Level 2 HMI System

The IPACT Level 2 system monitors material make-up values, and will automatically insert extra steps of any material which is getting so far behind that the extra material required cannot be distributed over steps in the next round.

A major Level 2 function is the ability to execute sequences of rounds automatically in virtually any conceivable fashion.  For example, if one wanted to run four iterations of Round A, followed by three additional coke steps, followed by three iterations of Round B, followed by two additional coke steps, followed by five iterations of Round C, followed by "infinite" iterations of Round D, it would be a simple procedure to set this up and run it all automatically, without any operator intervention necessary.  This makes it practical to run different burdening practices, side washing practices, or blanketing practices automatically and therefore precisely.

The operator can, if desired, manually insert extra steps or rounds at any point in the sequence for any number of repetitions.  This would allow, for example, the operator to interrupt a burdening sequence with some rounds of a lower burden ratio if furnace conditions required it.

The Level 2 system also allows retrieval, editing, and storage of round data from the Level 1 system via a screen similar to the Level 1 round editing screen.

The IPACT Level 1 system is designed so that stockhouse/furnace parameters are tunable and not "hard-coded".  Examples of these parameters would be hopper and skip volume and weight limits, stockrod depth limits, conveyor purge times, and valve open hold times. These parameters are accessible from a Level 2 HMI screen.  (On systems with no Level 2, these parameter editing screens could be moved to Level 1).

Alarm annunciation and logging screens are available on the Level 2 system, but in addition to these "standard" features, IPACT provides an innovative Level 2 alarm feature called Block Control Language - BCL.

The purpose of the Level 2 BCL is to allow users to formulate their own alarms easily, and in a language that they are familiar with - PLC ladder logic.  Using BCL screens, maintenance personnel can write their own "logic" for generating alarms, and then see the alarms generated and logged by the Level 2 system - all without disturbing the Level 1 logic which actually controls furnace operations.  This is a very powerful tool to aid maintenance personnel and practice engineers in diagnosing/optimizing the performance of the furnace and associated equipment.

The IPACT Level 2 system also has the capability to generate reports such as turn reports, material usage reports, furnace burdening reports, etc.  Similar to the alarm package, IPACT has incorporated the ability for the user to easily configure ad-hoc reports tailored to his or her needs at the time.  This capability is a powerful tool for process improvement as well.

Historical data storage, playback, and analysis are also available in the Level 2 system.  Data scanning and archiving can be done with IPACT’s products or by feeding other packages such as BBN’s statistical package RS/1.

Integrated Process Automation & Control Technologies