The Challenge: Brock Solutions was contracted by a prominent OEM to supply a
control system for three new clay guns to be installed in a Blast
Furnace of a large United States steel producer.
Three existing clay guns were to be replaced with three new
higher capacity clay guns. The new guns can inject 300% more clay with
more pressure applied during the injection process thus providing deeper
plugs. With more clay injected in the taphole, the refractory lining is
better protected resulting in reduced repairs to the furnace lining.
The Solution:
Brock Solutions supplied a complete hardware and software solution to
perform the exact sequencing and timing needed for the clay gun to find
the taphole opening and plugging the taphole. This operation is crucial
to prolong the life of the nozzle and avoid clay spillage into the trough.
As well as the control and coordination of the consistency was achieved
in terms of the amount of clay pushed into the taphole.
The customer required an Allen-Bradley PLC & HMI for the controls and
a Square ‘D’ MCC as part of their plant standard. Brock supplied a
fully self contained Electrical Control Room and three new control desks.
The Results:
- Repeatable results and Minimized operator error
- Reduced repairs resulting in a continuous maintenance savings
- Improved reliability against equipment failure
- Significantly increased flexibility in equipment operations.
The equipment can be operated from three different locations
- Enhanced troubleshooting capabilities by providing in depth status of:
equipment, operation, maintenance and safety thus reducing downtime
- A fully wired and tested power control room minimized simplified
overall installation and commissioning time and cost
Complete system simulation resulted in faster start-up and an asset tool
for maintenance and operator personnel training. Start-up went as planned and
within given timeframe resulting in no production delays.
