WELCOME

PROCESS COMPUTER R30

UPGRADATION IN WRM

FUNCTIONAL ENTITIES OF
PROCESS COMPUTER

R30 - Process computer

R30E - Production computer

R10 MESY: Mill Fault Monitoring System

PREVIOUS SYSTEM CONFIGURATION

LEVEL 3

PROD CC
R30E
PROC
CC

MESY
R10

R30
PG
HM

DRIVE
MONITOR

E
t
S
W

S7400
SIEMENS
3 NOS

SIEMENS
150AK
PLCS 18
NOS

6RA70
DIGITAL
DRIVES
ANALOG
DRIVES
SIEMENS
MODEL PAC

FIELD
DEVICES

REPLACED BY
NEW SYSTEM

FUNCTIONS OF PROCESS
COMPUTER

Reference calculation & regeneration of main

drives
Cascade control
Loop Control
Bar tracking and Cobble detection
Reference calculation & regeneration of shears
Control of cooling water boxes and air blowers
Reference calculation & regeneration of pinch roll
and laying head

FUNCTIONS OF PROCESS
COMPUTER

Reference calculation & regeneration of stelmor

conveyor and tractor chain
Control of dividing head and trimming in coil
forming station
Static error RPM correction
Logging
Simulation of mill events
Communication with Production Control Computer

FUNCTIONS OF PRODUCTION CONTROL

SYSTEM R30E
Data management
Material tracking
Rolling and Cooling programs management
Data logging
Roll shop management
Communication with Weigh scales, Hook reading
unit, Process computer, Planning computer etc

FUNCTIONS OF MILL FAULT

MONITORING SYSTEM (MESY) R10

combines mill fault printing,

with a visual display through monitor that gives
information regarding type and location of the fault
so that necessary action can be taken
immediately

NEED FOR UPGRADATION

Lack of spares support

Lack of technical support

Frequent breakdowns

Memory constraints

Inferior Diagnostics features

PROJECT EVOLUTION

A non AMR project was approved in 2005

Technical & commercial offers were opened in july
2006
Offers received from
SMS meer
DANIELI AUTOMATION
SKODAEXPORT
ABB
Price bid was opened in may 2008
Subsequently project awarded to ABB

PRE COMMISSIONING PLANNING

Reference data for all main and auxiliary

drives for different profiles taken from 11th
Jan11 to 15th Feb11
Activities to be followed up regarding
familiarization about new system listed out

PRE COMMISSIONING ACTIVITIES

Panel erection started on 4th Feb11

Internal wiring of the panels was done
Configuration and Networking of the system were
done
HMD parallel outputs from CPH GeFanuc plc are
taken to the new system
Level 1 server made ON on 24th March
Level 2 server made ON on 27th March
UPS panels were erected on 29th March

MAIN COMMISSIONING ACTIVITIES

Logic development
Communication setups
Old panels removals
Wiring in new panels
I/O checking
Jogging and trial running
Phantom rolling
Rolling

LOGIC DEVELOPMENT

Logic was developed for

Shear control
Water boxes
Loopers
Drive references
Sequential interlocking

Communication Setups

Communication between ABB system and 150A/K

PLCs had to be confirmed from test jig PLC as
capital shutdown was not started
Commn card,512, in our test jig was made ready on
31st March
ABB was unsuccessful to establish commn with CPU
AC800PEC
A program made ready in our PLC to send the
DATA
ABB tried to control/read the data from our PLC
but not successful

Communication setup with 150A/k PLC

Communication was tried with CPU AC 800M

Communication was tried with OPC server software
and data could be read using TTY converter
This was possible with communication protocol
3964 instead of 3964R
Finally data integrity was confirmed with PLC10
Communication with 150A/K PLCs was established
by using TTY converters and PC Adapter cards
(moksi) cards and OPC server software in server 1

Communication setup with HRU(ECR2)

Ethernet commn between Siemens system

HRU ( Hook Reading System) in ECR2 and
ABB was tried but could not be established
Later it was tried to establish communication
between VIP and Siemens by assigning
ethernet ports but was unsuccessful
Finally Siemens had set up communication by
assigning some parameters in the system

