Since 80’s DANIELI group has begun a long and successful relationship with Deacero, Mexican leader in steel production. As part of this collaboration, Danieli Automation has started a project to modernize and digitalize old electrical and automation systems in the Rolling Mill and Meltshop in Deacero Celaya plant.

Revamping activity involved the modernization of AC converters to power system DC-Links and inverters to power motors in the Rolling Mill #3 that produce rebars and wire rod products.

Moreover, the replacement of the old medium voltage drive with the new AC medium voltage LCI drive (ABB brand) to handle FFB block of Wire Rolling Mill. Commissioning for the LV drives and MV drive were performed in November 2021.

Let’s see more in the detail:

NEW DRIVES IN ROLLING MILL #3

To ensure continuity and efficiency in the process, new drives cabinets were installed to replace obsolete ones. All drives are connected by Profibus DP network, while the motors power involved in the drive modernization are 350KW for Stand 5 & 6, 800KW for stand 11, 550KW for stand 12, 137KW and 230Kw respectively for shear 1 and shear 2.

Thanks to this revamping, the motor current and torque control are really improved in comparison with old equipment. Condition monitoring system (CMS) is part of the supply and it is realized through smarts sensors applied on the motors that makes predictive maintenance possible for the low voltage motors. By monitoring and analyzing data coming from CMS, users can avoid unexpected down-time, optimize efficiency and improve safety.     

NEW SHEAR CV3 IN ROLLING MILL #3

Has been installed a new single blade rotary shear CVSA 040 with a cutting force of 40 tons. The revamping operations involved the dismantling of the previews CV, civil adaptation job, and finally the installation of the new shear with new motor, new drive and process automation control.

The shear is provided with 415KW power motor (130KW was the previews one) and it’s able to cut a product section up to 38mm (25 mm with the old one the previews one). New DC-Link regenerative and inverter are included into Danieli Automation new cabinets, together with drive and PLC regulation.

NEW MEGADRIVE BGV

Obsolete ABB Tyrak-LCI MV drive was replaced with the new ABB Megadrive LCI. The new technology allows a faster speed and accurate current control. Moreover, the new drive could be connected to the PLC by means of Fieldbus protocol. As a consequence, the new digitalization permits now to extract and collect more data in real time.

The new Megadrive is air-cooled and 12-pulse thyristor, and controls a 5.4 MW synchronous motor.