Training Hireg Rev01

HiREG®

Electrodes Regulator Training

DANIEL

I

Know-How in Process Control

Danieli Automation HeadquartersVia B.Stringher, 433042 Buttrio (UD) Italy

Tel. (39) 0432.518111Fax (39) 0432.673177E-mail: [email protected]

DANIELI AUTOMATION

This document contains proprietary information of Danieli Automation S.p.A. not disclosable, not reproducible. All Rights Reserved

• Aim of the application• Power Supply layout• Measuring system• Current and Voltage Transformer• M.V. Interface Transformer table• Hardware connection to PLC• PLC Interface• Electrode Regulator: Position Control

Loop• Linearization and regulation

parameters• Counter pressure: pressure control

loop• Cold test• Hot Test• Data Analysis (Fda® )

HiREG® – Training program


REGULATION PRINCIPLESREGULATION PRINCIPLES


• Impedance regulation:Istantaneous control of the arc length by hydraulic electrodes position control

• Individual regulators for each phase, with phase balancing

• Electrode saving function1. Overcurrent reaction.

2. Not conductive material reaction

• Logging and real time trends for machine tuning and performance improvement

HiREG®– Aim of the application

Pos

REACTOR POSITIONPRIMARY VOLTAGE

CURRENT VALUETAP CHANGER POSITION

REGULATOR

SET-POINTCALCULATION

V

I

Z set

Z measure

Z error

TUNING PARAMETERS

INITIALCONTACT

LOGIC I

V

Speed

Control Loop Regulation

Standard PLC

PivottiR


HiREG® Position Control Loop

Regulation Algorithm

Ki * I ‑ Ku * U = 0

Main Parameters:PAR. I , PAR. U : inputs U, I parametering and limiting functionsKi : conversion table from primary current to secondary current Kiph : function for the balancing of the phasesKu : table for the furnace working points


HIREG BLOCK DIAGRAMHIREG BLOCK DIAGRAM


HiREG® - Automation Block Diagram

HiREGHiREGEAFEAF


HIREG HYDRAULICHIREG HYDRAULIC


HiREG® Hydraulic Overview

InletInlet

Regulation Regulation ValvesValves

UnlockingUnlockingValvesValves

Line PressureLine Pressuretransducerstransducers

Lifting Lifting ColumnsColumns

OutletOutlet

Counter PressureCounter PressureTransducersTransducers

AccumulatorsAccumulators

Counter PressureCounter PressureRegulation ValveRegulation Valve


HiREG® Valve system

Actuator: Valve Tech. Spec.

Signal command ±10VDigital Regulator ± 10000


HiREG® Valve system

Actuator: Valve Electrical drawing


MV TYPICAL LAYOUTMV TYPICAL LAYOUT


HiREG® Power Supply Layout

Transformer HV-MVTransformer HV-MV

BreakerBreaker

P.F. CompensationP.F. Compensation

Series ReactorSeries Reactor

Furnace transformerFurnace transformer

Secondary system and ElectrodeSecondary system and Electrode


FIELD SIGNALS MEASUREFIELD SIGNALS MEASURE

PT and CT connection


HiREG® Measuring system

Voltage transformer PT (TV)

Important: Avoid shortcircuit condition for PT (TV)

50Hz



Adaptive Current transformer TA

Trafo connection Delta/Delta

Diris

Important :always verify short circuit condition for CT (TA)

5/5 A



Trafo connection Star/Delta

Adaptive Current transformer TA

5/5:√3 A




Trafo connection Star-Delta/Delta

5/5:√3 A



HiREG® Voltage and current transducer

RMS converterRMS converter Input 0:100V or 0:8A Input 0:100V or 0:8A

ACAC Output 0:10 V DCOutput 0:10 V DC Time response < Time response <

50ms50ms Precision < 0.5%Precision < 0.5% Cl.= 0.5Cl.= 0.5 Supply 230 V 50Hz Supply 230 V 50Hz

or 110 V 60 Hzor 110 V 60 Hz


HIREG ELECTROTECNICHIREG ELECTROTECNIC

Main Principles


HiREG® Electrical Parameters (1)

Base electrical circuit:

Base circular diagram


Real Circular DiagramReal Circular Diagram

APPARENT POWER [MVA]

RATED POWER [MVA]

MAX. POWER [MVA]

POWER FACTOR [-]

LOAD CURVES [V]ELECTRODES CURRENT [kA]

ARC LENGTH [mm]

For each tap of the reactor (if any), a circular diagram can be produced to represent the allowed working area for the furnace.



