2. PROCESS CONTROL COMPUTERS AT DURGAPUR STEEL PLANTS BASIC OXYGEN FURNACES

3. §HELP REDUCE PROCESSING TIME §MONITOR PROCESS IN REAL-TIME §HELP INCREASE IN PRODUCTIVITY §ACHIEVE C / TEMP. HIT RATE % §MANAGEMENT INFORMATION SYSTEM §ENSURE QUALITY OF PRODUCT §HELP REDUCE PROCESSING TIME §MONITOR PROCESS IN REAL-TIME §HELP INCREASE IN PRODUCTIVITY §ACHIEVE C / TEMP. HIT RATE % §MANAGEMENT INFORMATION SYSTEM §ENSURE QUALITY OF PRODUCT OBJECTIVES

4. AUTOMATION LEVELS AUTOMATION LEVELS fLEVEL 0 - FIELD INSTRUMENTS /SENSORS CAPTURING ANALOG AND DIGITAL DATA. fLEVEL 1 - BASIC AUTOMATION SYSTEM HAVING A SUPERLOOP OF TWISTED PAIR CABLE CONNECTING PCUs, WSAs, CIUs. fLEVEL 2 - VAX 3300 SYSTEMS ONE FOR EACH CONVERTER; CONNECTED TO CIUs OF LEVEL 1 & COLLECT DATA FROM LEVEL 1 AND PASS SET POINTS. fLEVEL 3 - VAX 3800 CLUSTER CONNECTED TO LEVEL 2. fLEVEL 0 - FIELD INSTRUMENTS /SENSORS CAPTURING ANALOG AND DIGITAL DATA. fLEVEL 1 - BASIC AUTOMATION SYSTEM HAVING A SUPERLOOP OF TWISTED PAIR CABLE CONNECTING PCUs, WSAs, CIUs. fLEVEL 2 - VAX 3300 SYSTEMS ONE FOR EACH CONVERTER; CONNECTED TO CIUs OF LEVEL 1 & COLLECT DATA FROM LEVEL 1 AND PASS SET POINTS. fLEVEL 3 - VAX 3800 CLUSTER CONNECTED TO LEVEL 2.

5. LEVEL I - LEVEL II - LEVEL III COMMUNICATION CIU (L1) VAX (L2) VAX (L3) RS-232DECNET NETWORK 90 SUPERLOOP WSA (SUPERVISORY) PCUs (22) FIELD ( I/O) DISPLAYS SEND COMMANDS TO PLSs CHANGE SET POINTS, NODE ETC. OPERATOR -> BULK MATERIAL ADDITION

6. SMS HARDWARE MicroVAX 3800 Cluster - 2 M/Cs called Level 3 Systems MicroVAX 3300 Computers - 4 M/Cs, 1 for each Converter and 1 for VAD MicroVAX 3100 - for BOF Lab Cluster Monitor 8 Terminal Servers, 2 Repeaters, 500 m Fiber Optic Line DEC Router, 45 Terminals and 20+ printers including 1 Laser printer, 1 Plotter and 1 Line printer Connections to Control Room and Blower desks at 9M, VAD,LDS,LTS, CCP, Mixer Bay, Scrap Yard, Welfare Building, LAB Commissioned by DEMAG (Germany) MicroVAX 3800 Cluster - 2 M/Cs called Level 3 Systems MicroVAX 3300 Computers - 4 M/Cs, 1 for each Converter and 1 for VAD MicroVAX 3100 - for BOF Lab Cluster Monitor 8 Terminal Servers, 2 Repeaters, 500 m Fiber Optic Line DEC Router, 45 Terminals and 20+ printers including 1 Laser printer, 1 Plotter and 1 Line printer Connections to Control Room and Blower desks at 9M, VAD,LDS,LTS, CCP, Mixer Bay, Scrap Yard, Welfare Building, LAB Commissioned by DEMAG (Germany)

8. SYSTEM SOFTWARE OPEN VMS 5.5-2 VAX FORTRAN, DECNET, DECFORMS, GKS, TCP/IP, ORACLE RDB, VOLSHAD, CLUSTER MONITOR MODAS ( Case Tool ) APPLICATION SOFTWARE DIALOG BASED & BACKGROUND PROGRAMS L II CONVERTER SPECIFIC SOFTWARE L II TEE,CCP,LTS,VAD SPECIFIC SOFTWARE L III ( Scheduling, Tracking ) L II TO L III AND L III TO LIV COMMUNICATION S/W

