Steel Manufacturing Industry & Schneider Electric

Transcription

1 Steel Manufacturing Industry & Schneider Electric Company introduction Selected references - Iron Making - Energy Management April 2012

2 Index Schneider Electric at a glance Schneider Electric in Mining, Minerals and Metals Schneider Electric in Steel Manufacturing Selected Schneider Electric References Iron Making Selected Schneider Electric References Energy Management Schneider Electric - Industry Business - K. Lachmann - Date 2

3 Schneider Electric the global specialist in energy management Balanced geographies FY 2011sales billion sales (last twelve months) of sales in new economies (last twelve months) North America 23% Rest of World 18% Western Europe 32% Asia Pacific 27% people in 100+ countries of sales devoted to R&D Diversified end markets FY 2011 sales Utilities & Infrastructure 24% Industrial & machines 22% Data centres 16% Non-residential buildings 29% Residential 9% Schneider Electric - Industry Business - K. Lachmann - Date 3

4 Our Business driver: to help customers to deal with their major Concerns How to increase the safety of my personnel? How to comply with sustainable development (environmental impact)? How to maximize my output and its benefits (revenues and margin)? How to optimize my capital expenditure? How to optimize my operational expenditures? Energy is critical to my production but I need to reduce my CO 2 footprint Schneider Electric - Industry Business - K. Lachmann - Date 4

5 Our Unique Value Propositions Global presence, International networking capabilities, Local mind-set A A Comprehensive Production & Energy Optimization Offer dedicated to Mining, Minerals and Metals Customers Best in Class products, Solutions and Services combined in an Integrated Architecture Worldwide Project & Service capabilities Schneider Electric - Industry Business - K. Lachmann - Date 5

6 Our Projects and Services Capabilities 4 Global Projects and Engineering 600+ contracts, 1 to 50 M (2011) Centers Beijing (China), Grenoble (France) Mumbai (India), Nashville (USA) Potential engineering study capacity hours/year 10+ System Integration Centers close to you Australia, Brazil, Canada, China, France, Gulf, India, Indonesia, Mexico, Spain, Turkey, USA, etc. 50+ years experience in Projects & Engineering Local and Regional Project & Services Organization in 100+ countries Schneider Electric - Industry Business - K. Lachmann - Date 6

8 Mining, Minerals and Metals in Schneider Electric 4 Major Segments 14 Global Strategic Customers Cement Mining Aluminium Steel AGl Global lteam of f250+ people Marketing, Sales and Business Support Experts Multiple National Strategic Customers 4 Global Projects and Engineering Centers China, France, India, USA 10+ Automation System Integration Centers Multiple Local Projects and Services Organization Schneider Electric is present in over 100 countries. 50+ years of experience in Projects and Engineering Only some are displayed Schneider Electric - Industry Business - K. Lachmann - Date 8

9 Mining, Minerals and Metals Sales 2011: ~500M Laiwu Steel China Energy Management System 7M ArcelorMittal (210KT) France Electrical Distribution and Process Control System for Continuous Annealing (w/ Ansaldo) 7M Votorantim Brazil Five (5) Cement Plants MV-LV Electrical Distribution and Process Control System 24M SNIM / SNC Lavalin (GuelbII) Mauritania Movable Substations, Process Control System and Water Management System 20M Cliff Natural Resources (Bloom Lake II) Canada Electrical Distribution and Process Control System for Mine 3.5M Vale (Vargem Grande) Brazil Movable Substations and Process Control System 19M Schneider Electric - Industry Business - K. Lachmann - Date 9

11 Steel Manufacturing Finished Product Production Resources Assets People Raw Material ENERGY Others Billets Slabs Coils Others Revenue Cost Our Goal: To Help our Customers To Produce More with Less Grow in a Sustainable Way Schneider Electric - Industry Business - K. Lachmann - Date 11

