Steel & Heavy Manufacturing

Fulfill product demand while reducing downtime and production costs

Steel & Heavy Manufacturing Industry Expertise

Secure, maintain, and sustain.

By combining practical applications of technology advancements with quality management and personnel safety, you can gain an accurate understanding of your operations and meet regulatory compliance.

Our Team offers the following capabilities and experience in the Steel & Heavy Manufacturing industry:

Legacy Control System migrations, upgrades & modifications
Control System Integration
Process Control Design & Automation
Sequential Logic Programming
Cybersecurity, IT/OT/IIoT, process control network design and architecture, & virtualization, s95 enterprise integration
UL-Certified Panel Design, Fabrication, & FAT
Process Data Historians
Machine Safety Risk Assessments & Safety Requirements Specifications
Asset Performance Management (APM) and Manufacturing Execution Systems (MES)
Industrial Digitalization and Industry 4.0 solutions

Our Team is experienced in a variety of projects

Greenfield Implementations

Brownfield Modifications

Network Infrastructure Upgrades

Conveying Systems

Hot Roll Mills

Cold Roll Mills

Furnaces

Continuous Casting

Water Treatment

Overhead Cranes

Coil Car Transporters

Coil Winding/Unwinding

Project Spotlights

Integrating Data for Optimization

A metal processing company needed assistance with data connectivity for several areas of their facility. Many of their processes were controlled by older hardware with no network connectivity in place. The machines were connected on a secure backbone and to a cloud-based AI service for improved process insights. Network connectivity allowed for equipment optimization, leading to a higher quality product.

HCL Recovery for Steel Processing

A chemical manufacturing company needed new spray roasters for a plant expansion to accommodate new coil processing lines. The project included a greenfield implementation of a DCS for two Spray Roasters at a Steel Mill performing acid regeneration for the CPL, PLTCM, and HDGL process lines. The control system platform selected was a Rockwell PlantPAx DCS solution within a VMware Virtual Environment (vSphere). Using best practices in design, installation, and deployment, the company improved upon previous implementations at other facilities regarding maintainability, supportability, and future scalability.

Legacy Control System Upgrade

A steel manufacturing company was running its operations on legacy controls software & hardware that the vendor no longer supported, and spare parts could no longer be purchased. This resulted in equipment downtime when failures occurred, and extended downtime to replace the old systems and bring the equipment back online to resume production. During the project, the legacy DeviceNet and ControlNet networks were migrated to Ethernet/IP on the Vacuum Tank Degasser, VFD and Soft starters were upgraded for the Vacuum Tank Degasser, and the legacy Siemens WinCC application for the Continuous Caster was migrated to the latest Siemens WinCC offering. In addition, a water treatment migration and upgrade of Wonderware v2017 to v2023R2 was completed including virtualizing all assets. After the completion of the project, the company has networking solutions that are more flexible, maintainable, and expandable. They also have OEM support that allows the company to add new/modified processes into the solution if desired.

Coil Wrapping Machine Control System

A packaging company wanted to expand on its current coil wrapper design to include feature enhancements such as using an electric actuator instead of a hydraulic unit and performing film sealing. The new electric actuator had a lot of challenges due to the uniqueness of operation. Switching seamlessly between position control to torque control mode while in movement also created a challenge. The project included a consultation and complete programming of new coil wrapping machine which was faster and more efficient than the previous model. This new OEM equipment performs the automated process of wrapping and sealing panacea on various sizes of steel coil. It was integrated into the DCS as an i-Device for expanded automation functionality of the existing DCS (Siemens).

Read Our Case Studies

Platforms

As a vendor-agnostic system integrator, we have experience with a wide variety of platforms to provide you with the solutions that best fit your systems and facilities. Our experience includes Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), Safety Instrumented Systems (SIS), Human Machine Interfaces (HMI), and Plant Historians.

Our Platforms

Run your plant with confidence

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Execute Customized Solutions

Experience Sustainable Results

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Steel & Heavy Manufacturing