The Challenge
A leading U.S. steel producer needed to upgrade aging Human Machine Interface (HMI) systems at its Ladle Metallurgy Furnace (LMF) stations. The legacy applications were not only difficult to maintain but also lacked the streamlined functionality operators had grown accustomed to on newer systems.
The client sought an engineering partner who could:
- Modernize the HMI platform while preserving operational continuity.
- Ensure smooth operator adoption by maintaining familiar screen layouts and workflows.
- Implement scalable architecture to support future plant expansions.
They turned to Axis because of our proven expertise in steel industry automation, successful prior work on similar furnace HMIs, and our dual certifications with both Wonderware and Ignition platforms.
Why We Were Chosen
Our team had previously executed upgrades on comparable LMF systems at the same site, delivering measurable improvements in reliability and usability. The client valued that we not only understood the technical landscape of Wonderware InTouch and Ignition, but also how those systems integrate with plant-wide controls and operator workflows.
This combination of deep engineering discipline and industry-specific insight gave the client confidence we could deliver the solution without disrupting critical production schedules.
The Solution
Engineering Approach
We implemented a multi-phase conversion strategy:
- Application Development
- Built two new Wonderware InTouch 2017 applications to replace the outdated LMF 1/2 applications.
- Updated all screens to align with the proven LMF 3/4 graphics library, ensuring operator familiarity.
- Reduced reliance on indirect tags in favor of direct tags for main screens, boosting system stability.
- Enhanced Functionality
- Added permissive popups and .ini file configurations consistent with newer HMI stations.
- Centralized alarming: all acknowledgments handled within InTouch, with a general alarm summary for simplified navigation.
- Programmed automated ladle car movements, reducing operator burden and improving consistency in operations.
- Ignition Integration
- Introduced Ignition licensing and architecture, including redundant frontend and backend gateways, unlimited tags, and OPC UA connectivity.
- Installed software and licenses on multiple servers and ~10 client stations.
- Delivered a flexible architecture that supports both current operations and future scalability.
- Deployment & Testing
- Conducted a three-phase rollout: parallel testing with legacy systems, full-scale pilot on one furnace, and final migration with decommissioning of old applications.
- Provided 10 days of on-site startup support to ensure smooth handover and operator confidence.
What Worked – and What Didn’t
- Worked well: Standardizing the HMI screens with LMF 3/4 drastically reduced operator training needs. The centralized alarm system improved efficiency and reduced missed acknowledgments.
Challenges: Parallel operation required additional hardware and licensing, adding complexity in the short term. However, this step proved critical for risk mitigation and seamless operator transition.