Georgsmarienhütte - Steel

Continuous PROFIBUS Monitoring Ensures 24/7 Production at Georgsmarienhütte Steel Mill

The rolling mills, which have long been operated via PROFIBUS communication, operate continuously and are subject to a constant aging process. With the PROFIBUS-INspektor® and the INBLOX® series, this can be permanently monitored and maintenance can be carried out planned.

Steel supplier Georgsmarienhütte appreciates the modularity of the INBLOX® series

To ensure continuous production, all major manufacturing companies in Germany operate around the clock. This means their systems run continuously, with minimal downtime for cleaning and maintenance tasks. To maintain optimal system availability, continuous monitoring is essential.

Georgsmarienhütte GmbH relies on the INBLOX® series products from Indu-Sol GmbH for their PROFIBUS-based systems. This case study explores how Georgsmarienhütte GmbH, a major European specialty steel supplier, leverages InduSol's INBLOX® series for robust PROFIBUS monitoring.

Georgsmarienhütte GmbH is one of the 39 companies in the GMH Group.

Georgsmarienhütte GmbH, founded in 1856 near Osnabrück, is a key player in the GMH Group. With 1,300 employees at its main site, the company operates a state-of-the-art steel mill and hot rolling facility, producing bar steel and semi-finished products ranging from 20mm to 150mm.

Steel from Georgsmarienhütte GmbH is used wherever the highest levels of stress and strain are encountered.

In 2001, Georgsmarienhütte modernized its rolling mill, implementing extensive fieldbus systems. By 2005, they had transitioned to PROFIBUS.

Markus Köhne from the Automation Systems Department explains, The rolling mill is just a single production line. However, there are several PLC controllers or individual systems that are networked together.

System Flexibility and Continuous Monitoring

InduSol's automation solutions are engineered for scalability, accommodating both current performance requirements and future technological advancements. These robust systems are built to withstand the demanding environment of 24/7 steel production. When upgrades become necessary, our experts conduct thorough assessments to determine the scope of mechanical or electrical enhancements needed.

Industrial bus systems revolutionized connectivity and introduced comprehensive network monitoring. Markus Köhne, Automation Systems Specialist at Georgsmarienhütte, explains:

Working with bus systems is very convenient because they are easy to install, says Markus Köhne. However, we’ve always sought ways to comprehensively monitor the entire bus system, not just test cables for continuity. Continuous monitoring is crucial for us as we aim to keep the systems operational as long as possible without frequent overhauls.

With the introduction of InduSol's INBLOX® series, Georgsmarienhütte found their ideal solution.

INBLOX® products enable us to consolidate and monitor multiple controllers and PROFIBUS lines on a single production line using one device, Köhne states. It has become our standard for every PROFIBUS system.

After initially using Indu-Sol's PROFI-TM Professional for real-time communication quality measurements, Georgsmarienhütte adopted the INspektor® family for continuous monitoring. The PROFIBUS-INspektor® allows for permanent monitoring of the telegram traffic in PROFIBUS systems under production conditions, enabling operators to always know the network's status and take proactive measures to avoid shutdowns.

Rolling mill, cooling bed

Rolling mill, rolling stand 2

Rolling mill, RSB block

The INBLOX® product line, developed by the network specialists from Thuringia, is an intelligent modular automation component that combines repeater functionality with permanent analysis for PROFIBUS DP/PROFIBUS PA.

Key Features of INBLOX®:

Modular design: Up to 25 galvanically isolated BUS segments
Integrated diagnostics and repeater functionality
Scalable configuration with head module and up to five expansion modules
Web server for real-time network quality display
Historical analysis of telegram errors, repetitions, and device restarts
Customizable alerts for network condition deterioration

Georgsmarienhütte deployed seven INBLOX® devices in their rolling mill, monitoring every PROFIBUS segment. A complete INBLOX® device consists of a head module and up to five expansion modules, enabling a clear star-shaped network structure. When the E-head module is combined with the DP Diag+ Rep expansion module, both logical diagnostics and physical analysis are performed through bit-form evaluation. The collected data is displayed via the web interface as bar charts or oscilloscope traces, providing a continuously readable Q-value to assess network quality.

This allows the operator to conduct historical analyses of:

telegram errors
telegram repetitions
device restarts
deviations from typical signal patterns
simple LED displays
remote querying

Additionally, the head module offers various ways to alert the user to any deterioration in network conditions.

E-head, along with a DP Diag+ Rep module and the alarm module

Maximum expansion configuration with one E-head module, four DP Diag+ Rep modules, and one alarm module.

Challenges of Maintaining a Continuously Operating Production Line

Ensuring System Uptime: For steel manufacturers like Georgsmarienhütte, unplanned downtime due to production line issues can be catastrophic. Their reliance on PROFIBUS networks for communication between programmable logic controllers (PLCs) necessitates constant monitoring to identify and address potential problems before they escalate.

Shifting from Basic Testing to Comprehensive Monitoring: While initial practices involved rudimentary cable continuity tests, Georgsmarienhütte sought a more advanced solution for comprehensive monitoring of the entire bus system. This would enable proactive measures to prevent abrupt shutdowns.

After it was successfully installed and the required learning points have been won, the INBLOX® system has significantly improved Georgsmarienhütte's ability to predict and prevent network issues.

Köhne emphasizes, The devices operate reliably, and for us, there is no suitable alternative for bus monitoring.

Georgsmarienhütte plans to integrate INBLOX® into their control system for remote access and implement PROmanage® network management software. PROmanage® provides centralized, fieldbus-agnostic monitoring of multiple INspektor® devices and switches. Installed on a central computer, it collects data on communication quality across industrial networks, enabling real-time assessments of the monitored fieldbus and facilitating early planning of corrective actions.

Markus Köhne summarizes: At the moment, we are satisfied. The existing systems in our area are well-monitored and operating smoothly. We will see where this journey takes us.