Torpedo Ladle Tracking SystemObjective:
Efficient coordination of torpedo ladles for serving Hot Metal “capacity buffers” for the Blast Furnaces and “feed buffers” for the Steel Making Shops
Improved KPIs:
Efficient & optimum management of hot metal movement
Generic Yard Management SystemObjective:
Solution for smart Material Handling
Features:
Easy to use human machine interface for real time visibility of all yard activities
Hand held terminal for the operator to perform field verification and server communication
Interfaces with business planning systems, process lines and crane automation systems
Centralised database to manage all activities from receipt to dispatch of materials
Benefits:
Real- time visibility and tracking of inventory and shipment
Reduced material handling time
Streamlining work order management to reduce vehicle loading, unloading, and waiting time
Prioritisation of transportation as per business needs
Online reports on crane performance, yard inventory execution time and VIVO time
Handheld terminals for the operator for communication with server
Smart SolutionsObjective:
It helps enable devices on the network, data streaming, data analysis, MIS reports/exceptions, & control/enhance business operations
Process Flow:
Smart Devices >> Cloud Search >> Web Applications
Connected WorkforceObjective: Smart solution for identification & tracking of manpower deployed inside plants
The Solution has 4 critical components – Lora Wan, BLE Beacons, Android / IOS Mobile App & Cloud application
LoRaWAN Network – LoRa Network to be installed depending on the Plant/office coverage and reach [only if the solution is used in collaboration with SafePass Cards]
BLE Beacon – BLE Beacons to be installed across the plant/office demarking various Zones.
The BLE beacons will be configured as either:
» Entry Beacon – Demarking and indicating to the Mobile App that the worker is entering the plant/office
» Exit Beacon – Demarking and indicating to the Mobile App that the worker is exiting the plant/office
» Hazardous Beacon – Demarking a Hazardous area within the Plant / Office
» Safe Beacon – Demarking normal working zones within the plant / Office
Mobile App via Bluetooth capable of detecting the various beacons, collecting beacon information, and sending data, alerts via the internet as well generating user alerts via buzzer/vibration
Application to generate additional reports and alerts
Smart BarricadeObjective:
Remotely controlled smart access control systems deployable at any Process hazard areas
Features:
Works with all Employee/Contractor gate pass
Authentication via gate pass cell database over the cloud
Real-Time Access & control
MIS, Reports, Exceptions & Alarms
Benefits
Remotely controlled
Scalable
Traceability ONLINE
Smart Fleet Management SystemObjective:
E-Tracking and Optimization of mobile equipment
Key Functions:
GPS-enabled tracking of each fleet’s route
Live ETA at various stops
Data retrieval of passengers/occupants from Cloud
Health Status Alarm of RFID/GPS
MIS, Reports, Exceptions & Alarms
Benefits:
Enhanced Tracking and Optimization
UniLORD (Universal Lora wan Solutions)Objective:
Implementation of smart solutions under LoRaWAN network for effective operation and monitoring on real-time basis.
Application:
Spindle run time monitoring system
Digitised CO sensors
Smart energy meters
Anchor bolt monitoring
Smart sprinklers
Centralized Condition Monitoring SystemObjective:
The CCMS improves equipment reliability by automatically diagnosing and alerting equipment faults
Benefits:
Online condition monitoring of critical all across plants
Generates alarm/warning and SMS for maintenance
Standardisation of maintenance system
DC Motor Spark Monitoring SystemObjective:
Real-time monitoring of Sparks in DC motors
Improved KPIs:
Continuous monitoring in real-time
Machine Vision based, safe and non-intrusive methodology
Capable of detecting very short-lived sparks (~40 ms)
Enables proactive maintenance
Pipe Conveyor Monitoring SystemObjective:
An online system capable of measuring the Overlap & Sway of the Pipe conveyor is needed which can trigger the alarm for corrective action
Features & Benefits:
Online Pipe diameter,
Sway orientation
Overlap data for monitoring & control
Early warnings identify pre-mature failures
Belt adjustment can be done to maintain Blast Furnace burden
Track Rail Inspection System (Trains)Objective:
To develop an automatic Inspection system to measure multiple inspection parameters, and process and visualize rail track on the fly
Key features:
Motorized vehicle
Contact-free measurement
Continuous measurement
Track joint detection
Rail-road crossing detection
Local data storage
Geo-mapping of inspection data
Roll Shop Management SystemObjective:
The Roll Management monitors the usage of grooves, rolls, roll sets, roll modules and guide boxes in terms of the rolled tonnage and indicates when set limits are reached
Digital Features:
Application migrated to web-based
Backup and running rolls module
Roll shop inventory and production linking for all stands 1 to 16
NTM roll inventory and linking are in progress
Roll shop status module was deployed
Mill Chatter detection SystemObjective:
Chatter marks on coils generated in Cold Rolling Mill often lead to rejection and downgrade downstream. In absence of an online chatter detection system, chatter defects are not detected in real-time which may take upto some days of actual rolling. So, no corrective action can be taken immediately and material rolled with this defect is always exposed to chatter defects