12 Steel Manufacturing Production Resources Assets People Raw Material ENERGY Others Cost Our Mission: To Help Customers to Optimize Their Production Resources By: Optimizing The Overall Steel Production Process Finished Product Billets Slabs Coils Others Revenue Any Optimization of the Overall Steel Production Process will Optimize i the Production Resources Schneider Electric - Industry Business - K. Lachmann - Date 12

13 Steel Manufacturing Optimization Business The Profiting from the Steel Business Operation The Running of a Steel Plant Production The Making of Steel (Facilities and Process) Schneider Electric - Industry Business - K. Lachmann - Date 13

14 Steel Manufacturing Optimization Business Minimize Production Resource Cost The Profiting from the Steel Business Operation The Running of a Steel Plant Production The Making of Steel (Facilities and Process) X = Optimize Production Resource Consumption Minimized Production Resource Cost Per Ton Optim mization Prefeasibility Lifecycle Upgrade Schneider Electric - Industry Business - K. Lachmann - Date 14

15 Our Presence in Steel: 150+ M Sales (2011) DOUBLE efficiency and save US$3 million annually! The state-of-the the art automation technology facilitates energy management across our enterprise and has provided us with a professional and efficient diagnostics helps us optimise our energy efficiency. Mr. Wenyi Wang, Project Manager, LY Steel Process Automation for Break-Through Steelmaking Schneider Electric responsible for Basic Engineering (Process Automation / Energy Distribution) of ULCOS pilot blast furnace with Top Gas Recycling. Schneider Electric - Industry Business - K. Lachmann - Date 15

17 Blast Furnace Process Automation OS1 Vijeo Citect Clients (OS) OS12 ALARM PRINT REPORT PRINT Ethernet intranet Office LAN Vijeo Citect WEB client Vijeo Citect Web Server I/O SERVER1 (redundant) Ethernet TCP/IP 100Mbit/s Engineering Station Unity Pro Industrial Ethernet 100Mbit/s Raw Material TOP Body Hot Stave Coaling & Injection Circulating Water Schneider Electric - Industry Business - K. Lachmann - Date 17

18 Blast Furnace Schneider Electric - Industry Business - K. Lachmann - Date 18

19 Blast Furnace #7 Novolipetsk Iron and Steel Corporation (NLMK), Russia Production Capacity: 3.4 million tonne/year free-standing furnace modern refractory and cooling solutions advanced air supply system for cold air blasting. up-to-date charge make up solution, bell-less top charging, pulverized coal injection, reliable hydraulic equipment at the foundry, multiple process data recorders a top notch automation system Sachem expert system General contractor Stroitelno-montazhniy Trest NLMK LLC (NLMK s Construction and Assembly Unit) Metallurgical equipment manufacturer PAUL WURTH Hot testing August 2011 Schneider Electric - Industry Business - K. Lachmann - Date 19

20 Blast Furnace #7 Novolipetsk Iron and Steel Corporation (NLMK), Russia Schneider Electric: main supplier of automation systems and low voltage equipment for the production complex Scope S p of Supply ppy (extract) >50 PLC Quantum Hot Standby >30 PLC Quantum, Premium, M340 > SCADA tags Vijeo Citect >110 Licenses >180 Control cabinets >400 Control panels >250 IMCC >75 VSD >15 LV Substation etc. Schneider Electric - Industry Business - K. Lachmann - Date 20

21 Techint Ternium Siderar Revamping Blast Furnace 1 Automation scope Charging operation Funace operation Stoves & Blast Gas Cleaning Fuel oil Slag granulation (INBA).. Schneider Electric - Industry Business - K. Lachmann - Date 21

22 Techint Ternium Siderar Revamping Blast Furnace 1 Automation scope Unity Pro platform with Modicon Quantum HSBY and Modicon Premium configurations Ethernet, RIO and MB+ networks 90+ drops Benefits of this solution Process improvement with higher performance pf plc scan time Integration of Terniums programming standard Easy troubleshooting for the maintenance people thanks to advanced diagnostic tools Increased reliability reducing the time required to operate the supervision of the system Schneider Electric - Industry Business - K. Lachmann - Date 22

