Synopsis of Cold Reduction Mill Drives and Automation Controls Upgrade

Situation: A leading steel manufacturer operated a 34-year old Cold Reduction Mill. Issue: Meeting the intensifying quality and commercial demands of the market was increasingly challenging with the antiquated mill equipment and drives and controls. Requirement: A drives and automation controls upgrade to meet the steel manufacturers objectives for improved tension control; enhanced tail-spotting capabilities; reduced percentage of product wasted; improved product consistency; increased equipment reliability; reduced maintenance costs; and increased safety. Technology: DC drives, Allen-Bradley PLC 5/40C, RSView, PanelViews, ControlNet, SAFphire Programmable Linear Controller, Ethernet TCP/IP.

Brock Solutions' Role: Designing the electrical system. Assembling/building electrical control panels and an ergonomic operator pulpit. Replacing aging MG sets with new DC drives and digital drive controllers. Converting the mill’s hardwired relay logic to a PLC system, and tying all existing I/O (i.e., field device push buttons, pilot lights, solenoids, motor starters, limit switches, etc.) into the PLC. Designing, developing, and implementing new operator Human Machine Interface (HMI) consoles. Developing a new data collection system and interfacing it to an existing Level 2 system. Integrating the new controls system into existing Hydraulic Automated Gauge Control (HAGC) and X-Ray systems. Conducting simulation tests prior to site installation. Performing site installation, commissioning, start-up and operator training.

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