Electric arc furnace operator manual

Document Nr.
Revision
z AGHA STEEL INDUSTRIES PVT
AUTOMATION LTD DP0V8B-GD11-A8100-EB105 00
y
PAKISTAN
Job Contractual item DANIELI item

AP0V8BA0 D1
Title
Ac electric arc furnace

Operator manual
Level 1
Approvals
Remarks
00 27/12/2017 Issue ComarD ComarD PivottiR
Rev. Date Description Drawn Checked Approved

According to law Danieli Automation Spa considers this document to be a company secret and therefore prohibits any person to reproduce or disclose it in whole or part to third parties,
without specific written authorization of Danieli Automation Spa Management
Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 1/126 #2089265

Ac electric arc furnace - Operator manual - Level 1
yDANIELIAUTOMATION OPERATOR MANUAL 1
Table of contents
1 Overview 6
2 Main Control Pulpit 7
2.1 Main Control Desk ....................................................................................................................................8
2.1.1 Desk EAF Section 1 .................................................................................................................................8
2.1.2 Desk EAF Section 2 ...............................................................................................................................10
2.1.3 Desk Keyboards .....................................................................................................................................12
2.2 HMI .........................................................................................................................................................16
2.2.1 Keyboards...............................................................................................................................................17
2.2.2 Installation of HMI...................................................................................................................................17
2.2.3 Pages organization .................................................................................................................................18
2.2.4 Pages layout ...........................................................................................................................................18
2.2.5 All the HMI Bars......................................................................................................................................19
2.2.5.1 DownBar: Alarms & Messages...............................................................................................................19
2.2.5.2 The Icon Bar: the Menu Functional Icons...............................................................................................20
2.2.5.3 The UpperBar : Semaphore and “Ready to Operate” ............................................................................21
2.2.6 Login Function ........................................................................................................................................22
2.2.7 Common And Configurable Pages.........................................................................................................22
2.2.7.1 Command buttons ..................................................................................................................................22
2.2.7.2 Setup data entry .....................................................................................................................................24
2.2.8 Data Manager Window...........................................................................................................................24
2.2.9 Permissives Detail Window ....................................................................................................................25
2.2.10 Drive Detail Window ...............................................................................................................................26
2.2.11 HMI General Purpose Screens...............................................................................................................27
2.2.11.1 Startup Page...........................................................................................................................................28
2.2.11.2 Historical Trends: Menu..........................................................................................................................29
2.2.11.3 Historical Trends.....................................................................................................................................30
2.2.11.4 HMI System Menu Window ....................................................................................................................31
2.2.11.5 Network Diagnostic Page .......................................................................................................................32
2.2.11.6 HMIs Configuration Window...................................................................................................................33
2.2.11.7 UPS Power System Window ..................................................................................................................34
2.2.11.8 Messages Summary Page .....................................................................................................................35
2.2.11.9 Alarms Summary Page ..........................................................................................................................36
2.2.11.10 Alarms Filter Combo box........................................................................................................................38
2.2.12 HMI Pages..............................................................................................................................................39
2.2.12.1 EAF Area Screens..................................................................................................................................39
2.2.12.1.1 EAF Menu Bar ........................................................................................................................................40
2.2.12.1.2 EAF Overview Page ...............................................................................................................................41
2.2.12.1.3 EAF Main Cooling Water Page ..............................................................................................................42
2.2.12.1.4 EAF Shell Panels Cooling Page .............................................................................................................43
2.2.12.1.5 EAF Secondary Cooling Water Page .....................................................................................................44
2.2.12.1.6 EAF Hydraulic Unit Page ........................................................................................................................45
2.2.12.1.7 EAF Medium Voltage Page ....................................................................................................................46
2.2.12.1.8 EAF SVC Interface Page........................................................................................................................47
2.2.12.1.9 EAF SVC Cooling ...................................................................................................................................48
2.2.12.1.10 EAF Readay to Melt................................................................................................................................49
2.2.12.1.11 EAF Movements Page............................................................................................................................50
2.2.12.1.12 Electrodes Detail Window ......................................................................................................................51
2.2.12.1.13 Furnace Tilting Detail Window................................................................................................................52
2.2.12.1.14 Auto-Tapping Detail Window..................................................................................................................53
2.2.12.1.15 EBT and Walkaway Detail Window ........................................................................................................54
2.2.12.1.16 Grease Unit Detail Window ....................................................................................................................55
2.2.12.1.17 EAF Local Pulpits Window .....................................................................................................................56
2.2.12.1.18 EAF Thresholds Page ............................................................................................................................57
2.2.12.1.19 EAF_06_Setup3 .....................................................................................................................................58
2.2.12.1.20 EAF Thresholds Page 2 .........................................................................................................................59
2.2.12.1.21 EAF Tilting Curve Setup window ............................................................................................................60
2.2.12.1.22 EAF Commands Window .......................................................................................................................61

2.2.12.2 MORE Area Screens ..............................................................................................................................62

2.2.12.2.1 MORE Menu Bar ....................................................................................................................................63
2.2.12.2.2 MORE Overview Page ...........................................................................................................................64
2.2.12.2.3 MORE Utility page ..................................................................................................................................65
2.2.12.2.4 MORE Local Pulpits Window .................................................................................................................66
2.2.12.2.5 MORE Common Thresholds Page.........................................................................................................67
2.2.12.2.6 MORE Injectors Thresholds Page..........................................................................................................69
2.2.12.2.7 MORE Dispensers Thresholds Page .....................................................................................................70
2.2.12.2.8 MORE Injectors Setpoints Page.............................................................................................................72
2.2.12.2.9 MORE Dispensers Setpoints Page ........................................................................................................73
2.2.12.2.10 MORE Commands Window ...................................................................................................................74
2.2.12.2.11 Manual Setpoints Window......................................................................................................................77
2.2.12.2.12 Valves Trains - OxygenJet Pages .........................................................................................................79
2.2.12.2.13 Dispensers Pages ..................................................................................................................................80
2.2.12.2.14 Catfis Window ........................................................................................................................................82
2.2.12.3 ISAC Area Screens ................................................................................................................................83
2.2.12.3.1 ISAC Menu Bar.......................................................................................................................................84
2.2.12.3.2 ISAC Bins Charging Overview Page ......................................................................................................85
2.2.12.3.3 ISAC Bins Charging Overview Page ......................................................................................................86
2.2.12.3.4 ISAC Local Pulpits Window....................................................................................................................87
2.2.12.3.5 ISAC Thresholds Setup Page.................................................................................................................88
2.2.12.3.6 ISAC DRI Bins Inertization Page ............................................................................................................89
2.2.12.3.7 ISAC Bag Filter Page .............................................................................................................................90
2.2.12.3.8 ISAC Bins Charging Setup .....................................................................................................................91
2.2.12.3.9 ISAC Scrap Charging Setup...................................................................................................................92
2.2.12.3.10 ISAC Additives (Lime/Carbon) Recipe for EAF ......................................................................................93
2.2.12.3.11 ISAC Additives (Lime/Carbon) Recipe Setup for EAF............................................................................94
2.2.12.3.12 ISAC HBI/ DRI Recipe for EAF...............................................................................................................95
2.2.12.3.13 ISAC HBI/ DRI Recipe Setup for EAF ....................................................................................................96
2.2.12.3.14 ISAC Scrap Recipe for EAF ...................................................................................................................97
2.2.12.3.15 ISAC Scrap Recipe Setup for EAF .........................................................................................................98
3 Local Stations 99
3.1 =GD11E10PLC01– EAF_AUT ...............................................................................................................99
3.1.1 EAF Local Control Station GD11E10LCS02 ..........................................................................................99
3.1.2 EAF Hydraulic Unit Control Station GD11E10LCS03...........................................................................102
3.1.3 EAF Back-Up Movements 1 GD11E10LCS04 .....................................................................................104
3.1.4 EAF Back-Up Movements 2 GD11E10LCS05 .....................................................................................106
3.2 =GB11E10PLC01–ISAC_AUT .............................................................................................................108
3.2.1 RMH Charging Local Control Station GB11E10LCS11........................................................................108
3.2.2 RMH Normal Belt NBC01 & Dust Chain CHR01 Local Control Station GB11E10LCS12 ....................110
3.2.3 RMH Normal Belt NBC02 Local Control Station GB11E10LCS14 .......................................................111
3.2.4 RMH Reversible Shuttle Belt RSC01 Local Control Station GB11E10LCS15 .....................................112
3.2.5 RMH ISAC Charging Local Control Station GB11E10LCS16 ..............................................................114
3.2.6 RMH Weighing Belt 1÷2 Local Control Station GB11E10LCS21 .........................................................116
3.2.7 RMH Weighing Belt 3÷4 Local Control Station GB11E10LCS22 .........................................................118
3.2.8 RMH Elevator Belt EBC01 & Dust Chain CHR02 Local Control Station GB11E10LCS31...................120
3.2.9 RMH Weighing Belt 5 & Vibrating Extractor 3 Local Control Station GB11E10LCS32 ........................121
3.2.10 RMH Normal Belt Conveyor NBC03 Local Control Station GB11E10LCS33.......................................123
3.2.11 RMH Vibrating Conveyor & Rotating Channel Local Control Station GB11E10LCS34........................124

List of Figures
Fig. 1 Main control desk 7

Fig. 2 EAF main control desk (=GD11E10MCD01) 8
Fig. 3 EAF main control desk (=GD11E10MCD01) 10
Fig. 4 EAF automation main control desk (=GD11E10MCD01): keyboards S20-S21-S22 12
Fig. 5 EAF automation main control desk (=GD11E10MCD01): keyboards S23-S24-S25 14
Fig. 6 Main Pages 18
Fig. 7 Display Standard Layout 18
Fig. 8 Alarms & Messages bar 19
Fig. 9 Example of icons 20
Fig. 10 Example of icons: a typical Area Bar 20
Fig. 11 Upper bar 21
Fig. 12 Ready To Process icon 21
Fig. 13 Login window 22
Fig. 14 Data Manager window 24
Fig. 16 Drive detail window 26
Fig. 17 Startup Page 28
Fig. 18 Trend Menu 29
Fig. 19 Trends page 30
Fig. 20 HMI System Menu window 31
Fig. 21 Network Diagnostic 32
Fig. 22 HMIs Configuration Window 33
Fig. 24 Messages Summary 35
Fig. 25 Alarms Summary Page 36
Fig. 26 Alarms Filter combo box 38
Fig. 27 EAF menu bar 40
Fig. 28 EAF Plant main overview page 41
Fig. 29 EAF Main cooling water page 42
Fig. 30 EAF Shell Panels Cooling page 43
Fig. 31 EAF Secondary cooling water page 44
Fig. 32 EAF Hydraulic unit page 45
Fig. 33 EAF Medium voltage page 46
Fig. 34 EAF SVC 47
Fig. 35 EAF SVC Cooling 48
Fig. 36 EAF Furnace Breaker Permissives page 49
Fig. 37 EAF Movements page 50
Fig. 38 EAF Electrodes detail window 51
Fig. 39 Furnace Tilting detail window 52
Fig. 40 Furnace Tilting detail window 53
Fig. 41 EBT and Walkaway detail window 54
Fig. 42 Grease unit detail window 55
Fig. 43 EAF Local pulpits window 56
Fig. 44 EAF Thresholds page water cooling 57
Fig. 45 EAF Thresholds page water and fluids 58
Fig. 46 EAF Thresholds page Tilting 59
Fig. 47 EAF Tilting curve Setup window 60
Fig. 48 EAF Commands window 61
Fig. 49 MORE menu bar 63
Fig. 50 MORE Overview Page 64
Fig. 51 MORE Utility page 65
Fig. 52 MORE Local pulpits window 66
Fig. 53 MORE Alarms and Thresholds - Common page 67
Fig. 54 MORE Alarms and Thresholds - Injectors page 69
Fig. 55 MORE Alarms and Thresholds – Dispensers page 70
Fig. 56 MORE Setpoints - Injectors page 72
Fig. 57 MORE Dispensers Setpoints Page 73
Fig. 58 MORE Commands window 74
Fig. 59 MANUAL Setpoints window 77
Fig. 60 Valves Trains - OxygenJet 1 page 79

