USS 84' PL Upgrade

84 Inch Pickle LineAutomation & Drives Upgrade M M 1

84” PKL Automation Upgrade Project Goals - Electrical• Replace the Following Control Equipment: – Mixed Bag of Reliance, GE Fanuc, & Relay Line Control – Clark Drives – Reliance Drives – GE DC2000 Drives – Reliance & GE Fanuc Remote I/O – Mixed Bag of HMI 2

84” PKL Automation Upgrade Project Goals – Electromechanical (Existing)• Upgrade the Following Existing Subsystems: – Shears – Taylor Winfield Welder – Wet Section Acid Concentration Control – Wet Section Acid Temperature Control – Independent Loop Cars – Steering Units – Peabody Oiler 3

84” PKL Automation Upgrade Project Goals – Electromechanical (New)• Control the Following New Subsystems: – 110,000 lb Tension Leveler – Rotary Head Side Trimmer – New Exit Bridle – New Exit Pinch Rolls – New Coil Banders 4

84” PKL Automation Upgrade New System Configuration Supervisory C-Net MAST_CNET 100 Patch Panel KVM KVM Entry Sect. Switch 300 500 Center Sect. Master Power Delivery Section L2 Application Server Ethernet Master Power Power C-NET C-NET C-NET C-NET C-NET C-NET C-NET Blank Blank Blank Blank Blank Blank Blank Master Ethernet Ethernet CPU CPU L2 Database Server C-NET C-NET C-NET C-NET C-NET C-NET C-NET C-NET C-NET C-NET C-NET PS Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank CPU CPU CPU Citect Primary I/O Server PS PS Citect Secondary I/O Server Maintenance PC L2 Server HMI Server Prog. / Prog. / Maintenance PC Interface Interface HMI Client HMI Client Burner Pulpit #1 Passline Pulpit #2 Passline Pulpit Passline 2 Scrap 352 353 Control Station Control Station HMI HMI T HMI HMI HMI T Passline 1 Scrap HMI HMI HMI #4 Bridle #5 Bridle Cutter Desk 1CD1 Cutter Desk 1CD6 Middle X-Ray Welder Control Station 550 551 564 563 Control Station Top Control Station Trimmer Adj. 183 Scale Control Station 160 DI: 00 DI: 00 #1 Bridle Del. Shear 151-1 154-1 Delivery Loop 150-1..2 Welder 273 Electronics #6 Bridle DO: 00 DO: 00 HMI HMI HMI (New) FLEX I/O 156 HMI AI: 00 AI: 00 273 HMI HMI HMI FLEX I/O FLEX I/O 150 FLEX I/O 151 153 FLEX I/O 154 AO: 00 AO: 00 FLEX I/O SSI FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O (Lasers) DI: 24 DI: 10 SSI DO: 6 DO: 06 (Lasers) AI: 00 Bottom AI: 00 582 FLEX I/O AO: 00 AO: 00 FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O 581 #2/#3 Bridle RIO 3 2 558 #4 Bridle RIO #5 Bridle RIO DI: 08 DI: 00 DI: 00 DO: 16 DO: 08 DO: 08 AI: 00 AI: 00 AI: 00 AO: 00 AO: 00 AO: 00 372 373 374 HMI Inspection HMI HMI HMI HMI 180 FLEX I/O MCC 3 319 351 382 580 Entry Steering. Control Station Control Station 316 317 321 380 381 560 Temate 115 116 West S. Trim 318 #6 Corr. Roll Control Station #2 Corr. Roll 250-1..2 515 East S. Trim #5 Corr. Roll 561 562 Tens. Leveller 360 HMI HMI Roll Station #3/#4 Corr. 315 Sub-Master T/L HPU Roll HPU Entry Loop Sub-Master DI: 16 Station Station Station Coil Prep DI: 18 Squaring Side Trimmer DI: 1 T/L RIO Wet Section DI: 21 Welder Power DI: 9 SubMaster SubMaster SubMaster SubMaster Submaster Submaster DO: 16 Power Shear HMI DI: 10 DI: 17 Coil Exit DO: 8 Steering Steering FLEX I/O Power Power Power Ethernet DO: 4 DO: 4 DO: 4 Ethernet Power Power Power 4AI-2AO 4AI-2AO 4AI-2AO DO(120V) AI: 00 Resolver