Multi-phase startup for four strand continuous caster

The four-strand continuous caster underwent a multi-phase power and control revamp at the Gerdau plant in Cartersville, GA. One strand was commissioned in September in conjunction with the control system upgrade of the bar mill and the remaining three strands in December of 2015. Russula supplied the new automation solution.

The existing power and control equipment for the 4 strand continuous caster was upgraded with Allen Bradley automation systems. To modernize the current AC drives and control system, five PLCs type AB PLC5 (4 for the lines and 1 for the common controls) were replaced with new AB ControlLogix 1756 L7 processors. The existing Control Technique drives were replaced with new AB PowerFlex 755 series.

The current GE iFix HMI system was kept in place and readapted to communicate with the processors.

This project illustrates the high flexibility Russula offers when faced with different technological solutions and its total independence from electrical equipment manufacturers.