Retrofit of surface-planing machine 7G220-F11
The specialists of “ASC” enterprise completed the activities on retrofit of surface-planing machine 7G220-F11 in the territory of roll-turning division of shop T-1 at OJSC “Seversky Tube Plant”.
The scope of activities covered the design works, delivery of equipment and commissioning of retrofitted machine.
Replaced were:
- 6 feed DC drives were replaced by asynchronous servomotors of HDP series and frequency converters ACSM1 of “ABB” company. The positioning system was implemented on basis of application software of frequency converter;
- digital-to-analog voltage converter of a planing table drive was replaced by modern thyristor converter DCS800 of “ABB” company;
To facilitate operator handling of the machine and to enable operation of the machine via control panel by less qualified staff, the control system, based on numerical control device NC-110, was replaced by S7-300 controller of “Siemens” company and OP 227 panel. However all functional capabilities of numerical control device of 7G220-F11 machine have been retained.
27.04.2012
Russia’s first ever wireless tram
On the 20th of April, 2012, the tram car model 71-405-11 (product of OJSC “Uraltransmash”) with traction electrical equipment, designed and produced by CJSC “ASC”, took its first test run on the city tramlines without supply from overhead contact system. The test run took place with pantograph kept down.
This tram model is considered to be innovative, since for the first time in Russia there’s been created a tram car that can be fed not only from overhead contact system, but also from rechargeable lithium-ion battery, installed on the car.
As compared to the conventional, even most up-to-date trams, the new car has the following advantages:
- capability of operation at nonelectrified tramlines, which, during construction of new lines, ensures significant economy owing to exclusion of overhead contact system, new supply substations, expenses on their connection, and reduced number of planning permissions;
- 100% usage of recuperative energy (electric energy, produced by motors under generator conditions during braking), which is stored in full in accumulator battery and then is used for acceleration.
All dynamic features of the tram car when fed from accumulator battery comply with GOST requirements. By preliminary estimates, that can be made based on results of the test run, specific energy consumption by the car, taking into account the auxiliary power consumption, will enable totally autonomous run not less than 70km, and allowing for short-time recharges at terminal stops or while the tram is on the move – more than 200km, which means a continuous double-shift operation.
25.04.2012
Modernization of automated control systems of pipe-bending machine 1420-TVCH
The works on modernization of existent automated control system of pipe-bending machine 1420-TVCH were finished at LLC “Neftegasdetal factory” in the town of Chaikovsky.
Modernization resulted in:
- generation of documentary process data reports for certification of pipe branches;
- information support for maintenance staff of the machine.
To provide compliance with technical requirements, developed for reports on technological pipe bending, the additional sensors were installed into control system. The data from sensors are collected in logic controller and then forwarded to existent operator workstation for report generation. The display of data on newly installed sensors at existent operator workstation has been provided. The passport generation program for certification of pipe branches was improved. The design documentation was updated. To expand functionality of programmable logic controller the additional 4-slot rack was installed. The rack is connected to master controller via Ethernet.
Control system of the machine is built on basis of programmable controller ControlLogix 5000 of “Allen-Bradley” manufacture. Visualization system is executed on basis of SCADA-system RSView32 of “Rockwell Automation” company. Pipe branch passport generation system has been created with Delphi environment of “Borland” company.
24.04.2012
Process control system of a 2500 ton-force press
At the end of the previous year and at the beginning of the current year the specialists of “Automated systems and complexes” enterprise fulfilled the adjustment and commissioning works for the 2500 ton-force forging plant of “Skoda” manufacture, Czech republic, in shop No.37 at OJSC “VSMPO-AVISMA” Corporation”, the town of Verkhnyaya Salda. The forging plant includes a forging press itself and two manipulators of “Glama” manufacture, Germany.
The specialists of CJSC “ASC” performed the design of electric equipment and control systems of the 2500 ton-force press, as well as delivery of object-oriented electric equipment and commissioning of total technological complex (including a high-pressure pump-and-accumulator station).
To handle the basic automation tasks of the forging plant a programmable controller Simatic S7-416-2DP of “Siemens” manufacture with distributed peripherals – field stations ET200M was applied. Equipment control is executed via operator’s workstation, implemented with the use of SCADA-system WinCC.
