• Water descaling area. At 5 roll table sections in water descaling area the variable-speed AC drives, based on frequency converters SINAMICS G120, were applied instead of soft-starters. This enabled to decrease the roll tables speed and, correspondingly, the hot billet speed by its passing through water descaling unit. OP177B operator panel, located at control desk, is used to indicate the condition of frequency converters. This panel also indicates the operation of water descaling unit.
• Central cooler area. At 4 sections of receiving roll tables of cooling beds the variable-speed drives, based on frequency DC converters SIMOREG DC MASTER 6RA70, were applied instead of fixed-speed DC drives. PLC SIMATIC S7-300 and operator panel OP177B are used for drive control. The control system provides for automatic rails destacking into cooling beds 1-2 and 3-4 with exact bumpless stop, as well as matching of roll table speeds to the operating speed of stamping machine, installed before the central cooler.
• Rail-conditioning unit in thermal department of rail and beam shop. The new rail-conditioning unit includes 14 roll table sections, 6 transfer arrangements with lifting and displacement mechanisms, 4 adjustable end stops, lifting roll, mangle, nondestructive testing line, 2 flatters, 2 drilling-parting machines. The control system of transfer mechanisms provides for: rails transfer along all processing chain at preset speeds; exact bumpless stop of the rails; coordinated operation with equipment of such foreign companies, as BRONX, NDT, GEISMAR, MFL.   

         Within November-December 2011 the specialists of our enterprise fulfilled the design and commissioning activities for relay protection and automation data processing systems at OJSC “Pervouralsk novotrubni plant”, 35 kV closed switchgears, “Trubnaya” substation. The automation objects are 35 kV closed switchgear cells with installed control and measuring instruments: SINEAX A210 counters and SIPROTEC 7SJ62 multifunction protective relays.

          For system implementation the controller Simatic S7 CPU 315-2DP of “Siemens” manufacture, which receives and processes data from the instruments via Profibus DP net and is installed in one of closed switchgear cells, was used.

•  centralized data acquisition from relay protection and automation equipment and control of position of high-voltage switches of 34 kV closed switchgear cells;
•  control and processing of grounding signals in incoming feeders (additional protection in incoming feeders has been provided);
•  automatic running of basic parameter archive for relay protection and automation equipment;
•  simplified maintenance of electric equipment, continuous diagnostics and equipment status control with output of easy-to-read alphanumeric current status messages;
•  remote on/off switching control of 35 kV closed switchgear cells.

In December 2011 the specialists of our enterprise finished the activities on engineering of monitoring and control system for electric drive of car dumpers No.1 and No.2 in Vostochny port – the town of Nakhodka. Car dumpers are designed for discharging the cars with cargos laden in bulk. Such modernization has contributed to increase in efficiency of coal discharging and minimization of dynamic stresses on metal structure of car dumper. The project provides for replacement of operator station, replacement of controller Schneider Electric by more powerful one - Quantum 140CPU31110, as well as installation of additional sensors for secure rotor positioning and automatic positioning of open car into car dumper rotor.

          In December 2011 the specialists of our enterprise completed the set of design, erection and commissioning activities on modernization of server backup system for microprocessor centralization at Vostochny port – the town of Nakhodka, Primorski krai. Replacement of existent server equipment by more powerful and up-to-date facilities and modification of system architecture contributed to enhancement of reliability indexes of microprocessor centralization system.

          In December 2011, at Vostochny port – the town of Nakhodka, Primorski krai, the specialists of our enterprise completed the activities on design of electric drive system for hydro-station of reclaimer no.1 bucket wheel based on variable-frequency drive of “ABB” manufacture that was supposed to replace the existent direct start system. Such upgrading has contributed to increase in efficiency of main pumps of bucket wheel hydro-station and enhancement of dynamic performance of the machine, while excluding its overloads.

•  replacement of old drill pumps HBT-600 by drill pumps HBT-1000 kL of hydraulic unit power 950-1000 kW with adjustable-frequency electric drive;
•  replacement of electric equipment for pump block and circulation system machinery control by modern PLC-controlled hardware platform.    

•  automatic start (stop) of supercharging pumps by start (stop) of drill pumps;
•  automatic start (stop) of auxiliary systems of drill pump motors (lubrication, ventilation, heating) by start (stop) of drill pumps;
•  control of treatment unit machinery and tank block machinery.

• video frame of the condition of electric circuit assembly;
• video frame of flow chart of drill pump block along with display of the status of supercharging pumps, drill pumps, drill pump auxiliary machinery, readings and states of technological sensors;
• video frame of the state of automated control system;
• list of operational availability of machines;
•  archive of warnings and failures;
•  archive of operator actions.