SPECIAL BAR MILL (SBM)

FURNACE

APSEB

TG 4
(TPP)

FURNACE
POWER FLOW

220 KV

MRS

11 KV

GSB 4

220 KV

33 KV

LBSS 6
11 KV

11 KV

6 LBDS 2

6 LBDS 3

2MVA
63LC04
Tr 01

Furnace
LCSS

5F1
3F1
1F1

415 V

63 LC 04

LBSS 7
11 KV

6 LBDS 1

2MVA
63LC04
Tr 02

630KVA
Emergency
Transformer

7F1
8F1
10F1

4F1

Diesel Generator
750 KVA

415 V
5F1

Emergency LCSS

415 V

Furnace LV MCC

3F2

6
15F1

2000 A

Spare

3200 A

Spare

2000 A

C A Fan 2

1000 A

Furnace LV MCC
Feeder 2
630 A
Siemens UPS

2000 A

MCC 2 Descaler Pump

3000 A

from
63LC04 Tr
01

630 A

3000 A

63 LC 04
FURNACE LCSS
3000 A

Bus Coupler

MCC 1 Cold Charging

Fluids
2000 A
Furnace LV MCC
Feeder 1

2000 A

C A Fan 1

1000 A

Spare

1000 A

Spare

Incomer 1
Incomer
2 from
63LC04 Tr
02

Marshalling feeder

Discharging roller VVF cabinet

4 KVA Control Trf 3

spare

40KVA UPS 2 panel automation sys

UPS bypass switch

415/240V control transformer 2

55KW

4KVA

40KVA

40KVA

7.5KVA

160A

160A

45KW

Furnace LV MCC
Section 1

Charging roller vvvf cabinet

from
63LC04 fdr
8F1

Bus Coupler

2000A

2000A

Incomer 2

4KVA

45KW

4KVA

110KW

110KW

7.5KVA

110KW

40KVA

132KW

20A

20A

132KW

15KW

132KW

3.7KW

3.7KW

132KW

15KW

132KW

15KW

FURNACE LV MCC

4KVA control transformer

Dilution air fan 45KW

4KVA Control Transformer

spare

Mixed Gas booster fan 1 110KW

415/240V control transformer

Mixed Gas booster fan 2 110KW

40KVA UPS 1 panel autoamtion sys

spare

Control panel for grease lub standby

Control Panel for lubrication grease sys

Main Hydraulic Pump 4 132KW

Hydraulic Recirculation Pump 2 15KW

Main Hydraulic Pump 3 132KW

Slurry Pump 2 (stand by) 3.7 KW

Slurry Pump 1 3.7 KW

Main Hydraulic pump 2 132 KW

Hydraulic Recirculation Pump 1 15KW

Main Hydraulic Pump 1 132 KW

Actuator distribution panel 15KW

Incomer 1
from
63LC04
fdr 4F1

Emergenc
y I/C from
Emergenc
y

LCSS

Furnace LV MCC
Section 2

FURNACE AUTOMATION

The furnace automation starts the billet control when

it engages the photocell located close to the furnace
charging door and finishes when the discharged billet
disengages the photocell located immediately after the
discharging door.
There are two PLCs for furnace automation:

Combustion

PLC (3532-A9001.A04)
Handling PLC (3532-A9001.A05)

The RI/O (Remote Input/output Panels)

communicating with the two PLCs:
Combustion

RIO (3532-A9001.A03)
Handling Charging RIO (3532-A9002.A03)
Handling Discharging RIO (3532-A9003.A03)
Water System RIO Combustion RIO (3532-A9005.A03)
Furnace MCC RIO Combustion RIO (3524-A9001.A53)

FURNACE AUTOMATION

PROFIBUS(Process Field Bus) is a standard for

fieldbus communication in automation technology.
PROFIBUS DP(Decentralized Peripherals) is used to
operate sensors and actuators via a centralized
controller in production (factory) automation
applications
PROFIBUS DP copper cable uses two core screened
cable with a violet sheath, and runs at speeds between
9.6kbit/s and 12Mbit/s.
High speedPROFIBUSonly permits the use of copper
cable for short distancesand fiber optic cables(via
OLM-optical link modules) are used for long distances.

10

FURNACE AUTOMATION

Redundant Automatic/Fault tolerant System:

Reduces

risk of production loss by means of parallel

operation of two systems.
The redundant structure of the S7-400H ensures
requirements to reliability at all times. This means:
all essential components are duplicated.
This redundant structure includes the CPU, the
power supply, and the hardware for linking the two
CPUs.
Y-links are the redundant interface modules.

