End Line Inspection Implementation
Tubular Products, Vereeniging,
ArcelorMittal, South Africa
Joao Bordalo
Senior Architect, MES Demand
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
General
Profile - ArcelorMittal
► ArcelorMittal is the world's number one steel company, with
320.000 employees in more than 60 countries. It has led the
consolidation of the world steel industry and today ranks as the only
truly global steelmaker with an industrial presence in 27 countries.
► ArcelorMittal is the leader in all major global markets, including
automotive, construction, household appliances and packaging.
The Group leads in R&D and technology, holds sizeable captive
supplies of raw materials and operates extensive distribution
networks.
► Its industrial presence in Europe, Asia, Africa and America gives
the Group exposure to all the key steel markets, from emerging to
mature. ArcelorMittal will be looking to develop positions in the highgrowth Chinese and Indian markets.
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General
Markets - ArcelorMittal
Market position and market share estimates by region*
No 1 in Eastern
Europe and CIS
No 1 in
Western Europe
No 1 in
North America
11%
26%
23%
74%
89%
77%
No 1 in
South America
24%
No 1 in Africa
53%
47%
76%
Number 1 in 5 regions and 4 continents
General
Profile - Tubular Products Division
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Tubular Products is in 21 operating locations in 11 countries world wide,
headquartered in Luxembourg with a capacity of over 3 mill. Tons.
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Automotive with locations in Brampton, Hamilton, London & Woodstock
(Canada), Monterrey (Mexico) and Chevillon, Hautmont & Vitry Le Francois
(France). Although organized within other Tubular Products units South
Africa, Marion, Shelby, and Karvina also manufacture & supply automotive
product.
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Energy with locations in Aktau (Kazakhstan), Annaba (Algeria), Galati &
Roman (Romania), Ostrava (Czech Republic), Vereeniging (South Africa)
and greenfield in Jubail Industrial City (Saudi Arabia) and Calabar (Nigeria).
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Mechanical located in Iasi (Romania), Karvina (Czech Republic), Krakow
(Poland), LaSalle (Canada), Marion & Shelby (USA) and Temirtau
(Kazakhstan).
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General
Markets - Tubular Products Division
Head Office, Luxemborg
Canada, Brampton
Canada, Hamilton
France, Hautmont
France, Chevillon
Czech Republic, Ostrava
France, Vitry
Polan, Krakow
Canada, Woodstock
Canada, LaSalle
Canada, London
Czech Republic, Karvina
USA, Shelby
USA, Marion
Romania, Iasi
Kazakhstan, Temirtau
Mexico, Monterrey
Romania, Roman
Romania, Galati
USA,
Pittsburg
Business
Service
Kazakhstan, Aktau
Algeria, Annaba
Saudi Arabia, Jubail
Nigeria, Calabar,
South Africa, Vereeniging
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Energy
General
Markets : Tubular Products ArcelorMittal South Africa
Energy
Energy Products:
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Line Pipes
Seamless (API,EN, ASTM)
Customer base includes Oil &
Gas and Engineering companies
in America, Asia, Africa &
Europe
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General
Works Layout - Tubular Products ArcelorMittal South Africa
End Line
Inspection
General
ELI Plant Up Close - Tubular Products ArcelorMittal South Africa
Control Desk
Reject Table
INLET
Alignment & Rotation Rollers
Ultrasonic Machine
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Project Objectives
► Business Objective
▪ API Accreditation for Tubular Products Plant
▪ API: American Petroleum Institute
API standards address several key aspects of the oil and gas industry, including exploration
and production, refining, fire protection and safety, petroleum measurement and marine
transportation. These standards also reference offshore production, drilling, structural pipe,
pipeline, health and environmental issues, valves, storage tanks, etc.
