Tata Steel

Tata Steel needed to upgrade its aging kiln control system without disrupting continuous steel production operations. The upgrade had to be completed within an extremely constrained maintenance window while achieving full connectivity with modern enterprise systems.

Rockwell Automation executed a kiln control system upgrade within a 16-hour maintenance window, replacing legacy controls with a modern connected architecture. The compressed timeline required extensive pre-engineering and simulation to ensure the entire cutover could be completed without overrunning the available window.

Tata Steel completed the full kiln control upgrade within the 16-hour window with no production overrun. The new connected architecture provided Tata Steel with modern process visibility and control capabilities, moving the facility closer to Connected Enterprise integration.

16-hour control system cutovers in steelmaking require simulation and validation work that dwarfs the actual installation time. Connected Enterprise architecture in steel starts with modernizing individual process control units within tight maintenance windows. Extensive pre-engineering investment pays dividends when the actual cutover must succeed in a single compressed window.