DANIEL

Know-How in Process Control

HiREG
Electrodes Regulator Training

DANIELI

AUTOMATION

Danieli Automation
Headquarters
Via B.Stringher, 4
33042 Buttrio (UD) Italy

Tel. (39) 0432.518111

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

HiREG Training program

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
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REGULATION PRINCIPLES

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HiREG Aim of the application

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

Standard PLC

Individual regulators for

each phase, with phase
balancing

Control Loop Regulation

Electrode saving
function
1. Overcurrent reaction.

TUNING PARAMETERS

Speed

2. Not conductive material

reaction

Logging and real time

trends for machine tuning
and performance
improvement

Z error
REGULATOR

Pos
INITIAL
CONTACT
LOGIC

V
I

Z measure

REACTOR POSITION
PRIMARY VOLTAGE
CURRENT VALUE
TAP CHANGER POSITION

SET-POINT
CALCULATION

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Z set

HiREG Position Control Loop

Regulation Algorithm

Ki * I Ku * U = 0

Main Parameters:
PAR. I , PAR. U
Ki
Kiph
Ku

: inputs U, I parametering and limiting functions

: conversion table from primary current to secondary current
: function for the balancing of the phases
: table for the furnace working points
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HIREG BLOCK DIAGRAM

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HiREG - Automation Block Diagram

EAF

HiREG

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HIREG HYDRAULIC

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HiREG Hydraulic Overview

Lifting
Columns

Unlocking
Valves

Line Pressure
transducers
Regulation
Valves

Accumulators

Counter Pressure
Transducers
Counter Pressure
Regulation Valve

Inlet

Outlet
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HiREG Valve system

Actuator: Valve Tech. Spec.

Signal command 10V

Digital Regulator 10000

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HiREG Valve system

Actuator: Valve Electrical drawing

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MV TYPICAL LAYOUT

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HiREG Power Supply Layout

Transformer HV-MV
Breaker
P.F. Compensation
Series Reactor
Furnace transformer
Secondary system and Electrode
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FIELD SIGNALS MEASURE

PT and CT connection

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HiREG Measuring system

Voltage transformer PT (TV)

50Hz

Important: Avoid shortcircuit condition for PT (TV)

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HiREG Measuring system

Adaptive Current transformer TA

5/5 A

Diris
Trafo connection Delta/Delta
Important :always verify short circuit condition for CT (TA)

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HiREG Measuring system

Adaptive Current transformer TA

Trafo connection Star/Delta

5/5:3 A
Important :always verify short circuit condition for CT (TA)
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HiREG Measuring system

Trafo connection Star-Delta/Delta

5/5:3 A
Important
:always
verify
shortS.p.A.
circuit
condition
for
CT (TA)
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proprietary information
of Danieli Automation
not disclosable,
not reproducible. All Rights
Reserved

HiREG Voltage and current transducer

RMS converter
Input 0:100V or 0:8A
AC
Output 0:10 V DC
Time response <
50ms
Precision < 0.5%
Cl.= 0.5
Supply 230 V 50Hz
or 110 V 60 Hz

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HIREG ELECTROTECNIC

Main Principles

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HiREG Electrical Parameters (1)

Base electrical circuit:

Base circular diagram

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HiREG Electrical Parameters (2)

Real Circular Diagram

For each tap of the
reactor (if any), a circular
diagram can be produced
to represent the allowed
working area for the
furnace.
APPARENT POWER [MVA]
RATED POWER [MVA]
MAX. POWER [MVA]
POWER FACTOR [-]
LOAD CURVES [V]
ELECTRODES
CURRENT
[kA]
ARC LENGTH [mm]

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HiREG Electrical Parameters (3)

Theory of Series Reactor

Profile

MV BUSBAR
P_fu+jQ_fu+jQ_react

P_fu/S_2 = 0,77-0,78

Power
Melting
Refining

SERIES REACTOR

Boring
P_fu+jQ_fu

P_fu/S_1 > 0,8

FURNACE
TRANSFORME
R
P_arc
I_arc)

(V_arc

S_1

P_arc
P_fu
EAF

2
S_

losses

Boring :

P.F.<0.75 Varc < 300400

Melting :

P.F. >0.75 max Power

Refining :

CC = 6

R.I. Arc coverage condition

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HIREG HW INTERFACES

Fail safe logic

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HiREG Hardware connection to PLC

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HIREG INTERFACE SIGNALS

With main automation PLCs

EAF or LRF

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HiREG PLC Interface (1)

