Caster automatin revamping

Next-Generation caster automation for Gerdau Petersburg

Automation revamping for continuous casting
Automation revamping for continuous casting

System description

Polytec successfully completed a major Level 1 automation revamping project for the beam blank continuous caster at Gerdau’s Petersburg steel plant, reinforcing a long-standing partnership built on innovation, reliability, and technical excellence.
The project involved the complete modernization of the automation platform for Caster B, originally commissioned in 1999 and based on SMS Concast technology. The objective was to replace obsolete control systems with a state-of-the-art automation architecture while ensuring full operational continuity and seamless integration with the existing production environment.
The new control platform improves process reliability, enhances operator experience, increases maintainability, and provides a solid foundation for future digitalization initiatives.

Automation revamping for continuous casting

System highlights

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Operations

  • Complete Level 1 Automation System redesign
  • Migration and replacement of 3 PLC systems
    • 1 Common PLC
    • 2 Strand PLCs
  • New distributed I/O systems
  • Electrical panels and control cabinets
  • Operator desks and control pulpits
  • New Human Machine Interface (HMI)
  • Casting platform control system modernization
  • Ladle turret automation integration
  • Casting platform automation integration
  • Interface with existing drives
  • Integration with QMOS
  • Interface with iba data acquisition system
  • Tracking and production reporting integration
  • Interface with evacuation and downstream handling systems
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Benefits

  • Complete Level 1 automation revamping
  • Modernization of a critical beam blank caster
  • Full replacement of obsolete PLC and I/O infrastructure
  • New operator pulpits and HMI environment
  • Seamless integration with existing plant systems
  • Modernized automation for both casting strands
  • Complete synchronization of casting platform and ladle turret
  • Zero-impact migration strategy minimizing production disruption
  • Turnkey engineering, software development, installation, commissioning, and start-up

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From feasibility study through design and implementation, we’ll support you in developing the best solution.

sales@bmgroup.com