EAF

P_fu+jQ_fu

P_fu+jQ_fu+jQ_react

P_arc + losses = P_fu

S_2

S_1

SERIES REACTOR

FURNACE TRANSFORMER

P_arc = 3 (V_arc x I_arc)

MV BUSBAR

P_fu/S_2 = 0,77-0,78

P_fu/S_1 > 0,8

Theory of Series ReactorTheory of Series Reactor

ProfileProfile

Boring : P.F.<0.75 Varc < 300÷400 CC = 6

Melting : P.F. >0.75 max Power

Refining : R.I. Arc coverage condition


Power

Boring

Melting

Refining


HIREG HW INTERFACESHIREG HW INTERFACES

Fail safe logic


HiREG® Hardware connection to PLC


HIREG INTERFACE SIGNALSHIREG INTERFACE SIGNALS

With main automation PLCs

EAF or LRF


HiREG® PLC Interface (1)

HIREG_WC_REMHIREG_WC_REM DATA TO FURNACE PLCDATA TO FURNACE PLC

dp couplerdp coupler: 64 bytes: 64 bytesSTRCT: STRCT: EREG_REMEREG_REM

DBW000DBW000 INTF_WS_WATCHDOG_RGINTF_WS_WATCHDOG_RG watchdogwatchdog ININ 0÷300000÷30000 Always Always changingchanging 0000

DBX002.00DBX002.00 INTF_BS_GEN_FLTINTF_BS_GEN_FLT Regulator generic alarmRegulator generic alarm BBBB 0>10>1 1= true1= true 0000

DBX002.01DBX002.01 INTF_BS_TRP_FLTINTF_BS_TRP_FLT Regulator higher priority failureRegulator higher priority failure BBBB 0>10>1 1= true1= true 0000

DBX002.02DBX002.02

DBX002.03DBX002.03

DBX002.04DBX002.04 INTF_BS_BRK_OPN_CNSINTF_BS_BRK_OPN_CNS furnace breaker open consentfurnace breaker open consent BBBB 0>10>1 1= true1= true 0000

DBX002.05DBX002.05

DBX002.06DBX002.06 INTF_BS_ARC_ONINTF_BS_ARC_ON Furnace Arc OnFurnace Arc On BBBB 0>10>1 1= true1= true 3131

DBX002.07DBX002.07

DBX003.00DBX003.00 INTF_BS_ELS_LW_QTAINTF_BS_ELS_LW_QTA Electrodes have all reached requested quotaElectrodes have all reached requested quota BBBB 0>10>1 1= true1= true 3131

DBX003.01DBX003.01

DBX003.02DBX003.02

DBX003.03DBX003.03

DBX003.04DBX003.04 INTF_BS_EL_CUR_HIGHINTF_BS_EL_CUR_HIGH Phase 123 cumulative high currentPhase 123 cumulative high current BBBB 0>10>1 1= true1= true 0000

DBX003.05DBX003.05 INTF_BS_EL_CUR_HHIGINTF_BS_EL_CUR_HHIG Phase 123 cumulative high high currentPhase 123 cumulative high high current BBBB 0>10>1 1= true1= true 0000

DBX003.06DBX003.06

DBX003.07DBX003.07

DBX004.00DBX004.00 INTF_BS_EL1_LW_QTAINTF_BS_EL1_LW_QTA Electrode 1 has reached requested quotaElectrode 1 has reached requested quota BBBB 0>10>1 1= true1= true

DBX004.01DBX004.01 INTF_BS_EL1_CUR_HIGHINTF_BS_EL1_CUR_HIGH Electrode 1 high currentElectrode 1 high current BBBB 0>10>1 1= true1= true 0000

DBX004.02DBX004.02 INTF_BS_EL1_CUR_HHIGINTF_BS_EL1_CUR_HHIG Electrode 1 high high currentElectrode 1 high high current BBBB 0>10>1 1= true1= true 0000

DBX004.03DBX004.03 INTF_BS_EL1_POS_FLTINTF_BS_EL1_POS_FLT Electrode 1 Encoder faultElectrode 1 Encoder fault BBBB 0>10>1 1= true1= true 0000

