1. Background

Today there is any hardly any segment of society left untouched with the influence and impact of Information Technology. It acquires more urgency and importance to understand and apply the application of I.T. in the most important core industry i.e. STEEL.

India is endowed with the adequate supply of main raw material of steel making that is Iron ore. So much so that India is exporting iron ore in large quantity to steel manufacturers all over the world. It is no wonder that steel manufacturers in Japan and South Korea and many other countries even after importing raw material from India are able to produce steel at a cheaper rate. Though Indian steel manufacturers have realized the importance of IT, quite early but the application of IT in the process of steel making in India begun as late as in 90ies. Unlike SAIL, many other foreign steel manufacturers have used IT even much earlier.

The present article describes the application of IT in SAIL. Steel Authority of India(SAIL) is India’s largest (40% share) and one of the world’s leading steel producers with a turnover of around 20,000 Crores. SAIL has four integrated steel plants at Bhilai, Durgapur, Rourkela and Bokaro having a total capacity of over 11 Million Tones of crude steel. Three plants at Salem, Durgapur and Bhadravati produce stainless and alloy steels. A subsidiary at Burnpur produces heavy structure and another at Chandrapur is a bulk producer of alloy steels. SAIL has 1,40.000 employees on its roll.

2. Classification of IT Applications in SAIL

· Plant based applications

· Commercial Applications in the areas of Employees, Materials, Maintenance, Finance, Production Planning & Control, Quality Control, Marketing (Sales Invoice, Shipping etc.)

· Process Applications

§ Shop floor Information Systems

§ Process Control and Regulation Applications

· Marketing based applications

o Order booking and processing

o Stockyard inventory management

o Export order processing

o Branch office automation

· Corporate level applications

o Employees

o Centralised procurement

o MIS

3. Evolution

1969+decade

The computerization in SAIL begun in 1969 with the computerized payroll and accounting on IBM 1401 at Durgapur Steel Plant. The next ten years saw the installation of Burroughs mainframe computers in other three integrated steel plants. The applications developed in-house by a dedicated EDP department were again mainly Pay Roll (Wages, Incentives etc.) and Accounting (Finance, Materials etc.).

1980+decade

Entering 80ies with the development of powerful minis and micros, even small steel plants and other units of SAIL could afford to buy and develop applications on such computers..

· In 1985-86, SAIL also set up a centralized IT department in its corporate office to give greater thrust to the introduction of IT.

· SAIL also planned and begun introducing IT its Central Marketing Organisation (CMO) in late 80ies to provide customer satisfaction. CMO has more than 50 branches, stockyards and offices located all over the country.

1990+decade

The modernization of steel plants beginning in early 90ies brought the whose change in its process of steel manufacturing and also brought a quantum change in the automation and computerization at the plants. It was not only the process but SAIL computerized many commercial applications ranging from Production Planning and control at plants to its now customer centric marketing division. It was the first PSU to introduce email and home page (www.sail.co.in) in 1994. It sets up its VSATs based Intranet which provided 64KBps connectivity to all its sales branches to its plants and marketing offices. Its mines and other offices continued to be on the NICNET.The dispatch information from the plants are generally available in the stockyards before the material arrives. The information of availability of the material in its various branches/stockyards is available ONLINE.

2000+decade

SAIL has been a pioneer in this decade to set up a e-marketplace web site called metaljunction.com where last year materials worth 700 crores were transacted. It included purchases also by SAIL and TISCO through reverse auction. The metal junction has also been selling steel through forward auction and plan to do it for other allied materials like Ferro alloys. SAIL has been now actively considering the extension of application of Computers to stay competitive for the long time.

4. Plant based applications

4.1 Process Applications

The Process Automation concept in the steel industry is as old as the process itself. At the beginning, the plant processes were supervised and controlled manually. Subsequently the technological development in industrial process, change from batch to continuous processes and the increasing trend towards larger plant to take advantage of economies of scale led to the development of better instrumentation & control system. Initially the main objectives of automation system design were improvement of the process control and to make the production system run as automatic as possible.

