Steel Plant PLC/DCS Modernization Project

Client : Chongqing Steel Group Co., Ltd.

Industry : Steel Manufacturing

Construction Date : August 2023

Project Value : $1,250,000

Hong Kong Saul Electric Co., Ltd.

Project Background

The client, a major steel producer, was operating with aging PLC and DCS systems across its melt shop and rolling mill. These outdated systems caused frequent process interruptions, limited automation, and high maintenance costs, affecting productivity and product quality.

Challenges

Obsolete PLC/DCS hardware with increasing failure rates
Lack of integrated process control and real-time data visibility
Requirement to upgrade without halting critical steelmaking operations
Complex integration with legacy field devices and sensors

Our Solution

Hong Kong Saul Electric Co., Ltd. delivered a comprehensive modernization package:

Replaced legacy PLCs with Siemens S7-1500 controllers and upgraded DCS for coordinated process control
Implemented a unified SCADA system for real-time monitoring, alarms, and historical data analysis
Phased migration to ensure uninterrupted steel production
Customized interfaces for seamless integration with existing field equipment
Provided operator and maintenance training for the new systems

Results & Benefits

Production efficiency improved by 15%
Unplanned downtime reduced by over 50%
Enhanced process automation and product quality consistency
Real-time data access enabled predictive maintenance and faster troubleshooting
Improved safety and operational reliability

Contact Us

For more information about our steel plant automation and modernization solutions:
Email: zoe0159@163.com
Phone: +86 18030274856

Outcome

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Hong Kong Saul Electric Co., Ltd.