Arcelor Mittal - Cleveland 84 Hot Strip Mill Revamp

A-M Cleveland Hot Mill

Width: 26 to 72 Thickness: 0.056 to 0.700 Capacity: 3 Million Tons/Yr 7 Stand Finishing Train,72,000 HP 2 Downcoilers, 1000 HP each
Delivery Area Finishing Mill Area

5 Stand Roughing Train, 56,000 HP

3 Pusher Type Furnaces, 450 Tons/Hour Delay T ableEach R oughing Mill Area Furnace Area Area

C r oiles Rn u u -o t T le ab s P lp u it F is in M in h g ill P lp u it
Cr p o S ear h

D lay e T le ab s

R g in M ou h g ills P lp u it

S cale bea e r kr

P lp u it
2

A-M Cleveland Hot Mill

Goals and Requirements

New Windows PC Based Level 2 Setup/Data Collection System New Level 1 Control System on Modern Open Platform New Digital Drive Regulators for Main Drives, Loopers, and Screwdowns (Retained Existing Power Infrastructure and Drive Power Modules) New Operator Desks New Integrated L1/L2 HMI System New iBA data flight recorder Increased Bending on Last three Finishing Stands to Improve Shape Control New Hydraulic Loopers (last 3) New Flatness Gauge Minimal Installation (Take Advantage of Existing Terminations) Phase-In over normal down-turns

A-M Cleveland Hot Mill

Old System Configuration

Obsolete Level 2 Main Frame Computer GEM 80 PLC Installed in late 80s DOS based programming interface Originally 300 series controllers Several PLCs upgraded to 400 series (supporting GEMLAND) Analog GE Silco Drives PDP-11 System on Coilers/Delivery-End Previous Partial Upgrade (2000/2001) GE Universal Stand Controllers (Obsolete) Genius I/O Installed but not Commissioned Cimplicity HMI

A-M Cleveland Hot Mill

Control Platform Selection Criteria

Off The Shelf Single-vendor Homogeneous Architecture End User Free From OEM Proprietary Hardware High Performance For Demanding Real-time Applications Multi-tasking Program Execution Proven Product Life Cycle History Scalable To Meet A Broad Control Spectrum Windows Based Programming Tools Multiple Programming Languages Very High Speed /Bandwidth Communication Network(s) Compatible with Genius LAN & I/O Open Architecture VME Compatible With Cimplicity PE HMI

A-M Cleveland Hot Mill

Control Platform Selection

GE Fanuc Rx7i PLC for Distributed Level 1 Control GE Fanuc Cimplicity PE HMI SCADA Nodes and Viewers

Level 1 And 2 Integrated HMI Dell GX260 and GX270 PCs for HMI

GE Fanuc Cimplicity ME Windows PLC Programming Software Genius LAN Remote I/O GE Fanuc Reflective Memory High Speed Control Network

VME Reflective Memory for RX7i PCI Bus Reflective Memory for PCs

Dell Poweredge 2650 server for Level 2 Control Digital Alphaserver 4100 for Roughing Mill, Finishing Mill and Coil Temperature Control models

A-M Cleveland Hot Mill

New System Configuration Philosophy

Pyramid Hierarchy Distributed Processing High-Speed Control LAN (Reflective Memory)

Common Programming LAN Common L1/L2 HMI Remote I/O (Genius)

Level 2

Human Interface

Level 1 Supervisory Control

Drives and Auxiliary I/O

Delivery Area

Finishing Mill Area

Furnace/Rougher Area 7

A-M Cleveland Hot Mill

New System Configuration
Maintenance Process Data Acquisition (Flight Recorder) Level 2 HMI Server(s) Programmers/Viewers

RX7i Delivery Master

RX7i Mill Master

RX7i Screw Master

RX7i DT Master

RX7i

RX7i

Xport/Position Masters

RX7i

RX7i

RX7i

RX7i

RX7i Auxiliary Submaster

Coiler Submasters

Looper Submasters

RX7i

RX7i

RX7i

RX7i

RX7i

RX7i

RX7i

RX7i Shear Drive

RX7i Depiler Drives

Mill Stand Drives

RX7i

RX7i

RX7i

RX7i

RX7i

RX7i

RX7i

RX7i Pusher Drives

Stand Controllers (Screw Drives)

