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    Ukraine, 69091 Zaporizhzhia
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03
Jun 19

The System of precise stop and passing defects through the mill stand in the reversing mill stand 1200 Metallurgical Plant

After hot drawing and pickling of rolls steel surface has many asperities, leave alone the fact that during the pickling in continuous units rolls are welded together and seams are formed. Whereas, when a defect or suture enters the mill stand, it is necessary to reduce the speed of the strip to prevent deformation of the rollers and provide better rolling. One roll can be rolled in a reversing mill to 3-7 times (passages). During the first pass, the speed reduction is carried out by the operator (notes defects). The automated system detects defects and on the next pass will automatically reduce speed during their passage through the cage.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

On reversing mill 1200 of «Zaporizhstal» plant is installed the four-rolls stand with working rolls with a diameter of 430 mm and supporting 1300 mm. Working rolls are driven by electric power of 3200 kW through pinion stand and rotate with the maximum circumferential speed of 10 m / s. During the rolling the working roll’s speed does not exceed 8.5 m / s. The mild steel 08kp (ps) rolled in the rolling mill with the size of 0.6 x 1030 mm (a tin semi-finished rolled stock) and 0.5 x 1,020 mm. The hardware-software complex of a precise stop and passing through defects in the stand reversing mill 1200 is intended for automatic control of round the clock exact stop at the end of the roll.

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The following effect was obtained as a result of implementation of the system:

  • improving the reliability of the machine work by applying modern microprocessor-based means of automation and as a consequence, reduced downtime of production equipment and consumption of energy resources through the fault of failures in an outdated control system;
  • increasing the productivity of the machine by automatic and accurate stop and reversing of rolling;
  • increasing productivity of the machine by automatic reducing the speed of the rolling mill when it passes the defects through the stand and minimize the rolling time on low speed;
  • providing «bumpless» exploitation of mill rolls by automatic reducing the speed of the rolling mill when it passes the defects through the stand as well as a precise stop;
  • more efficient use ejector and equipment by reducing the downtime of production equipment and consumption of energy resources through the fault of failures.
03
Jun 19

The system of ordering a blast for a blast furnace BF-2

In the process of melting in the blast furnace is required a continuous and uniform flow of air under an excess pressure of 0.2-0.5 MPa, heated to a temperature of 1000-1400°С. The amount of air supplied is usually 2-2.5 m3 / min per 1 m3 of the furnace’s extent/ (up to 7,000-11,000 m3 / min).

The temperature and amount of flow of air is determined by the physico-chemical processes of melting, which in its turn greatly influences the change of furnace productivity and fuel consumption. The exposure the hot blast to the blast furnace process is especially effective when enriching it with oxygen supplied to the intake manifold blowing machine. In addition, directly to the tuyeres of the furnace can be supplied extra fuel – natural gas, coal dust, oil.

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The development of the system of ordering a blast provides:

  • day and night automatic equipment control according to set schedules of compliance the temperature;
  • optimization process of smelting process;
  • long-distance monitoring and control with ARM controller complex;
  • reducing fuel consumption;
  • increasing the productivity of the furnace.
  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

03
Jun 19

The speed modes convolution machines control system

Convolutional machines are intended for coiling the strip by bending the band between the rollers. The alternating current motor drive of each convolution machine is individual (AC motors with squirrel-cage rotor type ARM 2P74-10b 10 kW, 500 V, 50 Hz, 550 rev / min). Energy delivery to eight motors of each convolution machine is carried out by reversing variable frequency inverter with rated current of 400 A, voltage of 380 V and cycles of 50 Hz. The system provides a backup inverter for three convolution machines.

