Application of electrical automation technology in metallurgical industry with the rapid development of automation technology, as well as the need to improve production quality and production efficiency of the metallurgical industry, the application scope and application of the steel industry has increased year by year. The automation level of iron and steel industry is not only a symbol of industrial modernization, but also can make the enterprise obtain huge economic benefits.
Automatic control of the whole process of high strength steel production line can not only improve the quality of steel products, but also improve the efficiency of production, save the capital, improve the economy, and promote the rapid development of steel industry.
SLRM continues to enhance its capabilities to meet the rapidly changing global market needs. To stay on the leading edge of technical advancement, SLRM has entered technology to manufacture high strength and advanced high strength steel for the automobile sector.
At SLRM, we continue to improve and innovate in order to produce high-quality products and develop systems that can deliver them to the end user’s doorstep in excellent condition.
The Level‐1 automation system consists of Rockwell Control Logix system. One PLC Controller with redundant processor has been provided for complete Blast furnace complex consisting of Stock House, Hot Blast Stoves, BF auxiliary, SGP, GCP, Cooling water supply facilities etc. Conventional MCC systems with hardwired interlock have also been provided for control of various motors. The PLC is provided with dual redundant processor, memory and power supply units.
In case of failure of main processor the standby processor shall take over automatically without any break / bump. Three numbers HMI stations and one number engineering station are provided in the BF main control room for monitoring and control the process and equipment. Normally one HMI station shall be dedicated to control of stoves and blast furnace proper and the second shall be dedicated to control and monitoring of stock house.
The third shall be dedicated for Water supply & other services facilities. However, the role of each HMI station is interchangeable, and the control and monitoring of the total plant can be done through any one HMI station if need be. The HMI stations are connected to the PLC dual communication bus independently such that loss of one communication bus does not affect the monitoring and control of the process. The operator cum engineering stations have been provided for programming of PLCs. Provision has been made with two number of HMI stations such that HMI station 3 & 4 shall be used as operator cum engineering station.
The basic engineering of instrumentation and automation for SLR 1x25m2 sinter plant is compiled on the basis of specialized letter of appointment of sinter, ventilation and mechanical water supply and drainage. In line with process requirement, instrumentation and automation covers the design of 25m2 main building of sinter machine, proportioning room, main exhaust room, tail ESP, head ESP, water treatment station and sinter bunker. Software configuration for PLC control station and computer operation station, software support platform advancement and system completeness conforming to the principle of advanced, reliable, economical and practical technology.
The design philosophy adopts “Three-electro” integration. Control process is completed via primary PLC control station through field instrumentation collecting data during production process. The secondary layer is that computer operation station under support of multitask system software is executed for supervision and operating instruction of production process and equipment running status. All fault alarm will be undertaken and achieved through foundational automation part. All the detecting parameters transmitted to the computer system of the main building. The detecting control of proportioning system is completed by proportioning computer system, panel type instrument adopted for water treatment station, end ESP, head ESP and main exhaust for alarm indication at respective operation room, principal parameter sent to main building computer system.
PCI automated control system design, combined advancement and practicality principles, adopts new technology to improve automation system equipment, enhance automation system, expand the application range of automation system, realize production automation management, reduce personnel allocation, reduce operating cost, optimize production, reduce production cost, ensure product quality and enhance comprehensive benefits. PLC system adopts Siemens S7-400.
The Level‐1 automation system consists of Allen Bradley - Rockwell Automation’s Control Logix PLC system. One PLC Controller with redundant processor has been provided for complete Power Plant consisting of Boiler, Turbine, Air Cooled Condenser and Balance of Plant etc. One PLC Controller with redundant processor has been provided for Burner Management system (BMS). All the process of the power plant is controlled through these PLCs.
The PLC is provided with dual redundant processor, memory and power supply units. In case of failure of main processor, the standby processor shall take over automatically without any break / bump. Three numbers HMI stations and one number engineering station are provided in the Power Plant Control room for monitoring and control the process and equipment. Normally one HMI station is dedicated to control of Boiler process, the second station is dedicated for the control of Turbine process and the third station is dedicated to the control of the Air-Cooled condenser and pump house.
