Techniques for the Successful Commissioning and Tuning of Level 2 Models

摘要

A successful Level 2 model commissioning is determined by the performance improvement in the measured deliverables and the time required to reach this performance, while incurring minimal impact on productivity. Commissioning a new model to these standards is no longer considered exceptional or out of the ordinary but is the norm expected by today's customer. This paper discusses techniques used to successfully commission and tune Level 2 models and control functions. These techniques include first principle-based simulation, either on a discrete piece basis for the models or on a real-time basis for the in-bar control functions, the replaying of captured real-world I/O in a software mill simulator, a realistic and thorough factory acceptance test, and the real-time shadowing of live inputs with the full automation system. Once the models are commissioned, analytical, and statistical methods using large sets of historical data are used to optimize performance and to develop and test new models and control strategies. Finally, concepts are presented detailing how software design facilitates the implementation of these techniques in a manner that both minimizes maintenance and maximizes portability to future computing platforms. Examples are provided from the recent commissioning of new Roughing Mill, Finish Mill, Shape, and Coiling Temperature models at the ISG-Mittal Cleveland 84" Hot Strip Mill.