tandem cold mill revamp

11

84” Tandem Cold Mill Revamp 84” Tandem Cold Mill Revamp

L CL CL C

P GP G

12345

P GP G

ArcelorMittal-ClevelandArcelorMittal-Cleveland

22

Five stands Hydraulics screws 1st two stands Electro-mechanical screws stands 3 thru 5 Positive & Negative Bending on all 5 stands Shape Sprays on stand 5 XRay before/after stand 1, after stand 5

L CL CL C

P GP G

12345

P GP G

A-M Cleveland Cold MillA-M Cleveland Cold Mill Mill ConfigurationMill Configuration

33

Level 2 and Setup Model: DEC-Alpha AGC/HGC: Multibus 80/486 and Proprietary HMI Mill Master and Auxiliaries: GEM-80 and Imagem HMI Coil Handling and Other: Modicon Quantum PLC

A-M Cleveland Cold MillA-M Cleveland Cold Mill Existing Control System ConfigurationExisting Control System Configuration

44

A-M Cleveland Cold MillA-M Cleveland Cold Mill Goals and RequirementsGoals 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

55

A-M Cleveland Cold MillA-M Cleveland Cold Mill New System ConfigurationNew 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 (Ethernet) New Siemens Drives (MG-Set Field Exciters and Armature Supplies) iBA flight recorder GE Fanuc Cimplicity ME/PE Windows PLC Programming and HMI VersaMax Remote I/O

66

A-M Cleveland Cold MillA-M Cleveland Cold Mill Application Highlight – HMIApplication 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

77

A-M Cleveland Cold MillA-M Cleveland Cold Mill Application Highlight – Mill MasterApplication Highlight – Mill Master

88

A-M Cleveland Cold MillA-M Cleveland Cold Mill Application Highlight – Strip PropulsionApplication Highlight – Strip Propulsion

FPM Stand Speed Setup and Limit CheckingFPM Stand Speed Setup and Limit Checking Digital “Master Rheostat” Speed Distribution with Threading Lead Speed Digital “Master Rheostat” Speed Distribution with Threading Lead Speed

and Progressive Tandem Jogand Progressive Tandem Jog ““Smart” S-Ramp Acceleration and DecelerationSmart” S-Ramp Acceleration and Deceleration Geometric Speed Bias CascadingGeometric Speed Bias Cascading Constant Speed Threading / Tail-outConstant Speed Threading / Tail-out Head-on-Tail Treading / Tail-outHead-on-Tail Treading / Tail-out Auto-Slowdown (Coil Tail-Out)Auto-Slowdown (Coil Tail-Out) Stand Dummy FunctionStand Dummy Function Fault DetectionFault Detection Auto Tail SpottingAuto Tail Spotting

1 0 0 0

2 0 0 0

3 0 0 0

4 0 0 0

5 0 0 0

0

R U N

S L O W

S T O P

" O p e r a t o r P r e s e t " a d j u s t a b l e v i a H M I

" S e t p o i n t s " d e t e r m i n e d b yR U N , S L O W , a n d S T O Pp u s h b u t t o n s

F i x e d " T h r e a d S p e e d "

" L i n e R e f e r e n c e " a f f e c t e d b ya u t o m a t i c s l o w d o w n - s t o p f o re n d o f c o i l

" A c t i v e S e t p o i n t " i n d i c a t i o n

99

A-M Cleveland Cold MillA-M Cleveland Cold Mill Application Highlight – Tension ControlApplication Highlight – Tension Control

Inter-Stand Tension Control by Roll GapInter-Stand Tension Control by Roll Gap Transition to tension by roll gap at or above thread speedTransition to tension by roll gap at or above thread speed Tension by speed transitions out steplesslyTension by speed transitions out steplessly

Inter-Stand Tension Control by Speed (Thread and Tailout)Inter-Stand Tension Control by Speed (Thread and Tailout) Transition to tension by speed below thread speedTransition to tension by speed below thread speed Remains active with “wide” dead-band to assist tension by gapRemains active with “wide” dead-band to assist tension by gap

Comes into play on gross tension errorsComes into play on gross tension errors Prevents strip looping and strip breaksPrevents strip looping and strip breaks

1010

A-M Cleveland Cold MillA-M Cleveland Cold Mill Application Highlight – Strip In StandApplication Highlight – Strip In Stand

Strip Detection via Roll ForceStrip Detection via Roll Force Strip Detection via Tension SensingStrip Detection via Tension Sensing Strip TrackingStrip Tracking

Guarantee proper strip-in-stand pickup and dropout sequenceGuarantee proper strip-in-stand pickup and dropout sequence Reduce the likelihood of premature pickup or dropout of a given SISReduce the likelihood of premature pickup or dropout of a given SIS Provide backup sequencing to roll force detectionProvide backup sequencing to roll force detection

1111

A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – AGCApplication 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

1212


P = Primary Input SensorB = Backup Input Sensor

1313


Bumpless mode switchingBumpless mode switching Manual gap level interventionManual gap level intervention Manual gap interventionManual gap intervention Mill stop eventMill stop event Mill limit eventMill limit event Sensor failureSensor failure AGC LoopsAGC Loops

Entry Feed Forward (into stands 1 and 2)Entry Feed Forward (into stands 1 and 2) Volumetric (Mass Flow)Volumetric (Mass Flow) GaugemeterGaugemeter Thickness X-ray MonitorThickness X-ray Monitor

