integrated process control in the steelworks electrics and automation

INTEGRATED PROCESS CONTROL IN THE STEELWORKSINTEGRATED PROCESS CONTROL IN THE STEELWORKSElectrics and Automation

ELECTRICS and AUTOMATION

Steelworks

SMS SIEMAG

CONTENTS

Electrics and automation 2

Integrated process control 4

Highlights 6

Energy distribution and drive systems 8

Level 1-automation 10

Level 2-automation 12

Level 3-production planning systems 14

Safety strategy 16

Plug & Work test 18

Modernization strategies 20

Services 23

3

Electrics and AutomationSMS SIEMAG

2

ELECTRICS AND AUTOMATIONELECTRICS AND AUTOMATION for steelworks

HOLISTIC SYSTEM

COMPETENCE

Modern metallurgical plants from SMS Siemaghave a high availability and fulfill today’s ever-increasing end product quality requirements. Ittakes harmonized system components to meetthese demands. That’s why SMS Siemag madethe decision, many years ago, to also offer theoverall electrics, automation and drive technolo-gy for the plants alongside the mechanics, tech-nological controls and process models. Thatmeans we are your “main contractor” and offeryou the overall engineering, construction andcommissioning of a plant from a single source.

You benefit from short distances and directagreement between everybody involved becausethese factors create the best prerequisites foryour success. SMS Siemag makes its extensiveexpertise available to you from the start in orderto be able to identify, based on numerous crite-ria, the right type of steelworks and the requiredprocess routes. This is how we make the all-important decisions well in advance in order toensure high economic efficiency, productivityand the environmental protection of your steel-works.

PARTNER FOR EAF, LF, BOF,

CONARC AND AOD

SMS Siemag offers you all types of steelworks:electric steelworks with ARCESS electric arc furnaces or CONARC® furnaces, BOF convertersteelworks and stainless steelworks with AODconverters.

Special to our line is that all units are harmonizedwith each other in terms of their interfaces. Ourautomation technology plays a crucial role here.That’s because only automation technologyallows you to produce a wide range of high-quali-ty steels in a modern steelworks – saving bothmoney and resources in the form of raw materi-als and energy. The aim is to produce thedesired steel grades, with precise chemicalanalysis at the specified temperature and therequired steel weight, by means of optimizedprocess control. All this goes to show: SMSSiemag offers you ingenious solutions… andmore.

SAFEGUARDING YOUR COMPANY'S

FUTURE VIA MODERNIZATIONS

You can efficiently increase your productivity,flexibility and product quality by means of target-ed modernizations. SMS Siemag offers themechanical, automation and electrical compo-nents as well as special conversion expertisethat ensure minimum downtimes.

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4

INTEGRATED PROCESS CONTROLINTEGRATED PROCESS CONTROL PROCESS ROUTESPROCESS ROUTES

X-PACT®

The automation systems of SMS Siemag are groupedunder the name X-Pact®. This applies to all plant types.Crucial for us is high economic efficiency as well as thetransparency of the control solutions. Our automationcovers levels 0 to 3.

OUR

PROCESS EXPERTISE

Central to automation in steelworks are the processmodels for the cost-optimized calculation of the requiredenergy, charge materials, and alloys. Why? Because youcan only efficiently control the complex overall “steel-works” system with its wide range of units using thesemodels.

It’s imperative that all process data is made available,checked, adjusted and communicated to the subsequentsystem along the entire process chain - from the rawmaterial via the melting and secondary metallurgicaltreatment to the handover to the casting machine.

Based on the steel grades to be produced, the overallprocess route is planned in terms of the requiredautomation technology, controlled online and monitored.All this is possible because the technology systems ofSMS Siemag seamlessly interact with each other.

Electric steelworks route.

SCALABLE SYSTEM CONCEPTS

All systems in the steelworks are based on platformsthat have a scalable design. The extensive separationinto different levels (basic modules, technology mod-ules, system-specific modules) means you only have tomake adjustments and changes where they are actuallyrequired.

To give you an example: when you implement newtechnologies, all you do is change the technology mod-ules. So here is a structure that brings you these advan-tages: It improves both the maturity level and servicelife of the technology modules, plus it ensures the sta-bility of the system-specific modules in the case of newIT modules or device-related changes.

Converter steelworks route.