Delivery Area

Finishing Mill

Delay Tables

Roughing Mill

Furnace Area

A-M Cleveland Hot Mill

Level 2

Dell Poweredge 2650 servers Digital Alphaserver 4100 HP Storage Works Smart Array 1500 8.4TB MS Visual Studio .NET 2003 Microsoft SQL Server 2000 CONNX VMS to SQL Server interface Polyserve Shared storage between Windows Servers

A-M Cleveland Hot Mill

Level 2

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A-M Cleveland Hot Mill

Main Drives
ME2000 Motor E Field Exciter Load Balance Loop
P -I- D Controller
+ +

Rx7i Per Stand Main Drive Software Regulator

+

Main Drive Hardware

Flux to Field Current

+ -

Field Curre nt Lo op P - I-D Controller

Terminal Volts Loop

Cro sso ve r Volts
+

P -I- D Controller
-

Flux Bias
+ +

Limit

Flux to Field Current

+ + -

ME2000 Motor F Cabinet

Fiel d Curre nt Lo op P -I- D Controller

Feed Forward Flux Ref

Ba se RPM
Limit ABS

Voltage Isolator
GT

Voltage Isolator
Ar mature Resistance

RX7i Mill Master Cabinet Speed Loop

MOR

Silco I
Ar mature Vo lts Lo op Po wer Amp
+

Motor F
Voltage Divider Voltage Divider

Motor E
Voltage Divider

ArmatureCurrent Loop
+

P -I-D Controller
-

P -I-D Controller
-

P - I-D Controller
-

PT

Current Isolator Current Isolator

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A-M Cleveland Hot Mill

Main Drives

Software Implementation of Main Drive Regulator (Per Main Drive Rack, Total of 7) 2 Millisecond Scheduled Task: Armature Current Regulator Motor Speed Regulator Motor Terminal Voltage Regulator (extended speed range operation) Motor Armature Current Load Balance Regulator Spindle Tail Spot Position Regulator (for roll change) Background Unscheduled Task: Armature Circuit Breaker Sequencing

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A-M Cleveland Hot Mill

Electric Loopers
R X 7 i S o f tw a r e L o o p e r D r iv e R e g u la t o r
T e n s io n R e f ( P S I) S tr ip W id t h ( In c h e s ) S tr ip T h ic k ( In c h e s ) P a s s lin e ( I n c h e s ) L o o p e r H e ig h t ( D e g r e e s )

E le c t r ic a l L o o p e r D r iv e H a r d w a r e

R e q u ir e d T o rq u e C a lc u la tio n 2 5 0 V D C E x c ite r

T o r q u e ( f t * lb s ) T o rq u e C o n v e r s io n

F ie ld C u rre n t Is o la to r

A rm a tu r e C u rre n t

S ilc o II A rm a tu re C u rre n t Loop

M o to r A r m a tu r e V o lts Loop Power Am p
+

P o s it io n R ef
+ -

P o s it io n Loop
P -I-D C o n tro lle r
+ -

Speed Loop
P -I-D C o n tro lle r

L im it

P -I- D C o n tro lle r

-

P -I- D C o n tro lle r

-

V o lt a g e I s o la t o r

G B

PT

CEM F S e le c t
+

A rm a tu re C u rre n t I s o la t o r

P o s itio n Feedback

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A-M Cleveland Hot Mill

Electric Loopers

Software Implementation Of Looper 1,2, & 3 Drive Regulator 2 Millisecond Scheduled Task Armature Current Regulators (L1, L2, & L3) 6 Millisecond Scheduled Task Motor Speed Regulator (L1, L2, & L3) Strip Tension Regulator (L1, L2, & L3) Looper Real-time Geometry Solver (L1, L2, & L3) (Calculates Geometric Relation Between Desired Strip Tension And Required Motor Torque To Achieve That Tension As Loop Angle Changes)

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A-M Cleveland Hot Mill

Loopers
degrees inches inches inches inches inches inches degrees degrees inches Inches Inches Inches Inches

Looper Real-time Geometry Solver (L1, L2, & L3)

