{"id":6473,"date":"2021-08-04T22:45:19","date_gmt":"2021-08-04T20:45:19","guid":{"rendered":"https:\/\/onload.reinhausen.com\/de\/?p=6473"},"modified":"2023-05-30T17:49:16","modified_gmt":"2023-05-30T15:49:16","slug":"digital-steel","status":"publish","type":"post","link":"https:\/\/onload.reinhausen.com\/en\/06-2021\/digital-steel\/","title":{"rendered":"Digital Steel"},"content":{"rendered":"
\n

D<\/span>aniele Giro would love it if his trans\u00adform\u00aders could talk to him. They could tell him on their own when they are break ing down or need main\u00adte\u00adnance. Any out\u00adage wears on his nerves and costs his employ\u00ader a for\u00adtune. With\u00adout pow\u00ader, the pro\u00adduc\u00adtion of Accaierie Bertoli Safau (ABS) is at a stand\u00adstill. The loss\u00ades are gigan\u00adtic in this case: Every hour, the two elec\u00adtric arc fur\u00adnaces in the steel\u00adworks near the north\u00adern Ital\u00adian city of Udine melt around 200 tons of scrap met\u00adal down into valu\u00adable spe\u00adcial steel for the auto\u00admo\u00adtive indus\u00adtry, the rail\u00adway or for gas pipelines.
\n<\/p>\n

\n
<\/div>

Daniele Giro, head of high and medi\u00adum volt\u00adage dis\u00adtri\u00adb\u00adu\u00adtion, can check the sta\u00adtus of the trans\u00adformer direct\u00adly from his con\u00adtrol room.<\/p><\/div>\n

<\/div>

A total of nine trans\u00adform\u00aders keep the volt\u00adage sta\u00adble at the ABS plant.<\/p><\/div>\n<\/div>\n

Mea\u00adsured by aver\u00adage price per ton, this means that sev\u00ader\u00adal tens of thou\u00adsands of euros per hour would quick\u00adly go down the drain for the com\u00adpa\u00adny. \u201cIf you con\u00adsid\u00ader that it some\u00adtimes takes sev\u00ader\u00adal days for a defec\u00adtive trans\u00adformer to get up and run\u00adning again, you can image how great the loss is,\u201d says Giro. As the head of high and medi\u00adum volt\u00adage divi\u00adsion, he is respon\u00adsi\u00adble for keep\u00ading the plant grid, with nine big oil trans\u00adform\u00aders and around 30 MV elec\u00adtri\u00adcal rooms, sta\u00adble and fail\u00adure-free.<\/p>\n

This is no easy task\u2014ABS alone con\u00adsumes approx\u00adi\u00admate\u00adly the same amount of ener\u00adgy as the ein\u00adtre city of Udine with its 100,000 inhab\u00adi\u00adtants. This is pri\u00admar\u00adi\u00adly due to the two elec\u00adtric arc fur\u00adnaces, the core of the steel\u00adworks. They func\u00adtion like an over\u00adsized weld\u00ading unit. Inside the melt\u00ading pot, there are elec\u00adtrodes made of graphite through which thou\u00adsands of amperes pass. This caus\u00ades elec\u00adtric arcs between the elec\u00adtrodes that increase the tem\u00adper\u00ada\u00adture to more than 2,000 degrees Cel\u00adsius. This makes it pos\u00adsi\u00adble to melt hun\u00addreds of tons of scrap steel in one \ufb01lling every hour. \u201cWe basi\u00adcal\u00adly recy\u00adcle the mate\u00adr\u00adi\u00adal and give the scrap met\u00adal new life,\u201d says Giro.<\/p>\n

\n
\n
ACCAIERIE BERTOLI SAFAU S.P.A.<\/h5>\n
\n

The com\u00adpa\u00adny was found\u00aded in 1988 from the fusion of the two steel\u00adworks \u201cOfficine Bertoli\u201d, found\u00aded in 1813, and \u201cSAFAU\u201d, found\u00aded in 1934.<\/a> The com\u00adpa\u00adny is part of the Danieli Group and today employs around 1,000 work\u00aders at the two pro\u00adduc\u00adtion loca\u00adtions in Car\u00adgnac\u00adco in Udine province and Sisak in Croa\u00adt\u00adia. It also has its own research cen\u00adter in Metz, France.<\/p>\n<\/div>\n<\/div>\n

The plant gets the ener\u00adgy need\u00aded for this over a high-volt\u00adage line. Two step down trans for\u00adm\u00aders \ufb01rst reg\u00adu\u00adlate the volt\u00adage from 230 kilo\u00advolts to 21 kilo\u00advolts, which reach the pro\u00adduc\u00adtion sys\u00adtems via the plant\u2019s inter\u00adnal grid. Four pow\u00ader trans\u00adform\u00aders are used for the elec\u00adtric arc fur\u00adnaces alone. They have the tough est job. With around 200,000 tap-change oper\u00ada\u00adtions per year, the on-load tap-chang\u00aders switch more fre\u00adquent\u00adly than many sim\u00adi\u00adlar units in a typ\u00adi\u00adcal pri\u00adma\u00adry sub\u00adsta\u00adtion do in their entire ser\u00advice lives. Three addi\u00adtion\u00adal trans\u00adform\u00aders are respon\u00adsi\u00adble for the sup\u00adply of the remain\u00ading sys\u00adtems, such as the rolling mills.<\/p>\n

