2023 - Volta Redonda - Brazil

CSN two-strand slab caster automation and drives upgrade

Russula is pleased to announce that the first and second phases of the automation and drives modernization for the two-strand continuous slab caster were successfully completed and put into operation at Companhia Siderúrgica Nacional (CSN). The existing drives were replaced with a top-of-the-line model ABB DCS880. Fifty-eight drives were retrofitted in three days. Verification, testing and commissioning took another three days for a record total downtime of six days. Legacy automation equipment was replaced with new, first-line control technology. The upgrade improved plant safety and reliability of the casting process.

58 drives retrofitted in just six days

Phase 1 project plan

Before the new drives were installed, the PROFIBUS DP and Ethernet networks were tested during the scheduled weekly maintenance shutdowns. Russula provided training and an installation manual, containing connection drawings, to the CSN team. All the cables and modules of each of the 58 drives were color and code tagged to be able to identify network nodes and casting strands.

Russula pre-fabricated drives kit for quick replacement

Russula was responsible for the pre-assembly, energization, parameterization and application development of the new ABB DCS880 drives. An existing control system study was also performed.

In January 2023, the CSN and Russula team commissioned the second phase of the automation and drives upgrade for the two-strand slab caster at CSN. The objective of the upgrade was to replace the legacy automation equipment with new, first-line control technology. Four existing PLCs and control boards were replaced with new ones, all fully assembled in Russula’s workshop in A Coruña, Spain. The upgrade improved plant safety and reliability of the casting process, as well as spare parts availability.  

Second phase automation upgrade commissioned in January 2023

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