SSS Technical services specialize in the integration of steel making, power generation, PC based measurement and automation applications like Power Plant Control Systems, Automatic Water Cooling Control, Argon Oxygen Decarburization, SSS-016 Immersion digital thermometer, molten metal CARBON & SILICON measurement & Monitoring system, SSS-019 is a rugged portable digital pyrometer planned specifically for use in the foundry environment, SSS Oxygen Activity Measurement System, Field alarm systems, SSS mV.Source is precision portable calibrating tool for Thermocouple instruments, Cubicle, Field Alarm Unit, Lance Assembly, Expendable Thermocouple Tips, Compensating Cable.
SSS Technical services specialize in the integration of steel making, power generation, PC based measurement and automation applications like Power Plant Control Systems, Automatic Water Cooling Control, Argon Oxygen Decarburization, SSS-016 Immersion digital thermometer, molten metal CARBON & SILICON measurement & Monitoring system
 
Projects
   
  • LRF Automation
  • AOD Automation
  • ARC Furnace
  • Power Plant    Automation
  • Automatic Water    Cooling Control
 
Computer Based Automatic Control System For L.R.F
 
 
1. Computer Based Automatic Control System For L.R.F.  
2. Technical Proposal - Introduction  
3. Project Appreciation  
4. Hardware for the System  
 
 
Computer Based Automatic Control System For L.R.F. Top
AIM Development of COMPUTER based online Automatic Control System
   
SCOPE OF SSS
Supply of National Instruments make hardware along with customised software.
Installation and Commissioning
 
SCOPE OF USER
Site preparation and cabling
Cables and cabling as and where necessary.
 
Deliverables
National Instruments make Field point system along with its controller and accessories.
1. Personal Computer.
2. Customised software to be installed in Personal Computer, which will be custom developed using LabView.
3. Manual for operation of the system.
   
 
Technical Proposal - Introduction Top
The electrode movement and its controls of LRF is to be precisely Controlled using a PC based automatic control system. SSS is to develop Personal Computer based L.R.F control system to interface the existing hardware, based on National Instruments Hardware.
There will be 3 electrodes. These electrode movements are to be controlled independently and collectively based on the current requirement, defined in the programme. Based on the field requirement, the computer is to select the right amount of current and voltage selection. The challenge is also to communicate with Spectrometer, Temperature measurement system, Weighing machine etc. to get upto date data of the chemistry, Temperature of the melt, weight of the liquid metal etc.
   
A. Weight of the liquid metal
B. Weight of slag
C. Chemical Composition of Liquid metal
D. Required chemical composition
E. Temperature of liquid metal
   
Based on the above parameter and in consultation with your experts/consultants, SSS will develop a process control Software for controlling the electrode current and its movements. When start command from the computer is given, then the PC will automatically set the required Current parameters without any operator intervention, after the required input parameters are provided Manually/Automatically.
 
Reason for going to a PC based automation.
A. Old system is mechanically unreliable
B. Maintenance costs are high
C. More precise current control is possible with latest instrumentation
D. More precise level-1 and level-2 control
E. Faster heat time
F. Loss of process expertise from personnel changes is minimised due to PC automation
G. Lower operating cost due to improved technology
     
PROJECT APPRECIATION Top
Design and operating details.
The Computer controlled LRF. Presently precise Electrode/Current control is not obtained due various limitations. To over come this, a modified Computer system is to be developed which will select the required Current and its electrode movement with precise calculation, maintain database and then control the field actuators.
 
Alloy addition.
We shall be providing an alloy addition wizard so that the addition can be accurately and economically determined.
STANDARD
L.R.F.CONTROL
SSS. L.R.F.CONTROL ADVANTAGE
Single Control panel with Multiple
instrumentation
Single monitor with multiple screens More information, Less Capital cost
Experience based Chemistry / Temperature Estimates. Computer modeled Time, Energy and refractory saving
Manual Collection of Data
Automatic acquisition (e.g. Weight, Chemistry, Temperature, Aims etc.)
Note: To effect this, the system should have Automatic weighing, Communication with Spectrometer, Communication with Temperature
measuring instruments etc.
Convenience and accuracy
Manual adds calculation Adds wizard Least cost material, accurate chemistry control
Operator dependent practice and processing Automated processing Automated processing
Manual record keeping Automated heat summary. Convenience, Quality control
Remote viewing of live data not possible Remote viewing and if required, controlling is possible through internet.
* Condition apply
More convenient and
systematic control
Networking with Lab, Pyrometer, Weighing scales MIS etc. not
possible
Networking with Lab, Pyrometer, Weighing scales MIS etc. is easily attained after interfacing with such instrumentation. Accurate and perfect control
 
SSS AIM:
A. Quality of current practice
B. Temperature control
C. Slag chemistry control
D. Shorter and faster heat times
E. Grade specific practices.
   