DBX004.04DBX004.04 INTF_BS_EL1_SP_ZEROINTF_BS_EL1_SP_ZERO Electrode 1 speed is zeroElectrode 1 speed is zero BBBB 0>10>1 1= true1= true 0000

DBX004.05DBX004.05 INTF_BS_EL1_HISP_VLVINTF_BS_EL1_HISP_VLV Electrode 1 high speed valve opening commandElectrode 1 high speed valve opening command BBBB 0>10>1 1= true1= true 3333

DB 156 To Furnace PLC



DB 156 To Furnace PLC

DBX010.00DBX010.00 INTF_BS_RCT_BRK_CLS_ENAINTF_BS_RCT_BRK_CLS_ENABB

Saturable reactor: furnace breaker Saturable reactor: furnace breaker closing enabledclosing enabled BBBB 0>10>1 1=true1=true 3131

DBX010.01DBX010.01

DBX010.02DBX010.02 INFT_BS_RCT_CUR_REACHINFT_BS_RCT_CUR_REACH Saturable reactor target current is Saturable reactor target current is reachedreached BBBB 0>10>1 1=true1=true 3131

DBX010.03DBX010.03

DBX010.04DBX010.04 INTF_BS_RCT_CUR_ALR_HIGINTF_BS_RCT_CUR_ALR_HIGHH

Saturable reactor current over high Saturable reactor current over high limit-STOP CONVERTERlimit-STOP CONVERTER BBBB 0>10>1 1=true1=true 3131

DBX010.05DBX010.05 INTF_BS_RCT_CUR_ALR_LOWINTF_BS_RCT_CUR_ALR_LOW Saturable reactor current under low Saturable reactor current under low limit-STOP CONVERTERlimit-STOP CONVERTER BBBB 0>10>1 1=true1=true 3131

DBW012DBW012 INTF_WS_EL1_VLT_RGINTF_WS_EL1_VLT_RG electrode 1 _ voltage electrode 1 _ voltage ININ 0÷12000÷1200 VV 0÷12000÷1200 0000

DBW014DBW014 INTF_WS_EL1_CUR_RGINTF_WS_EL1_CUR_RG electrode 1 _ currentelectrode 1 _ current ININ 0÷50.000÷50.00 KAKA 0÷50000÷5000 0000

DBD016DBD016 INTF_WS_EL1_POSINTF_WS_EL1_POS electrode 1 actual absolute positionelectrode 1 actual absolute position FLFL 0÷60000÷6000 mmmm 0÷60000÷6000 3333

DBW020DBW020

DBW042DBW042 INTF_WS_PRIM_VLINTF_WS_PRIM_VL Primary voltagePrimary voltage ININ 0÷42.000÷42.00 KVKV 0÷42.00 KV0÷42.00 KV 0000

DBW052DBW052 INTF_WS_RCT_CUR_REFINTF_WS_RCT_CUR_REF Saturable reactor current referenceSaturable reactor current reference ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3131

DBW054DBW054 INTF_WS_RCT_CUR_LIM_HIGINTF_WS_RCT_CUR_LIM_HIGHH

Saturable reactor current high limit Saturable reactor current high limit valuevalue ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3131

DBW056DBW056 INTF_WS_RCT_CUR_LIM_LOWINTF_WS_RCT_CUR_LIM_LOW Saturable reactor current low limit valueSaturable reactor current low limit value ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3131



DB 156 From Furnace PLCDBW100DBW100 INTF_WC_WATCHDOG_RGINTF_WC_WATCHDOG_RG watchdogwatchdog II

NN0÷300÷30000000

Always Always changingchanging 0000

DBX102.0DBX102.000

INTF_BC_EL1_LIFT_RGINTF_BC_EL1_LIFT_RG electrode 1 lifting (regulator)electrode 1 lifting (regulator) BBBB

0>10>1 1= true1= true 0000

DBX102.0DBX102.011

INTF_BC_EL1_LOWR_RGINTF_BC_EL1_LOWR_RG electrode 1 lowering (regulator)electrode 1 lowering (regulator) BBBB

0>10>1 1= true1= true 0000

DBX102.0DBX102.022

INTF_BC_EL1_AUTO_RGINTF_BC_EL1_AUTO_RG electrode 1 automatic (regulator)electrode 1 automatic (regulator) BBBB

