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Building Intelligent VHF Radio networks for Steel Plant applications
Communication needs of individual shops of an integrated steel plant are found to be distinctively different from one another. It is solely dependent on process route and operating practices, often overlooked leading to poor network utilization. Over the years, we have established customized radio-communication networks by ingenious exploitation of various software techniques to meet such challenges. The paper illustrates unique features of some key installations at Blast furnace, Material handling plant, Hot and Cold rolling mills of a Steel Plant. Besides enhancement in operational flexibility and logistics, there are substantial economic benefits with average ROI of 7.5 commensurate with such efforts.
Success of a good radio network does not only depend on the quality of the hardware, but to the careful study, design and development of customized system according to specific user requirements and needs. we have instituted customized radio-communication networks by carefully assessing the user’s needs and exploring various radio software techniques. This paper illustrates unique features of some key installations at Blast Furnace, Material Handling Plant, Hot and Cold Rolling Mills of a Steel Plant. Such efforts lead to enhanced operational flexibility and substantial economic benefits with average Return On Investment of 7.5.
An intelligent radio network design has essentially three features: voice quality, coverage and availability. The network should also offer secure communication, DTMF (conventional telephone signalling) and data. The above features have been used while designing the networks in various shops of steel plants. Typical software features included Private line (PL)/Digital Private Line (DPL) coding, DTMF signalling tones, Remote relay switching, caller identification etc. These resulted in Mobile to Mobile, Landline to Mobile calls, selective calling, group calling etc.
Raw
Material Handling Plant
The communication needs of the shop, having a wide area of operation, were carefully studied and a two-tier network consisting of two groups was designed. The operation requirements demanded penetrations of Group I by II and not vice-versa which was made possible by software programming of the radios. Incorporation of the system led to minimal wagon retention time (less demurrage), reduced standard deviation of Fe component etc.
Blast furnace and the associated slag granulation plant (SGP) are located wide apart leading to communication delays and poor recovery of liquid slag. The slag is transported in locomotives and system required location of ladles at key locations. A radio network was designed which provided signals (using DTMF) to indicate the empty/full status of ladles at SGP as well as the voice communication. Installation of the system led to reduced track time of ladles and improved yield of liquid slag by 100 T/day.
The communication needs required working of mill personnel in one large single group. The network was designed by considering wide range coverage from slab yard to coiler and system reliability under harsh environmental conditions. The system also covered crane to ground communications with every radio transmission to be identified with the caller. Incorporation of such communication facility resulted in mill delay reduction by 5% leading to improved productivity.
The operational requirements of a cold rolling mill is entirely different from a hot rolling mill. Unlike HRM, cold rolling mill is divided into a number of functional zones. A hybrid wireless network comprising of VHF radios, telephones, desktop computers and email connectivity through dial-up telephone lines facilitating both voice and data transfer was designed for meeting the varied inter and intra zones communication needs. The system resulted in better co-ordination and enhanced productivity in the shop.
An intelligent network is the best way to provide the quality of service required by the steel industry and maximise network capacity and utilization. Network cells typically have a 25 km radius, compared to cellular phone cells of just a few km. The network also has ability to minimize interference often experienced in VHF network. Such networks are good options in steel industry located in remote locations requiring secure, reliable and cost effective solutions.
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