Fig. 61 Coal Dispenser 1 page 80

Fig. 62 Catfis window 82
Fig. 63 ISAC menu bar 84
Fig. 64 ISAC Bins Charging Overview Page 85
Fig. 65 ISAC Continuous Charging Overview Page 86
Fig. 66 ISAC Local pulpits window 87
Fig. 67 ISAC Thresholds page 88
Fig. 68 ISAC DRI Bins Inertization Page 89
Fig. 69 ISAC Bag Filter Page 90
Fig. 70 ISAC Bins Charging Setup 91
Fig. 71 ISAC Bins Charging Setup 92
Fig. 72 ISAC Additives (Lime/Carbon) Recipe for EAF 93
Fig. 73 ISAC Additives (Lime/Carbon) Recipe Setup for EAF 94
Fig. 74 ISAC HBI/ DRI Recipe for EAF 95
Fig. 75 ISAC HBI/ DRI Recipe Setup for EAF 96
Fig. 76 ISAC Scrap Recipe Recipe for EAF 97
Fig. 77 ISAC Scrap Recipe Setup for EAF 98
Fig. 78 EAF Local Control Station (=GD11E10LCS02) 99
Fig. 79 Hydraulic Unit Control Station GD11E10LCS03 102
Fig. 80 EAF Back-Up Movements 1 (=GD11E10LCS04) 104
Fig. 81 EAF Back-Up Movements 2 (=GD11E10LCS05) 106
Fig. 82 RMH Charging Local Control Station (GB11E10LCS11) 108
Fig. 83 RMH Normal Belt NBC01 & Dust Chain CHR01 Local Control Station (GB11E10LCS12) 110
Fig. 84 RMH Normal Belt NBC02 Local Control Station (GB11E10LCS14) 111
Fig. 85 RMH Reversible Shuttle Belt RSC01 (GB11E10LCS15) 112
Fig. 86 RMH ISAC Charging Local Control Station (GB11E10LCS16) 114
Fig. 87 RMH Weighing Belt 1÷2 Local Control Station (GB11E10LCS21) 116
Fig. 88 RMH Weighing Belt 3÷4 Local Control Station (GB11E10LCS22) 118
Fig. 89 RMH Elevator Belt EBC01 & Dust Chain CHR02 Local Control Station (GB11E10LCS31) 120
Fig. 90 RMH Weighing Belt WBC05 & Vibrating Extractor EVE03 Local Control Station
(GB11E10LCS32) 121
Fig. 91 RMH Normal Belt Conveyor NBC03 Local Control Station (GB11E10LCS33) 123
Fig. 92 RMH Vibrating Conveyor & Rotating Channel Local Control Station (GB11E10LCS34) 124

List of Tables
Tab. 1 Standard colors for alarms in Alarm Bar 19
Tab. 2 Standard colors for alarms in Alarm Summary Page 19

1 OVERVIEW
This manual describes the automation of the Electric Arc Furnace (EAF) Machine.
The manual is divided in two main sections:

! Section 1 is oriented to the “Main control station” operators
! Section 2 is oriented to the “Local control stations” operators
Section 1 describes:
! Main Control Desk commands
! HMI screens
Section 2 describes:
! Local Control Stations commands
! Operator Panels screens

2 MAIN CONTROL PULPIT

The main control desk is located directly in front of the operator and contains all the controls necessary
to manage the machine and process.
The operator assigned to the Main Control Desk performs the following activities:
! Prepare the machine
! Survey the machine during the process in order to guarantee its regular function
! React to any equipment fault in order to avoid operator injuries, avoid machine damages,
minimize production lost
! Report to the maintenance personnel any equipment malfunctionings and alarms
In order to control and survey the machine the operator must use:
1. Main Control Desk commands
2. Operator Assistant screens
3. HMI screens
The desk consists of a central section with direct hardwired buttons and Operator Assistant for
immediate action commands and of HMI for supervision and for slow reaction commands:
Fig. 1 Main control desk
The Main Control Desk commands are always enabled.

2.1 MAIN CONTROL DESK
2.1.1 DESK EAF SECTION 1
Fig. 2 EAF main control desk (=GD11E10MCD01)

Tags/objects
P1S1 MORE Emergency Pressing this push button the movements of
the modules will be stopped.
P1H1 MORE Emergency Stop The light is lit up when the MORE emergency
has been pressed.
P15 Functional Keyboard Keyboard: see below
P1S4 MORE Lance 1 control

2.1.2 DESK EAF SECTION 2
Fig. 3 EAF main control desk (=GD11E10MCD01)

Tags/objects
S01 General Emergency This is a “two positions latching twist release
operator” with key removable in any position.
Pressing this button the unit and all
movements will be stopped
S02 Emergency Reset The lamp is lit up when the emergency is
activated. Pressing the button the alarms are
reset.
S10 Movements Fast Stop Pressing this push button the unit and all
movements will be stopped.
S05 Furnace Mode Three positions switch used to select the
Maintenance-Clamps-Operative furnace mode (maintenance – clamps –
operative). A key is necessary to turn it.
S07 Furnace Breaker Two positions switch. When it is in ON position
Closing Enable ON-OFF the closing of the furnace breaker will be
enabled. A key is necessary to turn it.
S09 Furnace Tilting ON-OFF Two positions switch. When it is in ON position
the tilting of the furnace will be enabled. A key
is necessary to turn it.
S20 Functional Keyboard Keyboard: see below

2.1.3 DESK KEYBOARDS
Fig. 4 EAF automation main control desk (=GD11E10MCD01): keyboards S20-S21-S22
Buttons
Electrodes Automatic Regulation Pressing this button the automatic regulation of
1-2-3 electrodes will be activated.
The lamp is lit up when the regulation is in automatic
mode
Manual Regulation Pressing this button the manual regulation of electrodes
will be activated.
The lamp is lit up when the regulation is in manual mode
Lock Pressing the electrodes movements will be locked.
The lamp is lit up when the electrodes movement is
locked
Unlock Pressing the electrodes movements will be unlocked.
The lamp is lit up when the electrodes movement is
unlocked
Lift/Lower slow Pressing this button will lift or low all 3 electrodes with
slow speed.
Lift/Lower fast Pressing this button will lift or low all 3 electrodes with
high speed.
Electrode 1 Lock Pressing the electrode movements will be locked.
The lamp is lit up when the electrode movement is
locked
Unlock Pressing the electrode movements will be unlocked.
unlocked
Lift/Lower slow Pressing this button will lift or low electrode with slow
speed.
Lift/Lower fast Pressing this button will lift or low electrode with high
speed.
Clamps open Pressing this button will open electrode clamps
Clamps close Pressing this button will close electrode clamps
locked
unlocked
speed.
speed.


locked
unlocked
speed.
speed.
Electrical Tap charger incerase Pressing on this button will increase tap charger
references
Tap charger decrease Pressing on this button will decrease tap charger
Set current increase Pressing on this button will increase current
Set current decrease Pressing on this button will decrease current
El. Spray Spray Pressing this button will open/close spray valve on
Furnace electrodes
breaker
Reset Pressing this button will send Reset furnace breaker
Open Pressing this button will open furnace breaker
Close Pressing this button will close furnace breaker

Fig. 5 EAF automation main control desk (=GD11E10MCD01): keyboards S23-S24-S25
Buttons
Furnace Lift Pressing this button will lift furnace roof
roof
Lower Pressing this button will low furnace roof
Open Pressing this button will open (horizontal) furnace roof
Close Pressing this button will close (horizontal) furnace roof
Automatic opening Pressing this button will automaticly open furnace roof
Automatic closing Pressing this button will automaticly close furnace roof
Lock rotation Pressing this button will lock horizontal rotation
Unlock rotation Pressing this button will unlock horizontal rotation
Furnace Tilting enabling Pressing this button will enable/disable furnace tilting
movement
Lock movements Pressing this button will lock furnace movement
Unlock movements Pressing this button will unlock furnace movement
Tapping slow speed Pressing this button will move furnace to tapping
position with slow speed
Tapping high speed Pressing this button will move furnace to tapping
position with fast speed
Slagging slow speed Pressing this button will move furnace to slagging
position with slow speed
Slagging high speed Pressing this button will move furnace to slagging
position with fast speed
Slagging Slagging door open Pressing this button will open furnace slag door
door
Slagging door close Pressing this button will close furnace slag door
Bottom gas Argon ON-OFF Pressing this button will open /close argon delivery valve
Nitrogen ON-OFF Pressing this button will open /close nitrogen delivery
valve
Stirring line Start Pressing this button will start stirring on line 1
1
Gas flow increase Pressing this button will increase gas flow in stirring line
1
Gas flow decrease Pressing this button will decrease gas flow in stirring line
1
2
2
2
3

3
3

2.2 HMI
The HMI (Human Machine Interface) is an interface for the operator useful to control and supervise the
machine.
Each HMI pulpit is provided with keyboard and monitor. By means of the screen-terminal systems the
operator is able to:
! Watch to the plant status;
! Prepare the machine;
! Perform commands or activate operating sequences;
! Change process set-points;
! Manage the alarms (display, identify, print);
! Check the trend of the process main variables.

2.2.1 KEYBOARDS
If the HMI is provided with a keyboard, some of the most important screen pages can be directly
recalled without using the mouse:
Key Page
ESC Exit open page
F11 Messages summary
F12 Alarms summary
2.2.2 INSTALLATION OF HMI

For installation refer to the document “HMI Installation General Steps” that is provided in the
Documentation folder of HMI:
<application path> / Documents

2.2.3 PAGES ORGANIZATION

The available functions and data are displayed to the operator organized by dedicated screens (also
called “pages”).
Those pages are organized in such a way to operate a clear functional distinction.
The available pictures are organized with few main screens, which summarize all the machine
overview.
From each main picture, using specific icons in Overview Area it’s possible to access to each other
Main page; using functional icons in icons area it’s possible to access the common screens or specific
pages for the overview section from which they are called.
Main Overview Main Overview Main Overview

section #1 section #2 ... section #n
Fig. 6 Main Pages
2.2.4 PAGES LAYOUT

The standard layout of the pages is:
Page header (Upper Bar): Danieli - supplier logo, page title, Ready-To-Process icon, time and
date indication
Functional Icons area: icons of common and specific screens
Overview icons area: icons to call any other Main Overview pages (if any)
Picture/data area: Area dedicated to the page with data and pictures
Page bottom (Down Bar) : Alarms/Messages buttons-“last arisen area”, Debug and
Acknowledge buttons, Exit/Shutdown buttons, Help button
Fig. 7 Display Standard Layout

2.2.5 ALL THE HMI BARS
2.2.5.1 DownBar: Alarms & Messages
In this area alarms and messages are reported in the form of two lines in which last alarm occurred
and last message are shown.
Fig. 8 Alarms & Messages bar
Links:
Alarms Opens Alarm Summary Page
summary
Messages Opens Messages Summary Page
summary
Debug Opens Debug window, available for administrator level
Login Opens the Login window
Commands:
ACK Represented by a green V, it permits to acknowledge the alarm currently
shown in the alarm bar
SHUTDOWN Closes the application, only for administrator user
Alarms colors are in accord with the following summary tables:
Type of Alarm Description Foreground Color

Priority 3 (High) Must be acknowledged Red
Priority 2 (Medium) Must be acknowledged Yellow
Priority 1 (Low) Must be acknowledged White
All Alarms not active but not already Blue
acknowledged
Tab. 1 Standard colors for alarms in Alarm Bar
Type of Alarm Description Foreground Color

Priority 3 (High) Must be acknowledged Red
Priority 2 (Medium) Must be acknowledged Yellow
Priority 1 (Low) Must be acknowledged White
Priority 3 (High) Already acknowledged Dark grey
Priority 2 (Medium) Already acknowledged Dark grey
Priority 1 (Low) Already acknowledged Dark grey
All Alarms not active but not already Blue
acknowledged
Tab. 2 Standard colors for alarms in Alarm Summary Page

2.2.5.2 The Icon Bar: the Menu Functional Icons

These little pictures with functional indication allow the operator to jump in the new page containing
information and commands. You can access them by clicking the icon with a pointing device or by
using the keyboard. In this last case you have to select the desired icon using up/down arrow keys and
then press <Enter>.
Positioning the mouse pointer over each icon, after a few seconds a tip-text will appear. This tip-text
contains the name of the page or window that will be open pressing on it: it will automatically disappear
after some seconds from its showing or as soon as the mouse pointer is moved outside the icon area.
Fig. 9 Example of icons
If more than one PLC is supervised by the HMI, a second bar is provided, clicking on the last icon on
the right, i.e. the “Area Bar”. This bar contains the button links to all the available areas.
Fig. 10 Example of icons: a typical Area Bar

2.2.5.3 The UpperBar : Semaphore and “Ready to Operate”

In this bar the page title, date-time and the application version are available.
Fig. 11 Upper bar
Links:
Semaphore Opens the PREPARATION page (see below)
Danieli Logo Shows for a few seconds version and last update of the HMI
application (only for administrator)
The “Ready to Operate” information regards the possibility to proceed with the process and is
displayed using a colored icon. The meaning of the used colors is shown below.
RED: NOT READY
GREEN +YELLOW: WARNING
GREEN: READY
Fig. 12 Ready To Process icon
Clicking on Ready To Operate icon the Ready to Process / Plant Preparation page is displayed.