HIREG_WC_REM

DATATOFURNACEPLC

dpcoupler
:64bytes
STRCT:
EREG_REM

DBW000

INTF_WS_WATCHDOG_RG

watchdog

IN

030000

Always
changing

00

DBX002.00

INTF_BS_GEN_FLT

Regulatorgenericalarm

BB

0>1

1=true

00

DBX002.01

INTF_BS_TRP_FLT

Regulatorhigherpriorityfailure

BB

0>1

1=true

00

DBX002.02

DBX002.03

DBX002.04

INTF_BS_BRK_OPN_CNS

furnacebreakeropenconsent

BB

0>1

1=true

00

DBX002.05

DBX002.06

INTF_BS_ARC_ON

FurnaceArcOn

BB

0>1

1=true

31

DBX002.07

DBX003.00

INTF_BS_ELS_LW_QTA

Electrodeshaveallreachedrequestedquota

BB

0>1

1=true

31

DBX003.01

DBX003.02

DBX003.03

DBX003.04

INTF_BS_EL_CUR_HIGH

Phase123cumulativehighcurrent

BB

0>1

1=true

00

DBX003.05

INTF_BS_EL_CUR_HHIG

Phase123cumulativehighhighcurrent

BB

0>1

1=true

00

DBX003.06

DBX003.07

DBX004.00

INTF_BS_EL1_LW_QTA

Electrode1hasreachedrequestedquota

BB

0>1

1=true

DBX004.01

INTF_BS_EL1_CUR_HIGH

Electrode1highcurrent

BB

0>1

1=true

00

DBX004.02

INTF_BS_EL1_CUR_HHIG

Electrode1highhighcurrent

BB

0>1

1=true

00

DBX004.03

INTF_BS_EL1_POS_FLT

Electrode1Encoderfault

BB

0>1

1=true

00

DBX004.04

INTF_BS_EL1_SP_ZERO

Electrode1speediszero

BB

0>1

1=true

00

DBX004.05

INTF_BS_EL1_HISP_VLV

Electrode1highspeedvalveopeningcommand

BB

0>1

1=true

33

DB 156

To Furnace PLC

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HiREG PLC Interface (2)

To Furnace PLC

DB 156
DBX010.00

INTF_BS_RCT_BRK_CLS_ENA
B

Saturablereactor:furnacebreaker
closingenabled

BB

0>1

1=true

31

DBX010.01

DBX010.02

INFT_BS_RCT_CUR_REACH

Saturablereactortargetcurrentis
reached

BB

0>1

1=true

31

DBX010.03

DBX010.04

INTF_BS_RCT_CUR_ALR_HIG
H

Saturablereactorcurrentoverhigh
limitSTOPCONVERTER

BB

0>1

1=true

31

DBX010.05

INTF_BS_RCT_CUR_ALR_LOW

Saturablereactorcurrentunderlow
limitSTOPCONVERTER

BB

0>1

1=true

31

DBW012

INTF_WS_EL1_VLT_RG

electrode1_voltage

IN

01200

01200

00

DBW014

INTF_WS_EL1_CUR_RG

electrode1_current

IN

050.00

KA

05000

00

DBD016

INTF_WS_EL1_POS

electrode1actualabsoluteposition

FL

06000

mm

06000

33

DBW020

DBW042

INTF_WS_PRIM_VL

Primaryvoltage

IN

042.00

KV

042.00KV

00

DBW052

INTF_WS_RCT_CUR_REF

Saturablereactorcurrentreference

IN

01650.0

016500

31

DBW054

INTF_WS_RCT_CUR_LIM_HIG
H

Saturablereactorcurrenthighlimit
value

IN

01650.0

016500

31

DBW056

INTF_WS_RCT_CUR_LIM_LOW

Saturablereactorcurrentlowlimitvalue

IN

01650.0

016500

31

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HiREG PLC Interface (3)

From Furnace PLC

DB 156
DBW100

INTF_WC_WATCHDOG_RG

watchdog

I
N

030
000

Always
changing

00

DBX102.0
0

INTF_BC_EL1_LIFT_RG

electrode1lifting(regulator)

B
B

0>1

1=true

00

DBX102.0
1

INTF_BC_EL1_LOWR_RG

electrode1lowering(regulator)

B
B

0>1

1=true

00

DBX102.0
2

INTF_BC_EL1_AUTO_RG

electrode1automatic(regulator)

B
B

0>1

1=true

00

DBX102.0
3

INTF_BC_EL1_UNL_RG

Electrode1unlocked(regulator)

B
B

0>1

1=true

00

DBX102.0
4

INTF_BC_EL1_HIGH_RG

electrode1inhighpos.(regulator)

B
B

0>1

1=true

00

DBX102.0
5

INTF_BC_EL1_LOW_RG

electrode1inlowpos.(regulator)

B
B

0>1

1=true

00

DBX102.0
6

INTF_BC_EL1_HSPD_RG

electrode1highspeed(regulator)