9. INFORMATION FLOW BETWEEN DIFFERENT LEVELS AT S.M.S DURGAPUR STEEL PLANT Heat status e.g., HS,BS,TS,TE Each heats data like bulk material addition, temps, lance position. Co/co 2 at tap end Converter activities as seen in event log Mode of converter operation Set point passing for o2 and bulk materials after metallurgical calculations like : * Process aim, hot metal ordering main & 2 nd blow calculation, end blow & alloying additions * Heat Number * Heat Data * Heat Status * Steel/Hot Metal/Slag Analysis * CCP/LTS, Teeming Data * Scrap Yard/ Mixer Data Schedule/Plan for the day Ladle details Grade Specifications / Definitions Actual Steel Grades * Heat Number * Teeming /CCP Cast Data * Heat Data * Steel/H.Metal/Slag Analysis Data * Backlog details of the above, if any. Schedule Data Actual grades of cast from laboratory Level 4 terminal Level 1 to Level 2Level 2 to Level 1 Level 3 to Level 2 Level 4 to Level 3 Level 3 to Level 4 Query Reports M.I.S. Reports Teeming Reports Graphic Printouts Heat Reports Level 2 to Level 3

10. Level 2 System Tasks Heat Number Generation Metallurgical Calculations Heat status monitoring Select Mode of operation Analysis data entry from Lab Event log generation Data transfer Level 3 Systems Heat Number Generation Metallurgical Calculations Heat status monitoring Select Mode of operation Analysis data entry from Lab Event log generation Data transfer Level 3 Systems

11. Level 3 System Tasks §Heat Tracking §Ladle Tracking §Shop Scheduling §Grade definitions §Data Transfer to PPCS §Database Upkeep §Software development §Heat Tracking §Ladle Tracking §Shop Scheduling §Grade definitions §Data Transfer to PPCS §Database Upkeep §Software development

13. Level 2 Models Process Aim calculation Hot Metal /Scrap Ordering Blowing Calculation 2nd Blow Calculation Reblow Calculation Alloying Calculation Feedback Calculation Process Aim calculation Hot Metal /Scrap Ordering Blowing Calculation 2nd Blow Calculation Reblow Calculation Alloying Calculation Feedback Calculation

14. Process aim calculation It is a feasibility check It reads grades and re-blow pattern The model predicts aim Carbon percentage and the temperature of liquid steel at the end of blow

15. PIC 60 DISPLAY PROCESS AIM CALCULATION 15-JAN-03 11:16:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631 PETRO COKE N LADLE DATA STEEL LADLE NO 15 USE LOCAL LADLE DATA N EMPTY LADLE 0 WALL LIFE 75 BOTTOM LIFE 23 PREHEATING DUR 0 LADLE SKULL WT 0.00 BLOW. PATTERN NO. 751 BOT. STIR PAT NO. 19 ORDERED STEEL WT 122.00 PRESET ADDITIONS 0 NUM BATCHES [ ½ ] 1 KILLED STEEL Y ADDITIONS FeSi 200 Al 50 SiMn 1650 FeMn 0 Carbon 450 DESULPHURIZER 0 SYNTHETIC SLAG 0 ALL OTHERS 0 TOTAL 2350 C CONTENTS C AIM EOB 0.080 C AIM LDL 0.200 TAPPING DATA MAX SiMn 1700 TAP TMP LOSS 9 EXP TAP DUR 9 WAIT TIME 5 TAP CORR INP -60 TEMPERATURES AIM TMP EOB 1674 AIM TMP LDL 1630 AIM TMP CAST 1563

16. Hot metal and scrap ordering calculation Hot metal, scrap or iron ore can be fixed Mixer and ladle number are a must Bulk materials are calculated Download order to mixer and scrap yard bay Basicity can be adjusted

17. PIC 61 DISPLAY HOT METAL AND SCRAP ORDERING CALCULATION 15-JAN-03 11:20:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631 HOT METAL DATA MIXER NO 2 HM LDL NO 06 HM EXP TMP 1269 HM ORDER WT 125.00 HM DEM WT 125.00 HM ACTUAL WT 0.00 DESLAGGED (Y/N) N EXP ANALYSIS END OF BLOW C Mn P S IMS 0.178 0.062 0.042 0.035 EOB 0.080 0.040 0.021 0.035 CONVERTER AIM DATA INT-DESL DUR 0 INT-MEAS DUR 5 INT-STOP EXP TMP 1674 EXP C-CONTENT 0.178 BLOWING END AIM TMP EOB 1703 C AIM EOB 0.080 P MAX EOB 0.032 AIM BASICITY 3.0 S MAX EOB 0.100 DEM IRON ORE 0 DEM % BAUXITE 0.00 SCRAP DATA MENU NO 7 TRIM TYPE S00003 BOX NO ORDER WT 9.11 DEM WT 0.00 ACTUAL WT 0.00 ADDITION DATA LIME 9469 DOLOMITE 2000 IRON ORE 224 LIMESTONE Mn ORE FLUOSPAR

