Bar Mill Pusher Billet Reheating Furnace Control and Burner Safety Re-Vamp

Client

Major Egyptian steel manufacturer

Services / Products

• Furnaces / Burners
• Control Panels
• Combustion Design / Equipment
• SCADA Systems
• PLC Systems
• Project Management
• Commissioning

Scope of Service

Our client wanted to update a bar mill furnace to improve and update furnace controls and improve burner safety to meet safety requirements.  We were awarded a contract to carry out the entire works.

The main aspects of this project were to restore the combustion system to the design level of safety operation, eliminate the adverse effects on zone, and hence furnace, performance of individual burner failures, improve reliability and enable remote furnace control and monitoring, via a new SCADA.

As a secondary objective improved scaling loss and Natural Gas consumption were anticipated.

The existing 23 burner control units were replaced along with pneumatically controlled safety valves in each burner gas supply. The original PLC and SCADA system were replaced with modern units and the software configured to control the process temperatures, recuperator controls, billet handling and pusher and push bar co-ordination and burner safety systems.

Two SCADA nodes were provided, one in the furnace local control room, for maintenance use, and one remotely in the Mill pulpit to enable the roller to control and monitor furnace operational factors. The whole system was then re-commissioned.

Benefits of our work

• Compliance with Company and Statutory Health and Safety Requirements
• Improved operational flexibility
• Improved operational reliability and resilience
• Reduced scaling and Natural Gas usage
• Modernised plant