Nucor Kingman bar and wire rod mill upgrade

2017 - Kingman, AZ - USA

In 2017, Russula performed an electrical upgrade at the Nucor Steel Kingman plant in Arizona, USA. The new mill control system incorporated the latest Russula automation solutions to produce steel bar and wire rod from steel billets that are coming from other Nucor Steel plants in Seattle, Utah and Nebraska.

The Russula automation scope of supply covered the entire electrical upgrade, starting with an on-site assessment to determine the current automation functionality, engineering, equipment supply, installation supervision, and commissioning support.

Automation Scope of Supply

Complete on-site assessment

New Allen Bradley ControlLogix controllers

Allen Bradley ControlLogix and Point IOs series for the Remote IO

ABB DCV700 drives replaced with ABB DCS800 for the most critical equipment

ABB ACV700/DCV700 drives integration for the rest of the equipment including the ABB LCI block integration into the new control system

HMI system based on Wonderware software

High speed data acquisition system

Factory Acceptance Test in the Russula workshop

Hardware & software engineering

Manufacturing, documentation and on-site testing

Installation supervision

Commissioning

On-site production support

Training

After start-up support

Critical drives were upgraded from DCV700 to DCS800 and integrated along with the rest of the drives with the new control system. The LCI block will be also be integrated via a gateway to interface with the Contrologix PLC.

The Nucor Steel Kingman marked the 12th electrical and control modernizations of its kind that Russula has been awarded in the past three years in North America. Seven modernizations have been successfully completed and four are currently in progress.