� TECHNOLOGY �
goal was to optimize processes, increase production capacity, and enhance energy efficiency.
Key areas for improvement
The modernization project, which began in February 2021 and concluded in December 2022, focused on upgrading the bar mill’ s automation and control systems to boost efficiency and reliability. ABB replaced the obsolete Rolling Mill Controller( RMC) and S100 technology I / O with the more advanced AC 800PEC controllers and fast I / O XF801s.
Why are these upgrades important to Tata Steel’ s production? In essence, the new controllers allow for greater precision in controlling the speed, tension, and timing of steel production processes. This level of accuracy is vital because bar mills operate at extremely high speeds, where even small errors can lead to defects, wasted material, or machine wear and tear. By implementing more responsive and faster control systems, Tata Steel can ensure that every stage of the production process is optimized. This results in smoother operations, fewer production delays, and an increase in both output quality and quantity.
In particular, the new system allows for faster detection and resolution of issues, significantly reducing downtime. The improved diagnostic capabilities help operators quickly identify faults and take corrective action, enhancing overall efficiency. This ensures that Tata Steel can meet increasing market demand while maintaining consistent, highquality production standards, ultimately helping the company stay competitive in a rapidly growing sector.
A unified approach
One of the critical success factors of the project was the strong, longstanding collaboration between Tata Steel and ABB. This deep-rooted relationship allowed both teams to work closely together throughout the project, navigate challenges and deliver the desired results.
ABB’ s involvement extended well beyond the completion of the modernization project, demonstrating its commitment to long-term support and continuous improvement. As a trusted partner, ABB continues to provide remote monitoring and diagnostic services to Tata Steel, ensuring that the bar mill operates at peak performance. Leveraging its expertise in automation and control systems, ABB offers comprehensive support in identifying and resolving operational challenges, such as cobbles— defects that can occur during the steel rolling process.
With the introduction of the new controllers and I / Os, ABB can remotely analyze system data to detect anomalies and inefficiencies in real time. This proactive approach enables ABB to pinpoint the root causes of issues quickly and recommend optimized solutions, reducing downtime and minimizing the risk of production interruptions.
Results
The modernization project delivered significant, quantifiable improvements across key performance indicators( KPIs). Tata Steel achieved a doubledigit increase in productivity and equipment availability. This growth was driven by ABB’ s precision length optimization, improvements in the rotary entry system( RES) and selfadaptive shear control systems, all of which worked together to streamline operations and boost output.
Programmable logic controllers( PLC) related delays saw equally substantial improvements, with a reduction of almost 70 %. Additionally, the upgrade resolved concerns with the obsolete Advant AC450 PLC, ensuring seamless operations moving forward. By minimizing downtime, ABB’ s solutions allowed Tata Steel to maximize operational efficiency and meet the growing demand in the Indian market more effectively.
18 Green Steel World | Issue 17 | April 2025