27NORDIC STEEL & MINING REVIEW 2003

A customer-oriented organizationABB has now formed a strong but simplifiedorganization with Power Technologies andAutomation Technologies as its core busi-ness. The Metals and Mining business inVästerås, headed by Per Eckemark, is organ-izationally part of the Automation Technolo-gies division. It has three Centers of Excel-lence, CoE, that have worldwide responsibil-ity for marketing and technological develop-ment.

CoE Metallurgy Products is responsible forelectromagnetic products for metallurgicalprocesses. Recently, it has developed a newelectromagnetic product, the EM Stabilizer,for applications also in processing lines.

CoE Hot Rolling Mills is responsible forelectrical equipment and control systems forhot rolling mills.

CoE Underground Mining is responsiblefor mine hoist systems, including both theirmechanical and electrical parts. In addition,it has developed an Integrated Mine Auto-mation System, IMAS, based on the ABB In-dustrialIT automation platform.

Metals and Mining in Västerås also has theoverall responsibility for ABB’s activities to-wards the Swedish Market. Sales managerfor the Swedish Market is Petter Oscarsson.

He works closely together with accountmanagers to ensure that the customers dobusiness with only “One ABB”. The sameconcept applies to CoEs in other countries aswell.

EM stabilizerABB’s Electromagnetic Stabilizer, EM Stabi-lizer, has been developed primarily for use inhot dip galvanizing lines, but it can be ap-plied in other processing lines as well.

High-pressure air knives, high strip speedand a long free path cause vibration and os-cillation in hot dip galvanizing lines. Thisproblem leads to variations in the zinc layerthickness, zinc splash between the air knivesand scratches on the coating. The EM Stabi-lizer minimizes vibration, reduces the oscil-lation amplitude and provides more efficientoperation of the air knives and cooling box-es. In addition, it helps ensure a uniformcoating thickness and reduces zinc splashand scratches. Controlling vibration and os-cillation with the EM Stabilizer also makes itpossible to increase the line speed, therebyachieving higher productivity. It improvesthe availability of the air knives by reducing

zinc clogging of their nozzles. Other featuresinclude the absence of physical contact, in-stallation close to the air knives as well assimple and reliable operation.

Enhanced EMS products formetallurgical processesABB is launching its enhanced EMS prod-ucts for arc furnaces, ladle furnaces, alumin-ium melting furnaces as well as for continu-ous casting together with the ElectroMagnet-ic Brake for slab casters. The most recent de-velopment is the AF-EMS for arc furnaces.

New IDC featuresfor rod and bar millsIn Profile Rolling Mills, the well-knownRolling Mill Control with hundreds of instal-lations worldwide has now been adapted foruse with ABB’s IndustrialIT concept for roll-ing mills. ABB’s Interstand Dimension Con-trol (IDC) System provides a useful tool forthe continuous improvement and control ofthe rolling process and especially the toler-ances from head to tail of round, long prod-ucts. IDC installations at our customers’plants, such as Fundia Special Bar Mill atBoxholm in Sweden, has led to the introduc-tion of several new features and improve-ments in IDC technology.

One of those features of the new IDC con-cept is its openness. It is easy to integrate intoany existing automation system via a net-work or digital/analog I/Os and it can be con-figured as a control or measuring system. In-stallation and commissioning can take placeduring normal production.

DEVELOPMENTSIN METALS AND MININGIn last year’s Nordic Steel and Mining Review, we presented ABB’s organ-izational changes in relationship to the value-based solutions for customersin Metals and Mining. This article summarizes the most recent develop-ments in the ABB Metals and Mining operations.

By Martin D. Blake, MDB Communications and Wenqing Cui, Met-als and Mining, ABB Automation Technologies

The newly developedEM Stabilizer forprocessing lines.

The enhancedEMS products forthe metals industry.

28 NORDIC STEEL & MINING REVIEW 2003

The other new IDC feature is its scalabil-ity. Customers can start by installing an IDCsystem on a small scale and expanding it stepby step when their investment budgets allowthis. The customer himself can carry out thefirst step by just installing a Stand-aloneMeasuring System. Later on, this system canbe upgraded to a Stand-alone Control Sys-tem or an Integrated Control System with theaddition of the IDC control system based onAC800M controllers.

IDC systems have been installed at, forexample, Ovako Steel, Fundia Special Bar,Fine section Mill and Fagersta Stainless Steelin Sweden, as well as at Hylsa Steel in Mexi-co and SMI in the US.

