The Japan Steel Works, LTD., Muroran Plant uses the Control and Measurement Station CX2000, UP series program controllers, and UT series digital indicating controllers for operation of its heat treating furnaces.
The Japan Steel Works (JSW), LTD., Muroran Plant is located in an industrial area looking over Muroran port in Muroran City, Hokkaido. JSW manufactures large, medium and small sized steel castings and forgings, steel plates and pipes, pressure vessels for oil refinery and petrochemical applications, wind power generation equipment, and other industrial products. The Muroran Plant has five heat treatment shops and the treatment operation is performed to large sized products for nuclear, thermal and hydraulic power generation and for parts for oil refinery / natural gas plant, and to small/medium sized products for industrial equipment. We spoke with Mr. Hori and Mr. Satoh in Heat Treatment Shop of Materials Manufacturing Department.
Mr. Hori: "Heat treatment operation has to be carried out under the exact thermal control of atmosphere temperature in the furnace and of product temperature in the furnace to satisfy our customer’s requirements of quality. We think that heat treatment is very important process during product manufacturing."
That important process is carried out with several key instruments: for the furnace operation control station they use the Control and Measurement Station CX2000; for recording of atmospheric and material contact temperature, they use the µR20000 industrial chart recorder; for program control of heat treatment patterns, the UP series program controller; and for controlling temperature in each zone of the heat treatment furnaces; the UT series digital indicating controller.
Mr. Hori: "We decided to introduce the CX2000 because we can enter precise heat treatment programs through communication with a PC, and because of its large number of measurement inputs."
The CX2000 enables program control on up to 6 loops individually, allowing precise control that matches the application. Also, values measured during program pattern display and operation can be displayed simultaneously, so you can ascertain the progress of the program at a glance.
Data recorded by the CX2000 can be saved electronically to media or DAQLOGGER data logging software. Apparently they used to have to read temperature data from a chart into Excel for analysis, but now with the CX2000 they can immediately perform an analysis from the electronic data, and this saves an incredible amount of time and labor on tasks such as verifying temperature data.
The µR20000 industrial chart recorder records atmospheric and material contact temperature in the electric furnace. By using the alarm function, they can prevent errors such as temperature deviations which have a serious influence for quality.
Mr. Satoh: "When a shop worker notices an alarm, they check the heating rate, the cooling rate and abnormal plot points on the chart and prevent an accident for temperature. Yokogawa’s recorder has high reliability, so we use it with confidence. "
In order to verify that a completed product meets the customer's specifications, they must submit a record of the temperature results, so it is very important to have the data plotted on chart paper.
The Muroran Plant puts comprehensive effort into energy savings, and they use the PR300 Power Monitor for monitoring energy consumption.
Mr. Satoh: "Currently our plant is focusing not only on manufacturing but also on energy savings. We monitor power consumption with the PR300, allowing us to check what combustion conditions lead to the most every savings and in what cases we lose energy, so this is very useful for energy savings."
They have also installed the PR300 at the electric furnaces for constant measurement of power consumption, and this is used to check for equipment abnormalities. Additionally they have purchased several DX2000 Paperless Recorders that they can easily carry to key locations as needed for "spot checks" of temperature.
Mr. Satoh: "We have continued to use many Yokogawa products for many years because they are highly reliable."
The Japan Steel Works, LTD., Muroran Plant
Mr. Toshihiro Hori
Mr. Seigou Satoh
Heat Treatment Shop,
Material Manufacturing Dept.
In the iron and steel industry, it is crucial to improve the quality of not only products but also manufacturing and operation technologies, as well as to address environmental and energy-efficiency issues. Yokogawa helps customers to create the ideal plant and evolves with them for mutual growth.
The Daqstation DX1000/2000 series is a data acquisition system with display. Its HMI supports custom graphics for industry applications, audit trail and advanced security conforming to FDA 21CFR Part 11.
CX defines the next generation in process control by fusing recording, control and networking into a single, compact product.
The UT55A and UT52A temperature controllers employ an easy-to-read, 14-segment large color LCD display, along with navigation keys, thus greatly increasing the monitoring and operating capabilities. A ladder sequence function is included as standard. The short depth of the controller helps save instrument panel space. The UT55A/UT52A also support open networks such as Ethernet communication.
PR300 is a panel-mounted meter designed to meet two user needs: a power facility meter and a meter for monitoring energy consumption.
The UP35A is a program controller with available 4 patterns and 40 segments (max.) and multi-channel contact I/O. It also includes a ladder sequence function. The UP32A is a compact program controller with up to 4 patterns and 40 segments available. It also includes a ladder sequence function.
The UP55A is a newly-released 1/4 DIN sized program controller provides up to 30 program patterns, and simultaneous monitoring of 8 PV events, 16 time events, and 8 alarms. Also a ladder sequence function is included as standard.
The μR series are the compact industrial recorders with the recording widths of 100 mm (μR10000) and 180 mm (μR20000). Measured data can be saved to an SD memory card while recording on chart paper.
Contact a Yokogawa Expert to learn how we can help you solve your challenges.