BOF Automation Revamp
IPACT has migrated an existing BOF supervisory computer system from a DEC PDP/RSX11M platform to an OpenVMS platform. This included all of the models, HMI screens, I/O driver, and communication services to remote nodes. The migration was part of a larger continuous caster upgrade, for which IPACT provided support for new scheduling requirements, and message coordination between the LMF, the Caster, the Blast Furnaces, the BOF, and the scheduling conformance computer.Several major enhancements were made to this system during the revamp. A distributed SPC system was installed with all data on a single server and each node able to access charts relevant to the associated area. Over 50 charts were provided with the system, tracking everything from turndown temperature and chemistry to test weight performance on scales.
A Level I system was added to perform flux and alloy additions control. This system received orders from Level II and sent production data back to Level II. Operators are allowed to acknowledge and "trim" weights before execution as well as to easily schedule additional charges. In the same HMI/SCADA system that was added to interface to this flux and alloys Level I, an interface to the existing oxygen control system was added to improve the precision of oxygen control.
Based on the success of the additions system above, IPACT was chosen to automate the flux additions at a second BOF shop. On this system, SPC functionality was also added to track the "empty weight" of the hoppers and alert the operators and maintenance personnel when out-of-control conditions indicating the need for taring occurred.
Integrated Process Automation & Control Technologies