5. Automation: Level 1
HPCi controller,
MV and DC drives
Key advantages for the user:
• High reliability / availability
• Optimal maintainability
• Few and simple interfaces
• Unified open platform
Basic functions • Easy connection to legacy hardware
• Real time operating system systems
• Functional multitasking • Minimum installation and start-up time
• Global / Local data transfer • Simple training
• Remote and local I/O • Reduced spares
5
Team Account Planning Session
6/11/2012
6. Automation: Level 1
Engineering environment
P80i – Programming Toolkit for C80-HPCi
Integrated
environment for support tool
• Program editors (FBD, SFC, LD), IEC-1131
compatible
• Programs and networks configuring tools
• Hardware configuration tools
• Debugging and commissioning tools
Multi-user networked access
• Several P80i users can edit applications on
the same C80-HPCi
6
Team Account Planning Session
6/11/2012
8. Automation: Level 2
Supervision functions
• Primary Data Input Management
o Using the main entry coil
characteristics (PDI) sent by
Level 3 computer (Customer) PDI
• Product tracking & coil data sheet
management
• Preset determination
• Speed optimization
• Mathematical Models
• Data collection & quality tracking
• Elaboration of reports
(coil, shift, day, …)
8
Team Account Planning Session
6/11/2012
9. Process: technological controls
AGC - Thickness Control - Principles
Dynamic adjustment of the AGC gains
for single stand Mill to compensate for changes in
hardness and all rolling mill conditions
AGC PRINCIPLES Set-up and product data
Mathematical AGC Dynamic Model
Model Level 1
PDI Level 2
Force
Set-up AGC Gains Calculation
Tension Corrections Rolling Mill Measures
Roll
Force
FB : to center exit
thickness
FF : to anticipate Feed Feed Back
entry deviation Forward
Gap Correction
Hydraulic Gap
Gap Correction AGC
MassFlow Gauge
AGC Control
Exit Gauge
Entry Gauge
Inertia
Compensation MassFlow
Measure
MF : to measure stand
in gap thickness and to
cancel measurement delay
Torque Control
Speed measures Strip Speed Speed measures
estimation
Entry speed Exit speed 9
Team Account Planning Session
6/11/2012
10. Process: simulation
Full simulation:
• Digital sensors, Absolute encoders, Thickness, Tension, Speed,
Flatness, Pulse Generators, Motor Currents…
Major advantages:
• Reliability
• Shortening commissioning
periods
• Eliminating costly parallel
operation
• Training operators on the
new system before the
switchover
10
Team Account Planning Session
6/11/2012
11. Automation: Aid in maintenance
Operator aid on HMI
Display of Missing Permissives
• Automatic sequences
• Line run modes
Display of faults
• Grouped faults
• History events
History
• Storage of variables and events
• Display of recorded data
11
Team Account Planning Session
6/11/2012
12. Automation: Aid in maintenance
Operator aid - Process Data Acquisition
Key features
• Independent sample rates for each channel
• Recording of up to 1024 analog + 1024 digital channels
• Fastest data acquisition cycle is 1 ms for all signals
• Drivers are available for the most known PLCs in the market, including GE Energy C80-HPCi
• Acquisition from direct input or networks
• Step-wise X-Y zoom in and zoom out
• Calculations via a built-in formula editor:
mathematical and logic functions
• Y/T, Y/X and FFT displays window options
• Data export to ASCII format and to databases
using ODBC (including Excel format).
12
Team Account Planning Session
6/11/2012
13. Automation: architecture
Example for Tandem Cold
Mill
13
Team Account Planning Session
6/11/2012
14. Electrical and Power MV drives – MV7000
LV drives – LV7000
Motors
100 MW
Electrical rooms & pulpits
200 kW
14
Team Account Planning Session
6/11/2012
15. Electrical and Power: Drives
Low Voltage Drives: LV7000
• High performance drives from 0.75 kW
to 3600 kW
• 3 AC or Common DC bus power supply
• Frequency, speed and torque control
• 4-quadrant and active front-end
inverter applications available
• Air or liquid-cooled possible
15
Team Account Planning Session
6/11/2012
16. Power Conversion – Products – LV Drive
Inverter
• Air cooled
Fan • 600kW
• 440V - 690V
a.c.