COMMISSIONING ACTIVITIES

15-04-11

Capital shutdown started

All PLC backups taken
16-04-11 Clearance was given for revamping
the Process Computer System
17-04-11 Process Computer System system made
off and cable removing work started
18-04-11 Cable termination in new panels started

WRM AC 800PEC Controller Communication Configuration

IBA Analyzer

24 PORT EATHER NET SWITCH

PEC-PDA

CI854
PROFI BUS INTERFACE
CARD

PROFIBUS

SIEMENS S7 400 PLC

CONTROL NET WORK

CI856
S100 I/O RACK
INTERFACE CARD

TK575

ABB S100 I/O RACK

AC 800PEC

PEC-PEC

CI861
VIP INTERFACE
CARD

VIP 10Mbps

24 PORT EATHER NET SWITCH

ABB S800 I/O RACK

ModuleBus

CI853
SERIAL INTERFACE
CARD

SIEMENS 3964R

SIEMENS 150A/K PLC

S100 I/O Hardware

I/O Communication

CEX Bus

DSBC
176

CI856

DSTK
227L0

DSTC
176

Comm.card
Connector
Back Connector

AC 800PEC Controller Details

IBM PowerPC 750FX

500 MHz

128 Mbyte RAM

16 Mbyte Flash Memory

Performance

Very fast analog and digital process I/Os

with a typical cycle time of 25 s
Low-speed I/Os with a typical cycle time
of 10 ms

