Ims Tcm Upgrade 2 (3)

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IMS Presentation – Arcelor Mittal ClevelandIMS Presentation – Arcelor Mittal Cleveland

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

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ArcelorMittal-ClevelandArcelorMittal-Cleveland

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A-M Cleveland Cold MillA-M Cleveland Cold Mill IMS IntroductionIMS Introduction

Founded in 1992Founded in 1992 Design/Build/Commission Distributed Design/Build/Commission Distributed

PLC and Coordinated Drive Control PLC and Coordinated Drive Control SystemsSystems

Strong Process Knowledge in Multiple Strong Process Knowledge in Multiple Industries; Especially Steel-MakingIndustries; Especially Steel-Making

Expertise in Multiple Control Platforms Expertise in Multiple Control Platforms and HMIand HMI

Extensive “Phase-In” Retrofit Extensive “Phase-In” Retrofit Experience Experience

Emphasis on Integration/Factory Emphasis on Integration/Factory TestingTesting

In-House Panel Assembly/WiringIn-House Panel Assembly/Wiring Offices in Cleveland and PittsburghOffices in Cleveland and Pittsburgh

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Five stands Hydraulics 1st two stands Electro-mechanical screws stands 3 thru 5 XRay before/after stand 1, after stand 5

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

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Level 2 and Setup Model: DEC-Alpha AGC/HGC: Multibus 80/486 and ?? 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 MillExisting Control System ConfigurationExisting Control System Configuration

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A-M Cleveland TCMA-M Cleveland TCM New AGC/Tension ControlNew AGC/Tension Control

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Mass Flow B ias

Speed B ias

*

* S tand 1-2 T ension Established

M assflow

FeedForw ard

Gauge-m eter

Inertia-Com p

X-RayM onitor

M assflow /Feed Forw ard

(by Speed)

DeliveryX-Ray

M onitor

Inter-StandTensionControl

Mas

s F

low

Spi

ll-B

ack

Tension Lim

it

ConstantForce

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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

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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 New Siemens Drives (MG-Set and Armature Supplies) iBA flight recorder GE Fanuc Cimplicity ME/PE Windows PLC Programming and HMI VersaMax Remote I/O

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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

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

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

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

Speed and Progressive Tandem JogSpeed and Progressive Tandem Jog ““Smart” S-Ramp Acceleration and DecelerationSmart” S-Ramp Acceleration and Deceleration Speed Bias CascadingSpeed Bias Cascading Constant Speed Threading / Tail-outConstant Speed Threading / 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

1000

2000

3000

4000

5000

0

RUN

SLOW

STOP

"Operator Preset" adjustable via HMI

"S e tpo in ts " de te rm ined byR U N , S L O W , a n d S T O Ppush buttons

Fixed "Thread Speed"

"Line Reference" affected byautom atic s lowdown-stop forend of coil

"Active Setpoint" indication

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

ControlControl Pass-Line Height CompensationPass-Line Height Compensation Inter-Stand Tension Control by Roll Gap at Run SpeedInter-Stand Tension Control by Roll Gap at Run Speed Inter-Stand Tension Control by Speed (Thread and Tailout)Inter-Stand Tension Control by Speed (Thread and Tailout)

Over-rides Tension Control by Roll Gap on Gross ErrorsOver-rides Tension Control by Roll Gap on Gross Errors

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

StandStand 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 Reduce the likelihood of premature pickup or dropout of a

given SISgiven SIS Provide backup sequencing to roll force detectionProvide backup sequencing to roll force detection

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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 Low

Feedback Low High LowAGC Monitor Low --- Low

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

P = Primary Input SensorB = Backup Input Sensor

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

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 Entry Feed Forward (into stands 1 and 2)and 2)

Volumetric (Mass Flow)Volumetric (Mass Flow) GaugemeterGaugemeter Thickness X-ray MonitorThickness X-ray Monitor

CompensationsCompensations Automatic gain compensationAutomatic gain compensation Oil film compensationOil film compensation

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A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – HGC and Application Highlight – HGC and

ScrewsScrews 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

Kp * X

Ks * (X)1 /2

position error

C

B

spee

d

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A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – Screw Application Highlight – Screw

MasterMaster

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A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – HGC Application Highlight – HGC

MastersMasters

2020

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

BendingBending Work roll balance/positive roll bendingWork roll balance/positive roll bending Work roll negative roll bendingWork roll negative roll bending 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

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A-M Cleveland Cold MillA-M Cleveland Cold MillApplication Highlight – Drive Application Highlight – Drive

ControlControl 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 field supplies communicating via ProfibusSiemens field supplies communicating via Profibus

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

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A-M Cleveland Cold MillA-M Cleveland Cold MillProject Execution – Design Project Execution – Design

ScheduleSchedule

2323

A-M Cleveland Cold MillA-M Cleveland Cold MillProject Execution – Outage Project Execution – Outage

ScheduleSchedule

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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 AutoslowdownTest Autoslowdown 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

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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 2 coils in Mill at Once2 coils in Mill at Once

Head End StopHead End Stop Split CoilsSplit Coils

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A-M Cleveland Cold MillA-M Cleveland Cold MillWrap-up and QuestionsWrap-up and Questions

INTEGRATED MILL SYSTEMSINTEGRATED MILL SYSTEMS