In the earlier days the process plants were controlled and supervised manually with local measurements of the process parameters with operating personnel near to the process line itself. The subsequent development in process sensors and controllers contributed to the gradual up gradation in plant automation. The trend continued and led to centralized plant control and supervision.

With the development of electronic instrumentation, use of the standard compatible sensors, transducers, controllers, actuators etc. during 1960’s, the modular structuring of plant automation system became a reality. The modular concept could be optimally adapted to each functional requirement offering advantages such as –

- Separation of functions for better dedicated control

- Easy trouble shooting and better maintenance

- Low inventory of spares

Today with the use of modern automation components the system capability has increased manifold. The increase in system capacities is the result of further development in the areas of –

- Microprocessor chip technology, computer architectures and communication technology.

The process automation system in a plant is characterized by :

- An open system architecture

- A distributed functional area

- A real time operating system, and Standard language programming

The aim of any process automation system in a metallurgical industry is to optimize the materials input & energy utilistion, and control the process in such a way that the customer’s demand for product quality is met each time and every time. The system has also to contribute towards humanization of work place and take care of environmental aspects of the process. In the competitive market scenario the process automation has become indispensable due to growing customer demand for better product quality with closer tolerances. The need of the day is for total commitment to customer satisfaction irrespective of their geographical location.

4.1.1 Automation approach : -

o Bottom-up approach, is characterized by first removal of bottlenecks on measurement and control area in the existing plant and then step by step extend to complete automation, without total plant shutdown.

o Top-down approach, which is normally adapted for new plant/new unit, where the system is designed and implemented from the start.

A recent trend is “Integrated plant automation” wherein computer based system interconnects process control, supervisory and monitoring computers and production planning computers. In such cases the automation aims are enlarged to encompass activities starting from order scheduling to transparent processing and upto just in time delivery.

4.1.2 System architecture

The system architecture has been developed based on hierarchical control philosophy with modular structure. The automation functions have been distributed over different levels such as –

Level-0- The process

Level-1- Direct process control level

Level-2- Plant supervision with process optimization level

Level-3- Production planning & control

Level-4- Plant management

The hierarchical automation functions being carried out at various levels are depicted at Annexure I. Some of the process automation applications in SAIL are given at Annexure-II. The details of a typical process application at DSP, SAIL is given at Annexure-III.

4.2 Business and other applications at Plants

4.2.1 COMPUTER MANAGED MAINTENANCE SYSTEM

· Steel production outfits are essentially maintenance oriented. Productivity is directly related to availability of plants & machinery. One or the other plant is always under capital repair.

· No. of items required for maintenance annually run into 200-300 thousands. Captive repair shops are dedicated. Expenditure on maintenance at integrated plant typically runs into Rs.400-500 crores per annum.

· Information tracking & monitoring required and make or buy decisions required.

OBJECTIVES

· Improvement in productino equipment availability by minimum 5%.

· Reduction in spare parts & material inventory by minimum 7%.

· Incrased productivity/throughput of captive repair shops by minimum 10%.

MODULES

The CMMS consists of 3+1 modules as detailed below:

1. Preventive maintenance sub-system.

· To improve equipment inspections & recordings.

· To improve equipment availability by reducing breakdowns thru systematic maintenance planning.

· To improve information availability for maintenance planning activities.

· To improve maintenance documentation & history records.

2. Engineering shops sub-system

· To improve capacity utilization of engineering ships in all projects

· To improve planning & forecasting of job completion date.

· To reduce manual document preparation of technical cards, job tickets etc.

3. Material requirement planning sub-system

· To generate ship purchase indent on computer

· To reduce internal lead time

· To monitor purchase clearance placement of order & receipt of goods

· To exercise budgetary control of procurement

· To make available on-line status of items for stock consumption pattern & purchases dues in.

· To help in make and buy decisions.

4. Condition based monitoring system [CBMS]

· To introduce CBMS in critical areas and integrate the CBMS on-line with preventive maintenance sub-system.

· To link above sub-system with the integrated CMMS decision support system to provide:

- Total information system

- Analysis for make & buy decision

- Provide linkages with other import substitution, budget & forecasting modules.

