TES by Bram Harimukti

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SEMEN BATU RAJA REPORTING SYSTEM FUNCTION DESIGN SPECIFICATION

Approvals For Use Siemens

Role

M. Ali Jinnah. R Hasan Basri Client Eddy Juarsyah M. Beny

Lead Engineer Project Manager

M. Suherman

Project Manager

Revision History Rev Date

Role Automation System Engineer Production Reporting System Engineer

Check

Signature

Date

Signature

26-04-2011 26-04-2011 Date

Approve

Description

P A B

Preliminary For comment For comment

For Approval

Baturaja_Reporting System Functional Design Specification This document and the copyright is owned by Siemens Indonesia. It may neither be copied nor submitted to third parties for copying without permission of the company

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INDEX INDEX........................................................................................................................................................ 4 FIGURES................................................................................................................................................... 6 1

OVERVIEW ........................................................................................................................................ 7 1.1 INTRODUCTION .................................................................................................................................. 7 1.2 SCOPE .......................................................................................................................................... 8 1.3 USER REQUIREMENT SPECIFICATION ............................................................................................. 13

SYSTEM SPECIFICATION .............................................................................................................. 14 2.1 REPORTING SYSTEM DIAGRAM ..................................................................................................... 14 2.2 SYSTEM REQUIREMENTS .............................................................................................................. 16 3.3.2 PCS7 OS Servers (WinCC Servers)................................................................................... 16 2.2.2 Ms. Visual Basic 6 Program Applications............................................................................ 16 2.2.3 IIS, ASP.Net ....................................................................................................................... 16 2.2.4 Ms. SQL Server 2005 ......................................................................................................... 16 2.2.5 Ms. Excel 2003 ................................................................................................................... 16 2.2.6 Industrial Ethernet Network for System Bus ....................................................................... 16 2.3 REPORTING SYSTEM METHOD ...................................................................................................... 17

SYSTEM FUNCTION........................................................................................................................ 18 3.1 WINCC ....................................................................................................................................... 18 3.3.2 WinCC Recording Data ...................................................................................................... 18 3.1.2. WinCC Viewing Data .......................................................................................................... 19 3.2 VISUAL BASIC (VB) 6 PROGRAM APPLICATION ............................................................................... 20 3.2.1 VB6 MTBF.......................................................................................................................... 20 3.2.1.1

3.2.2 3.2.2.1

Operating Instructions......................................................................................................................... 21

VB6 Excel Exporter ............................................................................................................ 22 VB6 Excel Exporter Login Form ......................................................................................................... 24

3.3 WEB SERVER REPORTING SYSTEM ............................................................................................... 31 3.3.1 Web Server Viewing Data................................................................................................... 31 3.3.2 User Page .......................................................................................................................... 32 3.3.2.1 3.3.2.2 3.3.2.3

Default Login....................................................................................................................................... 32 Home Page ......................................................................................................................................... 33 Production Report ............................................................................................................................... 34

3.3.2.3.1 Cement Mill Hourly Report....................................................................................... 34 3.3.2.3.2 Coal Mill Hourly Report............................................................................................ 34 3.3.2.3.3 Kiln Hourly Report ................................................................................................... 35 3.3.2.3.4 Raw Mill Hourly Report ............................................................................................ 35 3.3.2.3.5 Cement Mill Daily Report ......................................................................................... 36 3.3.2.3.6 KCC (Kiln Coal Clinker) Daily Report....................................................................... 36 3.3.2.3.7 Raw Mill Daily Report .............................................................................................. 37 3.3.2.3.8 Packer Daily Report................................................................................................. 37 3.3.2.3.9 Daily Summary Production Report (“Harian Produksi”)............................................ 38 3.3.2.3.10 OEE Monthly Report.............................................................................................. 38 3.3.2.3.11 OEE Yearly Report ................................................................................................ 39 3.3.2.3.12 MTBF_MTTR Report ............................................................................................. 39 3.3.2.3.13 Energy Meter Report ............................................................................................. 40 3.3.3 Web Report Management................................................................................................... 41 3.3.3.1 3.3.3.2

Delete Report...................................................................................................................................... 41 Create Report ..................................................................................................................................... 42

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3.3.3.3 3.3.3.4

Download Report ................................................................................................................................ 43 Search Report..................................................................................................................................... 44

3.3.3.4.1 Search Report By Date............................................................................................ 44 3.3.3.4.2 Search Per Equipment (MTBF_MTTR).................................................................... 45 3.3.3.4.3 Search Per Department (MTBF_MTTR) .................................................................. 45 3.3.4 User Management .............................................................................................................. 46 3.3.4.1 3.3.4.2

3.3.5 3.3.5.1 3.3.5.2

Register User (Viewer) ....................................................................................................................... 46 Change Password .............................................................................................................................. 47

Database Diagram.............................................................................................................. 48 Production Report Database Diagram ............................................................................................... 48 Web Report Database Diagram ......................................................................................................... 49

ATTACHMENT................................................................................................................................. 51

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FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46

Automation Architecture ........................................................................................................... 8 Function Block Diagram ......................................................................................................... 14 WinCC Recording Data .......................................................................................................... 18 WinCC Viewing Data.............................................................................................................. 19 VB6 MTBF Block Diagram ..................................................................................................... 20 VB6 MTBF Menu.................................................................................................................... 21 VB6 Excel Exporter Printing Data........................................................................................... 22 VB6 Excel Exporter Configuration file .................................................................................... 23 VB6 Excel Exporter Login Form ............................................................................................. 24 VB6 Excel Exporter Hourly Report Menu............................................................................ 25 VB6 Excel Exporter Daily Report Menu .............................................................................. 26 VB6 Excel Exporter “Rekap Harian Produksi Report” Menu ............................................... 27 VB6 Excel Exporter OEE Report Menu............................................................................... 28 VB6 Excel Exporter MTBF_MTTR Report Menu................................................................. 29 VB6 Excel Exporter Energy Meter Report Menu................................................................. 30 Web Server Viewing Data................................................................................................... 31 Default Login Page ............................................................................................................. 32 Home Page ........................................................................................................................ 33 Cement Mill Hourly Report.................................................................................................. 34 Coal Mill Hourly Report....................................................................................................... 34 Kiln Hourly Report .............................................................................................................. 35 Raw Mill Hourly Report ....................................................................................................... 35 Cement Mill Daily Report .................................................................................................... 36 KCC Daily Report ............................................................................................................... 36 Raw Mill Daily Report ......................................................................................................... 37 Packer Daily Report............................................................................................................ 37 “Harian Produksi” Report .................................................................................................... 38 OEE Monthly Report........................................................................................................... 38 OEE Yearly Report ............................................................................................................. 39 MTBF_MTTR Report .......................................................................................................... 39 Energy Meter Report .......................................................................................................... 40 Delete Report ..................................................................................................................... 41 Delete Report ..................................................................................................................... 41 Create Report ..................................................................................................................... 42 Report Created ................................................................................................................... 42 Download Report 1............................................................................................................. 43 Download Report 2............................................................................................................. 43 Search Report By Date 1.................................................................................................... 44 Search Report By Date 2.................................................................................................... 44 Search Report Per Equipment (MTBF_MTTR) ................................................................... 45 Search Report Per Department (MTBF_MTTR).................................................................. 45 Register User...................................................................................................................... 46 Change Password .............................................................................................................. 47 Production Report Database Diagram ................................................................................ 48 Web User Database Diagram ............................................................................................. 49 Report Database Diagram .................................................................................................. 50

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OVERVIEW

1.1 Introduction This document defines how PT. Siemens Indonesia will meet all the elements of the User Requirements of the Reporting System described in the following documents: Document No.

CLIENT ENGINEERING DOCUMENTS Document of Reporting System Backup program of PCS7

Document No.