2.2.6 LOGIN FUNCTION

During application start-up the operator, through the mask shown in the figure, is requested to login,
i.e. to insert the ID and password.
Fig. 13 Login window
Once inserted ID and password, three effects are possible:

! Operator is requested to re-login because ID or password are not correct;
! Entering on the HMI is allowed as operator: only some commands and thresholds/setpoints can be
respectively performed and changed.
! Entering on the HMI is allowed as administrator: all commands and thresholds can be respectively
performed and changed.
2.2.7 COMMON AND CONFIGURABLE PAGES

In this chapter we will describe the most common features of HMI windows.
2.2.7.1 Command buttons

Usually the commands are located near the device to be controlled; they are drawn with a text or
symbol that helps the operator to identify the command that will be sent.
Clicking over a device the related command window will appear:

Clicking on the command button the CONFIRM window will be shown to let the operator decide
whether to confirm or abort the command (aborting is possible also by pressing ESC key on the
keyboard while confirming is possible by pressing ENTER key).

2.2.7.2 Setup data entry
To introduce numeric data click on field you want to modify (or press ENTER on highlighted field) and
then write the data using the keyboard numeric pad; once finished press ENTER to send data to PLC
or ESC to leave the previous value unchanged.
2.2.8 DATA MANAGER WINDOW

It is possible to save the selected setpoints or thresholds on hard disk and to recovery later these
settings if necessary. This is achievable by means of the Data Manager window, here described.
Fig. 14 Data Manager window
Characteristics of this window:

! One window such as this, is generally provided for each area or PLC (ex. EAF-RMH-FTP: 3
windows
! It is recalled by the button with the “floppy disk” icon. These buttons are generally placed directly
on the pages containing the data to be saved (i.e. threshold or setpoint pages, wire feeders,
additives overview…)
! Pressing SAVE button, the current values of the variable will be saved on a new recipe, whose
name is assigned by PLC. The recipe will be saved on the hard-disks of all the active HMIs.
! Pressing LOAD, after selected a recipe, the values contained on the recipe will be loaded on HMI
and sent to the PLC.
! Only administrator level users are enabled to access this window.
! The list of tags to be saved or loaded by this window is configured on the Access97 database
called “DataManager.mdb”, situated on the Setup folder of the HMI application. The list of tags is
contained on the table called “TAGS”. Please be careful on changing the data contained in order to
avoid any misfunctioning.
! The recipe data is contained on the same database, in the table called “DATA”. To reset the data
or to delete some recipes, it is possible to open this table and delete some or all the rows
contained on the table.

2.2.9 PERMISSIVES DETAIL WINDOW

It is shown after pressing the buttons near the device the permissives are related to. The button shows
a green “V” when all the permissives are OK, while it shows a red “X” when one or more permissives
are not satisfied on the whole. When an permissive is not satisfied the row where it is positioned will
become red and the text will become yellow. In normal conditions the text is dark gray over a lighter
gray background.
Fig. 15 Permissives detail window

2.2.10 DRIVE DETAIL WINDOW

It is shown after pressing the DRIVE button near the relative device. The button becomes red if there is
some fault on the drive.
TABLE: on the left side you can find the drive status, on the right the faults. Each row on the right is red
with yellow text when a fault is present. Dark gray text over a lighter gray background on normal
conditions.
Fig. 16 Drive detail window

2.2.11 HMI GENERAL PURPOSE SCREENS

Information on the screen is organized in many pages. Each page is related to a specific set of data
coming from or going to the plant.
In this section the description of the general screens is provided: these pages are common to all areas
and they change only slightly between a plant and the other (i.e. the plant name, or the menu bar).
These pages functions remain essentially unchanged.

2.2.11.1 Startup Page
Page name: 1CM_10_Startup

Description: It automatically appears after starting the WINCC application.
The “Startup page” contains customer’s name, date and version of the application,
displayed to the operator after the system start-up.
This page is automatically displayed at HMI startup and pass the control to the Menu
page requested by operator.
Fig. 17 Startup Page

2.2.11.2 Historical Trends: Menu
Page name: 0ST_90_AllTrend

Description: It is shown after pressing on the Trend icon.
The values of the most important variables for the melting process (flows,
temperatures, speed, levels, etc.) are continuously stored on the HMI hard disk.
The stored data depend on hard disk space of the HMIs (default 7 days). The
collecting frequency can be altered during system set-up.
From this page it is possible to access all the 16 trends: for each one the trend title is
provided together with the 8 variables tag names that are trended inside.
Fig. 18 Trend Menu
BOX LINKS
Trend X (*) Opens the Trend X page
(*) X is the trend number

2.2.11.3 Historical Trends
Page name: 0ST_90_Trend

Description: It is shown after pressing on the Trend icon.
The values of the most important variables for the melting process (flows,
temperatures, speed, levels, etc.) are continuously stored on the HMI hard disk.
The stored data depend on hard disk space of the HMIs (default 7 days). The
collecting frequency can be altered during system set-up.
From this page it is possible to access all the trends: for each one the trend title is
provided together with the variables that are trended inside.
Fig. 19 Trends page
Buttons:
Trend commands Commands are provided for zooming and moving through data,
pens and trends.

2.2.11.4 HMI System Menu Window
Page name: 0ST_02_Menu_HMISystem

Description: It is shown after pressing on the HMI System icon.
In this window the operator can choose to view the HMI Configuration, to log off the
system or shut down the HMI.
Fig. 20 HMI System Menu window

2.2.11.5 Network Diagnostic Page
Page name: 1CM_10_Network1

Description: It is shown after pressing on the Network icon
In this page the operator can see the status of the plant network.
Fig. 21 Network Diagnostic
TAB LINKS
Network 1 & 2 Opens the PLANT NETWORK pages
Devices:
RIO, … Clicking on each device, additional information such as the device
description is showed on the box on the high right corner of the window.
Devices:
RIO, … Clicking on each device, additional information such as the device
description is showed on the box on the high right corner of the window.

2.2.11.6 HMIs Configuration Window
Page name: 1CM_02_HMIConfiguration

Description: It is shown after pressing on the HMI system icon.
In this page the operator can set the HMI station number and the names of the HMIs
stations. Please note that these names are valid only for the HMI station in which
these values are set.
Fig. 22 HMIs Configuration Window
BUTTONS
Language Selects the current HMI language
Users and Users management
passwords
Edit Used to modify the interlocks texts for the HMI maintenance
permissives
Trends config import Used to export trend pens configuration
Trends config export Used to import trend pens configuration
Save Saves on file the current configuration
Reset Resets the configuration to the last saved file
BUTTONS
SAVE Accepts the values and refreshes the text files in which these values are
stored.
LOAD Retrieves the values from the text files in which these values are stored.

2.2.11.7 UPS Power System Window
Page name: 1CM_30_UPS

Description: It is shown after pressing on the UPS icon on Medium Voltage or network Diagnostic
page. In this page the operator can see the UPS systems.
Fig. 23 UPS Systems Window

2.2.11.8 Messages Summary Page
Page name: 0ST_92_MessagesSummary

Description: It is shown once pressed the related button in down bar.
The events summary page shows the events occurred during the plant running.
The list of messages may consist of many pages. In this case, it is possible to move
between all the pages using the scroll bar on the right side of the list.
Fig. 24 Messages Summary
Buttons:
Report and Printing Sends the displayed list of messages to the default printer

2.2.11.9 Alarms Summary Page
Page name: 0ST_91_AlarmsSummary

Description: It is shown once pressed the related button in down bar.
The alarm summary page is one of the most important pages of the HMI system. It
displays the alarms list and offers some alarm management commands. There are
three types of alarms being displayed: trip, warning and delayed alarms. The list of
alarms may consist of many pages. In this case, it is possible to move between all the
pages using the scroll bar on the right side of the list.
The color of alarms follows the standard explained at the beginning of this document.
Fig. 25 Alarms Summary Page
BUTTONS
DISPLAY To display all alarms, the acknowledged or the unacknowledged
ACNOWLEDGE To acknowledge all alarms, the displayed ones or only the selected
ones
Alarms History Opens the ALARMS AND EVENTS HISTYORY DISPLAY page
BUTTONS
DISPLAY To display all alarms, the acknowledged or the unacknowledged
ACNOWLEDGE To acknowledge all alarms, the displayed ones or only the selected
ones
Alarms History Opens the ALARMS AND EVENTS HISTYORY DISPLAY page

Buttons:
Change Area Opens the combo box used to change the displayed area alarms
All Alarms Acknowledge of all the alarms
Selected Acknowledge of only the selected alarms
Page Acknowledge of the current page alarms
All Displays all alarms
Ack Displays only acknowledged alarms
Unack Displays only unacknowledged alarms
Not Active Displays only no more active and not yet acknowledged alarms
Real-Time Displays the actual alarms
Historical Displays the alarms in historical mode
Screen Sends the displayed list of alarms to the default printer
All Sends the complete list of alarms to the default printer

2.2.11.10 Alarms Filter Combo box
Page name: 0ST_91_AlarmsSummary

Description: This window is opened clicking on “Area selection” combo box on alarms page.
Clicking each description in combo box the alarms for the relative area will be filtered
on the alarms summary display.
Fig. 26 Alarms Filter combo box

2.2.12 HMI PAGES

In this chapter the HMI screens of each area will be described.
2.2.12.1 EAF Area Screens
In this section the description of all the screens for the ELECTRIC AREA FURNACE plant is provided:
these pages are specifical to this area and in common have the icons bar, that will be described on the
next paragraph.

2.2.12.1.1 EAF Menu Bar
Page name: EAF_00_Bar

Description: This menu bar contains the more important icons used to navigate through this area
pages. It appears on top of all the pages.
Fig. 27 EAF menu bar
ICON LINKS
Trends Opens the TRENDS MENU page
Network Opens the plant NETWORK page
Cooling water Opens the COOLING WATER page
Hydraulic unit Opens the HYDRAULIC UNIT page
Medium Voltage Opens the MEDIUM VOLTAGE page
SVC Interface Opens the SVC page
Movements Opens the MOVEMENTS page
Commands Opens the COMMANDS window

Pulpits Opens the LOCAL PULPITS window
Thresholds Opens the THRESHOLDS page

2.2.12.1.2 EAF Overview Page
Page name: EAF_10_Over

Description: The page displays a general overview about the most important parts of the machine,
such as electrodes, furnace current position, medium voltage measures, sampling
equipment, main consumption.
Fig. 28 EAF Plant main overview page
LINKS
Electrode arms Opens MEDIUM VOLTAGE page
Primary measures box Opens MEDIUM VOLTAGE page
Arms support column Opens MOVEMENTS page
Shell Opens SHELL COOLING page
Furnace bottom Opens TAPPING STIRRING page
Permissives buttons Opens PERMISSIVES window for the device

2.2.12.1.3 EAF Main Cooling Water Page
Page name: EAF_13_WaterCool

Description: It is shown after pressing on the Cooling Water icon
In this page the operator can see the input and output flows and temperatures of the
cooling network, the status of the emergency circuit.
Fig. 29 EAF Main cooling water page

DEVICES LINKS
Valves Opens commands window for the relative valves.
BOX LINKS
Shell circuits Opens SHELL PANELS page
Electrical parts Opens SECONDARY COOLING page

2.2.12.1.4 EAF Shell Panels Cooling Page
Page name: EAF_13_WaterCoolShell

Description: It is shown after pressing on the Cooling Water icon
In this page the operator can see the shell, EBT and modules panels temperatures.
Fig. 30 EAF Shell Panels Cooling page

2.2.12.1.5 EAF Secondary Cooling Water Page
Page name: EAF_13_WaterCoolSec

Description: It is shown after pressing the Secondary Cooling device on the Cooling Water page.
In this page the operator can see the input and output flows and temperatures of the
cooling network for the secondary area.
Fig. 31 EAF Secondary cooling water page
BUTTONS
Valves I/O Sends the OPEN or CLOSE commands for the relative valves.

