The X-Pact® Plug & Work integration test represents an advanced approach to the commissioning and optimization of the flat rolling complexes. In our test centers we utilize the concept of a digital twin of the plant to simulate all automation processes and to run extensive tests aimed at optimizing the automation as well as the related production processes even before the flat rolling complex is assembled and put into operation. Each plant simulation is unique and takes into account the special technological features of the plant, including all relevant components and systems.
Digital commissioning of automation
All the automation processes that will be used to control the plant are simulated in the digital twin environment. This includes the control systems, sensors, actuators, and other elements of the automation layer. The procedure for checking the drive interfaces, measuring systems, and the interfaces with all other packages is the same as that used on site. Once the individual plant modules have been tested, they are combined to create an integrated system, and the interaction between them is checked.
With the digital twin, we conduct extensive tests to ensure that the automation processes are working as intended. They can also optimize these processes for efficiency, reliability, and product quality before the physical plant is assembled.
Developed by SMS group, this concept of integration testing allows digital commissioning of automation under realistic conditions. Potential issues can be identified and resolved without having to conduct tests on the actual physical systems, saving time and reducing the risk of delays or problems during the actual commissioning phase.
Operator training
Training of the Aluminum Dynamics operating and maintenance crews, planned for June 2024, ensures the customer's team is fully integrated into the commissioning process. Operators and maintenance personnel can be trained using the digital twin, which helps to reduce the learning curve and improve the safety and efficiency of the workforce once the actual plant is up and running. Even after the plant is put into service, the digital twin can continue to be used for process optimization and predictive maintenance, thereby enhancing the lifecycle of the plant and reducing downtimes.
The use of a digital twin in the aluminum industry, particularly for complex systems such as flat rolling mills, offers significant advantages in terms of risk reduction and cost savings, and ensures a smoother start-up phase. It also provides a valuable tool for ongoing process