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Functions of panel controllers:

  • Receiving the input discrete signals from control equipment located on the cover panel;
  • The reception from the local network of digital codes CAN output of the frequency converters;
  • Logical processing of the received information;
  • Formation and transmission of digital signals to the display indicators located on the cover panel;
  • Transferring of control data via CAN (assignment of speed to frequency converters).
  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

03
Jun 19

The hardware-software complex of controlling of on-off cull ejector of the cross-cutting machine APR-1

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The complex is intended to:

  • round the clock automatic control of mechanisms and electrical equipment of the ejector in order to provide the functions of sorting second-class sheets and accounting products;
  • ensuring reliable and safe exploitation of the machine equipment.
  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Main features and capabilities of the complex:

  • reception of logic (physical) signals from the diagnosed equipment;
  • the total number of discrete input channels – not less than 16 («dry» contact);
  • the total number of digital output channels – not less than 16 (relay);
  • normalization and individual galvanic isolation of the received signals;
  • calculation and forming of control actions in accordance with a predetermined algorithm work ejector equipment;
  • processing the received signals and information, analysis and fault detection and deviations of the technological process in accordance with a predetermined algorithm of work of ejector;
  • alarm system in case of emergency in the diagnosed equipment;
  • round the clock operation mode;
  • the possibility of further expansion of control functions without significant changes of hardware of control system;
  • uninterrupted operation in a actually existing electrical fluctuations;
  • the ability to display the technological parameters on the display panel;
  • maintenance of the alarms report in text form – the protocol of change of the of state diagnosed equipment and output of defined signals beyond the permissible limits;
  • the possibility of accumulation of statistical data on the process and reporting for certain periods of time (shift, day, month, etc.);
  • connection via RS-232/485 network;
  • the possibility of organizing connection with MIS or a higher-level control and diagnostics system via RS-485/422.
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The purpose of creation of a complex of controlling of cull ejector is to obtain economic benefit by means of:

  • increasing the reliability of the ejector by applying of modern microprocessor means of automation and sensors;
  • sorting second-class sheets;
  • accounting of products;
  • more efficient use ejector and equipment by reducing the downtime of production equipment and consumption of energy resources through the fault of failures.
31
May 19
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System diagnostics of bell-type furnaces thermal separation

Packing band cutting machine control system is intended for:

  • automatic control of machinery and electrical equipment of packing band cutting machine to provide the functions of cutting the band;
  • ensuring reliable and safe exploitation of the machine equipment.

 

 The purpose of the automatic cutting machine control system is to obtain economic benefit.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Control actions:

The purpose of the automatic cutting machine control system is to obtain economic benefit by means of:

  • increasing the reliability of the machine’s work through the use of modern means of automation;
  • improving the quality of the packaging band by optimizing and improving the accuracy of the cut;
  • more efficient use of the cutting machine by reducing the downtime of production equipment and consumption of raw materials and energy resources.

The control panel allows to cut the band both in manual and automatic mode at the specified length (from 1 to 12 meters). With the control panel the operator should be able to operate machinery and electrical equipment of the machine, with the further possibility of adjustment of the cut length of the strip. The set cut length is displayed on the control panel.

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The control panel provides:

  • reception of logic (physical) signal from the machine controls and delivery control signals to control the process of cutting the strip;
    • he total number of discrete input channels – 12;
    • the total number of digital output channels – 8 (relay);
  • calculation and forming of control actions in accordance with the predetermined algorithm of equipment operation;
  • round the clock operation mode;
  • the possibility of further expansion of control functions without significant changes of hardware of control system;
  • uninterrupted operation in a actually existing electrical fluctuations;
  • the ability to display the technological parameters on the display panel;
  • convenient service of control system;
  • the possibility of further change, extension of functionality and scalability of the system, including the forces of craft services.
30
May 19
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System diagnostics of bell-type furnaces thermal separation

Main indicator of metallurgical production is quality of the products. Thus one of the most important elements of the technological process is heat treatment. All kinds of hot-rolled and cold-rolled steel have to be heat-treated: sheets, pieces, wires, rails, pipes, tapes, etc.

Main indicator of metallurgical production is quality of the products. Thus one of the most important elements of the technological process is heat treatment. All kinds of hot-rolled and cold-rolled steel have to be heat-treated: sheets, pieces, wires, rails, pipes, tapes, etc.

During cold rolling, stamping or drawing the grains of the metal deform and crush. This effect is called hardening. The hardening increases metal hardness and reduces its ductility, causes brittleness. Recrystallization annealing is used to eliminate hardening. In the shops of cold rolling, recrystallization annealing is used as:

  • procedure prior to the cold processing of metals by pressure – in this case, the material becomes more ductile, easier for its further processing;
  • output type of heat treatment – end product or semi-finished product get the required production specifications;
  • intermediate step in the metal cold deformation process: annealing makes possible to remove hardening effectively.