Product Features:
Real-time Chatter Detection
Long Term vibration trend
FFT analysis of stand vibration
Coil Wise Chatter severity prediction
Daily MIS
Data download
Configurable as per requirement
V.Eye (An eye for crop optimization)Objective:
Real-time vision-based system for accurate computation of cut profile of the head and tail ends of Transfer Bar to reduce yield loss due to crop cut. The system also provides accurate speed measurement of the hot strips to assist precision cutting by crop shear
Principle of operation:
Imaging of the head & tail end of the transfer bar after the last pass of the roughing mill
Determination of the optimum shear lines
Downloading of the reference cut position to the shear control system
Accurate speed measurement & feedback to shear control system
Benefits:
Reduction in yield loss due to crop cut up to 0.1%
Reduction in average crop cut length up to 60%
Avoids cobbles in mills
Tru-SpanObjective:
Based on stereo photometry and triangulation principles, Tru- SPAN measures the hot/cold coil widths with immaculate precision. Powered by a line laser, the new generation Tru-SPAN is also capable of carrying out width compensation in presence of a moderate bow in the surface
Improved KPIs:
Yield loss
Downstream rejections
Surface Quality Inspection SystemObjective:
Discretion alarms are raised only for significant defects missing zero defects and resulting in accurate classification and revised gradation standards
Principle of operation:
Acquisition of images
Processing of the images
Detection of “flaws”
Segmentation into “objects of interest”
Classification of these images into defects, e.g. silvers, scratches, edge damage, holes etc.
Severity indication
Real time result display
Detection of defects upto size 1mm2
Modular & scalable architecture
Hole Detection System (HDS)Objective:
A precision vision machine that will not let go of any holes undetected. Built on image processing, sophisticated and efficient algorithms are used to detect holes on the fly. Salient features include triggering of Audio/Visual alarm, customized report generation, and advanced analysis of hole defects
Benefits:
Real-time detection of holes during rolling
100% coverage of sheet surface
Supports quality control & grading of sheets
Helps monitoring of the casting & rolling processes
Generates coil defects database to facilitate analysis
Archival of data
Smart Raking SystemObjective:
To facilitate the removal of slag optimally from molten iron
Solution:
IR camera differentiates steel and slag.
Imaging algorithm detects the endpoint of raking
Feature & Benefits:
Improved yield
Independent of human skill and experience
Slag Detection SystemObjective:
To avoid slag carryover into the ladle during tapping
Solution:
IR cameras differentiates between steel and slag based on their emissivity.
Imaging algorithm detects slag at the end of the tapping cycle
Feature & Benefits:
Cases of Phos Reversal go down.
To improve the quality of the steel
Opti BOF: SMS Level II SystemObjective:
Consistency in the end blow chemistry and temperature through different models which provides assistance in the planning of heats
Process Optimisation: Charge Balance, Alloying Calculation, Dynamic Calculation
Tracking: Hot Metal Ladles, Steel Ladles
Production Planning: Daily Schedule Receipt, Heat Planning, Transfer Of Process Data
Reduction in the standard deviation of turndown temperature
Reduction in reblows
Reduction in time consumption
Reduction in a variation of turn down phosphorous for a given grade
Standardization of operational practices
Slab Auto De-grader for SMSObjective:
An automated ML model with gradient boosting algorithm to determine the best possible alternate for unplanned transitions/degradation due to chemistry
Innovation:
Automated searching of the most suitable alternative in terms of Order availability, defect generation due to grade mixing (transition loss) and cost margin
A novel approach involving machine learning (Gradient Boosting Algorithm) and search optimization has been used
Pro-active correction of the unplanned outages via automated system-driven efficient decisions instead of manually dependent systems at early steelmaking stages
Benefits:Scrap Yard Management SystemObjective:
Auto scrap loading information system eliminates manual-based data logs of scrap charged in BOF and other manual practices coupled with autonomous scrap charging to improve overall productivity
Features & Benefits:
Completely automated scrap management system
Able to identify the requirement as per the work order received to charge the scrap
Complete interface with the level II system and identify the required scrap recipe
Camera Lidar system enables to generate a position reference for the crane system to operate
Casting Online Diagnostics system (Break out prediction system)Objective:
CODS continuously monitors the embedded thermocouple values in real time and generates early alarms to arrest potential sticker breakouts
UPS:
Gives a breakout ability factor
Improved KPIs:
Improved KPIs, 80% true/false sticker alarms
Slab Dimension Measurement SystemObjective:
To develop a system that comprehensively measures various casting parameters like Length, Width, Thickness, Bulging and Taper to provide real-time feedback to the operation about the casting quality
Previous Practice:
Length (Auto-Encoder based), Width (Manual), Thickness (Manual), Taper (None), Bulging (None)
New Initiative:
A hybrid of Machine Vision and Laser technology has been developed to measure Slab dimension
Features & Benefits:.