The adjustment works for manipulators were executed jointly with specialists of “Glama” company, Germany.
The commissioning works resulted in the press being accepted into service, while the following was achieved:
- High pressing speed (about 140-160mm\sec);
- High accuracy and operational speed in “Forging” mode (up to 30 strokes/min, accuracy -2/+3 mm);
- High accuracy and operational speed in “Smoothing” mode (40-45 strokes, accuracy -2/+3 mm);
- Complete integration of manipulators’ system into process control system of the forging press.
23.04.2012
Commissioning activities at AVTOVAZ conveyor line.
The specialists of CJSC “ASC” together with specialists of “Fives Cinetic” and “Renault” companies have finished the commissioning works at three sections of a new conveyor line:
- hold station for the painted car bodies,
- buffer line with the unit for planting the car body into car suspension,
- assembly line for unit-power plants.
For implementation of control system the controllers Simatic S7 CPU319F of “SIEMENS” company, that collect and process the data from distributed devices via PROFInet, have been applied. The frequency converters Sinamics G120D are used for machinery control.
The visualization system is implemented on basis of SCADA-system Odil v3.0.3.
19.04.2012
Commissioning activities at “XingChengSteelCo.” plant in the town of JiangYin, PRC
In February-March, 2012, the specialists of our enterprise together with foreign specialists (from Italy, China) performed the investigation works at a single-strand slab casting machine at metallurgical plant “XingCheng Steel Co.” in the town of JiangYin, PRC, aimed at revealing the ways to improve the product quality.
The tests were conducted for the most widely-used steel grade “Medium Carbon HSLA (High-strength, low alloy)”. Each test was based on shifting the final reduction point and observing the change in internal structure of metal by samples. The tests were conducted for different percentage ratio of completely hardened steel in the final reduction point, which varied from 60 % to 90 %.
The samples obtained for Center Segregation Line corresponded to the following classes:
- Class 3 of “Mannesmann” standard
- Class 2 of ”Mannesmann” standard
Besides the afore-mentioned tests, there were also conducted several tests, intended to define the actual position of completely hardened steel over a length of the strand inside the machine. These tests were designed to check the validity of operation of mathematical model for cooling and dynamic reduction.
19.04.2012
Implementation of high-voltage soft starters for motors
At the end of 2011 and in the beginning of 2012 the specialists of our enterprise successfully commissioned a number of soft starters for high-voltage synchronous and asynchronous motors. The soft starters have been developed by “ASC” specialists and refer to serial products of CJSC “ASC”.
Individual soft start system for high-voltage electric drives of pump units.
In the course of reconstruction of presses 103 and 106 in shop No. 21 at OJSC “VSMPO-AVISMA” Corporation”, the town of Verkhnyaya Salda, the specialists of CJSC “Automated systems and complexes” performed the works on commissioning of individual soft start system for asynchronous and synchronous electric drives of high-pressure plunger pump units of pump-and-accumulator stations which supply the presses’ hydraulics. The electric drive of plunger pumps employs the high-voltage asynchronous motors of DOR 560-08 type with power of 800 kW and synchronous motors of MC 321-8/8 type with power of 700 kW and of SDN-2-16-386U3 type with power of 800 kW. Voltage rating of motors is 6 kV. Soft starters PAD-V-K-100-6k-1 are used for smooth acceleration of the motors.
Group soft start system for high-voltage electric drives of smoke exhausters.
The works on commissioning of group soft start system for two high-voltage asynchronous electric drives of smoke exhausters of gas-cleaning plant of arc steel-making furnace 60 have been finished in shop No.21 at LLC “Kamastal”, the town of Perm. The smoke exhausters are driven from asynchronous motors of DA304M-560-1250-8U1 type with power rating of 1250 kW and voltage of 6 kV. The group soft start system ensures the alternate smooth acceleration of machines and automatic switching to direct mains supply via standard high-voltage motor cell. Soft start of the machines is implemented via high-voltage thyristor voltage converter of PAD-V-G-150-6k-2 type.