2.2.12.1.6 EAF Hydraulic Unit Page
Page name: EAF_12_HydrUnit

Description: It is shown after pressing on the Hydraulic icon.
In this page the operator can see all the information about the pumps, valves, levels
and pressures and he can perform the commands to control the unit.
Fig. 32 EAF Hydraulic unit page
BUTTONS
Start Sends the START HYDRAULIC UNIT command to PLC
Stop Sends the STOP HYDRAULIC UNIT command to PLC
DEVICES
Pumps Opens FORCED STAND-BY COMMAND window for the related pump
Permissive Opens the PERMISSIVES window for the related device
boxes

2.2.12.1.7 EAF Medium Voltage Page
Page name: EAF_30_MediumVoltage

Description: It is shown after pressing on the Medium Voltage icon.
In this page the operator can find the status of the MV equipment (medium cell, tap
changer, transformer, switches). There are also the current and average values for
MV measures.
Fig. 33 EAF Medium voltage page
BUTTONS
boxes

2.2.12.1.8 EAF SVC Interface Page
Page name: EAF_30_SVC_Interface

Description: It is shown after pressing on the SVC icon and then the Single Line Tab.
In this page the operator can find the status of the SVC equipment.
Fig. 34 EAF SVC

2.2.12.1.9 EAF SVC Cooling
Page name: EAF_30_SVC_Interface2

Description: It is shown after pressing on the SVC icon and then the cooling Tab.
In this page the operator can find the status of the SVC equipment.
Fig. 35 EAF SVC Cooling

2.2.12.1.10 EAF Readay to Melt
Page name: EAF_05_ReadyTo

Description: In this page all the permissives for the furnace breaker switch closing consent.
Fig. 36 EAF Furnace Breaker Permissives page
BUTTONS
RESET Sends the RESET command to PLC
ALL AREA DEVICES
Systems status Clicking on each one of the plant system status boxes on the right of the
screen, the alarms page will be open showing the alarms for the selected
area.

2.2.12.1.11 EAF Movements Page
Page name: EAF_20_Movement

Description: It is shown after pressing on the Movement icon located in the upper bar or the
columns supporting electrodes on the furnace drawing on the overview page.
This page displays status and data for electrodes, clamps, roof lifting, ladle position.
Fig. 37 EAF Movements page
BUTTONS
Permissives Opens the PERMISIVE window for the related device
ICON LINKS
Device Details Opens the DETAILS window for the related device
Grease unit Opens GREASE UNIT page
BUTTONS
boxes
BOX LINKS
Ladle Car Opens CARS SYSTEM MOVEMENTS window

2.2.12.1.12 Electrodes Detail Window
Page name: EAF_20_Movement_Electrodes

Description: It is shown after selecting the detail icon in the EAF movements page, in the
Electrodes data box.
Main data is already represented on the EAF movements overview. This detail window
offers permissives check for those represented data. It also displays general position,
commands and lock statuses.
Fig. 38 EAF Electrodes detail window
BUTTONS
START STARTS automatic cycle
STOP STOPS automatic cycle
Permissives boxes Opens the PERMISIVE window for the related device

2.2.12.1.13 Furnace Tilting Detail Window
Page name: EAF_20_Movement_Tilting

Description: It is shown after selecting the Tilting detail icon in the EAF movements page, on the
Furnace Tilting schematic side view layout box. Detail data of furnace tilting is
represented here with devices permission to move devices to positions.
Fig. 39 Furnace Tilting detail window
BUTTONS

2.2.12.1.14 Auto-Tapping Detail Window
Page name: EAF_20_Movement_AutoTapping.

Description: It is shown after selecting the Auto-Tapping icon in the EAF movements page, on the
Furnace Tilting schematic side view layout box. Detail data of automatic tilting cycle is
represented here with commands and permission for automatic tapping and zero level
cycles. The graph in the middle of the page displays the Cycle steps for tilting angle vs
ladle weight.
Fig. 40 Furnace Tilting detail window
BUTTONS
AUTO Enables AUTOMATIC cycle for zero level tapping
MANUAL Disables AUTOMATIC cycle for zero level tapping
CYCLE START Starts AUTOMATIC cycle for zero level tapping

2.2.12.1.15 EBT and Walkaway Detail Window
Page name: EAF_20_Movement_AutoTapping.

Description: It is shown after selecting the detail icon in the EAF movements page, on the EBT
data box. Detail data of EBT is represented here with permission for moving and
locking. The positions and moving are represented graphicaly on the pages right
under WALKWAY.
Fig. 41 EBT and Walkaway detail window
BUTTONS

2.2.12.1.16 Grease Unit Detail Window
Page name: EAF_12_Grease.

Description: It is shown after selecting the Grease unit detail icon in the EAF movements page,
under the GREASE UNIT data box. It displays all the information about grease
lubrication, with appropriate commands and permissives.
Fig. 42 Grease unit detail window
BUTTONS
AUTOMATIC Starts AUTOMATIC grease lubrication cycle
MANUAL Starts MANUAL lubrication commands, stops automatic cycle
STOP STOPS grease lubrication pump
LINE1/2 Sets Pump flow to Line 1
Sets Pump flow to Line 2

2.2.12.1.17 EAF Local Pulpits Window
Page name: EAF_08_Pulpit

Description: It is shown once pressed the Pulpits button located in the upper bar.
Here the operator can check for each pulpit the remote/local status, if emergency or
fast-stop buttons have been pressed and also if any alarm related to pulpits is active.
Fig. 43 EAF Local pulpits window
TAB LINKS
EAF Opens EAF Pulpits window
MORE Opens MORE Pulpits window

2.2.12.1.18 EAF Thresholds Page
Page name: EAF_06_Setup

Description: It is shown once pressed the Thresholds button located in the upper bar.
In this page the operator can check all the thresholds for the alarms of the entire plant.
The administrator is able even to change them.
Fig. 44 EAF Thresholds page water cooling
BUTTONS
Data Opens the DATA MANAGEMENT window
Management
TAB LINKS
Water Opens the WATER COOLING TRESHOLDS window
Fluids &water Opens the WATER and FLUIDS TRESHOLDS window
Tilting Opens the TILTING TRESHOLDS window

2.2.12.1.19 EAF_06_Setup3
Page name: EAF_06_Setup3

Fig. 45 EAF Thresholds page water and fluids

2.2.12.1.20 EAF Thresholds Page 2
Page name: EAF_06_Setup2

Description: It is shown once pressed the Tilting tabulator above setup data area.
In this page the operator can check the Tilting thresholds for the alarms of tilting
angles and weight. The administrator is able even to change them. It could be done
using the table icon on the right side of the setup data.
Fig. 46 EAF Thresholds page Tilting
BUTTONS
FORCE Selected data Table Request for automatic tilting
TABLE
Management
Graph Opens the graph window
TAB LINKS
Fluids Opens the FLUIDS TRESHOLDS window
Tilting Opens the TILTING TRESHOLDS window

2.2.12.1.21 EAF Tilting Curve Setup window
Page name: 0ST_01_GraphXYSetup

Description: It is shown after pressing the related icon on the right side of the Tilting Thresholds.
In this page the operator can set the tilting angle Angle by specific Weights using a
graph setup. New values must be send to PLC to take effect.
Fig. 47 EAF Tilting curve Setup window
BUTTONS
OK SEND TO PLC Sends the setup data table and command to the PLC
RESET LOAD PLC DATA Sends the COUNTERS ENABLE/RESET commands to PLC
ALL POINTS SET Move the all graph setup points up simultaneously

2.2.12.1.22 EAF Commands Window
Page name: EAF_07_Command

Description: It is shown after pressing the related icon on the upper bar.
In this page the operator can send the general commands to the PLC.
Fig. 48 EAF Commands window
BUTTONS
Horn enable/disable Sends the HORN ENABLE/DISABLE command to the PLC
Counters enable/reset Sends the COUNTERS ENABLE/RESET commands to the PLC
Machine prep. req. Sends the MACHINE PREPARATION REQUEST command to the
PLC
Profiles Sends the ELECTRICAL/AUXILIARIES/DISPENSERS IN
AUTOMATIC PROFILE commands to the PLC
Hydr.unit start/stop Sends the HYDRAULIC UNIT START/STOP commands to the PLC
Trafo cool. Start/stop Sends the TRAFO COOLING START/STOP command to the PLC
Postcombustion Sends the PREHEATING POSTCOMBUSTION BURNERS
burners ENABLE/DISABLE command to the PLC

2.2.12.2 MORE Area Screens

In this section the description of all the screens for the MORE PLANT is provided: these pages are
specifical to this area and in common have the icons bar, that will be described on the next paragraph.

2.2.12.2.1 MORE Menu Bar
Page name: 90-DANBar

Description: This menu bar contains the more important icons used to navigate
through this area pages. It appears on top of all the pages of this area.
Fig. 49 MORE menu bar
ICON LINKS
Trends menu Opens the TRENDS MENU page (the same of other areas)
HMI System Opens the HMI SYSTEM menu (the same of other areas)
Thresholds Opens the THRESHOLDS pages
Setpoints Opens the SETPOINTS pages
Commands Opens the COMMANDS window
Setpoints Opens the MANUAL SETPOINTS window
selection
Valves trains Opens the INJECTORS VALVE TRAINS pages
Dispensers Opens the COAL DISPENSER pages
Catfis Opens the CATFIS window
Change Area Opens the CHANGE AREA menu (the same of other areas)
Upper Level Opens the upper level page (the same of other areas)

2.2.12.2.2 MORE Overview Page
Page name: MORE Overview

Description: The page displays a general overview about the most important parts of
the MORE SYSTEM.
Fig. 50 MORE Overview Page
BUTTONS
SAMPLE Sends the SAMPLE setpoint loading/removing command to
the PLC
STEP 0 Sends the STEP0 setpoint loading/removing command to
the PLC
DECARBURAT Sends the DECARBURATION setpoint loading/removing
ION command to the PLC
Interlock boxes Opens the INTERLOCKS window for the related device
HOT AREAS
OxygenJet # Opens the VALVES TRAIN page for the related device
Dispenser # Opens the COAL DISPENSER page for the related device
DATA ENTRY FIELDS
Decarburation - Send to the PLC the duration of decarburation
time
ANIMATIONS
White Flame Oxygen Injection in progress
Yellow Flame Fuel Injection in progress
Black Flame Carbon Injection in progress
Thunderbolt Arc present

2.2.12.2.3 MORE Utility page
Page name: Utility MORE

Description: It is shown after pressing on the HMI System icon in the upper bar, then
the HMI Configuration icon (it is enabled only for Administrator) and then
the “MORE tools page” icon.
In this window the Administrator can set some HMI parameters and use
some Windows applications.
Fig. 51 MORE Utility page
ICONS
Calculator Executes the Windows Calculator application.
Explorer Executes the Windows Explorer application.
Notepad Executes the Windows Calculator application.
BUTTONS
Extended Keypad Enables/Disables the use of the screen numeric pad in the
- ENABLE data entry fields.
DATA ENTRY FIELDS
Spare Password Selects the password that must be used for the “Valve
Stand Ventilation” command

2.2.12.2.4 MORE Local Pulpits Window
Page name: Local Pulpits - MORE

Description: It is shown after pressing on the Pulpits icon located in the upper bar.
In this page the operator can check for each pulpit the remote/local
status, if emergency or fast-stop buttons have been pressed and also if
any alarm related to pulpits is active.
Fig. 52 MORE Local pulpits window
BUTTONS
X Closes the window
TABS
SYH Opens SYH Pulpits window
RMH Opens RMH Pulpits window
FTP Opens FTP Pulpits window
WTP Opens WTP Pulpits window

2.2.12.2.5 MORE Common Thresholds Page
Page name: Alarms and Thresholds - Common

Description: It is shown after pressing on the Thresholds button located in the upper
bar.
In this page the operator can check all the thresholds for the alarms of
the common parts. The Administrator is able even to change them.
Fig. 53 MORE Alarms and Thresholds - Common page
ICON LINKS
Data Management Opens the DATA MANAGEMENT window
BURNERS/INJECTORS - COMMON FUEL/OXYGEN - DATA ENTRY FIELDS (for Administrator use
only)
Inlet pressure LL Sends to the PLC the threshold of the low pressure
below which the injectors are shut off
Inlet pressure L Sends to the PLC the alert threshold of low pressure
Inlet temperature LL Sends to the PLC the threshold of low temperature below which
the injectors are shut off
Inlet temperature HH Sends to the PLC the threshold of high temperature
above which the injectors are shut off.
A value of 100 in this field disables the temperature
sensor.
Pressure Test Time Sends to the PLC the duration of the pressure test.
Minimum flow for Sends to the PLC the minimum flow setpoint for the
Injectors LOW flame Oxygenjets in Low Flame mode. When the LOW
FLAME MODE is enabled, the minimum flow setpoint
of oxygen and fuel are fixed at these values for all the
Oxygenjets. This limits override also setpoints of the
STEP0, SAMPLE and DECARBURATION.