However, the role of each HMI station is interchangeable, and the control and monitoring of the total plant can be done through any one HMI station if needed. The HMI stations are connected to the PLC through dual communication bus independently such that loss of one communication bus does not affect the monitoring and control of the process. The operator cum engineering stations have been provided for programming of PLCs
Conventional MCC systems with hardwired interlock have also been provided for control of various motors. Majority of the motors are driven by VVVF drives which helps in achieving efficient power consumption.
The Level‐1 automation system consists of Rockwell Control Logix system (adopts Allen Bradley 1756 - L73 ControlLogix 5573 Controller). One PLC Controller with redundant processor has been provided. EOF Automation system monitors and controls the process of Energy Optimizing furnace through Valve stand, Hydraulics Tilting system, Cooling water system with Emergency system, Gas cleaning Plant (with 2x1MW ID Fans & SIEMENS Drives), Furnace & Ladle Feeding system with Bin Weighing systems. Basic reporting of Alloy consumption and Gaseous consumption is generated with this system.
Distributed control system (DCS) is the technology platform which realizes the level 1 and level 2 automation. Level 1 and level 2 controls can be achieved normally through programmable logic controllers (PLCs), micro-processor-based systems as well as programmable controllers (PCs) /work stations, as required. In DCS, each of the automation systems of the shop is subdivided in accordance with the functional requirements and covers the open loop and closed loop control functions of the different sections of the production shop.
LRF1&2 DCS System adopts ABB AC800M, PM861 Controller, Monitors and controls the process of Electrode regulation which includes the Hydraulics System,2x8MVA Transformers, 6.6kv VCB, Vessel Car, Argon purging system and cooling water system with Emergency system. Basic reporting of Power, Arcing, and Argon consumption is generated with this system.
Monitors and controls the process of VD Hydraulics System, VD line pneumatic valve auto operation, VD bag house pulsing. Monitor and control the process of Furnace Feeding system with Bin Weighing systems. Basic reporting of Alloy consumption is generated with this system. PLC system adopts Siemens S7-400.
Monitors and controls the process of VD pumps and Drives. PLC system adopts Siemens S7-300.
Monitors and controls the process of 4 stands wire feeding machine. PLC system adopts Siemens S7-1200.
Monitors and controls the process of ID fans with drives, dust discharging motors, bag house pulsing and duct line pneumatic valve auto operation. PLC system adopts Siemens S7-300.
CCM COMMON PLC system adopts Siemens S7-400, monitors and controls the process of Common Equipment s of CCM like Hydraulics System, Turret System, Tundish Car 1 & 2, Cross Transfer System, TOCB System, Slide Gate Power Pack, EMS DM Water cooling system, Emergency Cooling water system and steam exhaust fans. All casting parameter trend back up available with this system.
CCM STRAND-1, 2 & 3 PLC system adopts Siemens S7-400, monitors and controls the process of Respective Strand related Equipments like AMLC, EMS System, Mould Oscillation System, Withdrawal & Straightener Units, Dummy Bar system, Auxiliary Withdrawal, CEPR, Torch Cutting Machines & Strand Roller Tables. All casting parameter alarm generation and trend back up available with this system. Recipes of Different Sections and Grade wise generated and uploaded in PLC as and when required.
Basic automation Level 1: including programmable automation units (PLCs), operation and monitoring (HMIs) SCADA systems, in centralized or distributed topology, interconnected via field bus and local area networks (LAN).
The mill is also operational with advanced rolling equipment such as reducing and sizing mill , high-speed shear, pinch rolls and along with controlled temperature rolling and controlled cooling to meet the processing requirements of various grades of carbon and alloy steel.
We have online hot bar inspection facility through Oribis gauge supplied by M/s Pomini. The Oribis gauge guarantees an accurate measurement of the bar dimensions by constant rotation around the bar.
For historical analysis we have iba software. Iba System with comprehensive connectivity for acquiring high resolution process data. Triggered or time-based data storage in measurement files or in iba HD-Server. Several data recordings are possible at the same time. Additional data storage types and output interfaces for transferring data outside the iba system. Acquisition of descriptive additional information via text signals. Individually configurable live displays with client-server architecture. Use of data by maintenance, production, quality assurance, technology, data analysts and much more.