18. Main blow calculation Done after start of heat Actual hot metal weight and temperatures are given as input to the model Model advices oxygen amount to be blown ( 1 st blow ) It also outputs expected steel composition at endpoint and slag weight

19. PIC 62 DISPLAY MAIN BLOW CALCULATION 15-JAN-03 11:38:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631 CONVERTER AIM DATA INT – STOP EXP. TMP 1673 BLOWING END AIM TMP EOB 1674 C AIM EOB 0.080 AIM BASICITY 3.0 DEM % BAUXITE 0.00 PROCESS DATA BLOW. PAT NO. 751 BOT STIR PAT NO. 19 DEM O2 FLOW 430 LANCE HT 165 EXP BATH WT 126.99 HOT METAL DATA LDL NO : 06 ORDER WT 125.00 ACT WT 130.00 ACT TMP/TIME 1211 / 11:20 CHARGING TIME 11:11 BATH ANALYSIS C Mn P S IMS 0.157 0.048 0.026 0.035 EOB 0.080 0.031 0.014 0.036 SLAG ANALYSIS FeO CaO MgO SiO2 IMS 18.27 48.95 4.87 16.59 EOB 23.79 45.43 4.53 15.43 SCRAP DATA BOX NO CODE : S00003 ORDER WT 9107 Kg ACT 10000 Kg MODEL ADVICES O2 AMOUNT 6045 LIME 9863 DOLOMITE 2000 IRON ORE 252 MN ORE FLUOSPAR BAUXITE LIMESTONE

20. Second / Re-blow calculation After taking sample and temperature during first blow, this calculation can be done Model advices oxygen amount and bulk material additions/coolants Expected end values Re-blow is necessary if percentage of Carbon is too high, slag is too viscous

21. PIC 63 DISPLAY SECOND BLOW AND REBLOW CALCULATION 15-JAN-03 11:38:24 HEAT NO. 02311369 STEEL GRADE R16 AXLE STEEL CHARGE ID 23631 ACTUAL PROCESS STATUS MAIN BLOWING 2 NUM OF REBLOWS 0 CONVERTER AIM DATA AIM TMP EOB 1674 C AIM EOB 0.080 P MAX 0.032 S MAX 0.100 DEV. LANCE H T -10 ORE MAX 0 LIMESTONE MAX 0 PREV. ADD ADVICE ACT LIME 9863 11275 DOLOMITE 2000 894 IRON ORE 252 1716 MN ORE FLUOSPAR BAUXITE LIMESTONE OXYGEN PU MEASURED DATA TMP EXP 1674 TMP ACT 1660 TMP TAKEN TECTIP C SAMPLE CODE SAMPLE TAKEN PREV. BLOWING PERIOD ADVICE ACT LANCE HT 165 0 O2 AMOUNT 6045 6084 QUICK TAPPING [Y/N] N ANALYSIS DATA C MN P S PRE 0.157 0.048 0.026 0.035 ACT 0.090 0.080 0.035 0.040 NXT 0.050 0.070 0.029 0.039 FE TOTAL IN SLAG 14 % NEXT BLOWING PERIOD TMP EXP 1674 LANCE HT 155 O2 AMMOUNT 200 IRON ORE 0 LIMESTONE 0 BAUXITE 0 MN ORE 0

22. Offline alloying calculation Done before Tap Start This model advices three different combinations of alloys C, SiMn, FeSi, FeMn are calculated

23. PIC 66 DISPLAY OFFLINE ALLOYING ADVICE 15-JAN-03 12:09:23 HEAT NO.: 02311369 CHARGE ID : 23631 EXP. STEEL WT.: 127.0 LADLE ANALYSIS : CMnSiPS C LOSS AIM: 0.2000.6000.0800.0400.030 10.00 ACTUAL 0.0280.0120.0500.0050.031 RESULT 1RESULT 2RESULT 3 SiMn1056SiMn0 1289 FeMn345FeMn0 213 Coke611Coke0 447 COST (1) – RS 30902.0 COST (2) – RS 0.0 COST (3) – RS 38566.2 ELEMENTCSI-FESI MN-FEMN SI-SIMNMN-SIMN YIELD :45 65 85 65 85