► Operational Objective
▪ Shorter Project Delivery
▪ Object and Graphical Standards
▪ Standard PLC Tag Naming Convention
▪ Reliable Data Tracking [Integration with Plant MES]
▪ Operator Accountability
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Solution
► Existing WONDERWARE Install base:▪ Wonderware Historian [5000 tags]
▪ Active Factory 9.2
▪ INTOUCH 10
▪ ARCHESTRA 3.0
► Existing Portal [ProcessNet]
▪ Visualization
► Existing Reporting tools utilized
▪ MS Reporting Services
► Additional Requirements for solution
▪ Consulting [Adopted WONDERWARE’s Best Practices BMA]
▪ Training [ARCHESTRA and INTOUCH’]
▪ Implementation [Functional Specification, Project Schedule,
Commissioning]
▪ Time Frame of 12 weeks
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
System Architecture
Concept Network Topology
SAP R/3
ERP
MES
Plant Centric Information System
DB Server
Intranet Server
Workstations
Plant IS
”SCADA” / MES
Historian
Expert System
Model Software
Process Control
PLC / DCS / SSS
Author
Sensors/ Field Devices
Intelligent Devices
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“SCADA”
Engineering
System Architecture
- TP ELI Plant System Topology Plant Information
Network
Tubular Pipes
Information
System
Process Control
Information
System : Key
Data
Reporting Services
Server
Router
Application Server
TP
TP EWS
WAN
GUI
Control
Information
Network
AOS
Downstream
ELI
Wonderware
Historan
IDE
SCADA
Control
Network
ELI
PLC - ABB
Standard ArchestrA
PLC - ABB
PLC - ABB
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Implementation
Schedule
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Operational Specification Written and Approved by line Management
(1x week)
Setting up the environment: WW Historian, ARCHESTRA, MES Database,
IO Servers and IP assignments
(2x Week)
Consulting with WONDERWARE. Setting of standards and best practices.
(1x week)
Development of ARCHESTRA environment (scripts etc) using INTOUCH
objects, deployment
(3x weeks)
Development of Information object in ARCHESTRA
(1x week)
Commissioning
(3x weeks)
11 weeks total
Implementation
ARCHESTRA: BMA
$UserDefined
$B_Userdefined
$M_Limits
$M_Limit_Switch
Base Object Derivation Standard
Base
Master
Application
$M_Proxy
$A_ELI_Proxy
Implementation
ARCHESTRA: Deployment / Plant Model
Implementation
ARCHESTRA: Data Handling
Implementation
Data Flow
Implementation
Animation of End Line Inspection Plant
INLET
Alignment
Rolls 1
Rotation
Rolls 1
Alignment
Rolls 2A
Alignment
Rolls 2B
Rotation
Rolls 2
UT
UT
Scale
Implementation
SCADA: Plant Overview
Implementation
SCADA:ELI Overview
Implementation
SCADA : Drive Status
Implementation
SCADA: Manual Override
Implementation
ARCHESTRA: MESINFO Object
Implementation
MES GUI
Implementation
Database Schema
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Goals & Benefits Achieved
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Reduced Engineering Costs on system expansion or duplication
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This project has been shown that ArchestrA can be a vertical as well as a
horizontal tool for integration
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Standardised Environment :- great stepping stone for future automation
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Contribution To Plant Operations due To Accreditation:
 80 % of normal throughput
 88 000 Ton (Budget 2008)
 130 Million Rand (Budget 2008)
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Lessons Learnt
► Hardware and Software (OS) requirements for SYSTEM PLATFORM
► Networking Environment
► Stand-Alone Server for the Development Environment (IDE)
► Deploy redundancy [Our Future Plan]
► For optimum performance use stored procedures
► Use a SQL connection for every object writing to the Database
► Consult with WONDERWARE to ensure that standards and best
practices are employed
► Training is essential
Agenda
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Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Conclusion
► Process Control Information Systems are a company strategic asset, it
needs reliable and flexible systems that can populate the databases
correctly
► ArchestrA is a powerful system technology that supports our company
strategy as outlined above
BUSINESS SYSTEMS
AUTOMATION SYSTEMS
DATABASES
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Acknowledgements
Acknowledgements
Cobus Muller
Frikkie Fourie
Hannes van Wyk
Marius Swanepoel
Roche Bester
Andries Wentzel
Willie Essendrup
Wimpie Lubbe
Markus van de Merwe
Jos Peters
- General Manager, Tubular Products
- Systems Engineer [TPSA]
- Senior Engineer Mechanical [TPSA]
- SNR Analyst MES DEMAND Vereeniging, IM
- Senior Engineer Metallurgy [TPSA]
- Electrical Technicians [TPSA]
- Electrical Technicians [TPSA]
- Electrical Technicians [TPSA]
- WONDERWARE SA Regional Manager
- WONDERWARE SA Technical Consultant
Agenda
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General
Project Objectives
Solution
System Architecture
Implementation
Goals & Benefits Achieved
Lessons learnt
Conclusion
Acknowledgements
Questions
Questions