CLIENT ENGINEERING DRAWING

The Functional Design Specification together with the documents supplied by the customer, when agreed by Semen Baturaja and Siemens Indonesia, will become the main contractual document defining how Siemens intend to implement the project. It defines how the task will be carried out, the system and services to be supplied and the facilities to be made available.

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1.2

Scope

Figure 1

Automation Architecture

The Reporting System Area: a. b. c. d. e.

Raw Mill (R1R01) Coal Mill (K1R01) Kiln & Cooler (W1R01 & U1R01) Cement Mill (Z1R01) Packer (X1R01)

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This document covers the design and construction of the Production Reporting System for PT. Semen Baturaja that consists of: A. Hourly Report A.1 A.2 A.3 A.4

Raw Mill Coal Mill Kiln Cement Mill

B. Daily Report Per Area (Dept) B.1 B.2 B.3 B.4

Raw Mill Kiln, Coal, & Cooler Mill Cement Mill Packer

C. Daily Summary Production Report (RHP) D. Effectiveness Production Report D.1. Overall Effectiveness Equipment (OEE) Per Area (Dept) D.1.1 OEE Kiln D.1.2 OEE Vertical Mill D.1.3 OEE Finish Mill PBR D.1.4 OEE Crusher Batu Kapur D.1.5 OEE Coal Mill D.1.6 OEE Crusher Tanah Liat D.1.7 OEE Finish Mill PPG D.1.8 OEE Finish Mill PPJ D.2. Daily Energy Meter D.3. Mean Time Base Failure, Mean Time To Repair (MTBF_MTTR) Raw Mill Department D.3.1 A1J13M1 Belt Conveyor Motor D.3.2 A1L11A1 Reclaimer Limestone D.3.3 C1J32M1 Belt Conveyor Motor D.3.4 C1L03A1 Reclaimer Clay D.3.5 E1A01A1 Dosimat Silica D.3.6 E1B01A1 Dosimat Iron Sand D.3.7 N1P10A1 Compressor Motor D.3.8 N1P20A1 Compressor Motor D.3.9 N1P30A1 Compressor Motor D.3.10 N1P40A1 Compressor Motor D.3.11 R1A01A1 Dosimat Limestone D.3.12 R1J01M1 Belt Conveyor Motor D.3.13 R1M03M1 Vertical Mill Motor D.3.14 R1S01M1 Classifier Motor Baturaja_Reporting System Functional Design Specification This document and the copyright is owned by Siemens Indonesia. It may neither be copied nor submitted to third parties for copying without permission of the company

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D.3.15 D.3.16 D.3.17

R1S05M1 R1U20M1 R1U21M1

Mill Fan Motor Belt Bucket Elevator Motor Air Sluice Motor

D.3.18 D.3.19 D.3.20 D.3.21 D.3.22 D.3.23 D.3.24 D.3.25 D.3.26 D.3.27 D.3.28 D.3.29 D.3.30 D.3.31 D.3.32 D.3.33 D.3.34 D.3.35 D.3.36 D.3.37 D.3.38 D.3.39 D.3.40 D.3.41 D.3.42 D.3.43 D.3.44 D.3.45 D.3.46 D.3.47 D.3.48

Kiln Feed Department H1H01A1 J1J01M1 J1J03M1 J1P11E1 J1P11E2 J1P11E3 J1P11E4 J1P11E5 J1P11E6 J1P11M1 J1P11M2 J1P11M3 J1P11M4 J1P11M5 J1P11M6 J1P12M1 J1U24M1 J1U26M1 W1A01A1 W1A05M1 W1A10M1 W1A15M1 W1A20M1 W1A23M1 W1V72A1 W1V73M1 W1V74M1 W1V82A1 W1V83M1 W1V84M1 W1W03M1

Cf Extraction ID Fan Motor ID Fan Motor Ep-Retifier 1 Ep-Retifier 2 Ep-Retifier 3 Ep-Retifier 4 Ep-Retifier 5 Ep-Retifier 6 Ep-Rapping Gear 1 Ep-Rapping Gear 2 Ep-Rapping Gear 3 Ep-Rapping Gear 4 Ep-Rapping Gear 5 Ep-Rapping Gear 6 Filter Fan Screw Conveyor Motor Screw Conveyor Motor Dld Feeder Rotary Blower Motor Belt Bucket Elevator Motor Belt Bucket Elevator Motor Fluxoslide Fan Fluxoslide Fan Pfister Feeder Rotary Blower Motor Rotary Blower Motor Pfister Feeder Rotary Blower Motor Rotary Blower Motor Kiln Drive Motor

D.3.49 D.3.50 D.3.51 D.3.52 D.3.53 D.3.54 D.3.55 D.3.56 D.3.57 D.3.58

Cooler Department U1J11M1 U1J12M1 W1K01A1-3 W1K01A1-4 W1K01A1-5 W1K08M1 W1K10M1 W1K11M1 W1K12M1 W1K13M1

Pan Conveyor Motor Pan Conveyor Motor Grate Drive No. 3 Grate Drive No. 2 Grate Drive No. 1 Drag Chain Motor Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor

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D.3.59 D.3.60 D.3.61 D.3.62 D.3.63 D.3.64 D.3.65 D.3.66 D.3.67 D.3.68 D.3.69 D.3.70 D.3.71 D.3.72 D.3.73 D.3.74 D.3.75 D.3.76 D.3.77

D.3.78 D.3.79 D.3.80 D.3.81 D.3.82 D.3.83 D.3.84 D.3.85 D.3.86 D.3.87 D.3.88 D.3.89 D.3.90 D.3.91 D.3.92 D.3.93 D.3.94 D.3.95 D.3.96 D.3.97 D.3.98 D.3.99 D.3.100 D.3.101 Â

W1K14M1 W1K15M1 W1K16M1 W1K17M1 W1K18M1 W1K20M1 W1K21M1 W1K22M1 W1K26M1 W1K27M1 W1K50M1 W1M01M1 W1P11E1 W1P11E2 W1P11M1 W1P11M2 W1P15M1 W1P36M1 W1V91M1

Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor Cooling Air Fan Motor Sealing Air Fan Motor Sealing Air Fan Motor Nose Ring Fan Motor Hammer Breaker Motor Esp-Retifier 1 Esp-Retifier 2 Esp-Rapping Gear 1 Esp-Rapping Gear 2 Esp Fan Motor Booster Fan Motor Primary Air Fan Motor

Cement Mill Department U1J43M1 Steel Plate Conveyor Motor U1J81M1 Bucket Elevator Motor Z1A01A1 Gypsum Feeder Z1A06M1 Belt Conveyor Motor Z1B01A1 Clinker Feeder Z1D01A1 Limestone Feeder Z1J02M1 Bucket Elevator Motor Z1J03M1 Belt Conveyor Motor Z1J10M1 Bucket Elevator Motor Z1J19M1 Bucket Elevator Motor Z1J19M2 Feed Screw Conveyor Motor Z1J28M1 Bucket Elevator Motor Z1M03M1 Finish Mill Motor Z1M23U1 Roller Press Motor Z1M27A1 Hydraulic Unit (Local Control Panel) Z1M29A1 Lubrication Unit (Local Control Panel) Z1P12M1 Screw Conveyor Motor Z1P13M1 Screw Conveyor Motor Z1P17M1 Sepax Fan Motor Z1P55M1 Filter Fan Motor Z1P57M1 Jet Pulse Fan Motor Z1S01M1 Sepax Separator Motor Z1S10M1 Grit Separator Motor Z1S14M1 Grit Separator Fan Motor

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Coal Mill Department D.3.102 F1J41M1 D.3.103 F1L11A1 D.3.104 F1L21A1 D.3.105 K1A01M1 D.3.106 K1A02M1_1 D.3.107 K1J03M1_1 D.3.108 K1J03M1_2 D.3.109 K1M03M1 D.3.110 K1M05A1 D.3.111 K1M06M1 D.3.112 K1M07A1 D.3.113 K1M11A1 D.3.114 K1P12M1 D.3.115 K1P16M1 D.3.116 K1S01M1 D.3.117 K1T36M1