0>10>1 1= true1= true 0000

DBX102.0DBX102.033

INTF_BC_EL1_UNL_RGINTF_BC_EL1_UNL_RG Electrode 1 unlocked (regulator) Electrode 1 unlocked (regulator) BBBB

0>10>1 1= true1= true 0000

DBX102.0DBX102.044

INTF_BC_EL1_HIGH_RGINTF_BC_EL1_HIGH_RG electrode 1 in high pos. (regulator)electrode 1 in high pos. (regulator) BBBB

0>10>1 1= true1= true 0000

DBX102.0DBX102.055

INTF_BC_EL1_LOW_RGINTF_BC_EL1_LOW_RG electrode 1 in low pos. (regulator)electrode 1 in low pos. (regulator) BBBB

0>10>1 1= true1= true 0000

DBX102.0DBX102.066

INTF_BC_EL1_HSPD_RGINTF_BC_EL1_HSPD_RG electrode 1 high speed (regulator)electrode 1 high speed (regulator) BBBB

0>10>1 1= true1= true 0000

DBX102.0DBX102.077

DBX103.0DBX103.000

DBX103.0DBX103.011

DBX103.0DBX103.022

DBX103.0DBX103.033

DBX103.0DBX103.044

DBX103.0DBX103.055

DBX103.0DBX103.066

DBX103.0DBX103.077



DB 156 From Furnace PLC

DBX108.00DBX108.00 INTF_BC_ARC_INT_CMDINTF_BC_ARC_INT_CMD furnace breaker arc interruption furnace breaker arc interruption (command)(command)

BBBB

0>10>1 1= true1= true 0000

DBX108.01DBX108.01 INTF_BC_BRK_CLS_STAINTF_BC_BRK_CLS_STA furnace breaker closed (status)furnace breaker closed (status) BBBB

0>10>1 1= true1= true 0000

DBX108.02DBX108.02 INTF_BC_BRK_OPN_CMDINTF_BC_BRK_OPN_CMD furnace breaker opening request (command)furnace breaker opening request (command) BBBB

0>10>1 1= true1= true 0000

DBX108.03DBX108.03 INTF_BC_CLAMPSINTF_BC_CLAMPS electrodes clamps modeelectrodes clamps mode BBBB

0>10>1 1= true1= true 0000

DBX108.04DBX108.04 INTF_BC_MAINTINTF_BC_MAINT Furnace in maintenance modeFurnace in maintenance mode BBBB

0>10>1 1= true1= true 0000

DBX108.05DBX108.05 INTF_BC_HEAT_ENDINTF_BC_HEAT_END Furnace Heat EndFurnace Heat End BBBB

0>10>1 1= true1= true 0000

DBX108.06DBX108.06 INTF_BC_BCK_ENDINTF_BC_BCK_END Furnace Bucket EndFurnace Bucket End BBBB

0>10>1 1= true1= true 0000

DBX110.00DBX110.00 INTF_BC_RCT_AUTOINTF_BC_RCT_AUTO Saturable reactor automatic modeSaturable reactor automatic mode BBBB

0>10>1 1= true1= true 3131

DBX110.01DBX110.01 INTF_BC_RCT_RUNINTF_BC_RCT_RUN Saturable reactor is runningSaturable reactor is running BBBB

0>10>1 1= true1= true 3131

DBX110.02DBX110.02 INTF_BC_RCT_BYPINTF_BC_RCT_BYP Saturable reactor is by-passedSaturable reactor is by-passed BBBB

0>10>1 1= true1= true 3131



DB 156 From Furnace PLC

DBW112DBW112 INTF_WC_PRIM_VLTINTF_WC_PRIM_VLT primary - voltageprimary - voltage ININ 0÷50.000÷50.00 kVkV 0÷50000÷5000 0000

DBW114DBW114

DBW116DBW116

DBW118DBW118 INTF_WC_TAP_POS_RGINTF_WC_TAP_POS_RG tap changer position tap changer position ININ 1÷321÷32 1÷321÷32 0000

DBW120DBW120 INTF_WC_CUR_SET_RGINTF_WC_CUR_SET_RG current curve position (SET)current curve position (SET) ININ 1÷61÷6 1÷61÷6 0000

