Synopsis of Reheat Furnace Packaged Control Room (PCR)

Situation: In 2008, a leading Canadian steel maker looked to expand capacity by purchasing a reheat furnace from a European OEM. The reheat furnace was sold as a complete package that included the furnace plus all associated electrical and mechanical controls. Challenges Facing the European OEM: The steel maker’s requirement for their reheat furnace automation and control system to meet Canadian Standards Association (CSA) certification The steel maker’s requirement for their reheat furnace automation and control system to meet compliance with the province of Alberta’s electrical codes Requirements for the hardware design to meet NEMA standards as opposed to IEC standards Delivery issues - How to lower the high costs associated with shipping from the OEM’s point of origin (Europe)? How to deliver the equipment within a stringent 7-month delivery time frame? OEM Requirement: A North American supplier for the project’s electrical controls and related hardware. The Choice: Brock Solutions was contracted to produce the hardware design, procure required hardware, and develop, test, and ship the hardware system.

Value Solution — Modular PCR Design and Pre-Installed and Fully Tested Controls: Brock applied a modular approach to the project by using a standard ISO-rated commercial container as the foundation for the PCR as opposed to providing a custom built electrical control room modified to meet customer specifications. The PCR container measures 40’ x 8’ x 8’, and was configured to support the installation of various electrical power and control panels, including Main Disconnect Panels, PLC Control Panels, Combustion Control Panels, Motor Control Cabinets (MCCs), and Relay Control Panels.

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