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Ims Tcm Upgrade 2 (3)

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Ims Tcm Upgrade 2 (3)

  1. 1. IMS Presentation – Arcelor Mittal Cleveland 1
  2. 2. ArcelorMittal-Cleveland84” Tandem Cold Mill Revamp LC LC LC 5 4 3 2 1 PG PG PG PG 2
  3. 3. A-M Cleveland Cold Mill IMS Introduction  Founded in 1992  Design/Build/Commission Distributed PLC and Coordinated Drive Control Systems  Strong Process Knowledge in Multiple Industries; Especially Steel-Making  Expertise in Multiple Control Platforms and HMI  Extensive “Phase-In” Retrofit Experience  Emphasis on Integration/Factory Testing  In-House Panel Assembly/Wiring  Offices in Cleveland and Pittsburgh 3
  4. 4. A-M Cleveland Cold Mill Mill Configuration LC LC LC 5 4 3 2 1 PG PG PG PG Five stands Hydraulics 1st two stands Electro-mechanical screws stands 3 thru 5 XRay before/after stand 1, after stand 5 4
  5. 5. A-M Cleveland Cold Mill Existing Control System Configuration Level 2 and Setup Model: DEC-Alpha AGC/HGC: Multibus 80/486 and ?? HMI Mill Master and Auxiliaries: GEM-80 and Imagem HMI Coil Handling and Other: Modicon Quantum PLC 5
  6. 6. A-M Cleveland TCM New AGC/Tension Control X -R a y M o n ito r Feed F o rw a rd Mass Flow Spill-Back M a s s flo wIn t e r -S t a n d G auge- T e n s io n m e te r C o n tro l * In e r tia - Com p C o n s ta n t F o rc e LC LC LC 5 4 3 2 1 PG PG PG PG Tension Limit S p e e d B ia s D e liv e r y X -R a y M a s s f lo w / M o n ito r M a s s F lo w B ia s F e e d F o rw a rd (b y S p e e d ) * S t a n d 1 - 2 T e n s io n E s t a b lis h e d 6
  7. 7. A-M Cleveland Cold Mill Goals and Requirements Address Obsolete Equipment Address GEM PLC update rates to improve threading, gage control and light gage running at higher speeds Improve Data Communication between PLC’s and Level II  Address lack of spare variables to make enhancements  Address data throughput for gage & tension control  Provide troubleshooting tools Provide a common equipment platform to provide ease of maintenance and common spares Provide Common HMI System that has access to mill wide data base Minimize Risk during improvements by shadowing Retain/capture software enhancements developed since previous upgrade Address Operator Station deterioration, wiring and devices Establish SPC Standards and Alarms 7
  8. 8. A-M Cleveland Cold Mill New System Configuration Pyramid Hierarchy w/ Distributed Processing Using GE Fanuc RX3i All New Supervisory Control Systems and Desk and Trunion Stations Interface to Existing L2 via Ethernet Interface to Existing Coil Handling System via Modbus TCP New Siemens Drives (MG-Set and Armature Supplies) iBA flight recorder GE Fanuc Cimplicity ME/PE Windows PLC Programming and HMI VersaMax Remote I/O 8
  9. 9. A-M Cleveland Cold Mill Application Highlight – HMI All inclusive L1 HMI unified package GE Fanuc Proficy PE Package L1 Ethernet Interface Common Template – consistent visual interface (layout) to ease initial training and subsequent user navigation through the various screen menus Consistent use of color to indicate alarm, warning, status, data entry Single programming environment Alarm/Event Logging IBA data collection and trending 9
  10. 10. A-M Cleveland Cold MillApplication Highlight – Mill Master 10
  11. 11. A-M Cleveland Cold Mill Application Highlight – Strip Propulsion FPM Stand Speed Setup and Limit Checking Digital “Master Rheostat” Speed Distribution with Threading Lead Speed and Progressive Tandem Jog “Smart” S-Ramp Acceleration and Deceleration Speed Bias Cascading Constant Speed Threading / Tail-out Auto-Slowdown (Coil Tail-Out) " O p e r a to r P r e s e t " a d ju s ta b le v ia H M I 5000 Stand Dummy Function RUN Fault Detection " L in e R e f e r e n c e " a f fe c te d b y 4000 Auto Tail Spotting a u t o m a t ic s lo w d o w n - s to p f o r e n d o f c o il 3000 " S e t p o in t s " d e te r m in e d b y R U N , S LO W , and S T O P p u s h b u tto n s 2000 " A c tiv e S e tp o in t " in d ic a t io n 1000 F ix e d " T h r e a d S p e e d " SLO W 0 STO P 11
