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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
GrafTech Cloud-Based Production Intelligence Generates Customers Savings
GrafTech Customer Conversations
Andy Messineo
ArchiTech™ Technical Development
Manager
27+ year in IT and Programming
Third year of FactoryTalk®
VantagePoint EMI
3
Introductions
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Corporate Overview
4
GrafTech International Ltd. (NYSE: GTI)
+125 Year Old Company
Headquartered in Independence, Ohio
Focus on Graphite & Carbon Material Sciences
Global Operations with +2000 Employees
Annual Revenues of +$1B (USD)
Operate Two Business Segments
– Industrial Materials
– Engineered Solutions
Company Profile Quick Facts
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Electric Arc Furnace and Graphite Electrodes
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© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Graphite Electrodes
Used in Scrap Recycling
No Melting Point
Electrical Conductor
Handles
10,000 F at
the Arc Tip
Electric Arc Furnace and Graphite Electrodes
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© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Electric Arc Furnace
Used in Scrap Recycling
Consumes Graphite Electrodes
60% of U.S. Steel
60% of U.S.
Steel is made
in Electric Arc
Furnaces
Crude Steel Production 1990 – 2018
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© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Operation Challenges for Steel Makers
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Translate & simplify
complex data into
bottom line results
Surface hidden
problems
and opportunities
Eliminate waste and
streamline production
flow
Reduce &
control
cost
Increase
productivity
Maintain
uninterrupted
production flow
Achieving Your Business Objectives
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
In-depth EAF analysis on-demand?
9
With arrival of ArchiTechTM System 4.0, we’re making it easier than ever to track and
manage your EAF operations data in one place
Features of 4.0 An improved design
ArchiTechTM navigation will be more
streamlined and user-friendly with
improved graphics and intuitive
controls.
More powerful tools
We’re introducing all new trending &
reporting tools. Information when you
need it, the way you want to see it for
informed decision making.
Customizable trends
You can make changes and publish
trends how you like or we’ll do it for
you---it’s all up to you.
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
ArchiTech™ System Server Based Alerts
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Examples of problems customers solved faster with ArchiTech™ System
• Regulation problems
• Bad water cooled cable
• Loss of furnace ground
• Five percent voltage drop
• Wrong power program loaded
• Loose rollers affecting regulation
• Single phasing and arc instability
• Electrical phase sequence
reversed
• LMF Electrodes being dipped for
an entire heat
Sometimes the problem found by the ArchiTechTM system ends up
being the proverbial “needle in a hay stack”
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
ArchiTech™ Predictive Maintenance Tools
11
T-Test
- Compare the averages of recent data to baseline data
- Equal variances, unequal sample sizes
Characteristic impedance increased on pit phase. Regulator responds by decreasing arc resistance (lower
voltage). Electrical prior phase voltage increases.
Electrical Balance: Secondary Circuit
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
12
ArchiTech™ Predictive Maintenance Tools
Electrical Balance: Regulator Reference
F-Test
- Determine if standard deviation of two populations are equal
- Compare variance of recent data to baseline data
- F is ratio of baseline variance to recent variance.
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
What if you could solve EAF problems faster?
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© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Small, self-contained, scalable, easy to
install and backed up by expert CTS
Size of bread
basket and
very durable
What if you could solve EAF problems faster?
24/7/365 advanced high-speed EAF
diagnostic, analysis and reporting system
Monitors Energy, Power
and Power Quality
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
14
Connects to metering VT’s and CT’s
Minimum of 32 samples per cycle
True RMS measurements
Harmonic distortion
Revenue accuracy
What if you could solve EAF problems faster?
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Developed to compliment and
backup existing supervisory systems
Easy to scale and customize
More than 10 years of software
development in the product
Now on ArchiTechTM System 4.0
PLC data & Communications
Chemical, mechanical, auxiliary signals
Configurable web tools and CSV files
Master and subservient protocols
Serial and Ethernet integration
Email or direct connection
15
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
ArchiTech™ 4.0
Data Collection
Microsoft SQL Database • MS SMTP server for data collection
• Custom parser software to insert data into database
ArchiTechTM Hardware • Collects data and sends to server
via Email message
16
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Legacy System
ArchiTech™ 4.0
Microsoft Windows Server • Microsoft IIS
• Non-Encrypted data connection to client
• Microsoft SQL Database
• Microsoft SMTP server for data collection
• ASP.net web site with Customer Login
• On-Site at GrafTech Data Center
Client • Microsoft IE 8 or greater
17
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Current Server Design
ArchiTech™ 4.0
Microsoft Active Directory • Used for portal login and
security on the portal items
Microsoft Active Directory Backup • Used as a backup security server
• Contains custom tools for adding users and
customers
Microsoft SQL Database • All furnace data
• All portal data
• SQL Reporting data
• MS SMTP server for data collection
FactoryTalk VantagePoint • Microsoft IIS
• Microsoft Reporting Services
• SQL Reporting data
• SSL encrypted data connection to client
Client • Microsoft IE 8 or greater
• Microsoft .NET 4.0 or greater
18
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
ArchiTech™ Predictive Maintenance Tools
Why is the System Hosted in the ‘Cloud’
• 100+ Worldwide Installations
• 24 hour availability
• Reliable high speed Internet
connection
• 24 hour monitoring
• Managed backups
• Scalability
19
ArchiTech™ on FactoryTalk VantagePoint
Customer Dashboard
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
20
ArchiTech™ on FactoryTalk VantagePoint
Today’s Heats
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
21
ArchiTech™ on FactoryTalk VantagePoint
Heat Trace
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
22
ArchiTech™ on FactoryTalk VantagePoint
Heat Trace (cont.)
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
23
1. Sudden drop in
hydraulic pressure
2. Power off
3. Rise in hydraulic pressure
ArchiTech™ on FactoryTalk VantagePoint
Hydraulic Pressure Trend
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
24
ArchiTech™ on FactoryTalk VantagePoint
Alert Statistics
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
25
ArchiTech™ on FactoryTalk VantagePoint
Multi-Furnace Comparison
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
26
ArchiTech™ on FactoryTalk VantagePoint
Furnace Properties
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
27
ArchiTech™ on FactoryTalk VantagePoint
ArchiTech™ Toolbox
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
Visual Basic Application
– Adds New Furnaces to Database
– Creates Furnace in VantagePoint
– Adds all data Tags to VantagePoint
– Secures the Customer, Location, &
Furnace in Vantage Point
– Create VantagePoint Users
– Adds Menu Item for the Furnace in
VantagePoint
– Creates Private Folder for Report
Storage in VantagePoint
28
ArchiTech™ on Factory Talk VantagePoint
System Evaluation and Selection
© 2015 GrafTech International Holdings Inc. All Rights Reserved.
2 Portal Systems Reviewed
– SAP
– Rockwell Automation®
Requirements
– Database Source of Microsoft SQL
– Highly Customizable Portal Layout
– Login Security
– Static Live Charts
– Dynamic Live Charts
– Excel Reporting
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
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Thank you!!
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We care what you think!
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