Resolver Resolver T/L Analog Analog Power Ethernet DO: 11 DO: 14 Ethernet C-NET C-NET C-NET DO(24V) DI(120V) 4AI-2AO 4AI-2AO 4AI-2AO C-NET C-NET C-NET Ethernet Ethernet Blank Blank Blank Blank Ethernet DI: 16 DI: 19 DI(24V) DI(24V) Analog Analog Ethernet 4AI-2AO 4AI-2AO 4AI-2AO Blank Blank Blank Blank Blank C-NET C-NET C-NET C-NET C-NET C-NET C-NET AO: 00 CPU 4AI-2AO 4AI-2AO 4AI-2AO 250 AI: 00 AI: 02 CPU Blank Blank Blank Blank Blank Blank Blank Blank C-NET C-NET C-NET C-NET C-NET C-NET SSI SSI DO DO 6 RTD C-NET C-NET SSI SSI PS CPU DO: 03 DO: 09 CPU Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank DO SLC Blank Blank Blank Blank Blank Blank Blank PS DI DI Blank Blank Blank Blank Blank 8 AO FLEX I/O SSI SSI SSI SSI SSI SSI SSI DI AO: 00 AO: 00 CPU CPU CPU DO DO PS PS PS FLEX I/O FLEX I/O CPU 186 FLEX I/O SSI SSI DI DI DO DO AI: 01 AI: 03 SSI SSI PS PS PS DO PS FLEX I/O DI DI DI DI DI DI AO: 00 AO: 00 390 FLEX I/O FLEX I/O FLEX I/O Leveler FLEX I/O FLEX I/O FLEX I/O Sumps 316-2 317-1 317-2 318-1 RINSE TANK RIO FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O Control Station Fume Exhaust Process Acid Control RIO TANK 1 RIO TANK 2 RIO TANK 3 RIO TANK 4 RIO DI: 6 DI: 29 DI: 6 DI: 5 DI: 6 DI: 9 DI: 3 DO: 4 DO: 25 DO: 0 DO: 0 DO: 0 DO: 4 DO: 0 Del. Corr. Roll FLEX I/O FLEX I/O FLEX I/O FLEX I/O #12 Corr. Roll 571 DI: 8 #10/#11 Corr. #8 Corr. Roll #1 Bander I/O #1 Bander I/O MCC 3 -1 Roll Station AI: 10 AI: 06 AI: 5 AI: 6 AI: 4 AI: 8 AI: 2 MCC 4 DO: 6 #7 Corr. Roll Station Station Oiler I/O HPU MCC #1 MCC #2 FLEX I/O DI: xx Remote I/O Station Valve Stand Valve Stand AO: 00 AO: 0 AO: 0 AO: 1 AO: 1 AO: 1 DI: 19 DI: 4 FLEX I/O FLEX I/O Tension Reel FLEX I/O Payoff Reel FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O FLEX I/O AO: 1 FLEX I/O Del Hydr. C. Shear & AI: 00Conveyors Hydraulics Flat. Misc. SCR Cab. Sideguide Exit PR & Crane I/O FLEX I/O DI: xx DO: xx T. Table -1 Crane & FLEX I/O DO: 4 DO: 3 DI: 59 DI: 05 DI: 09 DI: 18 DI: 05 DI: 20 DI: 26 DI: 09 DI: 12 DI: 36 363 364 365 366 367 AO: 00 DI: 00 Welder Welder Welder 189-1..3 176-1..10 FLEX I/O Repeater Misc. Misc. Entry P/L 1 P/L 2 DI: 46 DO: xx AI: xx HPU DO: 52 DO: 11 171-1..7 DO: 22 DO: 19 182-1 DO: 00 DO: 04 DO: 04 DO: 18 DO: 06 DO: 62 HMI DI: 11 Tilters DO: 29 578-3 AI: xx DI: 28 AI: 00 AI: 02 DO: 19 AI: 00 AI: 00 AI: 02 AI: 00 AI: 00 AI: 00 AI: 01 AI: 00 Prog. / #1 Scrap DO: 24 DO: 05 AI: 00 DI: 24 DI: 24 -2 Pickup Motor 362-1 AI: 02 TC: xx Conveyor AI: 01 DO: 17 DO: 17 AO: 00 AO: 00 AO: 00 AO: 00 AO: 00 AO: 00 AO: 00 AO: 00 AO: 00 AO: 00 362 361 HMI Client 390 AI: 01 590 Roll Starters AO: 00 VF VF AO: 00 570 (Notcher) AO: 00 361-2 361-1 170 190 191 187 171 181 182 174 177 178 179 189 176 573 AO: 00 -3 588 585 Drive 586 Drive 577 #9 Corr. Roll Station 575 578 576 M 578-2 M M 578-1 FLEX I/O Remote I/O OPCO Oil DI: xx DO: xx 572 East East East East East West West West West West #2 Gap #2 Lap #1 Gap #1 Lap Chop #2 Gap #2 Lap #1 Gap #1 Lap Chop M M M M M M M M M M E E E E E E E E E E DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa DCa M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E Entry Section Drives Center Section Drives Entry Looper Drives Exit Looper Drives Delivery Section Drives 5