UNDP sponsored project CMMS helped SAIL to develop a common application for its integrated steel plants to develop a database for the spare-parts. The development was done on COBOL in early 90ies which was later also converted on Ingress RDBMS.

4.2.2 Other Plant based computerized applications

- Computerized Material Management System

- Production Planning and Controls

- Sales invoicing and Accounting

- Personnel. Pay roll, Financial Accounting, Marketing (direct from plants),Transport,

4.2.3 Plant Networks

BSP,Bhilai has 3 ATM switches (155MB) along with 100 MB Ether net(5) switches to interlink plants computers. DSP,Durgapur has a Fiber ring (FDDI) with bridges to interconnect. RSP, Rourkella has a number of 100 MB Ethernet switches to interconnect.

5. Marketing based applications

CMO (Central Marketing Organisation) begun first in 1990 ies the computerization of its branch operation like booking of order, delivery from stockyard, its accounting and employees payroll through in-house Cobol based development on mini computers. It also developed a distributed database system for its inventory system. The databases developed on Oracle have been connected through SAIL’s intranet called SAILNET.

CMO has recently begun in-house the re-engineering of its applications on three-tier architecture using Web Technology with Centralised Database for its order booking and fulfillment. Such application shall also have accessibility to its key customers through Internet to monitor the progress of fulfillment of its orders.

CMO has also been working to provide uniform interface of its various modules to computerized applications at Plants. The classification of various computerized applications in CMO is available at Annexure IV.

Each of 43 branches and a few stockyards and other offices are having networked (10 MB) PC based computer systems. Software development center for marketing applications is located at Hyderabad .This center also operates a centrallised web enabled servers for Order booking by all branches. Each of CMO’s branches & offices are Wide Area Networked mainly through 64 KBPS VSATs and at a few places through ISDN and dial up times. SAIL’s intranet called SAILNET is also connected to all its plants, units and corporate office.

ANNUEXURE-I

PLANTS(S)

MANAGEMENT

LEVEL 4

PRODUCTION

SCHEDULING

& CONTROL

LEVEL 3

PLANT SUPERVISORY CONTROL

LEVEL 2

DIRECT

PROCESS CONRROL

LEVEL 1

AUTOMATION FUNCTINOS OF SYSTEM LEVELS

ANNEXURE-III

PROCESS CONTROL IN BOF STEEL MAKING

The Basic Oxygen Furnace of Durgapur Steel Plant is provided with PROCESS CONTROL COMPUTERS to achieve the target bath chemistry and temperature before tapping. The total process during a heat is controlled through four different levels of control system in a hierarchical way.Top priority in BOF steel making is to have the accurate information at the right time.

HARDWARE & Hierarchy of Different Levels

There are basically four different levels of automation and Process control. The controlling strategy is applied in a hierarchical way i.e. an upper level controls the lower level.

Level-0 : Field Equipment.

Field equipments like flow transmitters, level indicators, limit switches, valves, temperature sensors, motors, MCC's, drive systems etc come under this level. They take actual measurements/action and the values are passed on to Level-1.

Level-1 : Basic Automation System

This is designed as state-of-the-art control and instrumentation system. This is the basic Automation level which controls the Level-0 directly. Field equipments are connected to Level-1 system to the input/output cards through termination unit. Level-1 system gets the signals from field in the Input Output(I/O) cards .

In BOF shop, there is a Level -1 Super loop consisting of twisted pair cable. From the Super loop PCU, WSA and VAX - computers are connected .22 Process Control Units (PCU) form the backbone of the Level-1 Automation System. In Level-1 Bailey PCUs' are used, which can take analog as well as digital signals as input and after processing can give analog as well as digital output signals. A CIU(computer Interface Unit) connects to a Level II VAX system.

Level-2 : BOF and VAD Computer Systems.

Hardware:- There are 4 VAX 3300 Computers taking care of the calculations and feeding the set points to the Level-1 system.

