2. DONGBU STEEL 2003 OSIsoft Users Conference 1 Development of Real-time Information Management System(RIMS) to Continuous Galvanizing Line(CGL) at the Asan Bay Works, Dongbu Steel Co., Ltd. May 11-14, 2003 2003 OSIsoft Users Conference Dongbu Steel Co., Ltd. www.dongbusteel.co.kr

3. DONGBU STEEL 2003 OSIsoft Users Conference 2 Contents Who are we? Motivation The Goal What is new? The results Developed applications : #1~#4

4. DONGBU STEEL 2003 OSIsoft Users Conference 3 Products Who are we? Cold Rolled Galvanized Prepainted TP / TFS Pipe H Beam CHQ Wire P.E.B CD Bar

5. DONGBU STEEL 2003 OSIsoft Users Conference 4 Works & Offices Headquarters Inchon Works Asan Bay Works Pohang Works Who are we?

6. DONGBU STEEL 2003 OSIsoft Users Conference 5 What does the CGL (Continuous Galvanizing Line) make? By utilizing the “ sacrifice anode effects ” of zinc layer over steel it gives steel the corrosion resistance capability with lower production cost Motivation

7. DONGBU STEEL 2003 OSIsoft Users Conference 6 For what and...? Motivation Improvement of Quality Improvement of Quality Low Production Cost Low Production Cost By What and How?

8. DONGBU STEEL 2003 OSIsoft Users Conference 7 What we need? Motivation Challenge Data type Application Data reliability Storage Accessibility Analysis tools Large amount of real-time data Unrestricted for operator, maintenance and technical members Real-time monitoring On-line storage over 3 years Intranet / Internet Korean Language In-house control

9. DONGBU STEEL 2003 OSIsoft Users Conference 8 Improving Process Capabilities Pre Treatment Heat Treatment Zinc Coating Post Treatment Inspection Adherence Mechanical Property Coating Weight Coating Amount Grade The Goal

10. DONGBU STEEL 2003 OSIsoft Users Conference 9 The Legacy system LEVEL 3 LEVEL 2 Thickness Temp. Coating Current Tension Pressure... IRMSSIEMENSTOSHIBA Real-time measurement Coil Data, Production Result LEVEL 1 (PLC, DCS) RIMS User Real-time Data RIMS Server What is new?

11. DONGBU STEEL 2003 OSIsoft Users Conference 10 RIMS Architecture What is new?

12. DONGBU STEEL 2003 OSIsoft Users Conference 11 1 st Stage Development Results Tag820ea (Sensors : 270ea Coil Length Tracking : 550ea) Development Retrieval of archived Real-time Data Coil based data handling (from time based) Process Book and WEB Environment with VB and ASP Inquiry and Analyzing of Production Coils System Access Process Book and WEB with ASP OSWindows 2000 Service Process Book with Application Program Real-time Coil Inspection, Inquiry – 1 screens 6 charts Real-time Trend Data chart - 10 screens with 93 charts WEB with ASP The same as Process Book Inquiry and Analyzing of Production Coils 10 screen with 108 charts The results

13. 12 Main Task : Real-time Coil Inspection

14. DONGBU STEEL 2003 OSIsoft Users Conference 13 Customers are expecting no-defects. On every point, what is the history? Thickness, Pre-treatment, Heat treatment, Bath temp., Coating amount,Roll force, Elongation, Amount of oil etc. ? ? Main Task

15. DONGBU STEEL 2003 OSIsoft Users Conference 14 Ss Sm Sw ts-a tm-a tw-a ts-b tm-b tw-b ts-c ts-m SENSOR 1 SENSOR 2 SENSOR n product

16. DONGBU STEEL 2003 OSIsoft Users Conference 15 Main Screen Main Task : Results Coil Information Temperature Tension Coil Tracking Coil Length Thickness Width Winding Length

17. DONGBU STEEL 2003 OSIsoft Users Conference 16 Entry Main Task : Results

18. DONGBU STEEL 2003 OSIsoft Users Conference 17 Inspection Main Task : Results 1st product 2nd product 3rd product Upper LimitLower Limit Speed Thickness Temp. Coating Weight Pin Hole Width Process Status Data Searching re-scaling

19. DONGBU STEEL 2003 OSIsoft Users Conference 18 WEB version ChartSheet Main Task : Results

20. 19 Appl. #1 : Retrieval of Operation Data

21. DONGBU STEEL 2003 OSIsoft Users Conference 20 Menu Appl. #1 : Retrieval of CGL Operation Data 1 2 3 4

22. DONGBU STEEL 2003 OSIsoft Users Conference 21 Export to Excel Appl. #1 : Retrieval of CGL Operation Data

23. 22 Appl. #2 : Monitoring and Daily Report System - Line Operation and Quality Related Items

24. DONGBU STEEL 2003 OSIsoft Users Conference 23 Functions Upper Limit 관리하한선 RTDB Taking measures Report. Daily report via e-mail. At anytime Alarm Measured Value Time Operation Criteria RDB Lower Limit Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items

25. DONGBU STEEL 2003 OSIsoft Users Conference 24 Daily Report Sample #`1 Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items

26. DONGBU STEEL 2003 OSIsoft Users Conference 25 Daily Report Sample #2 Sheet E-mail Appl. #2 : On line monitoring and Daily Report System for Line operation and Quality related items

27. 26 Appl. #3 : Analysis of Measuring Devices

28. DONGBU STEEL 2003 OSIsoft Users Conference 27 Main Screen Major Measuring Devices * Thickness Gauge * Furnace Thermometers * Zinc Coating Weight * Tension Meters * Pin Hole Detector Appl. #3 : Analysis of Measuring Devices

29. DONGBU STEEL 2003 OSIsoft Users Conference 28 Furnace Temperature Appl. #3 : Analysis of Measuring Devices

30. DONGBU STEEL 2003 OSIsoft Users Conference 29 Zinc Coating Weight Appl. #3 : Analysis of Measuring Devices

31. DONGBU STEEL 2003 OSIsoft Users Conference 30 Tension Appl. #3 : Analysis of Measuring Devices

32. DONGBU STEEL 2003 OSIsoft Users Conference 31 Daily Report – Sensor Trouble Appl. #3 : Analysis of Measuring Devices

33. DONGBU STEEL 2003 OSIsoft Users Conference 32 Logging Logging Appl. #3 : Analysis of Measuring Devices

34. 33 Appl. #4 : Analyzing Zinc Coating Weight

35. DONGBU STEEL 2003 OSIsoft Users Conference 34 Analysis System Configuration Level 1 PLC Level 2 RIMS User Level 3. Quality Factor. Set Points Measured Value of Sensors Stored value in RIMS Lab. test results Air Knife CoatingWeightGauge Appl. #4 : Analyzing Zinc Coating Weight`

36. DONGBU STEEL 2003 OSIsoft Users Conference 35 Data Sources Air Knife Coating Weight Gauge Laboratory Test Results Appl. #4 : Analyzing Zinc Coating Weight`

37. DONGBU STEEL 2003 OSIsoft Users Conference 36 Analyzing Flow Statistical Analysis per Coil Analyzing C/W in Rolling Direction C/W OK? Daily Data Gathering Data Archiving Data Feedback Long-term Data Analysis Yes No Laboratory Test Result Analysis Tuning Appl. #4 : Analyzing Zinc Coating Weight`

38. DONGBU STEEL 2003 OSIsoft Users Conference 37 Results Appl. #4 : Analyzing Zinc Coating Weight`

39. DONGBU STEEL 2003 OSIsoft Users Conference 38 Questions