Stainless steel route.

Raw materialpreparation

Submerged arc furnace(SAF)

CONARC®

Arc furnaceDC-Twin-cathode EAF

Arc furnace(AC)

Arc furnace(DC)

Ladle furnace (LF) Vacuum

degassing (VD)

Rotary hearthfurnace

Coking plant

Raw materialpreparation

Compact blast furnace(CBF)

LD converter

CONARC®

Vacuum-degassing (RH)

Ladle furnace(LF)

Electric furnace

AOD converter

Ladle furnace

Vacuum plant(VOD)

Process route in electric

steelworks

Scrapyard managementPig iron supplyAdditives managementElectric-arc furnace or CONARC® furnace Secondary metallurgical treatmentsEnvironmental protection systemsLogistics systemsDrive systems

Process route in converter

steelworks

Scrapyard managementPig iron supplyAdditives managementConverter blowing process with control ofoxygen-blowing lances and sublancesSecondary metallurgical treatmentsEnvironmental protection systemsLogistics systemsDrive systems

Stainless steel route

Scrapyard managementPig iron supplyAdditives managementARCESS electric-arc furnaceAOD converter blowing processSecondary metallurgical treatmentsEnvironmental protection systemsLogistics systemsDrive systems

Production planning systems

Technological process modelsMaterial tracking & data servantsReporting

Technological controlsSequence controlsDrive controls

Energy distributionDrives

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THE HIGHLIGHTSTHE HIGHLIGHTS

BOF / AOD VALVE STATION

We supply everything you need from a single source– all the engineering, automation technology, andmechanical components for the valve stations of theinert gas and oxygen injection systems. That ensuresyou can count on high functional reliability for thesecomplex systems.

CONVERTER TILTING DRIVES

We adjust the drive technology to the different loadconditions with variable torques. The result is ahomogeneous load distribution to the drives thattakes into account and dynamically compensates forthe specific behavior of the liquid steel bath. It’s anadded advantage that the control technology is veryclosely harmonized with the tilting behavior becausewe also provide the core drive technology elements.

BUNKER SYSTEM LOGISTICS

Our logistics module for bunker systems includes themathematical description of the material deliveryroutes. This means you don’t have to spend moneyon additional programming for flexible feeding of thesteelworks with additives.

SLAG DETECTION IN THE BOF

The converter vessel is monitored by means ofacoustic measurement in order to determine thefoamed slag development. The acoustic pattern,which is evaluated online, permits the identificationof a trend in the foamed slag development. Over-flows can thus be counteracted in good time.

SLAG CONTROL IN THE EAF

A similar acoustic measurement process for monitor-ing the foamed slag is used in the EAF. Its purposehere is to systematically influence the slag control byvarying energy supply and coal injection, and to main-tain it at a specific level. The foamed slag ensuresbetter energy input into the heat and protects theEAF refractory lining.

FEOS method.

FEOS FOR THE

ELECTRIC ARC FURNACE

The FEOS (Furnace Energy Optimization System) isan EAF automation module for controlling the opti-mized and simultaneous energy input of all primaryand secondary energy carriers. Significant here is auniform energy input that is adjusted to the process.This means the interaction of primary electrical ener-gy with secondary energy sources via injector sys-tems for oxygen and coal. The aim is to use the elec-trical and fossil fuel energy as efficiently as possiblein order to reduce overall energy consumption and atthe same time achieve high productivity. There is amajor focus here on a control-based energy input.Parameters such as temperature and acoustics formthe basis for the process description. You can see,for example, that FEOS permits the input of addition-al energy where the water-cooled furnace wall is stillbelow the temperature limit. Using this process, it is

possible to increase the productivity significantlywhile at the same time adhering to the chemicalanalysis of the steel. This is where the individualprocesses are interlinked and interdependently con-trolled.

WIRELESS MEASUREMENT

IN THE EAF

One of our most recent developments is wirelesstransmission of the furnace vessel temperature. Itreplaces the costly and maintenance-intensive spe-cial cables that transmit the signals of the tempera-ture sensors in the water-cooled panels. So, thanksto our new technology, signals from several dozenmeasuring points are sent by a transmitter directlyand without interference from the sensor to a gate-way connected to the automation technology.

Gas regulation for anAOD converter.

Converter tilting drive.