Configuration : - 20 MB Memory, 2 x 170 MB H.Disks, Tape Drive – 296 MB

There is 1 MicroVAX 3100 Computer system in the Laboratory which is connected to the network directly to allow direct communication to all the systems.

Configuration : - 8 MB Memory, 80 MB H.Disks, Tape Drive – 96 MB

II

I

Level-3 : Steel Shop Computer(SSC) System.

This consists of Two(2) VAX 3800 systems which stores the total shop database and communicates with Level II and Level IV (PPC) systems.

Configuration : - 32 MB Memory, 2 x 400 MB H.Disks, 1 – 2GB Disk,Tape Drive – 296 MB

Functions of Level II Systems:-

Each computer runs the BOF application for the 3 Converters and one runs the VAD application. The computers are connected via a LAN and exchange data between them and the higher level using DECnet. These systems are designed to work independent of the Level-3 system.

The Level-2 systems are treating the heats according to the schedules given by the Level-3. They perform metallurgical Calculations and generate set points for important process parameters like -lance height, oxygen flow, oxygen consumption, charge balance, bulk material additions at different oxygen moments, alloying additions, vacuum treatment, stirring etc.The set points thus generated are downloaded to Level-1 after acknowledgement by the operator. The process values and actual values of materials discharged are received from Level-1 and after the heat is over, the data set for that heat are sent to the Level-3 system. Laboratory sends analysis to facilitate action by Blowers.

Functions of Level III Systems:-

One Computer is a hot system and the other is a hot stand-by. In the event of failure of the hot System, the Stand-by system which mainly caters to the P.P.C. data transfer, takes over automatically, without any intervention. This configuration is termed as VAX-Cluster. Uses are:

1. Ladle Tracking & Monitoring:

From the Ladle Dispatcher station, the operator places the Ladle for a particular heat. Also the placement position times and temperature entry provisions are there. If the Ladle number is not entered for a heat, next heat number does not get generated on the system.

2. Heat Tracking i.e. Status of heats all over the shop

The Status of the heat gets changed from time to time as the phase changes from Heat Start to Blow Start to Tap start and End. After that the status changes subject to operator entering Cast details.

3. Schedule preparation

Is done based on the order received from the P.P.C.S. and alteration/exchange is possible.

4. Steel Grade Definition

Can be defined for New grade and subsequently the same details are available at level – 2 Vax Systems for the Blower and other persons.

5. Sending Data to P.P.C. System Heat Data, Casting Data, Analysis of Steel, Hot Metal are sent from time to time and Steel Grade made is received from the P.P.C.S.

6. Database Maintenance storing 5 Years data

Data is stored on Oracle RDB as well as MS Access

Functions of Level IV P.P.C.System:-

The system, as the name suggests the production, planning and control for the total plant. It maintains a plant wide data-base and communicates with all the other computer systems in the plant using a Fiber Optic backbone network. The orders received are downloaded to Level-3 system via the plant wide network. It encompasses various modules like:

· Data Warehousing and Shipping

· Production Planning

· Quality Assurance Module

· Manufacturing Module

INFORMATION FLOW BETWEEN DIFF. LEVELS AT S.M.S., D.S.P.

Level 1 to Level 2 Level 2 to Level 1

·        Schedule data

·        Actual grades of Casts from Laboratory L4 terminal

·        Heat Number

·        Teeming/CCP cast data

·        Heat Data

·        Steel/H.Metal/Slag Analysis data

·        Backlog details of the above, if any

·        Schedule/Plan for the day

·        Ladle details

·        Grade Specification/definitions

·        Actual Steel grades

·        Heat Number

·        Heat Status

·        Heat Data

·        Steel / Hot Metal/Slag Analysis

·        CCP/LTS , Teeming Data

·        Scrap Yd/Mixer Data

L3

Teeming Reports

Heat Reports Graphic Printouts

Level 2

Level 2 to Level 3 Level 3 to

Level 3

Level 3 to Level 4 Level 4 to

Query Reports

M.I.S. Reports

STRATEGY OF OPERATING MODES.

