Roughing, intermediate, finishing and breakdown mill upgrade at Evraz

2015 - Pueblo, CO - USA

The electrical and automation upgrade of the Evraz rod and bar mill was carried out in three phases in order to cause the least disruption to production.

Phase 1– Roughing, Intermediate, Finishing & Breakdown Mill
Phase 2 – Rod Outlet Mill
Phase 3 – Finishing Block

A total of 23 days downtime was executed for the three phases not including the time required for the finishing block installation. A multi-phase revamp approach allowed Evraz to upgrade obsolete control equipment and minimize mill downtime, which in turn reduced the impact on production.

The multi-phase revamp approach permitted the plant to upgrade obsolete control equipment at their convenience and minimize mill downtime to reduce the impact on production. The upgrade of the mill, rod mill outlet and finishing block occurred over the course of two years.

Russula was responsible for installation supervision, commissioning, on-site operator/maintenance training and provided both on-site and off-site remote support after the start-up to guarantee a smooth transition back to production.

Phase 1

Phase 2

Phase 3

Scope of Supply

As an independent supplier of rolling mill equipment and controls, Russula chooses the best combination of PLC/Controller and drive hardware available on the market. For the Evraz rod and bar mill upgrade, the Russula solution included:

Automation

Rockwell ControlLogix PLCs

HMI – Wonderware Intouch

DC Drives: ABB DCS800 series

AC Drives: Rockwell PF 755

IBA high speed data acquisition system

Mill operator pulpit, with new operator desks, HMI and 6 video monitors

Drives and PLC

DC Drives & AC Drives: DCS800 & PF755 high performance drive

ControlLogix PLC developed using ControlLogix v20

ControlLogix Remote I/O

E-houses

3 E-houses with HVAC (PCRs – Power Control Rooms) house the drives for Phase 1

Services

Engineering

Installation supervision

Startup support

Start-up November, 2015

The electrical equipment and software home test was conducted in April, 2015 in the Russula workshop in A Coruña, Spain. The commissioning occured as scheduled in November, 2015.

About Russula

Russula supplies a full range of automation solutions from instrumentation and control systems through advanced drive technology and tailor-made control solutions for greenfield projects and revamps counting on thirty years of unparalleled experience in the steel industry.

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