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ENERGY DISTRIBUTION and DRIVE SYSTEMSENERGY DISTRIBUTION and DRIVE SYSTEMS

POWER SUPPLY STUDIES

The mains supply and distribution systems in steel-works must be considered in conjunction with thepublic power grids and the available infrastructure.Essential here is taking into account all the possibleinteractions. That’s why SMS Siemag carries outpower supply studies in close cooperation with thecustomer. These form, on the one hand, the basis forthe reliable supply of the works and, on the otherhand, the foundation for calculating interferenceaffecting the public power grid.

ENERGY LAYOUT

A steelworks usually works on a 33/35 kV level. It’san adequate level we can use to design a cost-opti-mized distribution network for the consumption-intensive units or systems – for example an EAFsteelworks or hot-strip rolling mill. Drawing on ourprocess expertise, we identify an efficient and at thesame time reliable layout for the equipment, such astransformers, thyristors, converters, and cables. Ourpower supply studies help us provide you withinvaluable pointers when it comes to selecting themost suitable EAF power supply – AC or DC – anddimensioning the compensation systems for top effi-ciency.

EAF OPERATED

WITH THREE-PHASE AC

Modern three-phase AC EAF furnaces have trans-former outputs of over 1.5 MVA/t. Today’s high-impedance furnaces have low reactances on the sec-ondary side as well as a reactor on the primary sideof the furnace transformer. The electrical high-currentsection from the transformer up to the electrodes isdesigned for extremely high voltages.

Switch for an electric-arcfurnace.

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DC FURNACE

DC electric-arc furnaces cause lower system distur-bances than AC furnaces, making them suitable forconnection to weak power grids. They are, however,more complex in design. To avoid undesired electricarc deflections and to achieve flawless bus-bar design,SMS Siemag carries out suitable computer simula-tions.

FURNACE SWITCH GEARS

OF NEW GENERATION

Dedicated to making things easier for you, we lookedat how to improve switching systems for electric-arcfurnaces that operate with currents of more than3,000 A and 36 kV. Cooperating closely with our sup-pliers, we developed a user-friendly solution thatcomplies with the latest IEC standard. It controls allswitching remotely, including extension and retrac-tion of the switch. This means that during parallelswitch operation, a switch can be replaced while theplant is running. The result? A vast increase in sys-tem availability.

Simplified diagram of load equalization control.

Calculation of loadtorques.

DRIVE SYSTEMS

We have defined drive groups for the steelworks, soyou benefit from uniform and lean interfaces.

CONVERTER TILTING DRIVES

The tilting of converters requires very specific basicknowledge with regard to the load behavior of liq-uids. We have extensive experience in this field,underlined by the fact that our controls have beenfinely adjusted for the frequency-converter-controlleddrives of converter tilting drives with two or four-motor technology. The basis of the controls are cal-culations of the load torque curves to ensure dynam-ic adjustment of the tilting drive. That preventsoverloading or spillovers.

LANCE DRIVES

Our systems achieve high positioning accuracy ininteraction with the frequency-converter-controlleddrives for the lance systems – both for the oxygen-blowing lances and the measuring sublances. This isimportant because the level of the steel bath variesdue to factors such as wear of the refractory lining.To allow for these variations, our systems use adap-tive measurements and position the lances just right.That means the metallurgical process takes placeunder optimal conditions.

DRIVE SYSTEMS FOR

LARGER OUTPUTS

We also deliver the blower drives for the gas purifica-tion systems. They can be designed for a conven-tional startup as direct start or soft starter or frequen-cy converter controlled, respectively. It goes withoutsaying that our design concepts fully comply withyour specific wishes.

BodyTotal

Tilt position in [degree]

Torques in [KN* m] x 10


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LEVEL 1 AUTOMATIONLEVEL 1 AUTOMATION

SYSTEM ENVIRONMENT

The system environment for the electrical andautomation-related equipment with X-Pact® has a scal-able design. That’s to say, each unit in the steelworkscomes with its own controller. This ensures the othersystems continue to work perfectly even during main-tenance or a malfunction in a unit or shop.

