Turbo compressor for a blast furnace
Gefeba was commissioned by Hüttenwerke Krupp Mannesmann GmbH to comprehensively modernize the automation and process control systems of an axial compressor with a booster compressor used to supply cold air to two blast furnaces. The existing system was based on ABB Freelance 2000 and Siemens S5 controllers and was to be completely migrated to a modern, high-availability PCS 7 S7-410-5H architecture. Particularly challenging was the implementation of a safe pump prevention control system as well as a multi-stage pump protection system to reliably protect the compressor even in the event of malfunctions. This system was to be fully integrated into the control system. In addition, all components of the control and network structure had to be designed with redundancy to ensure maximum availability in high-performance industrial operations.
Gefeba modernized the entire automation and process control system of the turbo compressor and also replaced all control cabinets for auxiliary units as well as the monitoring devices in the periphery of the electric blower. The entire solution was developed to be fully PCS-7-compliant. This marked the first time the customer utilized Control Module Types (CMT), for which gefeba developed a new master data library. Machine controllers, pump protection, and pump prevention were implemented in accordance with standards and equipped with custom screens following the APL style guide. Modern Advanced Process Graphics (APG), such as bar graphs and spider charts, were used for process visualization. In addition, gefeba integrated a comprehensive vibration and misalignment measurement system based on a Bently Nevada unit and developed its own interface modules for seamless Modbus connectivity to PCS 7. All control system components, as well as the Profinet IO system, were designed with redundancy. To ensure emergency operation without a central control system, essential functions were additionally implemented in SIMOCODE Pro, guaranteeing a controlled shutdown of the compressor even in the event of a complete control system failure.
The comprehensive modernization resulted in a highly available and future-oriented automation solution for industrial blast furnace operations. The new software, based on the PCS7 standard, enables safe, stable, and transparent process control while ensuring a high level of operational reliability. Thanks to redundant control and network structures as well as intelligent protection mechanisms, plant availability has been sustainably increased. At the same time, modern visualization solutions and customized software structures ensure intuitive operation and efficient process monitoring.
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We develop customized solutions—from analysis through the engineering phase to commissioning and support. Our focus is on maximum functionality, on-time delivery, and durability.
Our project work is supported by collaborations with leading technology partners such as Siemens, Rittal, B&R, and Proxmox, which provide the technological foundation for our project results and help expand them.