To implement this type of heat treatment in cold-rolling shop of JSC “Zaporizhstal” bell-type furnaces are used.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Bell-type furnace – is a batch furnace for heat treatment of sheet rolls, strips and wire coils. The main feature of the furnace – is presence of two bells: internal, which protects the metal from oxidation (muffle); and external – is lined with refractory bricks, on which are mounted the burners or electric heaters. Heating of the products is carried out in a protective gas atmosphere.

Bell-type furnace operating principle is determined by the technology process, which is divided into three approximately equal steps of: heating up to 650-800°С, cooling under the muffle to 150°With and without it and the last stage – unloading and loading. The equality of time in stages allows you to use three stands with one of the heating hood and two muffles. Download metal ends on lowering stand on top of the foot rolls muffle and heating bell. Then flushed with protective gas (usually a mixture of 95% N2 and 5% Н2) and using circulating fan is its circulation. Then turn on the burner. The products of combustion pass between the heating hood and the muffle, and with the help of the injector (injects Wednesday – the air compressor) are removed in the stacks and in smoke hog. The temperature of the smoke in front of the injector about 630-660 °С. n bell-type furnaces, the physical warmth of the smoke is usually not recycled, what can be considered one of the drawbacks of the furnaces.

The heating time in the bell-type furnace is the main factor affecting fuel consumption. The time depends on the heat transfer conditions at the sidewall of the metal rolls.

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Bell-type furnace from the viewpoint of automatic control is capacitive static object and it is characterized by following input parameters:

  • gas consumption;
  • air consumption;
  • consumption of shielding gas;
  • consumption of combustion products.
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The main disturbing effects in the metal heating process are:

  • change of shove’s characteristics (weight and size of the roll, metal brand its thickness, coiling density);
  • pressure change and caloric content of gas;
  • change of pressure in furnace.
  • Display panel
  • Cabinet of technology automation
  • Blocks of remote input/output

Control actions:

  • shove’s temperature;
  • temperature under the muffle;
  • pressure in the furnace;
  • pressure in the breeching.
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ECONOMIC EFFECT CAN BE ACHIEVED BY

  • analysis of the technical process and the timely prevention of emergency situations;
  • more efficient use of existing aggregates and equipment by reducing the downtime of production equipment and consumption of raw materials and energy resources;
  • improvement of reliability of aggregates and equipment;
  • improvement of quality and competitiveness of manufactured products.

Centralized supervisory control and diagnostics of electric equipment system is intended for:

  • automatic registration of monitored parameters, operator’s actions and events for the purpose of their subsequent analysis;
  • ensuring of reliable and safe exploitation of the bell furnaces’ equipment.
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CENTRALIZED SUPERVISORY CONTROL AND DIAGNOSTICS OF ELECTRIC EQUIPMENT SYSTEM HAS THE FOLLOWING FEATURES AND CAPABILITIES:

  • reception of discrete and analog (physical) signals from diagnosed electric equipment;
    • the total number of analog input channels – 192, из них:
      • 96 channels maximum amplitude of 500V (with the normalization);
      • 96 channels maximum amplitude of 100 mV;
    • the total number of discrete input channels – 96 (230V);
    • he total number of digital output channels – 96 (relay, 3-5A, 230V);
  • normalization and individual galvanic isolation of the received signals;
  • real-time scale of changes in the physical analog and digital signals in the manner of graphs;
  • mnemonic scheme displaying the progress of the technological process on the screen of the firmware complex for monitoring and archiving (CMA), and supervisory control device (USC);
  • maintenance of the alarms report in text form – the protocol of change of the of state diagnosed equipment and output of defined signals beyond the permissible limits;
  • continuous recording of terms of the received signals into an information file (buffer type endless tape) with a specified interval;
  • possibility of convenient revision, analyzing and printing data from the archive;
  • the minimum recording interval – 20 ms;
  • archive depth – not less than 24 h;
  • processing the received signals and information, analysis and fault detection and deviations of the technological process in accordance with a predetermined algorithm of equipment operation;
  • alarm system in case of emergency in the diagnosed equipment;
  • the accumulation of statistical data on the process and reporting for certain periods of time (shift, day, month, etc.);
  • Ethernet connection between the nodes;
  • the possibility of organizing connection with MIS or a higher-level control and diagnostics system via Ethernet or RS-485/422;
  • backup power to all components of the system in case of voltage disruptions;
  • ease of system maintenance;
  • the possibility of further change, extension of functionality and scalability of the system, including the forces of craft services.
30
May 19

