Case Study: Bluescope Steel Vietnam Process Lines

WINNER OF PACE ZENITH AWARD – 2006 !

Scope:

The BlueScope Steel coating facility is located South-East of Ho Chi Minh City in the Phu My Industrial area of the Ba Ria Provence. Kawasaki Heavy Industries (KHI) from Japan where engaged to design, supply and manufacture three (3) steel strip process lines for the facility The process lines consist of a Metal Coating (Zincalume®) Line (MCL), a Coil Paint Line (CPL) and a Coil Slitting Line (CSL). The new facility is part of Bluescope Steels strategic planning and development in the region and the first major facility in Vietnam.

KHI chose I S Systems from a number of international competitors and awarded I S Systems the contract as the principal electrical engineering supplier. The contract was for the supply, design, manufacture and commission of the strip transport systems for all three process lines including the safe access control systems.

Implementation:

The MCL was designed to have a production capacity of 125,000 tonness per annum (tpa). It consisted conventional strip transport equipment, a NOF furnace, a Skin Conditioning Mill and Tension leveling section and in line pre-treatment and paint coaters.

The CPL was designed to have a production capacity of 50,000 tpa. It consisted of similar strip transport equipment to the MCL. The coating section consisted of an S-Rap primary coater and a catenary oven followed by additional coater.

The CSL was a conventional slitting line with an annual capacity of 15,000 tpa. The CSL was capable of Recoiling, Slitting as well as cut to length.

I S Systems used its extensive experience of Siemens technology to develop an automation concept and control architecture specific to this project. The integrated technology products provided by Siemens formed the basis for a robust and flexible design. The cost of ownership and future developments were also considered and where important factors to the client. The structure of the basic automation system reflects the distributed field bus approach adopted by I S Systems. PLC’s from the SIMATIC S7 family where used for the control of basic open loop strip transport and associated process control systems. The chosen field bus network was Profibus.

To meet critical process requirements, high speed controllers with program execution times of 1msec were utilised. Controllers from the SIMADYN D family where used as part of the overall automation solution. The high speed controller where associated with the close loop control of bridles with multiple rolls (master/slave), tension reels, accumulators, Skin Conditioning Mill (SCM) and Tension Leveler (TL).

The main functions of these high speed controllers where:

 

  • Strip elongation control
  • SCM position control
  • SCM Rolling force control
  • Motor Torque control and load sharing
  • Roll bending force control

 

I S Systems selected the Siemens WinCC SCADA system as part of the automation solution specifically developed for this project. The WinCC system was tightly integrated into the basic automation system.

A well designed drive solution was critical to the success of this project. A number off issues need to be taken into account to correctly size and define the final drive architecture. I S Systems selected the Siemens Masterdrive inverters as the basis for the strip transport drive solution and design. Over a 180 Variable speed drives ranging from 4kW to 400kW where used on the project

The successful start up of the plant and the minimum number of problems encountered during commissioning can be directly attributed to the extensive factory testing undertaken by ISS. All the equipment manufactured and designed by ISS was rigorously tested prior to delivery to site.

Client: Bluescope Steel

 Bluescope Vietnam2

Bluescope Vietnam1