Torpedo Ladle Management System and LAN Functional Specification Document for BSP.

Introduction: The Torpedo Ladle Management System (TLMS), LAN and associated sub systems are being implemented in SAIL Bhilai Steel Plant (BSP). The system incorporates design of the process technology including preparation of flow sheet, operating norms and practices to design/ operate/ maintain the composite hot metal transportation system and individual equipment/ systems and sub systems thereof. The functional specification document addresses the requirements for the TLMS software as per the Contract technical specification for Hot metal handling system (PKG.- 031), Volume II (Part-A),and which has been given to M/s Associated Industrial Furnaces(P) ltd.(AIFL) Supply of hardware, civil ,mechanical and electrical requirements mentioned in the above mentioned document and at site and installation erection of the same is deemed out of scope for the proposed contract for the supply of the TLMS software ,between M/s Tata Steel Automation (TSA)and M/s AIFL. The same is delineated in the scope of work document attached as Annexure 1 of this document. Deliverables: TLMS Network and Network software Network design for fault tolerant self healing network, detailed BOM and assistance in vendor selection, preparation of RFP etc will be provided. Guidelines and documentation for execution of job on site as per acceptable technical standards will be provided. Subsequently during the commissioning of the network infrastructure by the vendor, TSA will provide detailed test parameters and benchmark standards to ensure that the deployed network infrastructure meets customer requirements in all aspects detailed in the contract. TSA will also assist M/s AIFL to develop, negotiate and deploy a maintenance contract with the network provider or any suitable party with commensurate Service Level Agreements to ensure the uptime of the whole system is maintained at a level desired/acceptable to the customer(BSL) at optimum cost. The contract will detail the various services, manpower, tools and spares requirements for the desired uptime and service level agreement with metrics to administer the contract and evaluate vendor performance on a regular basis. Networking Software Networking software will be detailed after further discussion with the BSP and AIFL during project engineering and detailed design stages of project.

Application software for TLMS.: The system software will consist of configurable, parameterized and user friendly, software with a Relational Data base management system in oracle at the backend. The software will be based on Tier III architecture and will have several web enabled screens (typically MIS (Management Information System) and reporting screens).Other MMI(Man machine Interfaces) will be stand alone clients as per contractual requirements for security and auditing purpose. The main software being used to develop the system are as below: i)Database The system will be developed using the latest release of Oracle and SQL versions available at the time of purchase .. ii)Graphical User Interfaces(GUI) The Screens (MMI/MIS) will be developed will be developed on the latest release of Visual Studio .Net package at the time of purchase. Some of the screens will be available to the common users on Internet Explorer over the LAN (Local Area Network), while restricted screens (password protected) will be deployed as packages at various locations (to be finalized at the time of detailed engineering of the system). Java or Ajax software may be used for some screens to show real time graphical trends and charts histograms et al. iii) Webserver software A Webserver required for the Tier III architecture , will be deployed on Microsoft IIS server . iv)RFID software Software to communicate with RFID systems will be developed on Visual Basic 6 or higher versions . v) Operating systems for all servers and clients will be Microsoft Windows XP SP 3 Professional versions for clients and Microsoft Windows Server 2003/2008 Server Enterprise version. General System Architecture : The RFID polling system will keep track of the various RFID readers deployed on site, track health of the RFID tags mounted on the Torpedo ladles and obtain real time information of the torpedo ladles moving across the hot metal circuit. The data captured by this software will be instantly stored in the Oracle database of the TLMS server.

The data base will consists of table with data sets comprising of values such as RFID tag data with time, various locations, various level -1 and level 2 inputs (from Mini PLCs and Thermal Imaging system),Inputs from Spout inspection systems, Level sensors from BOFs and refractory tracking systems and other maintenance data inputs as decided during the engineering design of the system. The data base will be further integrated to the Level 1 (M/s SVAI) and level 3 systems (ERP) of BSP Steel Plant for further data exchange with upstream /downstream systems as indicated in the figure below.

The database will be augmented with relational logic so that various other derived parameters such as Buffer status, Weight data, Fill status, ETA(Estimated Time of Arrival) at various waypoints, manual data entry from various locations and several operational / logical interlocks to be integrated in the system. The information stored in the database will be displayed on a variety of user screens and Interfaces which will be designed as per user requirement during detailed engineering stage. This information can be represented in the form of charts, graphs, histograms etc and can be exported in various formats such as MS Word or MS Excel spread sheets as per user requirements. There can be a total of 20 to 22 MMI screens, as per requirements defined in the contract specification document. This number can be reduced if required by the purchaser during the engineering and detailed design stages of project execution. Screens will be of three main types. MIS & Reporting screens (Some indicative examples below) i) Refractory Tracking system screens. ii).Thermal Imaging System interface screen iii)Torpedo Ladle Tracking screens. iv)Torpedo Ladle planning ,positioning annunciation screens. v)Torpedo ladle availability/history/throughput/ dumping /trends , statistical analysis ,reports on these and numerous other discrete performance indicators for the TLMS operations and maintenance teams.

These reports can be made available per Shift/Day/Week/Month/Year basis as per user requirements.

Manual Data Entry (MDE) screens (In these screens user intervention is required to enter data manually as per defined Standard operating procedure (SOP)). i) Torpedo position entry at TLC cooling station and TLC debricking area. ii) Torpedo Maintenance planning screens (2 nos). iii) Torpedo Location update screen. iv) MDE screens for updating data regarding Torpedo availability/utilization/service history/spout health/refractory health/operator performance/cast no/heat / hot metal weight /Dumping history information/temperature/chemistry and numerous other parameters which are to be updated manually on a regular basis for the optimal functioning of the TLMS system. v) Various Operator screens and Material tracking screens as defined in the contact. Configuration and Parameterization screens : These screens are user configurable and require one time configuration at the beginning .These screens are used if any system level changes occur .The configuration items are directly related to the database logic and these changes are done rarely. i) Operator User id and password ii) TLC fleet module (eg. when new TLC are added to fleet with same /different capacity) iii) Location modules (When new RFID readers may be installed or re-located or new source or destinations may be added to the hot metal circuit) etc. It is important to note that the required TLMS system as described in the contract is heavily operator dependant and on the timely entry of correct data by the operators .Any errors of omission /commission delays and negligence of the SOP provided with the system may result in inaccuracies and performance deterioration. System Interfaces