Minimum flow for Burner Sends to the PLC the minimum flow setpoint for the
LOW flame Burners/Carbonjets in Low Flame mode. When the
LOW FLAME MODE is enabled, the minimum flow
setpoint of oxygen and fuel are fixed at these values
for all the Burners and Carbonjets. This limits
override also setpoints of the STEP0, SAMPLE and
DECARBURATION.
CATFIS - DATA ENTRY FIELDS (for Administrator use only)

Temperature / Celox Sends to the PLC the maximum duration of the
maximum time temperature / Celox cycle
Sample max time Sends to the PLC the maximum duration of sample
cycle
Probe maximum inlet Sends to the PLC the probe maximum inlet position
position
TABS
Common Parts Opens “Alarms and Thresholds – Common Parts”
page
Injectors Opens “Alarms and Thresholds – Injectors” page
Dispensers Opens “Alarms and Thresholds – Dispensers” page

2.2.12.2.6 MORE Injectors Thresholds Page
Page name: Alarms and Thresholds - Injectors

bar and then the “Injectors” tab.
the Injectors. The administrator is able even to change them.
Fig. 54 MORE Alarms and Thresholds - Injectors page
ICON LINKS
MORE Data Opens the DATA MANAGEMENT window
Management
OXYGENJET # - DATA ENTRY FIELDS (for administrator use only)
Outlet pressure Sends to the PLC the threshold of maximum delta pressure
LL above which the injectors are shut off.
The PLC calculates the expected outlet pressure for the
actual flow. If the measured pressure is below the calculated
minus this threshold, the alarm rises and the PLC shut off the
injectors.
Outlet pressure H Sends to the PLC the alert threshold of high pressure. (it
indicates clogged injector or pipeline)
Cooling water Sends to the PLC the alert threshold of high temperature.
temperature H
Cooling water Sends to the PLC the threshold of high temperature above
temperature HH which the injectors are shut off.
A value of 100 in this field disables the temperature sensor.
TABS
Common Parts Opens “Alarms and Thresholds – Common Parts” page

2.2.12.2.7 MORE Dispensers Thresholds Page
Page name: Alarms and Thresholds – Dispensers

bar and then the Dispensers tab.
Dispensers. The administrator is able even to change them.
Fig. 55 MORE Alarms and Thresholds – Dispensers page
ICON LINKS
Management
COAL DISPENSERS - DATA ENTRY FIELDS (for administrator only)
Dispenser weight Sends to the PLC the threshold of the minimum dispenser
(empty/filled) L material weight.
The refilling cycle will start automatically (if enabled) if the
dispenser material weight drops below this value.
Use always a value greater than 0, there could be material
stack on the walls and/or measurement uncertainty of the
measurement instrument.
Dispenser weight Sends to the PLC the threshold of the maximum dispenser
(empty/filled) H material weight.
The refilling cycle stops when this weight is reached.
Main Pressure LL Sends to the PLC the threshold of low pressure below which
the material injection is shut off.
Main Pressure L Sends to the PLC the alert threshold of the low pressure.
Dispenser line Sends to the PLC the alert threshold of high pressure for the
pressure H coal line.
Dispenser line Send to the PLC the threshold of low pressure for the
pressure HH additive line above which the injection is shut off.
Dispenser Sends to the PLC the dispenser internal pressure setpoint for
working pressure the injection phase

Dispenser refilling Sends to the PLC the dispenser internal pressure setpoint for
pressure the refilling phase
Trend m factor Sends to the PLC the m factor value.
This is a calibration factor for the ceramic valve opening. The
coal flow is a straight function of the ceramic valve opening
(straight-line function). “m” value represents the angle of the
straight-line function, while “q” value is the origin.
This value is automatically updated from the AUTOTUNING
procedure of the Carbon Dispenser page.
Trend “q” factor Sends to the PLC the q factor value.
This value is automatically updated from the AUTOTUNING
procedure of the Carbon Dispenser page.
Transport air flow Sends to the PLC the air flow setpoint for the material
injection phase.
Purge air flow Sends to the PLC the air flow setpoint for the purging
phase.
Carbon injection Sends to the PLC the delay time setpoint to turn off the coal
delay-off time injection from a Stop coal command.
(0..50 sec) Sometimes can be beneficial to keep the injection on for a
good foamy and coating better the EAF walls.
TABS
Common Parts Opens “Alarms and Thresholds – Common Parts” page

2.2.12.2.8 MORE Injectors Setpoints Page
Page name: MORE Setpoints - Injectors

Description: It is shown after pressing on the Setpoints icon in the upper bar and then
the “Injectors” tab.
In this page the operator can check the flow setpoints of STEP0,
SAMPLE, DECARBURATION and MANUAL modes. The administrator is
able even to change them.
Fig. 56 MORE Setpoints - Injectors page
ICONS LINKS
OXYGENJET # - BUTTONS
SAMPLE Sends to the PLC the ENABLE/DISABLE SAMPLE
mode command for the related device
DECARB Sends to the PLC the ENABLE/DISABLE
DECARBURATION mode command for the related
device
OXYGENJET # - DATA ENTRY FIELDS (for administrator only)
Fuel/Oxygen – Sends to the PLC the flow setpoint for the STEP 0
STEP 0 mode.
Fuel/Oxygen – Sends to the PLC the flow setpoint for the SAMPLE
SAMPLE mode.
Fuel/Oxygen – Sends to the PLC the flow setpoint for the DECARBURATION
DECARB. mode.
TABS
OxygenJet 1-4 Opens “MORE Setpoints – OxygenJet 1-4” page
Dispensers Opens “MORE Setpoints – Dispensers” page

2.2.12.2.9 MORE Dispensers Setpoints Page
Page name: MORE Setpoints - Dispensers

Description: It is shown after pressing on the Setpoints icon in the upper bar and then
the Dispensers tab.
In this page the operator can check the flow setpoints of SAMPLE,
DECARBURATION. The administrator is able even to change them.
Fig. 57 MORE Dispensers Setpoints Page
ICONS LINKS
Dispenser # - BUTTONS
SAMPLE Sends to the PLC the ENABLE/DISABLE SAMPLE mode
command for the related device
DECARB Sends to the PLC the ENABLE/DISABLE
DECARBURATION mode command for the related device
Dispenser # - DATA ENTRY FIELDS (for administrator use only)
Carbon – SAMPLE Sends to the PLC the coal flow setpoint for the SAMPLE
mode.
Carbon – DECARB. Sends to the PLC the coal flow setpoint for the DECARBURATION
mode.
TABS
Dispensers Opens “MORE Setpoints – Dispensers” page

2.2.12.2.10MORE Commands Window
Page name: MORE Commands

Description: It is shown after pressing on the Commands icon in the upper bar.
In this page the operator can send the general commands to the PLC.
Here the operator has also the possibility to disable all the MORE system.
Fig. 58 MORE Commands window
BUTTONS
ENABLE Sends the MANUAL setpoints mode selection command
SETPOINTS to the PLC for all injectors.
– MANUAL In Manual mode it is the Operator that must select the
setpoints and decide when start/stop the Injectors.
ENABLE Sends the AUTOMATIC setpoints mode selection
SETPOINTS command to the PLC for all injectors.
– AUTOMATIC In Automatic mode the setpoints are completely managed
and updated by the PCS system supervisor. The Operator
must only give the first Start command.
The PCS delivers the Level 2 setpoints or the PSF
setpoints if this is enabled.
ENABLE Sends the ENABLE/DISABLE command for PSF mode to
SETPOINTS the PLC.
– PSF If this is enabled the PCS delivers the PSF setpoints
instead of the Level 2 Setpoint.
HARMONIC Sends the HARMONIC ANALYZER DISABLE command
ANALYZER – to the PLC.
MANUAL
HARMONIC Sends the HARMONIC ANALYZER ENABLE command to
ANALYZER – the PLC.
AUTOMATIC

STEP 0 Sends the STEP0 setpoints loading command to the PLC.

It takes effect for all injectors. The STEP0 mode
automatically removes the condition of Decarburation and
Sampling.
SAMPLE FLOW Sends the SAMPLE setpoints loading command to the
PLC.
The SAMPLE setpoints are defined in Setpoints Page.
It takes effect only for the injectors that are enabled to
work in this mode; the others keep working in normal
mode.
The SAMPLE mode automatically removes the condition
of Decarburation. This mode is normally used during
refining when it may be necessary to lower the Injectors
flow to not interfere with the activity of sampling.
DECARB. FLOW Sends the DECARBURATION setpoints loading command
to the PLC.
The DECARBURATION setpoints are defined in Setpoints
Page.
It takes effect only for the injectors that are enabled to
work in this mode; the others work with the STEP0
setpoints.
In DECARBURATION mode the oxygen and coal injection
can be started also without the arc presence with the
exception of fuel.
LOW FLAME Sends the ENABLE/DISABLE command for LOW FLAME
MODE mode to the PLC.
When the LOW FLAME MODE is enabled, the minimum
flow setpoint of oxygen and fuel are fixed as defined in
Common Setpoints Page for all injectors. This limits
override also setpoints of the STEP0, SAMPLE and
DECARBURATION.
In this condition, enabled injectors remain on also without
the presence of arc until the furnace is hot. This can be
used to purge the injectors with oxygen and fuel instead of
air.
As for normal mode, in LOW FLAME mode to restart
disabled injectors it is required the presence of the arc and
the hot furnace.
AIR PURGING Sends the ENABLE/DISABLE command for air purging to
the PLC.
When disabled, after a preset time without Electric Arc
presence, the system automatically closes the purging air
to all the lines.
To restart the air purging it must be used this command.
VALVESTAND Sends to the PLC the ENABLE/DISABLE command to
VENTILATION stop the system and to start the fuel valves train
ventilation.
When activated it sends the Disable Devices command to
the PLC for all the MORE devices. All devices are kept
disabled and the ventilation valves of the fuel vales train
and the ventilation valves of the dispensers are opened.
This command is protected with password. The password
is stored in the MORE UTILITY page.
OPEN FUEL Sends the OPEN/CLOSE command for the Fuel main
LINE valve to the PLC.
PRESSURE Sends the FUEL PRESSURE TEST command to the PLC.
TEST – This test can be performed only with injectors disabled.
FUEL / OXYGEN During the pressure test the PLC checks that the internal
pressure of the valves train remain constant.
OXYGENJET # / Sends the ENABLE/DISABLE command for the device to
BURNERS # - the PLC.
ENABLE

DISPENSER # - Sends the ENABLE/DISABLE command for the device to

ENABLE the PLC.
START Sends to the PLC the START injection command for all
enabled devices.
The START command has effect only if all the consents
are present, in particularly is required the presence of the
electric arc and the hot furnace.
NOTE: Every time an Alarm (TRIP) stops the cycle it is
necessary that the Operator press START again. If the
Electric Arc is not active the system (PLC) will stop the
Injectors immediately with the exception of SETP0 and
LOW FLAME modes that keep the injection on until the
furnace is hot.
STOP Sends to the PLC the STOP injection command for all
injectors. This command take effect immediately, it does
not require a confirmation.
X Closes the window.