Input Variables: c Looper angle ya Upstream Pass-line Height above Looper pivot yb Downstream Pass-line Height above looper pivot Constants: R Looper Roll Radius L Looper arm length Xa Looper pivot to Upstream Stand Centerline Xb Looper pivot to downstream stand centerline Calculation Results: a Upstream Strip Angle b Downstream Strip Angle z Loop Height above true pass-line s Stored Strip Lh Looper arm length projected on the horizontal Lv Looper arm length projected on the vertical y Pass-line Height above Looper pivot at the actual horizontal position of the looper roll

c = c 1 8 0 lh = L c o s c lv = L s in c xa = X xb = X
a b

+ lh lh

z a = lv y a + R z b = lv y b + R z a = a r c ta n a xa z b = a rc ta n b xb

y xb + b xa y = a X a + X b z = lv y + R xa x s = + b X a X cos a cosb 1 8 0 a = a 1 8 0 b = b
Stand (n)

Stand (n+1)
Downstream Pass line

b yb xb Xb

R zb c
Looper Pivot

za

Upstream Pass line

a ya

Xa

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A-M Cleveland Hot Mill

Hydraulic Loopers
R X 7 i S o f tw a r e L o o p e r D r iv e R e g u la to r H y d r a u lic L o o p e r D r iv e H a r d w a r e
T e n s io n R e f ( P S I) S t r ip W id t h ( I n c h e s ) S t r ip T h ic k ( I n c h e s ) P a s s lin e ( I n c h e s ) L o o p e r H e ig h t (D e g r e e s )

R e q u ir e d T o rq u e C a lc u la tio n

PT
T o r q u e ( f t* lb s )

T o rq u e A r m C a lc

F o rc e C a lc T o rq u e Loop
P -I-D C o n tr o lle r

B lin d _ P T

R od_PT

P o s iti on Ref

P o s it io n Loop
+

Speed Loop
+

L im it

P -I-D C o n tr o lle r
-

P -I-D C o n tro lle r

-

T o rq u e Fbk
+ -

V a lv e C ascade

B A

Speed

Spool Feedback

P o s it io n Feedback

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A-M Cleveland Hot Mill

Hydraulic Loopers

Software Implementation Of Looper 4,5, & 6 Drive Regulator 2 Millisecond Scheduled Task Looper Torque Regulators (L4, L5, & L6) Looper Torque Feedback (L4, L5, & L6) (Calculates Geometric Relation Between Looper Torque and Required Hydraulic Cylinder Linear Force) 6 Millisecond Scheduled Task Motor Speed Regulator (L4, L5, & L6) Strip Tension Regulator (L4, L5, & L6) Looper Real-time Geometry Solver (L4, L5, & L6) (Same as Electric Looper Calculation)

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A-M Cleveland Hot Mill

Hydraulic Loopers
h o r iz o n ta l d e g re e s

Looper Torque Feedback Calculation (L4, L5, & L6)

I n p u t V a r ia b le s : C L o o p e r A r m a n g le to th e

C o n s ta n ts : O A n g le b e t w e e n t o r q u e a r m a n d lo o p e r a r m . d e g r e e s d T o r q u e A r m le n g th in c h e s e R e f e r e n c e lin e le n g t h In c h e s C a lc u la t io n R e s u lt s : f T o r q u e A r m a n g le t o t h e r e f e r e n c e lin e g E f f e c t iv e t o r q u e a r m le n g t h . d e g re e s in c h e s
d (7 .8 7 ) E F (C + 3 6 .3 1 7 )
H y d r a u l ic C y li n d e r T o r q u e A rm

C = C 1 8 0 O = O 1 8 0 F = C + O f = d
2

+ e2 2 d e cos F

e d s in F g = f 1 8 0 F = F

76. 0

60. 0

g ( E ffe c tiv e T o rq u e A rm L e n g th )

C = L o o p e r a n g le to th e h o r iz o n ta l

6 .0 5 .1 2

1 0 .0

R 1 0 .2 5

f D
4 6 .2 5 H y d r a u l ic C y l in d e r 6 .3 1 7 R e f e re n c e L in e

e (4 6 .5 3 )

4 6 .5 3

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A-M Cleveland Hot Mill

Schedule
2004
Dec Jan Feb M ar Apr M ay Jun Jul Aug Sep O ct N ov D ec Jan Feb M ar