24. Level II VCS System This system is significant after tap end This system has data entry and monitoring screens for LADLE TREATMENT STATION CONTINIOUS CASTING PLANT TEEMING BAYS LADLE DESPATCHER PRODUCTION DATA ENTRY SCREENS OF TEEMING AND CONTINIOUS CASTING PLANT

26. Level 3 Models Heat Tracking In Shop Heat Scheduling Ladle Tracking Ladle Overview Data Storage Data Transfer To Level 4 PPC System Heat Tracking In Shop Heat Scheduling Ladle Tracking Ladle Overview Data Storage Data Transfer To Level 4 PPC System

27. Production status of steel shop Shows the status of last 10 heats One can know the heat number, status, area, start / end times.

28. DIALOG 23 DISPLAY PRODUCTION STATUS STEEL SHOP 01-JAN-03 10:19:51 HEAT NO. CHID LDL ST CONVERTERTRANSSECONDARY TRANS CASTING 02110767 22951 14 CE BOF–1 04:36 TEA-06:00 05:18 06:51 02310768 22952 08 CE BOF-3 05:02 TEA-4 07:09 05:45 07:50 02110769 22949 18 CE BOF-1 05:21 LTS-2 06:42CCM-1 06:51 06:15 06:44 08:12 02310770 22939 17 CE BOF-3 05:47 LTS-1 06:53CCM-2 07:03 05:45 07:00 09:00 02110771 22942 02 HS BOF-1 06:17 02310772 22943 01 BS BOF-1 05:55

29. Heat schedule Shows the planning of the shop Heat status, grade, route code Start / end time of different areas

30. NONO STHEAT NOCARG ID GRADE CODE HEAT START TAP. END 2. MET STAR 2.MET END CAST CAST ROUTE START END CODE 1CE0211077122942107482S06:2507:2608:48 09:15 100001 2CE0231077222943107482S06:3007:4508:0908:1108:31 10:04 300003 3CS0231077422963XCHEPA07:5709:1909:4209:4309:44 10:05 300110 4 BS0221077322966ASP12410730 200220 51786415 300004 6ASP3110 200003 7107482S 100110 8XCHEPA 300002 9107482S 200220 PIC 5O DISPLAY HEAT SCHEDULE - SSC 01-JAN-03 10:27:24 BDVLCT

31. Ladle tracking and Ladle data Shows a map like view of positions of ladles in the entire steel shop Ladle placement times are captured Temperatures/times at various points like preheating, porous plug in/out, gate preparation start/end are captured Status, location, last cast end, tap start, reference details, life of PP,WB,In,On etcetera

32. 10776 00:00 TEA-4 10755 00:00 LTS-1 17 = 02 = PIC 99/1 (2) LADLE STATUS 01-JAN-03 10:27:24 HEAT AND LADLE > SCHED. END > NEXT PROC. AREA > VADBOF –1BOF - 2BOF - 3 TEA - 4 TEA- 3 TEA–2TEA - 1 TEA –5 INJ PARK 04 06 11 13 21 25 PARK 05 19 26 CSTF 07 08 14 NUMBER ST VD HM IN USE 4 AT LPB 15 8 EXT MT 1 6 DRYER

33. Ladle overview Shows the ladle status / position in the shop One can know the ladle number, status, area and time of placement Current Heat Number attached with a ladle is displayed

34. PIC 72 DISPLAY STEEL LADLE OVERVIEW 01-JAN-03 10:27:24 LD L STATUSLOCLDBTINONPPWBCURRENT BEGIN HEAT 01- M DNLR6NEW SHEL. RPR 02C O PPDE220 41520 03C O PHLH318NEW000 TO MAKE 01-JAN 04:07 04C O USCC244442402310774 05C O USCC1279934902110775 06- M DNLR2000000F/D -> DBS 07C O PHCSF17 39 08- M DNBCP000000FOR CEM 09C O PPDE315 1318

35. Level 3 To Level 4 Data Flow LEVEL3LEVEL3 LEVEL4LEVEL4 HEATDATA CASTDATA ANALYSIS DATA GRADE LIST BILLET DATA

37. Level 4 PPC Modules Production and Planning Commercial Module Data Warehousing and Shipping Manufacturing Module Quality Assurance Module Production and Planning Commercial Module Data Warehousing and Shipping Manufacturing Module Quality Assurance Module