Some of our recent projects are:

Global Steel – Philippines

The 1676mm Semi-continuous Hot Strip Mill (HSM2) was put into operation by National Steel Corporation (NSC) in 1993, with United Engineering Inc. (USA) as the mill builder and General Electric Co. (USA) as the electrical and automation supplier.

The mill was shutdown late 1999 when NSC closed down its operations. In 2004, upon takeover by Global Steelworks International Inc. (GSII), the mill was rehabilitated and was put back into operation in May 2005.

Since then they have been facing problems in quality of finished products in terms of thickness, temperatures and width. A lot of cobbles and roll breaks have also occurred.

An investigative mill audit was carried out by Prizm Consultants, the problems were identified. Since the cobbles in the Finish mill were very high and the model had drifted it was decided to re-tune Finish mill setup model on top priority. Prizm re-commissioned the setup model found out problems like difference in setup and feedback speed of main drive, mass flow issues and improved the setup considerably bringing down the cobbles in the FM due to setup problems to zero. Width performance improvements are ongoing.

JSW Steel (Plate Mill) – USA

JSW Steel operates a plate mill in Baytown Texas, USA. United Engineering Inc was the mill builder and the part of the automation systems, like Level II and Level 1 gauge controller were upgraded in year 2000.

JSW was facing a lot of delays due to Level II systems apart from quality issues related to thickness of plate. The delays were mainly due to process hang-ups and old NT machines crashing. JSW had purchased a new alpha and were in the process of using this machine instead of the slower alpha they had commissioned the plant with.

Prizm Consultants carried out a comprehensive audit of the existing automation systems and suggested ways to improve performance of the existing systems. Prizm commissioned the new alpha and used it online. This helped in overcoming the process hang-up issues and reduced the delays considerably. The NT machines were upgraded by adding additional RAM. An online data storage mechanism was provided for the client so that they have data for analysis of quality problems. Re-tuning of models is ongoing.

JSW Steel, Toranagallu, India

1650mm JSW Hot Strip Mill was commissioned in 1996, United Engineering Inc was the mill builder and the electrical and automation systems were supplied by Westinghouse-Cegelac. VAI, UK upgraded the electrical and automation systems for JSW in 2006-2007.

Our consultants were hired to lead the level II systems/models implementation on site. Complete project management and on the job training was done by us. Our expertise and experience ensured that the project was implemented successfully.

Essar Steel, Hazira, India

2100 mm Essar Steel Hot Strip Mill was commissioned in 1995. SMS, USA was the mill builder and General Electric Co. (USA) was the electrical and automation supplier.

Between 2003 and 2005 our consultant was present on site to re-tune the models, reduce the delays in automation systems and assist the client with the Level II hardware/software upgrade project.