etap real time_steel plant

7/22/2019 ETAP Real Time_Steel Plant

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Typically located on a large compound and comprise ofvarious facilities, steel-working plants consume largeamount of supplies and services

The plant processing is sub-divided into the categoriesof Iron Making, Steel Making, and Rolling

A Steel plant is configured from tens of different types ofequipments, each of which is controlled independentlyby a control system.

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Centralized Monitoring and Control SolutionTo Ensure faster, reliable, economical and smooth operation

Optimized Generation ControlTo reduce energy loss and achieve maximum efficiency

Economical Dispatch of PowerTo reduce energy cost and increase equipment efficiency

Optimized Load SheddingPrevents Blackouts and Reduce negative effect on thefinancial, environmental and social performance of acompany

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New system can be added with the existing system, Thus,values initial implementation costCentralized Monitoring of entire system will reduce resourcecost as well as speed up decision making

Allow operators, engineers, and managers to make betterand more informed decisions in the critical aspects of theirbusiness

Advanced Monitoring provides intuitive, intelligent, and

integrated real-time monitoring via a state-of-the-art interfaceEnergy Accounting provides detailed energy consumptionand cost analysis. Reports are generated based on energytariffs and electrical power market exchange information.

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Simulation capability (with entire network) is used forOperator Training as well in Critical Decision MakingSimulation of the plant will be ended up with many otheradvantages such as checking the equipment adequacy (e.g.circuit breakers and relay coordination), tuning the controlstrategy (e.g. SVCs tuning up according to the condition ofoperation), adjustments of the circuit protection (e.g. under-voltage and under-frequency relays setting), and many

others.The need for simulation also increase during thereinforcement when even a small scope change in a plant(such as adding a motor) must be carefully judged


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Short-Term SavingsOptimal Supervisory ControlThis saving in energy cost is due to the overall systemoptimization and power loss reductions. Savings may beconsiderably for systems that have abnormal losses,circulation power, and/or energy cost penalties.Mid- to Long-Term SavingsOptimal Supervisory Control

This can be a major reduction in the equipment capitalizationcost by increasing equipment lifetime. This saving is achievedby continuously operating at a near-to-optimal condition andhence preventing possible overloads and under/over-voltagesituations.


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Optimized load preservation The critical loads in a Steel Plant include Furnace and Mills.These machines are very large and are the backbone of the

entire process. Due to disturbances at the supply, if thesemachines are shed, it typically takes hours to bring them backin operation. ETAP ILS monitors the entire system collectivelyand knows the status of every individual load and the amountof loading. It uses this knowledge to reprioritize the load

shedding list dynamically such that all critical loads are beingpreserved under foreseen or unforeseen circumstances witha lot of commercial saving (saves on production, time andresource cost losses).

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Eliminate unnecessary load sheddingProvides Commercial benefit by improving reliability andavailability of the process

Reduction of spinning reserve requirementsBy reducing the amount of required spinning reserve, thesavings on the fuel cost and maintenance for the dieselgenerators paid for ETAP ILS in the first year aloneFast response to electrical & mechanical disturbances< 100 ms from the detection of the disturbanceRobust calculation methodSimultaneous calculations and validated calculations reducefalse tripping and downtime of system

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Operator alerts for marginal operating conditionsProvides Commercial benefit by providing vital informationabout the stability and availability of the system

Offline test and validation of load shedding response- Can test various scenarios upfront before deploying. Thus,improves reliability, decrease downtime, eliminate nuisancetripping, increase system availability- Open system, can add new possible disturbances and letthe program determine optimal shedable load and verifyresults. This reduces maintenance cost as well as enableoperator skill enhancement.


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Hyundai SteelWith Advanced system monitoring tool along withsystem stability analysis capabilities

With ETAP Power System to determine the appropriatesystem response to a variety of configurations, changes,and disturbances in the networkWith Intelligent Load Shedding to provide optimal fastload preservation based on actual operating condition ofthe system, including generation operating status,system stability, and load operating conditions & status


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Jinan Iron and Steel Group CorporationETAP interfaced with the plants existing SCADAMonitors & tracks energy usage & distribution

Determines and predicts the appropriate systemresponse to a variety of changes and fluctuations in theelectrical networkMonitors electrical and physical parameters, loading &generation levels, network topology, and control logicsDetermines the source of potential problems andrecommends corrective actions to avoid power systeminterruptions.

etap real time_steel plant

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