Task N am e
P ro o f o f C o n c e p t F M A u x ilia r y M a s t e r F M M a in D r iv e s F M L o o p e rs D e liv e r y M a s te r a n d C T C F M M a s te rs F M F a c to r y A c c e p ta n c e T e s t F M S t a n d C o n t r o lle r s F M C o o r d in a te d C o n t r o l S h a d o w in g F M C o n t r o l S w itc h o v e r F M D e s k I n s t a lla t io n FM Level 2 D e la y T a b le M a s te r & S h e a r R M M a s te rs R M F a c to r y A c c e p ta n c e T e s t C o m p le tio n o f L 2 a n d P a c in g D e p ile r / P u s h e r D r iv e s C o ile r s Task 19 Task 20

2003
A ug Sep O ct N ov

2005
Apr M ay Jun Jul Aug Sep O ct

19

Methods

Design for Startup Design Specifications (FES/SES) Extensive Simulation/Testing Hands-on Training Phase-in Expertise

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A-M Cleveland Hot Mill

Testing

Proof-of-Concept Component-Level Hardware Testing Facilitates phased shipping for installation Offline Testing Equipment at Customer Site FM Test Drive/Motor FM Test Stand for Looper Integrated Factory Acceptance Test Temporary Equipment Setup for Components Already Shipped Complete Staging of HMI and Operator Desks Simulators

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A-M Cleveland Hot Mill

Project Execution: Phase-In Strategy

One Section at a Time Bottom-Up Approach 1. Finishing Mill Area (Best ROI) 1. Drives 2. Roughing Area (Replaced Remaining 2. Masters & Sub-Masters Gems) 3. Operator Desks 3. Furnace Area (Replaces Drives) 4. Level 2 4. Coilers (Replaces Obsolete PDP-11) 1 2 3 Delay T able Finishing Mill Area R oughing Mill Area D elivery Area Area Furnace Area

1a 1d 1b 1c 1e

C iles o r Rn u u -o t Tbe als P lp u it F is in M in h g ill

1f

Co rp Se r ha

D la ey Tbe als

R u h gM o g in ills P lp u it

S le ca be k r r ae

P lp u it

P lp u it
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A-M Cleveland Hot Mill

Bridge to Old System for Phase-In
GEM-80 GEM-80

GEMlanD DEC Alpha Bridge

RX7i

HMI

RX7i

Reflective Memory Ring

Level 2

RX7i

RX7i RX7i

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I/O Switching for Phase-In Approach

Analog Control RX7i Analog Control RX7i

A-M Cleveland Hot Mill

Old Motor Current Regulator

New Motor Current Regulator

Old Motor Current Regulator

New Motor Current Regulator

Push-Pin Terminal Blocks

OLD

NEW

SILCO SCRs

SILCO SCRs

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FM Main Drives Phase-In Approach

A-M Cleveland Hot Mill

Final Drive Regulator Design Tested On-site Using Test Drive/Motor Prior To Commissioning Temporary Mill Master Installed To Accept Analog Speed Referencing From Old System Reflective Memory Segment Installed Between Temporary Mill Master And New Drives Push-pin Switchover Schemes For Outputs Subset Of HMI Installed To Support New Main Drives Drives Commissioned Over Multiple Regular Weekly Maintenance Turns

25

Electric Loopers Phase-In Approach

A-M Cleveland Hot Mill

Temporary Analog I/O Installed in Looper Drive To Accept Analog Tension Referencing From Old System Ethernet Bridge Installed To Exchange Control Parameters With Existing Mill Master Reflective Memory Segment Installed Between Temporary Mill Master And New Electric Looper Drive Push-pin Switchover Schemes For Outputs Subset Of HMI Installed To Support New Looper Drives Drives Commissioned Over Multiple Regular Weekly Maintenance Turns

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A-M Cleveland Hot Mill

Hydraulic Loopers Phase-In Approach

Final Hydraulic Control System Design Tested On-Site using Test Stand Ethernet Bridge Expanded To Exchange Control Parameters With Existing Mill Master Reflective Memory Segment Installed Between Temporary Mill Master And New Hydraulic Looper Drive Subset Of HMI Installed To Support New Hydraulic Looper Drives Commissioned Over Single Mini-Outage (Mechanical Installation of New Hydraulic Looper)

