RUSSULA NEWSLETTER No. 11
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
RECENT PROJECTS<br />
Three consecutive projects at Gerdau Cartersville<br />
Following the recent modernization of the DC drives<br />
of the bar mill, Russula has won a contract for the 4<br />
strand continuous caster and complete bar mill control<br />
revamp at Gerdau Cartersville in GA, USA.<br />
The projects will be implemented in two phases during<br />
planned shutdowns. In the first phase, one strand of the<br />
continuous caster and the bar mill will be<br />
commissioned in September 2015. The second phase<br />
consists of the revamping of the other three continuous<br />
caster strands, scheduled for December 2015.<br />
A multi-phase revamp approach allows mills to upgrade<br />
obsolete control equipment and minimize mill<br />
downtime, which reduces the impact on production.<br />
Rolling mill drive upgrade completed in just six days<br />
The first project, implemented in December 2014, consisted<br />
of upgrading the main DC drives of the bar mill<br />
from ABB DCS600 to DCS800. The entire mill downtime<br />
for the uprade was only six days. Even though the<br />
upgrade was from the same drive family, due to the<br />
various sizes and configurations, it was necessary to<br />
propose solutions for each case, seeking the best technological<br />
improvement while minimizing the investment.<br />
The proposed solution is based on using DCR upgrade<br />
kits, which replace all electronic drive control while<br />
keeping intact the power stacks. The kits are highly<br />
modular, allowing the upgrade to be accomplished<br />
quickly. The main benefits were:<br />
- Gerdau Cartersville mill obtained the high<br />
performance offered by ABB DCS800 drives<br />
without having to change the power stacks, thus<br />
optimizing the economic investment.<br />
- Replaced obsolete equipment and software, which<br />
was expensive to maintain due to the high price of<br />
spare parts replacement for discontinued<br />
equipment.<br />
- Established a standard and transparent<br />
communication path between the PLCs and<br />
standard drives, expanding the communication<br />
capabilities of these systems with other external<br />
control systems.<br />
Control system upgrade for bar mill and continuous<br />
caster scheduled for September 2015<br />
This second project is currently under development<br />
and consists of the upgrade of the existing control<br />
system and HMI architecture for the bar mill. The<br />
current ABB AC450 PLCs with the ABB AS500 SCADA<br />
operator inferface will be replaced with the ABB<br />
AC800M series and Wonderware Intouch. Russula mill<br />
control will be implemented for the entire line from the<br />
first stand to the cooling bed.<br />
New DC drives supplied by Russula for the sideguards and<br />
screwdown of the DUO two high stand revamped in 20<strong>11</strong><br />
Gerdau Cartersville mill produces a line of angle bars,<br />
profiles and flats with diameters from 150 to 300 mm<br />
7 Russula Newsletter <strong>No</strong>. <strong>11</strong> April 2015 - Copyright © by <strong>RUSSULA</strong> S.A.