Case Study: a leading steel mill modernizes aging controls with LSI's phased ControlLogix and PowerFlex upgrade

Steel Mill - Customer Case Study

The customer, a leading steel mill, faced a significant challenge with its obsolete AutoMax DCS and Reliance drives, where spare parts were often defective. The OEM's proposed migration path required proprietary hardware and services, creating constraints. LSI - Logical Systems Inc was engaged to find a flexible solution to replace the aging system without causing unreasonable downtime.

LSI implemented a phased solution using Rockwell ControlLogix hardware and Baldor motors with PowerFlex 755 VFDs. By using the old system as a bridge and employing a "shadow" process for validation, LSI minimized disruption during the cutover. The results included maximized productivity with minimal downtime, reduced operational risks from new dependable hardware, and improved control through a new "cockpit" HMI approach. LSI's strategy successfully modernized the finishing line with 10,500 man-hours of project work.