Project Details

Year of Execution: 2007-2009

Facility: Cherepovets Steel Mill. Cold Rolling Production Plant

Location: Cherepovets, Russia

Project Value: $1M

Key Project Stakeholders:

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

Scope of Supply:

1. Mechanical: Weighing Units, Support Beams
2. E&A: SCADA/HMI System, PLC System, Field Instrumentation, Cables and Installation Materials
3. Services: Engineering, Manufacturingng, Application Software Development, • Factory Acceptance Test (FAT), Installation & Commissioning, Site Acceptance Test (SAT), System Handover

Project Description:

In 2007, Severstal, one of the world’s largest steel companies, started a program to improve the efficiency of its production. To do this, the company needed to know how much metal was used and lost at each production stage. A steel coils tracking and weighing system was developed to monitor the movement of metal through the plant, improve production records, and provide accurate data for measuring production efficiency.

To solve this challenge, Severstal selected a solution from Siemens VAI Metals Technologies, which included improvements to the existing mechanical 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)
• 1 E&A Hardware Design Engineer (wiring diagrams, hook-ups, data sheets, cable lists, etc.)
• 3 Functional Managers (Commercial, Procurement & Logistics, and Legal Support)

Subcontractors:

• Weighing System Package — Schenck Process GmbH
• PLC Cabinets — Moser GmbH
• Mechanical Design — Severstal-Proekt LLC
• Support Beam Manufacturing — Promenergo LLC
• Mechanical Installation Works — SpecMontazh LLC

Technical Description:

The Automation Weighing and Tracking System project for Skin Pass Mills (SPM 1 & 2), the Four-Stand Rolling Mill, and Pickling Lines (PL 1 & 2) includes:

Mechanical package:

• Weighing Units
• Support Beams

Electrical & Automation package:

• PLC Cabinets
• SCADA/HMI System
• Field Instrumentation

Automation Technical Solution / System Architecture:

• Control Level: PLC SIMATIC S7-300 (CPU 314C-2DP), DISOMAT Tersus;
• SCADA/HMI: Work station, SVAI Application Software (Process Explorer);
• MES Level: Server station; SVAI Application Software, MS SQL 2000 Local DB, Oracle DB client (interface with Plant Production Database)
• ERP Level: n/a
• COMMUNICATION: Industrial Ethernet, PROFIBUS DP, RS485

Project photo gallery: