Connected Enterprise Delivers Improvements at Ukrainian Sinter Plant

Connected Enterprise Improves Sinter Plant

Challenge

  • Ageing control infrastructure at Ukrainian sinter plant unable to leverage modern data-driven process advances

Solutions

Results

Major modernisation programme by Azov Controls – a Rockwell Automation Recognised System Integrator – gives metalworking plant access to multiple data-driven process improvements

Modernisation can deliver multiple technological, operational and legislative benefits, even in industries where automation has not traditionally played a key role.

One example would be in metalworking foundries, which are often highly mechanised and do not deploy automation on a scale similar to other major industries. Through modernisation however, these types of sites can realise significant performance gains, while also more effectively addressing ever-stronger legislation concerning energy use and harmful emissions.

Integrated Iron and Steel Works can actively use modern technologies to increase the efficiency of controlling industrial and business processes. A classic example of production automation is the "Enterprise in plain sight" system of visualisation and monitoring of technological processes, which was implemented at the Zaporizhstal PJSC in 2016.

Zaporizhstal PJSC turned to Ukraine-based Rockwell Automation Recognised System Integrator, Azov Controls LLC, to not only replace and build the control systems for its fifth and sixth sinter strands, but also design and populate a brand new central control room.

The display system operates 24 hours a day and the processing speed of the received data is a matter of seconds. This provides round-the-clock access to the most up-to-date information on production processes, online monitoring of production, making of informed decisions, and implementation of control actions.

The work undertaken by Azov Controls has resulted in a truly modern sinter shop control room at Zaporizhstal PJSC.

Challenge

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.

Solution

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.

The new central control room was built “from scratch" in a completely new building, with the layout being determined by the tasks to be undertaken by the operators. Console-type monitors were used for the local management of workstations and a mixture of 27 and 55 in industrial monitors are used in a video wall to display the information served by the FactoryTalk software.

Using this new infrastructure, the operational staff at Zaporizhstal PJSC are able to accurately and clearly monitor key parameters such as temperature, pressure, humidity, machine speed and equipment status, while also being able to obtain real-time information about possible malfunctions and issues.

Azov Controls, as a Rockwell Automation Recognised System Integrator, makes a commitment to deliver the highest technical solutions and customer service, leading with Rockwell Automation technologies. These integrators have a mutually supportive relationship with the Rockwell Automation sales and/or distributors they work with.

Results

The result of all the work undertaken by Azov Controls has resulted in a truly modern sinter shop control room at Zaporizhstal PJSC.

The new facility allows the operational services of the plant to not only monitor and control the main technological parameters of all workshop equipment, but also to perform automated management of these processes.

The deployment of Allen-Bradley PACs in conjunction with FactoryTalk software has delivered remote monitoring, far more accurate production process control, intelligent energy regulation and greater plant productivity.

The new central control room was built “from scratch” in a completely new building.

Indeed, according to Alexey Chernik, Head of the Automation & Drives Department at Azov Controls: “The capabilities of the system we created are actually beyond the scope of the original terms of reference; and at the moment the system is actively still developing and improving. The next stage of the reconstruction will be the modernisation of the control systems for the batch-feeding conveyors and sintering machine No. 4."

Mr. Dronov, Head of Automation at Zaporizhstall adds his thoughts: “We are very satisfied with the solutions delivered and we are currently striving to extract even more capabilities and savings out of the system. We have several other projects in the pipeline related to the sinter and blast-furnace shops and the data we are seeing from this new installation is already being used in the MES track-and-trace module at the plant.

Allen-Bradley, ControlLogix, FactoryTalk, LISTEN. THINK. SOLVE., PowerFlex, Rockwell Automation and SmartGuard are trademarks of Rockwell Automation, Inc.

EtherNet/IP and CIP Safety are trademarks of ODVA, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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