Synopsis Greenfield Strip Steel Air Knives Controls System

Situation: A company recognized as a global leader in steel processing committed to building a new multi-billion dollar carbon and stainless steel processing facility in the USA. Customer's Principle Objectives for the Capital-Grade Project: Position itself with one of the most sophisticated carbon and stainless steel processing operations in the world, and strengthen its market position in relation to NAFTA (North American Free Trade Agreement). Requirement: Construction engineering and the supply and installation of air knife equipment required for operation on several HDGL (Hot-Dip Galvanizing Lines) in the greenfield facility. Technology: Siemens S7 PLC, Wonderware InTouch running on an Industrial Application Server (IAS) open .NET architecture, ET200M remote I/O racks, Profibus-DP, Siemens S7-313 processor, Siemens WinCC Flexible, Schneider Stepper drives, Siemens MicroMaster drives, Siemens SIMATIC S120 drives, Danaher servo drives, Tyco proportional valves on Profibus, Profibus encoders.

Brock Solutions' Role: Design, develop, and deploy the drives and automation controls system to run the air knife systems. Overall scope of work included designing the electrical schematics and fabricating various electrical control panels, cabinets, junction boxes, etc.; supplying and installing hardware components such as AC motors, VFD drives, stepper and servo drives, etc.; programming PLCs and drives and developing new device interface code; designing and programming a HMI system; and conducting simulation testing and performing on-site commissioning.

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