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Tuesday 2 September 2014

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Plannja AB
Activity The coating line
Name Målningslinjen 
Plant The coating line
Location Luleå 
End Customer Plannja AB 
Plannja AB
Plannja is the largest manufakturer of thin steel sheet roofing material in Sweden. The company has 580 employees and has a turnover of close to 160 Euro and is part of the SSAB group.
Plannja Sweden has a turnover of more than 700 miljon Crowns and 200 employees.
Plannja manufactures thin steel sheet building products which are sold directly to the building market and to the private market through a net of retailers.
Plannja was established in 1967 as a separate division within Norbottens Järnverk in Luleå, which later become SSAB. In 1977 Plannja AB was started.
The coating line
The steel is protecten with a layer of paint. Two layers are applied; a primer and coating paint.

Plannja hardCoat is the quality which is primarily used.

The line is 320 m long and consists of two uncoilers, followed by a pre-treatment section where the steel is washed. On the top floor there is first a station to add primer followed by a drying oven. In the next station the coating paint is applied, followed by a drying oven. After a cutting section the finished steel is coiled to a recoiler.

Flue gas cleaning
Solvents and paint residue is removed by combustion at a temperature of 680 degrees Celsius in the flue gas cleaning plant on the roof.
Heat from the combustion is lead back to the ovens and re-used.

The coating line was previously controlled by two S5-135U. One with two CPU:s , the other with one. Later yet another S5-135U was added for cleaning of flue gases.

The process was monitored by the CP527 HMI system. Periferial I/O was connected throeugh ET100. The S5-135U system communicated via Sinec L1.

The exchange
Plannja decided to modernise the whole control system and replace the old S5 PLC with new S7-400. For process visualisation WinCC was chosen.
ISIS was chosen to carry out the exchange.
Special Characteristics
As usual there was a demand that the stop in production must be very short. To achieve this we prepared the exchange by carrying out several steps in the rebuild in advance.

1. ET100 is a completely obsolete bus which is not supported by S7. We switched the ET100 nodes for Profibus DP gradually during several planned maintenance stops before the change of PLC and connected them temporarily to the S5-135U.

2.WinCC was used parallel with the CP527 together with the S5-135U for a period. The WinCC applications could then be tested during production.

3.Phoenix adapters was used to avoid having to rewire the S5 front connectors at the same time as the PLC change. The front connectors will be gradually exchanged with S7 fron connectors during normal maintenance stops. This is because it is the easier to see the LEDs on the I/O boards.

The two PLCs with their three CPUs was replaced with one S7-416 CPU as the coating line can be considered as one unit.
The flue gas cleaning however got its own PLC with a S7-414 CPU. Communication between the PLCs and between PLCs and WinCC is through TCP/IP.

The work went very smoothly and production was started again half a week ahead of schedule.
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