HOPE IS NOT ENOUGH<\/h2>\n

Giro and his two co-work\u00aders have their hands full with keep\u00ading the tech\u00adnol\u00ado\u00adgy run\u00adning in this harsh envi\u00adron\u00adment. \u201cIt would be best if we could make a sys\u00adtem where inter\u00adrup\u00adtions nev\u00ader hap\u00adpen. While that is just a dream, we are doing what we can to get close to this ide\u00adal.\u201d Since Giro start\u00aded at ABS six years ago, he has con\u00adstant\u00adly been look\u00ading for solu\u00adtions to bet\u00adter mon\u00adi\u00adtor his trans\u00adformer \ufb02eet. Cur\u00adrent\u00adly, he has only had two peri\u00adods for year in which he is able to thor\u00adough\u00adly check the trans\u00adform\u00aders and per form main\u00adte\u00adnance work: dur\u00ading three weeks of sum\u00admer down\u00adtime in August and two dur\u00ading win\u00adter down\u00adtime over the Christ\u00admas hol\u00adi\u00addays.<\/p>\n

\u201cI would like to have a sys\u00adtem that allows me to check the con\u00addi\u00adtion of my trans\u00adform\u00aders at any time through\u00adout the year.\u201d Daniele Giro,Head of high and medi\u00adum volt\u00adage divi\u00adsion, ABS<\/cite><\/p><\/blockquote>\n

But what hap\u00adpens between these two peri\u00adods? Giro has only been able to hope that the main\u00adte\u00adnance work has been enough and every\u00adthing runs well. Actu\u00adal\u00adly, that wasn\u2019t enough for him. \u201c I would like to have a sys\u00adtem that allows me to check the con\u00addi\u00adtion of my trans\u00adform\u00aders at any time through\u00adout the year.\u201d The vis\u00adit two years ago by Ste\u00adfano Vig\u00adnali, Area Sales Man\u00adag\u00ader at Rein\u00adhausen Italia, was oppor\u00adtune. The two com\u00adpa\u00adnies have had a long\u00adstand\u00ading relationship\u2014on-load tap-chang\u00aders from Maschi\u00adnen\u00adfab\u00adrik Rein\u00adhausen are in- stalled in all trans\u00adform\u00aders at ABS, and the reg\u00adu\u00adlar ser\u00advice work by MR-tech\u00adni\u00adcians leads to active dis\u00adcourse. Vig\u00adnali had come to intro\u00adduce the ETOS\u00ae automa\u00adtion solu\u00adtion (see box).<\/p>\n

The elec\u00adtric arc fur\u00adnaces in the steel\u00adworks con\u00adsume as much elec\u00adtric\u00adi\u00adty as an entire city.<\/figcaption><\/figure>\n

The open oper\u00adat\u00ading sys\u00adtem makes it pos\u00adsi\u00adble to mon\u00adi\u00adtor, con\u00adtrol and reg\u00adu\u00adlate pow\u00ader trans\u00adform\u00aders. \u201cThe sys\u00adtem has a mod\u00adu\u00adlar struc\u00adture, so the users can decide for them\u00adselves which com\u00adpo\u00adnents of the trans\u00adformer they want to mon\u00adi\u00adtor. Sub\u00adse\u00adquent instal\u00adla\u00adtions are also pos\u00adsi\u00adble,\u201d explains the Rein\u00adhausen expert. For exam\u00adple, this can include mon\u00adi\u00adtor\u00ading the bush\u00adings and the transformer\u2019s oil or the intel\u00adli\u00adgent con\u00adtrol of cool\u00ading sys\u00adtems. For Vig\u00adnali, it is clear that ETOS\u00ae cre\u00adates more secu\u00adri\u00adty. \u201cIn steel\u00adworks, cement plants or any fac\u00adto\u00adries that have a pow\u00ader trans\u00adformer, mon\u00adi\u00adtor\u00ading is extreme\u00adly impor\u00adtant. I know of com\u00adpa\u00adnies that just have one trans\u00adformer \u2014 when it fails, all pro\u00adduc\u00adtion goes down.\u201d<\/p>\n