2.2.12.2.11Manual Setpoints Window
Page name: Manual Setpoints

Description: It is shown after pressing on the Setpoints Selection icon in the upper
bar.
In Manual Setpoints window the operator can select which device to set
in Manual mode, wich Step to activate for each device and temporary
modify the flow setpoints for each material.
Fig. 59 MANUAL Setpoints window
BUTTONS
ALL AUTOMATIC Sends the AUTOMATIC setpoints mode selection
command to the PLC for all injectors.
In Automatic mode the setpoints are completely
managed and updated by the PCS system supervisor.
The Operator must only give the first Start command.
The PCS delivers the Level 2 setpoints or the PSF
setpoints if this is enabled.
ALL MANUAL Sends the MANUAL setpoints mode selection command
to the PLC for all device s.
In Manual mode it is the Operator that must select the
setpoints and decide when start/stop the all devices.
MANUAL Sends to the PLC the ENABLE/DISABLE command for
MANUAL mode only for the related device.
ALL STEP 1..5 Sends the MANUAL STEP 1..5 setpoints loading
command to the PLC for all devices
1..5 Sends the MANUAL STEP 1..5 setpoints loading
command to the PLC for the related device.

START Sends to the PLC the START injection command for all
enabled devices.
The START command has effect only if all the consents
are present, in particularly is required the presence of the
electric arc and the hot furnace.
NOTE: Every time an Alarm (TRIP) stops the cycle it is
necessary that the Operator press START again. If the
Electric Arc is not active the system (PLC) will stop the
Injectors immediately with the exception of SETP0 and
LOW FLAME modes that keep the injection on until the
furnace is hot.
STOP Sends to the PLC the STOP injection command for all
injectors except for dispensers. This command take
effect immediately, it does not require a confirmation.
X Closes the window
DATA ENTRY FIELDS
Fuel/Oxygen/Carb Send to the PLC a temporary flow setpoint. It will be
on flow overwritten as soon as a new setpoint comes from the
PCS.

2.2.12.2.12Valves Trains - OxygenJet Pages
Page name: Valves Trains - Injectors

Description: It is shown after pressing on the Valves Trains icon in the upper bar and
then the OxygenJet # tab.
In this page the operator can see all the information about valves and
transducers. He can also control the fuel and oxygen consumption of the
device.
Fig. 60 Valves Trains - OxygenJet 1 page
BUTTONS
MANUAL - Sends to the PLC the ENABLE/DISABLE command for
ENABLE MANUAL mode for just this injector. The steps must be
selected from the MANUAL Setpoints window.
DEVICES
Fuel/Oxygen Opens the AUTO/MANUAL commands window for the device
Regulation (for Administrator only).
valves
DATA ENTRY FIELDS
Fuel/Oxygen Send to the PLC a temporary flow setpoint. It will be
flow overwritten as soon as a new setpoint comes from the PCS.
TABS
OxygenJet # Opens “Valves Trains – OxygenJet #” page

2.2.12.2.13Dispensers Pages
Page name: Dispenser

Description: It is shown after pressing on the Dispensers icon in the upper bar and
then the Dispenser tab.
In this page the operator can see all the information about valves and
transducers. He can also check the coal flow and consumption.
Fig. 61 Coal Dispenser 1 page
BUTTONS
AUTO REFILLING Sends the ENABLE/DISABLE command to the PLC for
- ENABLE the dispenser automatic refilling. Although if enabled, the
first refill must always be performed by the operator with
the start command.
REFILLING - Sends the REFILLING CYCLE START/STOP command
START to the PLC
INJECTION Activates the Data entry field “COAL – Force flow”
FORCE - ENABLE
AUTOTUNING - Sends to the PLC the START/STOP command for
START AUTOTUNING.
With the Autotuning action, the ratio of the coal flow and the coal
output valve opening is automatically calculated and this value is sent
to the “Trend m factor” and “Trend q factor” data variable in the
Dispenser Alarms and Thresholds page.
DEVICES
Regulation valve Opens the AUTO/MANUAL commands window for the
device (for Administrator only).
DATA ENTRY FIELDS
COAL - Flow Sends to the PLC a temporary coal flow setpoint. It will be
overwritten as soon as a new setpoint comes from the
PCS.

COAL - Force flow Send to the PLC the coal flow setpoint. (Available only in
MANUAL SETPOINT enabled). It will never be
overwritten by new setpoints from the PCS. It takes effect
also without the presence of the Electric Arc On and
Closed Roof conditions.
TABS
COAL # Opens “Dispenser #” page

2.2.12.2.14Catfis Window
Page name: Catfis

Description: It is shown after pressing on the Catfis icon in the upper bar.
In Catfis window the operator can see all the information about Catfis.
Fig. 62 Catfis window
BUTTONS
X Closes the window

2.2.12.3 ISAC Area Screens

In this section the description of all the screens for the ISAC PLANT is provided: these pages are
specifical to this area and in common have the icons bar, that will be described on the next paragraph.

2.2.12.3.1 ISAC Menu Bar
Page name: RMH_00_Bar

Description: This menu bar contains the more important icons used to navigate
through this area pages. It appears on top of all the pages of this area.
Fig. 63 ISAC menu bar
ICON LINKS
Trends menu Opens the TRENDS MENU page (the same of other areas)
HMI System Opens the HMI SYSTEM menu (the same of other areas)
Time Opens the RUNNING TIME window
Charging Opens the BINS CHARGING SETUP menu
Recipes Opens the CONTINUOUS RECIPES menu
Inertization Opens the DRI INERTIZATION page
Setpoints Opens the SETPOINTS SETUPS page
Data Save / Opens the DATA SAVE / LOAD window
Load
Bag Filter Opens the BAG FILTER page
Change Area Opens the CHANGE AREA menu (the same of other areas)
Upper Level Opens the upper level page (the same of other areas)

2.2.12.3.2 ISAC Bins Charging Overview Page
Page name: RMH_10_Charging1

the BINS CHARGING SYSTEM.
Fig. 64 ISAC Bins Charging Overview Page
DEVICES LINKS
Vibrator # Opens the VIBRATOR window for the related device
Weighing Belt # Opens the WEIGHING BELT window for the related device
DRI Bin# Opens the INERTIZATION window for the related device

2.2.12.3.3 ISAC Bins Charging Overview Page
Page name: RMH_10_Transport2

the CONTINUOUS CHARGING.
Fig. 65 ISAC Continuous Charging Overview Page
DEVICES LINKS
Transport Opens the Transport Device window for the related device
Device #
Weighing Belt # Opens the WEIGHING BELT window for the related device
DRI Bin# Opens the INERTIZATION window for the related device

2.2.12.3.4 ISAC Local Pulpits Window
Page name: RMH_08_Pulpit

Description: It is shown after pressing on the Pulpits icon located in the upper bar.
In this page the operator can check for each pulpit the remote/local
status, if emergency or fast-stop buttons have been pressed and also if
any alarm related to pulpits is active.
Fig. 66 ISAC Local pulpits window
BUTTONS
X Closes the window
TABS
MORE Opens MORE Pulpits window
ISAC Opens ISAC Pulpits window

2.2.12.3.5 ISAC Thresholds Setup Page
Page name: RMH_06_Setup

Fig. 67 ISAC Thresholds page
DRI BINS - DATA ENTRY FIELDS (for administrator use only)

Inlet Nitrogen Sends to the PLC the threshold of minimum nitrogen below
Flow Low Low the PLC will generate a fault plant alarm.
Inlet Nitrogen Sends to the PLC the threshold of minimum nitrogen below
Flow Low the PLC will generate alarm.
Bin # internal Sends to the PLC the alert threshold of high temperature,
temperature high above which, the related bin will start the inertization cycle
Bin # internal Sends to the PLC the alert threshold of high pressure, above
pressure high which, the related bin will open the charging gate to
depressurize
Bin # internal Sends to the PLC the alert threshold of low pressure, below
pressure low which, the related bin will open the nitrogen charging to
increase bin pressure

2.2.12.3.6 ISAC DRI Bins Inertization Page
Page name: RMH_14_DRINitrogen

Description: The page displays the status of the DRI inertization instruments.
Fig. 68 ISAC DRI Bins Inertization Page
DEVICES LINKS
Bins # Opens the BIN STATUS window for the related bin
Valve # Opens the VALVE window for the related device

2.2.12.3.7 ISAC Bag Filter Page
Page name: RMH_14_Filter1

Description: The page displays the status of the Bag Filter for the ISAC plant. The
page is entered by clicking on the bag filter icon in the upper bar or by
clicking on the hot area of bag filter in the overview pages
Fig. 69 ISAC Bag Filter Page
DEVICES LINKS
Fan Opens the SUCTION FAN window
Valve # Opens the VALVE window for the related device
BUTTONS
AUTO Enable the auto mode of bag filter
MANUAL Enable the manual of bag filter
START Start the auto bag filter cycle
STOP Stop the auto bag filter cycle
INERTIZATION Open the inertization valves for the bag filter
REQUEST
INERTIZATION Reset of the inertization package
RESET

2.2.12.3.8 ISAC Bins Charging Setup
Page name: RMH_10_Charging

Description: It is shown once pressed the Lime, Carbon, DRI/HBI label in the charging menu from
the upper bar. In this page the operator can check the status of the daily charging
cycle, send some commands and setup the charging parameters.
Fig. 70 ISAC Bins Charging Setup
BUTTONS
START Sends the CYCLE START request for the relative cycle to the PLC
STOP/RESET Sends the CYCLE STOP/RESET request to the PLC
PRESET Sends the PRESET BIN to be charged to the PLC
Permissive Opens the PERMISSIVES window for the charging cycle
Content set bin X Update the estimated weight in the related bin
DATA ENTRY FIELDS
Bin X Material Name Sends the requested material name for the related bin to PLC
Bin X Specific Weight Sends the specific weight of the material in the related bin to PLC
Bin X Estimated Set the estimated weight in the related bin to PLC
Weight
Vibrator Speed Bin X Sends the speed setpoint for charging vibrator when charging to
the related bin to PLC

2.2.12.3.9 ISAC Scrap Charging Setup
Page name: RMH_41_ChargingSetup

Description: It is shown once pressed the Scrap Charge label in the charging menu from the upper
bar. In this page the operator can check the status of the scrap charging cycle, send
some commands and setup the charging parameters.
Fig. 71 ISAC Bins Charging Setup
BUTTONS
STOP Sends the CYCLE STOP request to the PLC
AUTO Sends the AUTO mode request to the PLC. In auto mode, the
charging cycle start automatically when the estimated level in the
storage hopper fall below a preset level. The auto charging cycle
run until the high limit switch in the storage hopper is activated
Permissive Opens the PERMISSIVES window for the charging cycle
Content set Update the estimated weight in the storage hopper
DATA ENTRY FIELDS
Scrap Material Name Sends the requested scrap material name to PLC
Scrap Specific Weight Sends the specific weight of the scrap material to PLC
Scrap Estimated Set the estimated weight in storage hopper to PLC
Weight
Vibrator Speed for Sends the speed setpoint for charging vibrator EVE02
Scrap

2.2.12.3.10ISAC Additives (Lime/Carbon) Recipe for EAF
Page name: RMH_40_Tab_EAFConRecipe

Description: It is shown once pressed the Recipe label in the upper part of the window. In this page
the operator can check the status of the cycles, send some commands and check the
recipe completion status.
Fig. 72 ISAC Additives (Lime/Carbon) Recipe for EAF
TAB LINKS
Recipe Opens the RECIPE window
Setup Opens the RECIPE SETUP window
BUTTONS
STOP/RESET Sends the RECIPE STOP/RESET request to the PLC
SIMULATION ON/OFF Sends the ACTIVATE/DEACTIVATE SIMULATOR request to the
PLC
Arc Forcing ON /OFF Sends the ACTIVATE/DEACTIVATE ARC FORCING request to the
PLC
Permissive Opens the PERMISSIVES window for the relative cycle
DATA ENTRY FIELDS
Material Weight Sends the requested set weight for the recipe to the PLC
Material Flow Sends the requested set flow for the recipe to the PLC

2.2.12.3.11ISAC Additives (Lime/Carbon) Recipe Setup for EAF
Page name: RMH_40_Tab_EAFConSetup

