Russula Mill Control for 500,000 tpy wire rod mill at Isdemir

2015 -

Russula upgraded the automation system and drives of the two strand 500,000 tpy wire rod mill at Isdemir, in Iskenderun, Turkey. The goal of the upgrade was to improve operations. The Russula automation solution improved the laying head and pinch roll control for both A&B wire rod lines, provided consistent shear head and tail cuts and improved the water cooling box functionality. The combination of these improvements with Russula mill control will increase production rates.

Scope of Supply

The existing AC800M PLCs was reused along with the existing racks and IO hardware. The existing TYRAK-L DC converters with masterfieldbus communication communicates with the PLCs through a protocol converter by Process Electronic. Russula also supplied the engineering, valves and instrumentation for revamping the existing water boxes. The Russula control scope included:

Russula control scope

DCS800 drives for a shears and the Lines A & B laying head

DCR800 drives for Line A stands and finishing block

Two AC800M PCLs for Lines A & B mill control

Ethernet communication network between the PLCs and HMI

Profibus Network communication for the new remote I/O, drives and Simotion

3 HMI operator stations

IBA high speed data acquisition system

Engineering

Installation advisement

Commissioning

Offsite training

Results

The RUSSULA DCR kits provided an economical solution for Isdemir to upgrade the existing DC drives. They come complete with all the features of a modern digital drive. The performance of the drive with the DCR kit is the same as a new drive. Russula provided the DCR kits as a pre-engineered panel custom designed to retro-fit into the current electrical cabinets. All the control hardware and software including the pulse firing boards were replaced. New digital field supplies were supplied complete with thyristors.

The main operator pulpit and control desks were reutilized. New controllers were mounted in cabinets along with power supplies, communication modules and peripherals. The electrical equipment home test occurred in April, 2015 at the Russula workshop in A Coruña, Spain. The commissioning of the two strand wire rod mill happened during a summer shutdown.

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