Diagnostic tools for hot rolling millsABB has developed powerful diagnostictools based on its IndustrialIT automationplatform to minimize downtime. The struc-tured Status Lists provide a diagnostic sys-tem that quickly identifies any fault or unful-filled condition that stops the mill or pre-vents it from starting and provides informa-tion in clear text. The Status Lists are dynam-ically updated to ensure that they keep con-

tinuously abreast of the conditions in themill. The diagnostics for equipment not se-lected for use in the current production arefiltered out so that the list presents only infor-mation about the equipment in use. The Sta-tus Lists are grouped according to the work-ing sequences of the mill operator.

Start-up diagnostics. The start-up of arolling mill is divided into well-defined stag-es such as Ready for Switch On, Ready for

Start, Ready for Run, etc. Each stage has itsown Status List, which, in the event of unful-filled conditions, helps the operator meet theconditions so that the start-up can proceed.

Stop diagnostics. There are a number ofdifferent types of stop (various stop rates, de-layed stops, etc.). Each stop type has its ownStatus List that quickly informs the operatorabout the root cause of the stop order.

Interlock diagnostics. A rolling mill in-cludes a lot of equipment that can perform anumber of automatic operations and se-quences. Each operation normally has a setof interlock conditions that have to be ful-filled for operation to take place. Generationof status information is integrated into the in-terlocking logic. The list specifies in cleartext all unfulfilled conditions for the opera-tion.

The IndustrialIT automation platform has aunique software architecture known as As-pectObjects. This organizes the automationsystem into Objects, whose characteristicsare defined as Aspects. The architecture hasbeen developed so that information from au-tomation systems from other suppliers canbe easily integrated into the ABB IndustrialITsystem. The Objects are arranged in a PlantExplorer structure based on either function-ality or geographical location. This gives themill crew the big advantage that all informa-tion about the process objects such as draw-ings, descriptions, manuals, maintenancestatistics, etc., is immediately on hand whenrequired. No more searching for documenta-tion while production is waiting. Additionalinformation can be added to the system forthe most part irrespective of its form.

Enhanced measuring systemsAvestaPolarit has ordered another strip edgesensor for measuring the strip position andwidth, the so-called MeasureIT MillmateStrip Scanner System (MSS). The MSS sen-sor is to be installed on a 20-roll cluster millin Långshyttan, Sweden. This is the secondstrip scanner for the Långshyttan mill and, intotal, the eighth so far ordered by the Av-estaPolarit Group. The MSS sensor for theorder from the Långshyttan mill will be sup-plied with a new combination of accuratemeasurement of strip position and width.

MeasureIT Millmate ThicknessGauging SystemsAfter a one-year trial period with the Meas-ureIT Millmate Thickness Gauging System(MTG) the aluminium producer Alcan hasdecided, due to very satisfying results in theleveling line, to order three more MTG sys-tems for their production unit in Singen in

Integrated Control System with the addition of the IDC controlsystem based on AC800M controllers.

A typicalStatus Listmenu for hotrolling mills.

Millmate ThicknessGauging System.

29NORDIC STEEL & MINING REVIEW 2003

southern Germany. The installed MTGsystems worldwide have proven togive very stable and accurate thicknessmeasurement results. To date, four cli-ents have come back with repeat or-ders.

ASTAT crane motion controlThe steel industry is the most impor-tant user of large EOT cranes with ahigh lifting capacity. Like the rest ofthe process and manufacturing indus-tries, it demands from its equipmentsuppliers lower prices in combinationwith better performance. This has beena difficult market situation for manycrane builders, whose profits have notreached an acceptable level. The maincost driver has been the electricalequipment. Conventional frequencyconverter drives give rise to extra costsassociated with their supplementaryparts, like air conditioning and EMCprecautions. With its ASTAT Crane MotionControllers, ABB can offer improved availa-bility, integration into the crane’s informa-tion system and a surprising cost reductionfor an EOT crane for the steel industry ofabout 10 - 20 per cent. Another factor of im-portance is the ruggedness of the motioncontrol system. The ASTAT system is de-signed to operate at a temperature of 70° C,in areas with conductive dust as well as at 70per cent of the nominal line voltage. A com-monly asked question is the cost of slip-ringmotors. The price difference between a

crane duty motor of squirrel-cage or slip-ringtype is minimal as long as cast-iron motorsare compared. Light-alloy motors are alwayscheaper.

