www.avtronautomation.com

Metals Industry Solutions

Metals Industry Solutions

Ferrous and non-ferrousInitial startup to predictive maintenence repairsSupport by phone 24/7 or onsite in hoursHigh performance drives to complete process automation

Driving Productivity.

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Profit from Avtron’s Experience The Avtron Metals Team serves the global metals industry by working directly with mills and mill equipment builders to improve productivity in new and existing facilities. Whether the project is a line upgrade with high performance drives or installation of a complete process automation system, Avtron can handle the project – regardless of who made the original equipment. Since 1953, we have been helping worldwide industry solve productivity problems and reduce costs with innovative drive systems and related automation products.

With decades of experience as the manufacturer and systems integrator of Westinghouse metals industry drives, Avtron is uniquely qualified to supply process line drive and automation solutions. We designed the first Digital Front End (DFE) for drive systems, and custom electronics for industry leaders such as GE and Reliance Electric. We form close partnerships with mill builders to understand their mechanical designs and how best to control them. Our advanced electrical drive technology complements their technology.

Boosting Productivity — Reducing Costs

Aging and overworked mill equipment causes low throughput and breakdowns that are much too frequent. The resulting maintenance costs are bad enough, but they are only the tip of the iceberg compared to lost revenue and profits due to poor product quality, increasing downtime, and reduced output.

Added to these headaches are difficulties in getting parts and mill equipment serviced because the original manufacturers may no long make that equipment or supply parts for it. Even when parts are available, technical data and service personnel may not be available from that OEM. Struggling with a repair, upgrade, or retrofit because of poor support will extend downtime all the more.

Driving Performance

Front to Back Mill Experience

The Avtron Metals Team has automation and drive equipment experience in all areas of a mill, from melt shop to hot and cold rolling. We provide an American-made option for high performance drives and sophisticated process equipment. From single-stand to multi-stand continuous tandem rolling mills, we supply electric drives, process diagnostic monitoring systems, and other process automation equipment that improve productivity and quality in the finished product. For example:

PLC-based HGC & AGC regulates the thickness of the strip

Shape and flatness controls optimize strip quality

Custom rolling models improve surface quality and yields during product changes

Roll eccentricity compensation results in unparallel performance

In close cooperation with globaly based mill builders, Avtron has supplied some of the largest DC bridges for revamping rolling mills in the industry. Our system architecture emphasizes off-the-shelf products that seamlessly integrate with existing plant systems. We supply replacements and upgrades for all the major OEMs, including: Obsolete GE drive systems such as the Silcomatic, Silco, Siltrol, and DC2000 Drives Retrofits for Reliance drive systems such as the MaxLine, MaxPak, and AutoMAX™ system Upgrades for other drive equipment, including Ansaldo, Westinghouse, Siemens, and ABB

Avtron’s system solutions have proven we are the uptime and performance experts in North American and Asian mills. Generally, the system architecture uses “off the shelf” products that seamlessly integrate with existing plant systems. Our “Limited System” upgrades are cost-effective, easy to install, and designed for zero downtime. They can get a mill operating at peak performance for a fraction of the cost of an all-new system.

We Supply Productivity

Today, Avtron offers a comprehensive range of automation products, systems, and services for new and existing mills – ferrous and non-ferrous:

Turnkey Installations

Level 1 and 2 Automation Systems

System Engineering/PLCs/HMIs

Mechanical Mill Modifications

Digital DC and AC Drives and Systems

Field and Factory Service and Training

To supply the right solution, our engineers dig deeply into underlying issues that destroy productivity, such as downtime, maintenance, product quality, throughput, safety, control, and lack of flexibility. Avtron engineers work with you to answer the tough questions:

What equipment can be kept and what really needs to be replaced? How can we upgrade or replace equipment with minimum disruption? Should we install a digital retrofit or an entirely new drive? Which will be the most cost effective, an AC or DC drive?

By answering questions like these, we quote exactly what’s needed for the best results. But that’s only the beginning; our experienced project managers work hard to ensure the successful implementation of every mill project – on time and on budget. They will be deeply involved with scheduling, engineering, manufacturing, coordinating product shipments, creating documentation, and training. During installation and commissioning, they help expedite startup by making sure integration testing is coordinated, and that installation and supervisory personnel are familiar with the system’s operation.

Metals Industry Solutions

Avtron can get mill operation back to peak performance.

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Iron & SteelProduction

Flat ProductsHot Rolling

Flat ProductsCold Rolling

Flat ProductsCold Finishing

Long ProductsRolling

• Blast Furnace Skip Hoist

• BOF & BOP Vessel Tilt

• Slab, Billet, and Bloom Casters

• Blooming Mills

• Hot Strip Mills

• Steckel Mills

• Plate Mills

• Pickle Lines

• Reversing Mills

• Tandem Mills

• Skin Pass/ Temper Mills

• Leveling Lines

• Coating Lines

• Slitting Lines

• Cut-to-Length Lines

• Merchant Mills

• Bar and Rod Mills

• Tube Mills

Keep output rolling even in the face of aging or overworked equipment.

Avtron improves line control and diagnostics.

Avtron Systems with Powerful Diagnostics

Avtron provides superior product quality and systems of unparalleled reliability, with the engineering capacity to design the system best suited for your application. The biggest gains in productivity and finished product quality are often attributed to the automation system. Avtron PV (Performance View) automatically records events, status bits, drive values, and PLC data from the controllers on the process line.