23 Gerdau SA Blast Furnace + Sinter + Coke Brazil Customer profile Gerdau Group is the largest producer of long steel in the Americas, Mills in Brazil, Argentina, Canada, Chile, Colombia, the United States, Peru, Uruguay. Holds 40% stake in the Spanish company Sidenor. Currently, Gerdau has an installed capacity of 19.1 million metric tons of steel per year. Schneider Electric - Industry Business - K. Lachmann - Date 23

24 Gerdau SA Blast Furnace + Sinter + Coke Brazil Project scope Expansion the Acominas steel plant to raise production capcity from 3 to 6 million metric tons in two phases First phase: To raise capacity from 3 to 4.5 mtpa (duplication of reduction area) Three packages: Blast Furnace, Coke Plant and Sinter Plant. Scope of supply includes mechanical, electrical, instrumentation and automation items. Packages awarded to chinese OEM s CISDI: Blast Furnace ACRE: Coke Plant CIE: Sinter Plant Schneider Electric - Industry Business - K. Lachmann - Date 24

25 Gerdau SA Blast Furnace + Sinter + Coke Brazil The challenge Internat. coordination of Schneider Electric subsidiaries, and three different OEMs for different systems Provide local support for the OEMs and implement local customer specifications, standards d and preferences End User preference for Modicon Quantum PLC s thanks to previous experience with technical solution and support The solution Local presence in Brazil: automation technical support, training Supply chain coordination in China: Gerdau Acominas local team, Schneider Electrics local l system integrator t and panel builders network Key values for End User and OEM s: international cooperation, local support and warranty, spares availability. Schneider Electric - Industry Business - K. Lachmann - Date 25

26 Gerdau Acominas Blast Furnace Stockhouse BF Proper BF Top Hot Stove Gas Cleaning Indirect Water To Level 3 Servers Central Control Room PCI PCI Room Circulation Water BF Proper Schneider Room Electric Stockhouse - Industry Business Room - K. Lachmann BF Proper - Date Room Top Room HS Room TRT Room Room Direct Water Room 26

27 Gerdau SA Blast Furnace + Sinter + Coke Brazil Customer benefits OEMs confidence to work with Schneider Electric solutions thanks to the partnership between the end user and Schneider Electric Brazil and Schneider Eletric China One O stop shop for Automation, ti LV and MV packages The international coordination was key to satisfy the local customer requirements and preferences Schneider Electric - Industry Business - K. Lachmann - Date 27

28 EKO-Stahl GmbH Eisenhüttenstadt Germany Blast furnace 5A and Sinterplant Schneider Electric Process Automation 20+ units Modicon Quantum plc system Vijeo Citect redundant Scada system Decentralized I/O Communication Modbus+ Ethernet TCP/ IP Communication ~ I/O points Electrical Distribution Schneider Electric - Industry Business - K. Lachmann - Date 28

29 EKO-Stahl GmbH Eisenhüttenstadt Germany Blast furnace 5A Schneider Electric - Industry Business - K. Lachmann - Date 29

30 EKO-Stahl GmbH Eisenhüttenstadt Germany PCI (Pulverized Coal Injection) Schneider Electric - Industry Business - K. Lachmann - Date 30

31 Bhushan Power & Steel Limited, Rengali Blast Furnace + Sinter + Coke India Customer profile A fully integrated 1.5 Million TPA Steel making Company with turnover of INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in India Schneider Electric - Industry Business - K. Lachmann - Date 31

