ATI Z Mill Upgrade

Z-MillAutomation & Drives Upgrade 1

Z-Mill Automation Upgrade Project Goals• Replace the Following Equipment: – Reliance AutoMax Mill Master – Reliance Distributed Power Drives – Herb PC based AGC – Main Operator Desk and Local Mill-Stand Control Stations – Reliance Shark Remote I/O – Level 1 Human-Machine Interface (HMI) Systems 2

Computer Cabinet 201 Z-Mill Automation Upgrade Level 2 PC Level 3 Database HMI Maintenance (by customer) Level 2 Server PC iba PC  PDI KVM Extenders HMI Client PCs (3)  Process Data HMI Server PC Maintenance PC New System Configuration iba Data Acquisition PC Network Switch Network Patch Panel Printer Drive Programming Network iba Data Acquisition Network HMI/Inter-processor Network 220 Main Desk 321 Wind-Off Rewind 221 222 223 HMI HMI HMI Wind-On Rewind 320 Operator Station Wind-Off Payoff Left Reel Mill Right Reel Operator Station Wind-On Payoff HMI Operator Station Operator Station Operator Station Operator Station HMI Operator Station HMI KVM 10 FLEX I/O FLEX I/O 421 FLEX I/O 420 FLEX I/O FLEX I/O FLEX I/O 11 FLEX I/O FLEX I/O FLEX I/O 3 2 2 3 4 3 2 KVM N Crown Adjust Solenoids (12) P Crown LVDT Feedbacks (6) Wind-Off Master Mill Master/AGC Wind-On Master 400 200 Thickness Gauge Network 300 .40 .30 .20 Profibus Power Power Ethernet Ethernet Ethernet Ethernet Power C-NET C-NET C-NET C-NET Ethernet Profibus Ethernet 4AI-2AO 4AI-2AO Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank CPU CPU C-NET C-NET EWEB 16-DO Blank Blank Blank PS PS 32-DI CPU CPU HSC HSC HSC PS 1 1 1 1 1 1 Network X-Ray Gauge Switch Cabinet (IRM) Wind-Off I/O Mill Master I/O Gauge Status I/O Wind-On I/O 4 Left/Right Deviation Feedbacks (2) 4 8 9 5 6 7 FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O Pump & Motor FLEX I/O Pump & Motor DI: 4 DI: 27 DI: 7 DO:20 DI: 9 DI: 8 DI: 17 Starters DO: 25 Starters DO:28 DO:20 DO:22 DO:12 A Left Deflector Roll Encoder AI: 2Wind-Off Valve AO: 1 Wind-On Valve Stand I/O Left Reel Right Reel EAH MCC B Right Deflector Roll Encoder Stand I/O 430 Valve Stand I/O Valve Stand I/O Remote I/O 330 EAD MCC 232 233 (Bkt. BJ1) Remote I/O 230 C Left Strip Encoder (Bkt. AJ1) 231 D Right Strip Encoder EAH MCC EAD MCC (existing) (existing) E Screwdown Position Feedback F Lower Intermediates LVDT Fdbk. Cooling Tower Control G Upper Intermediates LVDT Fdbk. - Water Temperature AI - Oil Temperature AI - Oil Valve AO H Lower Intermediates Servo Valve J Upper Intermediates Servo Valve Screwdown HPU Inputs K Upper Screwdown Servo Valve L Upper Screwdown Pressure Xdcrs. (2) M Screwdown System Pressure Xdcr. 3 2 Wind-Off Drives 2 3 Left Reel Drives 4 5 Main Mill Drives 6 7 Right Reel Drives 3 2 Wind-On Drives (existing cabinet, new (existing cabinet, (existing cabinet, (existing cabinet, (existing cabinet, new DCS800 DCS800 drive sub-panels) DCS800 DCS800 new drive sub-panels) DCS800 DCS800 new drive sub-panels) DCS800 DCS800 new drive sub-panels) DCS800 DCS800 drive sub-panels) Brake Brake Brake Brake Brake Brake Supply Supply 410 Supply 210 211 Supply 212 Supply Supply 310 (New) (New) (New) DCSLink DCSLink (New) DCSLink (New) (New) SR6 Power SR6 Power SR6 Power Modules Modules Modules 1500 HP 1500 HP 1500 HP Payoff Diameter (existing) (existing) (existing) Payoff Diameter E B M E B M Feedback E B M E B M Feedback Wind-Off Wind-Off Wind-On Wind-On Rewind Motor Payoff Motor E M E M E M Rewind Motor Payoff Motor 3 Left Deflector Right Deflector Roll B Roll Tensiometers B Tensiometers (OS/DS) (OS/DS)

Z-Mill Automation Upgrade New System Configuration Pyramid Hierarchy  Remote I/O (ControlNet) Distributed Processing  New DC Drives Common Implementation Platform  DC Drive Digital Front End Retrofit Common L1/L2 HMI  New Setup Model (T. Sendzimir) Setup Level 2 Level 1 Mill Master/AGC Stand Control Sub-Masters Drives and Auxiliary I/O 4

Z-Mill Automation Upgrade Main Operator Screen 5

Z-Mill Automation Upgrade Pass Schedule Screen 6

Z-Mill Automation Upgrade Crown Control Screen 7

Z-Mill Automation Upgrade Annunciator Screen 8

Z-Mill Automation Upgrade Drive Fault Screen 9

Z-Mill Automation Upgrade Servo Diagnostic Screen 10

Z-Mill Automation Upgrade Roll Setup Screen 11

ATI Z Mill Upgrade

by Integrated Mill systems on Nov 29, 2011

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ATI Z Mill Upgrade — Presentation Transcript