Danieli Automation confirms its positive trend in the strip processing lines revamping in Tata Steel with a second successful start-up completed at the CAPL (Continuos Annealing Processing Line) in Trostre works, Wales.

It has been a strategical project, as the line is the heartbeat of the complete site, with 70% of the materials flowing through different plants inside the whole complex, therefore no delays on the plant restart could be accepted as they would compromise the overall productivity and material delivery to final producers.

The project includes complete replacement of the obsolete line automation system, MCC cabinets and DC converters for the existing strip transportation motors (more than 140 motors in all, with individual armature control) with the related erection activities assigned to Danieli Automation with addendum order before line shutdown.

During the project execution, an extremely thorough quality-control program had been planned for all equipment deliveries, as well as an extensive FAT for the new automation system –  this was partially performed using a remote connection with plant operators – with the aim to validate in advance all the scenarios according to the actual line behavior in close coordination with the customer, who had a very wide, close and active participative role with the Danieli Automation technical team.

The shutdown activities were executed with strong commitment between parties, everyone following the highest level of health and safety measures with particular focus on Covid-19 risk mitigation.

Special attention was paid to preparation for the shutdown, starting from site mobilization and performing in advance transportation of major part of the supply inside the electrical rooms reducing operating activities to be performed.

Almost 200 linear meters of electrical switchboards (DC converter and MCC), tens of mounting plates for automation and new control desks for entry/exit control pulpits have been dismounted, replaced and reconnected in only 10 calendar days by the several installation teams who have worked 24 hours continuously.

Thanks also to the mutual effort provided during the several phases of project execution and during the start-up, the commissioning team restarted the line with the new complete automation system, achieving in short time 99,87% line availability performance (value measured on 14 production days consecutively).

After which final acceptance was achieved according to the contractual schedule, the cooperation between parties has been strengthened with a remote assistance contract (8 hours/day, 7/7 days) where Danieli Automation’s engineers can provide support for troubleshooting and additional optimization according Tata Steel’s requests.

This new successful story is the natural result of the joint effort between Tata Steel and the Danieli Automation team, who’ve worked together as one, cohesive unit committed to a common target.

For any information please contact Giacomo Baccaro at   g.baccaro@dca.it