FAIL-SAFE

RING-TYPE BUS DESIGN

The operating and monitoring systems of the units inthe steelworks follow a ring-type bus design and areconnected with the subordinate controllers. That’s aclear advantage because this concept ensures greatersecurity. Even if a cable breaks, the data transferbetween the operating and monitoring system and thesubordinate controller is not interrupted. The bus sys-tem has become generally established in steelworks.Furthermore, we implement the logic programmablecontrollers in a redundant design to meet your safetyrequirements. That is why there are different classifi-cations depending on the safety concept. The automa-tion system is designed in accordance with the statu-tory safety standards plus any extra requirements youspecify. Depending on the classification, we use, forexample, safety relays up to complete safety con-trollers.

X-PACT® LOGISTICS MODULE

The X-Pact® logistics module supports the flexible andrapid parameterization of bunker systems for time-optimized filling and removal of charge materials.

Only the most sophisticated solutions ensure efficientoperation of the complex bunker systems in steelmak-ing units such as BOF / AOD / CONARC / LF. This iswhere the X-Pact® logistics module comes in. It con-trols the logistics algorithm for starting and stoppingthe furnace conveyor belts and removal systems.

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Automation configuration in failsafe ring-bus design.

The simple parameterization of the HMI system sup-ports monitoring of the path/destination.

Advantages of the logistics module

This module enables your operator to fully executecharge material recipes (material type, weight, feed-ing sequence for charge material and point in time ofcharge material feeding). It selects the optimal feed-ing path for the charge material from the availablebunkers to the respective unit.To keep the process flowing, additive recipes areprocessed in a staggered manner, while the meteringbunkers and buffer tanks that are already emptiedare refilled.It’s an added advantage that your operator can, atany time, supplement or delete recipes as a group ofmaterials to be simultaneously fed, as well aschange the recipe sequence.The module is used in all bunker systems of theprocess routes so the operator can respond to newprocess requirements – quickly and flexibly.

FEOS TECHNOLOGICAL

CONTROL SYSTEM

FEOS records all important processes in the electric-arc furnace in order to control them holistically using asuperordinate energy optimization system. It’s a sys-tem that follows a simple and user-friendly designwith refreshingly clear structures. The decisive actuat-ing signals are controlled interdependently based onthe input parameters (including continuous measure-ment of exhaust gas, temperature and acoustics),which are measured in real-time. These are:Energy controlInjector controlFoamed slag controlReactance control

Equally convincing are these results from real applications:High melting performanceNo operation interruption due to deactivations atthe temperature limit

Rapid response in the case of a simultaneousreduction of the switch frequencyReproducible and efficient input of electrical energyShort tap-to-tap times

HMI SYSTEMS

Our HMI systems form the connection between thesystem and operator. They offer a production-orientedprocess display with all relevant information regardingmaterial logistics and process. Also included areprocess-oriented displays that enable you to makepurposeful manual interventions in the process controlor the operation of the connected units. Then there isour proven operator-centered approach for user-friend-liness. We achieve this as a result of intensive cooper-ation between our employees and your operatingteams. This is effectively supported by integrating youin the Plug & Work tests.

Logistics module.

Here is what you’ll gain from the use of SMS Siemagprocess models: optimized and reproducible processcontrol which, in turn, leads to reduced productioncosts, improved product quality and higher produc -tivity.

EAF

Flexible charge material calculation for scrap, slagforming agents, alloying agents as well as HBI andDRIDynamic process control for efficient use of electri-cal energy and chemical energy (e.g. burners) inthe furnace

BOF

Flexible charge material calculation for scrap, pigiron, slag forming agents and alloying agentsCalculation of the oxygen for temperature, carbonand analysis for the end of blowing (blowing endpoint calculation)Dynamic process monitoring (blowing end pointcalculation) based on exhaust gas analysisSimple integration of sublance technology, bottomstirring, exhaust gas analysis and acoustic processmonitoring

AOD

Flexible charge material calculation for the opti-mization of scrap, slag forming agents, alloying andreducing agentsDynamic process control during the individualprocess phases (main decarburization, dynamicdecarburization, reduction)Calculation of the process status for temperature,steel / slag weight, chemical analysis, decarburiza-tion speed, oxidation speed, metal oxidation

CONARC®

Combination of the EAF and BOF process modelsFlexible charge material calculation for scrap, pigiron, slag forming agents, alloy agents as well asHBI / DRICalculation of the oxygen-blowing end point fortemperature, carbon and analysis


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LEVEL 2 AUTOMATIONLEVEL 2 AUTOMATION

TECHNOLOGICAL

PROCESS MODELS

The process models, which portray the metallurgicalprocesses for steel production in a mathematical andthermodynamic manner, are the brains of the steel-works. We have constantly optimized these modelsusing our comprehensive practical experience andadapted them to the latest technological findings.There are corresponding technological process mod-els for all units in the steelworks.

