project
Ethernet-Based CCM Control & Smart Secondary Cooling Upgrade — Maharashtra, India
Migration to Ethernet-connected CompactLogix control, PowerFlex 525 drives, a 10-inch HMI and FactoryTalk Optix with reporting and temperature-responsive secondary cooling.
Project profile
Engineering scope at a glance
- Industry
- Steel & Metals
- Geography
- India, Maharashtra, India
- Capability
- PLC/SCADA, Retrofit, Drives, Secondary Cooling Automation
- Publication
- Anonymous project record
Verified technologies
Control architecture and technology tags
- Allen-Bradley CompactLogix L33ER
- PowerFlex 40
- PowerFlex 525
- FactoryTalk Optix
- HMI
- SCADA
- Secondary Cooling Automation
Project Overview
A CCM control system was upgraded from DeviceNet-era communication and PowerFlex 40 drives to an Ethernet-based control and reporting architecture.
Existing Challenge / Requirement
The application required modern communications, updated drives and supervisory tools, plus process-feedback-based secondary cooling.
Elexorn Scope
- Allen-Bradley CompactLogix L33ER PLC
- DeviceNet-to-Ethernet communication migration
- PowerFlex 40-to-PowerFlex 525 migration
- 10-inch Allen-Bradley HMI
- FactoryTalk Optix SCADA
- Production and reporting solution
- Secondary cooling automation
- Billet exit-temperature measurement
- Cooling-water control based on measured exit temperature
- Commissioning and placement into operation
Control Architecture / Technology
- CompactLogix L33ER
- Ethernet Device Communication
- PowerFlex 525
- 10-inch Allen-Bradley HMI
- FactoryTalk Optix SCADA + Reporting
- Exit Temperature Measurement
- Smart Secondary Water Control
Engineering Approach
Exit-temperature measurement was integrated as process feedback for the secondary water-control decision.
Commissioning / Execution
The migrated controls, drives, HMI, SCADA, reporting and cooling logic were commissioned and put into operation.
Verified Result
Secondary cooling control was made responsive to measured billet exit temperature, enabling water-control decisions based on process feedback rather than fixed manual operation.
Reference architecture
Smart Secondary Cooling
Measured billet exit temperature provides process feedback to the secondary water-control logic.
Control
CompactLogix L33ERNetwork & drives
Ethernet CommunicationPowerFlex 525Operations
10-inch HMIFactoryTalk Optix + ReportingFeedback
Exit Temperature MeasurementProcess response
Smart Secondary Water Control
The feedback architecture is verified; no metallurgical improvement percentage is published.
Project media boundary
No customer logo, customer-identifying photograph or customer document is displayed. The diagrams on this page are Elexorn technical architecture graphics based only on the verified public scope.