Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

Ims Tcm Upgrade 2 (3)


Published on

  • Be the first to comment

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
  26. 26. 26
  27. 27. 27
  28. 28. 28
  29. 29. 29
  30. 30. 30
  31. 31. 31
  32. 32. 32
  33. 33. 33
  34. 34. 34
  35. 35. 35
  36. 36. 36
  37. 37. 37
  38. 38. 38
  39. 39. 39
  40. 40. 40
  41. 41. 41
  42. 42. 42
  43. 43. 43
  44. 44. 44
  45. 45. 45
  46. 46. 46
  47. 47. 47
  48. 48. 48
  49. 49. 49
  50. 50. 50
  51. 51. 51
  52. 52. A-M Cleveland Cold Mill Wrap-up and Questions 52