32 Bhushan Power & Steel Limited, Rengali Blast Furnace + Sinter + Coke India Customer challenges: Completion of System Engineering, Panel designing, Panel manufacturing and Dispatch Based on Mecon Technical Specifications Providing necessary support for equipments coming from SSIT for Blast Furnace of capacity 1004m3, Sinter Plant of capacity 104m2, Raw Material Handling Plant, Coke Oven of 0.45MT Capacity Completion of job based on availability of site Project scope: Design, Engineering, Manufacturing, Supply, Erection, Testing and Commissioning Programmable Logic Controllers (PLC) & Supervisory Controls and Data Acquisition (SCADA) system, for Raw Material Handling, Coal Preparation. Coke Screening, BF Ventilation, ESP & SMS Ventilation Systems. Schneider Electric - Industry Business - K. Lachmann - Date 32

33 Bhushan Power & Steel Limited, Rengali Blast Furnace + Sinter + Coke India Schneider Electric Solution: Modicon Quantum Hot Standby PLC System with RIO nodes Vijeo Citect SCADA for overall process Control & Monitoring Historical data & various process related reports. Archiving of upto 6 Months period Fiber Optic networking & Data Communication in the entire Steel Plant. Schneider Electric - Industry Business - K. Lachmann - Date 33

34 Bhushan Power & Steel Limited, Rengali Blast Furnace + Sinter + Coke India BF Main Control Room Blower Control Room PCI Room STOCK Control Room ESP Control (PLC inside id Sinter Plant) RMHP COKE SCREEN & QUENCHING AREA COAL PREPARATION AREA BF COOLING WATER Sinter PLC System SSIT Scope Local Source Gas Cleaning Control Room Schneider Electric - Industry Business - K. Lachmann - Date 34

35 Bhushan Power & Steel Limited, Rengali Blast Furnace + Sinter + Coke India Customer Benefits Modicon PLCs are the most reliable PLC equipment for industrial automation. No failures in the continuous site operations. Quantum PLC running under Dusty Environment Vijeo Citect SCADA helps in logging of various process related events & alarms. Historical trends for analyzing various process parameters The overall steel plant s data available on the network. Schneider Electric - Industry Business - K. Lachmann - Date 35

36 Techint Ternium Siderar Revamping Blast Furnace 1 Argentina Customer profile Manufacturer of flat and long steel products Production centers in Argentina, Mexico, Colombia, Guatemala and the United States One of the leading steel companies in Latin America and largest argentinian steel company hot rolled, cold rolled, hot dip galvanized, electro-galvanized, prepainted p and tinplate steel sheet products Project objective Expand production capacity to reach 4 mtpa Improve iron quality for easier processing in downstream facilities Schneider Electric - Industry Business - K. Lachmann - Date 36

37 Cosipa Blast Furnace Upgrade Brazil Companhia Siderúrgica Paulista (Cosipa) is a member company of the Usiminas System, Latin America s biggest flat steel complex Producer of uncoated flat steels for a wide variety of industries Schneider Electric - Industry Business - K. Lachmann - Date 37

38 Cosipa Blast Furnace Upgrade Brazil Migration of Blast Furnace #1 Existing automation system Entirely based on 584 Modicon controllers Close to critical status for maintenance and spares parts / components availability Challenge Modernizing the system during the blast furnace regular maintenance A safe modernization procedure Critical equipment importance for the whole plant No acceptance of delays Schneider Electric - Industry Business - K. Lachmann - Date 38

39 Cosipa Blast Furnace Upgrade Brazil Schneider Electric Solution a Smooth and Safe upgrade path Hardware New powerful Modicon Quantum automation platform Keep the existing I/O systems (200 Series - Controller 584), to reduce rewiring system, save time Preserves past investment through Modicon Quantums system with possibility to mix additional racks with the modern I/O modules Software Re-use existing software - a simple operation to upload and download for the new CPUs Upload procedure from the old controller to the new platform allowed to pre- test all the variables and software prior to comission Schneider Electric - Industry Business - K. Lachmann - Date 39

