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A steel manufacturing company was experiencing errors and downtime with their SCADA system. E Tech Group’s engineers swiftly identified and eliminated the error, getting production back online.
A steel manufacturing company needed to replace an outdated furnace control system and for remote support. The client had a redundant SCADA system where one of the SCADAs stopped working. The issue occurred because, over time, the SCADA system was generating error logs which caused the hard drive to fill up. The error occurred because to the company’s anti-virus system was locking SCADA files that were being accessed and written to by the SCADA system. The hard drive reached maximum capacity which resulted in the SCADA system halting.
E Tech engineers remotely identified the corrupted files causing the errors, cleaned the files allowing their system to start back up, and provided consultation to the client’s IT team. We installed HMIs and PLCs, along with a furnace safety system and a furnace control system.
E Tech Group engineers set up a secure way to remote into their system and worked with their IT department to come up with a better solution for the client’s server set ups. This involves coordination with E Tech Group’s IT team and the client’s IT team.
This project only took a half an hour, thanks to the ability to remotely support. This saved the cost of a flight, hotel room, and four hours minimum onsite. Plus, we set the client up to be able to troubleshoot the control system in-house in the future, lessening the need to outsource IT support.
E Tech Group has deep domain expertise in the metals industry, designing and implementing robust, strategically-designed control systems that integrate and optimize automated processes. Partnering with the best automation companies on the market, like Rockwell Automation and AVEVA, metals clients can expect streamlined, consistent processes on an adaptable, scalable automation system.
A steel company came to E Tech Group for help with their cold mill line automation. Improvements to the client’s cold mill yielded measurable financial savings by reducing defects and improving the safety of their automated processes.
E Tech Group was hired for a large project by a leading steel company to increase throughput and safety on the customer’s six-stand cold mill line. Additional project goals were to reduce head and tail off gage, reduce inner stand strip breaks, reduce electrical downtime, and improve safety.
The solution to the client’s goals would require creativity on the part of the system integrator and open communication with the steel company. E Tech Group worked closely with the client from start to finish on this targeted control system update.
E Tech Group conducted a mill drafting study to determine HP and speed limitations, reviewed the mill model, and set up proper procedures. E Tech Group control system engineers also conducted an equipment audit to determine the failure rate and root causes, and then began implementing the audit’s recommendations.
E Tech Group’s automation professionals implemented monitoring and tuning of the inner stand tension, MG set stand one custom 12 pulse drive to fit on existing gen base, screw down clutchless control, and regulated the voltage to the speed reg.
Additionally, a safety study was performed and the recommendations implemented. Installation, startup and commissioning were then performed.
This control system integration resulted in the client experiencing tangible results immediately upon implementation. This successful project proved the value of custom automation system upgrades:
This resulted in a quick ROI for the client, who now has an integrated control system that allows them to closely monitor processes on the cold mill to improve and ensure the quality of their products. E Tech Group’s automation solutions for metals clients employ strategic design and the best in automation technology today to keep manufacturers ahead of the competition curve, facilitating future growth and success.
When approaching an upgrade of your aging control system, focusing on the execution of the upgrade is natural. Often overlooked is the time and effort it takes to choose the right platform and approach for the upgrade. The upfront investment can have a tremendous payoff when you take a long-term view and consider all stakeholders’ needs from the system.
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