Modernization of electrical equipment for bar iron finishing section and central lubricating station of combination wire-rod mill 320/150.
The works for stage 1 of the project on modernization of electrical equipment have been completed. The large modernization scope and the necessity of replacing the HMI system of the mill, which had been in operation over 18 years, as well as the impossibility of a long-term unscheduled shutdown of the mill for reconstruction, which would entail significant financial losses, has determined the need for a phased implementation of modernization.
The design documentation and software were developed and handed over to Customer in April, 2024. In December 2024 the equipment manufactured by ASC was delivered; the dismantling, electrical installation and commissioning activities were performed as part of stage 1 of modernization.
The following equipment was put into operation:
- 1. The new server of HMI system of the mill. Hardware implementation:
- — Two servers HPE ProLiant DL380 Gen10 for SCADA WinCC;
- — Data recording system server ibaPDA.
- 2. The new controller for bar iron finishing section and central lubricating station (SA30). Hardware implementation:
- — SIMATIC S7-1500 CPU1518-4PN/DP, field station Odot as part of the controller.
1. The complete (with reversible power thyristor bridges of armature circuits and power supply to motor excitation windings) analog automatic control systems (ACS) for electric drives of machines of bar iron finishing section were removed from service:
In place of the dismantled cabinets, that contained the analog automatic control systems, the new cabinets, containing the complete digital devices with microprocessor control of dc drives, based on Sinamics DCM counterparts – packaged dc frequency converters «VARIANT DC» — were installed.
2. The new workstations were installed:
- — Operator workstation of control desk ПУ31 (WinCC client) – one of the three control desks for bar iron finishing section. The other two control desks — ПУ41 and ПУ42 – include the interface boxes (preparation for installation of the workstations during the subsequent stages of modernization);
- — The ER2 electrician on duty workstation (WinCC client);
- — The engineering workstation for automatic equipment group (in automatic equipment room ER1). Intended for maintenance and possible introduction of changes into SA30 controller software and design of SCADA-system WinCC.
- — The station of process data recording system ibaPDA (ibaPDA client server – in automatic equipment room ER1).
The newly installed digital electric drive control systems, field stations, workstations, SA30 controller and a new HMI system server of the mill are united into a single hardware-software complex by means of the data buses: Ethernet Bus (Terminal), Ethernet Bus (Process), Ethernet Bus (Info), Ethernet Bus (Management), Profinet Bus.
A set of dismantling, electric installation and commissioning works was performed within the period from October 28 to December 04, 2024, while, during a complete stop of bar iron finishing section within the period from November 12 to November 22, mill 320/150 continued to manufacture products, that is, the rolled wire.
The specialists of the subcontracting organization – AO INTEK-Pro (Joint Stock Company) — were involved in the performance of equipment disassembly and erection and fulfilled the scope of work allotted to them in a professional and timely manner.
The software-hardware complex of new equipment, put into commercial operation, was interfaced with existing APCS of the mill. The hardware and software parts of the new complex include elements that open up space for further modernization of electrical equipment of the mill, including the HMI system of mill 320/150 that had been in operation for more than 18 years.
Throughout all work stages, including development of engineering design documentation, piping and instrumentation documentation and software for modernization of electrical equipment of bar iron finishing section and central lubricating station of mill 320/150, the specialists of AO ASC enjoyed the technical and organizational support of operating personnel of a long product rolling shop, specializing in automatic equipment and electric drive, of managerial staff of the shop, of chief executives, project directors and procurement officers of OOO Amurstal (Limited Liability Company).