40 Cosipa Blast Furnace Upgrade Brazil ETHERNET REDE COSIPA PCI NOTE BOOK MANUTENÇÃO SERVIDOR PROCESSO PROCESSO SUPERVISÃO REDE MODBUS PLUS MODICON TSX QUANTUM QUANTUM REDUNDANTE PC MANUTENÇÃO MÓDULOS DE E/S CONTROLADOR 584 REGENERADORES CARREGAMENTO NORTE CARREGAMENTO SUL (Phase 1) Variáveis Analógicas do Regenerador Schneider Electric - Industry Business - K. Lachmann - Date 40

41 Cosipa Blast Furnace Upgrade Brazil Migration of Blast Furnace #1 Step 2 Upgrade of I/O system during regular maintenance period Schneider Electric Solution Re-use and migration of previous software Support of current CPUs (from the first upgrade) with simple upgrade easily migrated to new versions (if required) and support of any additional modules (networks) Benefits: Migration in a record time according to the user requirements (during the scheduled maintenance period) A safe migration strategy with a stepwise approach Open doors for immediate benefits: Ethernet communications, new software functionalities Schneider Electric - Industry Business - K. Lachmann - Date 41

42 Shagang Group Blast Furnace 5800m 3 China Schneider Electric - Industry Business - K. Lachmann - Date 42

43 Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project India The customer: Situated at a distance of 158 km from Calcutta With the successful commissioning of the modernized units, DSP is all set to produce million tones of hot metal, 1.8 million tones of crude steel million tones of saleable steel annually 1200MT/Day Blast Furnace Schneider Electric - Industry Business - K. Lachmann - Date 43

44 Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project India Customer challenges: Delivery and installation of the equipment within the shortest possible time with Zero defect Commissioning of the system within the Capital Repair period of the Blast Furnace ( 45 days) Heating of the Stoves with efficient Techno economics, possible due to monitoring and controlling features of PLC and SCADA Good interfacing with operation personnel for incorporation of required monitoring & control features as per the process requirement Various, Critical PID Loop controls for the entire process, integrated & controlled by a single processor Schneider Electric - Industry Business - K. Lachmann - Date 44

45 Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project Project scope: Design, Engineering, Manufacturing, Supply, Erection, Testing and Commissioning of Programmable Logic Controllers (PLC) & Supervisory Controls and Data Acquisition (SCADA) system, for achieving Blast Furnace #4 Stove Automation Project j requirements: This is a 1200MT/Day Blast Furnace The failure rate of the running TOSDIC DCS has increased and therefore M/s. DSP was looking for an alternative automation system A DCS equivalent solution India Schneider Electric - Industry Business - K. Lachmann - Date 45

46 Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project India Schneider Electric Solution Stove Automation achieved by the following equipments: Quantum Hot Standby PLC System with RIO nodes Standby Premium PLC system (13Nos.) for various PID Control Loops Magelis TSD for Control & Monitoring of these Premium PLC Citect SCADA for overall process Control & Monitoring Flow, Temperature and Pressure parameters from field being monitored and trended continuously. Historical data & various process related reports. Archiving of up to 6 Months period System Redundancy at every level Schneider Electric - Industry Business - K. Lachmann - Date 46

47 Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project India Ethernet Switch TCP/IP 10/100Mbps Primar y Secondary XBT-G 1 to 8 on Ethernet Stand Alone Premium CPU 1 to 8 on Ethernet Schneider Electric - Industry Business - K. Lachmann - Date 47

48 Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project India Schneider Electric - Industry Business - K. Lachmann - Date 48

51 Durgapur Steel Plant - Blast Furnace # 4, Stove Automation Project India Customer Benefits Modicon Quantum / Premium PLCs are the most reliable PLC equipment for industrial automation. No failures in the continuous site operations of over a year. Quantum / Premium PLC running under high Ambient Temperature & Dusty Environment. Citect SCADA helps in logging of various process related events & alarms. Historical trends for analyzing various process parameters. Various critical control elements for the process, integrated to a single Quantum System, thus reducing the Operational & Maintenance downtime. Schneider Electric - Industry Business - K. Lachmann - Date 51

