To support Steel Dynamics Heartland Division (SDI Heartland) in its mission for increased operational safety and reliability, ABB has played a key role in modernizing the aging substation equipment at the company’s steel processing plant. This partnership focuses on upgrading the switchgear doors, protection relays, and controls within SDI Heartland’s 18-breaker substation, a critical element for maintaining reliable power supply and preventing costly downtime.

Meeting the Demands of Advanced Steel Processing

SDI Heartland specializes in processing hot-rolled coils into high-value flat-rolled steel products, including pickled and oiled, cold-rolled, and galvanized materials. With advanced facilities that include a continuous pickle line, a two-stand reversing cold mill, batch annealing bases, a temper mill, and a galvanizing line, SDI Heartland can process up to one million tons of steel annually and galvanize 360,000 tons. Ensuring reliable power for these operations is essential, especially as the plant scales up production.

Upgrading Legacy Systems with Modern Protection Relays

Faced with the challenge of maintaining outdated relays, SDI Heartland turned to ABB’s Electrification Service team to replace the aging systems with advanced technology. ABB’s Relion® 615 series relays were selected for their versatility, offering integrated protection, control, monitoring, and supervision. To enhance safety, these relays include arc flash protection, utilizing optical arc flash detection with fiber-optic light sensors that trip at faults in milliseconds.

Proving Reliability in Action: A Step-by-Step Approach

To demonstrate the effectiveness of the new Relion® relays, ABB initially replaced two of the older units in SDI Heartland’s substation. The successful trial gave the team the confidence to proceed with replacing the remaining 16 relays across the medium-voltage network. The upgraded relays now provide real-time monitoring and control, allowing SDI Heartland to track the status of their feeders and optimize maintenance strategies.

Enhancing Operations with Advanced Communication Capabilities

One of the standout features of the new Relion® 615 series relays is their enhanced communication capabilities, which enable SDI Heartland to continuously monitor the performance of its electrical assets. This improvement is particularly valuable as the plant undergoes expansion, adding new galvanizing and paint lines that demand robust power management.

“We’ve always been impressed with ABB’s commitment to quality, safety, and service,” said Dave Fulford, Engineering and Maintenance Manager at SDI Heartland. “The expertise of their field engineers is why we continue to choose ABB to ensure our electrical systems operate at peak efficiency.”

Supporting Growth and Expansion Projects

As part of SDI Heartland’s ongoing expansion, which includes a second galvanizing line and a new paint line, the company once again selected ABB to provide switchgear and commissioning services for these new facilities. The longstanding partnership has enabled ABB to offer tailored solutions that keep pace with the plant’s evolving needs.

“We’ve been fortunate to maintain a strong relationship with SDI Heartland over the years,” noted Tim Gentry, Business Development Manager, ABB Electrification Service in the U.S. “As they continue to grow, we’re proud to provide reliable power solutions that help sustain their operations.”

Future-Proofing with User-Friendly Technology

The newly installed Relion® relays come equipped with user-friendly graphical displays, allowing SDI Heartland’s technicians to easily monitor equipment status and make informed maintenance decisions, ultimately reducing the risk of unexpected downtime. This modern technology ensures that SDI Heartland can continue to scale its operations with confidence and efficiency.

ABB’s Commitment to Sustainable Electrification Solutions

ABB’s Electrification Service division offers comprehensive support, from modernizing operations to advising on electrical distribution system health. Through these services, ABB helps companies minimize their total cost of ownership, boost performance, enhance energy efficiency, and reduce carbon emissions.

As a global leader in electrification and automation, ABB connects engineering expertise with cutting-edge software to optimize how businesses manufacture, power, and operate. With over 140 years of industry excellence and a workforce of 105,000 employees, ABB is dedicated to driving industrial transformation through innovative solutions.

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