Based on the standardized steel catalog, practicesand operating diagrams are predefined for each ofthe steel grade groups to be produced. These areadapted by the process model during the meltingtreatment according to the targets to be achieved atthe end of the treatment, such as analysis, tempera-ture, and steel weight.

During this process, the model receives all processdata online and carries out corresponding optimiza-tion calculations. It also takes into account the costsas well as energy balance and mass balance in orderto determine the efficient use of energy and material.The model determines, for example, the requiredcharge materials, alloying agents and optimal treat-ment time.

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Web-based steelworksreporting.

Complete historyRedundancy concepts for data security support

MELTING AND PROCESS MONITORING

Special software modules monitor the material, melt-ing and process monitoring in the steelworks. Theyfacilitate the coordination and synchronization of thedata to be exchanged between the individual units.

Based on the melting plan, each melt has a clearlyidentifiable number for monitoring in the overallprocess. That makes it possible to locate it (withanalysis, steel weight, temperature and additionaldata) within the process at any time.

REPORTING

All process data is logged for quality assurance pur-poses and can be made available in reports and evalu-ations in line with requirements, e.g. for operators ormanagement. Alternatively, you can, of course,choose to use interfaces to superordinate systems,such as SAP.

WEB SERVER

Your management can conveniently access the steel-works reporting via the web server. Plus there areretrieval options, for example, via conventional Inter-net browsers or smartphones.

Reporting system HMI

Data transfer

Perfo

rman

ce evaluatio

n

Internal m

aterial tracking

Coordination

(event han

dlin

g) Process

dataStrategy

Techno-logical ProcessModels

Archive database

Process model shell

Dynamic process control for the use of electricaland chemical energy in the furnace

LF

Flexible charge material calculation for alloys,coolants, deoxidization (wire feeder), slag buildupProcess forecast calculation and control for electri-cal heating and stirring (homogenization) taking intoaccount the treatment objectives (analysis, temper-ature, treatment time)

OFFLINE SIMULATION MODELS

Our offline simulation models are available to metal-lurgists like you to help you simulate the melt quali-ties using the recorded process data as well as testand where required optimize new parameters undersimulation conditions. Moreover, you can check pro-duction processes for new steel grades in advance.

CHARGE MATERIAL CALCULATION

Using our charge material calculation, you can deter-mine the optimized use and portions of the additives.These include pig iron, scrap, cold DRI and hot DRI.

CENTRAL DATABASE SYSTEM

All level 2 systems communicate via a central data-base, in which all information is archived and can beexchanged with external automation systems viastandard interfaces.

All process data is saved and processed for issuingreports or quality certificates. The parameter sets ofthe models, the steel quality and material specifica-tions, as well as the process specifications are storedcentrally. Also available here are dialogs that help yourtechnologists change the specifications for processtuning purposes or in order to change process para-meters. Your advantages:

A central system for the entire steelworksSimplified maintenanceConvenient handlingCentral administration and archiving of all data

It takes detailed planning of the production processto achieve the multiple goals of a large product vari-ety, top quality, fast delivery times, and minimumenergy consumption. You also need linkage with theproduction systems of suppliers and customers forseamless adjustment to new situations. Develop-ment here focuses on "Real Time Enterprise" (RTE), amethod that checks and responds to these changesin real time.

What restricts the available options are the technicaland technological limits of the plants themselves,and we have to take this into account during programplanning. All this adds up to a need for comprehen-sive production planning systems.

