• Home
  • Solutions
  • Projects
  • News
  • Work with us
  • Home
  • Solutions
  • Projects
  • News
  • About us
  • QEHS Policies
  • R&D+i
  • Work with us
  • Media
  • Contact us
  • Events
  • EN
    • ES
Home » Projects » Phase 1: Stacker Upgrade at Nucor Utah

Phase 1: Stacker Upgrade at Nucor Utah

2014 - Plymouth, UT - USA

Over the course of four years, Nucor Steel Utah and Russula upgraded the automation and drives of rolling mill #2. The project was broken down into three phases. For all phases of the project Russula supplied the electrical and controls solution, installation supervision, commissioning and training.

About the multi-phase upgrade
By replacing obsolete legacy equipment with modern rolling mill control equipment and methods and standardizing the network protocols, the Nucor Steel mill in Utah experienced improvements in maintenance, troubleshooting, control stability and functionality. Ultimately the upgrade, in conjunction with other process improvements, helped increase mill production and product quality. For example, the cold shear area increased from 220 fpm to 310 fpm without increasing wear on the cold shear brake and clutch.

One of the main advantages to doing a multi-phase upgrade is to size the control equipment in phase 1, taking into account the future capacity required when upgrading the rest of the plant equipment in phase 3. When the time comes to implement the successive phases, the switchover time is much faster.

In each phase, Russula re-utilized many existing components from the mill and replaced the obsolete components, which reduced the overall project cost and downtime. This approach is especially beneficial for steel plants with a mix of electrical and automation systems from different suppliers such as Nucor Utah. Hardward standards for the AC and DC drives, remote I/O, network protocol, controller platform, HMI and data acquisition system were selected at the beginning of the project and maintained throughout the subsequent phases.

04-1-min
Nucor Steel Utah new stacker controls layout

The first phase encompassed the upgrade of the rolling mill #2 stacker, evacuation area and storage tables. Russula supplied new Rockwell Powerflex 755 AC drives and new ABB DCS800 DC drives for the magnet power supplies. A selection of hardware was chosen specifically for this project, including Rockwell ControlLogix PLCs, Rockwell GuardLogix PLCs, and FactoryTalk HMI. GuardLogix, a safety PLC, was deployed in 4 defined safety zones with locking gates equipped with ´request to enter´ and ´reset´ buttons. All communication between the PLCs, drives, new operator desks and remote I/O stations are transmitted over Ethernet IP. The new control system improved the safety of the stacker for the operators and maintenance staff.   

Phase 1

nucor utah 1

Phase 2

nucor utah 2

Phase 3

nucor utah 3

Share

RUSSULA 2022 ® All Rights Reserved - Legal | Privacy | Cookies

Subscribe to our mailing list

(Your email will be used to send you news updates. You can unsubscribe at any time using the link in our emails. For more details, review our privacy policy.)
RUSSULA 2020 ® Todos los derechos reservados
    • EN
    • ES
    • Events
    • QEHS Certifications
    • OFFICES
    • Mill Pulse®
    This website uses cookies to improve your experience. We'll assume you're ok with this, but you can opt-out if you wish.Accept Settings
    Privacy & Cookies Policy

    Cookies policy

    This website uses cookies to improve your experience while browsing the website. Of these, the cookies that are classified as necessary are stored in your browser, as they are essential for the functioning of the basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt out of receiving these cookies. But opting out of some of these cookies may affect your browsing experience.
    Necessary
    Always Enabled
    Necessary cookies are absolutely essential for the website to function properly. This category only includes cookies that guarantee basic functionalities and security features of the website. These cookies do not store any personal information.
    Name Purpose Observations
    PHPSESSID The PHPSESSID cookie is native to PHP and allows websites to store serialized status data. On the website it is used to establish a user session and to pass status data through a temporary cookie, which is commonly known as a session cookie. These Cookies will only remain on your computer until you close the browser.
    Not necessary
    Cookies that may not be particularly necessary for the website to function and are specifically used to collect personal data from the user through analytics, advertisements and other embedded content are called non-necessary cookies. It is mandatory to obtain the consent of the user before executing these cookies on your website.
    Name Purpose Observations
    Google analytics (__utma, __utmb, __utmc, __utmz, _ga) These cookies are used to collect information about the use of our website by visitors. We use the information to compile reports and to improve the site. Cookies collect information anonymously, which includes the number of visitors to the site, the place of origin of the visitors' site and the pages visited. More information in Types of cookies used by Google .
    Youtube(ACTIVITY, APISID, HSID, LOGIN_INFO, PREF, SID, VISITOR_INFO1_LIVE, YSC, demographics, dkv) YouTube is used to provide useful videos or informational videos. Youtube stores information to be able to generate statistics on the visits of videos embedded in other pages. More information in Types of cookies used by Google .
    Google Maps (APISID, HSID, NID, PREF, S, SAPISID, SID, SSID, S_awfe, khcookie) Show where the offices of our different services are located using Google Maps. More information in Types of cookies used by Google .
    SAVE & ACCEPT