84” PKL Automation Upgrade New System Configuration Pyramid Hierarchy  New Operators Stations & Pulpit Distributed Processing  New Remote I/O (ControlNet) Common Implementation Platform  New DC Drives Common L1/L2 HMI  New MCC’s  New PCR’s Level 2 Human Interface Supervisory Control Drives and Auxiliary I/O Entry Section Center Section Delivery Section 6

84” PKL Automation Upgrade Level 2 Configuration 7

84” PKL Automation Upgrade Tension Study #1 Flattener & Peeler Upcut Shear #1 & #2 Tensiometer Roll Defelector Roll #2 Pinch Roll Unit #1 8 11 # 2 Flattener & 10 Steering Unit #6 Defelector Roll #1 Steering Roll #4 Steering Roll #2 Steering Roll #3 Tension Leveller Steering Roll #5 Steering Roll #1 12 Resquare Shear Bridle #4 Peeler Pinch Roll Unit #2 Idler Roll Tensiometer Roll 9 # 1 Payoff # 2 Payoff Acid Acid Acid Acid Bridle #2 Bridle #1 Welde Bridle #3 Reel Reel 1 2 LEGEND 5 6 7 4 LOAD CELL ROLLS DRIVEN ROLLS 3 STEERING ROLLS (NON DRIVEN) Cold Water Spray Section NON DRIVEN ROLL New Pull Through Side Chem Coat Section Steering Roll #11 Steering Roll #10 New Steering Roll #12 Steering Roll #9 Steering Roll #8 Steering Unit #7 New Pinch Roll Unit Turndown Roll #2 Wringer Rolls Bridle #5 Turndown Roll #1 Pinch Roll Unit #5 Hot Air Dryer New Notcher Wringer Roll Upcut Shear Tension Reel #1 Tension Reel #2 17 Sinker Roll Sinker Roll Sinker Roll Next Current Trimmer Exit Looper GAUGE (in) 0.250 0.100 New Bridle WIDTH (in) 70.000 67.000 Yield Strength (PSI) 30000 60000 Leveler Elongation % 0.8 3 15 16 13 14 Cross Section (in^2) 17.50 6.70 Entry Speed (FPM) 800 Tank Speed (FPM) 800 19 20 Exit Speed (FPM) 800 18 USX Irvin 84" Pickler Motor Loads USX Irvin 84" Pickler Strip Tensions 150.0 10000 LINE SPECIFICATIONS 125.0 9000 ENTRY EXIT STRIP MIN MAX MIN MAX 100.0 8000 STRIP THICKNESS (in) 0.047 0.250 0.047 0.250 75.0 STRIP WIDTH (in) 24 78 24 78 7000 CROSS SECTION (in2) 0.079 19.50 0.079 19.50 50.0 YIELD STRENGTH (psi) 16000 60000 0.648 16000 60000 25.0 6000 COIL WEIGHT (lbs) 94000 94000 0.0 5000 OUTSIDE DIAMETER (in) 36 80 28 80 INSIDE DIAMETER (in) 26 29 20 24 -25.0 4000 SPEEDS & RATES -50.0 3000 SPEEDS (fpm) SPEED CHANGE RATES (fpm/sec) -75.0 