Operators Console :
A. Control Hardware: National Instruments Field-Point along with SSS proprietary hardware.
B. Computer: Reputed make with 2.8GHZ, Pentium IV, 256MB RAM, 40 GB Hard disc, 42X CD ROM drive, Scroll mouse.
C. Monitor. 17” Colour(LCD), make :any standard
D. Operating system: Microsoft Windows-XP
E. Control Software: Developed through National Instruments LabVIEW 7.1 or later
F. Communication between Hardware and PC: through Ethernet port
Hardware for the system Top
A typical BLOCK DIGRAM of the proposed system is illustrated below.
   
  Computer Based Automatic Control System For L.R.F
 
 
 
 
AOD (Argon Oxygen Decarburization) is popularly used in the stainless steel making process. AOD has top lance for oxygen injection and several bottom tuyeres to blow oxygen or inert gas. The inert gas will be argon or nitrogen.
SSS developed a very innovative method of controlling the flow of these gases as well as chemistry of melt. This PC based system models carbon content and temperature of the melt during decarburization, and controls the reduction temperature and chemistry more accurately.
The system performs all tasks and do all calculations, vessel positioning, ratio setting of inert gas etc.
SSS PC BASED AOD control system and its procedures ensure unmatched consistency during entire operation. It also allows manual override of the system whenever required.
All metallurgical calculations are done automatically during its operation and necessary suggestions for additions are given whenever required. 
With this system,Minimum heat-to-heat time can achieved.
  • Minimum operating cost with improved and consistent quality.
  • Direct interfacing with spectrometer, Temperature measurement system, weighing scale etc. is possible. Thus eliminating tedious record keeping and human error.
  • Level II and level III controls are possible.
 
 
SSS- ARC Furnace Control System
PC based arc furnace regulation and control system with a superimposed powerful HMI station, provides an easy to upgrade and yet sophisticated approach to EAF optimization. The overall system is based on the integration of various functional components, which can be applied individually to a partial upgrade situation or supplied as a complete system for a new operating environment.

System components:

  1. Electrode regulation
  2. Furnace motion controls
  3. Harmonic analysis
  4. Demand Control
  5. Process and production monitoring
  6. Engineering, production and performance reports

Expected benefits:

  • Lower energy consumption (KWHR/TON)
  • Faster melting cycle
  • Reduced electrode consumption (including less breakage)
  • Reduced refractory consumption
  • Enhanced operator's understanding of process performance parameters through performance indicators
 
 
SSS know the Bits and Bytes of Power Plant Control Systems, about your Business ?
SSS can be contacted for automation of the power generation industry. SSS do automation & optimization solutions using National Instruments Hardware and Software. No matter what kind of power plant you are planning to build or currently operate we understand your processes and have the right solutions for your plant. Regardless, of the location of your plant , we shall be there to support you with long term service contracts, experienced service personnel and specific service solutions.
Another innovation from SSS is a PC based cooling system for cooling a continuously cast strand, e.g., a continuously cast steel slab/billets. In the continuous casting of slabs, particularly steel slabs, the slab is spray cooled in a secondary cooling zone after leaving the mold. To prevent crack formation on the slab surface, specific requirements are imposed on the spray cooling as regards uniformity, control of the spray intensity, adjustment to different slab widths, etc. Aside from these technical requirements, certain economic conditions such as low initial and maintenance costs, as well as low breakdown rates, must be satisfied.

SSS cooling system for secondary cooling zone which attempts to satisfy these complex requirements. In particular, controlled cooling is employed to avoid the formation of cracks on the slab surface. This cooling system is also intended to provide optimal results regardless of the shape and dimensions of the slab.
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SSS Technical services specialize in the integration of steel making, power generation, PC based measurement and automation applications like Power Plant Control Systems, Automatic Water Cooling Control, Argon Oxygen Decarburization, SSS-016 Immersion digital thermometer, molten metal CARBON & SILICON measurement & Monitoring system, SSS-019 is a rugged portable digital pyrometer planned specifically for use in the foundry environment, SSS Oxygen Activity Measurement System, Field alarm systems, SSS mV.Source is precision portable calibrating tool for Thermocouple instruments, Cubicle, Field Alarm Unit, Lance Assembly, Expendable Thermocouple Tips, Compensating Cable.
SSS Technical services specialize in the integration of steel making, power generation, PC based measurement and automation applications like Power Plant Control Systems, Automatic Water Cooling Control, Argon Oxygen Decarburization, SSS-016 Immersion digital thermometer, molten metal CARBON & SILICON measurement & Monitoring system, SSS-019 is a rugged portable digital pyrometer planned specifically for use in the foundry environment, SSS Oxygen Activity Measurement System, Field alarm systems, SSS mV.Source is precision portable calibrating tool for Thermocouple instruments, Cubicle, Field Alarm Unit, Lance Assembly, Expendable Thermocouple Tips, Compensating Cable.
 
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