11

INTERCONNECTION WITH
COMBUSTION RI/O AND DRIVES

13

HANDLING PLC INTERCONNECTION

WITH HANDLING RI/OS AND DRIVES

14

RUNNING MODES OF FURNACE

Manual mode
All the manual

Semi Automatic

Full Automatic

mode

mode

When all conditions

When all conditions

movements are
performed in
impulsive or jog
mode until the
intervention of a
sensor or an interlock
stops the movement.

l the modes can be

(both initial and

(both initial and
permanent
permanent
conditions) are
conditions) are
respected, the
respected, by
operator performs a
operating the
complete single cycle relevant start cycle,
of the selected section the operator can
by pushing the
perform a complete
relevant start cycle cycle without
push button.
interruptions of that
This cycle is
section.
normally used during
a restart of the mill
selected
from Furnace Main Desk in
or after maintenance

15

CP 1.

SENSORS: BILLET CHARGING

3532 B8001.BFZ E/R Photocell for billet head/tail

presence (Emitter +Receiver)
3532 B8101.BFZ E/R Photocell for wall protection
(Emitter + Receiver)
3532 B8001.BN
Encoder for billet coarse
positioning
3532 B8101.BSL
Laser system for billet fine
centering
3532 B8001.SE(SBE) Charging door open Proximity
Switch #1
3532 B8002.SE(SBE) Charging door open Proximity
Switch #2
3532 B8003.SE(SBE) Charging door closed Proximity
Switch #1
3532 B8004.SE(SBE) Charging door closed Proximity
Switch #2

16

CHARGING DOOR
Close Proximity
Switch 2 position

Open Proximity
Switch 2 position

Pneumatic
cylinder

Open Proximity
Switch 1 position

Close Proximity
Switch 1 position

17

CHARGING ROLLER TABLE

The Charging Roller Table consists of 8 rollers. Each roller is
driven by a gear motor having the following characteristics:
Nominal Power: 4 KW
Nominal Supply: 415 Vac, 50 Hz
Nominal Speed: 1500 rpm
PTC for winding temperature protection.
4 rollers are equipped with electromagnetic brake in alternate
configuration. (Motor no: 1,3,5 &7).
The rollers are installed inside the furnace and are watercooled.
The complete table is controlled by a VVVF converter drive
(45KW).
18
2nd motor is provided with Incremental encoder for billet coarse
positioning.

BILLET CENTERING

20

WALKING BEAMS

The purpose of Walking beams is to carry out the

billet shipment inside furnace.
It consists of:

5 fixed beams at charging side and discharging side.

4 walking beams.

25

WALKING BEAMS

Features:
They

are linked to a lifting frame supported on

wheels.
A set of wheels moves on a sloping levels during
lifting.
During shifting the frame moves on another set of
wheels independent on the first one.
Two hydraulic cylinders perform the frame lifting.
One hydraulic cylinder performs the frame shifting.
No overlapping between lifting and shifting.
26

SENSORS FOR WALKING BEAMS

MOVEMENT

3532 B8201.ZT
Linear transducer on lifting
cylinder #1
3532 B8202.ZT
Linear transducer on lifting
cylinder #2
3532 B8203.ZT
Linear transducer on travelling
cylinder
3532 B8201.BS
Cable reel encoder on lifting
frame (redundancy for lifting)
3532 B8202.BS
Cable reel encoder on travelling
frame (redundancy for travelling)
3532 B8301.BFZ E/R Photocell #1 for walking beams
stop
3532 B8302. BFZ E/R Photocell #2 for walking beams
stop

28

WALKING BEAMS MODES

Manual

Semi-

Full

Dischargin Charging

Waiting

Mode

Automatic

Automatic

g Priority

Priority

Cycle

It is

It is

This is the

If the

This

It is

intended for
maintenanc
e, or when
the operator
detects a
reason to
perform
functions
manually.

intended to
let the
operator
decide when
to initiate a
walk cycle.
All the
operations
are initiated
by the
operator but
performed
automaticall
y.

normal
operating
mode. All
the
operations
are initiated
and
performed
automaticall
y.

rolling mill
requires a
billet, the
beams keep
on the
progress
movement
without
taking into
account if at
charging
side is
present or
not a billet

functional
mode is
used to fill
in the
furnace. In
this case the
cycle is
stopped
when the
walking
beams move
a billet from
the charging
roller table

intended to
include a
Waiting
Cycle
during long
stop of the
mill.
Then.after a
timeout
without
beams
29
movement,
the system
start