Bucket Elevator Motor Stacker Coal Reclaimer Coal Drag Chain Feeder Twin Paddle Forward Screw Conveyor Motor Screw Conveyor Motor Atox Mill Motor Gear Lubrication Unit (Local Control Panel) Sealing Air Fan Motor Hydraulic Unit (Local Control Panel) Roller Lubrication Unit (Local Control Panel) Screw Conveyor Motor Mill Fan Motor Separator Motor Booster Fan Motor

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1.3

User Requirement Specification The User Requirement Specification (URS) for production reporting system: a. All the report must be in excel form for further processing. b. All the report can be seen either from CCR (Central Control Room) or intranet PT. Semen Baturaja. c. All the master report in excel files and e-mail correspondent that already received from PT. Semen Baturaja as the basis to develop the production reporting system. d. The Production Reporting System Data is taken from the controllers and manual entry form which is already specified from PT. Semen Baturaja. e. All the reporting system data will be kept until one year. f. The Production Reporting System Performance must not interrupt production operation activity.

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SYSTEM SPECIFICATION

2.1 Reporting System Diagram Figure 2 shows the boundary of the reporting system. It shows the data flows diagram.

Web Reporting System ASP.NET, IIS, VB6 (Excel Exporter), SQL Server 2005 C_DB_1294

Ind. Ethernet

HMI WinCC Server Redundancy, VB6 (MTBF), SQL Server 2005 C DB 1291, C DB 1292 Ind. Ethernet

AS (Controllers) S5 PLC S7 PLC

Profibus DP

I/Oâ&#x20AC;&#x2122;s Figure 2

Function Block Diagram

Baturaja_Reporting System Functional Design Specification This document and the copyright is owned by Siemens A&C Indonesia. It may neither be copied nor submitted to third parties for copying without permission of the company

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Description: Automatic Data from Automation System (PLC and I/Oâ&#x20AC;&#x2122;s) and Manual Data (Production data, MTTR data, etc) are recording continously using WinCC (Windows Control Centre) Redundancy Server as HMI (Human Machine Interface) and place the necessary data for reporting system into SQL Server 2005 database at C_DB_1294 computer. Visual Basic 6 Program Application is purposed for MTBF (Mean Time Base Failure) record which is takes the data from WinCC SQL Server 2005 database at C_DB_1291 or C_DB_1292 computer and processing this data, such as calculate failure duration time of equipment, before finally put the MTBF data into SQL Server 2005 database at C_DB_1294 computer. At C_DB_1294 computer, there has two program application: Visual Basic 6 Program Application Excel Exporter, Web Server using Dot Net Framework (IIS, ASP.Net, ADO.Net). Visual Basic 6 Program Application is purposed for creating report from SQL Server 2005 Database to excel files and HTML files both automatic and manual. Web Server is used for publish all HTML files into internet explorer. Here, all the Web Client can be seen production report, download production report file (excel file), and delete report file (only for specific user). The communication between computers are using ethernet communication to exchange the data.

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2.2 System Requirements 3.3.2 PCS7 OS Servers (WinCC Servers) The two physical PCS 7 OS Servers are configured as a redundant pair with a redundant synchronisation connection between them. Hadware and software requirements refer to PCS7 manual.

2.2.2 Ms. Visual Basic 6 Program Applications Ms. Visual Basic 6 Program Applications are configured as additional program in order to meet load sharing and performance of WinCC Servers.

2.2.3 IIS, ASP.Net IIS (Internet Information Service) V5 is configured as Web Server while ASP.Net is configured as Web Dynamization which is working at server side. The IIS and ASP.Net Platform based on Microsoft Net Framework V4. Internet Explorer (IE) V6 or higher is configured as default Web Browser.

2.2.4 Ms. SQL Server 2005 Ms. SQL Server 2005 is configured as database to store and view data using structure query languange. 2.2.5 Ms. Excel 2003 Ms. Excel 2003 is configured as default reporting form.

2.2.6 Industrial Ethernet Network for System Bus Siemens Scalance X205 and X005 industrial switches are connected via their ports to form a 100MB signal for AS to OS communications for process data.

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2.3 Reporting System Method The Reporting System is divided into 3 parts: a. Record Data b. View Data c. Print Data a. Record Data Recording Data of production report uses SQL Server 2005 as RDBMS Database which is integrate in WinCC Installation with instancing name “\WinCC” and also use WinCC features such as Global Script and Visual Basic 6 Program Application. The Basis Design is based on reporting format in excel file which is supplied from PT. Semen Baturaja. (Please see at attachment of The Master Report Form) Table Structure in Database is divided into 3 part: 1. Hourly Production Report Æ Area Department 2. Daily Production Report Æ Area Department, Summary Daily Report 3. Effectiveness Production Report Æ OEE, MTBF_MTTR, Energy Meter b. View Data Viewing Data of production report can be seen in WinCC Runtime using WinCC Object Web Browser Technology. c. Print Data Printing Data of production report uses excel and HTML. These features can be seen in Web Reporting System.

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SYSTEM FUNCTION

3.1 WinCC 3.3.2 WinCC Recording Data The WinCC Recording Data is based on Global Script with VBScript. Global Script has 3 tabs: Project Module, Standard Module, Action Script. The Correlation like this below:

Action Script (Trigger)

WinCC

Triggered By: Tag, Time

Project Module Function, Sub Procedure Error Script Logg in txt file

Use ADO (AxtiveX Data Object) (Object Connection and Object Recordset)

Database SQL Server

Figure 3

WinCC Recording Data

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3.1.2. WinCC Viewing Data

Figure 4

WinCC Viewing Data

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3.2

Visual Basic (VB) 6 Program Application

3.2.1 VB6 MTBF MTBF Generator is a VB-based application which is intended to provide information MTBF (Mean Time Between Failures), running hours and normal-stop hours. Those information are taken by performing alarm analysis of the events (equipment start events, equipment stop events and equipment failure events). The system block diagram is described by Figure 5

WinCC Runtime

WinCC OLEDB

VB 6.0 MTBF Generator

SQL Server 2005

Figure 5 •

VB6 MTBF Block Diagram

Running hours is measured by extracting the time difference between the equipment start time and equipment stop time. The stop events used for running hours measurement are all stop events (normal stop and fault stop).

•

Normal stop hours is measured by subtracting total stop hours and fault hours. Total stop hours is defined as total duration of all stop events (measured from equipment stop event including stop caused by failure to equipment start running event).

•

Fault hours is defined as the duration between equipment stop event time (caused by failure) and equipment start event time.

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3.2.1.1

Operating Instructions

The application will only be active when it detects the WinCC runtime on the local PC acts as a master, otherwise it will remain standby or inactive. For the operation modes, there are two modes which are: •

Automatic In automatic mode, the application will perform alarm logging analysis of WinCC runtime using WinCC OLEDB as its interface at 07:00. the time range of the alarm logging analysis is from 07:00 on the previous date up to 07:00 on the current date. After all information from the alarm logging are processed, the result will be stored to SQL Server 2005.

•

Manual In manual mode, operator must select the equipment first. After selecting the equipment operator is allowed to view the running hours, normal stop hours, failure hours and failure frequencies from 07:00 up to current time. The principle is the same as in automatic mode; the only difference is the time range of the alarm logging analysis.

MTBF Generator has no exit button command because it’s not intended to be closed to avoid the MTBF data not sent to SQL Server 2005 at 07:00. The main screen is shown in Figure 6.

