Transcript
HiREG®
Electrodes Regulator Training
DANIEL
I
Know-How in Process Control
Danieli Automation HeadquartersVia B.Stringher, 433042 Buttrio (UD) Italy
Tel. (39) 0432.518111Fax (39) 0432.673177E-mail: sales@dca.it
DANIELI AUTOMATION
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• Aim of the application• Power Supply layout• Measuring system• Current and Voltage Transformer• M.V. Interface Transformer table• Hardware connection to PLC• PLC Interface• Electrode Regulator: Position Control
Loop• Linearization and regulation
parameters• Counter pressure: pressure control
loop• Cold test• Hot Test• Data Analysis (Fda® )
HiREG® – Training program
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REGULATION PRINCIPLESREGULATION PRINCIPLES
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• Impedance regulation:Istantaneous control of the arc length by hydraulic electrodes position control
• Individual regulators for each phase, with phase balancing
• Electrode saving function1. Overcurrent reaction.
2. Not conductive material reaction
• Logging and real time trends for machine tuning and performance improvement
HiREG®– Aim of the application
Pos
REACTOR POSITIONPRIMARY VOLTAGE
CURRENT VALUETAP CHANGER POSITION
REGULATOR
SET-POINTCALCULATION
V
I
Z set
Z measure
Z error
TUNING PARAMETERS
INITIALCONTACT
LOGIC I
V
Speed
Control Loop Regulation
Standard PLC
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HiREG® Position Control Loop
Regulation Algorithm
Ki * I ‑ Ku * U = 0
Main Parameters:PAR. I , PAR. U : inputs U, I parametering and limiting functionsKi : conversion table from primary current to secondary current Kiph : function for the balancing of the phasesKu : table for the furnace working points
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HIREG BLOCK DIAGRAMHIREG BLOCK DIAGRAM
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HiREG® - Automation Block Diagram
HiREGHiREGEAFEAF
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HIREG HYDRAULICHIREG HYDRAULIC
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HiREG® Hydraulic Overview
InletInlet
Regulation Regulation ValvesValves
UnlockingUnlockingValvesValves
Line PressureLine Pressuretransducerstransducers
Lifting Lifting ColumnsColumns
OutletOutlet
Counter PressureCounter PressureTransducersTransducers
AccumulatorsAccumulators
Counter PressureCounter PressureRegulation ValveRegulation Valve
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HiREG® Valve system
Actuator: Valve Tech. Spec.
Signal command ±10VDigital Regulator ± 10000
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HiREG® Valve system
Actuator: Valve Electrical drawing
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MV TYPICAL LAYOUTMV TYPICAL LAYOUT
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HiREG® Power Supply Layout
Transformer HV-MVTransformer HV-MV
BreakerBreaker
P.F. CompensationP.F. Compensation
Series ReactorSeries Reactor
Furnace transformerFurnace transformer
Secondary system and ElectrodeSecondary system and Electrode
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FIELD SIGNALS MEASUREFIELD SIGNALS MEASURE
PT and CT connection
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HiREG® Measuring system
Voltage transformer PT (TV)
Important: Avoid shortcircuit condition for PT (TV)
50Hz
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HiREG® Measuring system
Adaptive Current transformer TA
Trafo connection Delta/Delta
Diris
Important :always verify short circuit condition for CT (TA)
5/5 A
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HiREG® Measuring system
Trafo connection Star/Delta
Adaptive Current transformer TA
5/5:√3 A
Important :always verify short circuit condition for CT (TA)
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HiREG® Measuring system
Trafo connection Star-Delta/Delta
5/5:√3 A
Important :always verify short circuit condition for CT (TA)
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HiREG® Voltage and current transducer
RMS converterRMS converter Input 0:100V or 0:8A Input 0:100V or 0:8A
ACAC Output 0:10 V DCOutput 0:10 V DC Time response < Time response <
50ms50ms Precision < 0.5%Precision < 0.5% Cl.= 0.5Cl.= 0.5 Supply 230 V 50Hz Supply 230 V 50Hz
or 110 V 60 Hzor 110 V 60 Hz
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HIREG ELECTROTECNICHIREG ELECTROTECNIC
Main Principles
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HiREG® Electrical Parameters (1)
Base electrical circuit:
Base circular diagram
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Real Circular DiagramReal Circular Diagram
APPARENT POWER [MVA]
RATED POWER [MVA]
MAX. POWER [MVA]
POWER FACTOR [-]
LOAD CURVES [V]ELECTRODES CURRENT [kA]
ARC LENGTH [mm]
For each tap of the reactor (if any), a circular diagram can be produced to represent the allowed working area for the furnace.
