Laiwu Iron & Steel Group Co., Ltd. was established in January 1970. After 34 years of construction and development, it has now become a production system with converter steel and electric furnace steel, including mining, sintering, coking, ironmaking and steelmaking. Continuous casting, rolling materials and the corresponding power, transportation, machinery, Jian'an and other categories complete, advanced technology and equipment, with an annual output of 2.2 million tons of steel production capacity of large-scale integrated steel enterprises. Laiwu Iron and Steel Group is Laiwu Iron & Steel Group Co., Ltd. as its core enterprise, with asset linkage as its link, and integrates production, scientific research, circulation, finance, and service into one economic complex. It is mainly based on steel products and develops high-tech metallurgy. Diversified business, large-scale iron and steel enterprise groups that cross regional, cross-industry, cross-ownership, and multinational operations. By the end of 2002, the companyâ€™s total assets were 13.244 billion yuan, and the ownerâ€™s equity was 3.383 billion yuan, forming a fixed asset value of 9.732 billion yuan and a net value of 6.708 billion yuan.
Although the Automation Department of Laiwu Steel Group has basically realized basic automation and process automation, these automated systems are based on unit production equipment as the core for testing and control. The production equipments are independent of each other, lack of information resources sharing and production process. Unified management, it is difficult to adapt to the requirements of modern steel production. Therefore, the automation department of Laiwu Steel Group decided to implement the real-time production information management system of Laiwu Steel Automation Department (also called the remote maintenance system of the Ministry of Automation of Laiwu Steel). The entire system is centered on the automation department, and each workshop is implemented in phases. At present, the iron district workshop system has been put into operation last year; the steel district workshop is under project implementation and is expected to start production in August this year. The entire project includes Beijing Dongfang Dingchen Technology Co., Ltd. for system design and technical support; the Ministry of Automation of Laiwu Steel is responsible for the implementation of specific projects.
The Automation Department of Laiwu Iron and Steel Group consists of four production workshops in the iron section, steel section, special steel and large H section steel. The control systems of various production workshops and teams are very complicated and mutually independent, and the scope of maintenance tasks is wide. Tasks can not be shared between teams and teams, and between workshops and management departments. The relevant personnel of production and management cannot grasp the real-time production information of various production processes in time. And due to the large and complex control system of the Automation Department of Laiwu Steel, the maintenance tasks are very heavy. Therefore, how to quickly improve the overall maintenance of the strength and level of each team, and effectively improve the quality of maintenance to ensure the smooth operation of the various production lines is necessary. The establishment of a real-time production information management system centered on GE's Proficy Historian can facilitate the remote monitoring and maintenance of all production line automation systems, make more rational use of the technical resources of workshops and teams, and realize the sharing of technical resources of each team. It is of great strategic importance and extremely practical application value to rapidly improve the overall maintenance level, reduce the failure rate, and ensure the smooth operation of the production line. It also creates a good basic platform for Laigangâ€™s future ERP and MES establishment.
The system architecture is based on the fiber optic backbone network platform of Laiwu Iron and Steel Group. It adopts a two-tier network structure separated from the control system layer and the management system layer. The control system layer connects the control networks of each production line under each shift and the management system layer is connected to Laiwu Steel. Backbone network; Real-time data at the production site is transmitted to the real-time production database through the control system layer communication, and is saved as historical data as needed. The real-time historical production database is used to release information to the backbone network through the management system layer communication, and remote users are linked to the backbone network. The client implements remote monitoring and remote maintenance. In addition, in order to ensure network security, necessary network security measures are adopted to ensure the stable operation of the automation systems at the production site.
The control system layer and the management system layer connect the network through the GE Proficy Historian real-time history database platform and the GE Proficy Realtime Information Portal real-time data analysis and web publishing platform. The control system layer collects real-time production information data into the iHistorian database through standard OPC, iFIX/FIX, and file interfaces.
The real-time production information management system structure diagram of Laiwu Steel Automation Department:
Beijing Dongfang Dingchen Technology Co., Ltd. developed a bottom-up layered system solution for production lines, teams, workshops, and management departments based on the status of Laiwu Steel's automation system. According to different levels of requirements, the powerful functions of the GE system software iHistorian, Realtime Information Portal, and iFIX have been successfully used.
Each control system of the production line (DCS/PLC) is the data source of the real-time historical database iHistotian. Through iHistorian's powerful data acquisition interface, most of the control system's data can be collected into iHistotian's real-time history database, including OPC collector, XML/text collector. For older control systems, data acquisition can be accomplished by adding the GE Proficy iFIX interface station and then using the iFIX data collector. In addition, some relevant test data and manual test data have also been successfully accessed in the real-time history database.
Each team consists of different production line control systems. Set up the GE Proficy iHistorian and Realtime Information Portal servers in the team to complete the data collection and data analysis of the production line. And finally through the company backbone network, will be on-site real-time data, monitoring screens, trend curves, alarms, all kinds of data analysis reports released to the workshop and management departments.
The workshop consists of different teams. The workshop and management department complete the monitoring, management, and maintenance of production status through the thin client applications of GE Proficy iHistorian and Realtime Information Portal.
Significance of the Project The project was implemented in phases. The Laiwu Steel District System has been put into practical operation for nearly a year, and the system has been operating stably. It provides comprehensive real-time data information, analysis results and analysis reports for the production managers of the Railway District and Automation Department. The steel area system has been further improved on the basis of the iron area practice, adding more production process requirements. Laiwu Steel's production and management personnel believe that Laigang's production management will be further improved after the steel zone system is put into operation. And plans to fully implement this system in the workshop belonging to the Automation Department. Prepare for Laigang's future MES system.