Manual Viewer Button in Hour

Source

Events

Time of Event Appearance Equipment Box Selection

Figure 6

VB6 MTBF Menu

in Hour

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3.2.2 VB6 Excel Exporter The VB6 Excel Exporter provides automatic (hourly and daily at 7.30 a.m.) and manual creation of the production report both in Excel file and HTML file also provides auto management data for reporting system, such as delete Excel, HTML files, database SQL Server 2005 older than one year at 7 a.m. Figure 5 illustrates the process of generating excel reports from SQL Server Database.

*.xls Template

File System Object

VB 6 Excel Exporter

Final *.xls Report

SQL Server Database ADODB

Figure 7

VB6 Excel Exporter Printing Data

1. The application makes a copy of excel report template using FSO object, and stores it as an excel file (*.xls) in the report destination folder. In the case where copying process does not succeed, the application logs error message in a txt file located in the application directory. 2. The application creates a new instance of Excel Application object, and then instructs it to open the copied excel file located in the destination folder. 3. The application creates a new instance of ADODB Connection object, and opens the connection with connection string. 4. The application uses SQL syntaxes to query all the necessary record from database into ADODB record set objects, and then writes the queried data into corresponding excel worksheets and cells. 5. Several data that are generated using Excelâ&#x20AC;&#x2122;s formula need to be stored back into SQL Server (e.g., from calculated daily data to monthly and yearly overview). In such cases, the application retrieves the data from Excel cells, and then uses INSERT or UPDATES SQL syntax to store the data back into corresponding table in SQL Server. 6. The reports are then being saved as both *.xls file and *.html file, and the application updates the report database in the SQL server.

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The VB6 Excel Exporter application comes with a configuration file (ExportConfig.ini) that must be placed in the same folder as the application. The file is used to set up all necessary settings to run the application. Figure 6 shows some example of configuration file contents.

Figure 8

VB6 Excel Exporter Configuration file

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3.2.2.1

VB6 Excel Exporter Login Form

When the application starts, a login form shows up and prompts user to input password. This login is used to grant access to create manual reports. The login form is shown in Figure 7.

Figure 9

VB6 Excel Exporter Login Form

If the login succeeds, the main form shows up. The main form has four Tabs, each containing user interface menu for creating different reports. The menus are: 1. Hourly Report (Figure 8) 2. Daily Report (Figure 9) 3. “Rekap Harian Produksi” (Figure 10) 4. “Rekap Efektifitas Produksi”, which contains 3 sub menus as follows: a. OEE Report (Figure 11) b. MTBF_MTTR Report (Figure 12) c. Energy Meter Report (Figure 13)

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Figure 10 VB6 Excel Exporter Hourly Report Menu

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Figure 11 VB6 Excel Exporter Daily Report Menu

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Figure 12 VB6 Excel Exporter â&#x20AC;&#x153;Rekap Harian Produksi Reportâ&#x20AC;? Menu

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Figure 13 VB6 Excel Exporter OEE Report Menu

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Figure 14 VB6 Excel Exporter MTBF_MTTR Report Menu

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Figure 15 VB6 Excel Exporter Energy Meter Report Menu

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3.3 Web Server Reporting System 3.3.1 Web Server Viewing Data Web Server (C_DB_1294)

SQL Server 2005 Database

IIS

ASP.NET

Web Client (Internet Explorer)

Figure 16 Web Server Viewing Data

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3.3.2 User Page 3.3.2.1

Default Login

Figure 17 Default Login Page On this login page, user should enter username and password that already registered and will be redirect into the main page. Only user known as an â&#x20AC;&#x153;Operatorâ&#x20AC;&#x153; who will be redirect into an administrator page and have an authority to delete or create report files.

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3.3.2.2

Home Page

Figure 18 Home Page On this homepage, users can access any reports through the menu at the upper page and on every page. At the right corner page, users can click the â&#x20AC;&#x153;LogOutâ&#x20AC;&#x153; button to exit this page and refuse their session. And at the bottom, users can get a contact information of IS & ENG PT. Siemens Indonesia.

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3.3.2.3

Production Report

Users can view and download Cement Mill Hourly Report that already generated through this page. If they choose to view the report, it will be shown automatically in a new browser window. If they choose to download the files, they can save it in an excel file. They can search a specific report based on its date.

3.3.2.3.1

Cement Mill Hourly Report

Figure 19 Cement Mill Hourly Report

3.3.2.3.2

Coal Mill Hourly Report

Figure 20 Coal Mill Hourly Report

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3.3.2.3.3

Kiln Hourly Report

Figure 21 Kiln Hourly Report

3.3.2.3.4

Raw Mill Hourly Report

Figure 22 Raw Mill Hourly Report

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3.3.2.3.5

Cement Mill Daily Report

Figure 23 Cement Mill Daily Report

3.3.2.3.6

KCC (Kiln Coal Clinker) Daily Report

Figure 24 KCC Daily Report

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3.3.2.3.7

Raw Mill Daily Report

Figure 25 Raw Mill Daily Report

3.3.2.3.8

Packer Daily Report

Figure 26 Packer Daily Report

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3.3.2.3.9

Daily Summary Production Report (“Harian Produksi”)

Figure 27 “Harian Produksi” Report

3.3.2.3.10

OEE Monthly Report

Figure 28 OEE Monthly Report

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3.3.2.3.11

OEE Yearly Report

Figure 29 OEE Yearly Report

3.3.2.3.12

MTBF_MTTR Report

Figure 30 MTBF_MTTR Report

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3.3.2.3.13

Energy Meter Report

Figure 31 Energy Meter Report

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3.3.3 Web Report Management 3.3.3.1

Delete Report

Figure 32 Delete Report User that has an authority to delete a specific list file in database SQL Server 2005 by clicking the delete button at selected reportâ&#x20AC;&#x2122;s row.

Figure 33 Delete Report

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3.3.3.2

Create Report

Figure 34 Create Report User that has an authority to generate back the list files into database SQL Server 2005 that already deleted by searching the file first using search engine and select the date report, then click the Create Report button.

Figure 35 Report Created

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3.3.3.3

Download Report

Figure 36 Download Report 1 User can download any report by clicking the download button

Figure 37 Download Report 2

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3.3.3.4

Search Report

3.3.3.4.1

Search Report By Date

Figure 38 Search Report By Date 1 User can search a specific file based on date report using search engine in every pages. This help user to find the report they want to see.

Figure 39 Search Report By Date 2 Selected report will show at the bottom of search engine.

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3.3.3.4.2

Search Per Equipment (MTBF_MTTR)

Figure 40 Search Report Per Equipment (MTBF_MTTR) User can sort the report by choosing the equipment then it will show the result automatically after they click the name.

3.3.3.4.3

Search Per Department (MTBF_MTTR)

Figure 41 Search Report Per Department (MTBF_MTTR) User can sort the report by choosing the department then it will show the result automatically after they click the name.

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3.3.4 User Management 3.3.4.1

Figure 42 Register User User should have a username and password first before accessing The Semen Baturaja Production Report system. They should use this page to register their username and password to the system.

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3.3.4.2

Change Password

Figure 43 Change Password User can change their password after they login to the system. They should insert the old password and replace it with a new one using this page.