B
B

0>1

1=true

00

DBX102.0
7

DBX103.0
0

DBX103.0
1

DBX103.0
2

DBX103.0
3

DBX103.0
4

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HiREG PLC Interface (4)

DB 156

From Furnace PLC

DBX108.00

INTF_BC_ARC_INT_CMD

furnacebreakerarcinterruption
(command)

B
B

0>1

1=true

00

DBX108.01

INTF_BC_BRK_CLS_STA

furnacebreakerclosed(status)

B
B

0>1

1=true

00

DBX108.02

INTF_BC_BRK_OPN_CMD

furnacebreakeropeningrequest(command)

B
B

0>1

1=true

00

DBX108.03

INTF_BC_CLAMPS

electrodesclampsmode

B
B

0>1

1=true

00

DBX108.04

INTF_BC_MAINT

Furnaceinmaintenancemode

B
B

0>1

1=true

00

DBX108.05

INTF_BC_HEAT_END

FurnaceHeatEnd

B
B

0>1

1=true

00

DBX108.06

INTF_BC_BCK_END

FurnaceBucketEnd

B
B

0>1

1=true

00

DBX110.00

INTF_BC_RCT_AUTO

Saturablereactorautomaticmode

B
B

0>1

1=true

31

DBX110.01

INTF_BC_RCT_RUN

Saturablereactorisrunning

B
B

0>1

1=true

31

DBX110.02

INTF_BC_RCT_BYP

Saturablereactorisbypassed

B
B

0>1

1=true

31

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HiREG PLC Interface (5)

From Furnace PLC

DB 156

DBW112

INTF_WC_PRIM_VLT

primaryvoltage

IN

050.00

kV

05000

0
0

DBW114

DBW116

DBW118

INTF_WC_TAP_POS_RG

tapchangerposition

IN

132

132

0
0

DBW120

INTF_WC_CUR_SET_RG

currentcurveposition(SET)

IN

16

16

0
0

DBW122

INTF_WC_RCT_POS

reactorposition

IN

16

16

0
0

DBW124

INTF_WC_ACT_PWR

Activepower

IN

01000.0

MW

010000

0
0

DBW126

INTF_WC_RCT_PWR

Reactivepower

IN

01000.0

MVA
R

010000

0
0

DBW128

INTF_WC_COSPHY

Cosphy

IN

01.000

01000

0
0

DBW142

INTF_BC_RCT_CUR_TRG_MA
N

Saturablereactortargetcurrentin
manualmode

IN

01650.0

016500

3
1

DBW144

INTF_BC_RCT_CUR_ACT

Saturablereactorrealcurrent

IN

01650.0

016500

3
1

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HIREG OWS

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HiREG Communication Overview

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HiREG Communication settings

DPI
CONFIGURATOR

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HIREG OWS PARAMETERS

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HiREG Electrical Parameters (1)

Reference document:

Admittance Table

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HiREG Transformer Table (1)

Transformer Primary side connection

Important: Electrode line

current

CT Settings

KI-KA Automatic
calculation

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HiREG Transformer Table (2)

KI
KA

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HiREG Regulation Parameters

Regulation
Valve settings

Additional
Settings
V/I presence

PI Regulator
settings

Notch Filter
Settings

Touch Down
Settings

Electrode
Speed settings

Boring phase
Settings

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HiREG Regulation Parameters

Phase Balance
PHASE 1

PHASE 2

PHASE 3

PHASE BALANCE

CURRENT

ARC LENGHT

PHASE BALANCE

0,9

CURRENT

1+

ARC LENGHT

PHASE BALANCE

0,9

0,9

CURRENT

1+ 1

1+ 2

(-1 + 2)

(-1 2)

(+1 2)

ARC LENGHT

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HiREG Linearization (1)

SPEED RESPONSE CP=680 PSI

400

EL2

EL1

300
200

speed [mm/s]

Sequence:
1. Zero Valve
2. BIAS 1 mm/s
3. Linearization

EL3

100
0
-10000

-6000

-2000
-100

2000

6000

10000

reference [mV]

-200
-300

Automatic cycle

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HiREG Regulation Parameters NLG

Gain increase in case of cave-in

Maintain symmetric
system response

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HiREG Plant Parameters

Typical Measuring setting: pay attention to the correct value

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HiREG Counter Pressure

Pressure control :
Counter pressure set ~80% Pb= Pcp Down Speed ~200mm/s (Pb: Pressure
balance)
Accumulator set ~65% Pcp
Backpressure

Backpressure
Trend

Set Points

Valve
Parameters

Alarms

Line pressure
Trends

Line Pressure
alarms

Switching
Settings
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HiREG Communication settings

DB MidddleWare
Location

Dispatcher
settings

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HiREG Reference documentation

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

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