BENEFITS OF X-PACT® LEVEL 3

X-Pact® Level 3 provides plant operators with all thetools they need for planning and control of the produc-tion processes in metallurgical plants and rolling mills.An effective link between the commercial side of thebusiness and the technological process automationsystems, Level 3 production planning offers thesebenefits:Maximization of overall production ratePlanning and minimization of inventories for inter-im products

LEVEL 3 – PRODUCTION PLANNING SYSTEMLEVEL 3 – PRODUCTION PLANNING SYSTEM


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Uniform product tracking throughout the produc-tion line Overall quality assurance up to final qualityapprovalIncreased compliance with delivery dates

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MANUFACTURING ORDERS

You can rely on our systems to convert your ordersinto technically executable manufacturing projects.That means, according to your specifications, anextensive calculation model generates the manufac-turing data for the product. Included here above all arethe following steps:

Definition of the steel gradesDefinition of the necessary production steps andpossible plant alternativesPlanning of the output of every production stage todetermine the necessary quantities of input materialDefinition of sample taking and test regulations

Material flow in a convertersteelworks.

THE FACTORY MODEL

A uniform planning system covering all areas isbased on a factory model. The factory model isimplemented in the planning system in the form ofan electronic planning table.

PRODUCTION PLANNING

It's vital to determine the doable delivery dates for allmanufacturing orders in advance. That's where ourcapacity and deadline planning comes in, examiningall the plants and plant alternatives available. As aresult, you get a sequence plan for the individualplants as well as a plan of the available input materi-als for each manufacturing order.

Manu-facturing

order

From customer order tomanufacturing order.

Hot metaldesulfurization

BOF converter 2

Argon rinsingstation 2

Ladle furnace 2

RH plantBOF converter 1

Argonrinsingstation 1

Ladlefurnace 1

Continuous castersCCM 1 – CCM 3

QUALITY TRACKING

There is a data exchange between the Level 2 sys-tems of the overall plant and the Level 3 system.That means Level 3 is informed at all times aboutevery production step and the product quality aftereach step. Inspection and lab data add to the accura-cy of the result. This forms the basis for qualityapproval of the final products before delivery.

Level 1 (unsafe partof controlsystem)

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SAFETY STRATEGYSAFETY STRATEGY

Worldwide, the importance of machine and plant safe-ty is growing. It's not just plant operators themselves,but also laws and standards that demand personal andenvironmental protection.

Essential for safe operation of our products is a coor-dinated approach during planning and design. Ourengineering and electrics divisions work together onthe main elements in our safety strategy:

The layout of the danger zoneThe risk assessmentThe electronic-mechanical function "Safety"The Emergency Stop plan

The hazard area layout divides the plant into variousdanger zones. It indicates all the plant-related safetyequipment as well as the plant limits.

The risk assessment identifies and evaluates all thepossible hazards inherent in a plant, and describesthe necessary precautions.

An in-depth Emergency Stop plan is drawn up foreach plant.

Together with you, we work out a practical solutionwith safety control functions that operate indepen-dently from the machine controls. This strategy alsocomplies with all safety laws and regulations. And itreduces the time and cost of testing, documentation,and commissioning. The safety control functions areextensively tested early on – during the Plug & Workprocess.

Extract from a dangerzone layout plan.

Monitoring of a danger zone.

Separation of safety functions andcontrol functions.

Machine safety.

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PLUG & WORK TESTPLUG & WORK TEST

A Plug & Work test set up in the test field.

Our long-established Plug & Work service is increasing-ly popular among our customers. At the heart of Plug& Work are production simulations that mimic realitydown to the smallest detail. You can benefit from ouryears of experience in engineering and process tech-nology, because we know exactly how processesbehave and what regulators achieve which productqualities. The simulation system we use in our Plug &Work strategy reflects this complex interplay of fac-tors.

MODULE AND INTEGRATION TEST

Plug & Work starts with module tests that put theindividual hardware and software componentsthrough isolated function checks. Next in line are inte-gration tests that examine the fault-free interaction ofthe modules. The usual procedure in the industry is toend pre-testing here, then continue trials after theplant has been erected on the construction site. Wego one step further.

VIRTUAL SYSTEM

AND PROCESS SIMULATION

The complete automation system is installed in oneof our test bays and connected with a simulation sys-tem. The customer-specific system design modules,including kinematic and dynamic parameters of thesystem behavior as well as the sensors, are preparedfor the simulation system. That’s how we create acomputer-aided simulation model to check the opera-tion and process flows of the system. For the opera-tor, it’s just like working with the real system: Alloperations and processes are displayed to the opera-tor in real time. He can virtually control production aswell as become familiar with maintenance processes.Via this practice-oriented procedure, we are able toadjust the automation system in advance for trouble-free processes and efficient operability.

