Arcelor Mittal - Cleveland 84" Hot Strip Mill Revamp

Arcelor Mittal - Cleveland 84” Hot Strip Mill Revamp

A-M Cleveland Hot Mill 7 Stand Finishing Train, 72,000 HP 5 Stand Roughing Train, 56,000 HP 2 Downcoilers, 1000 HP each 3 Pusher Type Furnaces, 450 Tons/Hour Each Width: 26” to 72” Thickness: 0.056” to 0.700” Capacity: 3 Million Tons/Yr

A-M Cleveland Hot Mill Goals and Requirements
New Windows PC Based Level 2 Setup/Data Collection System
New Level 1 Control System on Modern Open Platform
New Digital Drive Regulators for Main Drives, Loopers, and Screwdowns (Retained Existing Power Infrastructure and Drive Power Modules)
New Operator Desks
New Integrated L1/L2 HMI System
New iBA data “flight recorder”
Increased Bending on Last three Finishing Stands to Improve Shape Control
New Hydraulic Loopers (last 3)
New Flatness Gauge
Minimal Installation (Take Advantage of Existing Terminations)
Phase-In over normal down-turns

A-M Cleveland Hot Mill Old System Configuration
Obsolete Level 2 Main Frame Computer
GEM 80 PLC
Installed in late 80s
DOS based programming interface
Originally 300 series controllers
Several PLCs upgraded to 400 series (supporting GEMLAN-D)
Analog GE Silco Drives
PDP-11 System on Coilers/Delivery-End
Previous Partial Upgrade (2000/2001)
GE Universal Stand Controllers (Obsolete)
Genius I/O
Installed but not Commissioned
Cimplicity HMI

A-M Cleveland Hot Mill Control Platform Selection Criteria
“ Off The Shelf” Single-vendor Homogeneous Architecture
End User Free From OEM Proprietary Hardware
High Performance For Demanding Real-time Applications
Multi-tasking Program Execution
Proven Product Life Cycle History
Scalable To Meet A Broad Control Spectrum
Windows Based Programming Tools
Multiple Programming Languages
Very High Speed /Bandwidth Communication Network(s)
Compatible with Genius LAN & I/O
Open Architecture VME
Compatible With Cimplicity PE HMI

A-M Cleveland Hot Mill Control Platform Selection
GE Fanuc Rx7i PLC for Distributed Level 1 Control
GE Fanuc Cimplicity PE HMI SCADA Nodes and Viewers
Level 1 And 2 Integrated HMI
Dell GX260 and GX270 PC’s for HMI
GE Fanuc Cimplicity ME Windows PLC Programming Software
Genius LAN Remote I/O
GE Fanuc Reflective Memory High Speed Control “Network”
VME Reflective Memory for RX7i
PCI Bus Reflective Memory for PC’s
Dell Poweredge 2650 server for Level 2 Control
Digital Alphaserver 4100 for Roughing Mill, Finishing Mill and Coil Temperature Control models

A-M Cleveland Hot Mill New System Configuration Philosophy
Common Programming LAN
Common L1/L2 HMI
Remote I/O (Genius)
Pyramid Hierarchy
Distributed Processing
High-Speed Control LAN (Reflective Memory)

A-M Cleveland Hot Mill New System Configuration

A-M Cleveland Hot Mill Level 2
Dell Poweredge 2650 servers
Digital Alphaserver 4100
HP Storage Works Smart Array 1500 – 8.4TB
MS Visual Studio .NET 2003
Microsoft SQL Server 2000
CONNX – VMS to SQL Server interface
Polyserve – Shared storage between Windows Servers

A-M Cleveland Hot Mill Level 2

A-M Cleveland Hot Mill Main Drives

A-M Cleveland Hot Mill Main Drives
Software Implementation of Main Drive Regulator (Per Main Drive Rack, Total of 7)
2 Millisecond Scheduled Task:
Armature Current Regulator
Motor Speed Regulator
Motor Terminal Voltage Regulator (extended speed range operation)
Motor Armature Current Load Balance Regulator
Spindle Tail Spot Position Regulator (for roll change)
Background Unscheduled Task:
Armature Circuit Breaker Sequencing

