SIE01

Severstal Mini Mill Balakovo. Supply of Part of the Equipment for the Electric Steelmaking Shop

Electrics and Automation System for mini-mill steelmaking shop (Scrap Yard, Finger Shaft Furnace (FSF), Ladle Furnace (LF), Dedusting System, Continuous Casting Machine (CCM)). Engineering, Supply and Commissioning

Project Details

Year of Execution: 2009-2014

Facility: Severstal Mini Mill Balakovo. Steelmaking Shop

Location: Balakovo, Russia

Contract Price Level: $3M+

Key Project Stakeholders:

End User: Severstal
Customer: Severstal
General Contractor: STRABAG
EPC Contractor: Siemens VAI
Design Contractor: Severstal-Proekt
Systems Integrator: Siemens VAI

Scope of Supply:

E&A: Level 2 system Process Optimization, SCADA/HMI System, PLC System, MCC 0,4kV, SoftStart 10 kV, Field Instrumentation
Services: Engineering, Manufacturing, Application Software Development, Factory Acceptance Test (FAT), Commissioning, Site Acceptance Test (SAT), System Handover

Project Description:

The goal of Severstal’s project is to build a modern mini-mill with a capacity of 1 million tonnes of long steel products per year, mainly for the building construction industry.

To address this task, SEVERSTAL selected a solution offered by Siemens VAI Metals Technologies.

The project was divided into two parts:

Headquarters scope: technological equipment.
Local office scope (Russia): electrical and automation systems, as well as the technological part of the gas cleaning system.

My Role:

Technical Project Manager (TPM) responsible for Electrics and Automation (E&A) project scope, schedule, and financial performance.

Project Team:

8 Application Software Engineers (PLC, SCADA, Level2)
4 E&A Hardware Design Engineer (wiring diagrams, hook-ups, data sheets, cable lists, etc.)
3 Functional Managers (Commercial, Procurement & Logistics, and Legal Support)
1 Project administrator
1 Site Manager E&A

Subcontractors:

PLC, MCC Cabinets — RHG Gmbh, FEAG GmbH, LLC Avatri
Soft Starter 10kV - Solcon Industries Ltd.
Computers, Servers, Switches, UPS - LLC Langarden

Technical Description:

Project includes:

Electrical & Automation package:

PLC, MCC 0,4kV Cabinets
Soft Start Cabinets 10kV
SCADA/HMI System
Level 2 system Process Optimization
Field Instrumentation

Automation Technical Solution / System Architecture:

PLC SIMATIC S7-300 CPU 315, 317; S7-400, S7-400H (резервиров) CPU 414,416;
SCADA/HMI: Server station (redundant), Work station, SVAI Application Software; WINCC/SERVER V7.0, WINCC/REDUNDANCY V7.0
Level2 System: Server station (redundant), Work station, SVAI Application Software
COMMUNICATION: Industrial Ethernet, PROFIBUS DP