Description: It is shown once pressed the Setup label in the upper part of the window. In this page
the operator can set all the set-points for the recipe.
Fig. 73 ISAC Additives (Lime/Carbon) Recipe Setup for EAF
TAB LINKS
DATA ENTRY FIELDS
Bin X Material Name Sends the requested material name for the related bin to PLC
Bin X Material Code Sends the requested material code for the related bin to PLC
Bin X Material Priority Sends the requested material priority for the related bin to PLC
Bin X Low Speed Start Sends the low speed weight setpoint for the related bin to PLC
Bin X Charging Stop Sends the stop weight setpoint for the related bin to PLC
Bin X Low Speed Sends the low speed setpoint for the related bin to PLC
Bin X High Speed Sends the high speed setpoint for the related bin to PLC
Bin X Specific Weight Sends the specific weight of the material in the related bin to PLC

2.2.12.3.12ISAC HBI/ DRI Recipe for EAF
Page name: RMH_40_Tab_DRIRecipe

Description: It is shown once pressed the DRI Recipe label in the Continuous Recipe menu. In this
page the operator can check the status of the cycles, send some commands and
check the recipe completion status.
Fig. 74 ISAC HBI/ DRI Recipe for EAF
TAB LINKS
BUTTONS
PLC
Arc Forcing ON /OFF Sends the ACTIVATE/DEACTIVATE ARC FORCING request to the
PLC
CHECK BOXES
Bin selection for cycle Select the required bin the the related cycle
Select active power for Enabled / Disabled the level 1.5 option. If this option is enabled the
flow data DRI / HBI weight flow is calculated proportionally to the active power
of the EAF electrode
DATA ENTRY FIELDS
Material Flow Sends the requested set flow for the recipe to the PLC (only if
Active Power option is disabled)

2.2.12.3.13ISAC HBI/ DRI Recipe Setup for EAF
Page name: RMH_40_Tab_DRISetup

Fig. 75 ISAC HBI/ DRI Recipe Setup for EAF
TAB LINKS
DATA ENTRY FIELDS
Material Name Sends the requested name for the related material to PLC
Material Code Sends the requested code for the related material to PLC
Low Speed Start Sends the low speed weight setpoint for the related material to PLC
Charging Stop Sends the stop weight setpoint for the related material to PLC
Material Specific Sends the specific weight of the related material to PLC
Weight
Flow coefficient Sends the requested flow coefficient (in Active Power mode) for the
related material to PLC
Flow ratio Sends the flow ratio between HBI vs DRI (in Active Power mode &
bin 3, 4 contain different material) to PLC
RADIO BOXES
Bin X material select Select for the related bin, the material contain is wether HBI or DRI

2.2.12.3.14ISAC Scrap Recipe for EAF
Page name: RMH_40_Tab_ScrapRecipe

Description: It is shown once pressed the Scrap Recipe label in the Continuous Recipe menu. In
this page the operator can check the status of the cycles, send some commands and
check the recipe completion status.
Fig. 76 ISAC Scrap Recipe Recipe for EAF
TAB LINKS
BUTTONS
PLC
CHECK BOXES
Select active power for Enabled / Disabled the level 1.5 option. If this option is enabled the
flow data scrap weight flow is calculated proportionally to the active power of
the EAF
DATA ENTRY FIELDS
Material Flow Sends the requested set flow for the recipe to the PLC (only if
Active Power option is disabled)

2.2.12.3.15ISAC Scrap Recipe Setup for EAF
Page name: RMH_40_Tab_ScrapSetup

Fig. 77 ISAC Scrap Recipe Setup for EAF
TAB LINKS
DATA ENTRY FIELDS
Material Name Sends the requested name for the related material to PLC
Material Code Sends the requested code for the related material to PLC
Low Speed Start Sends the low speed weight setpoint for the related material to PLC
Charging Stop Sends the stop weight setpoint for the related material to PLC
Scrap Specific Weight Sends the specific weight of the material in scrap to PLC
Flow coefficient Sends the requested flow coefficient (in Active Power mode) for the
related material to PLC

3 LOCAL STATIONS
The main local boxes contain all the controls necessary to manage the machine and process.
3.1 =GD11E10PLC01– EAF_AUT
3.1.1 EAF LOCAL CONTROL STATION GD11E10LCS02
Fig. 78 EAF Local Control Station (=GD11E10LCS02)
Tags/objects
S01 Emergency This is a “two positions latching twist release
S02 Emergency Reset The lamp is lit up when the emergency is
activated. Pressing the button the alarms are
reset.
S03 Lamps Test/ Local Controls The light is lit up when the local commands for
Enabled the pulpit are enabled
S04 Local Controls Off-On Switch used to enable the local commands. A
key is necessary to turn it.
S05 Movements Fast Stop Pressing this push button the unit and all
P11 Steel Weight Tag with LCD display

H18 Alarm The lamp is lit up when any alarm concerning

the ladle car is active.
S23 Pre-heating position Pressing the button the ladle car will move in
this position. The light is lit up when the car is
in the requested position.
S20 EAF charging position Pressing the button the ladle car will move in
S19 EAF tapping position Pressing the button the ladle car will move in
S21 Extrastroke by-pass The lamp is lit up when the ladle car has
reached the extratravel position. In this case,
maintaining pressed the button it is possible to
move the car, otherwise impossible.
S24 Backward – 0 – Forward 3-position switch with automatic return to 0:
while the switch is in forward position the ladle
car 1 will be moving forward, while the switch is
in backward position the ladle car will be
moving backward. In position 0 the movement
is stopped.
S16 Ladle Car Emergency Pressing this button the unit and all
H17 Ladle Car Emergency ON The light is lit up when the emergency is active.
P41 Tilting Angle Tag with LCD display
S55 Joystick slagging/tapping Moving the joystick in this direction the furnace
will be tilted towards the slagging side./ Moving
the joystick in this direction the furnace will be
tilted towards the tapping side.
H51 Tilting enabled The lamp is lit up when the tilting from the local
tapping pulpit is enabled.
S52 Overinclination The lamp is lit up when the furnace is in tilted in
over-inclination.
S53 Furnace Tilting ON-OFF Two positions switch. When it is in ON position
the tilting of the furnace will be enabled. A key
is necessary to turn it.
S46 Unlock Pressing the button the frame will be unlocked.
The light is lit up when the frame is unlocked.
S47 Lock Pressing the button the frame will be locked.
The light is lit up when the frame is locked.
H31 Walkway in park position The lamp is lit up when the walkway is in park
position.
S34 Unlock Pressing the button the EBT will be unlocked.
The light is lit up when the EBT is unlocked.
S35 Lock Pressing the button the EBT will be locked.
The light is lit up when the EBT is locked.
S36 Closing Pressing the button the EBT will be closed. The
light is lit up when the EBT is closed.
S37 Opening Pressing the button the EBT will be opened.
The light is lit up when the EBT is open.
P62 Line 1 Flow Set/Actual LED display that shows the current and target
flows of the stirring gas.
S63 Line 1 High pressure by-pass Pressing the button the stirring by-pass valve
will be opened. The light is lit up when the
valve is open.
PS64 Decr. – 0 – Incr. 3-position switch with automatic return to 0:
(Stirring Line 1) while the switch is in Decr. position the stirring
flow will be decreased, while the switch is in
Incr. position the flow will be increased. In
position 0 the flow is steady.

P66 Line 2 Flow Set/Actual LED display that shows the current and target
flows of the stirring gas.
S67 Line 2 High pressure by-pass Pressing the button the stirring by-pass valve
will be opened. The light is lit up when the
valve is open.
S68 Decr. – 0 – Incr. 3-position switch with automatic return to 0:
(Stirring Line 2) while the switch is in Decr. position the stirring
flow will be decreased, while the switch is in
Incr. position the flow will be increased. In
position 0 the flow is steady.
S69 Nitrogen Selection Pressing the button this kind of gas will be
selected for stirring. The light is lit up when the
gas is selected.
S70 Argon Selection Pressing the button this kind of gas will be
selected for stirring. The light is lit up when the
gas is selected.

3.1.2 EAF HYDRAULIC UNIT CONTROL STATION GD11E10LCS03
Fig. 79 Hydraulic Unit Control Station GD11E10LCS03
Tags/objects
S01 Emergency Pressing this button the unit and all
H02 Emergency ON The lamp is lit up when the emergency is
activated
H05 Alarm The lamp is lit up when any alarm concerning
the hydraulic unit is active.
S03 Lamps test / Local Controls Pressing the button all the lamps of the pulpit
Enabled will light up to let the operator check if they are
correctly working.
The light is also lit up when the local
commands for the pulpit are enabled
S12 Main pump 1 start Pressing the button the selected pump will
start. The light is lit up when the pump is
running.
Main pump 1 stop Pressing the button the selected pump will
stop.
running.
stop.

running.
stop.
running.
stop.
running.
stop.
S61 Recirculation pump start Pressing the button the selected pump will
running.
S62 Recirculation pump stop Pressing the button the selected pump will
stop.

3.1.3 EAF BACK-UP MOVEMENTS 1 GD11E10LCS04
Fig. 80 EAF Back-Up Movements 1 (=GD11E10LCS04)
Tags/objects
H01 Local Controls Enabled The light is lit up when the local commands for
the pulpit are enabled
S07 Lifting When the button is pressed the roof will be
lifted up.
S08 Unlock – 0 – Lock 3-position switch with automatic return to 0:
(Roof Lifting) when the switch is moved in Unlock position
the roof lifting will be unlocked, when the switch
is moved in Lock position the roof lifting will be
locked.
S09 Opening When the button is pressed the roof will be
opened.
S12 Opening Pressing the button the duct will be opened.
The light is lit up when the position has been
reached.
S21 Unlock When the button is pressed the EBT will be
unlocked.
S22 Opening When the button is pressed the EBT will be
opened.
S11 Lifting When the button is pressed the electrodes will
be lifted up.

S32 Reverse – 0 – Forward 3-positions switch with automatic return to 0:

(Ladle Car EAF) while the switch is in forward position the ladle
car will be moving forward, while the switch is
is stopped.
S31 Furnace tilting Unlock-0-Lock 3-positions switch with automatic return to 0:
while the switch is in unlock position the tilting
is unlocked. If the switch is in lock position,
tilting is locked.

3.1.4 EAF BACK-UP MOVEMENTS 2 GD11E10LCS05
Fig. 81 EAF Back-Up Movements 2 (=GD11E10LCS05)
Tags/objects
H01 Local Controls Enabled The light is lit up when the local commands for
the pulpit are enabled
S07 Lifting When the button is pressed the roof will be
lifted up.
S08 Unlock – 0 – Lock 3-position switch with automatic return to 0:
(Roof Lifting) when the switch is moved in Unlock position
the roof lifting will be unlocked, when the switch
is moved in Lock position the roof lifting will be
locked.
S09 Opening When the button is pressed the roof will be
opened.
S12 Opening Pressing the button the duct will be opened.
The light is lit up when the position has been
reached.
S21 Unlock When the button is pressed the EBT will be
unlocked.
S22 Opening When the button is pressed the EBT will be
opened.
S11 Lifting When the button is pressed the electrodes will
be lifted up.

S32 Reverse – 0 – Forward 3-positions switch with automatic return to 0:

(Ladle Car EAF) while the switch is in forward position the ladle
car will be moving forward, while the switch is
is stopped.
S31 Furnace tilting Unlock-0-Lock 3-positions switch with automatic return to 0:
while the switch is in unlock position the tilting
is unlocked. If the switch is in lock position,
tilting is locked.