Electrical diagnostics system of the winder unit of hot-strip steel rolling plant

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The winder unit of hot-strip steel rolling plant has been designed for production of steel cross-section strip of 1.5…10 mm x 500…1830 mm, in rolls weighing up to 16 tonnes of slabs with thickness 145…175 mm. Length of the strip – up to 800 m. Productivity per shift – up to 4000 T.

Mill equipment consists of 5 heating furnaces for 8-ton slabs, rough crate group “Duo” and 4 crates “quarto”, intermediate roller with flying shears, finishing group of the crate “Duo” and 6 stands “quarto”, outlet roller conveyor system with laminar cooling of the strip, 6 winders (3 were designed for 16-ton rolls(winder 1…3) and 3 – for 8-ton rolls (winder 4…6)), and system of roll transfer to the warehouse and to cold rolling shop cold rolling unit.

Electrical equipment and software were developed for the winder equipment diagnostics automation. The introduction was made together with the staff of hot-strip mill of JSC “Zaporizhstal”.

Winders diagnostic system collects signals from winders electrical equipment of areas 1-6. Some signals are taken directly from the winders control area. Second part of the signals come from the winders electrical control cabinets.

Economic effect was achieved by improving the quality of service, timely elimination of anomalies of equipment operation, reducing unplanned downtime of the mill

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Winders electrical equipment diagnostics system was designed for:

  • automatic registration of controlled parameters, operator actions and events;
  • analysis of the technological process and the timely prevention of emergency situations;
  • increasing the efficiency of existing equipment usage by reducing equipment downtime and raw materials and energy consumption;
  • ensuring reliable and safe operation of the winder area equipment.

The system icludes following equipment:

  • Electrical diagnostics cabinet of winders 1-3;
  • Electrical diagnostics cabinet of winders 4-6;
  • Supervisory control automated workplace of administrator;
  • Remote input/output cabinet (control station of winders 1-3);
  • Remote input/output cabinet (control station of winders 4-6).
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System consists of three logic levels:

  1. Level of data collection is designed to receive and transmit signals to the level of processing and archiving; is performed on a PC-compatible controllers; software packages operated on the basis MICROMV Trace Mode are installed on all controllers;
  2. Level of data processing and archiving is designed for: receiving data via the communication channels from the hardware of data collection level, technological process visualization, real time analysis of electrical equipment condition, archiving, logging, alarming, reporting generation; is performed on a PC-compatible controller operated on MBP Trace Mode
  3. Level of Supervisory control is designed for remote archive analysis, long-term storage, report printing (statistical data and data from the archives in diagrams); functions on administrator automated workplace.

All the levels are interconnected via Ethernet.

Main functions and features of the diagnostics system:

Remote input/output cabinets ensure:

  • cyclic condition monitoring of control devices located at control stations winders (including manual mode);
  • automatic transmission of data on control devices condition(operator actions) for registration and archiving;
  • management of light-signal and alarm equipment on the post, on the basis of information received from the existing diagnostic system.

Winders electrical diagnostic equipment performs:

  • receiving signals from electrical equipment of the winders, receiving data for archiving from the data controller via the communication channels;
  • entry of channels value to the archive;
  • displaying of the technological process mnemonic;
  • displaying of channel values in trends;
  • alarm reporting;
  • automated technological process deviation analysis;
  • formation and transmission of information to the remote input/output cabinet for displaying winders control posts and external alarm system enabling on light-signal equipment;
  • communication between the automatic control system of the rolling mill and higher level management and diagnostics system.
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System software

System control and automation software is built on the basis of SCADA/HMI system Trace Mode 5.