52 JSW, Toranagallu BOF Converter Upgrade India The customer: JSW Steel Ltd. is among the largest Indian Steel Companies today with capacity of 7.8 MT most modern, eco-friendly steel plants with the latest technologies for both upstream & downstream processes The Challenges: Replace Honeywell TDS 3000 DCS System Schneider Electric - Industry Business - K. Lachmann - Date 52

53 JSW, Toranagallu BOF Converter Upgrade SERVER A SERVER B SERVER C SERVER D BMCS ENGG GCP ENGG CONV ENGG India ETH SW 1 ETH SW 2 ijeo Citect with Unity Fast Lin Quant tum Unity & Vi ks CONVERTER PLC GCP PLC BMCS/FACS PLC TOTAL 5 DROPS TOTAL 10 DROPS TOTAL 3 DROPS TYPE DI DO AI AO RTD TOTAL Schneider Electric - Industry Business - K. Lachmann - Date TOTAL

54 Converter Process India Schneider Electric - Industry Business - K. Lachmann - Date 54

55 Gas Cleaning and Cooling Plant India Schneider Electric - Industry Business - K. Lachmann - Date 55

56 Bulk Material Charging System India Schneider Electric - Industry Business - K. Lachmann - Date 56

57 Blast Furnace Cooling & Slag Handling Schneider Electric - Industry Business - K. Lachmann - Date 57

58 Bhushan Power & Steel Blast Furnace Cooling & Slag Handling India The customer: A fully integrated 1.5 Million TPA Steel making Company with turnover of INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in India Schneider Electric - Industry Business - K. Lachmann - Date 58

59 Bhushan Power & Steel Blast Furnace Cooling & Slag Handling India Schneider Electric - Industry Business - K. Lachmann - Date 59

60 Schneider Electric - Industry Business - K. Lachmann - Date 60

65 Automation reference list (extract) Blast furnaces Sinter plants Schneider Electric - Industry Business - K. Lachmann - Date 65

66 Process automation references Extract steel reference list (revision 2009, China) Application area Sinterplant Blast Furnace Process automation Modicon plc and/or Vijeo Citect Scada Schneider Electric - Industry Business - K. Lachmann - Date 66

67 Blast Furnace Oxygen Plant Schneider Electric - Industry Business - K. Lachmann - Date 67

68 DSP-SAIL - Oxygen Plant India The customer: Situated at a distance of 158 km from Calcutta With the successful commissioning of the modernized units, DSP is all set to produce million tones of hot metal, 1.8 million tones of crude steel and million tones of saleable steel annually Challenge Upgrading 80 MOD30 standalone controller to Quantum Unity HSBY Solution Vijeo Citect SCADA Servers with Unity Fast Links Configuring 60 PIDs. & 15 Manual Loaders Schneider Electric - Industry Business - K. Lachmann - Date 68

69 DSP-SAIL - Oxygen Plant India Automation Architecture TYPE DI DO AI AO TOTAL TOTAL Schneider Electric - Industry Business - K. Lachmann - Date 69

70 DSP-SAIL - Oxygen Plant India Example Operator Screen Schneider Electric - Industry Business - K. Lachmann - Date 70

71 DSP-SAIL - Oxygen Plant India Example Operator Screen Schneider Electric - Industry Business - K. Lachmann - Date 71

72 Bayi Iron & Steel Co., Ltd Oxygen Plant Customer Profile Subsidiary of Baosteel Group with steel capacity of 7 mtpa Fully integrated from mining, ore dressing, sintering, coking, iron-making, steel-making to steel rolling Manufacturer of long products, flat products and tubular products Project scope Control of Air Separation Plant (40000Nm3/h) Automation scope Unity Pro platform with Modicon Quantum and Quantum HSBY configurations Ethernet-network, redundant fiber rings Vijeo Citect Scada, Client/Server, redundant servers Engineering Tool Unity Application Generator Schneider Electric - Industry Business - K. Lachmann - Date 72