ControlIT AC 800PEC Control System

S100 I/O

S800 I/O

LEVEL 2 CLIENTS

LEVEL 1 CLIENTS

LVL1
SERV

LVL1
SERV

LVL2
SERV

LVL2
SERV

ETHERNET SWITCHES

C
P
U
1

C
P
U
2

C
P
U
3

C
P
U
4

C
P
U
5

LEVEL3
NW

ROUTER WITH FIRE WALL

CONFIGURATION OF PROCESS CONTROL

SYSTEM
PEC-PEC
CI85
CI85
CEX
CPU 1
4
6
C N/W

IBA

PROFIBUS

MODULE BUS

C N/W

CPU 2
CPU 3

IBA

CI86
1

CEX

S800 I/O
PCMs

CI861

CPU 4

CEX

S800 I/O

PRODCC & MILL

CI85
4

CI85
6

CI85
4

CI85
6

S100 I/O

S100 I/O

IBA

C N/W

CPU 5

CEX

CI85
6

LINE 1 &
2

LINE 3 &
4

150A/K
PLCs
S100 I/O MESY

IBA
OPC SERVER

RM &
IM

INTERLOCKS

IBA

C N/W

C N/W

CEX

S100 I/O

PROFIBUS

TTY
CONVERTERS
PC ADAPTOR(MOKSI)CARDS

6 NOS

XIBA

CI
8
5
4

CI8
CEX 5
6

CPU1

TB
850

CI
8
0
1

LVL 1

DP
8
2
0

DP
8
2
0

DP
8
2
0

DP
8
2
0

PEC-PEC
DSD
I
1
1
0

DSD
I
1
1
0

DS
DO
1
1
5

DS
DO
1
1
5

TB
8
2
0

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

DI
810

AI
830

AI
830

DO
810

DO
810

DO
810

DSD
P1
7
0

DSB
C
1
7
6

DSD
P1
7
0

DO
810

DO
810

AI
830

DO
810

DO
810

DO
810

DO
810

DO
810

DO
810

AI
810

AI
810

TB 807

DO
810

DSA
O 1
2
0

TB 807

TB
8
2
0

DI
810

DS
AO
1
2
0

TB 807

TB 806

TB
8
2
0

DI
810

DS
AO
1
2
0

DSAI
1
3
0

TB805

DSD
I
1
1
0

DSTC
176

MODU
LE
BUS

DSD
I
1
1
0

VIP COMMUNICATION
X

CPU2

CEX

CI
8
6
1

CI
8
6
1

VIP
NW
1

IBA
LVL 2

ETH SW
PEC-PEC

VIP
NW
2

CPU3

CI
8
5
4

CI8
CEX
5
6

IBA
LVL 1
PEC-PEC

DS
DI
1
1
0

DS
DI
1
1
0

DS
DI
1
1
0

DS
DI
1
1
0

DS
AI
1
3
0

DS
DO
1
1
5

DS
DO
1
1
5

DS
DO
1
1
5

DS
DO
1
1
5

DS
DO
1
1
5

DS
A
O
1
2
0

DS
A
O
1
2
0

DS
A
O
1
2
0

DS
A
O
1
2
0

DS
D
P
1
7
0

DS
D
P
1
7
0

DS
BC
1
7
6

DSTC176

DS
DI
1
1
0

CPU4

CEX

CI
8
5
4

CI8
56

IBA
LVL 1
PEC-PEC

DS
DI
1
1
0

DS
DI
1
1
0

DS
DI
1
1
0

DS
DI
1
1
0

DS
AI
1
3
0

DS
DO
1
1
5

DS
DO
1
1
5

DS
DO
1
1
5

DS
DO
1
1
5

DS
DO
1
1
5

DS
A
O
1
2
0

DS
A
O
1
2
0

DS
A
O
1
2
0

DS
A
O
1
2
0

DS
D
P
1
7
0

DS
D
P
1
7
0

DS
BC
1
7
6

DSTC176

DS
DI
1
1
0

CPU5

CEX CI8
56

IBA
LVL 1
PEC-PEC

DS
DI
1
1
0

DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DI
1
1
0

DS
DI
1
1
0
DS
DO
1
1
5

DS
DO
1
1
5
DS
BC
1
7
6

DS
BC
1
7
6

DSTC176

DS
DI
1
1
0

DS
DI
1
1
0

COMMISSIONING ACTIVITIES

20th &21st I/O checking of prod & proc cc

panels

22nd

I/O checking of MESY panel

23rd

Jogging of RM & IM

24th

Running of RM & IM and also

chopping shears

COMMISSIONING ACTIVITIES

25th

Jogging of IB,FB,PR,LH for line 1 & 2

26th

Running of IB,FB,PR,LH for line 3 & 4

27th

28th Phantom rolling started

I/O checking of AM2 panel completed,

Phantom rolling done by simulating HMDs

PROBLEMS DURING COMMISSIONING H/W

Analog Input cards:
DSTD connection units resistance network
was modified for -10v to +10v
Two Analog output channels were faulty
(fluctuating) and spare channels are used
Two Pulse counter modules of S100 are replaced by
four S800 modules on Profibus

ROLLING BEGINS

29th : Rolling trials started in line 1 : cobbles

took place with different logic errors
mainly in
water boxes
pinch roll logics modified
shears
etc..
30th : Rolling started in 4 lines: tuning done for
all lines

POST COMMISSIONING PROBLEMS

MESY communication is not taking place with

PLC1

CPU 925 & 926 cards changed from PLC 6

but no progress
Phantom rolling was normal for individual lines
without material but during rolling individual line
phantom rolling, other lines were affecting programming modified for individual run.

POST COMMISSIONING ACTIVITIES

Sl
No

DATE

PROBLEM

6th May

Phantom rolling was not

proper with material

14th May

RM & IM ref got off

CPU1 Cex cable hot removal

Cex cable swapped

with CPU 5

20th May

ABB decided to upgrade the

system for solving the
compatibility issues

Servers Firmware
upgraded
Two S100 Pulse
Counter of CPU1
Modules
changed to S800

27th May

30th May

VIP Commn was failed

between level 1 & level 2

CPU 2 restarted

31st May

ABB felt single CI 861 not

able to handle the data

One more CI861 is

added in VIP NW

ACTIVITY DONE

Programming
correction done

All CPUs firmware

upgraded

REMARKS

3rd
June

13th
June

24th
June

10 28th
June

Line 1 & 2 references got

off & on on its own

Line 3 & 4 references got

off, I/Os were freezed
for 10ms
and
level 2 commn was also
failed

Two analog input cards

have been added in
AM2(S800 I/O panel)
for measuring furnace
temperatures.