The System works mainly in four modes - COMPUTER, AUTOMATIC, SEMI-AUTOMATIC and MANUAL. The fifth mode, mainly local mode, is used only for maintenance purposes.

Computer Mode :

The computer does the calculations and the generated set points are down loaded to the Level-1. The blowing is done according to the blowing pattern. The BOF operator actions are limited to :

- Tilting of converter., Movement of skirt., Temporary correction in case of slopping., Temporary correction of main lance height., Temporary correction of oxygen flow.

Automatic Mode :

The computer does not send the set points to the Level-1. The calculations can be done on the computer and the calculated values can be entered on Level-1 manually. The BOF operator is using only the Level-1 equipment for controlling the blowing process. Mostly this mode is used.

Semi-Automatic Mode :

In this mode parts of the system are in Automatic Mode and part are in manual mode. This is used when some part of a particular system is malfunctioning.

Manual Mode :

In this case all operations of the individual drive systems are independent from any sequence interlocking. This mode is used only for special purposes. The mode is switched via the work stations only.

Local Mode :

In this case all operations of the individual drive systems are executed from local maintenance stations. The mode is switched on the local stations only.

The following calculations are performed at Level-2 at different points of time.

1. Process Aim Calculation.

2. Hot Metal and Scrap Ordering Calculation.

3. Main Blow Calculation.

4. Second Blow/Re-blow Calculation.

5. Ladle Alloying Calculation.

6. Feedback Calculation.

Process Aim Calculation :

The process cycle starts with Process Aim Calculation. The purpose of process aim calculation is to calculate the aim temperature and carbon content of steel bath. The calculation starts with aim analysis after tapping.

Hot Metal and Scrap Order Calculation :

Next, the ordering calculation is done. The purpose of the ordering calculation is to calculate the weight of the hot metal and scrap. The ordering calculation is carried out after the aims at the end of blow are known. The expected end point conditions in terms of steel composition and the necessary ladle additions are calculated. After checking by the operator the amount of hot metal and scrap are ordered.

Blowing Calculation :

The blowing calculation is done next. The purpose of the blowing calculation is to calculate the amount of bulk material additions, the expected steel composition and the temperature, all three belonging to the current process control practice.

The expected steel composition at end point and in the case of in-blow practice at the intermediate stop point is predicted. The expected slag weight and the composition at end point are also calculated.

Second Blow Calculation :

The second blow calculation has the purpose to calculate the amount of oxygen and the weight of coolant for the second blow period. From steel and slag composition from the current stop, if there is an oxygen advice, the expected values at the end of the next are calculated. The operator checks the advices and may change, if necessary, before sending the set points.

Re-blow Calculations :

The main purpose of this is to generate advices for oxygen and coolant for the re-blow. The calculation may also be used to fix the composition at the end re-blow. The re-blow is anon-schedule blowing period of the converter process. This is necessary when -temperature is low; carbon content is tooo high; phosphorous content is too high; slag is too viscous.

Tapping Calculation :

This is done to generate advices for ladle additions during tapping. The calculation will be carried out when the composition at the time of stop is available in the system. It is also possible to base this calculation on the quick tapping or direct tapping method. The operator checks all actual information regarding blowing periods at the end of blow.

Feedback Calculation :

The aim of feedback calculation is to calculate closing items of the heat and oxygen balance for both main and second blow calculation. The standard of the various relationships are updated with the values of the actual heat. These updated items must be used for the next heat. This feedback calculation is done after receiving steel sample analysis in the ladle. The model checks the data and relevant items are calculated. The presets are then updated. During a next call, the updates of these will be locked.

Conclusion:

The Role of Computers in Steel Melting Shop is of paramount importance, considering the low cycle time (1 Hour) of making Steel, which needs a quick system response and fast processing of information. The tasks, are accordingly, distributed across various levels of Automation, as an integrated approach. The Steel Making process relies heavily on availability of correct Information, in time and thus the Information Technology facilitates making of required grades of Steel.

