SIE03

Severstal. Automated Process Control System of Ladle Treatment Station (LTS) 1-3

Automation System (Modernization). Engineering, Supply, Installation and Commissioning

Project Details

Year of Execution: 2010-2012

Facility: Cherepovets Steel Mill. Steelmaking Production. Basic Oxygen Furnace (BOF) Shop. Steel Casting. Ladle Treatment Stations (LTS) No. 1, 2 and 3

Location: Cherepovets, Russia

Contract Price Level: $1M+

Key Project Stakeholders:

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

Scope of Supply:

E&A: Level2 system Technological Level, SCADA/HMI System, PLC System, Field Instrumentation, Cables and Installation Materials
Services: Engineering, Manufacturing, Application Software Development, • Factory Acceptance Test (FAT), Installation & Commissioning, Site Acceptance Test (SAT), System Handover

Project Description:

According to steel production capacity expansion program, it has become necessary to upgrade the software and hardware of the existing Automated Process Control Systems.

The new ACS shall comply with current requirements for reliability, performance, scalability, and information security. The implementation of the new system will increase the production capacity of LTS No. 1–3, improve the quality of the finished products, ensure the stability and efficiency of the production process, reduce equipment downtime, and improve the working conditions of both operating and maintenance personnel.

To solve this challenge, Severstal selected a solution from Siemens VAI Metals Technologies, which included improvements to the existing equipment and the implementation of a modern automation system.

My Role:

Project Manager responsible for project scope, schedule, and financial performance.

Project Team:

2 Application Software Engineers (PLC, SCADA, and databases)
2 E&A Hardware Design Engineers (wiring diagrams, hook-ups, data sheets, cable lists, etc.)
3 Functional Managers (Commercial, Procurement & Logistics, and Legal Support)

Subcontractors:

PLC Cabinets — FEAG Sangerhausen GmbH
Valves — LG Automation LLC
Industrial Safety Review — ANO “Soyuzexpertiza” SOEX
UPS — Cloraid Rus LLC
Electrical and Automation Installation Works — Norma Engineering Center LLC

Technical Description:

Project Severstal Ladle Treatment Station 1-3 includes:

Electrical & Automation package:

PLC Cabinets
SCADA/HMI System
Level 2 Process Optimization System
Field Instrumentation

Automation Technical Solution / System Architecture:

Control Level: PLC SIMATIC S7-300 (CPU 315-2DP), Multi-Lab III
SCADA/HMI: HMI Server (2pcs), HMI Operator workstations (incl. redundant), WinCC V7.0, SIMATIC NET IE SOFTNET-S7
Level 2: Server DB+ Operator workstations (3 pcs) application Software SVAI, local Data base Oracle 10g Standard Edition One (Heat data and technological parameters of LTS)
ERP Level: n/a
COMMUNICATION: Industrial Ethernet, PROFIBUS DP