Avtron’s PV can collect 768 analog inputs and 9728 logic inputs with up to 10ms resolution. Coupled with a large number of inputs, this increases the likelihood of catching the fault the first time it occurs. PV software then makes it easy to reduce this data to useful information, rapidly isolating the problem and pointing to its solution.

wiring. It also allows you to upgrade all or part of a drive system – as it fits your mill schedule and budget. By upgrading a mill in sections, it’s possible to complete an upgrade in a few hours of regularly scheduled maintenance downtime. Along with its DFE, Avtron supplies firing modules, transformers, and field wiring as needed for upgrades. Its Advanced Motor-Generator Set Controller (AMG) delivers process performance improvements worthy of a completely new drive system.

Avtron also has extensive experience upgrading M-G sets. We provide digital solutions for motor and generator field power supplies up to 510A DC. The forcing algorithms in our regulator allow performance close to static drives. For series and parallel M-G set applications, we supply automatic load sharing and other advanced controls.

Metals Industry Solutions

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High-Productivity Processing Lines

For treating and conditioning cold rolled aluminum and flat steel products, Avtron supplies the latest drive and control technologies for processes such as pickling, annealing, skin passing, galvanizing and color coating. To meet the productivity and quality demands on these lines, Avtron designs its high-performance drives and controls in a way that enables operators to supervise complex processes efficiently and control an entire inline operation. Avtron systems feature:

Ergonomically designed Human-Machine Interfaces (HMIs) that increase operator efficiency Temperature control systems for continuous lines that regulate the structure of a strip Dynamic drives and AC motors that reduce maintenance and improve uptime High-speed process control platforms for optimum control

Drives and Automation

Avtron has been a pioneer in developing drives, motors, and controls for all kinds of mill processes, applying these products on both new projects and line upgrades. In addition to our drive manufacturing expertise, from fractional kW to MW sizes, our application engineers have a deep understanding of the effects that motors and driven equipment have on each other. This allows us to engineer controls for the best throughput, while avoiding the kind of drive operation that leads to maintenance problems and downtime.

For instance, Avtron’s Digital Front End (DFE) controller provides distributed control functionality for optimum performance and cost-savings in mill upgrades. This DFE design generally allows you to retain existing motors, generators, and/or SCR power converters and field

Inefficient operations and troubleshooting?

Process Automation System

Quick problem- solving keeps Avtron customers coming back.

The reasons Avtron is a preferred provider of drive systems and process automation are many. We consistently deliver robust designs, supported by the engineers who created them, and backed by the best field service in the industry. Avtron’s ISO 9001-certified project management, engineering, and commissioning service teams provide assistance throughout each phase of a project.

In addition to talented design engineers, a dedicated full-time Customer Support Engineering Department is available to help customers maximize the use of their Avtron equipment. We maintain a 24/7 toll-free emergency hotline, allowing many technical problems to be resolved by phone. If on-site service is required, our technical coordinators quickly dispatch field service engineers and parts as required from the nearest location. Furthermore, we maintain a strategically located warehouse with an extensive inventory of spares. In addition, many products and components are available within our large network of distributors.

Avtron PV’s built-in teleservice feature connects our engineering and service centers via modem or VPN to your installation, making our concentrated resources available to your staff. This allows easier and faster troubleshooting and repair of a problem. It can also be used to establish “normal running conditions” as part of a Preventive or Predictive Maintenance Program.

Metals Industry Solutions

Beyond service and support, service contracts are available, which can be customized and created at the time your Avtron equipment or automation system is purchased. Service contracts can also be developed at any time during the life of your system. Under these contracts, Avtron engineers and service experts can provide:

Retrofits/Modernization Engineering Commissioning/Startup Training Inspection/Evaluation Predictive/Preventive Maintenance Power Quality Studies Transient Analysis Testing Repair Spare Parts Automation Program Revision Services

Program revision services provide software support on a contract basis to customers who have purchased automation systems from Avtron. This service allows customers to update their software with new algorithms and process routines as conditions change on the plant floor.

Downtime eatingup your profits?

Industry-Best Service and Support

Surveys consistently show that Avtron’s world-class service is a major reason customers keep coming back for solutions to their drive and automation problems. “Most important criteria are reliability, service, and cost; Avtron has been great at all of these.” “Avtron has very good products, product knowledge, and their service is great.” “These are very smart guys at Avtron and they always help us out.” “Other companies want to start charging us the minute we need support; Avtron is more interested in helping us out.” “High quality products, good service, and cost.” “Good service and I’m impressed with what I’ve learned about Avtron drive capabilities.”

We’ll be your partner for driving performance.

Metals Industry Solutions

For world class drive systems, process automation, and unmatched service, call on the Avtron Metals Team:

7900 East Pleasant Valley Road, Cleveland, Ohio 44131Telephone: 216-642-1230Email: metals@avtron.comOr visit our website at www.avtronautomation.com

For world class drive systems, process automation, and unmatched service, call on the Avtron Metals Team:

7900 E. Pleasant Valley Road, Cleveland, OH 44131Telephone: (216) 642-1230Email: metals@avtron.comwww.avtronautomation.com

For valuable reference information, request our Metals Industry Solutions CD