  12. 12. A-M Cleveland Cold Mill Application Highlight – Tension Control Pass-Line Height Compensation Inter-Stand Tension Control by Roll Gap at Run Speed Inter-Stand Tension Control by Speed (Thread and Tailout)  Over-rides Tension Control by Roll Gap on Gross Errors 12
  13. 13. A-M Cleveland Cold Mill Application Highlight – Strip In Stand Strip Detection via Roll Force Strip Detection via Tension Sensing Strip Tracking  Guarantee proper strip-in-stand pickup and dropout sequence  Reduce the likelihood of premature pickup or dropout of a given SIS  Provide backup sequencing to roll force detection 13
  14. 14. A-M Cleveland Cold MillApplication Highlight – AGC Speed of response Accuracy Process Gain SensitivityFeed Forward High Low HighGaugemeter Medium-High Medium LowVolumetric (Mass Flow) Medium High LowFeedback Low High LowAGC Monitor Low --- Low 14
  15. 15. A-M Cleveland Cold Mill Application Highlight – AGCP = Primary Input SensorB = Backup Input Sensor 15
  16. 16. A-M Cleveland Cold Mill Application Highlight – AGC Bumpless mode switching  Manual gap level intervention  Manual gap intervention  Mill stop event  Mill limit event  Sensor failure  AGC Loops  Entry Feed Forward (into stands 1 and 2)  Volumetric (Mass Flow)  Gaugemeter  Thickness X-ray Monitor Compensations  Automatic gain compensation  Oil film compensation 16
  17. 17. A-M Cleveland Cold MillApplication Highlight – HGC and Screws Dual position referencing (for clutchless operation) Position regulation Y Kp * X Force regulation C Position feedback K s * ( X ) 1 /2 Force feedback Force feedback null B x Servo-null balance control Position/force loop gain compensation Position feedback loss detection Anti-tilt protection speed Excessive roll force protection Eccentricity control w/ Auto Learning C  (No additional sensors required) B p o s it io n e r r o r 17
  18. 18. A-M Cleveland Cold MillApplication Highlight – Screw Master 18
  19. 19. A-M Cleveland Cold MillApplication Highlight – HGC Masters 19
  20. 20. A-M Cleveland Cold MillApplication Highlight – WR Bal/ Bending Work roll balance/positive roll bending Work roll negative roll bending Automatic bending control Open loop bending compensation Crown-in/roll balance pressure Crown-out pressure Increasing cylinder pressure Decreasing Increasing bending bending force Roll balance force pressure Max negative Zero Max positive bending force bending force bending force 20
  21. 21. A-M Cleveland Cold Mill Application Highlight – Drive Control Main drive MG-Sets (Five Mill Drives and Tension Reel)  Outer control loops in RX3i  Speed Control  Inertia Compensation  Torque to Current Conversion  Current Limit  Armature Current Control w/ Rate of Change Limit  CEMF Feed Forward Compensation  Zero Terminal Voltage Regulator  Generator EMF Limit  Frame Delay Compensation  Generator Field Sat Curve  Siemens field supplies communicating via Profibus Armature supplies (Screwdowns, Shape Roll, and Payoff Reel) 21
  22. 22. A-M Cleveland Cold MillProject Execution – Design Schedule 22
  23. 23. A-M Cleveland Cold MillProject Execution – Outage Schedule 23
  24. 24. A-M Cleveland Cold Mill Project Execution – Formal FAT at IMS in Eastlake Level 2 Models Communication Tests Modicon Subsystem Communication Tests Hardware Tests Overall System Simulation  Force Downloads from Level 2 to Level 1 with empty mill  Bring Mill Up from Outage and Calibrate Mills for Rolling  Enter New Roll Diameters Data  Bring Mills up to Idle Speed  Auto Zero Screws  Turn Bending on  Check that all systems are setup for next piece  Simulate Thread and Run Mill  Run Simulation of threading the Mill  Run the mill  Boost Setting  Run – Hold  AGC Control  Tension Control  Test Autoslowdown  Test Tail end Spotting  Test Roll Change Functions  Different Modes of Operation & check operation of functions  Rolling  Roll Change  Maintenance 24
  25. 25. A-M Cleveland Cold Mill Project Execution – TestingExceptions  Fast Stop  E-Stop  Inhibit Stand switch  Set Mill  Strip Break Logic/Cobble Simulation  Unavailable Modes  Dummy Stand  Unavailable stand  2 coils in Mill at Once  Head End Stop  Split Coils 25
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  52. 52. A-M Cleveland Cold Mill Wrap-up and Questions 52
  53. 53. INTEGRATED MILL SYSTEMS

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