ANNEXURE IV

CLASSIFICATION OF APPLICATION AREAS

Location/ Division	Class A	Class B	Class C
Branch Office & Stockyard	For Mild Steel: Demand Registration, Order Processing, Stock Accounting, Sales Accounting & Financial Accounting	Assets Accounting For Alloy Steel & Special Steel: Demand Registration, Order Processing, Stock Accounting & Sales Accounting	For Fertilizer & Chemicals: Stock Accounting and Sales Accounting
Regional Office	MIS
Head Office, Calcutta	MIS Products Planning Pricing	Financial Accounting and Payroll MIS for Alloy Steel & Special Steel Personnel Information Monitoring of Customer Complaints	MIS Fert. & Chem. Vigilance Information
Transport & Shipping		Monitoring of Import Shipments Monitoring of Claims MIS Branch Systems
Import and Export			Monitoring of Purchase Order
SRM’s Office	Interface with Steel Plants
Special Projects		Project Monitoring

Application areas falling in Class A are directly linked to the Branch operations. Focal points for all the activities of CMO are the Branch Offices. Automation at this level is necessary before an effective information system can be built up.

For effective implementation of the Branch System, it is necessary that the Products Planning function of CPPD, Pricing and Plant Interface Systems are also computerised. Hence these applications have been put in Class A.

ANNEXURE –II

SOME PROCESS AUTOMATION IN SAIL

S.No.	PLANT	SHOP	APPLICATION	COMPUTER SYSTEM
1.	RSP	RMH(Raw Material Handling System)	Wagon Tripler & Monitoring
2.	RSP	RMH	Belt Conveyor Control	PLC-NMI
3,	RSP	RMH	Shop floor MIS (Level 3)	VAX-3400
4.	RSP	Sintering Plant	Permeability & Moisture control and MIS	VAX-3100
5.	RSP	Coke Oven	Coal input handling	PLC(Allen Bradley)
6.	RSP	Coke Oven	Battery Scheduling	Toshiba Computers(DCS)
7.	RSP	Blast Furnace	Gate opening, Furnace charge, Locking, Slag Stagnation	PLCs(AB)
8.	RSP	Blast Furnace	Monitoring of process and guidance to operator	VAX-4100
9.	RSP	Steel Melting Shop(SMS)	Gate Feeding Control	PLCs
10.	RSP	Steel Melting Shop	Process Control	VAX-3300 VAX-3185
11.	RSP	Basic Oxygen Furnace (BOF)	Process Control	VAX-4100
12.	RSP	Soaking Pit, Blooming Mill, Hot Strip Mill	Shop floors MIS	PCs
13.	RSP	Hot Strip Mill	Reheating Furnace Control, Gauge Control, Coiler Control, MIS & Control	MICRO VAX-2, Siemens R-20, Siemens MMC-216, VAX 3185
14.	RSP	Cold Roll Mill(CRM)	Hood Annealing	PLCs
15.	RSP	Cold Roll Mill	Sheet Shearing	PLCs
16.	RSP	Energy Management	Generation, Load, MIS	HP-9000
17.	RSP	Traffic	To Weign Bridge	EC-Vnipower
18.	BSL	Sinter Plant(Including RMHS)	Process control + Shop floor MIS	MICRO VAX-II
19.	BSL	Blast Furnace	Process Controls like Burden calculations, Blowing Display guide etc. & MIS	Micro VAX-3400 (6 Nos.) With DECNET
20.	BSL	SMS	Process controls like Hot Metal tracking, Production scheduling, Mixer Management, etc.	HP-VX 9000/832
21.	BSL	Soaking Pit	Pit-heating control, Ingot tracking from Pit Side to soaking pits, cooling model etc.	Micro VAX-II
22.	BSL	CRM	Optimisation Modeling for mill set points, etc.	Siemens R 330
23.	BSL	Traffic Management	MIS	VAX-3400
24.	BSL	Coke Oven	Combustion Control	VAX-3400
25.	BSL	Concast at SMS	Modeling & MIS	DEC-2100 –3Nos.with Ethernet
26.	BSL	Hot Strip Mill	Mill parameters Controls set points, Calculation of finishing and tracking with slab yard etc. plus MIS	EC-alpha (3Nos.) with Ethernet