TOILING IN THE HEAT<\/h2>\n

Giro was primed to accept this sug\u00adges\u00adtion. The ABS phi\u00adlos\u00ado\u00adphy is to always invest in new tech\u00adnolo\u00adgies. As a mem\u00adber of the Danieli Group, a lead\u00ading plant man\u00adu\u00adfac\u00adtur\u00ader for the met\u00adal\u00adlur\u00adgi\u00adcal indus\u00adtry, ABS has the option to try out tech\u00adnol\u00ado\u00adgy that is not yet on the mar\u00adket. \u201cExper\u00adi\u00adment\u00ading is impor\u00adtant,\u201d says Giro. He did not shy away from exper\u00adi\u00adment\u00ading, even with his most impor\u00adtant pieces of equip\u00adment. Still, he played it safe at \ufb01rst. To learn more about ETOS\u00ae, Giro decid\u00aded to use it ini\u00adtial\u00adly on two trans-for\u00adm\u00aders and with all avail\u00adable modules\u2014because if it\u2019s worth doing, then it\u2019s worth doing right. One was a trans\u00adformer that has already been in oper\u00ada\u00adtion for sev\u00ader\u00adal years; the oth\u00ader was a brand new one which ABS com\u00admis\u00adsioned from an Ital\u00adian trans\u00adformer man\u00adu\u00adfac\u00adtur\u00ader.<\/p>\n

\u201cThe infor\u00adma\u00adtion col\u00adlect\u00aded by the sys\u00adtem is huge\u00adly impor\u00adtant for us. For the first time, we have the option of track\u00ading the con\u00addi\u00adtion in real time and are also learn\u00ading more about the trans\u00adformer.\u201d Daniele Giro, Head of high and medi\u00adum volt\u00adage divi\u00adsion, ABS<\/cite><\/p><\/blockquote>\n

The retro\ufb01t on the exist\u00ading trans\u00adformer was per\u00adformed dur\u00ading the down\u00adtime in August 2020. In mug\u00adgy heat with tem\u00adper\u00ada\u00adtures of 39 degrees Cel\u00adsius, the Rein\u00adhausen tech\u00adni\u00adcians worked, attach\u00ading the pre\u00adcon\ufb01gured ETOS\u00ae con\u00adtrol cab\u00adi\u00adnet to the trans\u00adformer, wiring the sen\u00adsors and \ufb01nal\u00adly check\u00ading every\u00adthing for func\u00adtion. The work began on a Mon\u00adday and was \ufb01nished on Fri\u00adday.<\/p>\n

MORE INFORMATION, MORE CONTROL<\/h2>\n

Since then, Giro has tak\u00aden a sig\u00adni\ufb01\u00adcant step toward his wish for a talk\u00ading trans\u00adformer. He can trace what is occur\u00adring with\u00adin the trans\u00adformer in detail on his screen in the con\u00adtrol room. In prin\u00adci\u00adple, Giro could even access the con\u00addi\u00adtion data from any com\u00adput\u00ader in the plant. This is made pos\u00adsi\u00adble by the inte\u00adgrat\u00aded web serv\u00ader in the cen\u00adtral pro\u00adcess\u00ading unit in the ETOS\u00ae con\u00adtrol cab\u00adi\u00adnet. Giro can read the tem\u00adper\u00ada\u00adture in the wind\u00adings, learn more about the qual\u00adi\u00adty of the oil and, of course, con\u00adtrol the on-load tap-chang\u00ader from any\u00adwhere. In addi\u00adtion to the options for mon\u00adi\u00adtor\u00ading, ETOS\u00ae also makes intel\u00adli\u00adgent con\u00adtrol of the trans\u00adform\u00aders possible\u2014such as the on-load tap- chang\u00ader or the cool\u00ading fans.<\/p>\n

Daniele Giro plans to dig\u00adi\u00adtize all of the trans\u00adform\u00aders on a grad\u00adual basis.<\/figcaption><\/figure>\n

This enables more ef\ufb01\u00adcient oper\u00ada\u00adtion, and thus ener\u00adgy sav\u00adings. \u201cThe infor\u00adma\u00adtion col\u00adlect\u00aded by the sys\u00adtem is huge\u00adly impor\u00adtant for us. For the \ufb01rst time, we have the option of track\u00ading the con\u00addi\u00adtion in real time and are also learn\u00ading more about the trans\u00adformer. Now, we know how it responds to cer\u00adtain events in oper\u00ada\u00adtion. We are still at the begin\u00adning, but I sus\u00adpect that the sig\u00adni\ufb01\u00adcant\u00adly improved data sit\u00adu\u00ada\u00adtion gives us a much bet\u00adter basis for deci\u00adsion-mak\u00ading and we will be able to plan bet\u00adter. We have tak\u00aden the \ufb01rst step.\u201d He does not want to lose too much time on the next steps. In the next three years, the automa\u00adtion of the oth\u00ader trans\u00adform\u00aders is set to progress rapid\u00adly.<\/p>\n

\n
\n
REINHAUSEN INSIDE<\/h5>\n
\n

ETOS \u00ae \u2013 the Embed\u00added Trans\u00adformer Oper\u00adat\u00ading Sys\u00adtem \u2013 is an open, mod\u00adu\u00adlar sys\u00adtem solu\u00adtion for mon\u00adi\u00adtor\u00ading, con\u00adtrol\u00adling and reg\u00adu\u00adlat\u00ading pow\u00ader trans\u00adform\u00aders. <\/a> There are six func\u00adtion pack\u00adages to choose from depend\u00ading on the mon\u00adi\u00adtor\u00ading require\u00adments.<\/p>\n