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3.3.5 Database Diagram 3.3.5.1

Production Report Database Diagram

Rekap Efektifitas Produksi Report

Rekap Harian Produksi Report

Daily Report

Hourly Report Figure 44 Production Report Database Diagram

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3.3.5.2

Web Report Database Diagram

Figure 45 Web User Database Diagram

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Figure 46 Report Database Diagram

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ATTACHMENT (MASTER REPORT)

BAKU

KOREKSI

HOURS

I / II

RAW MILL FEED ( COUNTER )

R1A01A1

C1R02A1

E1A01A1

E1B01A1

VERTICAL MILL TEMPERATUR HYDRAULIC PRESSURE

POWER MOTOR

DIFF. PRESS

: 2 RD 2300-03

HALAMAN

: 1 dari 1 EP FAN

CLASSIFIER

HOPPER

VIBRASI

TOTAL FEED

STORAGE BAHAN

N0.DOKUMEN

MILL FAN

PRESS. INLET

TEMP. INLET

J1P11

(J1P11)

R.90u

R.200u

H2O

N3P01

N4T01

INLET

OUTLET

(R1M01)

R1M08

R1M09

R1M01

R1M03

R1M01

R1S01

R1S05

N3T01

N6T01

N1P01

N1V01

M1J01

N5P01

D1S01

M1J01

N6P01

bar

mm/s

mbar

70-134

43-95

3-20

0-2630

44-125

0-100

0-2850

-15-10

0-100

0-12

S06

RESIDU ON

R1M01 I1 %

Ton

10-100

20-115

T/H

MOISTURE

REKAMAN MUTU PERFORMANCE OPERASI PENYIAPAN RAW MEAL

PT.SEMEN BATURAJA ( PERSERO ) SEKSI PENG.BAMEN

CF - SILO

Raw Mill Hourly Report

Level

08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 Std

MASALAH

0-450

0-100

0-35

0-25

210-500

183-434

ANALISA PENYEBAB

TINDAKAN

HASIL / KETERANGAN

0-250

Max.18 Max.1,5 Max.1

45-95

TGL OPERASI : T.TANGAN OPERATOR CCR

SHIFT I II III SHIFT

T.TANGAN KA.SI. PENGGILINGAN

I II III CATATAN :

1. Pengisian data harus Jelas, lengkap dan actual

2. Informasi harus dapat ditelusuri

3. Penyimpangan dari standart harus diberi penjelasan

Coal Mill Hourly Report REKAMAN PENGENDALIAN OPERASI COAL MILL

m3/min

65 s/d 75

60 s/d 78

STATUS ( Yes/ No )

70 s/d 100

R 90 U

240 s/d 400

STATUS ( Yes/ No )

110 s/d 140

SIEVING

% H 2O

0.7 s/d 3.0

FINE COAL CAL. BIN WEIGHT W1P82A1W01

12 s/d 20

: …………………………

BURNER BIN WEIGHT W1P72A1W01

3 s/d 10

Ton

Y/ N

Max. 90

30 s/d 65

Max. 9

Max. 20

STATUS

TEMP CAL BIN K1L12N1T01

60 s/d 80

: 2 RD 2301 - 06

Tanggal

SHIFT

TEMP BURNER BIN K1L11N1T01

POWER MOTOR K1P16M1 J01

Bar

AIR FLOW K1P16N5 F01

mm/Sec

No. Dokumen

PFISTER BIN

LOUVRE DAMPER K1P15M1Z01

THROT DAMP. POS K1T37M1Z01

mBar

CHAMBER 2 TEMP. K1P11N2T02

KW MOTOR C M K1M03M1J01

mBar

CHAMBER 1 TEMP. K1P11N1T01

GRINDING PRESS M07A1P01

MILL FAN

JET PULSE OUT TEMP C MILL K1M01N5T01

C MILL VIBRATION M01N4V01

IN TEMP C MILL K1M01N1T01

C MILL PRESS M01N3P01

Ton

INLET PRESS M01N2P01

Ton

DRIYING

CLASIFIER SPEED S01M1S02

GRINDING

FEEDER A01M1I01

CLASIFIER

COUNTER BELT WAIHGER F1J51 A1

FEEDING RAW COAL SILO WEIGHT L01A1W01

BIRO PRODUKSI BATURAJA

WATER CONTAINT

PT. SEMEN BATURAJA ( PERSERO )

STANDARD PENGENDALIAN

08.00 09.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00 22.00 23.00 24.00 01.00 02.00 03.00 04.00 05.00 06.00 07.00 Pengisian : Kumulatif :

Max. 260

65 s/d 75

PERMASALAHAN DAN TINDAKAN PENYELESAIAN M A S A L A H

TINDAKAN PENYELESAIAN

65 s/d 75

70 s/d 250

S/B

OP. CCR COAL MILL

Ka. SEKSI PEMBAKARAN

I II III Rekomendasi Kabag. Pembakaran :

Kiln Hourly Report

mg/ m3

Gr/ Lt

Y/N

PENYIMPANAN CLINKER SILO ( I / II / III / CCS / Int.Med.)

kcal/kg PRODUKSI, ton cli pershift

SPM mg/ m3 BAR BAR BAR U / D

STATUS

SPM

TEMPERATURE

SPM

LITER WEIGHT ( L/W )

mbar

FREE LIME

SILO-II LEVEL

SILO-I LEVEL

mBar

SILO-III LEVEL U1L11N1 L01

T/ J

INTER. SILO LEVEL U1L01N1L01

T/ Shift

PH B

CO B50A1 A03

T/ J

CLINKER PRODUCT

STORAGE SILO

O2 B50A1 A02

T/ Shift

CLINKER

2 RD 2301 - 02

O2 A50A1 A02

Emisi Dust J1S01A1DO1

Opacity J1S01A1OO1

Kiln Pos Up / Down

GRATE III W1K04A1 S03

mBar

PH A

GRATE II W1K03A1 S02

s/d

880

PH OUT GAS ANALYZER

HYD. PRESS

GRATE I W1K02A1 S01

s/d

380

EP Dust

Under Grate I Pressure W1K23N1 P01

s/d

870

COUNTER W1V82 A1 FLOW W1V82A1 F01

s/d

880

COUNTER W1V72 A1 FLOW W1V72A1 F01

s/d

380

SPEED J1J03M1

850

s/d

SPEED J1J01M1

40 s/d

Secukupnya

65 s/d

TEMP TAD W1B55N1 T01

Max. 85

OUT GAS W1B54N1 T01

OUT GAS T01

COOLER

SLC

GRATE III W1K04N1P01

KILN

: :

CO A50A1 A03

COAL FIRING

Secukupnya

PRESSURE TAD W1B55N2 P01

OUT MATERIAL W1A55N2 T01

OUT GAS W1A55N1 T01

TORQUE W1W01I1 I01

T/ J

OUT GAS W1A50N1 T01

SPEED W1W03M1 S01

COUNTER W1A01 A1

Current W1A10

STROKES

FLOW W1A01A1 F01

W1B50N1

IDF

SLC

GRATE I W1K02N6P01

Cy.1st Cy.4th

GRATE II W1K03N1P01

STR - B

Cy.4th

Emisi stack ESP W1S01A1 D01

STR - A Cy.1st

SEC. AIR TEMP. W1K01N2 T01

KILN

KILN HOOD PRESS W1K01N1 P01

KILN FEED

No. Dokumen Tanggal

HC,

REKAMAN PENGENDALIAN OPERASI KILN

BIRO PRODUKSI BATURAJA

( FCaO )

PT. SEMEN BATURAJA ( PERSERO )

08.00 09.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00 22.00 23.00 24.00 01.00 02.00 03.00 04.00 05.00 06.00

………………...……..

ton

360

850

840

M A S A L A H

360

- 0,2 s/d

Max. 80

Max. Max. 20 80

Max. 0,20

Max. 1,5

- 0,8

PERMASALAHAN DAN TINDAKAN PENYELESAIAN TINDAKAN PENYELESAIAN

1100 s/d

1250

STATUS S/B

< 1,5 =Y > 1,5 = N

Produk ………...….…… t/h Kumulatif :

JUMLAH PEMAKAIAN LISTRIK KILN COAL MILL .........................

Kwh

.........................

Kwh

SHIFT

PENGENDALIAN

07.00

OP. CCR KILN

Ka. SEKSI PEMBAKARAN

..............................

................................

..............................

................................

III

..............................

................................