During operation monitor displays a series of mnemonics, showing the current state of the process. Process equipment is conventionally shown on mnemonic. Switched on equipment is dislayed by the backlight or moving image.

Сonsidering the fact that one of the primary purposes of the system is technological process analysis and troubleshooting, special attention is paid to the visual displaying of received signals values in the form of trends and diagrams. The system is able to display signal values in real time for operational control as well as archival values for analysis (Image #3).

During operation system generates a report that is logged in messages of various types of operational information:

  • system information;
  • messages about critical situations;
  • alarms;
  • messages about changes in the modes of equipment operation;
  • operator actions registration.

Automated supervisory control workplace provides:

  • trend channel values displaying;
  • statistical reporting of rolling mill;
  • automatic copying of the archive files for long-term storage from winders electrical diagnostics cabinet;
  • graphical reporting documentation and archive data printout.
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29
May 19
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Software and hardware conveyor control complex

Our team has developed and implemented hot rolled coil conveyor process control system for thin-sheet hot rolling mill, JSC “Zaporizhstal”. The system provides emergency situations control, alarms and automatic shut down sections of the plant conveyors. SCADA TRACE MODE system and WinCon 8000 controllers have been selected as a tool of the process control system development.

Conveyors are an integral part of the hot-strip mill-1680. Continuous thin-sheet hot rolling mill has capacity of 3.5 million tons/year; is designed for production of steel strip with thickness of 2,0…8,0 mm, width 1000…1500 mm from the slabs coming from the blooming unit

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share

  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

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Software and hardware complex of transporter operation control

If all the equipment operates in normal mode, the winding interval of the roll is approximately 1.5 minutes. Then the winder unloads the roll of the cart, which transfers it to the conveyor, and at this time another winder starts winding. Winded rolls are moved from the winder further down the technological circuit by the means of transporters. Thus, transporters are very important unit. Transporter long-lasting operation stop may force operators to stop the operation of the mill because of the impossibility of unloading wounded rolls from the winder.

Transporters of JSC “Zaporizhstal” are conveyor type, which consist of consistent sections. For various reasons during transporter operation may occur a situation when mechanical connection between the engine and the circuit is lost resulting in the stop of this transporter section, as a result the rolls which moved on this transporter stop. At the same time, the previous transporter sections of the circuit continue to work, and the rolls begin to accumulate and damage each other.

If given situation occurs, automatic shut down of transporter emergency sections and previous to them sections is needed. The old systems of motor protection did not allow to detect the transporter section stop and notify the operator about emergency situation.

Transpoter process control system is designed for:

  • Clock control automation of mechanical and electrical equipment work of hot-rolled coils transporter
  • Alarm and automatic shut down of conveyors in accordance with the algorithm in case of emergency situation
  • Centralized supervisory control of transporter equipment
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Structurally transporter control system consists of the following parts:

  • Display panel
  • Cabinet of technology automation
  • Blocks of remote input/output

Display panel is designed to receive signals from the switches on the operator’s station and visualizing the current state of the transporters’ equipment.

Electrical equipment control of transporters, information collection and analysis is operated by controller of technology automation cabinet. The cabinet is equipped with the necessary means for galvanic isolation and conversion into digital form of the signals from the sensors and issuing control actions. The basis of the cabinet is industrial controller WinCon-8000 running on Windows CE.net. The application software is based on real-time system Micro TRACE MODE 6.

Devices of input/output are the hardware and software blocks of transporters’ equipment remote control, which are used for survey, processing and transmission of signals in real time from equipment to the automated process control cabinet. Output/input device is based on modules of remote data collection I-7000 of ICPDAS. Non-contact optical position sensors (Balluff, BOS) were used as rotation sensors of transporter drive rollers.

Automated control system was developed and implemented in the shortest possible time.

Due to introduction of transporters’ process control systems at JSC “Zaporizhstal” the amount of roll deformation during transportation has been reduced. Accident localization time and repair work became shorter, thereby decreased downtime of the transporter.

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