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Scope of SupplyProfile Mill Fingerprint

Advanced Service Offering

Customer : Scope of SupplyProject: : of 9Product : Profile Mill fingerprint ABB ref.:Customer Ref.: Dated.

Contents

1. Service Description........................................................................................................31.1 Life Cycle Index.......................................................................................................31.2 Technical Audit........................................................................................................41.3 Key Features...........................................................................................................4

2. Scope of Supply.............................................................................................................52.1 Life Cycle Index.......................................................................................................52.2 Technical Audit........................................................................................................52.3 Data Collection........................................................................................................7

3. Deliverables - Fingerprint Report...................................................................................84. Customer Benefits..........................................................................................................85. General Conditions.........................................................................................................8


1. Service Description

Profile Mill fingerprint is an audit service for profile or long products rolling mills in metal

industries, such as bar mill, wire rod mill etc. The fingerprint service includes a complete

life cycle audit for installed equipment coupled with detailed process and control

performance audit of the mill. The audit, thus, establishes the current mill performance,

compare it with industry benchmarks and recommend the improvement plan with

associated quantitative or qualitative benefits, as applicable.

The service offering has two modules as described below

1.1Life Cycle IndexLife Cycle Index is a very efficient method of measuring and recording the effectiveness

of the plant automation, drives, motors etc. across their entire lifecycle. Taking a

lifecycle approach to hardware or software effectiveness gives a more accurate view of

total cost, productivity and investment protection. ABB’s Lifecycle Index helps

customers sustain and in many cases increase performance of their process control

systems permanently. To achieve results like this, companies need to go beyond the

regular maintenance cycles, and keep their control system regularly optimized and

adjusted to the facility it serves. This is exactly Lifecycle Index service does. The index

generates process and equipment profiles that form the foundation for ways to optimize

the productivity and future performance of the plant. E.g., the profiles include the overall

lifecycle strategy, control level, network controller, I/O, prevention, and emergency, as

depicted in Figure 1 below.

Life Cycle Strategy

Functionality

PersonnelPreventiveStrategy

EmergencyStrategy

0%

50%

100%

Figure 1: Life Cycle Index for Mill Automation


1.2 Technical AuditThe fingerprint study includes a detailed technical analysis of various section of the mill

covering from the exit of reheat furnace to the downstream equipment. The technical

analysis is done using historical process data and state-of-the-art statistical algorithms

to evaluate the current performance of the mill. The analysis evaluates the performance

of drive control, looper control, mill pacing time, shear, pinch rolls, water box control etc.

The analysis of individual sections in turn generates the Key Performance measures for

overall mill indicating current performance and the gaps to improve in terms of energy,

productivity, quality, yield and mill availability.

Figure 2: Modules covered during technical audit

1.3 Key FeaturesSome key features of the profile mill fingerprint service are - Life Cycle assessment of drive and automation equipment

Detailed quantitative performance assessment for control and process variables

of different sections of the mill

Process performance benchmarking ensures tuning of plant control system

efficiently, benchmarked to industry best practices.

Detailed improvement plan with potential impact on mill energy consumption,

productivity, yield, and availability.


2. Scope of Supply

Profile Mill fingerprint is an offline audit service to assess the current life cycle status of

installed equipment and mill performance .The outputs

and recommendations from the Life Cycle Index depend on the information collected

from designated mill personnel during the visit. The output and recommendations from

the technical audit module of the service is applicable for the mill operation conditions

(production speed, mill setup and configuration, product grade) and time period for

which the historical data is collected.

2.1Life Cycle IndexThe scope of Life Cycle Index module include the following areas –

a) Motors and Drives

b) Automation

c) Level 2

d) Technology

Each of the above mentioned areas include sub-categories such as maintenance

strategy, functionality, preventive strategy etc., as depicted in figure 1. Life Cycle Index

is an on-site investigation based on a pre-defined questionnaire set asked during the

interaction with designated plant personnel.

2.2 Technical AuditThe technical audit module of the fingerprint services uses the historical mill data

collected during the site visit for a fixed production speed, mill setup and configuration

and product grade. It analyses the process data with state-of-the-art statistical

algorithms to evaluate the process and control performance of the mill. The

performance is quantified with Key Performance Indices (KPIs) for different sections of

the mill, which may include –

a) Inter-stand Control (Looper, Tension, R-factor) – It analyses Inter-stand control

parameters, as looper performance, MTC performance, R Factor variation etc.

b) Motor & Drives – this section evaluates the performance of drives on the

parameters as speed response, impact drop, torque profile etc.

c) Tracking – This section focuses on tracking performances based on HMD

signals, torque signal of nearby stands etc.

