RUSSULA NEWSLETTER No. 11
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RECENT PROJECTS<br />
Successful startup of Gerdau Corsa´s section mill drive<br />
and controls upgrade<br />
Russula upgraded the automation system and drives<br />
for Gerdau Corsa´s section mill. The mill was successfully<br />
started up at the end of October, early <strong>No</strong>vember<br />
2014. Gerdua Corsa´s 150,000 tpy section mill is located<br />
in Tlalnepantla, Mexico.<br />
As an independent provider, Russula has the flexibility<br />
to integrate the ideal combination of hardware and software,<br />
mutually agreed upon with the customer for their<br />
particular mill. For this project, Russula integrated the<br />
control system and drive hardware from four different<br />
suppliers.<br />
The Russula Automation and Service solution for this<br />
mill includes:<br />
- Siemens S7-400 PLCs<br />
- DC Drive Rebuilds - ABB DCS800<br />
- New DC drives - ABB DCS800<br />
- New AC Drives - ABB ACS800<br />
- HMI - Wonderware<br />
- Electrical, Software and HMI Engineering<br />
- Main operator control station<br />
- 3 Simotion controllers for the shears<br />
- Iba high speed data acquisition system<br />
Russula was responsible for the installation supervision,<br />
commissioning, operator/maintenance training<br />
and three months of production assistance.<br />
The Russula Mill Control Scope:<br />
- Rolling mill configuration and mill tuning<br />
- Cascade mill control<br />
- Inter-Stand manual control<br />
- Mill speed references and management of start<br />
and stop of each section<br />
- Tension control<br />
- Tracking and cobble detection<br />
- Shear cut control<br />
- Rest cut removal<br />
- Cooling bed entry and exit sequencing<br />
- Phantom billet<br />
- Alarm and Interlocking<br />
Even after many years of operation, DC motors<br />
are often in an excellent shape. Since the technology for<br />
power stacks and power circuits does not change<br />
rapidly, upgrading the drive electronics will often give<br />
the same result as replacing the entire drive. This is an<br />
attractive upgrade path for mills as the installation is<br />
quicker and the equipment less expensive than buying<br />
complete new drives.<br />
This is the fourth project Russula has implemented for<br />
Gerdau Corsa in Mexico in the past two years. With the<br />
successful startup of the section mill, Russula strengthens<br />
its relationship with Gerdau Corsa.<br />
Billet exiting the reheat furnace at Gerda Corsa section mill<br />
in Tlalnepantla, Mexico<br />
The small section mill produces 150,000 tons per year of 1-6<br />
inch steel strip, squares, rounds and channels<br />
<strong>11</strong> Russula Newsletter <strong>No</strong>. <strong>11</strong> April 2015 - Copyright © by <strong>RUSSULA</strong> S.A.