340 000 tpy bar mill revamp commissioned in just 7 days

Gerdau Ameristeel Wilton

Plant data:
Plant: Gerdau Ameristeel Wilton
Product: merchant bars
Capacity: 340 000 tpy
Downtime: 168 hours

Russula supplied a complete electrical and control solution for the revamp of a 12 stand continuous mill at Gerdau Ameristeel in Wilton, Iowa. The goals of the upgrade were to replace obsolete equipment and modernize the control system to the same standards as other Gerdau Ameristeel plants.

Russula supplied a new automation system for the mill using a recipe-based setup employing ABB’s AC800M controller, RSView HMI and IBA high speed data acquisition system. The main functions of the system include cascade speed control, tension and loop control and shear control. The existing DC mill drives were rebuilt to modern standards using ABB DCR600 digital front end controls.

The continuous mill upgrade was continuation of two successfully implemented projects by Russula. The first project was the control of a new divide shear and the second project an upgrade to Wilton´s reversing roughing mill. The complete upgrade to the continuous mill was commissioned in just 7 days. The record start-up time for this upgrade is a reflection of the handwork and dedication of the Russula and Gerdau Ameristeel Wilton engineering teams.