The project was huge! Technologically, the shop comprises six continuously operated sinter strands. In order to provide pollutant emissions control for these sinter strands, they are equipped with process-gas cleaning and air-aspiration systems to cater for the intense sources of dust generated by the sintering process.
In the course of this turnkey project, Azov Controls had to gain an in-depth understanding of the customer’s precise needs and then develop a system that met these needs; undertaking implementation, installation, commissioning and all other major project activities, including reconstruction and site surveys.
In addition to the scale of the project, time was another major factor. In view of maintaining as continuous production as possible, the works had to be performed under a tight schedule, using a phased approach – requiring incredibly robust management.
Each and every control and electrical component had to be replaced. The power and control circuit supply systems were to be completely reconstructed and new hardware components introduced.
The brains of the new control system is an Allen-Bradley® ControlLogix® L83 programmable automation controller (PAC), which communicates with a number of networked devices and cells using Cisco Industrial 3750 and 3010 Ethernet switches and multiple EtherNet/IP-based device level rings (DLR).
An Allen-Bradley SmartGuard™ 600 safety controller is another core component, delivering CIP and CIP Safety™ capabilities, while Allen-Bradley PowerFlex® 753 variable-speed drives are used for the mixing drum rotor and an Allen-Bradley PowerFlex DC drive controls the sinter belt.
From a software perspective, FactoryTalk® View Site Edition provides SCADA capabilities, hardware- and software-redundant FactoryTalk® View Server delivers the SQL functionality, with FactoryTalk® View Studio being used to configure, develop and test the HMI and visuals based upon existing graphics.