73 Bayi Iron & Steel Co., Ltd Oxygen Plant Crude Argon Example Operator Screen Schneider Electric - Industry Business - K. Lachmann - Date 73

74 Bayi Iron & Steel Co., Ltd Oxygen Plant Main Tower System Example Operator Screen Schneider Electric - Industry Business - K. Lachmann - Date 74

75 Bayi Iron & Steel Co., Ltd Oxygen Plant Liquid Oxygen Tank Example Operator Screen Schneider Electric - Industry Business - K. Lachmann - Date 75

76 Bayi Iron & Steel Co., Ltd Oxygen Plant Precooling of Air Oxygen Turbocompressor Recycled water Molecular Sieves Schneider Electric - Industry Business - K. Lachmann - Date 76

77 Raw Material Handling Plant Schneider Electric - Industry Business - K. Lachmann - Date 77

78 Bhushan Power & Steel India The customer: A fully integrated 1.5 Million TPA Steel making Company with turnover of INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in India Schneider Electric - Industry Business - K. Lachmann - Date 78

79 Bhushan Power & Steel Raw Material Preparation Plant India Schneider Electric - Industry Business - K. Lachmann - Date 79

83 Bhushan Power & Steel Raw Material Preparation Plant India Example Operator Screen Schneider Electric - Industry Business - K. Lachmann - Date 83

85 Tangsteel China

86 TangSteel: Energy Management System Executed by Project and Services Schneider Electric China Customer profile One of top 10 iron & steel sites in China Production capacity: 18M tons per year 22 energy types Customer Challenge Regulation compliance Reporting mandate Competitive cost pressures Schneider Electric Solution Energy audit Power monitoring Energy Management System Platform for the future Key production equipment: coking (6) sintering (4) blast furnace (4) converter (7) refining furnace (6) casting (10) heating furnace (10) rolling (9) Schneider Electric - Industry Business - K. Lachmann - Date 86

87 TangSteel: Energy Management System Level 3 functions Schneider Electric - Industry Business - K. Lachmann - Date 87

88 TangSteel: Energy Management System Overview of project scope 22 types of W.A.G.E.S Measurement management (power meter) Hierarchy (enterprise, plant and sector) Duration (hours, day, week, month and year) Categories Data acquisition (PLC, networking equipment and SCADA) Areas Different energy system Existing measurement, database, ERP Monitoring and control (SCADA) Information management (Ampla) Hierarchy (enterprise, plant and sector) Duration (shift, day, week, month and year), Every energy usage efficiency Energy decision making (Ampla) KPI & the performance target Management report point Measuring Management Data Acquisition Monitoring & Control Information Management Decision Making Schneider Electric - Industry Business - K. Lachmann - Date 88

89 TangSteel: Energy Management System Project Architecture 20 operator clients Servers including Ampla, storage etc. 80 k points data integration Backbone network link to 10 areas 10 set redundant I/O servers 70 sets M sets power meters Schneider Electric - Industry Business - K. Lachmann - Date 89

90 TangSteel: Energy Management System In real life Schneider Electric - Industry Business - K. Lachmann - Date 90

91 TangSteel: Energy Management System Customer Benefits One open and integrated Energy Management System (EMS) connected energy production to business system (SAP) Establish one consistent energy management process based on new EMS system Satisfy key management needs with below system capability Analyze Energy Consumption by Process Segments or Work Center Identify Key Energy Events with Production Context Identify Key Energy Consumption Equipments Allocate Energy Cost to Process Segments with real energy data Energy Cost Variance according to unit price change Energy Cost analysis for each batch production Schneider Electric - Industry Business - K. Lachmann - Date 91

92 Make the most of your energy Schneider Electric Klaus LACHMANN Steel Solutions Director Phone: +49 (0) 2102 / 404 ext Mobile: +49 (0) 172 / [email protected] Schneider Electric - Industry Business - K. Lachmann - Date 92