Rekomendasi Kabag. Pembakaran :

Cement Mill Hourly Report PT.SEMEN BATURAJA ( PERSERO ) SEKSI PENG.SEMEN

REKAMAN MUTU PERFORMANCE OPERASI CEMENT MILL

FEED

HOURS CLNK

GYP

Z1L02 Z1L01 %

FLY ASH SCREW

COUNTER

STOCK

HYDRAULIC ROLLER PRESS BELT SPEED

GRIT SEPARATOR

FINISH MILL

SEPAX SEPARATOR

N0.DOKUMEN

2 RD 2401-04

HALAMAN

1 dari 1

SEPARATOR FAN

KWALITAS PRODUK

STORAGE SEMEN LEVEL

Fly Ash

CLNK

GYP

Fly Ash

SPEED

POWER

GAP Z01

GAP Z02

SPEED

DAMPER FAN

POWER

VENT.

TEMP. CMN OUT

SPEED

FRESH AIR

DAMP

SPEED

R.90u

R.45u

SO3

BLAINE

CEMENT FREE LIME

Z1L11

Z1B01A1

Z1A01A1

Z1J13A1

SPEED

RATE

Z1A06

SPEED

POWER

GAP

Z1M27

S10 S01

S13 I1

M03

P54

Z1M01N7 T01

S01 I1

Z1S02

P16 I1

P1711

R90U

R45U

SO3

BLNE

FCAO

Ton

M33 S01

M33 I01

Bar

Cm2/g

15 - 100

1-8

22 - 100

69 - 94

37 - 100

8,1 - 35,8

12 - 32,7

110 - 150

40 - 90

60 - 100

80 - 120

49 - 78

69 - 100

82 - 94

Z1 J 19 M2

SILO I

SILO II

Z1L04N1L01 Z1L05N1L01

9 - 95

08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00

Std

16 - 92 11 - 94

0-235

MASALAH

ANALISA PENYEBAB

TINDAKAN

957 - 1350 15 - 45

HASIL / KETERANGAN

Max.10 Max.25

1,5-3,5* Min.3000* MAX. 4** Min.3150**

TGL. OPERASI : SHIFT

T. TANGAN OPERATOR CCR

I II III SHIFT

T. TANGAN KA.SI. PENGGILINGAN

I II III H20 Gypsum ( % )

1. Pengisian data harus Jelas, lengkap dan actual

2. Informasi harus dapat ditelusuri

Catatan : * untuk semen type I, dan ** untuk semen komposit

Fly Ash masuk ( Ton )

STEEL BIN

Z1L06 Z1L07 TON

TON

Raw Mill Daily Report PT.SEMEN BATURAJA (PERSERO) TARGET PRODUKSI R. MEAL SHIFT I = LIME STONE

TON CLAY

TARGET PRODUKSI R. MEAL SHIFT II = PASIR SILIKA

PASIR BESI

% H2O

Ton dry

Ton wet

% H2O

Ton dry

Ton wet

% H2O

Ton dry

Ton wet

% H2O

TON

RAW MEAL

SHIFT Ton wet

No. Dokumen Halaman Tanggal

LAPORAN HARIAN PENGGILINGAN BAHAN MENTAH

Ton dry % H2O Avg

TARGET PRODUKSI R. MEAL SHIFT III = FREK KEHALUSAN > STD

PRODUCT Raw Meal

: 2 RD 2400-04 : 1 dari 2 :

Kwh/ Ton

R+200u

Y/T

R+90u

Y/T

JAM OPERASI

TON JUMLAH % H2O>1

Y/T

% Silo≤45

Y/T

6.00

0.0

0.00

0.0

0.00

0.0

0.00

0.0

0.00

0.0

#DIV/0!

0.00

0.0

0.00

0.0

0.00

0.0

0.00

0.0

0.00

0.0

#DIV/0!

III

0.00

0.0

0.00

0.0

0.00

0.0

0.00

0.0

0.00

0.0

#DIV/0!

0.0

0.00 0.0

TOTAL

0.0 Standard / Shift

KOMENTAR : SHIFT I

KOMENTAR : SHIFT II

Power Mwh meter : : : :

Vm motor Mfan Rmtrafo Total

Kwh / shift 0.00 0.00 0.00 0.00

0.00

PARAF :

Power Mwh meter : : : :

INSTRUKSI : RENCANA PRODUKSI RAW MEAL =

LIME STONE

CLAY

PASIR

( Ton )

(Ton)

BESI

SILIKA

C/T

I II Kwh / hari :

19.92

Max.1,5

Max.18

Max.1

Min.45

Max.1

KOMENTAR : SHIFT III

Kwh / shift 0.00 0.00 0.00 0.00

0.00

PARAF :

STORAGE ( JAM 07:00 ) PILE

Vm motor Mfan Rmtrafo Total

0.98

Vm motor Mfan Rmtrafo Total

Power Mwh meter : : : :

Kwh / shift 0.00 0.00 0.00 0.00

PARAF : TON / HARI

Baturaja,

Ka Bagian Penggilingan Bta

0.00

KCC Daily Report REKAMAN HARIAN PERFORMANCE OPERASI PEMBAKARAN PABRIK BATURAJA

PT. SEMEN BATURAJA (PERSERO) BIRO PRODUKSI

SHIFT

Factor Clinker

Heat Comsump

(Kcal/Kg)

STOCK CLINKER

PRODUKSI Pemakaian Bahan & Produk, ton KilnFeed

FineCoal

Solar

Jam Operasi Kiln

Clinker

Jam Operasi Coal

Pemakaian Listrik Coal Mill

Pemakaian Listrik Kiln kWh

kWh/ ton

kWh

Halaman

STOCK COAL

2 RD 2301-02 2 dari 2 KUALITAS PRODUK

Intern.Silo

Silo I

Silo II

Silo III

Cover Storage

Open Storage

Raw Coal Silo

Fine Coal Burner Bin

Fine Coal Calciner Bin

Ton

kWh/ ton

No Dokumen

CLINKER % Fcao

Y/ T

COAL

Liter Weight

Y/ T

% H2O

Y/ T

% R90 U

Y/ T

0.00

0.50

1,233.85

7.72

19.00

0.00

0.50

1,233.85

7.72

19.00

III

0.00

0.50

1,233.85

7.72

19.00

TOTAL

0.00

Standard Per Shift

Max. 45

SHIFT I TARGET PRODUKSI CLINKER SHIFT I

Max 1,5

Y<=1,5

SHIFT II

TON

TARGET PRODUKSI CLINKER SHIFT II

Power MWh Meter

1100<LW<1250

Y<=1,5

Max. 9

Y<= 9

SHIFT III

TON

TARGET PRODUKSI CLINKER SHIFT III

Power MWh Meter

TON

Power MWh Meter

Kiln Drive Trafo

0.00

IDF - A Trafo

0.00

Kiln Drive Trafo

0.00

IDF - A Trafo

0.00

Kiln Drive Trafo

232323.00

IDF - A Trafo

23331.00

Kiln Aux. Trafo

0.00

IDF - B Trafo

0.00

Kiln Aux. Trafo

0.00

IDF - B Trafo

0.00

Kiln Aux. Trafo

132232.00

IDF - B Trafo

21231.00

Cooler Trafo 1

0.00

Boster Fan

0.00

Cooler Trafo 1

0.00

Boster Fan

0.00

Cooler Trafo 1

2321325.00

Boster Fan

0.00

Cooler Trafo 2

0.00

Filter Fan

0.00

Cooler Trafo 2

0.00

Filter Fan

0.00

Cooler Trafo 2

0.00

Filter Fan

13223.00

0.00

Coal Mill Drive Trafo

0.00

Coal Mill Drive Trafo

Total Coal Mill Drive Trafo ID Fan

0.00 0.00

Total Coal Mill Aux. Trafo

0.00 Total

ID Fan

: :

0.00

PARAF KEPALA SEKSI PEMBAKARAN :

