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Steel and Cement

Steel and cement production plants are complex systems with large-scale and energy-intensive production processes that operate under high temperature and pressure. Steel production involves the processing and melting of iron, while cement production involves the firing of limestone and other raw materials under high temperatures. Such plants have to operate continuously, which necessitates an uninterrupted supply of energy.

If energy continuity is not ensured in steel and cement production facilities, production processes can stop, leading to huge cost losses. In addition, effective cooling solutions are essential to prevent overheating of the machinery used during production. Ensuring energy efficiency is essential for reducing costs as well as increasing environmental sustainability. As energy consumption is high in these facilities, the integration of efficient energy management systems is inevitable.

Failures in steel and cement production plants can significantly disrupt production processes. Therefore, maintenance-friendly and fast response solutions are required. Any malfunction in the production line can cause both production stoppage and serious cost increases. Therefore, it is essential that the energy distribution systems used in steel and cement production are modular, flexible and durable.

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The Need for Forming for High Safety:

Safe operation of the panels is very important for this sector. For this reason, it is recommended to form electrical enclosures. The partitioning process, called forming or internal separation in electrical panels, aims to ensure human and equipment safety by increasing safety measures inside the panel. This process maximizes safety by limiting malfunctions (fire, etc.) to a certain area and preventing technical personnel from contacting energized parts during intervention.

Electrical enclosures have different levels of formability. These levels determine the internal structure of the enclosure and the way the compartments are separated. The highest level of internal separation is called Form 4b. Form 4b means that all compartments inside the enclosure are completely separated from each other and provide the highest level of safety.

Switchboards with Form 4b format are especially preferred in high-risk environments and critical applications. These panels protect both life safety and equipment safety by preventing the spread of faults. They also provide a safe working environment during maintenance and repair operations.

For enclosures with Form 4b format, the application of segmented covers is also generally recommended. Sectional covers facilitate access to only a certain part of the enclosure and protect the safety of the sections.

In summary, Forming or internal separation is an important practice to improve safety in electrical enclosures. Different forming levels offer solutions suitable for different needs and risk levels. Forming Form 4b and split cover application is recommended to provide the highest level of safety required by this sector.

You can read more about the formulation in our blog post by clicking here.

High Corrosion Resistance Requirement:

Bu sektörün ihtiyacı korozyon dayanımını sağlamada tüm EAE Elektroteknik ürünleri ağır çevre şartlarında yüksek korozyon dayanımı ile öne çıkmaktadır. 

Corrosion is the process of wear of metals or metal alloys by oxidation or other chemical effects. Electrical panels need to be protected from these corrosive effects according to their environmental conditions.

• Paint application on DKP sheet: This method can provide limited protection against corrosion. Although external environments are more corrosive, similar corrosive effects can occur in internal spaces over time. For this reason, the corrosion resistance provided by applying paint on DKP sheet should not be preferred for use in internal environments.

• Paint application on galvanized sheet or galvanized sheet: This method, which is widely used in industrial environments, provides effective protection against corrosion. It should be generally preferred in both internal and external applications. It is very advantageous when evaluated in terms of price and performance.

All EAE Elektroteknik products use ready galvanized sheet metal, even if they are painted, which is the second option. This feature increases the corrosion resistance of the products in harsh environmental conditions as described above.

The Need for Proper Ventilation:

Especially frequency converters in MCC panels used in this sector cause excessive temperature increase. For this reason, there is a need for proper ventilation to prevent the panels from heating up.

Temperature rise directly affects the performance of the devices in the panel or rack cabinet. Temperature rise tests, which are as important as short circuit in panel type tests, are critical for the safe and efficient operation of the devices. Since the temperature increase reduces the current carrying capacity, the temperature inside the panel/rack cabinet must be brought to the ideal level with proper ventilation.

The temperature inside the panel/rack cabinet rises due to the ambient temperature and the heat emitting devices (breaker, busbar, server, etc.) inside.This temperature increase is calculated by considering the electrical loss power values in the catalogs of each device used.

The IP degree of protection also contributes to the temperature increase by preventing the heat from escaping.Therefore, it is important to choose the right IP level for the enclosure/rack cabinet, not a high one. A higher IP protection rating does not always mean better protection and the wrong choice can lead to excessive temperature rise and therefore damage to the devices.

After determining the temperature increase, the panel or rack cabinet can be cooled by the following methods according to the value obtained:

• Natural Ventilation
• Fan Cooling
• Cooling with Air Conditioning

As EAE Elektroteknik, you can use our PanelTemp heat software for cooling calculations inside the panel up to 1600A. Click here for more information about PanelTemp. You can also find our blog post about fan cooling here. You can contact your Customer Representative for our air conditioning solutions.

You can also read our blog post on fan cooling by clicking here.

The Need for Accurate Determination of IP Protection Rating:

The protection of electrical panels against environmental factors and the determination of the degree of protection against solid and liquid objects is ensured by performing the tests specified in the IEC 60529:1989 standard. These tests are expressed in numbers (IP code) indicating that the panels provide certain levels of protection.

The first digit in the IP code indicates the level of protection against solid objects, the second digit against liquids.

A high IP rating does not provide sufficient assurance for outdoor use, i.e. enclosures with a high IP rating do not mean that they are EXTERNAL!

There is a misconception in the market that products with a high IP protection rating can be used outdoors.

