SCADA & Process Automation Coke Works

Supervision System for Coke Plants

AIST Cokemaking TC & ACCCI Mesh Jt Meeting September 2013Steve Hlavach General ManagerDave McWilliams Engineering ManagerJeff Mason VP Sales & Marketing

Integrated Mill Systems

In order to meet the supervisory system challenges outlined by the user, Integrated Mill Systems (IMS) presented a superior alternative from the initial specification which required supplying a specific vendor supervisory/HMI package. The customer’s input was vital in order to validate the IMS supervisory system solution with respect to the specification

requirements.

Current process requirements provide a level of flexibility and a path for future. At this stage it became apparent that the user requirements could not be met using the supervisory system/HMI

The specified system originally required two separate communication networks and associated screen development for local and global systems. This would require extensive mapping, hardware, and two different HMI hardware platforms.

Global communication was also sought to provide several benefits to the customer’s maintenance processes and functions.

Maintain process area operational capabilities, even when a communication loss occurs.

Disconnect caused by segmented coordination by production staff of their respective processes

Operation stations must continue process operations even in the event of subsystem failures

For each modification to a given machine screen, all other machines would have to be individually changed.

Automation characteristics of coke plants

Combination of process control (battery systems) with machine interlocking coordination (pusher machines, coal charging, transfer cars, quench cars),

Distributed automation and supervision architecture

High degree of redundancy, allowing critical operations to be performed even when other systems fail

Manage multiple technologies working together

The system design and staging was done at the IMS facility to reduce startup time and eliminate any potential errors, resulting in a faster customer’s ROI.

A powerful template for large production systems independent of the manufacturing process

A platform which is scalable to customer needs without costly redesign and extensive programming

A faster review cycle with the customer which results in accelerated installation time

Supervision System Characteristics

Graphical interface that allows production and operations oversee the coke system:

System overview and parametersReal-time information processingProcess trendsAutomatic and manual operation of coke machinesAlarms and fault detectionProgrammable controller, drives, and network hubs. Process and production tuningMaintenance and troubleshooting

System complexity

New SCADA solution

Scalable,' view-anywhere’ supervisory control and maintenance system:

Scalability to meet current system requirements with a designed-in capability for easy expansion to meet current and developing production needs

Redundant global servers communicating with global process and client servers throughout the production campus

Use of wireless and fiber optic communications to reduce cost and ensure network survivability

‘View-anywhere’ supervision stations capable of acting as a maintenance or operator terminal for any process area

Continuous power backup system capabilities to reduce impact of downtime or outages

High availability supervision system concept

Development and testing

Systematic development engineering

Template creation

Methodology

Constant dialog with user

Design documents submittals

Exhaustive testing before startup

Example: Operator Screens

Live data information

Permissive screens

Calibration screens

Setup

Fault

Trends

Example: Maintenance Screens

Overview

Setup

Drives Fault

Communication

Alarms

Leading edge supervision system

Advanced supervisory system which reduced development and startup time:

Multiple redundancy allowing a safer and continuous operation

A powerful template for large production systems independent of the manufacturing process

A platform which is scalable to customer needs without costly redesign and extensive programming

A faster review cycle with the customer which results in accelerated installation time

In summary, the scope of the project had to address the following:

Several operators and maintenance personnel scattered over hundreds of acres of a facility

Maintenance required to support a large process campus with limited resources, minimizing downtime

Data sharing between all process areas to ensure continuous operation.

• Coke Oven Machine Lubeck 153

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