0.00

0.00 Total

KOMENTAR : SHIFT I

PRODUKSI CLINKER KOMULATIF :

0.00

Total Coal Mill Aux. Trafo

ID Fan

132123.00

2743665.00 Coal Mill Aux. Trafo

13223.00

0.00

Total

KOMENTAR : SHIFT II

KOMENTAR : SHIFT III

PARAF KEPALA SEKSI PEMBAKARAN :

148469.00

TON Baturaja,

22/01/2011

Kepala Bagian Pembakaran PBR Catatan :

3123.00

Max. 20

Y<= 20

Cement Mill Daily Report

REKAMAN HARIAN PERFORMANCE OPERASI CEMENT MILL PABRIK BATURAJA

PT. SEMEN BATURAJA (PERSERO) BIRO PRODUKSI

PRODUKSI SEMENT PORTLAND TIPE-I

MOISTURE

No Dokumen

2 RD 2300-04

Halaman

PRODUKSI SEMENT PORTLAND KOMPOSIT KUALITAS PRODUK STANDAR

SHIFT

Gypsum

Third

Pemakaian Bahan & Produk, ton Clinker

Gypsum

Third

Fly Ash

Cement

Jam Operasi

Pemakaian Bahan & Produk, ton

Pemakaian Listrik kWh

kWh/ ton

Clinker

Gypsum

Third

Fly Ash

Cement

Jam Operasi

Pemakaian Listrik kWh

kWh/ ton

% SO3

Residue 90µm

Y/ T

Blaine

Residue 45µm

Y/ T

0.00

III

0.00

TOTAL

0.00

Standard Per Shift

0.00

0.00 -

0.00

0.00 -

Max. 45

0.00

TON

TARGET PRODUKSI SEMEN SHIFT II

Roller Press Trafo

0.00

ID Fan Trafo

Mill Motor Trafo

0.00

Auxiliaries Trafo

0.00 -

0.00

1.5 - 3.5* Max 4**

Max 10

Max 1

Max. 45

: :

TARGET PRODUKSI SEMEN SHIFT III

TON

Roller Press Trafo

0.00

ID Fan Trafo

0.00

Mill Motor Trafo

0.00

Auxiliaries Trafo Total

: :

PENERIMAAN FLY ASH :

PARAF KEPALA SEKSI PENGGILINGAN SEMEN :

TON/ HARI

Roller Press Trafo

0.00

ID Fan Trafo

0.00

Mill Motor Trafo

0.00

Auxiliaries Trafo Total

: :

0.00

KOMENTAR : SHIFT III

TON

PENERIMAAN FLY ASH :

PARAF KEPALA SEKSI PENGGILINGAN SEMEN :

PRODUKSI SEMEN KOMULATIF :

TON

0.00

KOMENTAR : SHIFT II

TON

Max 1

Power MWh Meter

0.00

Max 25

SHIFT III

Power MWh Meter

KOMENTAR : SHIFT I

INSTRUKSI: RENCANA PRODUKSI SEMEN =

Power MWh Meter

PENERIMAAN FLY ASH :

0.00

SHIFT II

Total

0.00

SHIFT I TARGET PRODUKSI SEMEN SHIFT I

0.00

OPC Min 3000* PCC Min 3500**

TON

PARAF KEPALA SEKSI PENGGILINGAN SEMEN :

0.00

TON Baturaja,

Catatan : * Untuk Semen Portland Tipe I, Dan ** Untuk Semen Portland Komposit

Kepala Bagian Penggilingan PBR

0.00 0.00

Rekap Harian Produksi Report (RHP) PT. SEMEN BATURAJA (PERSERO)

No. Dokumen

REKAP HARIAN PRODUKSI

BIRO PTP

: 1 RD-2424-01 : 1 dari 1

Halaman Tanggal Operasi

PABRIK BATURAJA

I. PENGENDALIAN PROSES Kumulatif

Pengisian storage Limestone & Clay -

Lime stone - 2 , ton kumulatif

Clay - 1 , ton kumulatif

% H2O

Clay - 2 , ton kumulatif

% SO3

B a h a n

Clay

Harian

Gypsum Umpan C. Mill -

% H2O

Fine coal

Clinker Outlet Kiln

Kiln feed

Solar

% FCaO

% C3S

% SO3

% 200 u

% C2S

R+90 u

% 90 u

% C3A

R+45 u

% C4AF

% C 3S % C 2S

LSF

% C 3A

% C 4AF

% FCaO Terak Dispath & Kirim

Cement Outlet C.Mill

% FCaO

% H2O

LSF

B a k a r Raw coal

Raw meal

% RCO 3

% H2O

Lime stone - 1 , ton kumulatif

Parameter

Lime stone

% RCO 3

% 200 u

% FCaO

Harian

% 90 u

Dispath

Ke PPG

Ke PPJ

Blaine cm2/gr

Ď , gram / ml NHV. Kcal/kg

Mingguan

Bulanan

L/W, gr/lt

Temp.oC

LSF SM -

II. PENGGILINGAN BAHAN MENTAH Performance operasi / Pemakaian Bahan Uraian Produksi Raw meal , ton

Harian

Stock bahan

Bulanan

0.0000

Bahan

Tahunan

0.0000

Operasi Raw Mill , jam

Raw meal , CF silo

Tanah liat , ton

Clay storage 1

Pasir Silika , ton

Clay storage 2

Pasir Besi , ton

Pasir Silika

Kwh / ton Raw Meal

IDO Hot Gas Mill , klt

Crusher Bamen : -

Lime stone storage 2 Vertical Mill :

Pasir Besi

III . PEMBAKARAN

2636

Performance operasi / Pemakaian Bahan Uraian

ton

Lime stone storage 1

Batu kapur , ton

Mill power , Kwh

Hambatan operasi

Harian

Stock bahan

Bulanan

Produksi Terak, ton

Lokasi

Tahunan

Hambatan operasi ton

Kiln :

Terak silo 1

Operasi Kiln, jam

Terak silo 2

Operasi Coal Mill, jam

Terak silo 3

Heat Cons, kcal/kg terak

Terak Inter. Silo

Dumping Clinker D.Truck PBR

Coal Mill :

Umpan Kiln, ton

Terak Inter. Bin

Solar Kiln, klt

Terak Cover Storage, ton

Fine coal, ton

Raw coal, ton

Open St.

Solar Kiln, klt

Kiln power , Kwh Coal Mill power , Kwh

Tot. Persediaan Terak

Kum. DT

0 -

Angkutan Terak :

IDO, klt

Raw coal, ton Silo

Clinker Dispath , grb

Terak

Kirim Ke PPG , grb

PPG, %

Kirim Ke PPJ , grb

PPJ ,%

Semen 1

Semen 2

IV. PENGGILINGAN SEMEN & PENGANTONGAN Performance operasi / Pemakaian Bahan Uraian

Harian

Produksi Cement Mill , ton

Prod. Cmt. Packer , ton

Stock bahan

Bulanan

Tahunan

Lokasi Semen silo 1

0.00

Terak , ton

Gypsum , ton

Fly Ash, ton

Cement Mill PPG :

Gypsum, ton

PPG & PPJ Ton Cm.Mill, PPG

Kantong Semen, 3 ply , lbr

Ton Packer, PPG

Kantong Semen, 4 ply , lbr

Ton Cm.Mill, PPJ

Cement Mill power , Kwh

5 #DIV/0! Bulan ini

Produksi Terak, ton RKAP

98,600

% pencapaian prod. Terak

Real Prod. Terak ( - ) RKAP Prod. Tambang Harian :

Total Persediaan, ton

Kantong Semen, 2 ply , lbr

V. PENCAPAIAN RKAP :

Cement Mill PBR :

Semen Feed Bin

Operasi Cmt. Packer, jam

Kwh / ton Semen

Hambatan operasi ton

Semen silo 2

Operasi Cement Mill , jam

Cement Packer power, Kwh

Bulanan

Cement Mill PPJ :

Cement Packer :

Ton Packer, PPJ

217

Jam opr. Cm.Mill, PPJ

#DIV/0!

