Advanced automation at Gerdau Pindamonhangaba improves special steel billets and heavy bar cooling

For over a decade, the Gerdau specialized steel plant located in Pindamonhangaba, São Paulo, Brazil and Russula have collaborated to implement productivity improvement projects. Today, the team collaborates again to automate the cooling bed, which will improve the temperature cooling of the special steel billets and heavy bars for Rolling Mill #1.

Cooling beds carefully cross transfer and cool hot rolled bars after the hot rolling process. The scope of the revamp is from the roller table entry side to the discharging area of the cooling bed. The existing manual temperature control will be substituted with an advanced automation solution to improve plant safety and product quality. 

Scope of Supply:

Russula will supply a Siemens Simatic S7-1500 PLC, four Sinamics G120 AC drives, a completely new WinCC HMI system with touch screen monitors, hardware and software engineering, installation supervision and commissioning support. The existing mechanically coupled motors controlling the cooling bed, will be replaced with new AC electrically synchronized motors.

• Low voltage AC single drives
• Sinamics G120 AC drives
• S7-1500 PLC
• Simatic ET 200SP I/O
• Operator and engineering stations
• WinCC HIMI System
• Software and HMI engineering
• Installation advisement
• Commissioning support
• Training

Key Improvements Implemented

• System Automation: Replacement of manual controls with an automated system, enabling dynamic motor speed adjustments based on the target material temperature.
• Motor Replacement: Installation of four new AC electric motors, eliminating the mechanical coupling system and enabling more efficient electronic control.
• New Control Architecture: Implementation of a Siemens S7-1500 PLC, with Profinet communication networks and an HMI system based on WinCC.
  • Advanced Sensing: Installation of sensors and thermal imaging cameras for continuous monitoring of bar temperature and positioning, ensuring uniform cooling.
  • Integration with Gerdau’s Automation System: Direct communication between the new system and other plant equipment, ensuring a continuous and optimized flow of information.

Benefits:

• Enhanced Operational Efficiency: Reduced response time in speed regulation of the cooling bed and improved adaptability to varying production requirements.
• Enhanced Product Quality: Continuous monitoring of bar temperature, ensuring that products meet the desired quality standards.
• Reduced Maintenance Costs: Replacement of mechanical systems with modern electric drives, minimizing wear and operational failures.
• Improved Safety: Elimination of manual temperature measurements, reducing risks for operators.