Mode

Mode

WALKING BEAMS TYPICAL TIME CYCLE

31

KICK-OFF MACHINE OR
DISCHARGING DEVICE

36

KICK-OFF MACHINE OR
DISCHARGING DEVICE

The purpose of kick-off machine is to transfer the hot

billets from the last position of the fixed beams to the
discharging roller table.
The kick-off (discharging) machine is divided into two
separate/independent sections(half machines) each
comprising three arms.
The lifting and shifting movement of each machine is
carried out by a hydraulic cylinder controlled by a
proportional valve.
No overlapping between lifting and travelling
movement.
Each half-machine is equipped with a stock detection
system (pneumatic system), used for sensing the billet
when the machine arms reach the correct position for
discharging

37

SENSORS FOR KICK OFF DEVICE

3532 B8401.ZT
3532 B8402.ZT
3532 B8401.BS
3532 B8402.BS
3532 B8401.SBE

Linear transducer lifting half-machine #1

Linear transducer lifting half-machine #2
Cable reel encoder shifting half-machine #1
Cable reel encoder shifting half-machine #2
Proximity home position half-machine #1

3532 B8402.SBE Proximity home position half-machine #2

3532 B8403.SBE Proximity stock detector forward half
machine #1 arm #2
3532 B8404.SBE Proximity stock detector backward half
machine #1 arm #2
3532 B8405.SBEProximity stock detector forward half
machine #2 arm #5
3532 B8406.SBE Proximity stock detector backward half
machine #2 arm #5
=3532 B8401.BFZ E/R Photocell outside furnace for billet tails
detection

38

KICK-OFF DEVICE OPERATION

Backward
Forward

40

DISCHARGING ROLLER TABLE

The Discharging Roller Table consists of 9 rollers.
Each roller is driven by a gear motor having the
following characteristics:
Nominal Power: 4 KW
Nominal Supply: 415 Vac, 50 Hz
Nominal Speed: 1500 rpm
PTC for winding temperature protection.
The rollers are installed inside the furnace and
are water-cooled.
The complete table is controlled by a VVVF
converter drive (55KW).

45

DISCHARGING DOOR
Similar to the Charging Door the Discharging
Door is movement is powered by compressed air
and controlled by pneumatic solenoid valves.
The following sensors are in place for discharging
door open/close position.

3532

B8401.SE(SBE)
Discharging door open
Proximity Switch #1
3532 B8402.SE (SBE)
Discharging door open
Proximity Switch #2
3532 B8403.SE (SBE)
Discharging door closed

Proximity Switch #1
3532 B8404.SE (SBE)
Discharging door closed

Proximity Switch #2

46

MOTOR OPERATED VALVE (MOV)

These are the isolation/gate valves with electric
actuators i.e., they are operated by an electric
motor (2.5KW, 415V, 72 rpm, 310Nm).
These valves are not connected to PLC and it is
operable only by means of local push buttons.
There are 12 no's of MOVs in the mixed gas
circuit.
Each MOV is equipped with two mechanical limit
switches, two torque switches and a thermostat.

53

COMBUSTION AIR FANS

The furnace is equipped with two combustion air
fans, one running and one in stand by.
C A Fan motor details:

Power:

450 KW
Speed: 1480 rpm
Operating Voltage : 415V

The motor is controlled by VVVF Drive.

54

MIXED GAS BOOSTER FANS

The furnace is equipped with two booster fans,
one running and one in stand by.
Booster motor details:

Power:

110 KW
Speed: 1500 rpm
Operating Voltage : 415V

The motor is controlled by VVVF Drive.

61

DILUTION AIR FAN

The dilution air fan is meant to reduce the waste gas
temperature in order to protect the recuperator by
overheating.
Dilution Air Fan Motor Details:

Power:

45 KW
Speed: 1465 rpm
Operating Voltage : 415V
It is Direct On Line Start type motor.

A temperature control valve is provided at the outlet of

DA fan.
The operator, through the HMI, can select either the
66
Automatic or the Manual running mode.

FURNACE DRIVES
The drives used are Siemens SINAMICS G 130 and G
120 type drives.
They are Variable Voltage Variable Frequency (VVVF)
drives.
There are 6 drives:

Combustion

air fan 1 (450KW) (3532-A8601.A44)

Combustion air fan 2 (450 KW) (3532-A8602.A44)
Mixed gas booster fan 1 (132 KW) (3532-A8701.A44)
Mixed gas booster fan 2 (132 KW) (3532-A8702.A44)
Charging side roller table inside furnace (45KW) (3532A8101.A44)
Discharging side roller table inside furnace (55KW) (353277
A8301.A44)

Thank
You
78