Penerimaan Batubara

Jam opr. Cm.Mill, PPG Ton / Hari

Ton / Bulan

Kumul.s/d bulan ini

Baturaja, 02-01-2010

279,400 -

(98,600) (279,400) 0 * Lime Stone * Clay

Harian

Ka Bag. Eng. Produksi

Note : 1. Dok. dianggap sah bila dibubuhi dg tanda tangan asli penanggung jawab dok. 2. Lap ini bukan data resmi utk kepentingan ext. prsh

No. Revisi : 01 Tgl. Revisi : 01-06-2003

Packer Daily Report

REKAMAN MUTU

PT SEMEN BATURAJA

PERFORMANCE OPERASI CEMENT PACKER

(PERSERO)

SHIFT / GRUP

PRODUKSI PACKER P1

DO CURAH

PCC

B BAG

CPSL

TON

ZAK PECAH (PCS/JNS) JAM OPERASI

TON

ZAK

TON

ZAK

TON

TRM PNDG TON

DISTRIBUSI KANTONG

KAPASITAS 50 KG

P1 ZAK

No. Dokumen : 2.RD.2302 - 17 Halaman : 1 dari 1

T/J

2 PLY PCC

2 PLY OPC

3PLY

40 KG

BBAG

L +K

INTR

1 PLY

TON

PSTD

BGR

PSTD

BGR

PSTD

LP +

JHT

BTA

BKL

0.00

II /

0.00

III/

0.00

TOTAL (ZAK) HARI INI =

ZAK

TOTAL (TON) HARI INI =

KUMULATIF BULAN INI =

ZAK

KUMULATIF (TON)

SEMEN TRANSIT PPJ (KA) TON

ZAK

PPG (KA)

TON

ZAK

PPG (TRUCK)

TON

ZAK

TON

VIA (KA) ZAK

TOTAL (TON ZAK + TON CURAH)

0 TON

KUMULATIF (TON ZAK + TON CURAH)

PNJ. LB LING

VIA (TRUCK)

TON

ZAK

TON

TOT

JENIS PEMAKAIAN KANTONG

JAM

ZAK

TON

ZAK

TOT

1 PLY

PSTD

BGR

PSTD

3 PLY

BGR

PSTD

40 KG

TON

SPT

PENYELESAIN

BBAG

JHT

III TOT

0 0

TANGGAL :

0 TON SAMPLE MONITORING BERAT / ZAK

TOT

MASALAH

1 2 3 4 5 6 7 8

BOBOT (KG) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

LAMA

AVG

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 GANGG OPRS (JAM) LIST. / INST

2 PLY PCC

2 PLY OPC

0 TON

VIA (KA)

50 KG SHIFT

PENJ. PENJW

PACKER I

ZAK

PPJ (TRUCK)

PENJUALAN KT BUMI

0 TON

22-January-2011

1. Harus di isi dengan data yang akurat

0.00 MEKANIK 0.00 OPERASI 0.00

2. Bila ada hambatan, kelainan (sample, penggantian kantong, dll) agar ditulis

SPT

1 2 3 4 5 6 7 8

PACKER II

TOT

BOBOT (KG)

AVG

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

PEMAKAIAN LISTRIK : :

KwH MTR I KwH MTR II

KwH / HARI KwH / TON SHIFT

0 0

: PRP OPR

I II III

3. Alasan pending, harus ditulis

0 (2,5 kw) PRP KA SIE

OEE Monthly Report PT SEMEN BATURAJA (PERSERO)

OEE KILN SYSTEM REPORT

Doc. No :

Page :

Area Department :

Kiln

Month OEE Report :

Tgl

Jam Operasi Sedia Realisasi

Hari Stop Bln

Produksi Bln

Kum

TCT

Kum

0.00556

SUM/AVG

Availability

Performance Rate

Quality Rate

OEE

OEE Target

0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%

100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%

59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59% 59%

0.00%

100.00%

0.00%

59.00%

OEE Yearly Report PT SEMEN BATURAJA (PERSERO)

OEE KILN SYSTEM REPORT

Doc. No :

Page :

Area Department :

Kiln

Year OEE Report :

Month

Jam Operasi Sedia Realisasi

Hari Stop Bln

Produksi Bln

Kum

TCT

Kum

Availability

Performance Rate

Quality Rate

OEE

OEE Target

January

0.00556

0.00%

100.00%

0.00%

59.00%

February

0.00556

0.00%

100.00%

0.00%

59.00%

March

0.00556

0.00%

100.00%

0.00%

59.00%

April

0.00556

0.00%

100.00%

0.00%

59.00%

May

0.00556

0.00%

100.00%

0.00%

59.00%

June

0.00556

0.00%

100.00%

0.00%

59.00%

July

0.00556

0.00%

100.00%

0.00%

59.00%

August

0.00556

0.00%

100.00%

0.00%

59.00%

September

0.00556

0.00%

100.00%

0.00%

59.00%

October

0.00556

0.00%

100.00%

0.00%

59.00%

November

0.00556

0.00%

100.00%

0.00%

59.00%

December

0.00556

0.00%

100.00%

0.00%

59.00%

0.00556

0.00%

100.00%

0.00%

59.00%

SUM/AVG

MTBF_MTTR Monthly Report

MONTHLY MTBF& MTTR RAW MILL DEPARTMENT EQUIPMENT

PT SEMEN BATURAJA (PERSERO)

Doc. No :

‐

Page :

Equipment Name : Month Report :

Day

Normal

Stop Hours Failure

Failure Freq

Running Hours

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

SUM

MTBF

Repair Repair Hours

Repair Freq

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

January

MTTR 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

MTBF_MTTR Yearly Report

YEARLY MTBF& MTTR RAW MILL DEPARTMENT EQUIPMENT

PT SEMEN BATURAJA (PERSERO)

Month : January February March April May June July August September October November December

SUM

Normal

Stop Hours Failure

Failure Freq

0 0 0 0 0 0 0 0 0 0 0 0

Running Hours

MTBF

0 0 0 0 0 0 0 0 0 0 0 0

Doc. No : Page : Equipment Name : Year Report :

Repair Repair Hours Repair Freq 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

MTTR 0 0 0 0 0 0 0 0 0 0 0 0

Daily Energy Meter

DAILY REPORT ENERGY METER

PT SEMEN BATURAJA (PERSERO)

No. Dokumen : Halaman : Tanggal :

DEPARTMENT AREA RAW MILL

CEMENT MILL

KILN

COAL MILL

COOLER

Vm Motor : Mfan : RMTrafo :

0.00 0.00 0.00

Kwh Kwh Kwh

Roller Press Trafo : Mill Motor Trafo : Auxiliaries Trafo : ID Fan Trafo :

0.00 0.00 0.00 0.00

Kwh Kwh Kwh Kwh

Kiln Drive Trafo : Kiln Aux Trafo : IDF-A Trafo : IDF-B Trafo : Booster Fan : Filter Fan :

0.00 0.00 0.00 0.00 0.00 0.00

Kwh Kwh Kwh Kwh Kwh Kwh

Coal M. Aux Trafo : K1TR02_J02 Mill Fan : Mill Motor :

0.00 0.00 0.00 0.00

Kwh Kwh Kwh Kwh

Cooler Trafo 1: Cooler Trafo 2: C1TR01_J02

0.00 0.00 0.00

Kwh Kwh Kwh

Total

0.00

Kwh

Total

0.00

Kwh

Total

0.00

Kwh

Total

0.00

Kwh

Total

0.00

Kwh

Comment :