Wayfinding System at Germany’s Largest Steel Mill
At Oxygen Steel Plant 2, one of Germany’s largest steel producers, the existing automation infrastructure was to be comprehensively modernized and made future-proof. The challenge was to gradually replace existing TELEPERM-M and S5 controllers with modern PCS-7 technology without disrupting production processes. Due to the size and complexity of the plant, existing functions had to be retained, numerous process improvements integrated, and, at the same time, the highest standards for plant availability, data security, and production quality met. Modernization while the plant remained in operation was of particular importance, as even brief interruptions would have had a significant impact on steel production.
gefeba, in collaboration with ThyssenKrupp Steel, implemented the phased migration to a modern PCS-7 control system architecture. All modules and faceplates were developed in close cooperation and optimally tailored to the steel mill’s requirements. Redundant data distributors and modern telegram tools were used for communication with the process computers. In addition, frequency converters, power converters, and transducers were fully integrated into the central engineering system, allowing parameterization and diagnostics to be performed directly from the control system. The entire weighing and dosing system was also upgraded. Another key focus was on batch-based data acquisition. Measurement values and messages are not only archived chronologically but are also directly assigned to individual production batches and can be easily evaluated and exported. Prior to commissioning, the entire automation software was tested at the gefeba Simulation Center using the Siemens SIMIT tool. Under realistic conditions, interlocks, control systems, switching operations, and protective functions were comprehensively tested and optimized.
The successful retrofit resulted in a high-performance, future-proof control system that creates optimal conditions for further production optimization. The extensive simulations enabled a virtually error-free commissioning and reduced conversion and downtime to a minimum. At the same time, the operating personnel received intensive training during the simulation phase, ensuring a smooth transition to production operations. The new automation system improves process efficiency, increases plant availability, and ensures that Germany’s largest steel mill will continue to meet the highest standards for productivity, transparency, and operational safety in the future.
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