Backup • Used as a backup security server

• Contains custom tools for adding users and customers

Microsoft SQL Database • All furnace data

• All portal data

• SQL Reporting data

• MS SMTP server for data collection

Rockwell Vantage Point • Microsoft IIS

• Microsoft Reporting Services

• SQL Reporting data

• SSL encrypted data connection to client

Client • Microsoft IE 8 or greater

• Microsoft .NET 4.0 or greater


ArchiTechTM 4.0

Why as Hosted System in the „Cloud‟

17

• 100+ Worldwide Installations

• 24 hour availability

• Reliable high speed Internet connection

• 24 hour monitoring

• Managed backups

• Scalability


My ArchiTech™ System Dashboard - Example

In-depth EAF analysis on-demand?

Transforming EAF data into valuable, actionable insights


ArchiTechTM 4.0

Customer Portal: Today‟s Heats

19

Demo St Marys EF #1


ArchiTechTM 4.0

Customer Portal: Heat Trace

20

Demo St Marys EF #1


ArchiTechTM 4.0

Customer Portal: Heat Trace (cont.)

I

21


ArchiTechTM 4.0

Customer Portal: Current Trend

I

22


Real Time Data Analysis


ArchiTechTM 4.0

Multi-Site Comparison

24


ArchiTechTM 4.0

Alerts Statistics

25


Electrical Imbalances

• Circuit Impedance

• Static VAR

• Regulator Reference

• Valve or Drive

• Mechanical

• Power Program

Electrical imbalances from changes in…

How do you detect unintended changes in your EAF operation?

Quickly detecting and locating the source of electrical imbalances can be challenging


ArchiTechTM 4.0

• 2 Portal Systems Reviewed

• SAP

• Rockwell

• Requirements

• Database Source of Microsoft SQL

• Highly Customizable Portal Layout

• Login Security

• Static Live Charts

• Dynamic Live Charts

• Excel Reporting

System Evaluation and Selection

27

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Questions?

AP09: GrafTech International: Taps Cloud Generating Millions($$) in Annual Savings for Customers

Technology

business objectives

furnace data

architech data

portal data sql reporting

complex data

eaf operations data

arrival of architechtm

collection system