New drive systemsfor mine hoists and rolling millsTo satisfy the requirements for higher driveperformance and higher network quality,ABB has developed a new generation ofdrives. Two basic series are available:ACS600 for 690 V and ASC6000 SD for3,150 V systems. The new drive using DTC,

Direct Torque Control, is now proventechnology for mine hoist applicationsthrough more than two years of serv-ice in the first installation in the Py-häsalmi Mine in Finland. This installa-tion uses MV technology based on theACS6000 SD drive with synchronousmotor. The new generation of drivesoffers unequalled speed and torquecontrol performance as well as a lowimpact on the supply network by con-trolling the power factor to unity witha minimum of harmonics distortion.

Currently, two mine hoist systemswith the new drive system (one at Py-häsalmi Mine and the other at the StGotthard tunnel) are in operation. Athird system has recently been deliv-ered to INCO’s Creighton Mine inCanada. The DC motor for the double-drum main cage hoist at this mine wasreaching the end of its life. After con-sidering various options, INCO decid-

ed to order a new drive based on latest tech-nology, with a synchronous motor andACS6000 SD drive.

ABB is currently installing two hoists inAvestaPolarit’s Kemi Chromite Mine innorthern Finland using LV technology withinduction motors based on ACS600 driveswith high-speed machines. The 3.3 m fric-tion hoist with skip, cage and counterweightis powered by a 1,500 kW, 1,000 r.p.m. in-duction motor, while a 75 kW, 1,000 r.p.m.induction motor drives the single-drum aux-iliary hoist. It is interesting to note that the

Old motors are upgraded to new ones with the ASTATcrane motion control system.

USA:Carpenter Powder Products600 Mayer StreetBridgeville, PA 15017, USATel. (412) 257-5102Fax (412) 257-5154E-mail ltemples@cartech.com

Sweden:Carpenter Powder Products ABP.O. Box 45, SE-644 21 Torshälla, SwedenTel. +46 16 34 98 00Fax +46 16 35 76 70E-mail CPPAB@Cartech.comHomepage: http://carpenterpowder.com

Germany:Carpenter Powder Products GMBHDüsselthaler Strasse 9D-40211 Düsseldorf, GermanyTel. +49 (0) 211/172/32-50Fax +49 (0) 211/172/32-55E-mail Anval-Burkard@t-online.de

CARPENTER POWDER PRODUCTS is a world leading producer of gas atomized (spherical) powders in Iron-,Nickel- and Cobalt-base alloys. Our production facilities are situated at Torshälla, Sweden, and Bridgeville, PA,USA.

CARPENTER POWDER PRODUCTS screened powders are used worldwide for the following main applications:– Thermal Spraying– Brazing– Plasma Transferred Arc Welding (PTA)– Hot Isostatic Pressing (HIP)– Metal Injection Moulding (MIM)

CARPENTER POWDER PRODUCTS also supplies Hot Isostatic Pressed Billets and Bars for direct use or forfurther processing by rolling or forging.

30 NORDIC STEEL & MINING REVIEW 2003

Kemi Mine specified AC drives for the newhoists. In fact, DC drives have never beenused in this mine. Installation of the newhoists is scheduled for completion in Augustthis year.

IMAS, Integrated mineautomation systemIMAS is an integrated automation systemthat is based on the IndustrialIT platform.IMAS provides integrated solutions for allactivities associated with underground min-ing, ranging from haulage to crushing, hoist-ing and ventilation. Third party productsused to control equipment in the mine can beintegrated into IMAS, as is also the case withlinks from the mining company’s businessand maintenance systems. For such automa-tion projects ABB cooperates closely withthe customer, starting with feasibility studiesand continuing right through to the comple-tion of the project.

New orders and ongoing projectsSince last year, Metals and Mining at ABBSweden has experienced positive changes interms of the order intake. So far this year,Metals and Mining has received several con-tracts in Sweden, China, Russia, Poland, Tur-key and Italy for the supply of electricalequipment and control systems for the min-ing industry and rolling mills as well as ofelectromagnetic stirrers for steelworks andaluminium plants.

Mining projectsRecently, LKAB’s Svappavaara ore concen-tration and pelletizing plant in northern Swe-den ordered new automation and processelectrical systems. This upgrading projectwill be divided into six phases extendingover a period of three years. It includes theinstallation of a new control system, newlow-voltage switchgear, new frequency con-verters as well as engineering, installation,commissioning and project management.

‘ABB will deliver a state-of-the-art Indus-trialIT solution including intelligent switch-gear systems equipped with INSUM, elec-tronic units that supervise each single motor,’says Petter Oscarsson. INSUM is an intelli-gent system that provides protection, controland monitoring functions for optimized mo-tor management.

