Fine-tuned control solutions improve process stability
minimize downtime and maximize quality
RUSSULA KNOWS THE PROCESS AND THE SYSTEMS
ROLLING MILL CONTROL
Unique combination of long product rolling process and electrical system knowledge ensures our automation solutions increase mill productivity and provide consistent production. The main control features that impact positively on the stability of the process are:
- Tension/Loop Control automatically reduces tension along the mill and eliminates dimensional defects.
- Cascade Control reduction factors are used to calculate the mill cascade speed reference, using the mill exit speed and each stand reduction. This parameter directly relates to rolling fundamentals, simplifies the setup and operator control.
- Shear Cut Control tracks the bar along the mill to determine the optimum point for cutting. Head, tail and divide cuts are implemented guaranteeing high precision and reliability. Russula has developed optimization algorithms that optimize the bar length using all available shears in the mill.
- Laying Head Control. Correct positioning of the laying head synchronized with the bar front end ensures that it always enters at the correct position and eliminates snagging in the cooling conveyor.
- Mill Pulse (MES System). The Mill Pulse Suite is a new, fully integrated manufacturing execution system designed specifically for continuous, hot rolling processes. Monitor production progress, key plant performance indicators and mill efficiency through an intuitive, easy to use interface.
High efficiency, Low emissions. Maximum productivity
REHEAT FURNACE CONTROL
Our expertise in reheat furnaces automation has exceeded our clients’ expectations in fuel efficiency optimization and scale reduction. Since the company founding in 1988, we have automated new and existing, analogue and digital reheat furnaces for all kinds of products.
Our approach is to automate by levels and gradually improve the furnace performance.
Field devices and instrumentation
Combustion and handling system
Combustion Process Control
-Zone temperature control (air to fuel ratio, cross control)
-Furnace and combustion air pressure control
-Gas safety interlocking
-Flame supervision (burner control units)
-Recuperator control and protection (air injection, hot air exhaust)
-Burner management system (digital burners)
-Gas pressure control (digital burners)
-Indirect/direct furnace cooling supervision
-Billet charging (billet positioning)
-Walking beam / Pusher
-Hot billet discharge (rolling mill pacing)
-Billet data input (stocked billet queue)
-Material tracking along the furnace
-Exit billet information
Heating and Cooling Ramps
-According to a defined temperature curve
-Delay multiplier tables
-Furnace stop modes (planned or unplanned)
Exit billet temperature feedback
-By means of a pyrometer at the roughing mill.
-Deviation from desired temperature zones to correct heating strategies.
-Provides information on furnace refractory aging.
Upgrade obsolete systems with Minimum downtime
We offer solutions that integrate equipment from all the major drive suppliers. We have decades of experience selecting, assembling and commissioning ABB, Siemens and Rockwell drives.
Our competitive advantage is we know the drives and the process.
Over the years, AC drives technologies have evolved to improve the speed accuracy control, no matter the load conditions. The low maintenance cost of AC drives makes them an attractive option for new rolling mill applications. For certain applications we recommend an AC multidrive configuration. AC multidrive consist of a single supply source and a common DC bus, which feeds a certain number of Inverters. This solution simplifies the total installation and saves in cabling and space, reduced line currents and simpler braking arrangements, reduced component counts, and increased reliability.
With over three decades experience, we offer integrated solutions for all major DC drive suppliers on the market. The complexity of rolling mills requires a systems integrator that not only knows the drives but also the process.
DC Rebuilding Kits
Russula rebuilds older drive installations (Veritron, Tyrak, DCV700, and DCS600) and modernizes them with up to date technology. Drive modules are customized according to your specifications. Since power stack and power circuit technology develops at a slower pace, often times upgrading the drive control unit will provide the same result as replacing the entire drive. This solution is not only more cost effective, but it also requires less downtime compared to upgrading the complete drive.
All the drives are assembled and mounted in our workshop, where our engineers work in a controlled environment to make sure every component is tested and complies successfully with our strict quality standards.
After building the drives or DCRs, technical experts from our workshop can install or supervise the installation at your plant. Our engineers are experienced and specialized in AC and DC drive configurations and the rolling mill process, which reduces considerably the downtime of your rolling mill and expedites the switchover to the new drives.
A REAL-TIME WINDOW INTO YOUR PROCESS
DATA ACQUISITION SYSTEMS
High Speed Data Acquisition (HSDA) systems are designed to capture and record signals from the process, providing a real time status of your process, keeping track and storing signal data for days, months or even years.
DATA ACQUISITION SYSTEMS
iba is a versatile tool for maintenance and production. Client/server architecture, flexible recording, simple configuration due to auto-detection, and compatible with different automation manufacturers and generations are the many remarkable features of the iba HSDA system.
Integrated video recording
Visualize what is happening in your rolling mill by complementing your iba system with synchronized video recording. Video feed is continuous and event-triggered. The precise linking of measured data and visual information provides an unprecedented quality of process analysis, enabling operators to match visible process events happening on the production floor while viewing the corresponding measured data at the same time on a screen.
iba during commissioning
The installation and start-up of a new control system often has many unpredictable problems that can extend the commissioning time. The more information that the team has to review and troubleshoot the root causes of the problems, the faster the startup. The iba system receives data and collects data history from critical signals in the process, allowing the startup team to visualize the signals, create historical reports and anticipate possible failures that have not yet occurred.