TRAINING

The first step of our customer training involves layingthe theoretical foundation in classroom training ses-sions. This is where our technologically skilledemployees pass on their expertise to your team.Additional instruction on the operation and mainte-nance of the measuring systems integrated in ourautomation systems is carried out by qualified special-ists. Based on this initial training and instruction, theoperator training on the “virtual system” continues aspart of Plug & Work. This already takes place duringthe construction phase of the system, i.e. long beforecommissioning. The final step involves onsite trainingat the construction site. Your personnel is integratedinto the system commissioning by us and familiarizedwith the systems and processes under practical appli-cation conditions.

Customer trainingin the test field.

Original CAD drawing ofmechanical system.

Test using originalequipment.

Customer trainingin the test field.


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MODERNIZATION STRATEGIESMODERNIZATION STRATEGIES

As a metallurgical plant operator you must continu-ously expand your production facilities to maintainyour leading position with excellent product quality.

Yet, nowadays, you cannot achieve such facilityexpansions simply through the use of newly devel-oped mechanical parts. They must also be integratedinto the automation so that the improvement in theend product really is accomplished. That’s why weoffer integrated modernization solutions geared toimproving all aspects of production technology.

SMS Siemag has developed a strategy that enablesproduction to continue throughout alteration or mod-ernization work. Compared with conventional meth-ods, it gives you a much higher protection againstfailure, shorter commissioning time, steeper run-upcurves, and therefore an early return on investment.

REASONS FOR

MODERNIZATION PROJECTS

Improved product propertiesBetter production/productivityReduced production costsIncreased availabilityReplacement of old systems

During their implementation, SMS Siemag revampstrategies take into account all aspects of modernmetallurgical automation systems:

Integration of new process technologiesReproducible process sequencesImproved ergonomics and safety technologyReplacement of obsolete systemsProven quality of product properties using techno-logical values in the entire process

CHALLENGE FACED BY

AUTOMATION SUPPLIERS

More often than not, you cannot expand your exist-ing automation to the required degree. The reasonsfor this can be factors such as a lack of softwarespecialists, the system limits have been reached, orthere are no expansion assemblies available.

Then it’s essential to find an economic solution forautomation expansion or a partial replacement. Thatmeans that, for integration purposes, you need touse system interfaces, which may come from sever-al automation generations. Equally imperative here isan outstanding understanding of the functions andtechnology in order to be able to analyze existing,well-established automation functions. We are ideallyprepared for these challenges due to the extensiveexperience of our employees and our focus on met-allurgical and rolling mill technology systems.

PROCEDURE

These are the main steps in a revamp project: cur-rent-state analysis, alteration work planning, planttest, re-commissioning, and optimization.

CURRENT-STATE ANALYSIS

The first step to successful modernization is an in-depth assessment of the current state of the automa-tion system. That includes an examination of the sen-sory systems installed to find out whether they canbe re-used. This check simultaneously determineshow new sensory and measuring systems can beinstalled. Significant here is that the current-stateanalysis examines all the relevant electrical andautomation system components as well as the com-plete technological process sequence.

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The second key stage is considering and selectinginterfaces to the automation systems and IT infra-structure that will stay in place. Essentially, theknowledge gained here goes into a motor and com-ponent list, a technological process description, and adocumentation of the interfaces for each alterationphase.

PLANNING THE ALTERATION PHASES

We plan the phases for the major revamp stages ofmechanical, media, and electrical systems in closecooperation with you. These plans are mapped out indetail prior to the individual alteration steps. It allmeans you save time and money, because carryingout more operations in parallel before, during, andafter production standstills slashes overall stoppagetimes. According to pre-defined milestones, each

standstill is tracked and if necessary re-planned byexpert construction managers working hand in hand.

RE-COMMISSIONING

The steps described above reduce many of the risksinherent in alterations. Due to our many years' expe-rience in commissioning metallurgical plants we canget your plant up and running again within a mini-mum timeframe.

The high point of the whole project is the plant run-up after the revamp. Yet, before this happens, weteam up with you to carefully plan production of thematerial quality and dimensions you require. The datarecorded during monitoring operation is applied topre-optimize our process models, clearing the wayfor immediate production start with marketable prod-uct quality.