3.2 =GB11E10PLC01–ISAC_AUT
3.2.1 RMH CHARGING LOCAL CONTROL STATION GB11E10LCS11
Fig. 82 RMH Charging Local Control Station (GB11E10LCS11)
Tags/objects
H02 Emergency active The lamp is lit up when the emergency is
activated.
P10 Selected Storage Bin Display The LEDs display the selected storage bbin.
S11 Increase selected bin number The 2 pusbuttons are used to adjust the
S12 Decrease selected bin number number of the selected bin
S14 Charging cycle start Pressing the button charging cycle start is
requested. The lamp will blink while the cycle is
preset and is lit up when it is running

S15 Charging cycle stop Pressing the button the charging cycle will
stop.
S16 Charging cycle preset Pressing the button to preset the bin for the
charging cycle. The lamp blinks quickly if the
preset is not accepted. The lamp blink slowly
when the preset is accepted and the shuttle
conveyor is not yet in the selected bin position
and lid up when it is reached
S17 Charging cycle reset Pressing the button charging cycle reset is
requested.
H18 Charging position reached The lamp is lit up when the reversible shuttle
belt has reached the preset position
H19 Bin in position full The lamp is lit up when the selected bin is full
S21 Vibrating extractor EVE01 start Pressing the button vibrating extractor start is
requested. The lamp will blink while the
extractor is fault and is lit up when it is running
S22 Vibrating extractor EVE01 stop Pressing the button the vibrating extractor will
stop.
S23 Vibrating extractor EVE01 speed 3-positions switch with spring return to 0: when
increase / decrease the switch is put in plus position vibrator speed
will increase, the speed decreases while the
switch is put in minus position
S31 Normal belt conveyor NBC01 start Pressing the button belt conveyor start is
requested. The lamp will blink while the belt
conveyor is fault and is lit up when it is running
S32 Normal belt conveyor NBC01 stop Pressing the button the belt conveyor will stop.
H33 Normal belt conveyor NBC01 The lamp is lit up when the belt conveyor is
controlled from other LCS12 controlled from other LCS
S34 Normal belt conveyor NBC01 off Keep pressing the button to bypass the off-
track bypass track fault for the belt comveyor. The lamp is lit
up while bypassing
S41 Dust collecting belt CHR01 start Pressing the button collecting belt start is
S42 Dust collecting belt CHR01 stop Pressing the button the collecting belt will stop.
H43 Dust collecting belt CHR01 The lamp is lit up when the collecting belt is

3.2.2 RMH NORMAL BELT NBC01 & DUST CHAIN CHR01 LOCAL CONTROL STATION GB11E10LCS12
Fig. 83 RMH Normal Belt NBC01 & Dust Chain CHR01 Local Control Station (GB11E10LCS12)
Tags/objects
activated.
up while bypassing
H23 Dust collecting belt CHR01 The lamp is lit up when the collecting belt is

3.2.3 RMH NORMAL BELT NBC02 LOCAL CONTROL STATION GB11E10LCS14
Fig. 84 RMH Normal Belt NBC02 Local Control Station (GB11E10LCS14)
Tags/objects
activated.
up while bypassing

3.2.4 RMH REVERSIBLE SHUTTLE BELT RSC01 LOCAL CONTROL STATION GB11E10LCS15
Fig. 85 RMH Reversible Shuttle Belt RSC01 (GB11E10LCS15)
Tags/objects
activated.
H21 Storage Bin SBN01 The lamp is lit up when the shuttle belt is ready
to discharge in the bin.
H25 Emergency Discharge The lamp is lit up when the shuttle belt is ready
in the emergency discharge position
S11 Reverse - 0 - Forward 3-positions switch with automatic return to 0:
(Translation) when the switch is put in forward position the
belt will be moving forward, when the switch is
put in backward position the belt will be moving
backward.
S12 Stop Translation Pressing the button the movement is stopped.

S13 Reverse - 0 - Forward 3-positions switch with automatic return to 0:

(Rotation) when the switch is put in forward position the
belt will be moving forward, when the switch is
put in backward position the belt will be moving
backward.
S14 Stop Rotation Pressing the button the movement is stopped.
S15 Overtravel Bypass The lamp is lit up when the shuttle belt has
reached the extratravel position. In this case,
maintaining pressed the button it is possible to
move the car, otherwise impossible.
S31 Bin 03 charging slide gate open Pressing the button to open the slide gate. The
lamp will blink while slide gate is opening and
is lit up when it is opened
S32 Bin 03 charging slide gate close Pressing the button to close the slide gate. The
lamp will blink while slide gate is closing and is
lit up when it is closed
S41 Bin 04 charging slide gate open Pressing the button to open the slide gate. The
S42 Bin 04 charging slide gate close Pressing the button to close the slide gate. The

3.2.5 RMH ISAC CHARGING LOCAL CONTROL STATION GB11E10LCS16
Fig. 86 RMH ISAC Charging Local Control Station (GB11E10LCS16)
Tags/objects
activated.
stop.

controlled from other LCS controlled from other LCS

3.2.6 RMH WEIGHING BELT 1÷2 LOCAL CONTROL STATION GB11E10LCS21
Fig. 87 RMH Weighing Belt 1÷2 Local Control Station (GB11E10LCS21)
Tags/objects
activated.
P10.1 Discharged Weight WBC01 LED display with weight
P10.2 Discharged Weight Flow WBC01 LED display with material flow
S11 Weighing belt WBC01 speed 3-positions switch with spring return to 0: when
increase / decrease the switch is put in plus position belt speed will
increase, the speed decreases while the switch
is put in minus position

S12 Weighing belt WBC01 start forward Pressing the button the belt starts in the
S13 Weighing belt WBC01 start reverse requested direction. The lamp will blink while
the extractor is fault and is lit up when it is
running
S14 Weighing belt WBC01 stop Pressing the button the belt will stop.
running
S31 Elevator belt conveyor EBC01 start Pressing the button belt conveyor start is
S32 Elevator belt conveyor EBC01 stop Pressing the button the belt conveyor will stop.
H33 Elevator belt conveyor EBC01 The lamp is lit up when the belt conveyor is
S34 Elevator belt conveyor EBC01 off Keep pressing the button to bypass the off-
up while bypassing

3.2.7 RMH WEIGHING BELT 3÷4 LOCAL CONTROL STATION GB11E10LCS22
Fig. 88 RMH Weighing Belt 3÷4 Local Control Station (GB11E10LCS22)
Tags/objects
activated.

running
S21 Bin 03 discharging slide gate open Pressing the button to open the slide gate. The
S22 Bin 03 discharging slide gate close Pressing the button to close the slide gate. The
S23 Bin 03 emergency slide gate open Pressing the button to open the slide gate. The
S24 Bin 03 emergency slide gate close Pressing the button to close the slide gate. The
running
S41 Bin 04 discharging slide gate open Pressing the button to open the slide gate. The
S42 Bin 04 discharging slide gate close Pressing the button to close the slide gate. The
S43 Bin 04 emergency slide gate open Pressing the button to open the slide gate. The
S44 Bin 04 emergency slide gate close Pressing the button to close the slide gate. The
S54 Elevator belt conveyor EBC01 off Keep pressing the button to bypass the off-
up while bypassing

3.2.8 RMH ELEVATOR BELT EBC01 & DUST CHAIN CHR02 LOCAL CONTROL STATION GB11E10LCS31
Fig. 89 RMH Elevator Belt EBC01 & Dust Chain CHR02 Local Control Station (GB11E10LCS31)
Tags/objects
activated.
S14 Elevator belt conveyor NBC01 off Keep pressing the button to bypass the off-
up while bypassing

3.2.9 RMH WEIGHING BELT 5 & VIBRATING EXTRACTOR 3 LOCAL CONTROL STATION GB11E10LCS32
Fig. 90 RMH Weighing Belt WBC05 & Vibrating Extractor EVE03 Local Control Station (GB11E10LCS32)
Tags/objects
activated.
running
H24 Weighing belt WBC05 controlled The lamp is lit up when the belt conveyor is
from other LCS controlled from other LCS
S25 Weighing belt WBC05 emergency Pressing the button to open start the weighing
discharge belt to the emergency discharge bin

S26 Weighing belt WBC05 stopper open Pressing the button to open the stopper. The
lamp will blink while stopper is opening and is
lit up when it is opened
S27 Weighing belt WBC05 stopper Pressing the button to close the stopper. The
close lamp will blink while stopper is closing and is lit
up when it is closed
stop.

3.2.10 RMH NORMAL BELT CONVEYOR NBC03 LOCAL CONTROL STATION GB11E10LCS33
Fig. 91 RMH Normal Belt Conveyor NBC03 Local Control Station (GB11E10LCS33)
Tags/objects
activated.

3.2.11 RMH VIBRATING CONVEYOR & ROTATING CHANNEL LOCAL CONTROL STATION GB11E10LCS34
Fig. 92 RMH Vibrating Conveyor & Rotating Channel Local Control Station (GB11E10LCS34)
Tags/objects
activated.
S11 Vibrating conveyor start forward Pressing the button the conveyor starts in the
S12 Vibrating conveyor start reverse requested direction. The lamp will blink while
the conveyor is fault and is lit up when it is
running
S13 Vibrating conveyor VTS01 stop Pressing the button the conveyor will stop.
H14 Vibrating conveyor VTS01 The lamp is lit up when the conveyor is

H21 Rotating channel in work position The lamp blinks when the channel is moving
toward the work position and is lit up when
channel is in the work position
H22 Rotating channel in park position The lamp blinks when the channel is moving
toward the park position and is lit up when
channel is in the park position
S23 Rotating channel speed increase / 3-positions switch with spring return to 0: when
decrease the switch is put in plus position rotating speed
S24 Rotating channel start forward Pressing the button the channel starts in the
requested direction. The lamp will blink while
the channel is fault and is lit up when it is
running
S25 Rotating channel start reverse Pressing the button the channel starts in the
requested direction. The lamp will blink while
the channel is fault and is lit up when it is
running
S26 Rotating channel stop Pressing the button the rotating channel will
stop.
running
H34 Weighing belt WBC05 controlled The lamp is lit up when the belt conveyor is
from other LCS controlled from other LCS
S35 Weighing belt WBC05 emergency Pressing the button to open start the weighing
discharge belt to the emergency discharge bin
S36 Weighing belt WBC05 stopper open Pressing the button to open the stopper. The
lamp will blink while stopper is opening and is
lit up when it is opened
S37 Weighing belt WBC05 stopper Pressing the button to close the stopper. The
close lamp will blink while stopper is closing and is lit
up when it is closed


Electric arc furnace operator manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Electric arc furnace operator manual

Uploaded by

Copyright:

Available Formats

Document Nr.

Job Contractual item DANIELI item

Ac electric arc furnace

00 27/12/2017 Issue ComarD ComarD PivottiR

Rev. Date Description Drawn Checked Approved

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 1/126 #2089265

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 2/126 #2089265

2.2.12.2 MORE Area Screens ..............................................................................................................................62

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 3/126 #2089265

Fig. 1 Main control desk 7

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 4/126 #2089265

Fig. 61 Coal Dispenser 1 page 80

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 5/126 #2089265

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 6/126 #2089265

The manual is divided in two main sections:

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 7/126 #2089265

2 MAIN CONTROL PULPIT

Fig. 1 Main control desk

The Main Control Desk commands are always enabled.

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 8/126 #2089265

2.1 MAIN CONTROL DESK

2.1.1 DESK EAF SECTION 1

Fig. 2 EAF main control desk (=GD11E10MCD01)

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 9/126 #2089265

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 10/126 #2089265

2.1.2 DESK EAF SECTION 2

Fig. 3 EAF main control desk (=GD11E10MCD01)

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 11/126 #2089265

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 12/126 #2089265

2.1.3 DESK KEYBOARDS

Fig. 4 EAF automation main control desk (=GD11E10MCD01): keyboards S20-S21-S22

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 13/126 #2089265

Clamps open Pressing this button will open electrode clamps

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 14/126 #2089265

Fig. 5 EAF automation main control desk (=GD11E10MCD01): keyboards S23-S24-S25

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 15/126 #2089265

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 16/126 #2089265

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 17/126 #2089265

2.2.2 INSTALLATION OF HMI

<application path> / Documents

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 18/126 #2089265

2.2.3 PAGES ORGANIZATION

Main Overview Main Overview Main Overview

Fig. 6 Main Pages

2.2.4 PAGES LAYOUT

Fig. 7 Display Standard Layout

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 19/126 #2089265

2.2.5 ALL THE HMI BARS

2.2.5.1 DownBar: Alarms & Messages

Fig. 8 Alarms & Messages bar

Alarms colors are in accord with the following summary tables:

Type of Alarm Description Foreground Color

Type of Alarm Description Foreground Color

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 20/126 #2089265

2.2.5.2 The Icon Bar: the Menu Functional Icons

Fig. 9 Example of icons

Fig. 10 Example of icons: a typical Area Bar

Certified by OneDoc DP0V8B-GD11-A8100-EB105 Rev.00-E 21/126 #2089265

2.2.5.3 The UpperBar : Semaphore and “Ready to Operate”

Fig. 11 Upper bar

RED: NOT READY

GREEN +YELLOW: WARNING

Fig. 12 Ready To Process icon