AP10 - GrafTech Cloud-Based Production Intelligence Generates Customers Savings

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

GrafTech Cloud-Based Production Intelligence Generates Customers Savings

GrafTech Customer Conversations

Andy Messineo

ArchiTech™ Technical Development

Manager

27+ year in IT and Programming

Third year of FactoryTalk®

VantagePoint EMI

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Introductions

© 2015 GrafTech International Holdings Inc. All Rights Reserved.

Corporate Overview

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GrafTech International Ltd. (NYSE: GTI)

+125 Year Old Company

Headquartered in Independence, Ohio

Focus on Graphite & Carbon Material Sciences

Global Operations with +2000 Employees

Annual Revenues of +$1B (USD)

Operate Two Business Segments

– Industrial Materials

– Engineered Solutions

Company Profile Quick Facts


Electric Arc Furnace and Graphite Electrodes

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Graphite Electrodes

Used in Scrap Recycling

No Melting Point

Electrical Conductor

Handles

10,000 F at

the Arc Tip

Electric Arc Furnace and Graphite Electrodes

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Electric Arc Furnace

Used in Scrap Recycling

Consumes Graphite Electrodes

60% of U.S. Steel

60% of U.S.

Steel is made

in Electric Arc

Furnaces

Crude Steel Production 1990 – 2018

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Operation Challenges for Steel Makers

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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


In-depth EAF analysis on-demand?

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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.


ArchiTech™ System Server Based Alerts

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Examples of problems customers solved faster with ArchiTech™ System

• Regulation problems

• Bad water cooled cable

• Loss of furnace ground

• 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”


ArchiTech™ Predictive Maintenance Tools

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T-Test

- Compare the averages of recent data to baseline data

- Equal variances, unequal sample sizes

Characteristic impedance increased on pit phase. Regulator responds by decreasing arc resistance (lower

voltage). Electrical prior phase voltage increases.

Electrical Balance: Secondary Circuit


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Electrical Balance: Regulator Reference

F-Test

- Determine if standard deviation of two populations are equal

- Compare variance of recent data to baseline data

- F is ratio of baseline variance to recent variance.


What if you could solve EAF problems faster?

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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


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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

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ArchiTech™ 4.0

Data Collection

Microsoft SQL Database • MS SMTP server for data collection

• Custom parser software to insert data into database

ArchiTechTM Hardware • Collects data and sends to server

via Email message

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Legacy System

ArchiTech™ 4.0

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

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Current Server Design

ArchiTech™ 4.0

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

FactoryTalk VantagePoint • 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

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Why is the System Hosted in the ‘Cloud’

• 100+ Worldwide Installations

• 24 hour availability

• Reliable high speed Internet

connection

• 24 hour monitoring

• Managed backups

• Scalability

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ArchiTech™ on FactoryTalk VantagePoint

Customer Dashboard


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Today’s Heats


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Heat Trace


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Heat Trace (cont.)


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1. Sudden drop in

hydraulic pressure

2. Power off

3. Rise in hydraulic pressure


Hydraulic Pressure Trend


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Alert Statistics


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Multi-Furnace Comparison


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Furnace Properties


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ArchiTech™ Toolbox


Visual Basic Application

– Adds New Furnaces to Database

– Creates Furnace in VantagePoint

– Adds all data Tags to VantagePoint

– Secures the Customer, Location, &

Furnace in Vantage Point

– Create VantagePoint Users

– Adds Menu Item for the Furnace in

VantagePoint

– Creates Private Folder for Report

Storage in VantagePoint

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ArchiTech™ on Factory Talk VantagePoint

System Evaluation and Selection


2 Portal Systems Reviewed

– SAP

– Rockwell Automation®

Requirements

– Database Source of Microsoft SQL

– Highly Customizable Portal Layout

– Login Security

– Static Live Charts

– Dynamic Live Charts

– Excel Reporting

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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We care what you think!

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Questions?

AP10 - GrafTech Cloud-Based Production Intelligence Generates Customers Savings

Technology

graphite electrodes

electric arc furnaces

arc tip

lmf electrodes

crude steel production

eaf operations data

arrival of architechtm

complex data