DBW122DBW122 INTF_WC_RCT_POSINTF_WC_RCT_POS reactor positionreactor position ININ 1÷61÷6 1÷61÷6 0000

DBW124DBW124 INTF_WC_ACT_PWRINTF_WC_ACT_PWR Active powerActive power ININ 0÷1000.00÷1000.0 MWMW 0÷100000÷10000 0000

DBW126DBW126 INTF_WC_RCT_PWRINTF_WC_RCT_PWR Reactive powerReactive power ININ 0÷1000.00÷1000.0 MVAMVARR

0÷100000÷10000 0000

DBW128DBW128 INTF_WC_COSPHYINTF_WC_COSPHY CosphyCosphy ININ 0÷1.0000÷1.000 0÷10000÷1000 0000

DBW142DBW142 INTF_BC_RCT_CUR_TRG_MAINTF_BC_RCT_CUR_TRG_MANN

Saturable reactor target current in Saturable reactor target current in manual modemanual mode ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 33

11

DBW144DBW144 INTF_BC_RCT_CUR_ACTINTF_BC_RCT_CUR_ACT Saturable reactor real currentSaturable reactor real current ININ 0÷1650.00÷1650.0 AA 0÷165000÷16500 3311


HIREG OWSHIREG OWS


HiREG® Communication Overview


HiREG® Communication settings

DPI CONFIGURATOR


HIREG OWS PARAMETERSHIREG OWS PARAMETERS



Reference document:

Admittance Table


HiREG® Transformer Table (1)

Transformer Primary side connection

Important: Electrode line current

CT Settings

KI-KA Automatic calculation


HiREG® Transformer Table (2)

KIKA


HiREG® Regulation Parameters

Regulation Valve settings

PI Regulator settings

Electrode Speed settings

Boring phaseSettings

Touch DownSettings

Notch Filter Settings

V/I presence

AdditionalSettings


HiREG® Regulation Parameters

Phase BalancePhase Balance PHASE 1PHASE 1 PHASE 2PHASE 2 PHASE 3PHASE 3

PHASE BALANCEPHASE BALANCE 11 11 11

CURRENTCURRENT 11 11 11

ARC LENGHTARC LENGHT == == ==

PHASE BALANCEPHASE BALANCE 11 0,90,9 11

CURRENTCURRENT 11 1+ 1+ ΔΔ 11

ARC LENGHTARC LENGHT --ΔΔ - - ΔΔ + + ΔΔ

PHASE BALANCEPHASE BALANCE 11 0,90,9 0,90,9

CURRENTCURRENT 11 1+ 1+ ΔΔ11 1+ 1+ ΔΔ22

ARC LENGHTARC LENGHT (-(-ΔΔ11 + + ΔΔ22)) (-(-ΔΔ11– – ΔΔ22)) (+Δ(+Δ11 – Δ – Δ22))


HiREG® Linearization (1)

Sequence:1. Zero Valve 2. BIAS 1 mm/s3. Linearization

Automatic cycle

SPEED RESPONSE CP=680 PSI

-300

-200

-100

0

100

200

300

400

-10000 -6000 -2000 2000 6000 10000reference [mV]

spee

d [

mm

/s]

EL3

EL2

EL1


HiREG® Regulation Parameters NLG

Gain increase in case of cave-in

Maintain symmetric system response


HiREG® Plant Parameters

Typical Measuring setting: pay attention to the correct value


HiREG® Counter Pressure

Pressure control :Pressure control :• Counter pressure set ~80% Pb= Pcp Down Speed ~200mm/s (Pb: Pressure Counter pressure set ~80% Pb= Pcp Down Speed ~200mm/s (Pb: Pressure

balance)balance)• Accumulator set ~65% PcpAccumulator set ~65% Pcp

Valve Parameters

Backpressure

Set Points

BackpressureTrend

Alarms

Line pressureTrends

Line Pressurealarms

SwitchingSettings


HiREG® Communication settings

Dispatcher settings

DB MidddleWareLocation


• Automation system technical specification - HiReg (o HiReg Plus) • Functional Specification - HiReg (o HiReg Plus) • Operator manual – HiReg OWS • Ac electric arc furnace - Furnace calculations - Working points, circ.diagram, electrode reg.table • Commissioning manual

HiREG® Reference documentation

Training Hireg Rev01

Documents

Transcript of Training Hireg Rev01