HiREG® Electrical Parameters (2)
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EAF
P_fu+jQ_fu
P_fu+jQ_fu+jQ_react
P_arc + losses = P_fu
S_2
S_1
SERIES REACTOR
FURNACE TRANSFORMER
P_arc = 3 (V_arc x I_arc)
MV BUSBAR
P_fu/S_2 = 0,77-0,78
P_fu/S_1 > 0,8
Theory of Series ReactorTheory of Series Reactor
ProfileProfile
Boring : P.F.<0.75 Varc < 300÷400 CC = 6
Melting : P.F. >0.75 max Power
Refining : R.I. Arc coverage condition
HiREG® Electrical Parameters (3)
Power
Boring
Melting
Refining
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HIREG HW INTERFACESHIREG HW INTERFACES
Fail safe logic
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HiREG® Hardware connection to PLC
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HIREG INTERFACE SIGNALSHIREG INTERFACE SIGNALS
With main automation PLCs
EAF or LRF
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HiREG® PLC Interface (1)
HIREG_WC_REMHIREG_WC_REM DATA TO FURNACE PLCDATA TO FURNACE PLC
dp couplerdp coupler: 64 bytes: 64 bytesSTRCT: STRCT: EREG_REMEREG_REM
DBW000DBW000 INTF_WS_WATCHDOG_RGINTF_WS_WATCHDOG_RG watchdogwatchdog ININ 0÷300000÷30000 Always Always changingchanging 0000
DBX002.00DBX002.00 INTF_BS_GEN_FLTINTF_BS_GEN_FLT Regulator generic alarmRegulator generic alarm BBBB 0>10>1 1= true1= true 0000
DBX002.01DBX002.01 INTF_BS_TRP_FLTINTF_BS_TRP_FLT Regulator higher priority failureRegulator higher priority failure BBBB 0>10>1 1= true1= true 0000
DBX002.02DBX002.02
DBX002.03DBX002.03
DBX002.04DBX002.04 INTF_BS_BRK_OPN_CNSINTF_BS_BRK_OPN_CNS furnace breaker open consentfurnace breaker open consent BBBB 0>10>1 1= true1= true 0000
DBX002.05DBX002.05
DBX002.06DBX002.06 INTF_BS_ARC_ONINTF_BS_ARC_ON Furnace Arc OnFurnace Arc On BBBB 0>10>1 1= true1= true 3131
DBX002.07DBX002.07
DBX003.00DBX003.00 INTF_BS_ELS_LW_QTAINTF_BS_ELS_LW_QTA Electrodes have all reached requested quotaElectrodes have all reached requested quota BBBB 0>10>1 1= true1= true 3131
DBX003.01DBX003.01
DBX003.02DBX003.02
DBX003.03DBX003.03
DBX003.04DBX003.04 INTF_BS_EL_CUR_HIGHINTF_BS_EL_CUR_HIGH Phase 123 cumulative high currentPhase 123 cumulative high current BBBB 0>10>1 1= true1= true 0000
DBX003.05DBX003.05 INTF_BS_EL_CUR_HHIGINTF_BS_EL_CUR_HHIG Phase 123 cumulative high high currentPhase 123 cumulative high high current BBBB 0>10>1 1= true1= true 0000
DBX003.06DBX003.06
DBX003.07DBX003.07
DBX004.00DBX004.00 INTF_BS_EL1_LW_QTAINTF_BS_EL1_LW_QTA Electrode 1 has reached requested quotaElectrode 1 has reached requested quota BBBB 0>10>1 1= true1= true
DBX004.01DBX004.01 INTF_BS_EL1_CUR_HIGHINTF_BS_EL1_CUR_HIGH Electrode 1 high currentElectrode 1 high current BBBB 0>10>1 1= true1= true 0000
DBX004.02DBX004.02 INTF_BS_EL1_CUR_HHIGINTF_BS_EL1_CUR_HHIG Electrode 1 high high currentElectrode 1 high high current BBBB 0>10>1 1= true1= true 0000
DBX004.03DBX004.03 INTF_BS_EL1_POS_FLTINTF_BS_EL1_POS_FLT Electrode 1 Encoder faultElectrode 1 Encoder fault BBBB 0>10>1 1= true1= true 0000
DBX004.04DBX004.04 INTF_BS_EL1_SP_ZEROINTF_BS_EL1_SP_ZERO Electrode 1 speed is zeroElectrode 1 speed is zero BBBB 0>10>1 1= true1= true 0000
DBX004.05DBX004.05 INTF_BS_EL1_HISP_VLVINTF_BS_EL1_HISP_VLV Electrode 1 high speed valve opening commandElectrode 1 high speed valve opening command BBBB 0>10>1 1= true1= true 3333