• 180kW ~
2.4MW
DELTA
Modules
AC Reactor
Reactor
DC Link Rectifier
16
Team Account Planning Session
| 16
6/11/2012
17. Power Conversion – Products – LV Drive
Inverter
• Water cooled
• 440V - 690V
a.c.
• 600 kW ~ 3.6
MW
17
Team Account Planning Session
| 17
6/11/2012
18. Electrical and Power: Drives
LV Drives on common DC bus
• Only one common DC bus 220 V Battery Battery
AC rectifier
is used to feed all AC Drives AC supply AC DC COMMON BUS
for strip transport
ACCB Transformer
• Any regenerating drives send Input
bridge
their power to other motoring converter
drives via the DC link PWM inverters
Induction M1 M2
• Battery support allows ride through motors
of mains power loss
• Energy saving because AC current much less than sum of individual
drives
• Full regeneration readily provided
• Ride through AC supply dips while maintaining strip tension
• AC input power factor : ~1, AC harmonics reduced
18
Team Account Planning Session
6/11/2012
19. Electrical and Power: Drives
Medium Voltage Drives:
MV7000
• Power range 4 up to 48 MW Inverter-phase leg:
• Voltage: 3.3 kV – 6.6 kV – 9.9 kV the heart of the converter
• Powerful IGBT, based on Press-Pack
technology
• Flexible design thanks to standar-
dized modules, Active Front End
design, DC-link configuration or
stand-alone drive solutions
• Parallel connection for high ratings
• Compact design with excellent
kW/m³ ratio
19
Team Account Planning Session
6/11/2012
20. Power Conversion – Products – MV Drive
RANGE Topology Voltage Power (MW)
(V)
MV74005AC FP- AC 4160 0.5
MV7401AC FP- AC 4160 0.9
MV7402AC FP- AC 4160 1.8
MV7403AC FP- AC 4160 3
MV7403 FP -WC 4160 2,5
MV7405 FP -WC 4160 5
MV7407 PP- WC 4160 7
Designed, manufactured and tested in Brazil
20
Team Account Planning Session
| 20
6/11/2012
21. MV7400-Air Cooled and Water Cooled
• IGBT based 3 Level PWM drive
– Active Front End (AFE) or
Diode Front End (DFE)
– IEGT devices (Transistor
type)
– Quick and easy change
– High efficiency
21
Team Account Planning Session
6/11/2012
22. Electrical and Power: Drives
MV7000 up to date technology
Control AC in Active Front End DC Capacitors 3-level NPP inverter (MEGAMODULE) AC out
Pre-charge
transformer +
CONTROL &
AUXILIARIES
Cooling unit NP
COOLING
WATER
_
MV73xx Drive Active Front End M
3~
Power Transformer Single Line Diagram with
3-Level NPP Inverter 22
Team Account Planning Session
6/11/2012
23. Electrical and Power: Energy Quality
Energy quality systems:
SVC and D-SVC
• Used to compensate electrical
disturbances generated by large-scale
consumers with fluctuating loads, like
electrical arc furnaces and large drives
• Solution based on thyristor TCR or IGBT
D-SVCs linked to fixed filters
• D-SVC solution is compact with enhanced
performances
• Control system based on our PECe/HPCi
system (as drives and level 1)
• Application software developed with P80i
programming tools
23
Team Account Planning Session
6/11/2012
24. Electrical and Power: Energy Quality
Steel plant performances with SVCs
Power Increase = more Production
• Shorter tap to tap melting time,
higher steel production
• Longer electrode life & less
refractory material consumption
Neighbourhood disturbance & Utility
• Minimum flicker perturbations
around
• No power factor penalties
• Voltage stability, less harmonics &
transients
More active power equals less tap-to-tap
time equals increased production
24
Team Account Planning Session
6/11/2012