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A-M Cleveland Hot Mill

Delivery Master Phase-In Approach

Feedback Signals Paralleled to Facilitate Shadowing FM Delivery Speed and Metal Detectors for Head/Tail Tracking Spray On/Off Status for Cooling Temperature Control (CTC) Finishing/Coiling Temperature Pyrometers for CTC Push-pin Switchover Scheme for Spray Solenoids and Table Speed Referencing

28

A-M Cleveland Hot Mill

Screwdown Drives Phase-In Approach

Temporary Analog I/O Installed To Accept Analog Speed Referencing From Old System Ethernet Bridge Expanded To Exchange Control Parameters With Existing Screw Master Reflective Memory Segment Installed Between Screw Master And New Screw Drives Push-pin Switchover Schemes For Outputs Subset Of HMI Installed To Support New Screw Drives Screw Drives Commissioned Over Multiple Regular Weekly Maintenance Turns

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A-M Cleveland Hot Mill

FM Masters Phase-In Approach

Integration Test Using New Desks and Simulator Racks Extensive Mill Rolling Simulations in Factory Environment Operator Involvement Looper Height Regulators Tested/Tuned on Production Turns Bridge to Existing System Used to Interface with Existing Desks Desks Replacement Deferred until All Level 1 Equipment Commissioned

S-Ramp Acceleration
120 Master Speed Ref. (%) 100 80 60 40 20 0 0 2 4 Time 6 8 10

L 2 R e fle c tiv e M e m o r y PDI

M A IN T _ S E T U P _ M O D E

F M M R e f le c t iv e M e m o r y
F S M _ F 7 _ M IM

PDI
FM M _ PD I

In c l u d e s N e x t P i e c e P D I

L e v e l 2 C o i l I n d e x B u ff e r

F M N e x t P o in t e r ( f r o m L 2 )

F S M _ F 7 _ M IM

S e tp o in ts
F M M _ F 7 _ S E T P O IN T S

F M M _ F 6 _ S E T P O IN T S

F S M _ F 6 _ M IM F M M _ F 5 _ S E T P O IN T S

F S M _ F 5 _ M IM F M M _ F 4 _ S E T P O IN T S

F S M _ F 4 _ M IM

M o d e l R e fle c t iv e M e m o r y
F S M _ F 3 _ M IM

F M M _ F 3 _ S E T P O IN T S

S e tu p
S E T U P _ V A L ID F S M _ F 2 _ M IM

F M M _ F 2 _ S E T P O IN T S

I n c lu d e s N e x t P i e c e S e tu p

M o d e l C o il In d e x B u ff e r

F M M _ F 1 _ S E T P O IN T S

F M N e x t P o in te r (fr o m L 2 )

30

A-M Cleveland Hot Mill

Main Desks Phase-In Approach

Mini-Outage Required to Demo Old and Install New Minimal Down-Time Required (Communications, E-Stop, and Power) Software Switch in PLC(s) Set to Use New Desks (Very Low Risk)

HC

E
C L
MILL

5'-1 11/16"
MILL STAN D

17'-3 9/16"

25'-3 1/16"

2'-4 1/8"
CENTER LINE TURNTABLE

2'-7 13/16"

26'-9 13/16"

11'-2 1/8"

E ND

MAX. CV C ROLLS

63'-8 3/8" 8'-7 1/4" 70'-7 1/2"

20'-1 3/8"

6'-11 1/8"

25'-3 1/16"

3'-5 9/16"

31

A-M Cleveland Hot Mill

Level 2 Phase-In Approach

Extensive use of DEC Alpha Bridge between Reflective Memory and GEMlanD Step 1: Coil Temperature Control Step 2: Finishing Mill through Delivery End

Used Furnace Supervisory Control System to Monitor Slab Charge Messages From The Old Level 2 to Get Handle to Slab PDI Tracking Hand-off to New System at Roughing Mill Exit Use Handle to Retrieve PDI from DB

Step 3: Furnace through Roughing Mill

32

A-M Cleveland Hot Mill

HMI Navigation

S e le c t H e lp fo r T h is S c r e e n

S e le c t th e A re a o f In te r e s t

S e le c t W h o Y o u A r e

S e le c t S c r e e n T y p e A s s o c ia te d w ith A r e a o f In te r e s t

33

A-M Cleveland Hot Mill

Help Screens

34

A-M Cleveland Hot Mill

Help Screens

35

A-M Cleveland Hot Mill

Help Screens

36