The document describes an automation upgrade project for the Leeuwkuil Mill in Vereeniging, South Africa. The project involved upgrading the mill's control system from an analog and S5 PLC hybrid system to a Totally Integrated Automation (TIA) system using Siemens components. The upgrade was conducted in two phases, replacing the drives and adding a mill PLC in phase 1, and adding a shear PLC, removing the S5 PLCs, and completing commissioning in phase 2. The TIA system integrated the PLCs, drives, SCADA system, and panels to provide benefits like centralized engineering, integrated diagnostics, and remote access to the SCADA system.

1. Technical Summary Siemens TIA Project: Leeuwkuil Mill, Mittal, Vereeniging 2005-2007

2. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Background Mill rolls special products 12 Stands Plant is a “hybrid” – analog/S5 PLC control: Loop control – analog control Shear length cutting – PLC control Problems with spares

3. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Requirements Upgrade two existing S5 PLC’s to S7 Replace drives with microprocessor-based drives (Siemens SIMOREG) Do away with analog control – new PLC functionality Configure mill stored setup (“recipe-based”) Replace operator desk Put in a SCADA (WinCC) and operator panels

4. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Phase 1 Phase 1 – commissioning Dec 2005/ Jan 2006 Replace drives with microprocessor-based drives (Siemens SIMOREG) Add Mill PLC (S7) to work in conjunction with existing S5 PLC’s (hardwired communication interface) Add SCADA and Multi Panel Remove old cables

5. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Phase 2 Phase 2 – commissioning Dec 2006/ Jan 2007 Add Shear PLC (S7) Remove S5 PLC’s Tune loop controllers without metal in mill (simulated) Commission 3 flying shears Commission length cutting Update WinCC with setup features

6. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Who/What/Why TIA…? Totally Integrated Automation Central Engineering from Simatic Manager of: Drives – Drives ES Basic SCADA – WinCC Panels – WinCC Flexible PLC’s

7. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Central Engineering PLC Drives SCADA/ WinCC Panels

8. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Easy Access to Drive Trace

9. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Mill Setup (WinCC User Archives)

10. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Drive Diagnostics/PLC SCL Decoding

11. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Profibus Diagnostics

12. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Value…? Totally Integrated Automation Controller tuning for loopers without metal in mill (prevent cobbles) Diagnostics Profibus N/W Drives Easy interfacing with S5 ET200U modules – Profibus feature WinCC uses Web Client functionality – any machine on the network can access SCADA without extra software/licenses