Individual soft start system for high-voltage electric drives of smoke exhausters.
The works on commissioning of individual soft start systems for smoke exhausters of gas-cleaning plant have been finished at OJSC “Chusovskoi metallurgical plant”, the town of Chusovoi, the Perm region. The electric drive of smoke exhausters employs the asynchronous motors of DAÇÎ4-560H-8U1 type with power rating of 630 kW and voltage of 6 kV. High-voltage complete converters of PAD-V-K-100-6k-1 type constitute the individual soft start system.
Individual soft start system for high-voltage electric drives of turbine compressors.
The two individual soft start systems for high-voltage synchronous motors of turbine compressors No.4 and No.5 have been commissioned in mill house at OJSC “Sukholozhskcement”, the town of Sukhoi Log, the Sverdlovsk region. Individual soft start system of turbine compressors No.4 and No.5 is designed for soft start of high-voltage synchronous motors (of STD-1600-2U4 type with power of 1600 kW and voltage of 6 kV) of afore-mentioned turbine compressors in mill house. Individual soft start system includes the complete high-voltage converter of PSD-V-K-200-6k-1 UHL4 type, semiconducting static exciter of VSP-315-75 UHL4 type and couplers to high-voltage cells of CJSC “ASC” production.
Individual soft start system for high-voltage electric drive of smoke exhauster.
In the course of reconstruction of electric drive of smoke exhauster of gas-cleaning plant of arc steel-making furnace of steel plant at OJSC “Bummash”, the town of Izhevsk, the individual soft start system for high-voltage asynchronous motor of smoke exhauster has been commissioned. The smoke exhauster is driven from asynchronous motor of DA302-17-54-8U1 type with power of 800 kW and voltage of 6 kV. High-voltage complete converter of PAD-V-K-125-6k-1 UHL4 type constitutes the individual soft start system.
06.04.2012
Commissioning works for a bundle stacker
The design and commissioning works for modernization of bundle reeling and stacking area have been finished at CJSC “Katur-Invest” in the town of Verkhnyaya Pishma.
A new bundle stacker of “SMS Meer” manufacture was put into operation. The control system was implemented with the use of already-existing controller SIEMENS S7-400 and frequency converter SINAMICS G120. The existent operator workstations were complemented with the display of data on the status of bundle stacker, as well as control functions. SCADA system WinCC of “SIEMENS” manufacture is used as a visualization system.
The equipment installed enables the improvement of the following key figures:
- Failure tolerance of “KONTIROD” unit;
- Improvement in quality of finished-products stacking.
19.03.2012
Upgrading of electric equipment of “KONTIROD” unit.
The engineers of CJSC “ASC” have finished the activities on upgrading of electric equipment of “KONTIROD” unit for CJSC “SP Katur-Invest” (the town of Verkhnyaya Pishma), an affiliate to “UGMK-Holding”.
The two mechanisms of copper rod mill were subject to upgrading: roughing stand No.1 and roughing stand No.2. The old DC machines were replaced by induction motors. Thyristor DC converters were, accordingly, replaced by frequency converters 110 kW of “SIMOVERT MASTERDRIVES” line with vector control.
Electric drives were adjusted and put into operation. The required modifications were made in software of SIMATIC S7 controllers.
The commissioning works were executed on a tight schedule and were finished in January, 2012.
19.03.2012
Modernization of electricity metering system
There have been completed the design and commissioning works on expansion (modernization) of existent electricity metering system at CJSC “SP “Katur-Invest” in the town of Verkhnyaya Pishma.
The new operator workstations, enabling the output of data on the working condition of exhaust and supply systems, were put on stream. The system provides for the display of basic technical-and-economic indexes of electricity consumption for each type of products (prescribed and actual values), as well as total hourly energy consumption (planned and actual values). The system ensures automatic generation of report on the key energy indicators of electricity for the different time intervals. Visualization system is implemented on basis of SCADA-system WINCC of “SIEMENS” manufacture. The operator workstations function on basis of hardware of “ADVANTECH” company.
The design documentation was revised and improved in terms of correction of ventilating schemes and visualization system.
15.03.2012