DB 156 To Furnace PLC
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HiREG® PLC Interface (2)
DB 156 To Furnace PLC
DBX010.00DBX010.00 INTF_BS_RCT_BRK_CLS_ENAINTF_BS_RCT_BRK_CLS_ENABB
Saturable reactor: furnace breaker Saturable reactor: furnace breaker closing enabledclosing enabled BBBB 0>10>1 1=true1=true 3131
DBX010.01DBX010.01
DBX010.02DBX010.02 INFT_BS_RCT_CUR_REACHINFT_BS_RCT_CUR_REACH Saturable reactor target current is Saturable reactor target current is reachedreached BBBB 0>10>1 1=true1=true 3131
DBX010.03DBX010.03
DBX010.04DBX010.04 INTF_BS_RCT_CUR_ALR_HIGINTF_BS_RCT_CUR_ALR_HIGHH
Saturable reactor current over high Saturable reactor current over high limit-STOP CONVERTERlimit-STOP CONVERTER BBBB 0>10>1 1=true1=true 3131
DBX010.05DBX010.05 INTF_BS_RCT_CUR_ALR_LOWINTF_BS_RCT_CUR_ALR_LOW Saturable reactor current under low Saturable reactor current under low limit-STOP CONVERTERlimit-STOP CONVERTER BBBB 0>10>1 1=true1=true 3131
DBW012DBW012 INTF_WS_EL1_VLT_RGINTF_WS_EL1_VLT_RG electrode 1 _ voltage electrode 1 _ voltage ININ 0÷12000÷1200 VV 0÷12000÷1200 0000
DBW014DBW014 INTF_WS_EL1_CUR_RGINTF_WS_EL1_CUR_RG electrode 1 _ currentelectrode 1 _ current ININ 0÷50.000÷50.00 KAKA 0÷50000÷5000 0000
DBD016DBD016 INTF_WS_EL1_POSINTF_WS_EL1_POS electrode 1 actual absolute positionelectrode 1 actual absolute position FLFL 0÷60000÷6000 mmmm 0÷60000÷6000 3333
DBW020DBW020
DBW042DBW042 INTF_WS_PRIM_VLINTF_WS_PRIM_VL Primary voltagePrimary voltage ININ 0÷42.000÷42.00 KVKV 0÷42.00 KV0÷42.00 KV 0000
DBW052DBW052 INTF_WS_RCT_CUR_REFINTF_WS_RCT_CUR_REF Saturable reactor current referenceSaturable reactor current reference ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3131
DBW054DBW054 INTF_WS_RCT_CUR_LIM_HIGINTF_WS_RCT_CUR_LIM_HIGHH
Saturable reactor current high limit Saturable reactor current high limit valuevalue ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3131
DBW056DBW056 INTF_WS_RCT_CUR_LIM_LOWINTF_WS_RCT_CUR_LIM_LOW Saturable reactor current low limit valueSaturable reactor current low limit value ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3131
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HiREG® PLC Interface (3)
DB 156 From Furnace PLCDBW100DBW100 INTF_WC_WATCHDOG_RGINTF_WC_WATCHDOG_RG watchdogwatchdog II
NN0÷300÷30000000
Always Always changingchanging 0000
DBX102.0DBX102.000
INTF_BC_EL1_LIFT_RGINTF_BC_EL1_LIFT_RG electrode 1 lifting (regulator)electrode 1 lifting (regulator) BBBB
0>10>1 1= true1= true 0000
DBX102.0DBX102.011
INTF_BC_EL1_LOWR_RGINTF_BC_EL1_LOWR_RG electrode 1 lowering (regulator)electrode 1 lowering (regulator) BBBB
0>10>1 1= true1= true 0000
DBX102.0DBX102.022
INTF_BC_EL1_AUTO_RGINTF_BC_EL1_AUTO_RG electrode 1 automatic (regulator)electrode 1 automatic (regulator) BBBB
0>10>1 1= true1= true 0000
DBX102.0DBX102.033
INTF_BC_EL1_UNL_RGINTF_BC_EL1_UNL_RG Electrode 1 unlocked (regulator) Electrode 1 unlocked (regulator) BBBB
0>10>1 1= true1= true 0000
DBX102.0DBX102.044
INTF_BC_EL1_HIGH_RGINTF_BC_EL1_HIGH_RG electrode 1 in high pos. (regulator)electrode 1 in high pos. (regulator) BBBB
0>10>1 1= true1= true 0000