CompensationsCompensations Active Eccentricity CompensationActive Eccentricity Compensation Automatic gain compensationAutomatic gain compensation Oil film compensationOil film compensation

1414

A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – HGC and ScrewsApplication Highlight – HGC and Screws Dual position referencing (for clutchless operation)Dual position referencing (for clutchless operation) Position regulationPosition regulation Force regulationForce regulation Position feedbackPosition feedback Force feedbackForce feedback Force feedback nullForce feedback null Servo-null balance controlServo-null balance control Position/force loop gain compensationPosition/force loop gain compensation Position feedback loss detectionPosition feedback loss detection Anti-tilt protectionAnti-tilt protection Excessive roll force protectionExcessive roll force protection Eccentricity control w/ Auto LearningEccentricity control w/ Auto Learning

(No additional sensors required)(No additional sensors required)

Y

x

C

B

K p * X

K s * ( X ) 1 / 2

p o s i t i o n e r r o r

C

B

spee

d

1515

A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – Screw MasterApplication Highlight – Screw Master

1616

A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – HGC MastersApplication Highlight – HGC Masters

1717

A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – WR Bal/ BendingApplication Highlight – WR Bal/ Bending

Work roll balance/positive roll bending on all standsWork roll balance/positive roll bending on all stands Work roll negative bending on all standsWork roll negative bending on all stands Automatic bending controlAutomatic bending control Open loop bending compensationOpen loop bending compensation

Roll balancepressure

Crown-in/roll balance pressure

Crown-out pressure

Increasingcylinderpressure

Zerobending force

Max positivebending force

Max negativebending force

Increasingbending

force

Decreasingbending

force

1818

A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – Drive ControlApplication Highlight – Drive Control

Main drive MG-Sets (Five Mill Drives and Tension Reel)Main drive MG-Sets (Five Mill Drives and Tension Reel) Outer control loops in RX3iOuter control loops in RX3i

Speed ControlSpeed Control Inertia CompensationInertia Compensation Torque to Current ConversionTorque to Current Conversion Current LimitCurrent Limit Armature Current Control w/ Rate of Change LimitArmature Current Control w/ Rate of Change Limit CEMF Feed Forward CompensationCEMF Feed Forward Compensation Zero Terminal Voltage RegulatorZero Terminal Voltage Regulator Generator EMF LimitGenerator EMF Limit Frame Delay CompensationFrame Delay Compensation Generator Field Sat CurveGenerator Field Sat Curve

Siemens three phase field supplies controlled via ProfibusSiemens three phase field supplies controlled via Profibus

Armature supplies (Screwdowns, Shape Roll, and Payoff Reel)Armature supplies (Screwdowns, Shape Roll, and Payoff Reel)

1919

A-M Cleveland Cold MillA-M Cleveland Cold MillProject Execution – Design ScheduleProject Execution – Design Schedule

2020

A-M Cleveland Cold MillA-M Cleveland Cold MillProject Execution – Outage ScheduleProject Execution – Outage Schedule

2121

A-M Cleveland Cold MillA-M Cleveland Cold MillProject Execution – Project Execution – Formal FAT at IMS in EastlakeFormal FAT at IMS in Eastlake

Level 2 Models Communication TestsLevel 2 Models Communication Tests Modicon Subsystem Communication TestsModicon Subsystem Communication Tests Hardware TestsHardware Tests Overall System SimulationOverall System Simulation

Force Downloads from Level 2 to Level 1 with empty millForce Downloads from Level 2 to Level 1 with empty mill Bring Mill Up from Outage and Calibrate Mills for RollingBring Mill Up from Outage and Calibrate Mills for Rolling

Enter New Roll Diameters DataEnter New Roll Diameters Data Bring Mills up to Idle Speed Bring Mills up to Idle Speed Auto Zero ScrewsAuto Zero Screws Turn Bending onTurn Bending on Check that all systems are setup for next pieceCheck that all systems are setup for next piece

Simulate Thread and Run Mill Simulate Thread and Run Mill Run Simulation of threading the MillRun Simulation of threading the Mill Run the millRun the mill

Boost SettingBoost Setting Run – HoldRun – Hold AGC ControlAGC Control Tension ControlTension Control

Test Auto-slowdownTest Auto-slowdown Test Tail end SpottingTest Tail end Spotting Test Roll Change FunctionsTest Roll Change Functions

Different Modes of Operation & check operation of functionsDifferent Modes of Operation & check operation of functions RollingRolling Roll Change Roll Change Maintenance Maintenance

2222

A-M Cleveland Cold MillA-M Cleveland Cold MillProject Execution – TestingProject Execution – Testing

ExceptionsExceptions Fast StopFast Stop E-StopE-Stop Inhibit Stand switchInhibit Stand switch Set MillSet Mill Strip Break Logic/Cobble SimulationStrip Break Logic/Cobble Simulation Unavailable ModesUnavailable Modes Dummy StandDummy Stand Unavailable standUnavailable stand Split CoilsSplit Coils

tandem cold mill revamp

Business

cleveland cold

speed setup

speed transitions

gage tension controlprovide

threading lead speed

gage control

revamp arcelormittalcleveland

common hmi system