Products with a high IP protection rating have a shorter exposure time to corrosion in outdoor environments, even if dust and water resistance is specified. The radiation effect of the sun must also be taken into account. These factors are not taken into account in the IP classification.

In addition, as IP increases, the heat inside the panel also increases. This reduces the current carrying capacity of the products. For this reason, it is important to determine the optimum IP value for the panel, neither high nor low.

High Durability Requirement with the right IK value:

The level of impact protection is called IK test in IEC 62262:2002 standard. In this test, a value is determined by checking that the damage caused by an object dropped from a certain height hitting the enclosure does not affect the IP protection degree of the enclosure. This value indicates the IK level of the cabinet. EAE Enclosures are IK10, which is the highest level.

Need for Seismic Resilience:

Turkey's location in an earthquake zone makes it mandatory to manufacture non-structural products such as electrical panels and rack cabinets resistant to seismic movements. In order to ensure energy continuity and protect life safety in the event of an earthquake, it is of great importance to use industry-independent seismic certified products and to strictly follow the manufacturer's installation instructions.

Seismic certification demonstrates that electrical enclosures and rack cabinets can maintain their structural integrity and functionality during earthquakes. At the same time, these certifications prove that the products have been tested in accordance with international standards and are designed to withstand a specific earthquake intensity.

The correct installation of seismic certified products in the field directly affects the performance and safety of the product. Failure to follow the installation rules set by the manufacturer can reduce the seismic resistance of the product and even cause it to be damaged during an earthquake.

At EAE Elektroteknik, we attach great importance to seismic resistance. Our products are tested and seismically certified in accordance with international standards. In addition, we have prepared detailed installation instructions for our products, aiming to ensure a safe and accurate installation for our customers.

In addition:

In the steel and cement industry, it is critical to choose systems with high standards in terms of energy continuity, safety and durability. EAE Elektroteknik offers solutions that meet these requirements and can be used safely in the sector.

PanelMaster Low Voltage Type Tested Panelboard Systems; 

It offers high safety and durability for use in steel and cement production facilities. In order to be used safely in these facilities, which are critical in terms of energy continuity and maintenance safety, it has type test certificates with high technical values obtained from internationally accredited laboratories and allows Form 4b applications in terms of operational safety.     
   
You can click here to examine our PanelMaster Panel System in more detail.                                     

PanelMaster Low Voltage Drawer Type Tested Panelboard Systems; 

designed to meet the requirements of high safety, flexibility and easy maintenance in power circuits and motor starting circuits, it is widely used in these projects.

• IEC 61439-1-2 Type Test Standard
• IEC 60068 Seismic Test Standard
• IEC 61641 Internal Arc Test Standard

You can click here to examine our PanelMaster Drawer Panel System in more detail.

E-Cabinet Type Tested Empty Panel Systems;

E-Kabin offers solutions to the needs of control, control and many different applications in the internal and external environments of steel and cement production facilities, including 304-316 stainless steel, with a wide range of products. E-Kabin panel products provide durable and long-lasting use in accordance with the harsh working conditions of steel and cement production facilities with its international accredited standards.

• IEC 62208 Type Test Standard for Empty Enclosures
• IEC 60529 Degree of Protection Provided in Switchboards 
• IEC 62262 Protection against External Mechanical Impact

E-Cabin solutions that can stand out for this sector can be Stainless and External Solutions.

E-Kabin Stainless Series Panels:

Our products can be produced in 304 or 316 quality upon request. Depending on the standard product design, size change, material thickness change and desired hole operations can be applied. 

It is also possible to manufacture painted or varnished in desired RAL codes. If desired, a lock system made of 316 quality stainless steel can be selected instead of the standard pendulum arm lock system with high chemical resistance. 

Interior accessories such as mounting profiles, mounting plates, front cover system etc. used in all E-Cabin series can also be used for stainless products.

Thanks to our manufacturing techniques, the welding bolts used for various in-door components are applied in such a way that they leave no traces on the outside of the door. This ensures a clean and smooth surface appearance.

You can click here to examine our stainless panels in more detail.

E-Cabin External Panels:

The external factors that panels are exposed to in external environments are much more than internal environments. Snow, rain, dust, mud, sand, etc. The panel must maintain its structural integrity and function in all these factors. Therefore, external panels should be designed accordingly.

One of the most important accessories in these products is the roof. The roof needs to be properly designed so that it does not let in water that accumulates when the door is opened, and it also needs to prevent water seepage or water walking from the opposite angle.

There is a misconception in the market that a high IP protection rating in external panels means external, but a high IP protection rating does not mean external. Although the relationship of products with high IP protection degree with dust and water is defined, the corrosion time in external environments is shorter, and the radiation effect of the sun should also be taken into account, which is not used in IP protection degree. Corrosion resistance is one of the most important points in external panels. You can find our article on corrosion resistance above.

E-Kabin H series external panels are produced as modular or monoblock for external environments.You can click here to review our E-Kabin external panel series.

You can click here to view the entire E-Kabin product portfolio in more detail.

KabinPLUS IT Infrastructure Solutions; 

The steel and cement industry offers infrastructures solutions necessary for the sustainability of a healthy data processing system in very difficult facilities due to the environmental conditions of the steel and cement industry. It offers durable, modular, long-lasting, high-security, aesthetic and user-friendly solutions, especially supported by seismic products. 

You can click here to examine our KabinPLUS products in more detail.