‘The complete installation will be basedon our concept for enhanced productivity,availability and service friendliness,’ empha-sizes Per Eckemark.

ABB has recently received a repeat orderfrom ALROSA, Russia’s largest diamondcompany and one of the world’s leadingrough diamond producers. This contract in-cludes the supply of 40 advanced hydrauli-cally controlled disc brakes, DC drive sys-tems, control systems and shaft signalingequipment for four hoist systems to be in-stalled in the Mir Mine. Together with thislatest order, ABB is equipping a total of tenmine hoists in ALROSA’s mines.

Poland has traditionally been a major cus-tomer of ABB’s mine hoists. The most recentorder was received from KGHM Polish Cop-per Ltd. for the replacement of a mine hoistin their Rudna No. 11 Mine. This 5.5 m di-

ameter hoist with skips in balance is one ofthe largest production hoists in Europe. Pow-ered by two 3,600 kW motors, the hoist has apayload of 33 tonnes. KGHM has been acustomer of ABB since the 1960s. The origi-nal brake, drive and control systems were infact supplied by ABB in 1972. All equip-ment will be replaced except the motors. Therevamp is scheduled to take place over ashutdown period of as short as 16 days at theend of this year.

China is the most important market forABB hoists and ABB is the largest foreignsupplier of hoist systems to China. This year,China has ordered several complete brakesystems for mine hoists for their coal indus-try as part of a campaign to increase safetyand reliability. Recently, ABB received anorder from Luan Mining Co., Shanxi Prov-ince, for the supply of two complete hoistsfor their new service shaft in the TunliuMine. The larger of the two hoists, a 4.0 mdiameter 4-rope friction hoist is powered bya 1.5 MW synchronous motor controlled byan ACS 6000SD drive.

The metals industryIn September last year, ABB received anoth-er order for a medium section mill project,this time from ProfilARBED, part of theArcelor Group. This is also the first majororder received by ABB from the steel indus-try in Luxembourg.

The delivery includes the power supplyinstallation with transformers as well as me-dium- and low-voltage switchgear. The drivesystems comprise frequency converters andmotors for both the main and the auxiliarydrives. The main drives consist of the newlydeveloped medium-voltage frequency con-verter system DriveIT ACS6000 SD with di-rect torque control. This will feed and controlsynchronous motors with outputs of up to 4MW. The drive system control is based onthe DriveIT Rolling Mill Drive, which com-bines the converter, motor and drive train inan optimal way. It allows the use of high-speed, high-power motors for the rolling

Per Eckemark, head of Metals and Mining, ABB Sweden, shaking hands with Mats Niemi,Purchasing Manager, LKAB, during the signing of the Svappavaara contract.

mill. This in turn makes it possible to selectmuch smaller motors, which leads to sub-stantial cost savings for the customer. Therolling mill’s control system is based on theOperateIT platform, which will give the oper-ators a state-of-the-art tool to follow and su-pervise the rolling process.

This project is being executed by a con-sortium, whose partners are ABB, SMS MeerGmbH (mechanical equipment), DSD Indus-trieanlagen GmbH (cabling and erection)and PERTUY Construction S.A. (civilworks).

According to Patrik Modig, ABB’s projectmanager, the project is running as scheduled.The PS Platform Tests will take place inABB’s facilities in October and will be fol-lowed by the Factory Acceptance Test priorto the shipment of the equipment to the site atthe beginning of 2004. It is interesting tonote that all the electrical rooms are beingshipped in “E” containers, which will permitmore extensive factory testing. This will helpto minimize some of the typical problemsnormally experienced at the beginning of thecold commissioning. Most of the ABB engi-neers now working on the project will alsoparticipate in the commissioning on site,which will also help to ensure a smooth start-up of the ABB equipment. Cold testing willcommence in March 2004, no-load testing inJune 2004 and production in September2004.

Last year, AvestaPolarit awarded ABB yetanother contract for the supply of the powerdistribution and drive systems as well as oth-er electrical equipment to their hot flat mill atTornio, Finland. Three new mill stands aswell as a new coiler will be added to the ex-isting rolling mill in order to double the pro-duction. This project is also divided into sev-eral phases to minimize disturbances in theproduction. The first production shutdowntook place in March this year in conjunctionwith the revamping of the roller table bridge.This will be followed in November by thesecond shutdown for the installation of newDC motors.