A-M Cleveland Hot Mill Electric Loopers

A-M Cleveland Hot Mill Electric Loopers
Software Implementation Of Looper 1,2, & 3 Drive Regulator
2 Millisecond Scheduled Task
Armature Current Regulators (L1, L2, & L3)
Motor Speed Regulator (L1, L2, & L3)
Strip Tension Regulator (L1, L2, & L3)
Looper Real-time Geometry Solver (L1, L2, & L3) (Calculates Geometric Relation Between Desired Strip Tension And Required Motor Torque To Achieve That Tension As Loop Angle Changes)

A-M Cleveland Hot Mill Loopers
Looper Real-time Geometry Solver (L1, L2, & L3)

A-M Cleveland Hot Mill Hydraulic Loopers

Software Implementation Of Looper 4,5, & 6 Drive Regulator
Looper Torque Regulators (L4, L5, & L6)
Looper Torque Feedback (L4, L5, & L6) (Calculates Geometric Relation Between Looper Torque and Required Hydraulic Cylinder Linear Force)
Motor Speed Regulator (L4, L5, & L6)
Strip Tension Regulator (L4, L5, & L6)
Looper Real-time Geometry Solver (L4, L5, & L6) (Same as Electric Looper Calculation)

Looper Torque Feedback Calculation (L4, L5, & L6)

A-M Cleveland Hot Mill Schedule

Methods
Design for Startup
Design Specifications (FES/SES)
Extensive Simulation/Testing
Hands-on Training
Phase-in Expertise

A-M Cleveland Hot Mill Testing
“ Proof-of-Concept”
Component-Level Hardware Testing
Facilitates phased shipping for installation
Offline Testing Equipment at Customer Site
FM Test Drive/Motor
FM Test Stand for Looper
Integrated Factory Acceptance Test
Temporary Equipment Setup for Components Already Shipped
Complete Staging of HMI and Operator Desks
Simulators

A-M Cleveland Hot Mill Project Execution: Phase-In Strategy
One Section at a Time
Finishing Mill Area (Best ROI)
Roughing Area (Replaced Remaining Gems)
Furnace Area (Replaces Drives)
Coilers (Replaces Obsolete PDP-11)
“ Bottom-Up” Approach
Drives
Masters & Sub-Masters
Operator Desks
Level 2

A-M Cleveland Hot Mill Bridge to Old System for Phase-In

A-M Cleveland Hot Mill I/O Switching for Phase-In Approach

A-M Cleveland Hot Mill FM Main Drives Phase-In Approach
Final Drive Regulator Design Tested On-site Using Test Drive/Motor Prior To Commissioning
Temporary Mill Master Installed To Accept Analog Speed Referencing From Old System
Reflective Memory Segment Installed Between Temporary Mill Master And New Drives
Push-pin Switchover Schemes For Outputs
Subset Of HMI Installed To Support New Main Drives
Drives Commissioned Over Multiple Regular Weekly Maintenance Turns

A-M Cleveland Hot Mill Electric Loopers Phase-In Approach
Temporary Analog I/O Installed in Looper Drive To Accept Analog Tension Referencing From Old System
Ethernet Bridge Installed To Exchange Control Parameters With Existing Mill Master
Reflective Memory Segment Installed Between Temporary Mill Master And New Electric Looper Drive
Subset Of HMI Installed To Support New Looper Drives
Drives Commissioned Over Multiple Regular Weekly Maintenance Turns

A-M Cleveland Hot Mill Hydraulic Loopers Phase-In Approach
Final Hydraulic Control System Design Tested On-Site using Test Stand
Ethernet Bridge Expanded To Exchange Control Parameters With Existing Mill Master
Reflective Memory Segment Installed Between Temporary Mill Master And New Hydraulic Looper Drive
Subset Of HMI Installed To Support New Hydraulic Looper Drives
Commissioned Over Single Mini-Outage (Mechanical Installation of New Hydraulic Looper)

A-M Cleveland Hot Mill Delivery Master Phase-In Approach
Feedback Signals Paralleled to Facilitate Shadowing
FM Delivery Speed and Metal Detectors for Head/Tail Tracking
Spray On/Off Status for Cooling Temperature Control (CTC)
Finishing/Coiling Temperature Pyrometers for CTC
Push-pin Switchover Scheme for Spray Solenoids and Table Speed Referencing

A-M Cleveland Hot Mill Screwdown Drives Phase-In Approach
Temporary Analog I/O Installed To Accept Analog Speed Referencing From Old System
Ethernet Bridge Expanded To Exchange Control Parameters With Existing Screw Master
Reflective Memory Segment Installed Between Screw Master And New Screw Drives
Subset Of HMI Installed To Support New Screw Drives
Screw Drives Commissioned Over Multiple Regular Weekly Maintenance Turns

A-M Cleveland Hot Mill FM Masters Phase-In Approach
Integration Test Using New Desks and Simulator Racks
Extensive Mill Rolling Simulations in Factory Environment
Operator Involvement
Looper Height Regulators Tested/Tuned on Production Turns
Bridge to Existing System Used to Interface with Existing Desks
Desks Replacement Deferred until All Level 1 Equipment Commissioned

A-M Cleveland Hot Mill Main Desks Phase-In Approach
Mini-Outage Required to Demo Old and Install New
Minimal Down-Time Required (Communications, E-Stop, and Power)
Software Switch in PLC(s) Set to Use New Desks (Very Low Risk)

A-M Cleveland Hot Mill Level 2 Phase-In Approach
Extensive use of DEC Alpha Bridge between Reflective Memory and GEMlanD
Step 1: Coil Temperature Control
Step 2: Finishing Mill through Delivery End
Used Furnace Supervisory Control System to Monitor Slab Charge Messages From The Old Level 2 to Get Handle to Slab PDI
Tracking Hand-off to New System at Roughing Mill Exit – Use Handle to Retrieve PDI from DB
Step 3: Furnace through Roughing Mill

A-M Cleveland Hot Mill HMI Navigation

A-M Cleveland Hot Mill Help Screens

A-M Cleveland Hot Mill Mill Tracking

A-M Cleveland Hot Mill Depiler

A-M Cleveland Hot Mill Pusher

A-M Cleveland Hot Mill Recorder

A-M Cleveland Hot Mill Furnace Map

A-M Cleveland Hot Mill Rougher(1)

A-M Cleveland Hot Mill Rougher(2)

A-M Cleveland Hot Mill Delay Tables

A-M Cleveland Hot Mill FM 1 st / 2 nd Coil Setup

A-M Cleveland Hot Mill FM Trial Setup

A-M Cleveland Hot Mill FM Trial Offset

A-M Cleveland Hot Mill FM Screws

A-M Cleveland Hot Mill FM Speeds

A-M Cleveland Hot Mill Runout Tables

A-M Cleveland Hot Mill Coiler

A-M Cleveland Hot Mill FM Hydraulics

A-M Cleveland Hot Mill Permissives

A-M Cleveland Hot Mill Roll Data Entry

A-M Cleveland Hot Mill Mill Startup

A-M Cleveland Hot Mill Alarm Summary

A-M Cleveland Hot Mill Alarm/Fault Detail

A-M Cleveland Hot Mill Maintenance – Machine Control

A-M Cleveland Hot Mill Maintenance – Equip. Enable/Disable

A-M Cleveland Hot Mill Maintenance – Auto Mill Modulus

A-M Cleveland Hot Mill Maintenance – Comm. Diagnostics

Arcelor Mittal - Cleveland 84” Hot Strip Mill Revamp

Arcelor Mittal - Cleveland 84" Hot Strip Mill Revamp

by Integrated Mill systems on Nov 29, 2011

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Arcelor Mittal - Cleveland 84" Hot Strip Mill Revamp — Presentation Transcript