Furthermore, you can rely on comprehensive sup-port, starting with continuous assistance during run-up, through to technology support from our develop-ment departments. Sometimes both sides recognizethe potential for joint improvements and sign a coop-eration agreement that might even lead to excitinginnovations! There are a large number of successfulprojects we have carried out that confirm the effec-tiveness of our revamp strategies.

TYPICAL

MODERNIZATION PROJECTS

AOD or BOF gas control stations

To improve process control and increase systemavailability, you need to modernize the process gascontrol as well as distribution and equip them withstate-of-the-art measuring and control technology.

It is usual in old systems for the flow rate of severalrinsers / nozzles to be controlled by one valve. A bigimprovement in modern gas control stations is that

Current-state analysis.

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SERVICESSERVICES

COMMISSIONING

Early on, during the Plug & Work tests, our experi-enced commissioning teams are on the spot in thetest field. Here, they prepare for successive transferof responsibility for the plant. As the final stage ofthe Plug & Work test, when the scope of supply andfunctioning has been confirmed, they test theautomation to make sure it's absolutely ready forcommissioning.

Essentially, commissioning on site consists of the fol-lowing stages:Cold commissioningHot commissioningSystem optimization during productionPerformance tests

Cold commissioning

Included in cold commissioning are all the activitiesnecessary for producing the first melt. Cold commis-sioning concludes with the first melt.

Hot commissioning

All mechanical and electrical functions are testedunder load during hot commissioning in order to veri-fy the functioning of the control systems.

System optimization during production

During this phase, the parameters of all the systemsare adjusted to ensure the new facility achieves therequired performance.

Performance tests

Finally, a test program we run through together withyou demonstrates that the plant meets the contractspecifications.

AFTER SALES SERVICE

There is even more we can do for you in the form ofour after sales service. This gives you continuedaccess to our expert know-how.

Specifically for X-Pact® electrics and automation, theSP/1 service portal from SMS Siemag offers you theoption of rapid support in troubleshooting.

Even during commissioning, we set up a service por-tal for optimal plant support. It is responsible for sta-ble, protected communication between two net-works. Via this portal, the SMS Siemag expertsaccess your plant's automation system to give youimmediate support in the form of remote diagnosisand maintenance – worldwide and from day 1.

BENEFITS OF THE SERVICE PORTAL

We can eliminate some 70 percent of faults immedi-ately. Alternatively, faults are isolated. Take forinstance defective parts. Our experts can usuallyidentify them online, possibly deactivate them, andsend a service technician to replace them on site.

the flow rate of each nozzle is individually controlled.The gas supply per rinser / nozzle is more precisedue to this procedure and contributes to the reduc-tion of fire-resistant material wear.

This applies in particular to AOD gas control stations.Here, the inert gas side is usually converted to sin-gle-jet control. To expand the control range for theprocess gas side (expansion of possible mixed gasratios), the control circuits are divided into circuits forlarge flow rates and small flow rates.

The gas control stations are supplied in a compactand maintenance-friendly design or alternatively as acontainer variant (BOF bottom stirring).

Modernization of converter tilting drives

You can considerably reduce your maintenance costsand increase your system availability if you modern-ize your electrotechnical equipment for converter tilt-ing drivers. What’s more, this enables your operatorsto react more precisely to changing requirements.

Included in the scope of delivery are the conversionof the drive regulation and control for synchronizationof the speeds and torques with modern static con-verters and with new, freely programmable control.The expanded high-end process control system withuser-friendly visualization of the converter tilting dri-ves replaces the conventional control panels. Thatgives you a far better overview and quicker diagnos-tics.

Gas control station for a100-t converter.

Gas control station for a300-t converter.

SMS SIEMAG AG

Electrical and Automation Systems Division

Wiesenstrasse 3057271 Hilchenbach, Germany

Phone: +49 (0) 2733 29-5895Telefax: +49 (0) 2733 29-775895

Ivo-Beucker-Strasse 4340237 Düsseldorf, Germany

Phone: +49 (0) 211 881-5895Telefax: +49 (0) 211 881-775895

E-mail: [email protected]: www.sms-siemag.com

“The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have thesecharacteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and willnot have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”

MEETING your EXPECTATIONSA/317E

1500/06/11 .Ky . Printed in Germany

integrated process control in the steelworks electrics and automation

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