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AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
AP09: GrafTech International: Taps Cloud Generating  Millions($$) in Annual Savings for Customers
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AP09: GrafTech International: Taps Cloud Generating Millions($$) in Annual Savings for Customers

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World leader in graphite material science and supplier of electrodes used in electric arc furnaces, GrafTech International provides its customers with an information solution which monitors production …

World leader in graphite material science and supplier of electrodes used in electric arc furnaces, GrafTech International provides its customers with an information solution which monitors production performance and enables operational excellence. The ArchiTech
furnace productivity system utilizes a cloud-based infrastructure and FactoryTalk VantagePoint. The system enables production performance benchmarking, detects and locates electrical imbalances, and provides real-time data and alerts, enabling operators to solve problems quickly. It also optimizes electrode consumption, energy, and power-on time, saving customers millions of dollars in operating costs on an annual basis.

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  • 1. Copyright © 2014 Rockwell Automation, Inc. All Rights PUBLIC INFORMATION Taps Cloud Generating Millions($$) in Customer Savings
  • 2. Business confidential GrafTech Customer Conversations Introductions 2 Andy Messineo Architect Technical Development Manager Dennis Kenemuth Arch Furnace Productivity System Global Manager
  • 3. Business confidential Corporate Overview GrafTech International Ltd. (NYSE: GTI) • +125 Year Old Company • Headquartered in Parma, Ohio • Focus on Graphite & Carbon Material Sciences • Global Operations with +3000 Employees • Annual Revenues of +$1B (USD) • Operate Two Business Segments • Industrial Materials • Engineered Solutions Company Profile Quick Facts 3
  • 4. Business confidential Crude steel production, 1980-2012 MM tonnes 5
  • 5. Business confidential 2012 VS 2013 Production 6
  • 6. Business confidential Operational Challenges for Steel Makers 7 Translate & simplify complex data into bottom line results Surface hidden problems and opportunities Eliminate waste and streamline production flow Reduce & control cost Increase productivity Maintain uninterrupted production flow Achieving Your Business Objectives
  • 7. Business confidential 8 With arrival of ArchiTechTM System 4.0, we‟re making it easier than ever to track and manage your EAF operations data in one place • Features of 4.0 • An improved design • ArchiTechTM navigation will be more streamlined and user- friendly with improved graphics and intuitive controls. • More powerful tools • We’re introducing all new trending & reporting tools. Information when you need it, the way you want to see it for informed decision making. • Customizable trends • You can make changes and publish trends how you like or we’ll do it for you---it’s all up to you. In-depth EAF analysis on-demand? ArchiTechTM is a registered trademark of GrafTech USA LLC.
  • 8. Business confidential Real Examples of Results 9 Actual examples – project description & results Est. Annualized Financial Impact ($) Power program changes improving refining period performance resulting in 2 minute reduction in power-on time and an additional 1 MWH/heat due to substantially improved foamy slag 3,000,000 DOE analysis of customer's fume collection system - set 4th hole draw to 55% - reduced power-on time and kWh/ton 210,000 Reduction in energy and electrode consumption 150,000 Increased power (tapped up), reduced electrode breakage 174,000 Reduced electrode breakage, improved productivity and reduce energy consumption 610,000 ArchiTech data showed an increase in oxygen / burner usage which was contributing to high electrode consumption. Several recommendations were made to help reduce oxidation including a power program adjustment 727,500 Significant decrease in electrode consumption (-12%), electrical energy consumption (-3.5%), and power-on time (-8.2%) 5,250,000