d) Water box control – This section analyses the temperature control performance

of the water box


e) Shear performance – This section analyses includes cut cycle and tracking

repeatability of the shear

f) Pinch roll – This section analyses torque and speed profile of the pinch roll

during the rolling to find out whether it grips the material properly

g) Input Billet Temperature Profile – It analyses the temperature profile of the

billets coming out of reheat furnace, and evaluate potential for thermal energy

savings.

h) Mill Pace time analysis – Furnace pace time, mill pace time, downstream

equipment pace time analysis is done to reveal the potential (based on

bottleneck analysis) for improving the productivity by operating close to optimal

pace time.

i) Mill Speed Analysis – Mill speed analysis can be done to identify the potential of

increasing the production speed by utilizing the design capacity of motors with

same R-factor for each stand.

j) Quantitative Assessment of overall mill performance – This section relates the

sectional KPIs calculated in modules above and calculates the overall mill

performance measures such as rolling energy consumption, productivity, yield

and quality impact, wherever applicable.

Figure 3: Snapshot for torque analysis summary for all stands


Figure 4: Illustration for shear performance analysis

Each of the sections, mentioned above, for technical audit quantifies the performance

by calculating pre-defined sectional KPIs. E.g. torque data analysis is done for large

number of billets for every rolling stand, the output of which is presented in the plot

depicted in figure 3. Figure 3 allows us to get the entire mill snapshot w.r.t. torque

performance for all stands. Figure 3 shows high number of peaks for stand 7 which can

further be analysed for possible reasons. Apart from such mill snapshots, histograms

indicating the statistical performance for a KPI are also included in the report as

illustrated in figure 4.

2.3 Data CollectionThe technical audit needs collection of pre-defined set of data. IBA data or any other

reliable data logger output in ‘text’ or ‘excel’ format can be used for the technical

analysis. Besides IBA data, the technical audit requires other mill information and data

such as, but not limited to –

a) Mill configuration – Number of stands, number of loopers, number of HMDs,

number of loopers and their distance relative to the reheat furnace outlet.

b) Furnace discharge pace time and downstream equipment productivity

c) Furnace energy rate

d) Motor and Roll Data – maximum rpm, gear ratio and roll diameter for each stand

Customer : Scope of Supply

Project: : of 9Product : Profile Mill fingerprint ABB ref.:Customer Ref.: Dated.

e) Shear related data – shear blade diameter, gear ratio for shear motor etc

f) Other set points, mill set up data or threshold values either from level -1, level-2

or manual interaction

3. Deliverables - Fingerprint Report

The deliverable of the fingerprint is a report which contains the following information –

a) Life cycle index and recommendations for life cycle management. Figure 1

shows the results of one such life cycle index which will further be appended

with recommendations with relevant implications of the proposed life cycle

implementation plan by the expert.

b) The report for technical audit module includes calculated process and control

performance indices depicted with snapshots as in figure 3 and figure 4. The

report also includes the expert analysis by comparing and correlating different

statistical measures among sections (modules). The analysis concludes with the

potential root cause of the control or process performance issues indicated by

the audit tool, along with the quantification of potential benefits by correcting

those issues, as applicable.

4. Customer Benefits

The fingerprint study helps the customer getting better insight into control and process

performance of their mill and provides further benefits as described below.

Improvement plan provides clear path to quickly resolve the performance gaps

highlighting potential quantitative benefits

Facilitates management decision process by focusing on high impact opportunities

for improvement.

Provides a solid foundation for life cycle management for various equipment &

systems in Profile Mills

5. General Conditions

a) Under this contract ABB agrees to provide fingerprint service for the agreed bar

and rod mill line installed in customer’s plant.

Customer : Scope of Supply

Project: : of 9Product : Profile Mill fingerprint ABB ref.:Customer Ref.: Dated.

b) The fingerprint outputs are valid only for the mill operation conditions (production

speed, mill setup and configuration, product grade) prevalent during the time for

which historical data is collected.

c) The historical data is collected usually for 3-4 days and the study outputs are valid

only for similar mill operation (production speed, mill setup and configuration,

product grade).

d) Travel expenses to be borne, at actuals, by the customer. Minimum 2 site visits are

required to the site, one for data collection (2-4 days) and another for results

presentation (1-2 days)

e) Customer has to provide all the data required by ABB to do the service. The quality

of the fingerprint output depends on the quality and amount of data provided.

However, ABB will maintain the confidentiality of the data that is provided to ABB

f) The fingerprint is an offline service with report including recommendations as a

deliverable. No hardware or software will be delivered to the customer.

g) Implementation of the recommendations or improvement plan in the fingerprint

report is not part of this service, but to be considered outside the scope of this

service.

project - abb group · web viewscope of supply project: : page 2 of 9 product : profile mill...

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