Features of process automation, basics in automation control in hot strip mill

1. BHUSHAN STEEL LIMITED
L2 –PROCESS AUTOMATION
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2. BHUSHAN STEEL LIMITED
 The automation industry has been centered on a five layer hierarchical
architecture for years but new technology is making it possible to streamline this
model to eliminate layers, increase performance, and lower software
maintenance costs. A commonly used architecture model to define
Manufacturing Operations Management
Level 5 - Business Systems
Level 4 - Plant Level (ERP, MRP, and MES)
Level 3 - Operation Unit Level
Level 2 - Machine/Process Automation Level
Level 1 - Controller Level
Level 0 - Sensor/Actuator Level
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3. BHUSHAN STEEL LIMITED
Level 5 - Business Systems
Level 4 - Plant Level (ERP, MRP, and MES)
Level 3 - Operation Unit Level
Level 2 - Machine/Process Automation Level
Level 1 - Controller Level
Level 0 - Sensor/Actuator Level
LEVEL 0
LEVEL 3
LEVEL 2
LEVEL 4
LEVEL 1
LEVEL 5
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4. BHUSHAN STEEL LIMITED
 Level 0 – Sensor & Actuator
The basic automation level which provide Action & feedback to PLC and
control logic drives, hydraulic or pneumatic valves are controlled based on
the feedback of automation sensors, like proximity switches, encoders, and
position transduces etc.
Encoder Proximity Switch
Actuator
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Energized De-energized
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5. BHUSHAN STEEL LIMITED
 Level 1 – Basic Automation
The basic automation level provide automatic control of process or
equipment, with the help of PLC and control logic. Here drives, hydraulic or
pneumatic valves are controlled based on the feedback of automation
sensors, like proximity switches, encoders, and position transduces etc.
Supervision is done by operator with the help of HMI. It works as
independent system, the example of basic automation is, Roll change
sequence, AGC control, Looper control, coiler wrapper roll control, material
handling in RHF (charging and discharging of slabs), RHF furnace combustion
etc.
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 Level 2 – Process Automation
Process automation system controls and supervises the production.
Here the process computer accurately calculates the process parameter with the
help of different mathematic models and pass the information to Level 1 system.
On successful completion of event its values is adapted and stored in data base.
During next process the adapted coefficients based on the measured online
values is implemented. The example of Level 2 system – rolling strategy, pass
schedule calculation, cooling strategy in laminar cooling system, temperature
model.
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Basic Automation Level
Process Control Level
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Primary data Pre-calculation
Models, Table,
Neural net
Pre-adjustment Measurement
Post Calculation
L2 Process Flow DiagramL2 Process Flow Diagram
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
Level 3 - Operation Unit Level / Production Scheduling and Control:
This level solves the decision making problems like resource allocation,
production target, maintenance management, and so on.
Tasks of this level includes –
• Production dispatch
• Inventory control
• Production supervision, production reporting, etc.
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9. BHUSHAN STEEL LIMITED
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 Level 4 - Plant Level (ERP, MRP, and MES)
Market and Customer analysis
Orders and sale statistics
Production planning
Capacity and order balance, etc.
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11. BHUSHAN STEEL LIMITED
L2 SYSTEM DESCRIPTION
Basically four process computer is used in L2 System:
M1 – Non-control system
ADH – Actual data handler
M2 – Control system
PCFC – Profile flatness and contour model
Cooling Section – Laminar cooling model
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M1 – Non-control system:
It directly interact with L1 system, L2.5 and supporting system ( RHF, Roll shop ) for
basic data input for process , PDI data.
Basic function for M1:
 Interface with L1
 Interface with L2.5
 Interface Furnace L1 & L2
 Interface Roll Shop
 Maintaining Data base for L2
 L2 HMI
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 ADH – Actual data handler:
Collect all the process online data (Input and Output data) like strip
temperature, water flow for cooling, stand speed, strip speed, roll forces etc.
Maintaining Database for Actual process data from field devices via L1.
Provide required Actual process data to L2 models for calculation in M2
server and cooling section Server.
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 M2 – Control system:
Based on the input from M1 and ADH mathematical model calculated the set
points for process, and adapts the successful process parameters.
Major models used here are – Pass schedule calculation (roll force and
reduction distribution, gauge meter model, roll bending model thermal model
for strip, roll thermal crown /wear model
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 PCFC – Profile flatness and contour model:
Based on the feedback from of strip profile from IMS gauge, flatness from
IMS gauge , thermal crown and wear of work roll, roll force & bending force
from level 1 and pre-calculated setup for each stand reduction it helps to
controls the strip profile and flatness of strip.
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 Cooling Section – Laminar cooling model:
Phase transformation model at laminar cooling is based on thermodynamics
( Gibbs free enthalpy)
Laminar cooling section capable for dual phase rolling , here it takes real time
computation of strip temperature along the entire run out roller table
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17. BHUSHAN STEEL LIMITED
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 To achieve the material physical properties and grain structure coiling
temperature is controlled by adjusting the cooling flow rate in laminar section.
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18. BHUSHAN STEEL LIMITED
Thanking You
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