DBX102.0DBX102.055
INTF_BC_EL1_LOW_RGINTF_BC_EL1_LOW_RG electrode 1 in low pos. (regulator)electrode 1 in low pos. (regulator) BBBB
0>10>1 1= true1= true 0000
DBX102.0DBX102.066
INTF_BC_EL1_HSPD_RGINTF_BC_EL1_HSPD_RG electrode 1 high speed (regulator)electrode 1 high speed (regulator) BBBB
0>10>1 1= true1= true 0000
DBX102.0DBX102.077
DBX103.0DBX103.000
DBX103.0DBX103.011
DBX103.0DBX103.022
DBX103.0DBX103.033
DBX103.0DBX103.044
DBX103.0DBX103.055
DBX103.0DBX103.066
DBX103.0DBX103.077
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HiREG® PLC Interface (4)
DB 156 From Furnace PLC
DBX108.00DBX108.00 INTF_BC_ARC_INT_CMDINTF_BC_ARC_INT_CMD furnace breaker arc interruption furnace breaker arc interruption (command)(command)
BBBB
0>10>1 1= true1= true 0000
DBX108.01DBX108.01 INTF_BC_BRK_CLS_STAINTF_BC_BRK_CLS_STA furnace breaker closed (status)furnace breaker closed (status) BBBB
0>10>1 1= true1= true 0000
DBX108.02DBX108.02 INTF_BC_BRK_OPN_CMDINTF_BC_BRK_OPN_CMD furnace breaker opening request (command)furnace breaker opening request (command) BBBB
0>10>1 1= true1= true 0000
DBX108.03DBX108.03 INTF_BC_CLAMPSINTF_BC_CLAMPS electrodes clamps modeelectrodes clamps mode BBBB
0>10>1 1= true1= true 0000
DBX108.04DBX108.04 INTF_BC_MAINTINTF_BC_MAINT Furnace in maintenance modeFurnace in maintenance mode BBBB
0>10>1 1= true1= true 0000
DBX108.05DBX108.05 INTF_BC_HEAT_ENDINTF_BC_HEAT_END Furnace Heat EndFurnace Heat End BBBB
0>10>1 1= true1= true 0000
DBX108.06DBX108.06 INTF_BC_BCK_ENDINTF_BC_BCK_END Furnace Bucket EndFurnace Bucket End BBBB
0>10>1 1= true1= true 0000
DBX110.00DBX110.00 INTF_BC_RCT_AUTOINTF_BC_RCT_AUTO Saturable reactor automatic modeSaturable reactor automatic mode BBBB
0>10>1 1= true1= true 3131
DBX110.01DBX110.01 INTF_BC_RCT_RUNINTF_BC_RCT_RUN Saturable reactor is runningSaturable reactor is running BBBB
0>10>1 1= true1= true 3131
DBX110.02DBX110.02 INTF_BC_RCT_BYPINTF_BC_RCT_BYP Saturable reactor is by-passedSaturable reactor is by-passed BBBB
0>10>1 1= true1= true 3131
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HiREG® PLC Interface (5)
DB 156 From Furnace PLC
DBW112DBW112 INTF_WC_PRIM_VLTINTF_WC_PRIM_VLT primary - voltageprimary - voltage ININ 0÷50.000÷50.00 kVkV 0÷50000÷5000 0000
DBW114DBW114
DBW116DBW116
DBW118DBW118 INTF_WC_TAP_POS_RGINTF_WC_TAP_POS_RG tap changer position tap changer position ININ 1÷321÷32 1÷321÷32 0000
DBW120DBW120 INTF_WC_CUR_SET_RGINTF_WC_CUR_SET_RG current curve position (SET)current curve position (SET) ININ 1÷61÷6 1÷61÷6 0000
DBW122DBW122 INTF_WC_RCT_POSINTF_WC_RCT_POS reactor positionreactor position ININ 1÷61÷6 1÷61÷6 0000
DBW124DBW124 INTF_WC_ACT_PWRINTF_WC_ACT_PWR Active powerActive power ININ 0÷1000.00÷1000.0 MWMW 0÷100000÷10000 0000
DBW126DBW126 INTF_WC_RCT_PWRINTF_WC_RCT_PWR Reactive powerReactive power ININ 0÷1000.00÷1000.0 MVAMVARR
0÷100000÷10000 0000
DBW128DBW128 INTF_WC_COSPHYINTF_WC_COSPHY CosphyCosphy ININ 0÷1.0000÷1.000 0÷10000÷1000 0000
DBW142DBW142 INTF_BC_RCT_CUR_TRG_MAINTF_BC_RCT_CUR_TRG_MANN
Saturable reactor target current in Saturable reactor target current in manual modemanual mode ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 33
11