MIN MAX ACCELERATE NORMAL DECEL -100.0 2000 ENTRY 60 2500 400 400 PROCESS 60 800/1000 250 250 -125.0 1000 EXIT 60 1500 250 250 -150.0 JOG 150 Payoff Reel Flattener #1 Bridle Entry Looper #2 Bridle #3 Bridle #4 Bridle #5 Bridle Exit Looper #6 Bridle #5 Pinch Rolls Tension Reels 0 #1 Entry Entry #2 #3 Deflect #4 #1 #4 #5 Exit Exit Exit #6 #6 Side Payoff Leveler Leveler Tensio% Load (Roll 1) -34.1 13.8 -20.7 66.1 -79.9 81.8 81.9 31.2 63.6 -80.0 11.4 54.2 Reel Bridle Looper Looper Bridle Entry Exit Bridle or Roll Bridle Tank Tank Bridle Looper Looper Looper Bridle Bridle Trimm n Reel U.S. STEEL CORPORATION -20.7 67.0 -79.9 81.8 81.9 30.4 64.4 -80.0 11.4 Entry Entry Exit Entry Entry #2 Entry Entry Exit Entry Entry Center Exit Entry Exit er Exit% Load (Roll 2)% Load (Roll 3) -21.0 68.0 -79.9 81.8 81.8 31.2 65.2 28.6 11.4 Tension Zone 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 MON VALLEY WORKS% Load (Roll 4) -21.0 -79.9 81.8 81.9 31.0 Tension (lbs/10) 660 681 907 947 961 5686 9068 9068 3644 3651 1444 1536 1720 1000 1020 1034 1061 2528 2616 2650 IRVIN PLANT 0.0 150.0 0.0 0.0 0.0 0.0 0.0 Tension (PSI) 985 1016 1353 1414 1434 8487 13534 13534 5439 5449 2155 2292 2567 1493 1523 1543 1584 3774 3904 3955Slip (yes = 150) CONTINUOUS PICKLE LINE 8

84” PKL Automation Upgrade Weld Tracking Screen 9

84” PKL Automation Upgrade Feeder Screen 10

84” PKL Automation Upgrade Entry Passline Screen 11

84” PKL Automation Upgrade Welders Screen 12

84” PKL Automation Upgrade Shearman Screen 13

84” PKL Automation Upgrade Side Trimmer Screen 14

84” PKL Automation Upgrade Steering Unit Screen 15

84” PKL Automation Upgrade Coil Delivery Screen 16

84” PKL Automation Upgrade Typical Permissive Screen 17

84” PKL Automation Upgrade Fault Summary Screen 18

84” PKL Automation UpgradeAuto Sequence Monitor Screen 19

Increase crane speed and shortenacceleration ramps without increasedload swayAdd restricted area, speed limitationsand automated positioningPrevent damages due to swingingload

USS 84' PL Upgrade

by Integrated Mill systems on Nov 27, 2011

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USS 84’ PL Upgrade — Presentation Transcript