Founded in 1940 and a production capacity that now exceeds 27 million tons, Nucor Corporation is the 14th largest steel producer in the world. Nucor has production facilities all over the United States. One of its main long-bar steel facilities is located in Jewett, Texas.
Nucor Steel contracted Russula for the comprehensive control upgrade of their "Texas 1" (TX1) and "Texas 2" (TX2) bar mills, located in Jewett, Texas, USA.
The project included drive's upgrade, PLC's upgrade and HMI development. Russula was responsible for the assembly of the hardware, software development, installation supervision, commissioning and operator/ maintenance training.
Both upgrades were carried out in two phases during planned shutdowns. A multi-phase revamp approach allowed Russula to upgrade the obsolete control equipment and minimize downtime, which reduced the impact on production.
In May 2013 the TX 1 stacker was upgraded with a new control system and new drives, including a PLC for improved operator safety. Later that same year, the TX1 continuous mill including all mill stands and shears were upgraded.
In November 2014 the TX2 jump mill, continuous rolling mill and cold shear were completely upgraded, while the descaler was upgraded in 2015.
The new Russula Mill Control provided better cascade speed control, low tension and loop control and superior shear performance, minimizing metallic waste.
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