DBW144DBW144 INTF_BC_RCT_CUR_ACTINTF_BC_RCT_CUR_ACT Saturable reactor real currentSaturable reactor real current ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3311
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HIREG OWSHIREG OWS
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HiREG® Communication Overview
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HiREG® Communication settings
DPI CONFIGURATOR
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HIREG OWS PARAMETERSHIREG OWS PARAMETERS
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HiREG® Electrical Parameters (1)
Reference document:
Admittance Table
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HiREG® Transformer Table (1)
Transformer Primary side connection
Important: Electrode line current
CT Settings
KI-KA Automatic calculation
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HiREG® Transformer Table (2)
KIKA
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HiREG® Regulation Parameters
Regulation Valve settings
PI Regulator settings
Electrode Speed settings
Boring phaseSettings
Touch DownSettings
Notch Filter Settings
V/I presence
AdditionalSettings
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HiREG® Regulation Parameters
Phase BalancePhase Balance PHASE 1PHASE 1 PHASE 2PHASE 2 PHASE 3PHASE 3
PHASE BALANCEPHASE BALANCE 11 11 11
CURRENTCURRENT 11 11 11
ARC LENGHTARC LENGHT == == ==
PHASE BALANCEPHASE BALANCE 11 0,90,9 11
CURRENTCURRENT 11 1+ 1+ ΔΔ 11
ARC LENGHTARC LENGHT --ΔΔ - - ΔΔ + + ΔΔ
PHASE BALANCEPHASE BALANCE 11 0,90,9 0,90,9
CURRENTCURRENT 11 1+ 1+ ΔΔ11 1+ 1+ ΔΔ22
ARC LENGHTARC LENGHT (-(-ΔΔ11 + + ΔΔ22)) (-(-ΔΔ11– – ΔΔ22)) (+Δ(+Δ11 – Δ – Δ22))
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HiREG® Linearization (1)
Sequence:1. Zero Valve 2. BIAS 1 mm/s3. Linearization
Automatic cycle
SPEED RESPONSE CP=680 PSI
-300
-200
-100
0
100
200
300
400
-10000 -6000 -2000 2000 6000 10000reference [mV]
spee
d [
mm
/s]
EL3
EL2
EL1
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HiREG® Regulation Parameters NLG
Gain increase in case of cave-in
Maintain symmetric system response
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HiREG® Plant Parameters
Typical Measuring setting: pay attention to the correct value
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HiREG® Counter Pressure
Pressure control :Pressure control :• Counter pressure set ~80% Pb= Pcp Down Speed ~200mm/s (Pb: Pressure Counter pressure set ~80% Pb= Pcp Down Speed ~200mm/s (Pb: Pressure
balance)balance)• Accumulator set ~65% PcpAccumulator set ~65% Pcp
Valve Parameters
Backpressure
Set Points
BackpressureTrend
Alarms
Line pressureTrends
Line Pressurealarms
SwitchingSettings
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HiREG® Communication settings
Dispatcher settings
DB MidddleWareLocation
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• Automation system technical specification - HiReg (o HiReg Plus) • Functional Specification - HiReg (o HiReg Plus) • Operator manual – HiReg OWS • Ac electric arc furnace - Furnace calculations - Working points, circ.diagram, electrode reg.table • Commissioning manual
HiREG® Reference documentation
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