CPU3 message was CEX module

hot removal & hot
inserted found loose
connection at PEC
controller power
connector fixed
properly
CPU 3 CI856 card changed
with new one
Redundant
power supply provided for
all PEC controllers
Profibus commn for S800 was
changed to module bus
CPU3 & CPU2 Misbehaved
during normalization
All changes were reverted to
leveloriginal
2 application
settings

restarted

11
12
13

14

1st
Ju
ly
.
7th
Ju
ly
.
8th

ABB wanted to upgrade the CI856 cards changed

and upgraded with
CI856 cards for compatibility
new version

CPU 3 commn failed and

normalized on its own after
22ms

Ju
ly

19th
July

RM & IM references got off due

to CPU 1 commn. Failure
(faults hot removal of CEX
module and hot inserted)
at 9.40 am
Later found during mill
normalization, RM shear-1 is
o.k during simulation but RM
shears, 2,3 & 4 not operating

CEX cable for CPU 3

replaced with new
one and
S100 I/0 5V supply fuse
holder found to be
loose tightened,
All S100 I/Os fuse
holders tightness
checked and found
No action
taken
ok
CPU1 and its I/Os
power reset done
and program
reloaded. Simulation
done for all the
lines, found o.k.
Rolling clearance
given at 4.15pm.

15

20-09-11

CPU 3 FAILED.
ALL I/Os GOT OFF.
IB LOOPER COBBLE
TOOK PLACE AT
14.40 HRS
BOTH CI856S AND
S100 I/Os SHOWN
FAULT.
CPU3 WAS SHOWING
NO FAULT LED.

ON LOGGING CPU 3
COMMUNICATION ERROR
SHOWN SO THAT COULD
NOT BE DOWN LOADED
THE PROGRAM
PINGING WAS TAKING
PLACE
ON LOGGING THROUGH
SERVER CPU LOAD WAS
SHOWING 7.09%.
CPU LOG (THROUGH SERVER)
SHOWN THAT
INTERRUPTION:SCHEDULER
HAS STOPPED KICKING
WD FOR MORE THAN
4096 ms AT 1440.
CPU3 AND S100I/O RACK
MADE OFF & ON
DOWN LOADED THE
PROGRAM
HOWEVER AFTER DOWN
LOADING THE PROGRAM
RPS1 DIPPED 10V FOR 1 ms

PENDING POINTS
MESY Communication Is Not Fully Operational
OPC Server Is Going Down Regularly
Communication Failures Are Coming Frequently
UPS 1 (New) MESY Signal Is To Be Assigned Properly
It Is Not Appearing In CSR Pc
As Per ABB 24 Port Ethernet Switch Secondary
Communication Is Not working configuration is changed
triangularly
CI 861 Commn May Be Removed As The Program Was
Modified
Changed From Continuous Commn To Event Based

1. Installation of CLIENTS/ at various locations-(left out- as

per decision) , including ASO &HOOKING UP. Placing
monitors on top bracket at Pulpits
2. Separation of PHANTOM ROLLING for each line, and
hooking up to original simulation selection& push buttons
3. FB SHEAR LOGIC & Normalization
4.Segragation of MCBs group wise, area specific ( point no.2a
of MOM DTD 25-02-10)
5.MESY- CONFIGURATION , SET UP including Connectivity
with PLC1
6.IBA CONFIGURATION & STANDARDISATION
7.Level-2/ Material tracking-stabilization ,including Display
system
8. RSM Module completion.

9. Routing of HRU Power supply to new UPS-DB-feeder.

10. HMD indication/annunciation O/Ps -normalisation
11.Powering up of VSP _UPS supply to RSP1 of
AM1.1Panel
12. 2000MW Motor Bearing RTD hooking to the system
13.Hooking up of Furnace parameters to the system
14. Profibus Connectivity of S7-400 PLC
15 . Spindle positioning
16 .Steabilisation of various(critical) Rolling sections.
17. Dressing, tightening of all CABLES /TERMINATIONS,
Cleanining of false flooring(under)ofcomputer room,
rectification of gaps etc.
18. Marking/painting of of all cables,ofc etc at tunnels ?
cable cellars
19. UPS Battery cable normalisation & dressing

21. List of commissioning spares.

22. Replacement of cards wherever channels are
faulty or changed.( ex.analog refence to
stelmore line-4- channel changed.( to compile ,if
any)
23. Analog I/p cards: Actual / required cards
deails- in view of removing the resistance for
voltage signals- at site( to check/decide)
24. Drawings and documents; pending (hard
copy) to be submitted as per design &engg- to
sort out.