The document outlines a new advanced supervisory control system for coke plants, designed to improve automation and coordination among various processes while ensuring operational continuity even during subsystem failures. Key features include a scalable architecture with redundant systems, real-time monitoring capabilities, and a user-friendly graphical interface for operators and maintenance personnel. The solution aims to enhance efficiency and safety, significantly reducing downtime and development time for large production environments.

1. Dave Hreha
Application Engineer
Schneider Electric
Advanced Supervision System for Coke
Plants
Dave McWilliams
Engineering Manager
Integrated Mill Systems

2. Automation Characteristics of Coke Plants
Overview
 Combination of process control (battery systems) with
machine interlocking coordination (pusher machines, coal
charging, transfer cars, quench cars)
 Distributed automation and supervision architecture
 High degree of redundancy
 Allowing critical operations to be performed even when other systems
fail
 Manage multiple technologies working together

3. Automation Characteristics of Coke Plants
Supervision System Characteristics
 Graphical interface that allows production and operations to
oversee the coke system:
 System overview and parameters
 Real-time information processing
 Process trends
 Automatic and manual operation of coke machines
 Alarms and fault detection
 Programmable logic controller (PLC), drives, and network status
 Process and production tuning
 Maintenance and troubleshooting

4. Case: The Challenge
Project and user requirements
 New control system for a coke plant with a supervision
system that could manage a complex environment:
 Several operators and maintenance personnel scattered over
thousands of acres
 Maintenance required to support a large process campus with limited
resources while minimizing downtime
 Data sharing between all process areas to ensure continuous
operation
 Maintain process area operational capabilities, even when a
communication loss occurs
 Disconnect caused by segmented coordination by production staff of
their respective processes
 Operation stations must continue process operations even in the
event of subsystem failures

5. Case: The Challenge
System complexity

6. Case: Proposed Solution
New automation / supervision solution
 Scalable, ‘view-anywhere’ supervisory control and
maintenance system:
 Scalability to meet current system requirements with a designed-in
capability for easy expansion to meet current and developing
production needs
 Redundant global servers communicating with global process and
client servers throughout the production campus
 Use of wireless and fiber optic communications to reduce cost and
ensure network survivability
 ‘View-anywhere’ supervision stations capable of acting as a
maintenance or operator terminal for any process area
 Continuous power backup system capabilities to reduce impact of
downtime or outages

7. Case: Proposed Solution
The architecture

8. Case: Proposed Solution
High availability supervision system concept
No single point of failure
8 paths for plant control

9. Case: Proposed Solution
Development and testing
 Systematic approach for
development / engineering
 Template creation
 Consistency / Methodology
 Constant dialog with user
Design document submittals
 Customer assistance
 Exhaustive testing before
start-up

10. Case: Proposed Solution
Main User Environment

11. Case: Proposed Solution
Example: Operator Screens
 Live data information
 Permissive screens
 Calibration screens
 Setup
 Fault
 Trends

12. Case: Proposed Solution
Example: Maintenance Screens
 Overview
 Setup
 Speed Drives Fault
 Communication Status
 Alarms

13. Conclusion
State of the art supervision system
 Advanced supervisory system which reduced development
and startup time:
 Multiple redundancy allowing a safer and continuous operation
 A powerful template for large production systems independent of the
manufacturing process
 A platform which is scalable to customer needs without costly
redesign and extensive programming
 A faster review cycle with the customer which results in accelerated
installation time

14. Thank You
Dave Hreha
Application Engineer
Schneider Electric
Dave McWilliams
Engineering Manager
Integrated Mill Systems