Typically located on a large compound and comprise of various facilities, steel-working plants consume large amount of supplies and

services The plant processing is sub-divided into the categories of Iron Making, Steel Making, and Rolling
A Steel plant is configured from tens of different types of equipments, each of which is controlled independently by a control system.
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The vast enterprise of supplying electrical energy in a Steel plant presents many engineering problems that provide the factory electrical engineers with a variety of challenges The challenges start from the beginning of the elementary phase of the planning/ reinforcement and continue during the operation of the plant.
Future changes in installed capacity brings many other problems, which are usually faced by electrical engineers and plant operators.

Maintain reliable, safe and secure power supply in the Plant Steel Plants are configured from many types of equipment Steel Plants operate 24 hours per day and downtime/ blackouts must be avoided in order to maintain stable operation

(One million dollar profit lost has been seen in a relatively small plant, due to one hour black out)

Equipment must be monitored continuously to ensure optimal performance and stability over time
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The extremely fast dynamic properties of the electrical process require quick response times of the order of milliseconds Reduction in overall production cost (i.e. reduced operational costs. Energy costs, environmental impact, resource cost, maintenance cost, etc) Lack of skilled resources/ high cost of training operators/ engineers

Centralized Monitoring and Control Solution To Ensure faster, reliable, economical and smooth operation Optimized Generation Control To reduce energy loss and achieve maximum efficiency Economical Dispatch of Power To reduce energy cost and increase equipment efficiency Optimized Load Shedding Prevents Blackouts and Reduce negative effect on the financial, environmental and social performance of a company contd

Prediction and Simulation of system abnormalities

Helps power engineers to overcome the said challenges

Operator and Engineer Training Simulator Reduced resource costs, availability of skilled resources, reduced training cost Solution Capable to utilize existing Hardware and Software (in case of reinforcement) Reduced system up gradation costs, infrastructure cost, faster ROI

New system can be added with the existing system, Thus, values initial implementation cost Centralized Monitoring of entire system will reduce resource cost as well as speed up decision making Allow operators, engineers, and managers to make better and more informed decisions in the critical aspects of their business Advanced Monitoring provides intuitive, intelligent, and integrated real-time monitoring via a state-of-the-art interface Energy Accounting provides detailed energy consumption and cost analysis. Reports are generated based on energy tariffs and electrical power market exchange information.
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Real-Time Simulation is a powerful set of analytical modules that allows the prediction of system behaviour in response to operator actions and events using real-time and archived data. Event Playback is especially useful for root cause and effect investigations, improvement of system operations, exploration of alternative actions, and replay of What If scenarios. Load Forecasting reliably predicts and trends system loading based on algorithms that adaptively correlate multiple input variables such as weather conditions as part of an accurate load forecast.

Simulation capability (with entire network) is used for Operator Training as well in Critical Decision Making Simulation of the plant will be ended up with many other advantages such as checking the equipment adequacy (e.g. circuit breakers and relay coordination), tuning the control strategy (e.g. SVCs tuning up according to the condition of operation), adjustments of the circuit protection (e.g. undervoltage and under-frequency relays setting), and many others. The need for simulation also increase during the reinforcement when even a small scope change in a plant (such as adding a motor) must be carefully judged

Reduce energy consumption, increase electrical system reliability, improve equipment utilization, predict system performance as well as optimize energy usage. Economic Dispatch allocates changing generation demand of a power system amongst controllable generator units to achieve optimum area economy. Reserve Management continuously monitors system operating capacity and dynamically calculates the system generation versus load forecast balance to ensure protection against contingency losses

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Short-Term Savings Optimal Supervisory Control This saving in energy cost is due to the overall system optimization and power loss reductions. Savings may be considerably for systems that have abnormal losses, circulation power, and/or energy cost penalties. Mid- to Long-Term Savings Optimal Supervisory Control This can be a major reduction in the equipment capitalization cost by increasing equipment lifetime. This saving is achieved by continuously operating at a near-to-optimal condition and hence preventing possible overloads and under/over-voltage situations.

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 these machines are shed, it typically takes hours to bring them back in operation. ETAP ILS monitors the entire system collectively and knows the status of every individual load and the amount of loading. It uses this knowledge to reprioritize the load shedding list dynamically such that all critical loads are being preserved under foreseen or unforeseen circumstances with a lot of commercial saving (saves on production, time and resource cost losses). contd

Eliminate unnecessary load shedding

Provides Commercial benefit by improving reliability and availability of the process

Reduction of spinning reserve requirements

By reducing the amount of required spinning reserve, the savings on the fuel cost and maintenance for the diesel generators paid for ETAP ILS in the first year alone

Fast response to electrical & mechanical disturbances

< 100 ms from the detection of the disturbance

Robust calculation method

Simultaneous calculations and validated calculations reduce false tripping and downtime of system contd

Operator alerts for marginal operating conditions

Provides Commercial benefit by providing vital information about 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 nuisance tripping, increase system availability - Open system, can add new possible disturbances and let the program determine optimal shedable load and verify results. This reduces maintenance cost as well as enable operator skill enhancement.

Hyundai Steel With Advanced system monitoring tool along with system stability analysis capabilities With ETAP Power System to determine the appropriate system response to a variety of configurations, changes, and disturbances in the network With Intelligent Load Shedding to provide optimal fast load preservation based on actual operating condition of the system, including generation operating status, system stability, and load operating conditions & status

Jinan Iron and Steel Group Corporation ETAP interfaced with the plants existing SCADA Monitors & tracks energy usage & distribution Determines and predicts the appropriate system response to a variety of changes and fluctuations in the electrical network Monitors electrical and physical parameters, loading & generation levels, network topology, and control logics Determines the source of potential problems and recommends corrective actions to avoid power system interruptions.