Efficient data analysis tools to analyze casting performance embedded in Level II
Breakout detection due to Taper Loss
Rhomboidity Measurement SystemObjective:
Real-time, precision vision machine for Rhomboidity measurement of Billets/Blooms to improve yield by a reduction in downstream rejects & reduce man-machine interface
Features & Benefits:
The system being real-time can measure each billet individually for Rhomboidity, giving an accurate value
Able to withstand high-temperature dust and harsh environments
Non-contact type system
COSMOS (Coke Oven Scheduling & Heating Monitoring System) – Coke Oven Level II SystemObjective:
Heating, scheduling & machine coordination in coke oven battery which leads to improved productivity, battery life, energy efficiency and quality of coke under reduced emission
Process:
Dynamic pushing schedule
Oven identification and machine coordination
Temperature visualization
Battery heating control model
MIS and data presentation
Data science-based models
KPI improves:
Energy saving of 6.09%
Standard deviation of Min 7.65 degree C° & max 18.14 degree C°
Online Flue Temperature Measurement of Coke OvensObjective: To eliminate manual measurement and provide an online temperature of each flue
Solution:
Using FO, radiation travels from each flue into a central station
A single Pyrometer multiplexes IR radiation to give the temperature of each channel
Benefits:
To get the online temperature of Flue
Input for the heating model
Eliminate manpower to measure
Tie Rod Load Cell Measurement in Coke OvensObjective: To provide Load changes that take place during different events of Oven operation
Solution: To install a high-temperature Loadcell on the tie rod
Benefits:
Cost reduced and safety improved as manual campaigns decreased
Predict oven health conditions
Improved Process Visualization
Tuyere EyeObjective: Visualizing the pulverized coal injection with analytics and eliminating manual observation of the tuyer platform
Solution:
Cameras are mounted on the tuyer peephole without compromising on human visibility
Live display of the PCI of all tuyers in the control room
Benefits:
Improved visibility of PCI for decision making
Analytics to aid in decision making and also analysis after-the-fact
Human Safety
Wireless Dip LanceObjective: Wireless enabled measurement of hot metal temperature at the cast house
Features & Benefits:
Easy to use & improved safety quotient at cast house
Improved ergonomics for operator
Provide BF (Process Visualization & Data Evaluation for Blast Furnace) : Blast Furnace Level – II SystemObjective: Visualisation, Simulation & Optimisation of BF processes which improve operational efficiency, furnace health and quality of hot metal
Auto Pelletizing DiscObjective: Develop an automated pellet size control system using Level II Automation System parameters to control the size distribution of green pellets
Result & Benefits:
Elimination of manual inspection of discs to identify discs producing reject and elimination of human judgement in size control
Effective control of reject and reduction of feed fluctuations to the induration machine
Implemented in all pelletizing disc (10 nos) of TSJ Jamshedpur
Auto Pellet TesterObjective: To provide a completely autonomous process of testing pellets without any delay in the process
Issues & Concerns:
Manual & cumbersome job
Time-consuming process
Benefits:
Fully autonomous process
Results in 1-minute
Real-time CCS testing
Overall high productivity
Grate ScanObjective: To develop an automated defect logging, tracking & positioning system for Pallet Cars thus enabling faster detection and maintenance of defective cars which lead to loss of pellets while transport
Automated system is required for
Individual car’s defects logging
Individual car tracking in chair
Auto positioning of the defective car
Key Features:
Defect logging
Pallet car tracking
Precise positioning of cars
Overall productivity improvement
Sinter Sizing EstimationObjective: Image-Analytics-based system to calculate the Sinter size distribution in real-time
Novelty: Using a CNN based Object detection + Instance segmentation model for estimating size distribution
Benefits:
Assessment of the sinter granulometry of sinter in real-time
Bad-sized Sinter diversion from BF line, minimizing the impact on Blast Furnace productivity
Sinter Plant Level II SystemObjective: A complete Level II system for process improvement and an overall increase in productivity at sinter plant through effective operation, management & visualization with analytical models
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and more recently with desktop publishing software like Aldus PageMaker including versions of Lorem Ipsum.
Lorem Ipsum is simply dummy text of the printing and typesetting industry. Lorem Ipsum has been the industry’s
standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a
type specimen book. It has survived not only five centuries, but also the leap into electronic typesetting, remaining
essentially unchanged. It was popularised in the 1960s with the release of Letraset sheets containing Lorem Ipsum passages,
and more recently with desktop publishing software like Aldus PageMaker including versions of Lorem Ipsum.