Metal/iron & steel industry

ThyssenKrupp Nirosta in Krefeld modernized its production facility in record time

Promag for cooling of mould of the continous casting with water injection on the slabs and protection of the rolls to spoil by too high temperatures

In a record time of just nine days, ThyssenKrupp Nirosta modernized its complex production facility in Krefeld, Germany, for manufacturing high-quality stainless steel. During the upgrade of the field instrumentation, which went off without a hitch, the old analog measuring system was replaced by modern PROFIBUS PA field devices from Endress+Hauser, which have been reliably measuring all process-related parameters since they were commissioned in 2002.

PROFIBUS PA: Fieldbus takes over communication The technical complexity involved in the manufacture of steel products requires that all process-related data are made available quickly and comprehensively so that the casting process can be controlled and monitored. Since the renovation in 2002, PROFIBUS PA measuring instruments from Endress+Hauser have provided the vertical integration of data. Over 100 field devices for measuring the parameters of flow, pressure/differential pressure, temperature and level were brought online in Krefeld. As an important process technology interface, they provide the exact measuring signals to the higher-level process control system. During the upgrade, approx. 10,000 meters (32,808 feet) of cable for the old analog technology had to be removed, and about 1,200 meters (3,937 feet) of new PROFIBUS cable laid in their place. The newly installed automation system (SIMATIC PCS 7) allows online access to all relevant process parameters in addition to operating and observing control and regulation processes.

Production begins again after nine days Extensive preparation work was necessary in order to meet the requirements set by management: the continuous casting plant was to be shut down for no more than nine days. Without incident, the first cast took place right on schedule at the modernized facility in continuous automatic operation.

View into the cabinet of the water treatment system.

Flow, pressure and temperature measurement in water distribution room

Which advantages of fieldbus technology do you believe to be the most important? It is no exaggeration to say that the process of creating high-quality stainless steel is challenging and demanding. All process steps must be fine-tuned to each other with the utmost precision: from melting the raw materials in the electric arc furnace, to the metallurgical treatment in the converter, until the ladles (transport containers for liquid steel) are made available to the continuous casting line. A critical factor to the quality of the steel is the systematic cooling of the slabs (steel blocks) with treated water during the casting process in the continuous casting line. The core of the steel slabs is, at first, still in a liquid state; the slabs are guided on casting rollers over a circular arc. The complex water cooling process is controlled by over 50 magnetic inductive flowmeters from Endress+Hauser. Now, back to your question: PROFIBUS PA has numerous advantages over conventional analog 4-20 mA technology. For one, the reduction in cabling means potential cost savings during installation.

Interview with Jrg Maas Head of Measuring Systems at ThyssenKrupp Nirostas Krefeld steel plant

For example, the wiring and PLC for the entire water treatment system are placed in just one cabinet. However, what is much more important to us is the great variety of process data, such as status and fault messages and diagnostic information of the measuring instrumentsnot to mention the data back-ups of the individual process

steps, which we now have available at all times. Documenting the status of the entire system used to require mountains of paper. Defective field devices can now be replaced with no problems, since all of the parameterization data is stored in the system, from where it can be immediately copied to new devices.

Instruments International Endress+Hauser GmbH+Co. KG Instruments International P.O. Box 2222 79574 Weil am Rhein Germany Tel. +49 7621 975 02 Fax +49 7621 975 345 http://www.endress.com info@ii.endress.com

CS 023B/11/en/10.06 71033660 Straub/INDD CS2