  • 9. Business confidential 10  Examples of problems customers solved faster with ArchiTech™ System • Regulation problems • Bad water cooled cable • “B” phase not regulating • Five percent voltage drop • Wrong power program loaded • Loose rollers affecting regulation • Single phasing and arc instability • Electrical phase sequence reversed • LMF Electrodes being dipped for an entire heat Sometimes the problem found by the ArchiTechTM system ends up being the proverbial “needle in a hay stack” ArchiTechTM System Server Based Alerts
  • 10. Business confidential 11 What if you could solve EAF problems faster?  Small, self-contained, scalable, easy to install and backed up by expert CTS Size of bread basket and very durable
  • 11. Business confidential 12  24/7/365 advanced high-speed EAF diagnostic, analysis and reporting system Monitors Energy, Power and Power Quality  Connects to metering VT’s and CT’s  Minimum of 32 samples per cycle  True RMS measurements  Harmonic distortion  Revenue accuracy What if you could solve EAF problems faster?
  • 12. Business confidential 13 What if you could solve EAF problems faster?  Developed to compliment and backup existing supervisory systems Easy to scale and customize More than 10 years of software development in the product Now on ArchiTechTM System 4.0 PLC data & Communications  Chemical, mechanical, auxiliary signals  Configurable web tools and CSV files  Master and subservient protocols  Serial and Ethernet integration  Email or direct connection
  • 13. Business confidential ArchiTechTM 4.0 Data Collection 14 Microsoft SQL Database • MS SMTP server for data collection • Custom parser software to insert data into database ArchITechTM ArchiTechTM Hardware • Collects data and sends to server via Email message
  • 14. Business confidential ArchiTechTM 4.0 Legacy System 15 Microsoft Windows Server • Microsoft IIS • Non-Encrypted data connection to client • Microsoft SQL Database • Microsoft SMTP server for data collection • ASP.net web site with Customer Login • On-Site at GrafTech Data Center Client • Microsoft IE 8 or greater
  • 15. Business confidential ArchiTechTM 4.0 Server Design 16 Microsoft Active Directory • Used for portal login and security on the portal items Microsoft Active Directory Backup • Used as a backup security server • Contains custom tools for adding users and customers Microsoft SQL Database • All furnace data • All portal data • SQL Reporting data • MS SMTP server for data collection Rockwell Vantage Point • Microsoft IIS • Microsoft Reporting Services • SQL Reporting data • SSL encrypted data connection to client Client • Microsoft IE 8 or greater • Microsoft .NET 4.0 or greater
  • 16. Business confidential ArchiTechTM 4.0 Why as Hosted System in the „Cloud‟ 17 • 100+ Worldwide Installations • 24 hour availability • Reliable high speed Internet connection • 24 hour monitoring • Managed backups • Scalability
  • 17. Business confidential 18 My ArchiTech™ System Dashboard - Example In-depth EAF analysis on-demand? Transforming EAF data into valuable, actionable insights
  • 18. Business confidential ArchiTechTM 4.0 Customer Portal: Today‟s Heats 19 Demo St Marys EF #1
  • 19. Business confidential ArchiTechTM 4.0 Customer Portal: Heat Trace 20 Demo St Marys EF #1
  • 20. Business confidential ArchiTechTM 4.0 Customer Portal: Heat Trace (cont.) I 21
  • 21. Business confidential ArchiTechTM 4.0 Customer Portal: Current Trend I 22
  • 22. Business confidential 23 Real Time Data Analysis
  • 23. Business confidential ArchiTechTM 4.0 Multi-Site Comparison 24
  • 24. Business confidential ArchiTechTM 4.0 Alerts Statistics 25
  • 25. Business confidential 26 Electrical Imbalances • Circuit Impedance • Static VAR • Regulator Reference • Valve or Drive • Mechanical • Power Program Electrical imbalances from changes in… How do you detect unintended changes in your EAF operation? Quickly detecting and locating the source of electrical imbalances can be challenging
  • 26. Business confidential ArchiTechTM 4.0 • 2 Portal Systems Reviewed • SAP • Rockwell • Requirements • Database Source of Microsoft SQL • Highly Customizable Portal Layout • Login Security • Static Live Charts • Dynamic Live Charts • Excel Reporting System Evaluation and Selection 27
  • 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Questions?

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